JP2001293379A - Exhaust gas cleaning metal carrier - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an exhaust gas cleaning metal carrier simple in constitution, preventing film-out, enhancing catalytic action and prevented from local heating. SOLUTION: The exhaust gas cleaning metal carrier 11 is obtained by inserting a honeycomb body 12, which is formed so as to comform to the outer shape of an outer cylinder 14 by bending a flat foil 21, in the outer cylinder 14 under pressure along with a heat insulating material 13. The honeycomb body 12 has a uniform hexagonal shape over the total width W at the bent parts C of the flat foil. In the other part of the honeycomb body 12, the total width W in the direction right-angled to an exhaust gas natural flow channel direction is quatered into lengths W1, W2, W3, W4 and directions wherein projected parts having a trapezoidal shape forming the half of a regular hexagonal shape are positioned are different by 180 deg. and a large number of cells having a regular hexagonal cross section are arranged in a close contact state in the exhaust gas natural flow channel direction.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal carrier for purifying exhaust gas from an internal combustion engine such as an automobile engine.

[0002]

2. Description of the Related Art A metal carrier is formed by winding a flat foil made of a heat-resistant metal such as ferritic stainless steel having a thickness of about 50 μm, and a corrugated flat foil into a corrugated foil, or The honeycomb body is formed by alternately stacking and laminating, and this is housed in an outer cylinder made of metal such as heat-resistant ferritic stainless steel and joined to each other by brazing etc. I have. The flow rate of the exhaust gas is larger in the central portion of the metal honeycomb body, and the temperature rises faster. Since flat foils are less likely to absorb thermal stress than corrugated foils, stress distortion is likely to occur at the joints between the flat foils and the corrugated foil, so that a so-called film-out phenomenon may occur. In a sine cell composed of a flat foil and a corrugated foil, an acute gap naturally occurs at the junction between the two, and a flat foil or a corrugated foil coated with a brazing material in advance is wound into an outer cylinder. When the heat treatment is carried out, the brazing material is eluted, and there is a disadvantage that an extreme coat pool is generated and the cell cross-sectional area is reduced.

A structure for preventing the above film out at a low cost is disclosed in Japanese Patent Publication No. 60-27807 (hereinafter referred to as a first conventional example). In the metal carrier described in this publication, one of the metal foils forming the flow path of the exhaust gas corresponds to a local raised portion or a protruding piece, and the other adjacent metal foil corresponds to the raised portion or the protruding piece, respectively. A carrier having a concave portion or a hole and having a structure in which both act in a shape-restricting manner.

[0004] Japanese Patent No. 2648281 (hereinafter referred to as a second conventional example) discloses a technique for preventing the temperature rise in the central portion of the carrier from becoming too high. This has a vortex formation structure composed of a plurality of superposed metal plate-like structures. This swirl flow forming structure has a bridge-like portion 2 and a narrower gutter-groove portion 3, and the bottom portion 4 of the first row of gutter-groove portions 3 is formed of the second row of bridge-like portions 2. It is in the same plane as the top part 5, and these are alternately juxtaposed. For this reason, since they are arranged shifted in the layer direction, the gutter-shaped portion 3 in the bridge-shaped portion 2 is formed.
Has an opening 6 on the side, and is separated from each other by a flat strip 7. The vortex flow forming structure is formed in a cylindrical body as a whole.

[0005]

In the first prior art example, a projecting piece and a concave portion are provided on each of two superposed layers which are wound at an interval in the radial direction, and the film out is performed by the shape restraining action of both. Preventing. Therefore, in order to obtain this effect, the molding pitch of these protruding pieces and recesses must be accurate, and extreme care must be taken when assembling them. Furthermore,
When one set of one protruding piece and one concavity is formed into one set, even if the film out of the set itself can be reduced, the film out between the sets is eliminated. It is unknown whether it is.

In the second conventional example, a bridge-like portion 2 and a gutter groove-like portion 3 having a smaller width than the bridge-like portion 2 are arranged so as to be shifted in the layer direction. This is because the molding arrangement of the first layer and the second layer is shifted in advance, or the first layer and the second layer having the same molding arrangement are overlapped and arranged in the layer direction. Any method of shifting the positions of the bridge-like portion 2 and the gutter-groove portion 3 in the second row with the layer is adopted. However, these are not simple combinations but have complicated structures and are economically expensive. In the second conventional example, the provision of the openings 6 contributes to weight reduction, but the provision of the flat strips 7 for partitioning has an adverse effect on weight reduction.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and has an object to provide a metal carrier for purifying exhaust gas and a method thereof which can prevent film out, improve catalytic activity, and prevent local heating of the carrier with a simple structure. The purpose is to provide.

