Holding sealing material, exhaust gas purifying apparatus, and method of manufacturing exhaust gas purifying apparatus

• US 8,574,335 B2
• Filed: 01/17/2012
• Issued: 11/05/2013
• Est. Priority Date: 01/20/2011
• Status: Active Grant

• Current Assignee: Ibiden Co., Ltd.
• Original Assignee: Ibiden Co., Ltd.
• Inventors: Ando, Hisashi, Okabe, Takahiko
• Primary Examiner(s): ORLANDO, AMBER ROSE
• Application Number:
  US13/351,225
• Publication Number:
  US 20120186209A1
• Time in Patent Office: 658 Days
• Field of Search: 55522-524, 422169-172, 422177-182
• US Class Current: 55/523
• CPC Class Codes: F01N 13/008 Mounting or arrangement of exhaust sensors in or on exhaust apparatus sensor arrangements for engine control F02D41/1439
• 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 3/2853 using mats or gaskets between catalyst body and housing
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A holding sealing material includes inorganic fibers, a mat shape, a first end face and a second end face and a penetration portion. The mat shape has a width direction, a length direction and a thickness direction. The first end face and the second end face are each provided approximately in parallel with the width direction. The penetration portion penetrates the holding sealing material in the thickness direction.

Claims

1. A holding sealing material comprising:

inorganic fibers;

a mat shape having a width direction, a length direction and a thickness direction;

a first end face and a second end face each provided approximately in parallel with the width direction; and

a penetration portion penetrating the holding sealing material in the thickness direction,

wherein the penetration portion of the holding sealing material is formed diagonally with respect to the thickness direction of the holding sealing material.

2. The holding sealing material according to claim 1,

wherein the holding sealing material has two or more of the penetration portions.

3. The holding sealing material according to claim 2,

wherein the holding sealing material has a pair of the penetration portions among the two or more penetration portions at positions approximately line-symmetrical with respect to a center line of the holding sealing material in the width direction, at positions approximately line- symmetrical with respect to a center line of the holding sealing material in the length direction, or at positions approximately point-symmetrical with respect to a center of the holding sealing material.

4. The holding sealing material according to claim 3,

wherein the holding sealing material has the pair of the penetration portions at positions approximately line-symmetrical with respect to the center line of the holding sealing material in the width direction, and

a distance between the pair of the penetration portions is about 50% of a length of the holding sealing material in the length direction.

5. The holding sealing material according to claim 1,

wherein each of the first end face and the second end face of the holding sealing material is provided with a step having at least one projected portion.

6. The holding sealing material according to claim 5,

wherein the holding sealing material has the penetration portion at a position other than the projected portion of the holding sealing material.

7. The holding sealing material according to claim 1,

wherein a number of the penetration portion is one.

8. The holding sealing material according to claim 1,

wherein a shape of the penetration portion of the holding sealing material is at least one of an approximately round-pillar shape, an approximately rectangular-pillar shape, an approximately cylindroid shape, an approximately truncated cone shape, and a pillar shape having a bottom face surrounded by an approximately straight line and an approximately arc line.

9. The holding sealing material according to claim 1,

wherein a diameter of a cross section of the penetration portion of the holding sealing material is from about 1 mm to about 100 mm.

10. An exhaust gas purifying apparatus comprising:

a casing provided with a hole;

an exhaust gas-treating body housed in the casing;

a holding sealing material wound around the exhaust gas-treating body and disposed between the exhaust gas-treating body and the casing, comprising;

inorganic fibers;

a mat shape having a width direction, a length direction and a thickness direction;

a first end face and a second end face each provided approximately in parallel with the width direction; and

at least one penetration portion penetrating the holding sealing material in the thickness direction; and

a position of the penetration portion of the holding sealing material wound around the exhaust gas-treating body being identical with a position of the hole of the casing,

wherein the penetration portion of the holding sealing material is formed diagonally with respect to the thickness direction of the holding sealing material.

