JP6463884B2 - Exhaust gas purification device, heat insulating material, and method for manufacturing heat insulating material - Google Patents

Description

The present invention relates to an exhaust gas purification device, a heat insulating material, and a method for manufacturing the heat insulating material.

Conventionally, in order to purify harmful substances such as harmful gases contained in exhaust gas discharged from an internal combustion engine such as an engine, an exhaust gas purification device has been provided in the exhaust passage (exhaust pipe through which the exhaust gas flows) of the internal combustion engine. ing.
The exhaust gas purification apparatus has a structure in which a casing is provided in an exhaust passage of an internal combustion engine, and an exhaust gas treatment body is disposed in the casing. Examples of the exhaust gas treating body include a catalyst carrier or a diesel particulate filter (DPF).

A holding sealing material made of an inorganic fiber aggregate is wound around the exhaust gas treating body and disposed in the casing. This holding sealing material prevents the exhaust gas treating body from being damaged by contact with the casing covering the outer periphery due to vibrations or impacts caused by traveling of an automobile or the like, and exhaust gas from between the exhaust gas treating body and the casing. Is disposed mainly for the purpose of preventing leakage.

In order to improve the purification efficiency of harmful substances by the exhaust gas purification device in which the catalyst is supported on the exhaust gas treatment body, the exhaust passage of the internal combustion engine and the temperature of the exhaust gas are temperatures suitable for catalyst activation (hereinafter also referred to as catalyst activation temperature). ) Must be maintained.

An exhaust gas purification apparatus in which a catalyst is supported on an exhaust gas treating body cannot exhibit a sufficient catalytic action unless the temperature is raised until a predetermined catalyst activation temperature is reached.
For this reason, the exhaust gas purification device is required to have a heat retention performance that prevents the temperature of the exhaust gas treating body from being lowered.

Here, there is a case where heat dissipation from the cone part which is a metal member located on the exhaust gas inflow side of the exhaust gas purifying apparatus may be a problem. In Patent Document 1, a vacuum heat insulating chamber and a heat storage member are provided outside the cone part. An exhaust gas purification device is disclosed.

JP 2003-314264 A

The structure of the exhaust gas purifying apparatus described in Patent Document 1 is complicated, and there is a problem that labor and cost for manufacturing the apparatus become large. Further, if the vacuum state of the vacuum heat insulating portion is broken by vibration or the like, there is a possibility that the heat insulating effect thereafter will be reduced.

An object of the present invention is to provide an exhaust gas purification apparatus that can insulate a cone portion in an exhaust gas purification apparatus with a simple configuration.
In addition, the present invention is excellent in heat insulating performance of the outer peripheral surface of the casing and the outer peripheral surface of the cone portion, can cover both the casing and the cone portion without causing positional displacement, and has a high durability during use. It aims at providing the heat insulating material which can achieve, and the manufacturing method of the said heat insulating material.

In order to achieve the above object, an exhaust gas purification apparatus of the present invention comprises an exhaust gas treating body,
A cylindrical casing having a first end located on the exhaust gas inflow side and a second end located on the exhaust gas outflow side, and containing the exhaust gas treating body;
A holding sealing material wound around the exhaust gas treatment body and disposed between the exhaust gas treatment body and the casing;
A first cone member disposed on the first end portion side of the casing, the diameter of which is gradually reduced as the distance from the first end portion of the casing increases;
A cylindrical member disposed on the second end portion side of the casing, the second cone member having a diameter that gradually decreases with increasing distance from the second end portion of the casing;
An exhaust gas purifying apparatus comprising a heat insulating material covering an outer peripheral surface of the casing and an outer peripheral surface of the first cone member,
The heat insulating material comprises a mat containing inorganic fibers,
A casing heat insulating portion wound around the outer peripheral surface of the casing;
A first cone heat insulation portion covering the outer peripheral surface of the first cone member,
The casing heat insulating portion and the first cone heat insulating portion are characterized in that at least a part of each side surface is continuously connected.

In the exhaust gas purifying apparatus of the present invention, the heat insulating material includes a casing heat insulating portion and a first cone heat insulating portion, and the casing heat insulating portion is wound around the casing to keep the exhaust gas treating body and the casing warm. The cone heat insulation part covers the outer peripheral surface of the first cone member to keep the first cone member warm.
Since the first cone member is located on the exhaust gas inflow side, the temperature of the exhaust gas is high and the temperature needs to be kept high. In the exhaust gas purification apparatus of the present invention, the first cone member is the first cone heat insulation. Since it is covered with the part, the heat radiation from the first cone member can be suppressed.
With the above configuration, it is possible to insulate the first cone member in the exhaust gas purification apparatus with a simple configuration. Moreover, since it does not have a vacuum part, it is excellent also in durability at the time of use.
Furthermore, since the casing heat insulating portion and the first cone heat insulating portion are continuously connected, there is no positional shift, and the casing heat insulating portion and the first cone heat insulating portion are composed of one member, so that the exhaust gas purification apparatus is assembled. Excellent workability.

In the exhaust gas purifying apparatus of the present invention, it is desirable that the number of the first cone heat insulating portions is one.
Moreover, it is desirable that the shape of the first cone heat insulating portion is a shape obtained by removing a sector having the same central point and central angle as the sector from the sector and having a small radius, or a crescent shape.
When the first cone heat insulating portion has the above shape, one cone heat insulating portion can form substantially the same shape as the outer peripheral surface of the first cone member, and covers the outer peripheral surface of the first cone member. it can.

In the exhaust gas purifying apparatus of the present invention, it is desirable that the number of the first cone heat insulating portions is two or more. Moreover, as for each shape of the said 1st cone heat insulation part, it is desirable that it is a triangle, a trapezoid, or a fan shape.
When the first cone heat insulating portion has the above shape, two or more cone heat insulating portions can be combined to form the substantially same shape as the outer peripheral surface of the first cone member, and the outer peripheral surface of the first cone member. Can be covered.

In the exhaust gas purification apparatus of the present invention, it is desirable that the central axis of the first cone member is deviated from the central axis of the casing.
An eccentric exhaust gas purification apparatus in which the central axis of the cone member is shifted from the central axis of the casing is preferable because the space around the exhaust gas purification apparatus can be effectively used when mounted on the vehicle, and the degree of freedom in design increases.

In the exhaust gas purification apparatus of the present invention, it is desirable that a slit is provided in the thickness direction of the heat insulating material at a portion where the casing heat insulating portion and the first cone heat insulating portion are continuously connected.
When the slit is provided, a portion where the casing heat insulating portion and the first cone heat insulating portion are continuously connected can be easily bent, so that the first cone heat insulating portion is the outer periphery of the first cone member. It becomes easy to arrange along the surface.

In the exhaust gas purifying apparatus of the present invention, it is desirable that the surface of the casing heat insulating part and the surface of the first cone heat insulating part be subjected to fiber scattering suppression treatment.
It is preferable that fiber scattering suppression treatment, such as application of an inorganic binder, is performed on the above portion, since fiber scattering is suppressed during the assembly operation of the exhaust gas purification device and when the exhaust gas purification device is used.

In the exhaust gas purifying apparatus of the present invention, it is desirable that a cover member is further provided to cover the surface of the casing heat insulating part and the surface of the first cone heat insulating part.
The cover member is preferably a three-dimensional molded body, and the cover member is preferably a metal foil or a metal mesh.
It is preferable to provide such a cover member because fiber scattering is suppressed during the assembly operation of the exhaust gas purification device and when the exhaust gas purification device is used.

In the exhaust gas purification apparatus of the present invention, the heat insulating material is
A second cone heat insulating portion covering the outer peripheral surface of the second cone member;
It is desirable that at least a part of each side surface of the casing heat insulating portion and the second cone heat insulating portion are continuously connected.
With the above configuration, the heat radiation from the second cone member located on the exhaust gas outflow side of the exhaust gas purification apparatus can be suppressed by the second cone heat insulating portion.
Moreover, since the 2nd cone heat insulation part is continuously connected with the casing heat insulation part, it does not produce position shift, and the casing heat insulation part, the 1st cone heat insulation part, and the 2nd cone heat insulation part are from one member. Therefore, the workability of assembling the exhaust gas purification device is excellent.

In the exhaust gas purifying apparatus of the present invention, it is desirable that the number of the second cone heat insulating portions is one.
In addition, the shape of the second cone heat insulating part is preferably a shape obtained by removing a sector having the same central point and central angle as the sector from the sector and having a small radius, or a crescent shape.

In the exhaust gas purifying apparatus of the present invention, it is desirable that the number of the second cone heat insulating portions is two or more. Moreover, as for each shape of the said 2nd cone heat insulation part, it is desirable that it is a triangle, trapezoid, or a fan shape.

In the exhaust gas purification apparatus of the present invention, a straight pipe member, which is a cylindrical member having a constant diameter, is disposed at the end of the second cone member opposite to the casing side.
The insulation material is
It further comprises a strip portion wound around the outer peripheral surface of the straight pipe member,
It is desirable that at least a part of each side surface of the second cone heat insulating portion and the strip portion are continuously connected.
With the above configuration, the heat radiation from the straight pipe member positioned on the exhaust gas outflow side further from the second cone member can be suppressed by the strip portion.
Further, since the strip portion is also continuously connected to the second cone heat insulating portion, there is no displacement, and the casing heat insulating portion, the first cone heat insulating portion, the second cone heat insulating portion, and the strip portion are one. Since it consists of members, it is excellent in workability of assembling the exhaust gas purification device.

