Patent Application
20070160509
This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2005-379936, filed on Dec. 28, 2005, the entire contents of which are incorporated herein by reference.
The present invention relates to a holding seal member for an exhaust gas purifying body, an exhaust gas purifier using the holding seal member, and a method for manufacturing the holding seal member.
An exhaust gas purifier is generally attached to an exhaust pipe of a vehicle. As shown in
According to a preferred embodiment of the present invention, there is provided an inorganic fiber holding seal member for holding an exhaust gas purifying body and preventing leakage of exhaust gas. The holding seal member has a surface including identification information.
The identification information is visually appeared on the surface of the inorganic fiber mat. Therefore, product name, the inner and outer sides of the holding seal member will not be mistaken.
In a preferred embodiment of the present invention, the holding seal member is one of a plurality of holding seal members cut out from an inorganic fiber sheet, and the identification information is a printed information printed by a printer on each holding seal member before the holding seal members are cut out from the inorganic fiber sheet.
In a preferred embodiment of the present invention, the identification information is a sticker indicating the identification information and adhered to the surface of the holding member.
In a preferred embodiment of the present invention, the printer is a device selected from the group consisting of a non-contact type printing device including a liquid ejection head for ejecting liquid, a transfer roller device, and a flat plate type pressing transfer device.
In a preferred embodiment of the present invention, the holding seal member is formed from an inorganic fiber mat impregnated with at least either one of an organic binder and an inorganic binder.
In a preferred embodiment of the present invention, the amount of the organic binder impregnated in the holding seal member is about 1 to about 10% by mass with respect to the mass of the holding seal member.
In a preferred embodiment of the present invention, the inorganic fiber has an average fiber diameter of about 6 μm or greater.
In a preferred embodiment of the present invention, wherein the holding seal member is formed from an alumina-silica fiber mat.
In a preferred embodiment of the present invention, the identification information is at least one of a product name, a product number, a manufacturing serial number, basic weight, product class, weight, product size, vehicle type information, and inner or outer side distinguishing mark of the holding seal member.
According to a preferred embodiment of the present invention, there is provided an exhaust gas purifier including a holding seal member prepared from an inorganic fiber mat. An exhaust gas purifying body includes a circumferential surface in which the holding seal member at least partially wraps around the circumferential surface. A tubular shell accommodates the seal member and the exhaust gas purifying body. The holding seal member has a surface including identification information.
In a preferred embodiment of the present invention, the exhaust gas purifying body is a catalyst carrier carrying a catalyst for purifying exhaust gas or an exhaust gas purifying filter.
According to a preferred embodiment of the present invention, there is provided a method for forming a holding seal member for an exhaust gas purifying body. The method includes preparing an inorganic fiber mat, relatively moving the inorganic fiber mat and a liquid ejection head of a liquid ejection device, and printing identification information on the surface of the inorganic fiber mat by ejecting liquid from the liquid ejection head.
Other aspects and advantages of the present invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
The invention, together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
A holding seal member for an exhaust gas purifying body according to a preferred embodiment of the present invention will now be discussed with reference to FIGS. 1 to 4.
A holding seal member 14a has a surface on which predetermined identification information, such as a manufacturing serial number, is printed by a holding seal member printing apparatus 11. The holding seal member 14a is cut out from an inorganic fiber mat 14. The printing apparatus 11 prints the identification information on the inorganic fiber mat 14 before the holding seal member 14a is cut out. Therefore, the printing subject is the inorganic fiber mat 14. The printing apparatus 11 includes an ink jet printing device, or liquid ejection device 13, for printing the identification information on the inorganic fiber mat 14 by ejecting an ink composition 15 in the form of liquid droplets or atomized liquid from a position distant from the inorganic fiber mat 14.