[0008]

In order to solve the above-mentioned problems, according to the present invention, a honeycomb carrier for supporting a catalyst made of a long thin metal foil is formed of a continuous triangular shape forming a half of a regular hexagon. A shape having a side and a horizontal portion extending by one side length in both directions from both ends is folded back by 180 degrees at a position for adapting a continuously formed thin metal foil to the shape of the outer cylinder. Having a honeycomb portion with cells formed therein,
The cross-sectional shape viewed from the exhaust gas natural flow path direction is a shape in which a large number of cells having a regular hexagonal cross section are closely arranged in a layer form, and the shape viewed from a direction orthogonal to the exhaust gas natural flow path direction is
Except for the 180-degree folded portion, the cells of the regular hexagonal cross section are divided into n in the length direction, that is, in the exhaust gas flow direction, and each 1 / n has a trapezoidal projection forming a half of the regular hexagon. Is a metal carrier for purifying exhaust gas, comprising a honeycomb body provided with a heat insulating material and having a honeycomb body provided with a space for generating a vortex between the directions by 180 degrees.

Therefore, since the honeycomb body does not have an acute angle portion, there is no occurrence of coat accumulation and the film-out phenomenon can be prevented. In addition, since the honeycomb portion has the above-described structure, the exhaust gas passing therethrough has a turbulent shape, the opportunity for the exhaust gas to come into contact with the catalyst increases, the catalytic reaction effect is effectively obtained, and the carrier is locally heated. Can be prevented. Further, the range of choice of the flow path of the exhaust gas is widened, the self-regulation of the exhaust gas is expected, the ventilation resistance is reduced, the output loss of the internal combustion engine is reduced, and the output can be improved.

According to a second aspect of the present invention, in the exhaust gas purifying metal carrier according to the first aspect, a diagonal line of a regular hexagon is horizontally positioned following a horizontal portion corresponding to one side of a regular hexagon. The upper half shape and the lower half shape from the diagonal line of the regular hexagon are 1% of the full width of the long flat metal foil.
/ N is formed in a direction symmetrical by 180 degrees for each / n, and then a horizontal portion corresponding to the length of one side of a regular hexagon is interposed, and a half of the upper half from the diagonal of the regular hexagon and a lower half The shape is formed in a direction symmetrical at 180 degrees every 1 / n of the entire width of the long flat metal foil. The forming is continuously repeated, and folded back at 180 degrees to adapt to the shape of the outer cylinder. Only the regular hexagonal cell in the corner part to be turned around is folded back over the lower half-shaped center line that is formed uniformly over the entire width of the long flat metal foil, and this bent part is contact-fixed. It has been formed.

In addition to the effects of the first aspect, a cell which can be formed by an easy manufacturing process, and in which the corner portion which is turned back and changed direction is formed uniformly over the entire width of the long flat metal foil is formed. Therefore, the risk of deformation or breakage due to a local load on the outer peripheral portion can be reduced.

According to a third aspect of the present invention, there is provided the exhaust gas purifying metal carrier according to any one of the first to third aspects, wherein the metal carrier is 180 degrees symmetrical in every 1 / n of the entire width of the long thin metal foil. Each of the end faces of the upper half shape and the lower half shape from the diagonal line of the formed regular hexagon is parallel, oblique, or arc-shaped with respect to the width of the long metal flat foil.

Accordingly, the exhaust gas passing through the honeycomb portion is
It has a more turbulent shape, increases the chance of contact of the exhaust gas with the catalyst, effectively obtains a catalytic reaction effect, and can further prevent the carrier from being locally heated.