The heat insulating material of the present invention comprises a mat containing inorganic fibers,
A substantially rectangular casing heat insulating portion in plan view having a long side extending in the longitudinal direction and a short side substantially perpendicular to the long side;
The first casing heat insulating part side surface which is one of the side surfaces on the long side of the casing heat insulating part and the second casing heat insulating part side surface which is the side surface on the long side opposite to the first casing heat insulating part side surface. The first casing heat insulating portion side surface and at least a part of the first cone heat insulating portion continuously connected,
When the heat insulating material is rolled into a cylindrical shape so that the two short sides of the casing heat insulating portion are in contact with each other, the diameter of the cone cylindrical portion formed as a space surrounded by the first cone heat insulating portion is It is characterized in that it gradually decreases as the distance from the side surface of the first casing heat insulating portion increases.

When the heat insulating material of the present invention is used, both the casing and the cone member can be covered with a single heat insulating material without causing positional displacement, and the cone portion in the exhaust gas purifying apparatus is insulated with a simple configuration. Can do. Moreover, the heat insulation structure with high durability at the time of use can be provided.
Furthermore, since it can be flat when stored and transported, it becomes a heat insulating material with high storage and transport efficiency.

In the heat insulating material of the present invention, the number of the first cone heat insulating portions is preferably one. Moreover, it is desirable that the shape of the first cone heat insulating portion is a shape obtained by removing a sector having the same central point and central angle as the sector from the sector and having a small radius, or a crescent shape.
When the first cone heat insulating portion has the above shape, one cone heat insulating portion can form the same shape as the outer peripheral surface of the cone member, and the outer peripheral surface of the cone member can be covered.

In the heat insulating material of the present invention, the number of the first cone heat insulating portions is preferably two or more. Moreover, as for each shape of the said 1st cone heat insulation part, it is desirable that it is a triangle, a trapezoid, or a fan shape.
When the 1st cone heat insulation part is the said shape, two or more cone heat insulation parts can be combined, and the substantially same shape as the outer peripheral surface of a cone member can be formed, and the outer peripheral surface of a cone member can be covered.
Moreover, since the length from the 1st casing heat insulation part side surface to the furthest position of a cone heat insulation part becomes short compared with the case where the number of cone heat insulation parts is made into one, it punches from a sheet | seat and produces a heat insulating material. The material yield is improved.

In the heat insulating material of the present invention, the shape of the first cone heat insulating portion is such that when the heat insulating material is rolled into a cylindrical shape so that the two short sides of the casing heat insulating portion are in contact with each other, It is desirable that the central axis is shifted from the central axis of the cylindrical portion surrounded by the casing heat insulating portion.
With the above configuration, it can be suitably used for an eccentric exhaust gas purification apparatus in which the central axis of the cone member is shifted from the central axis of the casing.

In the heat insulating material of the present invention, it is desirable that a slit is provided in a thickness direction of the heat insulating material at a portion where the casing heat insulating portion and the first cone heat insulating portion are continuously connected.
When the slit is provided, the portion where the casing heat insulating portion and the first cone heat insulating portion are continuously connected can be easily bent, so that the first cone heat insulating portion is arranged along the outer peripheral surface of the cone member. It becomes easy to arrange.

In the heat insulating material of the present invention, it is preferable that the surface of the casing heat insulating portion and the surface of the first cone heat insulating portion are subjected to fiber scattering suppression treatment.
When the surface of the casing heat insulating portion and the surface of the first cone heat insulating portion are subjected to fiber scattering suppression processing such as application of an inorganic binder, fiber scattering is suppressed during the assembly operation of the exhaust gas purification device and when the exhaust gas purification device is used. Therefore, it is preferable.

It is desirable that the heat insulating material of the present invention further includes a second cone heat insulating portion continuously connected to the side surface of the second casing heat insulating portion.
With the above configuration, both the first cone member located on the exhaust gas inflow side and the second cone member located on the exhaust gas outflow side can be covered with the cone heat insulating portion without causing a positional shift.
Moreover, since the casing heat insulating part, the first cone heat insulating part, and the second cone heat insulating part are made of one member, the workability of assembling the exhaust gas purification apparatus is excellent.

In the heat insulating material of the present invention, the number of the second cone heat insulating portions is preferably one.
In addition, the shape of the second cone heat insulating part is preferably a shape obtained by removing a sector having the same central point and central angle as the sector from the sector and having a small radius, or a crescent shape.

In the heat insulating material of the present invention, the number of the second cone heat insulating portions is preferably two or more.
Moreover, as for each shape of the said 2nd cone heat insulation part, it is desirable that it is a triangle, trapezoid, or a fan shape.

The heat insulating material of the present invention is a strip portion having a substantially rectangular shape in plan view, continuously connected on the side surface located on the opposite side to the side surface connected to the casing heat insulating portion among the side surfaces of the second cone heat insulating portion. It is desirable to further include.
With the above configuration, the outer peripheral surface of the straight pipe member positioned further on the exhaust gas outflow side from the second cone member can be covered with the strip portion without causing a positional shift.
Moreover, since the casing heat insulating part, the first cone heat insulating part, the second cone heat insulating part, and the strip part are made of one member, the workability of assembling the exhaust gas purification apparatus is excellent.

The method for manufacturing a heat insulating material of the present invention is a method for manufacturing a heat insulating material of the present invention,
It is characterized by performing a step of punching out the heat insulating material from one sheet so that all the parts constituting the heat insulating material are connected.
If it is the said method, the heat insulating material which can cover both the outer peripheral surface of a casing and the outer peripheral surface of a cone member can be manufactured by a simple method.

FIG. 1 is a perspective view schematically showing an example of the heat insulating material of the present invention. FIG. 2 is a perspective view schematically showing an example of a state in which the heat insulating material is rolled into a cylindrical shape so that two short sides of the casing heat insulating portion of the heat insulating material shown in FIG. 1 are in contact with each other. FIG. 3 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus of the present invention. FIG. 4 is a top view schematically showing another example of the heat insulating material of the present invention. FIG. 5 is a top view schematically showing another example of the heat insulating material of the present invention. FIG. 6A and FIG. 6B are top views schematically showing another example of the heat insulating material of the present invention. FIG. 7 is a cross-sectional view schematically showing an example of an exhaust gas purifying apparatus having an eccentric cone. FIG. 8 is a top view schematically showing another example of the heat insulating material of the present invention. FIG. 9A and FIG. 9B are top views schematically showing another example of the heat insulating material of the present invention. FIG. 10 is a cross-sectional view schematically showing an example of an exhaust gas purifying apparatus having a cover member. FIG. 11A and FIG. 11B are perspective views schematically showing how the exhaust gas purification apparatus shown in FIG. 10 is assembled. FIG. 12 is a top view schematically showing an example of the heat insulating material of the present invention including the second cone heat insulating portion. Fig.13 (a) is sectional drawing which shows typically an example of the exhaust gas purification apparatus of this invention by which the outer peripheral surface of the 2nd cone member is covered with the 2nd cone heat insulation part, FIG.13 (b) These are sectional drawings which show typically the example of the exhaust gas purification device which has the cover member which covers from the surface of the 1st cone heat insulation part to the surface of the 2nd cone heat insulation part. FIG. 14 is a top view schematically showing an example of the heat insulating material of the present invention having a strip portion. FIG. 15 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus of the present invention in which the outer peripheral surface of the straight pipe member is covered with a strip portion. FIG. 16 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus of the present invention having a cover member that covers from the surface of the first cone heat insulating portion to the surface of the strip portion. FIG. 17 is a top view schematically showing an example of the heat insulating material of the present invention in which another cone heat insulating portion and another casing heat insulating portion are connected to the strip portion. FIG. 18 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus of the present invention having two exhaust gas treating bodies.

(Detailed description of the invention)
Hereinafter, the exhaust gas purifying apparatus of the present invention and the heat insulating material of the present invention will be specifically described. However, the present invention is not limited to the following configurations, and can be applied with appropriate modifications without departing from the scope of the present invention. Note that the present invention also includes a combination of two or more desirable configurations of the present invention described below.

The exhaust gas purification apparatus of the present invention includes an exhaust gas treatment body,
A cylindrical casing having a first end located on the exhaust gas inflow side and a second end located on the exhaust gas outflow side, and containing the exhaust gas treating body;
A holding sealing material wound around the exhaust gas treatment body and disposed between the exhaust gas treatment body and the casing;
A first cone member disposed on the first end portion side of the casing, the diameter of which is gradually reduced as the distance from the first end portion of the casing increases;
A cylindrical member disposed on the second end portion side of the casing, the second cone member having a diameter that gradually decreases with increasing distance from the second end portion of the casing;
An exhaust gas purifying apparatus comprising a heat insulating material covering an outer peripheral surface of the casing and an outer peripheral surface of the first cone member,
The heat insulating material comprises a mat containing inorganic fibers,
A casing heat insulating portion wound around the outer peripheral surface of the casing;
A first cone heat insulation portion covering the outer peripheral surface of the first cone member,
The casing heat insulating portion and the first cone heat insulating portion are characterized in that at least a part of each side surface is continuously connected.