11. The exhaust gas purifying apparatus according to claim 10, further comprising:

at least one of an electrode member and a sensor which is connected to the exhaust gas- treating body, passes through the holding sealing material, and penetrates the casing,

wherein at least one of the electrode member and the sensor is disposed at the penetration portion of the holding sealing material and the hole of the casing.

12. The exhaust gas purifying apparatus according to claim 11, the exhaust gas purifying apparatus being manufactured by a method comprising:

housing the exhaust gas-treating body with the holding sealing material wound around the exhaust gas-treating body in the casing;

adjusting the position of the penetration portion of the holding sealing material wound around the exhaust gas-treating body with the hole of the casing; and

disposing at least one of the electrode member and the sensor in a manner connecting to the exhaust gas-treating body, passing through the holding sealing material and penetrating the casing,

wherein the exhaust gas-treating body with the holding sealing material is housed by stuffing the exhaust gas-treating body with the holding sealing material wound around the exhaust gas-treating body into the casing, or by inserting the exhaust gas-treating body with the holding sealing material wound around the exhaust gas-treating body in the casing and thereafter reducing an inner diameter of the casing, and

at least one of the electrode member and the sensor is disposed by disposing at least one of the electrode member and the sensor at the penetration portion of the holding sealing material and the hole of the casing.

13. The exhaust gas purifying apparatus according to claim 10,

wherein the holding sealing material has two or more of the penetration portions.

14. The exhaust gas purifying apparatus according to claim 13,

wherein the holding sealing material has a pair of the penetration portions among the two or more penetration portions at positions approximately line-symmetrical with respect to a center line of the holding sealing material in the width direction, at positions approximately line- symmetrical with respect to a center line of the holding sealing material in the length direction, or at positions approximately point-symmetrical with respect to a center of the holding sealing material.

15. The exhaust gas purifying apparatus according to claim 14,

wherein the holding sealing material has the pair of the penetration portions at positions approximately line-symmetrical with respect to the center line of the holding sealing material in the width direction, and

a distance between the pair of the penetration portions is about 50% of a length of the holding sealing material in the length direction.

16. The exhaust gas purifying apparatus according to claim 10,

wherein each of the first end face and the second end face of the holding sealing material is provided with a step having at least one projected portion.

17. The exhaust gas purifying apparatus according to claim 16,

wherein the holding sealing material has the penetration portion at a position other than the projected portion of the holding sealing material.

18. The exhaust gas purifying apparatus according to claim 10,

wherein a number of the penetration portion is one.

19. The exhaust gas purifying apparatus according to claim 10,

wherein a shape of the penetration portion of the holding sealing material is at least one of an approximately round-pillar shape, an approximately rectangular-pillar shape, an approximately cylindroid shape, an approximately truncated cone shape, and a pillar shape having a bottom face surrounded by an approximately straight line and an approximately arc line.

20. The exhaust gas purifying apparatus according to claim 10,

wherein a diameter of a cross section of the penetration portion of the holding sealing material is from about 1 mm to about 100 mm.

21. The exhaust gas purifying apparatus according to claim 10,

wherein the first end face and the second end face of the holding sealing material contact each other without a gap.

22. The exhaust gas purifying apparatus according to claim 10,

wherein the first end face and the second end face of the holding sealing material form a gap of a predetermined size.

23. The exhaust gas purifying apparatus according to claim 22,

wherein a distance between the first end face and the second end face of the holding sealing material is about 100 mm or less.

24. A method of manufacturing an exhaust gas purifying apparatus, comprising:

providing a holding sealing material which includes inorganic fibers, the holding sealing material having a mat shape which has a width direction, a length direction and a thickness direction, the holding sealing material having a first end face and a second end face each provided approximately in parallel with the width direction, the holding sealing material having at least one penetration portion penetrating the holding sealing material in the thickness direction;

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

housing the exhaust gas-treating body in a casing to dispose the holding sealing material between the exhaust gas-treating body and the casing having a hole; and

adjusting a position of the penetration portion of the holding sealing material wound around the exhaust gas-treating body with the hole of the casing,

wherein a diameter of a cross section of the penetration portion of the holding sealing material is from about 1 mm to about 100 mm.