Referring to
The method for manufacturing the inorganic fiber is not particularly limited. In one example, short fibers of about 0.5 to 10 mm are collected, fibrillated, and stacked or dispersed in water to prepare fiber dispersed liquid. The fiber dispersed liquid is poured into a mold and dried in a pressurized state to form a fiber aggregate (fiber mat). The thickness of the fiber aggregate is appropriately set in accordance with the type of inorganic fiber mat 14 that is formed, the type of exhaust gas purifying body to which the inorganic fiber mat 14 will be used for, and the bulk density. The fiber aggregate preferably undergoes a needle punching (needling) process. The needle punching process is performed to thin the stacked sheet so as to facilitate handling and to strengthen the engagement of the fibers between the stacked sheets. The needle punching process is preferably performed by punching a needle in a direction orthogonal to the layer, in particular, by quantitatively punching the needle in constant intervals. This intertwines fibers in a complicated manner between the layers of the stacked sheets and thus strengthens the bonding of the layers.
A binder may be impregnated in the inorganic fiber mat 14 before the cutting and molding so that the inorganic fiber mat 14 has a predetermined thickness, resilience, and air tightness. This prevents scattering of fibers and facilitates handling during attachment to an exhaust pipe. For example, the inorganic fiber mat 14 may be immersed in a liquid of binder. Examples of the binder include inorganic binders and organic binders. However, organic binders are preferable since characters may be printed clearly with ink. Inorganic binders include clay minerals such as montmorilonite, water glass, synthetic mica, montmorillonite, colloidal alumina, and colloidal silica. Examples of organic binders include water soluble resins, such as acrylic resin and polyvinyl alcohol, and latex, such as acrylic rubber, nitrile rubber, acrylonitrile-butadiene rubber (NBR), and stylene-butadiene rubber (SBR). The binders may be used alone or by in combination.
The organic binder absorption ratio of the following equation is used to express the amount of organic binder impregnated in the fiber stacked sheet.
Organic binder absorption ratio (mass %)=100×(dried mass of organic binder impregnated in fiber stacked sheet)/(mass of holding seal member)
The organic binder absorption ratio is preferably greater than 0% by mass and about 12% by mass or less, more preferably about 0.5 to about 10% by mass, and most preferably about 1.0 to about 10% by mass with respect to the mass of the holding seal member. If an organic binder is not used, the wetness of the ink may be too high and cause the ink applied to the inorganic fiber mat 14 to be blotted. As a result, the printed characters would not be clear. If the organic binder absorption ratio is about 12% by mass or less, the ink have excellent wetness and result in sufficient adhesion between the applied ink and the fiber of the inorganic fiber mat 14. As a result, the printed characters will be clear.
The amount of organic binder absorbed in the fiber sheet may be measured by performing an ignition loss test. The ignition loss test will now be described. First, the weight (A) of a magnetic plate is measured. A fiber mat, which has absorbed the binder, is placed in the magnetic plate and dried at 110° C. for 60 minutes. Then, the weight (B1) of the magnetic plate is measured. The weight B1 is the total weight of the fiber mat, the magnetic plate, and the dried binder. The, the magnetic plate containing the fiber mat undergoes heat treatment performed under the conditions of 600° C. and 60 minutes. The magnetic plate containing the fiber mat is then naturally cooled and dried under the conditions of 110° C. and 60 minutes. Afterwards, the weight (B2) is measured. The weight B2 is the total weight of the fiber mat and the magnetic plate.
The amount of weight reduction is theoretically equal to the weight of the dried binder, and is calculated from the expression of initial mat weight (B1-A)—heated mat weight (B2-A). The heating loss ratio of the following equation is used as an index for the absorbed amount of organic binder.
Heating loss ratio(%)=(amount of weight reduction/initial mat weight)×100
The average fiber diameter of the fiber material is appropriately set in accordance with the type of holding seal member. Preferably, the average fiber diameter is relatively wide (about 6 μm or greater) so that clear printing is realized without drastically lowering the adhesive property of the ink even if the organic binder absorption ratio is increased. If the average fiber diameter is about 6 μm or greater, the adhesive property of the ink is satisfactory and the printed character will be clear. Furthermore, the scattering of the inorganic fiber from the holding seal member 14a can be sufficiently suppressed. When forming a fiber mat having a fiber diameter of about 6 μm or greater, among the ceramic fibers mentioned above, alumina fibers are preferable in terms of easy formation.