FIG. 1 is a perspective view schematically showing an example of the heat insulating material of the present invention.
As will be described later, the heat insulating material shown in FIG. 1 is a heat insulating material that can be used in the exhaust gas purifying apparatus of the present invention.
A heat insulating material 10 shown in FIG. 1 is a casing heat insulating portion having a substantially rectangular shape in plan view, which has a long side 21 extending in a longitudinal direction (a direction indicated by a double arrow a in FIG. 1) and a short side 22 substantially perpendicular to the long side 21. 20
On one short side 22, a convex portion 23 and a concave portion 24 are formed. The convex portion 23 and the concave portion 24 are shaped so as to fit each other when the casing heat insulating portion 20 is wound around the outer peripheral surface of the casing in the exhaust gas purifying apparatus described later.
The substantially rectangular shape in plan view as the shape of the casing heat insulating portion 20 means that the shape of the casing heat insulating portion is rectangular when the shape of the entire casing heat insulating portion is viewed without considering the shapes of the convex portions and the concave portions.
Since the convex portion 23 and the concave portion 24 are formed on the short side 22, the short side 22 is not a side consisting of a single straight line, but the short side 22 is almost aligned with the long side 21 when the heat insulating material is viewed in plan. It can be said that it is a right-angled side.
In this specification, the length of a heat insulating material is defined as the length of a long side. The length of the long side is a length determined by ignoring the shapes of the convex portion and the concave portion, and is a length determined by a double-headed arrow L in FIG.

Two side surfaces on the long side 21 side of the casing heat insulating portion 20 are a first casing heat insulating portion side surface 25 and a second casing heat insulating portion side surface 26.
Among these, the 1st cone heat insulation part 30 is connected to the 1st casing heat insulation part side surface 25 continuously.
In the heat insulating material of the present invention, the number of the first cone heat insulating portions may be one or two or more.
In the heat insulating material 10, a plurality (six) of the first cone heat insulating portions 30 are provided, and each shape of the first cone heat insulating portion 30 is a trapezoid. The trapezoidal shape is such that the side connected to the first casing heat insulating part side surface 25 is a long base 31, the side away from the first casing heat insulating part side 25 is a short base 32, and one of the trapezoidal shapes It has a shape having a side 33 corresponding to a leg and a side 34 corresponding to the other leg.
In the present specification, “the shape of the cone heat insulating portion” means a shape when the cone heat insulating portion is viewed in plan.
In the heat insulating material of the present invention, since the first cone heat insulating portion and the casing heat insulating portion are continuously connected, they are usually the same material and are mat-like members having the same thickness.

Further, it is desirable that a slit 35 is provided in the thickness direction of the heat insulating material 10 at a portion where the casing heat insulating portion 20 of the heat insulating material 10 and the first cone heat insulating portion 30 are continuously connected.
The slit 35 is a cut provided to facilitate the folding of the cone heat insulating portion when the heat insulating material is rolled into a cylindrical shape to bend the cone heat insulating portion. The depth of the slit is preferably 20 to 80% of the thickness of the heat insulating material.

Moreover, it is desirable that the surface of the casing heat insulating part and the surface of the first cone heat insulating part be subjected to fiber scattering suppression treatment. In FIG. 1, the surface of the casing heat insulating portion that has been subjected to fiber scattering suppression processing is shown as a fiber scattering suppression processing portion 27, and the surface of the first cone heat insulating portion that has been subjected to fiber scattering suppression processing is the fiber scattering suppression processing portion 37. Are shown with hatching.
Moreover, it is desirable that fiber scattering suppression processing is also performed on the side surface of the first cone heat insulating portion exposed when the heat insulating material is rolled into a cylindrical shape and the cone heat insulating portion is bent. In FIG. 1, the surface of the 1st cone heat insulation part in which the fiber scattering suppression process is carried out is shown as a fiber scattering suppression process part 38 by hatching.
Examples of the fiber scattering suppression treatment include a treatment such as a coating of an inorganic binder (alumina sol, silica sol) on the heat insulating material. By performing the fiber scattering suppression treatment, erosion of inorganic fibers can be prevented.

The heat insulating material of the present invention comprises a mat containing inorganic fibers. The inorganic fibers constituting the mat are not particularly limited, and may be alumina-silica fibers, alumina fibers, silica fibers, or the like. Moreover, glass fiber and biosoluble fiber may be sufficient. What is necessary is just to change according to the characteristics requested | required of mat | matte, such as heat resistance and wind erosion resistance, and it is preferable to use the thing of the large diameter fiber and fiber length which can be adapted to the environmental regulation of each country.

Among these, low crystalline alumina inorganic fibers are desirable, and low crystalline alumina inorganic fibers having a mullite composition are more desirable. In addition, inorganic fibers containing a spinel compound are more preferable.

Further, in the case of inorganic fibers containing a low crystalline alumina and a spinel type compound, the crystallization ratio is preferably in the range of 0.1 to 30%, and more preferably in the range of the crystallization rate of 0.4 to 20%. The method for measuring the crystallization rate can be calculated from the integral intensity ratio of the mullite diffraction line (2θ = 26.4 °) and the γ-alumina diffraction line (2θ = 45.4 °).

The mat constituting the heat insulating material can be obtained by various methods, and can be manufactured by, for example, a needling method or a papermaking method.
In particular, a needle mat obtained by subjecting a base mat made of inorganic fibers to needle punching is desirable. The needle punching process refers to inserting and removing fiber entanglement means such as a needle with respect to the base mat.

In order to exhibit the entangled structure, the inorganic fibers constituting the mat obtained by the needling method have a certain average fiber length, for example, the average fiber length of the inorganic fibers is preferably 1 to 150 mm, More preferably, it is 10-80 mm.
If the average fiber length of the inorganic fiber is less than 1 mm, the fiber length of the inorganic fiber is too short, so that the entanglement between the inorganic fibers becomes insufficient, the winding property to the outer peripheral surface of the casing is lowered, and the heat insulating material is easily cracked. Become. Moreover, since the fiber length of an inorganic fiber will be too long when the average fiber length of an inorganic fiber exceeds 150 mm, since the number of fibers which comprise a heat insulating material will reduce, the compactness of a mat | matte will fall. As a result, the shear strength of the heat insulating material is lowered.

The average fiber length of the inorganic fibers constituting the mat obtained by the papermaking method is preferably 0.1 to 20 mm.
When the average fiber length of the inorganic fiber is less than 0.1 mm, the fiber length of the inorganic fiber is too short, so that the characteristics as a fiber are no longer substantially exhibited. Tangle is unlikely to occur. In addition, when the average fiber length of the inorganic fibers exceeds 20 mm, the fiber length of the inorganic fibers is too long, so that the entanglement of the fibers in the slurry solution in which the fibers are dispersed in water in the paper making process becomes too strong. When it is set as an aggregate, the fibers are likely to be accumulated unevenly.

Also, the basis weight of the heat insulating material (weight per unit area) is not particularly limited, is preferably a 200~4000g / ^{m 2,} and more desirably 1000 to 3000 g / ^{m 2.}
The thickness of the heat insulating material is desirably 5 to 15 mm.

FIG. 2 is a perspective view schematically showing an example of a state in which the heat insulating material is rolled into a cylindrical shape so that two short sides of the casing heat insulating portion of the heat insulating material shown in FIG. 1 are in contact with each other.
As will be described later, the heat insulating material of the present invention is used by winding the casing heat insulating portion around the outer peripheral surface of the casing.
The shape shown in FIG. 2 corresponds to the shape of the heat insulating material 10 when the casing heat insulating portion 20 is wound around the outer peripheral surface of the casing.
Since the two short sides 22 of the casing heat insulating portion 20 of the heat insulating material 10 are provided with the convex portion 23 and the concave portion 24, when the heat insulating material is rolled into a cylindrical shape so that the short sides 22 are in contact with each other, the convex portion 23 is provided. And the recess 24 are fitted into each other.
The first cone heat insulating portion 30 is rounded so that the side 33 corresponding to one leg of the trapezoid which is the shape of each first cone heat insulating portion 30 and the side 34 corresponding to the other leg are in contact with each other between adjacent trapezoids, As a result, a cone cylindrical portion 36 that is a space surrounded by the first cone heat insulating portion 30 is formed. The diameter of the cone tubular portion 36 is the largest at the first casing heat insulating portion side surface 25 and is the same as the inner diameter of the cylinder formed by the casing heat insulating portion 20, but gradually becomes smaller as the distance from the first casing heat insulating portion side surface 25 increases. Become.

Hereinafter, the exhaust gas purification apparatus provided with the heat insulating material of the present invention shown in FIGS. 1 and 2 will be described.
FIG. 3 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus of the present invention.
In the exhaust gas purification apparatus 100 shown in FIG. 3, the exhaust gas treatment body 120 is accommodated in a cylindrical casing 130. In FIG. 3, the direction in which the exhaust gas flows is indicated by an arrow G, and the casing 130 has a first end 131 located on the exhaust gas inflow side and a second end 132 located on the exhaust gas outflow side.
A first cone member 140 is disposed on the first end 131 of the casing 130 by joining means such as welding. The first cone member 140 is a cylindrical member whose shape gradually decreases as the diameter of the first cone member 140 increases from the first end 131 of the casing 130.
A second cone member 150 is disposed on the second end portion 132 of the casing 130 by a joining means such as welding, and the second cone member 150 has a diameter of the second end of the casing 130. It is a cylindrical member having a shape that gradually decreases with distance from the portion 132.