According to a fourth aspect of the present invention, a horizontal portion corresponding to the length of one side of a regular hexagon is left with respect to a long metal flat foil,
When the diagonal line of the regular hexagon is positioned in the horizontal direction, the upper half shape and the lower half shape from the regular hexagonal diagonal line are symmetrical by 180 degrees every 1 / n of the full width of the long flat metal foil. Then, the equivalent length of one side of the regular hexagon is interposed over the entire width of the long flat metal foil, and then the upper half shape and the lower half shape from the diagonal line of the regular hexagon. As in the previous case, the symmetrical direction is formed at every 1 / n of the entire width of the long flat metal foil, and the horizontal portion and the formed portion are continuously formed alternately in the same manner.
A folded portion is interposed at a point of a desired length in order to be folded at 0 degrees and stacked and arranged to adapt to the shape of the outer cylinder, and the folded portion is provided uniformly over the entire width of the long flat metal foil. Following the length of one side of the regular hexagon, three consecutive sides (b), (c), and (d) that form half of the regular hexagon
Then, a shape having horizontal portions (a) and (e) corresponding to the length of one side of a regular hexagon which is extended is uniformly formed over the entire width, and the center line of this shape is creased. As one
It is bent at 80 degrees, the bent portions are brought into contact with each other to form a second layer, and a third layer, a fourth layer, and so on are successively formed. This is a method for producing a metal carrier for purifying exhaust gas forming a honeycomb body.

Therefore, the metal carrier for purifying exhaust gas which can obtain the effects of claims 1 to 3 can be easily manufactured with a simple structure, and can contribute to cost reduction. In addition, since it is formed by molding only one kind of long metal thin foil and the vortex generation space is provided, the weight of the honeycomb body can be significantly reduced by that much. Therefore, when the purification is started, the amount of the honeycomb body 12 to be heated is small, so that the honeycomb body 12 is instantaneously heated, and the reaction start time can be shortened.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS.

The metal carrier 11 has a structure in which a heat insulating material 13 is wound around the entire outer periphery of the honeycomb body 12 and is pressed into the outer cylinder 14 in that state. The honeycomb body 12 is formed by a manufacturing method described later. The material is a known heat-resistant ferritic stainless steel foil having a thickness of 50 μm or less, and the processing such as application of a binder, spraying with a wax, and brazing with a vacuum may be performed by a known method. The material of the heat insulating material 13 may also be a refractory material such as a known alumina slurry,
The material of the outer cylinder 14 may be a known material such as a heat insulating ferritic stainless steel.

As shown in FIG. 2, a long flat foil 21 is cut into a predetermined number, leaving a length E corresponding to one side of a regular hexagon. For example, the total width W of the flat foil 21 is defined as the lengths W1 and W, respectively.
2, 4 and W4, the projection 22 formed on the flat foil 21 has a length W1, W2, W3, W
Four are formed alternately. That is, if the length W1 portion is projected upward with respect to the horizontal plane of the flat foil 21, the adjacent length W2 portion is projected downward, and the adjacent length W3 portion is projected upward. The length W4 is formed so as to protrude downward. The protruding shape is exactly the same for the upward shape and the downward shape, and is a trapezoidal shape that forms half of a regular hexagon.

Next, from the position where the horizontal portion 23 having an interval corresponding to the length of one side of the regular hexagon is left, the convex portion 22 of the upper (lower) half of the regular hexagon is formed again. That is, the upper (lower) half convex portion 22 and the horizontal portion 23 corresponding to the length of one side of a regular hexagon extending in the left-right direction of the drawing are alternately and continuously arranged at a desired length. And the first layer 201
01 is bent to have a shape adapted to the shape of the outer cylinder 14. At the bent portion C, the entire width W of the flat foil 21 is formed into a half trapezoidal shape without dividing the entire width W into four parts and integrally forming a regular hexagon. As shown in FIG. 3, the trapezoidal shape is inverted by 180 ° about the center line 24 so as to be arranged by a dotted line. That is, the portion 26 that has been inverted by 180 degrees at the center line 24 has a portion 26 ′ below the portion 25.
And a portion 27 following this portion 26 is also
Also located as part 27 ', part 28 is part 2
It is located at 8 '. Therefore, the portion 25 and the portion 26 'come into contact with each other to form a folded portion, and the portions 30, 29, 2
7 'and 28' form four sides of a uniform regular hexagon over the entire width W of the flat foil 21.

As shown in FIG. 3, a first layer 201 is formed by cells a, b, c, and d having a regular hexagonal cross section and a center line 2 is formed.
4 and the cell e is positioned at the cell e 'and the cell f is positioned at the cell f' to form a third layer 202 '. Then, between the first layer 201 and the third layer 202 ', a regular hexagonal cross section including four sides (parts 30, 29, 27', 28 ') of a uniform regular hexagon over the entire width W of the flat foil 21. Is formed. A cell B having a regular hexagonal cross section is formed by cells c, d, e ', and f' having a regular hexagonal cross section. Similarly, the first layer 201 and the third layer 20
Between 2 ′, a cell is formed. Therefore, these are 2
In the state before the flat foil 21 is turned over, the portion 202 that was supposed to be the second layer is turned upside down to form the third layer 202 ′ of the honeycomb body 12.