The average fiber diameter is measured in the following manner. First, a fiber material sample is pressurized (e.g., 20.6 MPa) and crushed. Next, the sample is sifted and homogenized and then adhered to an electron microscope sample stage using a holding strip such as double-faced adhesive tape or the like. Then, gold, platinum, and carbon are vapor deposited on the surface of the fibers adhered to the sample stage to produce a test body. The test body is then photographed under a predetermined magnification (e.g., 1500 ×) using the electron microscope, and the diameters of the fibers are read from the picture (measurement up to 0.1 μm is possible in 1500×measurement). The average fiber diameter is then obtained from a frequency distribution table of the measured fiber diameters and the number of fibers.
The inorganic fiber mat 14 is arranged at a cut-out position S, and then cut using a punching blade to manufacture a plurality of holding seal members 14a having a predetermined shape. A tongue 14c and a tongue holder 14b for receiving at least one part of the tongue 14c are formed on opposite ends of each holding seal member 14a in the lateral direction. As shown in
The direction for cutting of the inorganic fiber mat 14 is not particularly limited. Examples of tools for cutting the inorganic fiber mat 14 include scissors, a cutter, and punching blade formed by bending a strip of metal plate. A punching blade made from carbon copper is preferable in consideration of the thickness, hardness, and productivity of the inorganic fiber mat. Rims 14d and the holding seal members 14a (in
The printing apparatus 11 includes a conveying table 12 and a liquid ejection device 13. The conveying table 12 is movable in forward and rearward directions (toward the left and right as viewed in FIGS. 1 to 3). The liquid ejection device 13, which functions as a printing means, is arranged distant from the conveying table 12 and ejects the ink composition 15 on a printing subject.
A driving means (not shown) moves the conveying table 12 in the forward and rearward direction, or in the X direction, at a predetermined movement speed. The conveying table 12 may have a surface formed by a resin plate, a rubber plate, a foam body, or a stacked plate including or coated by fiber layers of non-woven cloth or felt etc. However, the conveying table 12 is not limited in such a manner and may be formed from any material as long as the inorganic fiber mat 14 can be held in a parallel state and the held object does not easily move and is not easily damaged by vibrations during conveyance. The drive of the conveying table 12 is controlled by a control device (not shown). Printing on the surface of the inorganic fiber mat 14 is performed by controlling the movement speed of the conveying table 12 and the ejection of the ink composition 15 from the liquid ejection device 13 in a cooperative manner. The feeding speed of the conveying table 12 during printing is appropriately set in accordance with the quality (e.g., clearness) of the printed characters and the productivity.
The liquid ejection device 13 is an ink jet printing device for printing the identification information by ejecting the ink composition 15 as liquid droplets or atomized liquid from a position distant from the inorganic fiber mat 14, which is the printing subject. The liquid ejection device 13 includes a liquid ejection head 13a, which ejects the ink composition 15 to the inorganic fiber mat 14, and a support 13b, which supports the liquid ejection head 13a. The support 13b, which spans over the conveying table 12 in the widthwise direction, is moved by a driving means (not shown) in the vertical direction (left and right directions with respect to the conveying direction). The liquid ejection head 13a ejects ink particles in accordance with an image signal or character signal provided from the control device. The printing control with respect to the inorganic fiber mat 14 includes the movement control such as forward or rearward movement of the conveying table 12 and the emission control of the ink composition 15. The size (dots) of the ink particles ejected from the liquid ejection head 13a during printing is appropriately set taking into consideration the quality (e.g., contrast ratio) of the printed character and the productivity.
Three liquid ejection heads 13a are embedded at equal intervals in the longitudinal direction with an ejector for the ink composition 15 facing outward from the lower surface of the support 13b. The method for ejecting the ink composition 15 from the liquid ejection head 13a is not particularly limited and is appropriately set in accordance with the type and the printing pattern of the inorganic fiber mat 14. For example, the ink composition 15 may be ejected by a piezoelectric element of which volume varies when voltage is applied or by using the pressure generated by bubbles formed by heating the ink composition 15. However, the method using the piezoelectric element is preferred since degeneration of the ink composition 15 is small as heat is not used, and clogging of the head is less likely to occur.