Inside the exhaust gas purification apparatus 100, a holding sealing material 110 is wound around the exhaust gas processing body 120, and the holding sealing material 110 is disposed between the exhaust gas processing body 120 and the casing 130.
The holding sealing material 110 is a mat containing inorganic fibers. The shape of the holding sealing material 110 is a substantially rectangular shape having a concave portion and a convex portion, similarly to the shape of the casing heat insulating portion 20 of the heat insulating material 10, and the holding sealing material 110 is wound around the exhaust gas treatment body 120. At this time, it is desirable that the concave portion and the convex portion of the holding sealing material 110 are fitted to each other.

The exhaust gas treating body 120 shown in FIG. 3 is a ceramic honeycomb structure such as a porous ceramic, and is used as a catalyst carrier. In the catalyst carrier, the exhaust gas flows into the through hole 125 having both the exhaust gas inflow side end surface 120 a and the exhaust gas outflow side end surface 120 b opened, and the exhaust gas is purified by the action of the catalyst supported on the partition wall 126 separating the through hole 125.
Further, the exhaust gas treating body may be a DPF (diesel particulate filter) in which either end of the through hole is alternately sealed.
The material constituting the exhaust gas treating body is not particularly limited, and non-oxides such as silicon carbide and silicon nitride, and oxides such as cordierite and aluminum titanate can be used.
Since these porous fired bodies are brittle materials, they are easily broken by a mechanical impact or the like. However, in the exhaust gas purifying apparatus of the present invention, the holding sealing material 110 is interposed around the side surface of the exhaust gas treatment body 120 to absorb the impact, so that the exhaust gas treatment body 120 is cracked by a mechanical impact or a thermal shock. It can be prevented from occurring.

The first cone heat insulation portion 30 continuously connected to the casing heat insulation portion 20 covers at least a part of the outer peripheral surface 141 of the first cone member 140. The first cone heat insulating part 30 desirably covers the entire outer peripheral surface 141 of the first cone member 140. In the exhaust gas purification apparatus 100 shown in FIG. 3, the heat insulating material 10 has the shape shown in FIG. Therefore, the entire outer peripheral surface 141 of the first cone member 140 is covered with the first cone heat insulating portion 30.

In the exhaust gas purification apparatus 100, the slit 35 of the heat insulating material 10 is located in the vicinity of the first end 131 of the casing 130, and the first cone heat insulating part 30 is bent along the shape of the first cone member 140. Yes.
Further, a fiber scattering suppression processing unit 27 and a fiber scattering suppression processing unit 37 are provided on the surface of the casing heat insulating unit 20 and the surface of the first cone member 30, respectively. A fiber scattering suppression processing unit 38 is also provided on the side surface of the first cone member 30.

The exhaust gas purification apparatus of the present invention can be assembled as follows, for example.
First, a wound body in which a holding sealing material is wound around the exhaust gas treating body is prepared, and the wound body is press-fitted into the casing. Subsequently, the first cone member and the second cone member are joined to the first end and the second end of the casing by welding or the like, respectively. Then, while winding the casing heat insulation part of the heat insulating material of this invention around the outer peripheral surface of a casing, the exhaust gas purification apparatus of this invention is manufactured by covering the outer peripheral surface of a 1st cone member with a 1st cone heat insulation part. be able to.
The first cone member and the second cone member are formed by preparing a long cylinder including a portion serving as the first cone member and the second cone member as a cylindrical casing and winding it. After the body is press-fitted, the first end side and the second end side of the casing may be processed into a cone shape by spinning (drawing).

Another example of the heat insulating material of the present invention that can be used in the exhaust gas purifying apparatus as shown in FIG. 3 will be described below.
4, 5 and 6 (a) and 6 (b) are top views schematically showing another example of the heat insulating material of the present invention.
The heat insulating material 11 shown in FIG. 4 has the same shape as the heat insulating material 10 shown in FIG. 1 except that each shape of the first cone heat insulating portion 40 is a triangle.
Moreover, the heat insulating material 12 shown in FIG. 5 is the same shape as the heat insulating material 10 shown in FIG. 1 except that each shape of the 1st cone heat insulation part 41 is a fan shape.
When the shape of the first cone heat insulating portion is a triangle or a sector, when the heat insulating material is rolled into a cylindrical shape, the sides of the adjacent first cone heat insulating portions do not touch each other. It is desirable to define When the triangular or fan-shaped shape is defined so that the sides of the adjacent first cone heat-insulating portions are in contact with each other, the tip of the cone cylindrical portion has a sharp shape, but the tip of the first cone member has a sharp shape. This is because it is not preferable that the cone cylindrical portion has a sharp tip.
In the heat insulating material 11 and the heat insulating material 12, when the heat insulating materials are rolled into a cylindrical shape, if the sides of the adjacent first cone heat insulating portions are not in contact with each other, a gap is generated between the first cone heat insulating portions. . Therefore, when it is set as the exhaust gas purification apparatus using these heat insulating materials, a part of the outer peripheral surface is covered with the first cone heat insulating portion instead of the entire outer peripheral surface of the first cone member.

The heat insulating material 13 shown to Fig.6 (a) is an example of the heat insulating material in which the number of 1st cone heat insulation parts is one. Others are the same shape as the heat insulating material 10 shown in FIG.
The 1st cone heat insulation part 42 of the heat insulating material 13 is the shape remove | excluding from the sector shape the sector shape with the same center point and central angle as the sector shape and a small radius. The first cone heat insulating part 42 is connected to the first casing heat insulating part side face 25 of the casing heat insulating part 20 only at a part thereof.
Even when such a heat insulating material 13 is rolled up into a cylindrical shape, the diameter of the cone cylindrical portion formed as a space surrounded by the first cone heat insulating portion 42 increases as the distance from the first casing heat insulating portion side surface 25 increases. The shape becomes gradually smaller.

FIG. 6B shows a modification of the heat insulating material shown in FIG.
The heat insulating material 13 ′ shown in FIG. 6B is the first cone heat insulating portion 42 of the heat insulating material 13 shown in FIG. 6A, and the first cone heat insulating portion 42 is the first casing of the casing heat insulating portion 20. The shape is such that the first cone heat insulating portions 42 a and 42 b are divided into two at the point where they are connected to the heat insulating portion side surface 25, and the divided first cone heat insulating portions 42 a and 42 b are arranged at both ends of the first casing heat insulating portion side surface 25.
In this way, the shape of the cone heat insulating part is a shape obtained by excluding a fan shape having the same central point and central angle as the fan shape and a small radius from the fan shape as a whole. It is included in “a shape excluding a sector having the same central point and central angle and a small radius from the sector”. Moreover, the number of cone heat insulation parts in this case is counted as one.

The exhaust gas purification apparatus of the present invention may be an exhaust gas purification apparatus having a so-called eccentric cone in which the central axis of the first cone member is shifted from the central axis of the casing. An exhaust gas purifying apparatus having an eccentric cone and a heat insulating material suitable for such an exhaust gas purifying apparatus will be described below.

FIG. 7 is a cross-sectional view schematically showing an example of an exhaust gas purifying apparatus having an eccentric cone.
The central axis of the casing is in the longitudinal direction of the casing (the direction indicated by the double-headed arrow b in FIG. 7 and the direction parallel to the flow direction of the exhaust gas) at the first end and the second end of the casing. It is the axis | shaft which connects the gravity center of the shape of the cross section of the casing cut | disconnected by the vertical cross section, respectively.
In the exhaust gas purifying apparatus 200 shown in FIG. 7, the central axis of the casing 130 is indicated by a one-dot chain line 133.

The central axis of the first cone member is at both ends of the first cone member, that is, at the end on the first end side of the casing and at the end farthest from the first end of the casing. It is an axis connecting the centroids of the cross-sectional shapes of the first cone members cut along the cross-section perpendicular to the longitudinal direction. In FIG. 7, the center axis of the first cone member 240 that is an eccentric cone is indicated by a one-dot chain line 242.

Since the direction of the alternate long and short dash line 133 that is the central axis of the casing and the direction of the alternate long and short dash line 242 that is the central axis of the first cone member are misaligned, the exhaust gas purification apparatus 200 shown in FIG. Device.

In the exhaust gas purifying apparatus 200 shown in FIG. 7, the second cone member 250 is also an eccentric cone, and its central axis 252 is deviated from the direction of the alternate long and short dash line 133 that is the central axis of the casing.
The central axis of the second cone member is at both ends of the second cone member, that is, at the end on the second end side of the casing and at the end farthest from the second end of the casing. It is an axis connecting the centroids of the cross-sectional shapes of the second cone members cut along the cross-section perpendicular to the longitudinal direction.
The other structure of the exhaust gas purification apparatus 200 is the same as that of the exhaust gas purification apparatus 100 shown in FIG.

