SHEET MEMBER AND EXHAUST GAS PROCESSING DEVICE AND MANUFACTURING METHOD OF THE SAME

Abstract

A sheet member including inorganic fibers, the sheet member having multiple inter-woven points formed on at least either a surface or a back side of the sheet member by a needling process, wherein a density ρ of the inter-woven points is in a range about 0.5 number/cm2≦ρ

Description

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects, features and advantages of the present invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings, in which:

FIG. 1 is an example of a structure of the sheet member of the present invention;

FIG. 2 is a figure of constitution of the exhaust gas processing device, in which the sheet member of the present invention is used as holding sealer and the exhaust gas processing device is constructed;

FIG. 3 is a figure showing a method to place a covered exhaust gas processing body into the casing by the pressing method;

FIG. 4 is a figure showing a method to place a covered exhaust gas processing body into the casing by a clamshell method;

FIG. 5 is a figure showing a method to place a covered exhaust gas processing body into the casing by a winding and closing method;

FIG. 6 is a figure showing a method to place a covered exhaust gas processing body into the casing by the sizing method;

FIG. 7 is a figure showing the sheet member of the present invention, in which the inter-woven points are formed by other patterning;

FIG. 8 is a figure showing the sheet member of the present invention, in which the inter-woven points are formed by still other patterning;

FIG. 9 is a figure showing the sheet member of the present invention, in which the inter-woven points are formed by further other patterning;

FIG. 10 is a figure showing a method to gather a sample for the inter-woven point density from the sheet member which forms the inter-woven points in a vertical arrangement pattern;

FIG. 11 is a figure showing a flow chart of a manufacturing method of the exhaust gas processing device of an embodiment of the present invention by the pressing method;

FIG. 12 is a figure showing a flow chart of a manufacturing method of the exhaust gas processing device of an embodiment of the present invention by a non-pressing method;

FIG. 13 is a figure showing an example of a structure of the exhaust gas processing device of the present invention;

FIG. 14 is a schematic figure of a test apparatus which measures pressure of a surface;

FIG. 15 is a graph showing a relationship between the inter-woven point concentration and surface pressure of the sheet member;

FIG. 16 is a graph showing a relationship between the inter-woven point concentration and a reconstructed surface pressure after 1 cycle;

FIG. 17 is a graph showing a relationship between the inter-woven point concentration and a reconstructed surface pressure after 1000 cycle; and

FIG. 18 is a figure showing a relationship between a compressed speed and a compressed surface pressure which are obtained for the sheet member of each inter-woven point concentration case.

Claims

1. A sheet member including inorganic fibers, the sheet member having multiple inter-woven points formed on at least either a surface or a back side of the sheet member by a needling process, wherein a density ρ of the inter-woven points is in a range about 0.5 number/cm2≦ρ<about 20 number/cm2.

2. The sheet member as claimed in claim 1, wherein the inter-woven points are formed in a row pattern distributed in a whole area or all over the whole area on at least either the surface or the back side of the sheet member.

3. The sheet member as claimed in claims 1 or 2, wherein the sheet member comprises binders.

4. The sheet member as claimed in any one of claims 1 to 3, wherein the inorganic fibers are a mixture of alumina and silica.

5. An exhaust gas processing device comprising: an exhaust gas processing body,a holding sealer used with at least a portion of outer surfaces of the exhaust gas processing body, anda casing housing the exhaust gas processing body around which processing body is wound the holding sealer,wherein the holding sealer includes inorganic fibers in a sheet member having multiple inter-woven points formed on at least either a surface or a back side of the sheet member by a needling process,wherein a density ρ of the inter-woven points is in a range about 0.5 number/cm2≦ρ<about 20 number/cm2.

6. The exhaust gas processing device as claimed in claim 5, wherein the inter-woven points are formed in a row pattern distributed in a whole area or all over the whole area on at least either the surface or the back side of the sheet member.

7. The exhaust gas processing device as claimed in claims 5 or 6, wherein the exhaust gas processing body is a catalyst carrier or an exhaust gas filter.

8. The exhaust gas processing device as claimed in any one of claims 5 to 7, wherein the exhaust gas processing body around which processing body the holding sealer is wound is placed into the casing by a clamshell method, a winding and closing method, or a sizing method.

9. The exhaust gas processing device as claimed in any one of claims 5 to 7, wherein the density ρ of the inter-woven points is in a range about 5 number/cm2≦ρ<about 20 number/cm2, andthe exhaust gas processing body around which is wound the holding sealer is placed into the casing by a pressing method.

10. A manufacturing method of an exhaust gas processing device including an exhaust gas processing body, a holding sealer, and a casing housing the exhaust gas processing body and the holding sealer inside; wherein the manufacturing method comprises:a step of providing the holding sealer,a step of winding the holding sealer onto at least a part of an outer surface of the exhaust gas processing body, anda step of placing the exhaust gas processing body around which processing body is wound the holding sealer into the casing by a clamshell method, a winding and closing method, or a sizing method,wherein the holding sealer includes inorganic fibers in a sheet member having multiple inter-woven points formed on at least either a surface or a back side of the sheet member by a needling process,wherein a density ρ of the inter-woven points is in a range about 0.5 number/cm2≦ρ<about 20 number/cm2.

11. The manufacturing method of an exhaust gas processing device as claimed in claim 10, wherein the density ρ of the inter-woven points is in a range about 0.5 number/cm2≦ρ<about 15 number/cm2.

12. A manufacturing method of an exhaust gas processing device including an exhaust gas processing body, a holding sealer, and a casing housing the exhaust gas processing body and the holding sealer inside; wherein the manufacturing method comprises:a step of providing the holding sealer,a step of winding the holding sealer onto at least a part of an outer surface of the exhaust gas processing body, anda step of placing the exhaust gas processing body around which is wound the holding sealer into the casing by a pressing method,wherein the holding sealer includes inorganic fibers in a sheet member having multiple inter-woven points formed on at least either a surface or a back side of the sheet member by a needling process,wherein a density ρ of the inter-woven points is in a range about 5 number/cm2≦ρ<about 20 number/cm2.

13. The manufacturing method of an exhaust gas processing device as claimed in claim 12, wherein the density ρ of the inter-woven points is in a range about 5 number/cm2≦ρ<about 15 number/cm2.

14. The manufacturing method of an exhaust gas processing device as claimed in any one of claims 10 to 13, wherein the inter-woven points are formed in a row pattern distributed in a whole area or all over the whole area on at least either the surface or the back side of the sheet member.