Method for manufacturing holding sealing material

Abstract

A method for manufacturing a holding sealing material includes needling a mat containing first inorganic fibers to manufacture a needle mat containing the first inorganic fibers entangled. A binder is allowed to adhere to the needle mat. A sheet-forming slurry containing at least second inorganic fibers and a binder is supplied on the needle mat to which the binder adhered. The sheet-forming slurry is maintained on the needle mat for a predetermined time. The sheet-forming slurry is dehydrated to manufacture a sheet-processed mat precursor laminated on the needle mat. The needle mat and the sheet-processed mat precursor laminated on the needle mat are dried.

1 . A method for manufacturing a holding sealing material, the method comprising:
 needling a mat containing first inorganic fibers to manufacture a needle mat containing the first inorganic fibers entangled;   allowing a binder to adhere to said needle mat;   supplying a sheet-forming slurry containing at least second inorganic fibers and a binder on the needle mat to which said binder adhered;   maintaining the sheet-forming slurry on the needle mat for a predetermined time;   dehydrating said sheet-forming slurry to manufacture a sheet-processed mat precursor laminated on said needle mat; and   drying said needle mat and said sheet-processed mat precursor laminated on said needle mat.   
     
     
         2 . The method for manufacturing a holding sealing material according to  claim 1 ,
 wherein   an amount of the binder adhered to said needle mat is less than a binder content of said sheet-forming slurry.   
     
     
         3 . The method for manufacturing a holding sealing material according to  claim 1 ,
 wherein   said predetermined time is from about 10 seconds to about 60 seconds.   
     
     
         4 . The method for manufacturing a holding sealing material according to  claim 1 ,
 wherein   said first inorganic fibers comprises at least one of alumina fibers, ceramic fibers, and silica fibers.   
     
     
         5 . The method for manufacturing a holding sealing material according to  claim 1 ,
 wherein   an average fiber length of said first inorganic fibers is from about 0.5 cm to about 10 cm.   
     
     
         6 . The method for manufacturing a holding sealing material according to  claim 1 ,
 wherein   an average fiber length of said second inorganic fibers is from about 0.2 mm to about 20 mm.   
     
     
         7 . The method for manufacturing a holding sealing material according to  claim 1 ,
 wherein   an average fiber diameter of said first inorganic fibers is from about 1 μm to about 20 μm.   
     
     
         8 . The method for manufacturing a holding sealing material according to  claim 1 ,
 wherein   an average fiber diameter of said second inorganic fibers is from about 1 μm to about 20 μm.   
     
     
         9 . The method for manufacturing a holding sealing material according to  claim 1 ,
 wherein   said binder in an amount of about 1 part by weight to about 30 parts by weight with respect to 100 parts by weight of said second inorganic fibers is used.   
     
     
         10 . The method for manufacturing a holding sealing material according to  claim 1 ,
 wherein   at least one of an organic binder and an inorganic binder are used as said binder.   
     
     
         11 . The method for manufacturing a holding sealing material according to  claim 10 ,
 wherein   said organic binder comprises at least one of rubbers, water-soluble organic polymers, thermoplastic resins, and thermosetting resins.   
     
     
         12 . The method for manufacturing a holding sealing material according to  claim 10 ,
 wherein   said inorganic binder comprises at least one of alumina sol and silica sol.   
     
     
         13 . The method for manufacturing a holding sealing material according to  claim 1 ,
 wherein   said sheet-forming slurry further comprises a flocculant.   
     
     
         14 . The method for manufacturing a holding sealing material according to  claim 13 ,
 wherein   said flocculant in an amount of about 0.1% by weight to about 3.0% by weight is used.