The heat insulating material of the present invention suitable for the exhaust gas purification apparatus of the present invention having an eccentric cone will be described below.
FIG. 8, FIG. 9 (a) and FIG. 9 (b) are top views schematically showing another example of the heat insulating material of the present invention.
The heat insulating material 14 shown in FIG. 8 is a heat insulating material which can be used for the exhaust gas purification apparatus of the present invention having an eccentric cone. The heat insulating material 14 is provided with a total of six trapezoidal first cone heat insulation parts, including two first cone heat insulation parts 43 having a high trapezoidal height and a medium trapezoidal height. There are two first cone heat insulation portions 44 and two first cone heat insulation portions 45 having a low trapezoidal height.
Rounding such heat insulating material 14 into a cylindrical shape, the first cone insulation portion 43 in the first casing heat insulating section height L ₁ is longer first in cone insulation portion 45 first casing insulation from the side 25 height L ₃ short from part side 25, a cone cylindrical portion.
Therefore, as shown in the cross-sectional view of the exhaust gas purification apparatus 200 shown in FIG. 7, the first cone heat insulating portion 43 is located above the first cone member 240 (the side where the distance from the end surface of the casing of the first cone member is long). And the first cone heat insulating portion 45 is disposed on the lower side of the first cone member 240 (on the side where the distance from the end surface of the casing of the first cone member is short), whereby the first cone which is an eccentric cone is arranged. The outer peripheral surface of the cone member 240 can be covered with the first cone heat insulating portion.

The heat insulating material 15 shown in FIG. 9A is an example of a heat insulating material that has one eccentric cone and can be used in the exhaust gas purifying apparatus of the present invention having an eccentric cone.
The 1st cone heat insulation part 46 of the heat insulating material 15 is a crescent moon type. The first cone heat insulating portion 46 is connected to the first casing heat insulating portion side surface 25 of the casing heat insulating portion 20 only at a part thereof.
Even when such a heat insulating material 15 is rolled into a cylindrical shape, a portion having a long distance and a short portion from the side surface 25 of the first casing heat insulating portion are generated in the first cone heat insulating portion 46. By arranging the long and short portions of the first cone heat insulating portion in accordance with the shape of the member, the first cone heat insulating portion covers the outer peripheral surface of the first cone member that is an eccentric cone. it can.

FIG. 9B shows a modification of the heat insulating material shown in FIG.
The heat insulating material 15 ′ shown in FIG. 9B is the first cone heat insulating part 46 of the heat insulating material 15 shown in FIG. 9A, and the first cone heat insulating part 46 is the first casing of the casing heat insulating part 20. This is a shape in which the cone heat insulating portions 46 a and 46 b are divided into two at the point where they are connected to the heat insulating portion side surface 25 and arranged at both ends of the first casing heat insulating portion side surface 25.
As described above, the shape of the cone heat insulating portion is a crescent shape as a whole, and the shape of the cone heat insulating portion is a crescent shape. Moreover, the number of cone heat insulation parts in this case is counted as one.

In the exhaust gas purifying apparatus of the present invention, a cover member that covers the surface of the casing heat insulating portion and the surface of the first cone heat insulating portion may be provided. An exhaust gas purification apparatus having a cover member will be described below.
FIG. 10 is a cross-sectional view schematically showing an example of an exhaust gas purifying apparatus having a cover member.
A cover member 310 is provided in the exhaust gas purification apparatus 300 shown in FIG. The cover member 310 is welded and fixed to the first cone member 140 by the welded portion 311, and is welded and fixed to the second cone member 150 by the welded portion 312.
The first cone heat insulating portion 30 is disposed between the cover member 310 and the first cone member 140, and the casing heat insulating portion 20 is disposed between the cover member 310 and the casing 130. . If the 1st cone heat insulation part 30 and the casing heat insulation part 20 are arrange | positioned in this way, the position of the 1st cone heat insulation part 30 and the casing heat insulation part 20 will be stabilized. Moreover, since the surface of the 1st cone heat insulation part 30 and the surface of the casing heat insulation part 20 are covered with the cover member 310 and are not exposed, the fiber scattering from the 1st cone heat insulation part 30 and the casing heat insulation part 20 is suppressed. . Therefore, in the exhaust gas purification apparatus 300 shown in FIG. 10, the fiber scatter suppression processing unit (fiber scatter suppression processing unit 27, fiber scatter suppression processing unit 37, and fiber scatter suppression in FIG. 3 is added to the first cone heat insulating unit 30 and the casing heat insulating unit 20. The processing unit 38) is not provided.
The other configuration of the exhaust gas purification apparatus 300 is the same as that of the exhaust gas purification apparatus 100 shown in FIG.

The exhaust gas purification apparatus having the cover member can be assembled by covering the divided cover member from the outside of the heat insulating material and fixing the cover member.
FIG. 11A and FIG. 11B are perspective views schematically showing how the exhaust gas purification apparatus shown in FIG. 10 is assembled.
First, as shown in FIG. 11 (a), an exhaust gas purification apparatus in which a casing heat insulating portion of a heat insulating material is wound around the outer peripheral surface of the casing, and the outer peripheral surface of the first cone member is covered with the first cone heat insulating portion. Prepare 100.
Next, an upper cover member 310a and a lower cover member 310b having a shape obtained by dividing the cover member into two parts are prepared, and the upper cover member 310a and the lower cover member 310b are covered from above and below the exhaust gas purification apparatus 100, respectively.
Then, as shown in FIG. 11B, the cover member 310a and the cover member 310b are fixed by welding or the like to form the cover member 310, and the exhaust gas purification apparatus 300 having the cover member 310 is formed.
At this time, it is desirable that the cover member 310a and the cover member 310b are fixed to the first cone member 140 and the second cone member 150 by welding or the like.

The cover members 310 (310a, 310b) shown in FIGS. 11 (a) and 11 (b) are three-dimensional molded bodies that are three-dimensionally shaped.
As the cover member, in addition to the three-dimensional molded body, a metal foil or a metal mesh can be used, and the first cone heat insulating portion and the casing heat insulating portion can also be formed by covering the surface of the heat insulating material with the metal foil or the metal mesh. The fiber scattering from the can be suppressed.

The heat insulating material of the present invention that can be used in the exhaust gas purifying apparatus of the present invention further includes a second cone heat insulating portion that covers at least a part of the outer peripheral surface of the second cone member, and the casing heat insulating portion and the second heat insulating material. It is desirable that at least a part of each side surface of the cone heat insulating portion is continuously connected.
Such an insulating material and an exhaust gas purification apparatus including the insulating material will be described below.

FIG. 12 is a top view schematically showing an example of the heat insulating material of the present invention including the second cone heat insulating portion.
In the heat insulating material 16 illustrated in FIG. 12, the second cone heat insulating portion 50 is continuously connected to the second casing heat insulating portion side surface 26. In the heat insulating material 16, a plurality (six) of the second cone heat insulating portions 50 are provided, and each shape of the second cone heat insulating portions is a trapezoid.
The form of the 2nd cone heat insulation part 50 can be made to be the same as that of the 1st cone heat insulation part 30 shown in FIG. 1 except that the position differs.
In the heat insulating material of the present invention, since the second cone heat insulating portion and the casing heat insulating portion are continuously connected, they are usually the same material and are mat-like members having the same thickness.
The slits and the fiber scattering suppression process are not shown in FIG. 12, but can be provided at the same positions as those provided in the first cone heat insulating portion 30 shown in FIG.

When the heat insulating material 16 is rounded into a cylindrical shape, a cone cylindrical portion that is a space surrounded by the second cone heat insulating portion 50 is formed in the same manner as the shape shown in FIG. The diameter of the cone cylindrical part surrounded by the second cone heat insulating part 50 is the maximum at the second casing heat insulating part side surface 26 and is the same as the inner diameter of the cylinder formed by the casing heat insulating part 20. As the distance from the casing heat insulating portion side surface 26 increases, the distance gradually decreases.
In addition, in the heat insulating material of the present invention including the second cone heat insulating portion, the number of the second cone heat insulating portions may be one or two, and the shape is not limited to the trapezoid, Similarly to the shape of the first cone heat insulating portion, the shape may be a triangle, a sector, a sector except a sector having the same central point and central angle as the sector and a small radius, or a crescent shape.
Moreover, it is good also as a 2nd cone heat insulation part of the shape corresponding to an eccentric cone.

Fig.13 (a) is sectional drawing which shows typically an example of the exhaust gas purification apparatus of this invention by which the outer peripheral surface of the 2nd cone member is covered with the 2nd cone heat insulation part.
In the exhaust gas purifying apparatus 400 shown in FIG. 13A, the heat insulating material 16 shown in FIG. 12 is used, and the second cone heat insulating portion 50 continuously connected to the casing heat insulating portion 20 is a second cone. At least a part of the outer peripheral surface 151 of the member 150 is covered.
About the slit and the fiber scattering suppression process in the 2nd cone heat insulation part 50, it can provide in the position similar to the position provided in the 1st cone heat insulation part 30 shown in FIG.
The other configuration of the exhaust gas purification apparatus 400 is the same as that of the exhaust gas purification apparatus 100 shown in FIG.

