HOLDING SEALING MATERIAL, METHOD FOR MANUFACTURING HOLDING SEALING MATERIAL, EXHAUSTED GAS PURIFYING APPARATUS, AND METHOD FOR MANUFACTURING EXHAUST GAS PURIFYING APPARATUS

• US 20140212340A1
• Filed: 04/02/2014
• Published: 07/31/2014
• Est. Priority Date: 10/05/2011
• Status: Active Grant

• Current Assignee: Ibiden Co., Ltd.
• Original Assignee: Ibiden Co., Ltd.
• Inventors: Saiki, Kenzo
• Granted Patent: US 9,638,084 B2
• Time in Patent Office: Days
• US Class Current: 422/179
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: D06H 7/00 Apparatus or processes for cutting, or otherwise severing, specially adapted for the cutting, or otherwise severing, of textile materials web delivery apparatus incorporating cutting devices B65H35/0006
• CPC Class Codes: F01N 3/0211 Arrangements for mounting filtering elements in housing, e.g. with means for compensating thermal expansion or vibration
• CPC Class Codes: F01N 3/2864 the mats or gaskets comprising two or more insulation layers
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A holding sealing material includes a one-sheet mat including inorganic fibers. The one-sheet mat includes a first mat with a first side face and a second mat with a second side face. A part of the first side face and a part of the second side face are foldably and integrally connected.

Claims

1. A holding sealing material comprising:

a one-sheet mat including inorganic fibers and comprising;

a first mat with a first side face; and

a second mat with a second side face, a part of said first side face and a part of said second side face being foldably and integrally connected.

2. The holding sealing material according to claim 1,

wherein a length of said first mat in a longitudinal direction is different from a length of said second mat in a longitudinal direction.

3. The holding sealing material according to claim 1,

wherein a portion where said first mat and said second mat are foldably connected is provided in a direction parallel to a longitudinal direction of said first mat and a longitudinal direction of said second mat.

4. The holding sealing material according to claim 3,

wherein the portion where said first mat and said second mat are foldably connected is from about 1/20 to about ⅓

a length of said one-sheet mat in a longitudinal direction.

5. The holding sealing material according to claim 3,

wherein the portion where said first mat and said second mat are foldably connected has a length of from about 5 to about 150 mm.

6. The holding sealing material according to claim 1,

wherein a portion where said first mat and said second mat are foldably connected is provided with a slit formed on at least one of a front face and a back face of said one-sheet mat in a thickness direction of said one-sheet mat.

7. The holding sealing material according to claim 6,

wherein a depth of said slit is from about ⅕

to about ⅘

a thickness of said one-sheet mat.

8. The holding sealing material according to claim 1,

wherein said first mat and said second mat each have a pair of fitting portions configured to fit to each other when the holding sealing material is wound around an exhaust gas treating body.

9. The holding sealing material according to claim 8,

wherein the pair of fitting portions of said first mat and the pair of fitting portions of said second mat each have a recessed portion and a projected portion, and arrangement of the recessed portion and projected portion of the first mat is different from arrangement of the recessed portion and projected portion of the second mat.

10. The holding sealing material according to claim 8,

wherein, when the holding sealing material is wound around a round pillar-shaped exhaust gas treating body, the pair of fitting portions of said first mat and the pair of fitting portions of said second mat satisfy a following formula (1) or (2), and the pair of fitting portions of said first mat and the pair of fitting portions of said second mat are located at different sites on an outer peripheral surface of the exhaust gas treating body, the formulas being:

when a≧

b×

L₁/L₂,

(b+c)×

L₁/L₂≦

a≦

(b−

c+L₂)×

L₁/L₂  

 

(1),

when a≦

b×

L₁/L₂,

(b+c−

L₂)×

L₁/L₂≦

a≦

(b−

c)×

L₁/L₂  

 

(2),

a;

distance from a “

starting position of the projected portion”

to a “

center of a connected portion”

of said first mat

b;

distance from a “

starting position of the projected portion”

to a “

center of a connected portion”

of said second mat

c;

length of the projected portion of each fitting portion

L₁;

length of said first mat in a longitudinal direction

L₂;

length of said second mat in a longitudinal direction.

11. The holding sealing material according to claim 1,

wherein two or more of portions where said first mat and said second mat are foldably connected are provided.

12. The holding sealing material according to claim 11,

wherein one of the portions where said first mat and said second mat are foldably connected is shorter and more scissile than another connected portion or connected portions.

13. The holding sealing material according to claim 1,

wherein said one-sheet mat has a thickness of from about 1.5 to about 15 mm.

14. The holding sealing material according to claim 1,

wherein said one-sheet mat further comprises identification information for identifying a folding direction on at least one surface.

15. The holding sealing material according to claim 1,

wherein a length of said first mat in a width direction perpendicular to a longitudinal direction is different from a length of said second mat in a width direction perpendicular to a longitudinal direction.

16. The holding sealing material according to claim 15,

wherein a difference between the length of said first mat in said width direction and the length of said second mat in said width direction is about 10 mm or less.

17. A method for manufacturing a holding sealing material, comprising:

preparing a mat material including inorganic fibers;

punching out from said mat material a one-sheet mat comprising a first mat with a first side face and a second mat with a second side face in such a manner that a part of said first side face and apart of said second side face are foldably and integrally connected; and

folding a portion where said first mat and said second mat are connected to layer said first mat and said second mat.

18. An exhausted gas purifying apparatus comprising:

an exhaust gas treating body;

a casing accommodating said exhaust gas treating body;

a holding sealing material wound around said exhaust gas treating body and placed between said exhaust gas treating body and said casing, said holding sealing material comprising;

a one-sheet mat including inorganic fibers and comprising;

a first mat with a first side face; and

a second mat with a second side face, a part of said first side face and a part of said second side face being foldably and integrally connected; and

the holding sealing material being placed between the exhaust gas treating body and the casing in such a manner that a portion where said first mat and said second mat are foldably connected is folded to layer said first mat and said second mat.

19. A method for manufacturing an exhaust gas purifying apparatus, comprising:

providing a holding sealing material, the holding sealing material comprising a one-sheet mat that includes inorganic fibers, said one-sheet mat comprising a first mat with a first side face and a second mat with a second side face, a part of said first side face and apart of said second side face being foldably and integrally connected, the holding sealing material being provided by folding a portion where said first mat and said second mat are foldably connected to layer said first mat and said second mat;

winding the holding sealing material around an exhaust gas treating body; and

accommodating said exhaust gas treating body wound with the holding sealing material in a casing.

20. A holding sealing material comprising a one-sheet mat that includes inorganic fibers, the one-sheet mat comprising:

a first rectangular mat being substantially rectangular in a plan view;

a second rectangular mat being substantially rectangular in a plan view and integrally connected to said first rectangular mat;

a border line between said first rectangular mat and said second rectangular mat being part of a side of a rectangle of said first rectangular mat in a plan view and part of a side of a rectangle of said second rectangular mat in a plan view; and

said first rectangular mat and said second rectangular mat being configured to be layered by folding said one-sheet mat along said border line.