The ink composition 15 is not particularly limited and a known ink composition containing a dye and pigment is used. The ink composition 15 contains water and organic solvent serving as solvent in addition to the dye and pigment. The organic solvent may be polyalkylene glycol type such as polyethylene glycol, alkylene glycol type such as propylene glycol, and pyrrolidone type such as glycerin, alcohol type. The pigment may be, for example, water soluble dye such as a direct dye, acid dye, and basic dye. Sedimentation of the dye component is less likely to occur by using the dye dissolved in liquid such as water or organic solvent.
The pigment may be an organic pigment or an inorganic pigment. The organic pigment may be, for example, an azo pigment such as azolake, condensed azo, and chelate azo, a polycyclic pigment, such as quinacridone, phtalocyanine, anthraquinone, dioxiazine, thioindigo, and isoindolynone, chinophtalone, a nitro pigment, a nitroso pigment, and aniline black. The inorganic pigment may be, for example, carbon black, titanium dioxide, silica, alumina, iron oxide, iron hydroxide, and tin oxide. The pigment is generally non-soluble in water and the organic solvent, and is present in a state dispersed in the solvent as particles. In addition, an organic or inorganic binder, a dispersing agent, a surface active agent, a pH adjuster, an antiseptic, and an antioxidant may be appropriately mixed into the ink composition 15 if necessary.
The viscosity of the ink composition 15 at 20° C. is about 2 to about 5 cSt, and preferably about 3 to about 4 cSt. If the viscosity of the ink composition is about 2 cSt or greater, the ink composition 15 hardly impregnates into the inorganic mat and the printed character will be clear. If the viscosity of the ink composition 15 is about 5 cSt or less, the ink composition 15 will not be clogged inside the liquid ejection head 13a. The viscosity of the ink composition 15 may be changed by mainly changing the amount and type of the solvent for dissolving dye or pigment.
The operation for forming the holding seal member 14a will now be described.
The inorganic fiber mat 14 impregnated with the binder is first mounted on the conveying table 12. The inorganic fiber mat 14 is then conveyed to a position under the liquid ejection device 13 (printing position). In this state, the inorganic fiber mat 14 is positioned in correspondence with the cut-out position S so that the holding seal members 14a expected to be cut out faces the ink ejecting position of the liquid ejection device 13.
The ink composition 15 is then ejected from the liquid ejection head 13a onto the surface of the inorganic fiber mat 14 to perform printing. Printing is performed in accordance with the identification information (e.g., ABCDE in
As shown in
When wrapping the holding seal member 14a around the circumferential surface of the exhaust gas purifying body 21, a seal 22 may be adhered to the portion of engagement between the tongue holder 14b and the tongue 14c. The exhaust gas purifying body 21 around which the holding seal member 14a is wrapped is then press fitted into the cylindrical metal shell 23 to assemble the exhaust gas purifier.
The holding seal member 14a for the exhaust gas purifying body in the preferred embodiment has the advantages described below.
(1) The identification information is printed on the surface of the inorganic fiber mat 14 by the liquid ejection device 13. Therefore, the holding seal member may be identified by product name or manufacturing serial number. The identification information is shown on only one surface of each holding seal member. Thus, the inner and outer sides of the holding seal member are not mistaken.
(2) A greater amount of information is shown on the inorganic fiber mat 14 compared to when just spraying (marking) a colored resin paint.
(3) The characteristics of the holding seal member 14a do not change since labels and colored resin paint that may burn in the shell are not used.
(4) When the inorganic fiber mat 14 undergoes printing performed the non-contact type liquid ejection device 13, which performs printing from a position distant from the printing subject, the dimensions of the holding seal member, such as length and width, do not need to be taken into consideration as would be necessary when contact type printing is performed by a transfer roll, a transfer plate (stamper), and the like. Further, the printing characters may be easily changed. When changing the dimension of the holding seal member, the printing characters may easily be changed by changing the information of the type and size of the printing characters input to the control device, which controls the conveying speed of the conveying table 12 via the driving means and the ejection of the ink composition 15 from the liquid ejection device 13.
(5) The non-contact type printing device does not press (compress) the inorganic fiber mat 14 as would when contact type printing, such as gravure printing or relief printing is performed with a transfer roller or a stamper. Thus, the thickness and the resilience of the inorganic fiber mat 14 are not changed.
