JP2002282707A - Laminated type metal carrier - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminated type metal carrier which exhibits sufficient cleaning performance and in which long life is obtained at a low cost. SOLUTION: A honeycomb core body 2 is constituted of many corrugated sheet-like foils 10-10, and the waves 11-11 of each corrugated sheet-like foil 10 have such a form that shapes of half of hexagon are continuously arranged at the interval corresponding to the length of a side of the hexagon. Lacked grooves 4 are provided at least one side of the exhaust gas flow-in side IN and/or the exhaust gas flow-out side OUT of the honeycomb core body 2, in which the projection directions of the waves 11 are arranged opposite so as to be turned upside down. The line of the lacked grooves 4 is guided by a groove guide plate 5 and laminated. The honeycomb core body 2 is accommodated in the outer cylinder 3 having a square tubular form. A laminated type metal carrier 1 is constructed by coating each corrugated sheet-like foil 10 by supporting a cleaning catalyst.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

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

[0002]

2. Description of the Related Art In general, a honeycomb core body made of a metal carrier is composed of a flat foil made of a metal such as a heat-resistant ferritic stainless steel having a thickness of about 50 μm and a corrugated flat foil corrugated foil. The wound honeycomb core body is formed by alternately stacking and winding so as to form a shape. Then, this honeycomb core body is housed in a cylindrical outer cylinder made of a metal such as heat-resistant ferritic stainless steel, the honeycomb core body and the outer cylinder are joined to each other, and the honeycomb core body is coated by coating. Supports a purification catalyst.

[0003] In this type of carrier, the sign cell formed of corrugated foil and flat foil has many sharp corners. Therefore, the cross-sectional area of the sign cell formed of corrugated foil and flat foil is increased by coating and catalyst loading. It is reduced more than expected and the purification ability of the carrier is reduced. In addition, due to the effect of thermal strain due to the time difference of heat transfer between the central part of the carrier and the part near the outer cylinder at the time of heating and cooling, the joint between the flat foil and the corrugated foil in the central part is broken, and a so-called film-out phenomenon occurs. However, a drawback that shortens the life of the carrier has been pointed out.

[0004] Even in the case of a laminated carrier formed by laminating a flat foil and a corrugated foil in a sandwich manner, the irregularities of the corrugated foil are crushed and the arrangement tends to be displaced. The result is the same as As a solution to this, for example, Japanese Patent Application Laid-Open No. Hei 1-236948 (hereinafter referred to as a conventional example) has been disclosed. In this conventional example, a flat plate-shaped portion and a corrugated plate-shaped portion are continuously formed alternately over a predetermined length, and are sequentially bent at the boundary portion to be stacked in multiple layers.

[0005]

In the above conventional example, a sine cell is imagined as a cell shape formed by laminating a flat plate-shaped portion and a corrugated plate-shaped portion. No effect is observed on the improvement of Also, it is expected that expansion and contraction of the flat plate-shaped portion due to thermal strain during heating and cooling can be absorbed and moderated by the corrugated plate-shaped portion formed continuously in the length direction of the metal foil. Improvements will be promised for the assurance of a longer service life. However, the risk that the unevenness of the corrugated plate-shaped portion is crushed and easily shifted from the flat plate-shaped portion is not improved at all.

The present invention has been made to solve the problems of the prior art. An object of the present invention is to provide a laminated metal carrier that can exhibit sufficient purification performance, achieve a long life, and can be manufactured at low cost.

[0007]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention relates to an exhaust gas containing a honeycomb core body housed in an outer cylinder, coating the honeycomb core body, and carrying a purification catalyst. A laminated metal carrier for purification, wherein the honeycomb core body is configured by laminating corrugated sheet-shaped foils in the thickness direction, and the shape of the waves is 1 / hexagonal.
2 is formed continuously with an interval corresponding to one side of a hexagon interposed therebetween, and the corrugated sheet-shaped foil is disposed opposite to the foil whose wave convex direction is inverted, and has a hexagonal shape. A cell having a cross section is formed, and on at least one of the exhaust gas inflow side and / or the exhaust side, a plurality of layers vertically adjacent to each other have a half-side of a hexagonal shape of a wave shape or the convex wave portion. It is characterized in that a missing groove in which a part of a connecting portion interposed between the convex wave portions is missing is provided so as to communicate with each other.

Therefore, in this laminated metal carrier, the interlayer contact surface between all the corrugated foils is one side of a hexagon and a hexagonal honeycomb structure is formed as a whole, so that the structural strength is improved and the length is increased. Life can be guaranteed. Since the divided cell shape is hexagonal, there is no acute angle portion such as a sine cell, and the cross-sectional area of the hexagonal cross-sectional cell divided by the corrugated foil is substantially equal to the cell cross-sectional area after coating. For this reason, a reduction in the cell cross-sectional area after coating does not occur so much, and it is possible to provide a metal carrier capable of sufficiently achieving improvement in purification performance. Furthermore, since each of the layers is constituted by a large number of corrugated foils, it is possible to save labor in the manufacturing process as compared with a configuration in which one corrugated foil is folded in a meandering shape and laminated. .