Moreover, the cover member which covers from the surface of the 1st cone heat insulation part to the surface of the 2nd cone heat insulation part may be provided.
FIG.13 (b) is sectional drawing which shows typically the example of the exhaust gas purification apparatus which has a cover member which covers from the surface of a 1st cone heat insulation part to the surface of a 2nd cone heat insulation part.
The exhaust gas purification apparatus 500 shown in FIG. 13B is provided with a cover member 310 similar to the cover member in the exhaust gas purification apparatus shown in FIG.
When the cover member 310 is provided, the second cone heat insulating portion 50 is disposed between the cover member 310 and the second cone member 150.
By providing the cover member, fiber scattering from the second cone heat insulating portion can also be suppressed.
The other configuration of the exhaust gas purification apparatus 500 is the same as that of the exhaust gas purification apparatus 100 shown in FIG.

As for the heat insulating material of this invention which can be used for the exhaust gas purification apparatus of this invention, it is desirable to further provide the strip part connected continuously with the side surface of the 2nd cone heat insulation part.
Such an insulating material and an exhaust gas purification apparatus including the insulating material will be described below.

FIG. 14 is a top view schematically showing an example of the heat insulating material of the present invention having a strip portion.
In the heat insulating material 17 shown in FIG. 14, the strip portion 60 having a substantially rectangular shape in plan view is formed on the side surface 51 located on the opposite side to the side surface connected to the casing heat insulating portion 20 among the side surfaces of the second cone heat insulating portion 50. Is provided. The strip portion 60 is connected to a part of the side surface of the second cone heat insulating portion 50.
In the heat insulating material of the present invention, since the strip portion, the second cone heat insulating portion and the casing heat insulating portion are continuously connected, these are usually the same material and are mat-like members having the same thickness. is there.
The slit is not shown in FIG. 14, but it is desirable to provide the slit on the outer side (the side to be extended) when the portion where the second cone heat insulating portion and the strip portion are connected is bent.
Moreover, it is desirable to provide the fiber scattering suppression treatment at a portion where the strip portion is exposed, and it is desirable to provide it on the surface that becomes the outside when the strip portion is rolled into a cylindrical shape.

When the heat insulating material 17 is rounded into a cylindrical shape, the strip portion 60 is rounded into a cylindrical shape.
The strip 60 rounded into a cylindrical shape can cover the outer peripheral surface of the straight pipe member disposed at the end of the second cone member in the exhaust gas purifying apparatus described later.
FIG. 15 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus of the present invention in which the outer peripheral surface of the straight pipe member is covered with a strip portion.
In the exhaust gas purification apparatus 600 shown in FIG. 15, a straight pipe member 160 that is a cylindrical member having a constant diameter is disposed at the end 152 of the second cone member 150 opposite to the casing 130 side. Yes.
In the exhaust gas purifying apparatus 600, the heat insulating material 17 shown in FIG. 14 is used, and the strip portion 60 continuously connected to the second cone heat insulating portion 50 is at least a part of the outer peripheral surface 161 of the straight pipe member 160. Covering.
A slit 65 at a portion where the second cone heat insulating portion 50 and the strip portion 60 are connected is provided at the boundary between the second cone member 150 and the straight pipe member 160. It is desirable that a fiber scattering suppression process is provided at a portion where the surface of the strip 60 is exposed.

The exhaust gas purifying apparatus 600 shown in FIG. 15 has a straight pipe member joined to the end of the second cone member by welding or the like to the exhaust gas purifying apparatus 100 shown in FIG. The heat insulating portion is wound around the outer peripheral surface of the casing, and the outer peripheral surface of the first cone member, the outer peripheral surface of the second cone member, and the outer peripheral surface of the straight pipe member are connected to the first cone heat insulating portion, the second cone portion, and It can manufacture by covering each with a strip part.

FIG. 16 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus of the present invention having a cover member that covers from the surface of the first cone heat insulating portion to the surface of the strip portion.
The exhaust gas purifying device 700 is provided with a cover member 710.
The cover member 710 is welded and fixed to the first cone member 140 by the welded portion 711 and is welded and fixed to the straight pipe member 160 by the welded portion 712.
And the surface of the 1st cone heat insulation part 30, the surface of the casing heat insulation part 20, the surface of the 2nd cone heat insulation part 50, and the surface of the strip part 60 are covered with the cover member 710.
The position from the 1st cone heat insulation part 30 to the strip part 60 is stabilized as it is the said structure.
Moreover, since the surface from the surface of the 1st cone heat insulation part 30 to the surface of the strip part 60 is covered with the cover member 710 and is not exposed, the surface of the 1st cone heat insulation part 30, the surface of the casing heat insulation part 20, the 2nd Fiber scattering from the surface of the cone heat insulation part 50 and the surface of the strip part 60 is suppressed.
Therefore, in the exhaust gas purification apparatus 700 shown in FIG. 16, the fiber scattering suppression processing unit (fiber scattering suppression processing unit 27, fiber scattering suppression processing unit 37, and fiber scattering suppression processing unit 38 in FIG. 3) is not provided in the heat insulating material 17.

The heat insulating material of the present invention that can be used in the exhaust gas purifying apparatus of the present invention may be one in which another cone heat insulating portion and another casing heat insulating portion are connected to the strip portion.
Such a heat insulating material is suitably used for an exhaust gas purifying apparatus including two exhaust gas treatment bodies.
FIG. 17 is a top view schematically showing an example of the heat insulating material of the present invention in which another cone heat insulating portion and another casing heat insulating portion are connected to the strip portion.
The heat insulating material 18 shown in FIG. 17 is connected continuously to the second casing heat insulating portion 80, which is a portion wound around the outer peripheral surface of the second casing, and the side surface of the second casing heat insulating portion 80. 3 cone heat insulation part 70, and the third cone heat insulation part 70 is continuously connected to the side face 61 opposite to the side face connected to the second cone heat insulation part 50 on the side face of the strip 60. ing.
That is, in the heat insulating material 18, the first cone heat insulating portion 30, the casing heat insulating portion 20, the second cone heat insulating portion 50, the strip portion 60, the third cone heat insulating portion 70, and the second casing heat insulating portion 80 are continuous. Connected.
Since the configuration of each part is the same as the configuration of the other heat insulating materials described so far, the detailed description thereof is omitted, but the second casing heat insulating portion 80, the casing heat insulating portion 20, and the third cone heat insulating portion. 70 and the 1st cone heat insulation part 30 can be set as the same structure, respectively.
Moreover, the relationship between the second casing heat insulating portion 80 and the third cone heat insulating portion 70 can be made the same as the relationship between the casing heat insulating portion 20 and the first cone heat insulating portion 30.
Furthermore, the relationship between the third cone heat insulating portion 70 and the strip portion 60 can be made the same as the relationship between the second cone heat insulating portion 50 and the strip portion 60.

FIG. 18 is a cross-sectional view schematically showing an example of the exhaust gas purifying apparatus of the present invention having two exhaust gas treating bodies.
In the exhaust gas purification apparatus 800, another exhaust gas treatment body 220 is provided on the downstream side of the exhaust gas. The exhaust gas treatment body 220 is a DPF, and has a columnar shape in which a large number of cells 225 are arranged in parallel in the longitudinal direction with a cell wall 226 interposed therebetween. One end of the cell 225 is sealed with a sealing material 228.
The exhaust gas flows into one cell 225 that opens to the exhaust gas inflow side end surface 220 a of the exhaust gas treatment body 220, and passes through the cell wall 226 that separates the cell 225. At this time, PM in the exhaust gas is collected by the cell wall 226, and the exhaust gas is purified. The purified exhaust gas flows out from another cell 225 opened in the exhaust gas outflow side end face 220b and is discharged to the outside.

A holding sealing material 210 is wound around the exhaust gas treatment body 220, and the holding sealing material 210 is disposed between the exhaust gas treatment body 220 and the second casing 180.
Around the second casing 180, a second casing heat insulating portion 80 that is a part of the heat insulating material 18 is wound.
A third cone member 170 is disposed at the first end 181 located on the exhaust gas inflow side of the second casing 180, and the third cone member 170 is opposite to the second casing 180 side. A straight pipe member 160 is disposed at the end of the tube.
A fourth cone member 190 is disposed on the second end 182 located on the exhaust gas outflow side of the second casing 180.

The third cone heat insulating portion 70 continuously connected to the second casing heat insulating portion 80 covers at least a part of the outer peripheral surface 171 of the third cone member 170.
The relationship between the third cone heat insulating portion 70 and the third cone member 170 can be the same as the relationship between the first cone heat insulating portion 30 and the first cone member 140.
In addition, since the structure from the 1st cone member 140 to the straight pipe member 160 shown on the left side in FIG. 18 can be made the same as the form demonstrated so far, the detailed description is abbreviate | omitted.

In the exhaust gas purification apparatus shown in FIG. 18, a wound body in which a holding sealing material is wound around an exhaust gas treatment body is press-fitted into a casing, and then the first to fourth cone members and the straight pipe member are joined by welding or the like. After that, the heat insulating material of the present invention can be manufactured by winding it from the first cone member to the outer peripheral surface of the second casing.

Hereinafter, the manufacturing method of the heat insulating material of this invention is demonstrated.
The manufacturing method of the heat insulating material of the present invention is characterized by performing a step of punching out the heat insulating material from one sheet so that all the parts constituting the heat insulating material are connected.