Thus, the honeycomb body 12 shown in FIG. 1 is completed by laminating up to the n-th layer. Thereafter, a heat insulating material 13 is wound around the entire outer periphery of the honeycomb body 12, and the outer cylinder 1
4, the metal carrier 11 can be obtained. At this time, as shown in FIG. 4, a cell 33 uniformly formed over the entire width of the long flat metal foil is formed at the corner portion which is turned back and changed direction, similarly to the cell A described above. ing.

As described above, according to the embodiment of the present invention, the following features can be obtained. (A) In the honeycomb body 12 of the present embodiment, since there is no acute angle portion, there is no occurrence of a coat pool and the occurrence of a film-out phenomenon can be prevented.

(B) In this embodiment, in the entire width W direction of the cells A and B, for each of the lengths W1, W2, W3 and W4,
Since the directions of forming the regular hexagonal cross section are different by 180 degrees, the exhaust gas passing through the honeycomb body 12 becomes turbulent, the chance of contact with the catalyst increases, and the catalytic reaction effect by mixing can be obtained. In addition, with such a configuration, the selection range of the flow path through which the exhaust gas passes increases, so that there is no portion where the pressure becomes extremely high, and the self-regulating effect of the exhaust gas can be obtained. Therefore, the output loss of the internal combustion engine is reduced, and the output can be improved.

(C) In the present embodiment, the honeycomb body 1 is bent by bending the flat foil 21, that is, by using only one long thin metal foil.
Since the second member 2 is formed, the structure is simple, the cost can be reduced, and the honeycomb body 12 can be reduced in weight. Therefore, when the purification is started, the amount of the honeycomb body 12 to be heated is small, so that the honeycomb body 12 is instantly heated, and the reaction start time can be shortened.

(D) In the present embodiment, since the flat foil 21 is formed in the shape of the honeycomb body 12 by folding the portion 26, the manufacturing method is simple. (E) In the present embodiment, in order to adapt to the shape of the outer cylinder 14, the corner portion which is folded back by 180 degrees and turned around is formed uniformly over the entire width of the long flat metal foil. Since the cells A and 33 are formed, the risk of deformation and breakage can be reduced with respect to a local load on the outer peripheral portion. (Modification) The above embodiment may be modified as follows.

In the above-described embodiment, the first layer is arranged such that a half of the hexagonal shape is alternately positioned on the upper side or the lower side in the exhaust gas flow direction. However, this is performed for the second layer to the (m-1) th layer (the layer immediately before the last layer), and the first layer and the mth layer which is the last layer are equivalent to the length of one side of a regular hexagon. Then, a shape having three consecutive sides forming a half of a regular hexagon and a horizontal portion extending by half the length of one side in both directions from both ends is uniformly formed over the entire width. You may. In this case, the possibility of deformation or breakage can be reduced with respect to the local load on the upper or lower part.

In the above embodiment, each 1 / n of the entire width of the long flat metal foil has an end face in the width direction of a half shape of a regular hexagon formed in the direction of 180 degrees symmetry,
The width was made parallel to the width of the long metal flat foil. However, a cut may be made so as to be formed obliquely or in an arc shape with respect to the width of the long flat metal foil. In addition, a part may be inclined. For example, as shown in FIG. 6, a long metal flat foil 37 in which a side of a middle surface 36 of a trapezoidal cross section that forms a half of a hexagon protruding upward or downward is inclined is formed. Further, as shown in FIG. 7, a long metal flat foil 39 in which the side of a middle surface 38 of a trapezoidal cross section that forms a half of a hexagon protruding upward or downward has a mountain-shaped oblique shape may be used. In these cases, the sides of the adjacent surfaces 36 and 38 are shaped so as to match each other. In order to clarify the oblique shape of the long flat metal foil 37, FIGS. 6 and 7 show a hexagon formed parallel to the width of the long flat metal foil shown in the above embodiment. The shape is indicated by a two-dot chain line.

The overall shape of the honeycomb body 12 is the outer cylinder 14
For example, as shown in FIG. 5, if the outer cylinder 14 is, for example, an octagonal polygon, as shown in FIG. 5, the flat foil 21 may be changed to be bent to fit this. .