(6) In a contact type printing device, problems such as inorganic fibers adhering to the transfer roller and the transfer plate, recesses in the printing plate becoming clogged, and the printed characters becoming illegible may occurs. However, such problems do not occur when using the non-contact type printing device, and the identification information is clearly printed on the inorganic fiber mat 14. Furthermore, the used amount of ink composition is reduced.
(7) Regardless of whether the inorganic fiber mat 14 is a non-woven cloth or felt, the particles of the ink composition 15 perpendicularly enters the inorganic fiber mat 14 from the surface. Thus, the printed characters are clear when seen from above the holding seal member 14a.
(8) The organic binder is impregnated in the inorganic fiber mat to obtain a predetermined organic binder absorption ratio. Therefore, information, such as the manufacturing serial number or indication of the inner or outer side, is more clearly printed on the inorganic fiber mat 14. Further, the possibility of erroneously reading the information is reduced.
(9) The identification information is clearly printed on the inorganic fiber mat 14 when fibers having an average fiber diameter of about 6 μm or greater are used.
(10) The inorganic fiber mat 14 on the conveying table 12 is positioned so that predetermined holding seal members at the cut-out position S are at the printing position of the liquid ejection device 13 immediately before printing. Therefore, printing is performed on the surface of each holding seal member that is to be cut out.
It should be apparent to those skilled in the art that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. Particularly, it should be understood that the present invention may be embodied in the following forms.
The color of ink composition 15 may be limited to only black. Alternatively, the color of the ink composition 15 may be cyan, magenta, yellow, and so on.
The inorganic fiber mat 14 is cut out from each holding seal member 14a after printing. Alternatively, the printing may be performed by the printing apparatus 11 after each holding seal member 14a is cut out from the inorganic fiber mat 14.
Printing is performed on the surface of the inorganic fiber mat 14 by moving the conveying table 12 in the X direction and the liquid ejection device 13 in the Y direction. However, printing may also be performed by fixing the conveying table 12 and moving only the liquid ejection device 13. Printing may also be performed by fixing the liquid ejection device 13 and moving only the conveying table 12.
The number of liquid ejection heads 13a attached to the support 13b of the liquid ejection device 13 is not particularly limited, and may be one, or two or more taking into consideration the printing efficiency and the like. The order of printing on the inorganic fiber mat 14 is appropriately set taking into consideration the printing efficiency and the like.
The number of holding seal members cut out from the inorganic fiber mat is not particularly limited may be one or more than two.
The exhaust gas purifying body in which the holding seal member is used may be an exhaust gas purifying filter, which collects the PM of the diesel particulate filter (DPF) etc., or a catalyst carrier, which is formed by a ceramic filter and the like, for carrying the catalyst for purifying the exhaust gas.
The printing performed on the inorganic fiber mat 14 is not limited to the ink jet method, and may be a type printing such as gravure printing or relief printing employing a rolling transfer device that uses transfer rollers with projections formed on the surface or a pressing transfer device such as a stamper that uses a flat plate with projections formed on the surface.
The holding seal member 14a is wrapped around the entire circumferential surface of the exhaust gas purifying body 21, as shown in
The identification information is directly printed on the inorganic fiber mat 14 by the liquid ejection device 13. However, the identification information does not have to be directly printed on the inorganic fiber mat 14, and a seal member (label) or IC chip in which the identification information is recorded (written) may be attached to the inorganic fiber mat 14. In this case, the printing apparatus is unnecessary, and the identification information is easily provided.
An example of the identification information is a two dimensional code such as character, a number, a symbol, a barcode, a QR code (Quick Response Code) and the like. The content indicated by the identification information is not particularly limited, and may be a product name, a product number, a manufacturing serial number, basic weight, product type, weight, product size, vehicle type, inner or outer side distinguishing mark of the holding seal member, and etc.
The printing characters are printed on only one surface of the holding seal member. However, the position of the printing characters is not particularly limited, and the printing characters may be printed on both surfaces of the holding seal member, on only the rear surface of the holding seal member, on a side surface of the holding seal member, and so on.
