Inorganic fiber-formed article, mat for exhaust gas cleaning apparatus, and exhaust gas cleaning apparatus

Patent metadata

Field	Value
Publication number	US-10024215-B2
Application number	US-201615558229-A
Country	US
Kind code	B2
Filing date	Mar 18, 2016
Priority date	Mar 23, 2015
Publication date	Jul 17, 2018
Grant date	Jul 17, 2018

Abstract

An inorganic fiber-formed article, composed of a mat-shaped inorganic fiber assembly, the inorganic fiber-formed article including needle marks that extend in a direction including a thickness direction of the mat-shaped inorganic fiber assembly, where the needle marks include needle marks A and needle marks B having a diameter smaller than that of the needle marks A, dense portions in which a plurality of the needle marks A lie densely are arranged apart, non-dense portions in which a needle mark density of the needle marks A is lower than that in the dense portions are present between the dense portions in both a first direction which is any mat-surface direction extending through the dense portions and a second direction orthogonal to the first direction, and the needle marks B are present at least in the non-dense portions.

First claim

The invention claimed is:

1. An inorganic fiber-formed article, comprising a mat-shaped inorganic fiber assembly, the inorganic fiber-formed article comprising:
needle marks that extend in a direction including a thickness direction of the mat-shaped inorganic fiber assembly,
wherein
the needle marks include needle marks A and needle marks B having a diameter smaller than that of the needle marks A,
dense portions in which a plurality of the needle marks A lie densely are arranged apart,
non-dense portions in which a needle mark density of the needle marks A is lower than that in the dense portions are present between the dense portions in both a first direction which is any mat-surface direction extending through the dense portions and a second direction orthogonal to the first direction, and
the needle marks B are present at least in the non-dense portions.

2. The inorganic fiber-formed article according to claim 1 , wherein the needle marks A have an average diameter of 450 to 700 μm, and an average diameter of the needle marks B is 35% to 65% of the average diameter of the needle marks A.

3. The inorganic fiber-formed article according to claim 1 , wherein the needle marks A are arranged in a row or in two rows in the dense portions.

4. The inorganic fiber-formed article according to claim 3 , wherein an arrangement direction of the needle marks A in each of the dense portions is substantially the same.

5. The inorganic fiber-formed article according to claim 4 , wherein a length of each of the dense portions is 2.0 to 12.0 mm on average, and a number of needle marks A in each of the dense portions is 3.0 to 8.0 on average.

6. The inorganic fiber-formed article according to claim 4 , wherein a distance (distance a) between dense portions adjacent to each other across the non-dense portions in the arrangement direction is 5.0 to 25.0 mm on average, and a distance (distance b) between dense portions adjacent to each other across the non-dense portions in a direction orthogonal to the arrangement direction is 4.0 to 15.0 mm on average.

7. The inorganic fiber-formed article according to claim 4 , wherein an arrangement pitch f of the needle marks B in the arrangement direction (Y direction) of the needle marks A in the dense portions is 0.5 to 1 time an arrangement pitch α of the dense portions in the Y direction.

8. The inorganic fiber-formed article according to claim 4 , wherein the needle marks B are arranged in a direction intersecting the arrangement direction of the needle marks A.

9. The inorganic fiber-formed article according to claim 8 , wherein an intersecting angle θ 1 between the direction in which rows of the needle marks B are arranged and the arrangement direction (Y direction) of the needle marks A is 90° to 175°.

10. The inorganic fiber-formed article according to claim 8 , wherein an intersecting angle θ 1 between the direction in which rows of the needle marks B are arranged and the arrangement direction of the needle marks A is more than 90° and less than 175°.

11. The inorganic fiber-formed article according to claim 10 , wherein the rows of the needle marks B are arranged in two intersecting directions.

12. The inorganic fiber-formed article according to claim 1 , wherein one or two rows of the needle marks B intersect each of the dense portions.

13. The inorganic fiber-formed article according to claim 1 , wherein the dense portions spread in two directions, an area of each of the dense portions is 2.0 to 36.0 mm 2 on average, and a needle mark density of the needle marks A in the dense portions is 20 to 300 marks/cm 2 on average.

14. The inorganic fiber-formed article according to claim 1 , wherein the needle marks B are present in both the dense portions and the non-dense portions.

15. The inorganic fiber-formed article according to claim 1 , wherein a needle mark density of the needle marks A is 1.0 to 50.0 marks/cm 2 on an average of the entire inorganic fiber-formed article.

16. The inorganic fiber-formed article according to claim 1 , wherein a needle mark density of the needle marks B is 1.0 to 80.0 marks/cm 2 on an average of the entire inorganic fiber-formed article.

17. The inorganic fiber-formed article according to claim 1 , wherein a ratio of a number of the needle marks B to a number of the needle marks A is 0.1 to 8.0 on an average of the entire inorganic fiber-formed article.

18. A mat, the mat comprising the inorganic fiber-formed article according to claim 1 .

19. An exhaust gas cleaning apparatus comprising a catalyst carrier, a casing that covers an outside of the catalyst carrier, and a mat interposed between the catalyst carrier and the casing, wherein the mat is the mat according to claim 18 .

Assignees

• Mitsubishi Chem Corp

Inventors

• Wakamatsu Toshihiro
• Kobayashi Tomoyuki

Classifications

• D10B2101/08

  Ceramic · CPC title

• D01D4/025

  Melt-blowing or solution-blowing dies · CPC title

• D04H1/46

  by needling or like operations to cause entanglement of fibres (D04H1/45 takes precedence; needling machines D04H18/00) · CPC title

• D01D7/00

  Collecting the newly-spun products ({D01D5/0076 takes precedence;} collecting newly-spun products with the imparting of twist D01H) · CPC title

• D04H1/4209 Primary

  Inorganic fibres · CPC title