First, a mat containing inorganic fibers is produced. The mat can be obtained by various methods. For example, the mat can be produced by a needling method or a papermaking method.
In the case of the needling method, for example, it can be produced by the following method. That is, first, for example, an inorganic fiber precursor having an average fiber diameter of 3 to 10 μm is prepared by spinning a spinning mixture using a basic aluminum chloride aqueous solution and silica sol as raw materials by a blowing method. Subsequently, the inorganic fiber precursor is compressed to produce a continuous sheet-like material having a predetermined size, subjected to a needle punching process, and then subjected to a firing process to complete the preparation of the mat.

In the case of the papermaking method, by mixing inorganic fibers such as alumina fibers and silica fibers, an inorganic binder, and water so that the content of the inorganic fibers in the raw material liquid becomes a predetermined value, and stirring with a stirrer Prepare a mixture. The mixed solution may contain a colloidal solution made of a polymer compound or a resin as necessary. Then, after pouring a liquid mixture into the molding machine with which the mesh for filtration was formed in the bottom face, the raw material sheet | seat is produced by dehydrating the water in a liquid mixture through a mesh. Thereafter, the preparation of the mat is completed by heating and compressing the raw material sheet under predetermined conditions.

If necessary, the mat may be subjected to a drying treatment by applying a binder solution containing an organic binder and / or an inorganic binder.

Since the mat is obtained as one large sheet-like member, the heat insulating material of the present invention can be obtained by punching it into the shape of the heat insulating material.
The insulation material can be punched with a Thomson blade, a guillotine blade, or the like.

Below, the effect of the exhaust gas purification apparatus of this invention is demonstrated.

(1) In the exhaust gas purification apparatus of the present invention, since the first cone member is covered with the first cone heat insulating portion, the first cone member in the exhaust gas purification apparatus can be insulated with a simple configuration.
In addition, since the casing heat insulating portion and the first cone heat insulating portion are continuously connected, there is no positional shift, and the casing heat insulating portion and the first cone heat insulating portion are composed of one member, so that the exhaust gas purification apparatus is assembled. Excellent workability.

(2) The exhaust gas purifying apparatus of the present invention is used in various forms such as having an eccentric cone, having a second cone member, having a straight pipe member, and having a second exhaust gas treating body. In addition, since the heat insulating portion can be provided at a necessary place in each embodiment, heat radiation from the exhaust gas purification device can be suppressed.

(3) The heat insulating material of the present invention can cover both the exhaust gas treating body and the cone member with a single heat insulating material without causing a positional shift, and with a simple configuration, heat insulation of the cone member in the exhaust gas purifying apparatus. It can be performed. Moreover, the heat insulation structure with high durability at the time of use can be provided.
Furthermore, since it can be flat when stored and transported, it becomes a heat insulating material with high storage and transport efficiency.

(Example)
Examples in which the present invention is disclosed more specifically are shown below. In addition, this invention is not limited only to these Examples.

(Sheet manufacturing example)
First, a mat containing inorganic fibers was prepared by the following procedure.
As an alumina fibrous base mat having an alumina-silica composition, a base mat having a composition ratio of Al ₂ O ₃ : SiO ₂ = 72: 28 (weight ratio) was prepared. A needle processing mat having a bulk density of 0.15 g / cm ³ and a basis weight of 1500 g / m ² was produced by performing a needling process on the base mat.

Separately, an acrylic latex emulsion was prepared by sufficiently dispersing acrylic latex in water, and this was used as a binder.

Next, the needle mat is cut into a total length of 1250 mm × width of 1200 mm in a plan view, and the binder needle is impregnated into the binder so that the amount of binder attached to 100% by weight of the cut needle mat is 1.0% by weight. did.

Thereafter, the needle mat impregnated with the binder was air-dried at a temperature of 140 ° C. for 6 minutes to produce a mat as one sheet.
The thickness of the mat was 9.1 mm.

(Examples 1-8)
The mat was punched using a Thomson blade having a predetermined shape to produce heat insulating materials according to Examples 1 to 8 having the following shapes. The length of the heat insulating material in the longitudinal direction (long side length) was 627 mm, and the width of the casing heat insulating portion (short side length) was 233 mm.

(Examples 1 to 6: Examples of heat insulating materials without slits)
Example 1: A shape having six trapezoidal first cone heat insulating portions (shape in FIG. 1).
The trapezoid was an isosceles trapezoid with an upper base of 35 mm, a lower base of 104 mm, and a height of 160 mm.
Example 2: A shape having six trapezoidal first cone heat insulation portions and six second cone heat insulation portions as in Example 1 (shape in FIG. 12).
Example 3: Shape having six triangular first cone heat insulating portions (shape of FIG. 4).
The triangular shape was an isosceles triangle having a base of 104 mm and a height of 160 mm.
Example 4: A shape having one first cone heat insulating portion having a shape in which a sector shape having the same center point and central angle as the sector shape and a small radius is removed from the sector shape (the shape shown in FIG. 6A).
The large sector shape had a central angle of 157 ° and a radius of 216 mm, and the small sector shape had a radius of 52 mm.
Example 5: A shape having six trapezoidal first cone heat insulating portions having different heights (the shape in FIG. 8).
The height of the trapezoid was 180 mm, 160 mm, and 140 mm in descending order.
The lower base of each trapezoid is 104 mm, the upper base of an isosceles trapezoid with a height of 160 mm is 35 mm, and the trapezoids with a height of 180 mm and 140 mm have an angle between each trapezoidal leg and the lower base of 160 mm in height. A trapezoid that is the same as an isosceles trapezoid.
Example 6: Shape having one crescent-shaped first cone heat insulating portion (shape of FIG. 9A).
The crescent shape was such that the radius of the outer arc was 300 mm, the radius of the inner arc was 1140 mm, and the distance between the center of the outer arc and the center of the inner arc was 1000 mm.
(Example 7: Example of heat insulating material provided with slits)
Example 7: In Example 1, a slit having a depth of 4 mm is provided at a portion where the casing heat insulating part and the first cone heat insulating part are continuously connected.
(Example 8: Example of heat insulating material provided with strips)
Example 8: A shape further having a strip portion connected to the second cone heat insulating portion in Example 2 (shape of FIG. 14). The shape of the strip is 204 mm long and 80 mm wide. Each of the parts where the casing heat insulation part, the first cone heat insulation part and the second cone heat insulation part are continuously connected, and the part where the second cone heat insulation part and the strip part are continuously connected are deep. A 4 mm slit was provided.

(Comparative Example 1)
About the heat insulating material used in Example 4, what separated the 1st cone heat insulation part from the casing heat insulation part was prepared.
(Comparative Example 2)
A three-dimensional molded body designed to have the same shape as that obtained when the heat insulating material used in Example 1 was rolled into a cylindrical shape was prepared.

(Evaluation)
(Production of exhaust gas purification device)
An exhaust gas purification apparatus was produced using the heat insulating material or the three-dimensional molded body.
The configuration of the exhaust gas purifying apparatus is configured to include two exhaust gas treatment bodies, one on the upstream side and one on the downstream side, and the heat insulating materials of the examples and comparative examples are heat insulating materials that are wound around the outer peripheral surface of the casing on the upstream side. Used as material. The 1st cone heat insulation part was arrange | positioned at the 1st cone member side.
The exhaust gas purification apparatus in which a heat insulating material is wound around the outer peripheral surface of the upstream casing is configured to have a cover member. Examples 1, 3, 4, 7 and Comparative Examples 1 and 2 are shown in FIG. An exhaust gas purification apparatus provided with a simple cover member.
About Example 2, it was set as the exhaust gas purification apparatus provided with the cover member as shown in FIG.13 (b).
About Example 5, 6, it is an exhaust gas purification apparatus which has an eccentric cone as shown in FIG. 7, Comprising: The 1st cone member is an eccentric cone corresponding to the shape of a heat insulating material, and also the exhaust gas which provided the cover member A purification device was obtained.
About Example 8, it was set as the exhaust gas purification apparatus which provided the cover member as shown in FIG. 16, and it arrange | positioned so that the 2nd cone heat insulation part and a strip part may cover the outer peripheral surface of a 2nd cone member and a straight pipe member. .

(Position deviation of the cone insulation)
In the assembling work of the exhaust gas purification apparatus, in Comparative Example 1, the position of the cone heat insulating part and the position of the casing heat insulating part may be shifted.
In Example 7, since the slit was provided in the heat insulating material, the heat insulating material was easily bent, and the positional accuracy of the first cone heat insulating portion was extremely good.
In Table 1, ◎ indicates that the positional accuracy of the cone heat insulating portion is extremely good, ◯ indicates that it is good, and × indicates that it is bad.

(Heat retention)
An exhaust gas at a predetermined temperature (600 ° C.) was introduced into the exhaust gas purification device, and the temperature of the exhaust gas after flowing out of the exhaust gas purification device through the two exhaust gas treatment bodies was measured to evaluate heat retention.
In Table 1, those with extremely good heat retention are shown as ◎, and those with good heat are shown as ○.

(Loadability when packing)
The three-dimensional molded body of Comparative Example 2 was bulky during storage and packaging. In other examples and comparative examples, the heat insulating material was in a mat shape and was not bulky.
In Table 1, those that are not particularly bulky are indicated by ◎, those that are not bulky are indicated by ○, and those that are bulky are indicated by ×.

