Mat material, exhaust gas purification device, and method for producing mat material
AssigneeIbiden Co., Ltd.
InventorsTakayuki KAWABE, Yuta KOGO, Tomohisa YAMAZAKI
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Abstract
A mat material including inorganic fibers, with an inorganic binder and an organic binder attached to the mat material, wherein a ratio [w1B/w1A] of a weight percentage w1B of the organic binder to a weight percentage w1A of the inorganic binder satisfies the following condition (1) or (2), where w1A is the weight percentage of the inorganic binder relative to a weight of the mat material as a whole, and w1B is the weight percentage of the organic binder relative to the weight of the mat material as a whole: 0<w1B/w1A≤0.8; or (1) 9≤w1B/w1A. (2)
Claims20
A mat material comprising
- inorganic fibers, with an inorganic binder and an organic binder attached to the mat material,
- wherein a ratio [w1B/w1A] of a weight percentage w1B of the organic binder to a weight percentage w1A of the inorganic binder satisfies the following condition (1) or (2), where w1A is the weight percentage of the inorganic binder relative to a weight of the mat material as a whole, and w1B is the weight percentage of the organic binder relative to the weight of the mat material as a whole:
- (1) 0<w1B/w1A≤0.8;
- or
- (2) 9≤w1B/w1A.
A method for producing a mat material, comprising:
- a needle-punched mat preparing step of preparing an inorganic fiber mass including inorganic fibers by needling;
- and
- an attaching step of attaching an inorganic binder and an organic binder to the inorganic fiber mass,
- wherein a ratio [w2B/w2A] of a weight percentage w2B of the organic binder to a weight percentage w2A of the inorganic binder satisfies the following condition (3) or (4), where w2A is the percentage of the inorganic binder for use in the attaching step, and w2B is the weight percentage of the organic binder for use in the attaching step:
- (3) 0<w2B/w2A≤0.8;
- or
- (4) 9≤w2B/w2A.
A method for producing a mat material, comprising:
- a defibrating step of defibrating inorganic fibers;
- a slurry preparing step of mixing the opened inorganic fibers with a solvent, an inorganic binder, and an organic binder to prepare a slurry;
- and
- a papermaking step of subjecting the slurry to papermaking to obtain an inorganic fiber papermaking sheet;
- and
- a drying step of drying the inorganic fiber papermaking sheet,
- wherein a ratio [w3B/w3A] of a weight percentage w3B of the organic binder to a weight percentage w3A of the inorganic binder satisfies the following condition (5) or (6), where w3A is the weight percentage of the inorganic binder contained in the slurry to be prepared in the slurry preparing step, and w3B is the weight percentage of the organic binder contained in the slurry to be prepared in the slurry preparing step:
- (5) 0<w3B/w3A≤0.8;
- or
- (6) 9≤w3B/w3A.
Dependencies are inferred from the claim text.