Holding seal members for test examples 1 to 8 shown in table 1 were formed through the method described below and an ink absorption test and printing test were performed. The results are shown in table 1.
<Method for Manufacturing Alumina Silica Fiber Mat>
A basic aluminum chloride aqueous solution with alumina content of 75g/l and Al atom/Cl atom=1.8 was prepared. Silica sol was added to the aqueous solution to adjust the composition of the alumina fiber so that alumina:silica=72±2: 28±2, and alumina fiber precursor was prepared. An organic polymer such as polyvinyl alcohol was added to the alumina fiber precursor and then condensed to prepare a spinning solution. Fiber spinning was performed through a blowing method using the spinning solution. The spun fiber was cut to an average fiber length of 12 mm. The fiber precursors were folded and stacked to manufacture an alumina fiber stacked sheet. Needle punching process was then performed on the alumina fiber stacked sheet at a rate of 500 locations per 100 square centimeters. The stacked sheet was then heated, and continuously baked at a maximum temperature of 1250° C. to form a continuous stacked sheet of alumina fiber having a coating weight of 1160 g/square centimeter. The average diameter of the alumina fiber was 7.2 μm, and the minimum diameter was 3.2 μm. The continuous stacked sheet was then cut, the organic binders such as acrylic resins were absorbed, and the holding seal members of each test example shown in table 1 were formed.
<Ink Absorption Test>
Each holding seal member was cut into a strip. While supporting one end of the strip-shaped seal member, the other end was immersed in 20 ml of aqueous ink contained in a dish. The elapsed time from immersion and the rising height of the ink impregnated to the holding seal member were measured. The results are shown in table 1 and
<Print Test (Bleeding Test)>
The characters printed on the holding seal member of each test example using the ink jet printing device were visually checked by five observers and the bleeding of the characters was observed. The rating was made in three levels, with three points for when the printed character was not bleeding, two points for when slight bleeding was recognized, and one point for when bleeding was recognized. The average points were calculated as the rating results of the five observers and categorized into “excellent” when the average point was 2.6 points or greater, “satisfactory” when 1.6 points or greater and 2.5 points or less, and “poor” when 1.5 points or less. The evaluation result for the bleeding test is shown in table 1.
<Print Test (Adhesion Test)>
The characters printed on the holding seal member of each test example using the ink jet printing device were visually checked by five observers and the adhesion of the ink and the fiber was observed. The rating was made at three levels with three points for when the ink was sufficiently adhered to the fiber, two points for when adhesiveness was slightly unsatisfactory, and one point for when ink was not sufficiently adhered to the fiber. The average points were calculated as the rating results of the five observers and categorized into “excellent” when the average point was 2.6 points or greater, “satisfactory” when 1.6 points or greater and 2.5 points or less, and “poor” when 1.5 points or less. The evaluation result for the adhesion test is shown in table 1.
From the results shown in table 1, the ink rising height exceeded 45 cm when the organic binder was not impregnated. In this case, the wetness of the ink was too high for the holding seal member and the ink was impregnated in excess. As a result, the printed character was unclear. The ink rise height was less than 39 cm when the organic binder was 15% by mass (test example 4). In this case, the ink lacked in wetness and the ink did not sufficiently adhere to the fiber of the holding seal member. Thus, the printed character was unclear. In test examples 5 to 8 in which the average fiber diameter was 7.2 μm, the rising height of the ink was high compared to test examples 1 to 4 in which the average fiber diameter was 5.8 μm. The graph of
The present invention includes the structures described below.
(a) The printing apparatus for printing the identification information on the surface of the inorganic fiber holding seal member wrapped around the exhaust gas purifying body includes a liquid ejection device for printing identification information by ejecting liquid from the liquid ejection head.
(b) For the inorganic fiber mat from which the holding seal members are arranged in a plurality of columns that can be cut out, the holding seal member printing apparatus prints identification information on each column of holding seal members
With the devices of (a) and (b), the number of liquid ejection heads for ejecting liquid (ink composition) does not need to be changed even if the number of holding seal members to be cut out from one sheet of inorganic fiber mat is increased or decreased.
The present examples and embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalence of the appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2005-379936 | Dec 2005 | JP | national |