Next, regarding technical ideas other than the invention described in the claims that can be grasped from the above embodiment and modifications,
These effects are described below. (1) In an exhaust gas purifying metal bile composed of an outer cylinder in which a catalyst supporting honeycomb carrier made of a long metal thin foil is housed together with a heat insulating material, the honeycomb carrier is seen from the natural exhaust gas flow path direction. In a shape in which a large number of cells having a regular hexagonal cross section are arranged in close contact with each other in a layered manner, when viewed from a direction perpendicular to the natural flow direction of the exhaust gas, the cells having the regular hexagonal section are
In the exhaust gas flow direction, the direction in which the trapezoidal protrusions that form half of the regular hexagon are located at 180 degrees, and the honeycomb portions are provided with alternately different shapes, and in the space of the honeycomb portions,
A metal carrier for purifying exhaust gas, wherein a vortex is generated.

Therefore, the same effect as the first aspect can be obtained.

[0031]

As described above, since the honeycomb body is an aggregate of cells having a regular hexagonal cross section, the honeycomb body has no acute-angled portions, so that there is no occurrence of coat accumulation unlike the case of a sine cell, and the occurrence of film out can be prevented. The cell is divided into n in the longitudinal direction, and the direction of forming a regular hexagonal cross section every 1 / n is 18
Since there is a difference of 0 °, a space for generating a vortex is provided there, and the turbulent flow shape in the passage of the exhaust gas increases the chances of contact with the catalyst uniformly, so that a catalytic reaction effect by mixing can be expected.

A honeycomb body formed by molding only one kind of long thin metal foil can be easily manufactured and contribute to cost reduction. Further, since a vortex generating space is provided, the weight of the honeycomb body is correspondingly increased. Can be greatly reduced. for that reason,
As an effect of this, at the time of start-up, the reaction start time can be shortened by instantaneous heating. Further, the range of selection of the exhaust gas flow path is widened, self-regulation of the exhaust gas is expected, the ventilation resistance is reduced, the output loss of the internal combustion engine is reduced, and the output can be improved.

[Brief description of the drawings]

FIG. 1 is a front sectional view showing an embodiment of a metal carrier for purifying exhaust gas.

FIG. 2 is a perspective view showing a structure of a flat foil constituting a honeycomb portion.

FIG. 3 is an explanatory view of a method for manufacturing a honeycomb body.

FIG. 4 is a perspective view of a part of the honeycomb body after manufacture.

FIG. 5 is a front sectional view showing an exhaust gas purifying metal carrier in a modified example.

FIG. 6 is a perspective view of a main part of a first modified example of a long metal thin foil forming a honeycomb body.

FIG. 7 is a perspective view of a main part of the second modified example.

[Description of References] a, b, B, c, d, e, e ′, f, f ′.
33: A regular hexagonal cell at a corner, C: a bent part,
W: full width, W1, W2, W3, W4: length, 11: metal carrier, 12: honeycomb body, 13: heat insulating material, 14: outer cylinder,
21, 37, 38 ... flat foil, 23 ... horizontal part, 24 ... center line, 25, 26 '... folded part, 201' ... second layer, 2nd
02 ': Third layer.

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[Procedure amendment]

[Submission date] April 21, 2000 (200.4.2
1)

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Claim 3

[Correction method] Change

[Correction contents]

[Procedure amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0012

[Correction method] Change

[Correction contents]

[0012] The invention described in claim 3 is the invention according to claim 1 or
3. The exhaust gas purifying metal carrier according to claim 2, wherein an upper half shape and a lower half from a diagonal line of a regular hexagon formed in a 180-degree symmetric direction for every 1 / n of a total width of the long thin metal foil. Each end face of the shape is parallel, oblique, or arc-shaped with respect to the width of the long flat metal foil.

[Procedure amendment 3]

[Document name to be amended] Statement

[Correction target item name] 0026

[Correction method] Change

[Correction contents]

In the above-described embodiment, the first layer is arranged such that a half of the hexagonal shape is alternately positioned on the upper side or the lower side in the exhaust gas flow direction. However, this is performed for the second layer to the (m-1) th layer (the layer immediately before the last layer), and the first layer and the mth layer which is the last layer are equivalent to the length of one side of a regular hexagon. min followed by a continuous three sides forming a regular hexagon half, may be a shape having a length component extending horizontal portion of the both end portions do we one side so as to uniformly molded over Zenhaba . In this case, the possibility of deformation or breakage can be reduced with respect to the local load on the upper or lower part.