Insulation 10, 11, 12, 13, 13 ', 14, 15, 15', 16, 17, 18
Casing insulation 20
Long side 21
Short side 22
1st casing heat insulation part side surface 25
2nd casing heat insulation part side surface 26
Fiber scattering suppression treatment provided on the surface of the casing heat insulating part 27
1st cone heat insulation part 30,40,41,42,42a, 42b, 43,44,45,46,46a, 46b
Slit 35
Cone cylinder 36
Fiber scattering suppression treatment 37 provided on the surface of the first cone heat insulating part 37
Fiber scattering suppression treatment 38 provided on the side surface of the first cone heat insulating portion 38
Second cone insulation 50
Strip 60
Exhaust gas purification device 100, 200, 300, 400, 500, 600, 700, 800
Exhaust gas treatment body 120, 220
Casing 130
Casing first end 131
Casing second end 132
Central axis of casing 133
First cone member 140, 240
Outer peripheral surface 141 of the first cone member
Second cone member 150, 250
Outer peripheral surface 151 of second cone member
Straight pipe member 160
Outer peripheral surface 161 of straight pipe member
Central axis 242 of first cone heat insulating part
Cover members 310, 710

Claims (27)

An exhaust gas treating body;
A cylindrical casing having a first end located on the exhaust gas inflow side and a second end located on the exhaust gas outflow side and containing the exhaust gas treating body;
A holding sealing material wound around the exhaust gas treatment body and disposed between the exhaust gas treatment body and the casing;
A first cone member disposed on the first end side of the casing, the diameter of which is gradually decreased as the diameter is separated from the first end of the casing;
A cylindrical member disposed on the second end side of the casing, and a second cone member having a diameter that gradually decreases with increasing distance from the second end of the casing;
A second exhaust gas treating body;
A cylindrical second casing having a first end located on the exhaust gas inflow side and a second end located on the exhaust gas outflow side, and housing the second exhaust gas treating body;
A second holding sealing material wound around the exhaust gas treating body and disposed between the exhaust gas treating body and the second casing;
A cylindrical member disposed on the first end side of the second casing, the diameter of which is gradually reduced as the diameter of the third member increases from the first end of the second casing. And the diameter of the second cone member disposed at the end opposite to the casing side and the end of the third cone member opposite to the second casing side is constant. A straight pipe member that is a cylindrical member of
An exhaust gas purifying device comprising a mat containing inorganic fibers, a part of which is wound around the outer peripheral surface of the casing and the outer peripheral surface of the second casing ,
The heat insulating material comprises a mat containing inorganic fibers containing a low crystalline alumina material and a spinel type compound having a crystallization ratio of 0.1 to 30%,
A first cone heat insulating portion covering at least a part of the outer peripheral surface of the first cone member;
A casing heat insulating portion wound around the outer peripheral surface of the casing;
A second cone heat insulation portion wound around the outer peripheral surface of the second cone member;
A strip portion covering at least a part of the outer peripheral surface of the straight pipe member;
A third cone heat insulating portion covering at least a part of the outer peripheral surface of the third cone member;
A second casing heat insulating portion wound around the outer peripheral surface of the second casing,
The first cone heat insulating portion, the casing heat insulating portion, the second cone heat insulating portion, the strip portion, the third cone heat insulating portion, and the second casing heat insulating portion are continuously connected. Exhaust gas purification device. The exhaust gas purifying apparatus according to claim 1, wherein the number of the first cone heat insulating portions is one. 3. The exhaust gas purification apparatus according to claim 2, wherein the shape of the first cone heat insulating portion is a shape obtained by removing a fan shape from a fan shape that has the same central point and central angle as the fan shape and a small radius, or a crescent shape. The exhaust gas purification device according to claim 1, wherein the number of the first cone heat insulating portions is two or more. The exhaust gas purifying apparatus according to claim 4, wherein each of the first cone heat insulating portions has a triangular shape, a trapezoidal shape, or a fan shape. The exhaust gas purification apparatus according to any one of claims 1 to 5, wherein a central axis of the first cone member is deviated from a central axis of the casing. The exhaust gas purification device according to any one of claims 1 to 6, wherein a slit is provided in a thickness direction of the heat insulating material at a portion where the casing heat insulating portion and the first cone heat insulating portion are continuously connected. . The exhaust gas purifying apparatus according to any one of claims 1 to 7, wherein fiber scattering suppression processing is performed on a surface of the casing heat insulating portion and a surface of the first cone heat insulating portion. The exhaust gas purification apparatus according to any one of claims 1 to 8, further comprising a cover member that covers a surface of the casing heat insulating portion and a surface of the first cone heat insulating portion. The exhaust gas purification device according to claim 9, wherein the cover member is a three-dimensional molded body. The exhaust gas purification apparatus according to claim 9, wherein the cover member is a metal foil or a metal mesh. The exhaust gas purification device according to any one of claims 1 to 11, wherein the number of the second cone heat insulating portions is one. The exhaust gas purifying apparatus according to claim 12 , wherein the shape of the second cone heat insulating portion is a shape obtained by removing a sector shape from a sector shape that has the same central point and central angle as the sector shape and a small radius, or a crescent shape. The exhaust gas purification device according to any one of claims 1 to 11, wherein the number of the second cone heat insulating portions is two or more. The exhaust gas purifying apparatus according to claim 14 , wherein each shape of the second cone heat insulating portion is a triangle, a trapezoid, or a fan. It consists of a mat containing inorganic fibers,
A substantially rectangular casing heat insulating portion in plan view having a long side extending in the longitudinal direction and a short side substantially perpendicular to the long side;
A first cone heat insulating portion at least partially connected to the first casing heat insulating portion side surface which is one of the long side surfaces of the casing heat insulating portion;
A second cone heat insulating part continuously connected at least partially with a second casing heat insulating part side surface which is a side surface on the long side opposite to the first casing heat insulating part side surface of the casing heat insulating part;
A strip portion having a substantially rectangular shape in plan view, which is continuously connected at least partially on the side surface located on the side opposite to the side surface connected to the casing heat insulating portion among the side surfaces of the second cone heat insulating portion,
A third cone heat insulating portion continuously connected to a side surface opposite to the side surface connected to the second cone heat insulating portion on the side surface of the strip portion;
Of the side surfaces of the third cone heat insulating portion, a continuous side surface is connected to the side surface opposite to the side surface connected to the strip portion, and the long side extending in the longitudinal direction and the short side substantially perpendicular to the long side A second casing heat insulating portion having a substantially rectangular shape in plan view having sides,
A heat insulating material comprising:
As the inorganic fiber, an inorganic fiber containing a low crystalline alumina material and a spinel type compound having a crystallization ratio of 0.1 to 30% is used.
When the insulating material is rolled into a cylindrical shape so that the two short sides of the casing heat insulating part and the second casing heat insulating part are in contact with each other,
The diameter of the cone cylindrical portion formed as a space surrounded by the first cone heat insulation portion becomes gradually smaller as the distance from the side surface of the first casing heat insulation portion increases .
The diameter of the cone cylindrical portion formed as a space surrounded by the second cone heat insulation portion becomes gradually smaller as the distance from the side surface of the second casing heat insulation portion increases.
The heat insulating material, characterized in that the diameter of a cone cylindrical portion formed as a space surrounded by the third cone heat insulating portion gradually decreases as the diameter of the second casing heat insulating portion increases from the side surface on the long side. . The heat insulating material according to claim 16 , wherein the number of the first cone heat insulating portions is one. 18. The heat insulating material according to claim 17 , wherein the shape of the first cone heat insulating portion is a shape obtained by removing a fan shape from the fan shape having the same central point and central angle as the fan shape and a small radius, or a crescent shape. The heat insulating material according to claim 16 , wherein the number of the first cone heat insulating portions is two or more. The heat insulating material according to claim 19 , wherein each shape of the first cone heat insulating portion is triangular, trapezoidal, or fan-shaped. The shape of the first cone heat insulating part is such that when the heat insulating material is rolled into a cylindrical shape so that the two short sides of the casing heat insulating part are in contact with each other, the central axis of the cone cylindrical part is the casing heat insulating material. The heat insulating material according to any one of claims 16 to 20 , wherein the heat insulating material is shifted from a central axis of a cylindrical portion surrounded by the portion. The heat insulating material according to any one of claims 16 to 21 , wherein a slit is provided in a thickness direction of the heat insulating material at a portion where the casing heat insulating portion and the first cone heat insulating portion are continuously connected. The heat insulating material according to any one of claims 16 to 22 , wherein the surface of the casing heat insulating portion and the surface of the first cone heat insulating portion are subjected to fiber scattering suppression treatment. The number of the said 2nd cone heat insulation parts is one, The heat insulating material in any one of Claims 16-23 . 25. The heat insulating material according to claim 24 , wherein the shape of the second cone heat insulating portion is a shape obtained by removing a fan shape from the fan shape having the same central point and central angle as the fan shape and a small radius, or a crescent shape. The number of the said 2nd cone heat insulation parts is two or more, The heat insulating material in any one of Claims 16-23 . 27. The heat insulating material according to claim 26 , wherein each shape of the second cone heat insulating portion is a triangle, a trapezoid, or a fan shape.

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