[0009]

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

A corrugated sheet-like foil 10 shown in FIG. 1 is laminated in the thickness direction to form a honeycomb core body 2 and has a thickness of 50 μm or less and a heat-resistant ferrite-based material of 10 μm or more. Stainless steel foil. As shown in FIG. 2, the shape of the wave 11 is such that a half of a hexagon approximated to a regular hexagon (hereinafter simply referred to as a hexagon) is continuously formed at intervals 13 corresponding to the length 12 of one side of the hexagon. It is the arranged shape.

As shown in FIG. 3, one side of the hexagon is provided on one side of the exhaust gas inlet side IN and the exhaust side OUT shown in FIG.
In the interval 13 between the waves 11 to 11 having the shape of FIG.
The cutout groove 4 cut out over a length of about m is provided.

The honeycomb core body 2 shown in FIG. 6 is composed of a number of corrugated foils 10 to 10. Then, for example, in FIG. 4, with respect to the first layer corrugated shape foil 10 _1, the second layer of the layer 10 _2, the convex direction of the wave cross sectional shape is inverted to 10 ₁ and the opposed vertical . In this manner, the corrugated sheet-like foils 10 ₁ to 10 n and 10 ₂ to 10 ₁₊ n of each layer are obtained.
Are arranged to face adjacent ones. As the method of inverting facing arrangement of the even-numbered layers 10 ₂ to 10 1 ₊ n,
Although illustration is omitted, a method of inverting the same corrugated foil as the odd-numbered layers 10 _{1 to} 10 n is used. When processing a corrugated metal foil, an odd-numbered layer is, for example, an upwardly convex type that expands upward. For the even-numbered layers, a method of processing using, for example, a downwardly convex shape that swells downward can be freely selected.

As described above, the honeycomb core body 2 is composed of the odd-numbered corrugated foils 10 _{1 to} 10 n and the odd-numbered corrugated foils 10 _{1 to} 10 n which are inverted even-numbered layers. As shown in FIG. 4 (a), the plate-shaped foils 10 ₂ to 10 1 ₊ n are arranged facing each other to form a set, and the sets are sequentially laminated. Therefore, by configuring the honeycomb core body 2 as described above, the honeycomb core body 2 becomes an aggregate of cells having a hexagonal cross section as shown in FIG.

The missing grooves 4 are provided in the corrugated foils 10 to 10 of all the layers as described above, and as shown in FIG. 10 are sequentially stacked, and the missing groove 4 is guided by the groove guide plate 5, so that the hexagonal cross-section cells are accurately formed without deviation. In this embodiment, the groove guide plates 5 are inserted into the rows of the missing grooves 4 to 4 on both the left and right ends of FIG. 1
Guides 0-10. The length of the groove guide plate 5 is substantially the same as the distance between opposing sides of the outer cylinder 3 described later. The honeycomb core body 2 aligned and stacked in the guide jig 6 is applied to a required portion (for example, an exhaust gas inflow side I) by a laser beam.
The groove guide plate 5 is removed from the honeycomb core body 2 by being welded and fixed to each other at the overlapping portion of the interval 13 at the N and the discharge side OUT.

The honeycomb core body 2 is housed in an outer cylinder 3 having a rectangular opening and a rectangular tube shape as a whole, and the two are joined by welding or the like to form a corrugated foil 10.
To 10 to carry a purification catalyst to complete the laminated metal carrier 1.

This embodiment configured as described above has the following effects.・ Corrugated sheet-shaped foils 10 to 10 each having a half sectional shape of a hexagon
Is a hexagonal aggregate as shown in FIG. Accordingly, since all internal angles of the hexagon are substantially 120 degrees and there are no acute angles, the cell cross-sectional areas before and after coating are substantially equal, unlike the conventional case. Therefore, good purification performance can be expected.

The corrugated foils 10 to 10 in adjacent cell portions are in surface contact with each other as shown in FIG. 5, so that the cell strength is increased and there is almost no fear of film out in the sign cell. In addition, since only two of the six surfaces are joint surfaces, weight reduction can be achieved.

The missing grooves 4 to 4 penetrating in the laminating direction of the corrugated foils 10 to 10 allow the exhaust gas to flow in a direction crossing the exhaust gas inlet side IN of the metal carrier 1. Therefore, the temperature difference between the central portion and the outer peripheral portion of the metal carrier 1 can be made uniform at an early stage.