25. The method according to claim 24, further comprising:

disposing at least one of an electrode member and a sensor in a manner connecting to the exhaust gas-treating body, passing through the holding sealing material, and penetrating the casing after the position of the penetration portion of the holding sealing material is adjusted,

wherein, at least one of the electrode member and the sensor is disposed by disposing at least one of the electrode member and the sensor at the penetration portion of the holding sealing material and the hole of the casing.

26. The method according to claim 24,

wherein the exhaust gas-treating body with the holding sealing material wound around the exhaust gas-treating body is housed in the casing before the position of the penetration portion of the holding sealing material is adjusted, and

the exhaust gas-treating body with the holding sealing material is housed by stuffing the exhaust gas-treating body with the holding sealing material wound around the exhaust gas- treating body into the casing, or by inserting the exhaust gas-treating body with the holding sealing material wound around the exhaust gas-treating body in the casing and thereafter reducing an inner diameter or the casing.

27. The method according to claim 24,

wherein two or more of the penetration portions are formed.

30. The method according to claim 24,

wherein each of the first end face and the second end face of the holding sealing material is provided with a step having of at least one projected portion.

31. The method according to claim 30,

wherein the penetration portion of the holding sealing material is formed at a position other than the projected portion of the holding sealing material.

32. The method according to claim 24,

wherein the penetration portion of the holding sealing material is formed diagonally with respect to the thickness direction of the holding sealing material.

33. The method according to claim 24,

wherein a number of the penetration portion is one.

34. The method according to claim 24,

wherein a shape of the penetration portion of the holding sealing material is at least one of an approximately round-pillar shape, an approximately rectangular-pillar shape, an approximately cylindroid shape, an approximately truncated cone shape, and a pillar shape having a bottom face surrounded by an approximately straight line and an approximately arc line.

35. The method according to claim 24,

wherein the first end face and the second end face of the holding sealing material contact each other without a gap.

36. The method according to claim 24,

wherein the first end face and the second end face of the holding sealing material form a gap of a predetermined size.

28. A method of manufacturing an exhaust gas purifying apparatus, comprising:

providing a holding sealing material which includes inorganic fibers, the holding sealing material having a mat shape which has a width direction, a length direction and a thickness direction, the holding sealing material having a first end face and a second end face each provided approximately in parallel with the width direction, the holding sealing material having at least one penetration portion penetrating the holding sealing material in the thickness direction;

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

housing the exhaust gas-treating body in a casing to dispose the holding sealing material between the exhaust gas-treating body and the casing having a hole; and

adjusting a position of the penetration portion of the holding sealing material wound around the exhaust gas-treating body with the hole of the casing,

wherein two or more of the penetration portions are formed, and

wherein a pair of the penetration portions among the two or more penetration portions are formed at positions approximately line-symmetrical with respect to a center line of the holding sealing material in the width direction, at positions approximately line-symmetrical with respect to a center line of the holding sealing material in the length direction, or at positions approximately point-symmetrical with respect to a center of the holding sealing material.

29. The method of according to claim 28,

wherein the pair of the penetration portions are formed at positions approximately line- symmetrical with respect to a center line of the holding sealing material in the width direction, and

a distance between the pair of the penetration portions is about 50% of a length of the holding sealing material in the length direction.

37. A method of manufacturing an exhaust gas purifying apparatus, comprising:

providing a holding sealing material which includes inorganic fibers the holding sealing material having a mat shape which has a width direction, a length direction and a thickness direction, the holding sealing material having a first end face and a second end face each provided approximately in parallel with the width direction, the holding sealing material having at least one penetration portion penetrating the holding sealing material in the thickness direction;

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

housing the exhaust gas-treating body in a casing to dispose the holding sealing material between the exhaust gas-treating body and the casing having a hole; and

adjusting a position of the penetration portion of the holding sealing material wound around the exhaust gas-treating body with the hole of the casing,

wherein the first end face and the second end face of the holding sealing material form a gap of a predetermined size, and

wherein a distance between the first end face and the second end face of the holding sealing material is about 100 mm or less.