[Procedure amendment 4]

[Document name to be amended] Statement

[Correction target item name] Explanation of sign

[Correction method] Change

[Correction contents]

[Description of References] a, b, B, c, d, e, e ′, f, f ′.
33: A regular hexagonal cell at a corner, C: a bent part,
W: full width, W1, W2, W3, W4: length, 11: metal carrier, 12: honeycomb body, 13: heat insulating material, 14: outer cylinder,
21: flat foil , 23: horizontal part, 24: center line, 25, 2
6 ': folded portion, 201': second layer, 202 ': third layer.

Continued on the front page F term (reference) 3G091 AA02 AB01 BA01 BA38 BA39 GA08 GA16 GA24 GB01X 4D048 BA39X BB02 BB12 CC38 4G069 AA01 AA08 BA17 BA18 CA18 EA20 EA22 EA25 EA26 EB10 FA01 FB66 FB72 FB75

Claims (4)

[Claims] 1. A honeycomb carrier for supporting a catalyst made of a long thin metal foil has three continuous sides forming a half of a regular hexagon and a horizontal portion extending by one side in both directions from both ends. Shape
The continuously formed thin metal foil has a honeycomb portion formed by folding back 180 degrees at a position for adapting to the shape of the outer cylinder and overlapping to form a cell. It is a shape in which a large number of cells having a regular hexagonal cross section are arranged in close contact with each other in a layered manner. It is divided into n in the length direction, that is, in the exhaust gas flow direction, and the direction in which the trapezoidal projections that form half of the regular hexagon are located 180 degrees differently every 1 / n, and vortices are generated between them. A metal carrier for exhaust gas purification, consisting of an outer cylinder in which a honeycomb body with a space is provided together with a heat insulating material. 2. A half-shape above a diagonal of a regular hexagon and a lower half when a diagonal of the regular hexagon is positioned in a horizontal direction, following a horizontal portion equivalent to the length of one side of the regular hexagon. The shape is formed in a 180-degree symmetrical direction every 1 / n of the entire width of the long flat metal foil. Then, a horizontal portion corresponding to one side of a regular hexagon is interposed, and The upper half shape from the diagonal of the square,
The lower half shape is continuously formed in a 180-degree symmetrical direction every 1 / n of the entire width of the long flat metal foil. Only the regular hexagonal cells at the corners that are turned back and turned around turn the lower half-shaped center line that is formed uniformly over the entire width of the long metal flat foil, and touch this bent part 2. The exhaust gas purifying metal carrier according to claim 1, which is formed by fixing. 3. For every 1 / n of the total width of the long thin metal foil, 18
From the diagonal line of the regular hexagon formed in the direction of 0 degree symmetry, each of the upper and lower half-shaped end faces is parallel, inclined, or arc-shaped with respect to the width of the long flat metal foil. The exhaust gas purifying metal carrier according to any one of claims 1 to 3, wherein 4. An upper side from a diagonal line of a regular hexagon when a diagonal line of the regular hexagon is positioned in a horizontal direction while leaving a horizontal portion corresponding to a length of one side of the regular hexagon with respect to a long metal flat foil. The half shape and the lower half shape are formed in a 180 ° symmetrical direction every 1 / n of the entire width of the long flat metal foil, and then the length of one side of the regular hexagon is set to the long metal. Interposed over the entire width of the flat foil, and then the upper half shape and the lower half shape from the diagonal line of the regular hexagon are symmetrical at the 1 / n intervals of the full width of the long flat metal foil as before. Similarly, the horizontal portion and the formed portion are alternately and continuously formed, and are folded back at 180 degrees to be laminated and arranged so that the folded portion is interposed at a point of a desired length in order to adapt to the shape of the outer cylinder. Now, the equivalent length of one side of a regular hexagon that is provided uniformly over the entire width of the long metal flat foil Subsequently, a shape having three continuous sides forming a half of a regular hexagon and a horizontal portion corresponding to the length of one side of the regular hexagon extended thereafter was uniformly formed over the entire width. Bend 180 degrees with the center line of the shape as a fold,
A second layer is formed by bringing the bent portions into contact with each other, and a third layer, a fourth layer, and so on are successively formed, and the layers are stacked up to m layers adapted to the shape of the outer cylinder to form the honeycomb body. A method for producing a metal carrier for purifying exhaust gas.