The honeycomb core body 2 is composed of a large number of corrugated foils 10 to 10 constituting each layer.
Therefore, as compared with a configuration in which one sheet of corrugated foil is bent in a meandering shape and laminated, labor in the manufacturing process can be saved. In other words, when the corrugated sheet-shaped foil is used in a meandering shape at the end of the core body, a loss of time required for the bending and a shape distortion of a hexagonal cross-sectional cell formed between the layers,
That is, there is a shift between the vertically adjacent protrusions,
There was also a time loss required for correction and adjustment. In contrast,
In the laminated metal carrier according to this embodiment, the corrugated foils 10 to 10 of the honeycomb core body 2 are single pieces having no continuity for each laminated layer, so that such a time loss can be reduced. In addition, by guiding the communicating missing grooves 4 to 4 by the groove guide plate 5, it is possible to guarantee the formation of the hexagonal cross section cell accurately and easily.

Further, as described above, since the labor in the manufacturing process can be omitted, the manufacturing can be performed at low cost. In addition, this invention is not limited to the said embodiment, and may be embodied in the following aspects.

The number of the groove guide plates 5 is one or three or more on one side of the exhaust gas inflow side IN or the exhaust side OUT. However, it is preferable that the number of the groove guide plates 5 be an optimum number according to the shape dimension of the guide jig 6.
Even in this case, the same effect as in the above-described embodiment can be obtained.

Unlike the above embodiment, the corrugated foils 10 to 10 are laminated along the long side direction of the opening of the outer cylinder 3. In the case of such a configuration, the heat transfer between the central portion of the honeycomb core body 2 and the long side end portion (between the short sides) is promoted by the communicating missing grooves 4, and the thermal distortion can be reduced.

When coating the corrugated sheet-shaped foils 10 to 10, use the groove guide plate 5 without removing it. In this way, the life of the metal carrier 1 can be further guaranteed.

The shape of the opening of the outer cylinder 3 is formed in a shape other than a square, for example, any one of a hexagon, an ellipse, and a circle. Even in this case, the same effect as in the above-described embodiment can be obtained.

[0025]

As described above, in the present invention, when a plurality of corrugated foils are laminated in the thickness direction to form cells having a hexagonal cross section, the corrugated foils are used in the present invention. By providing a missing groove guided by a groove guide plate for alignment and stacking, it is easy to manufacture and can reduce manufacturing cost, and also exhibits sufficient purification performance and long life with guaranteed accurate cell shape Demonstrate the effect that can achieve.

[Brief description of the drawings]

FIG. 1 is a partial front view of a corrugated foil.

FIG. 2 is a partially enlarged front view of a corrugated sheet-shaped foil.

FIG. 3 is a partially enlarged perspective view of a missing portion of a corrugated sheet-shaped foil.

FIG. 4A is an explanatory diagram of a laminating process of a corrugated sheet-shaped foil,
(B) is a partially enlarged perspective view of one set of corrugated foils.

FIG. 5 is a partially enlarged front view of the laminated metal carrier.

FIG. 6 is a partially enlarged perspective view of a laminated metal carrier.

FIG. 7 is a partially enlarged cross-sectional view of the laminated metal carrier.

FIG. 8 is a partially broken plan view of the laminated metal carrier.

[Explanation of symbols]

REFERENCE SIGNS LIST 1 laminated metal carrier 2 honeycomb core body 3 outer cylinder 4 missing groove 5 groove guide plate 6 guide jig 10
Corrugated sheet foil, 11 ... waves.

Continued on the front page F term (reference) 3G091 AA02 AB01 BA07 BA39 CA27 FC02 GA06 GA11 GA12 GA16 HA31 4D048 BA39X BB02 BB12 BB13 CA01 4G069 AA01 AA08 BA17 BA18 CA03 DA06 EA22 EA25 EB15Y

Claims (1)

[Claims] 1. A stacked metal carrier for purifying exhaust gas, wherein a honeycomb core body is housed in an outer cylinder, the honeycomb core body is coated, and a purifying catalyst is supported, wherein the honeycomb core body is provided. Is formed by laminating corrugated sheet-shaped foils in the thickness direction, and the shape of the wave is a convex wave formed to a half of a hexagon approximated to a regular hexagon (hereinafter simply referred to as a hexagon). Part is formed continuously with an interval equivalent to one side of the hexagon, and this corrugated sheet-shaped foil is placed opposite to the foil whose wave convex direction is inverted, forming a cell with a hexagonal cross section, On at least one side of the inflow side and / or the discharge side, a plurality of layers vertically adjacent to each other lack a part of a half-top of a wavy hexagon or a part of a continuous part interposed between the convex wavy parts. Are provided so that the missing grooves communicate with each other Laminated metal carrier, wherein the door.