JP2004290784A - Method for manufacturing catalyst carrier - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a catalyst carrier, which has carrier cells almost uniform in area, excellent in catalytic purifying capacity. <P>SOLUTION: A strip-like corrugated sheet and a strip-like flat sheet are superposed one upon another and wound to manufacture a primary metal catalyst carrier 2 having a larger outer diameter than that of a target size and this primary metal catalyst carrier 2 is cut so as to partially cut off an area excepting the winding core mark area of the metal catalyst carrier to manufacture a secondary metal catalyst carrier 1 having a target size. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for producing a catalyst carrier used in a catalytic converter for purifying harmful components contained in exhaust gas of an internal combustion engine or the like.
[0002]
[Prior art]
As a method for producing this type of catalyst carrier, there is a method as shown in FIGS. 6 and 7 (for example, see Patent Document 1).
[0003]
Hereinafter, a method for producing the catalyst carrier will be briefly described. As shown in FIG. 6A, one end of a band-shaped flat plate 51 is inserted into the slit at the tip of the winding shaft 50 and is sandwiched. Next, as shown in FIG. 6B, the winding shaft 50 is rotated by １ ／. Subsequently, as shown in FIG. 6C, one end of a band-like corrugated plate 52 is inserted between the winding shaft 50 and the flat plate 51. Next, as shown in FIG. 6D, the winding shaft 50 is wound, and the flat plate 51 and the corrugated plate 52 are wound in a state of being overlapped. Then, as shown in FIG. 6E, the initial winding is performed to form a cylindrical honeycomb body, and then the initial winding body 53 is manufactured. Further, subsequently, the flat plate 51 and the corrugated plate 52 are wound in an overlapped state, and the outermost flat plate 51 is spot-welded to remove the winding shaft 50, thereby completing the manufacture of a honeycomb structure (not shown) having a predetermined size. I do.
[0004]
Alternatively, as shown in FIGS. 7A and 7B, the contact surface with the end surface of the initial winding body 53 has substantially the same area, and the predetermined surface is clamped by a disk 55 detachable from the winding shaft 54. Wind up to size. Finally, the disks 55 on both sides are removed from the initial winding body 53, and the rotation supporting shaft 54 is removed, thereby completing the manufacture of a honeycomb structure (not shown) having a predetermined size. A catalyst carrier (not shown) is produced by subjecting the honeycomb structure to predetermined processing and processing.
[0005]
[Patent Document 1]
JP-A-8-173820, page 1, FIG.
[0006]
[Problems to be solved by the invention]
However, in the above-described method for manufacturing a catalyst carrier, a winding core trace space is formed at the trace where the winding shaft 50 and the rotation support shaft 54 are removed, and is formed in the winding core trace space (including the vicinity of the outer periphery). The carrier cell is significantly different in size, shape, and the like from other portions of the carrier cell, and the spatial area of the carrier cell is not the same. The catalyst purification performance of such a catalyst carrier differs between the core area and other areas. For this reason, there is a problem that the overall catalyst purification performance is reduced. In particular, in the case of a small catalyst carrier, the presence of the core trace space may be fatal in terms of catalyst purification performance.
[0007]
Accordingly, an object of the present invention is to provide a method for producing a catalyst carrier having carrier cells having substantially the same area and having excellent catalyst purification performance.
[0008]
[Means for Solving the Problems]
The invention according to claim 1 is a method for producing a catalyst carrier, wherein a band-shaped corrugated sheet and a band-shaped flat plate are wound in a state of being overlapped to produce a primary catalyst carrier larger than a target outer diameter size. A feature is that the primary catalyst carrier is cut so as to partially cut out an area excluding the core trace area to produce a secondary catalyst carrier of a target size.
[0009]
According to a second aspect of the present invention, there is provided the method for producing a catalyst carrier according to the first aspect, wherein the cutting of the primary catalyst carrier is performed except for the outermost peripheral area corresponding to the height of the corrugated sheet. .
[0010]
The invention according to claim 3 is the method for producing a catalyst carrier according to claim 1 or 2, wherein when the secondary catalyst carrier is a cylindrical body having a diameter R1, a diameter R2 of the primary catalyst carrier. Is characterized in that R2 ≧ 2 × (r1 + R1 + h), where r1 is the radius of the core trace area and h is the height of the corrugated sheet.
[0011]
According to a fourth aspect of the present invention, there is provided the method for producing a catalyst carrier according to any one of the first to third aspects, wherein the cutting of the primary catalyst carrier is performed by wire discharge cutting. And
[0012]
The invention according to claim 5 is the method for manufacturing a catalyst carrier according to claim 4, wherein the center of the primary catalyst carrier is set as a wire entry start point, and the wire is moved outward in the radial direction. By cutting the secondary catalyst carrier, moving the wire inward in the radial direction along the same path and returning it to the center of the primary catalyst carrier, a plurality of such cutting paths are sequentially repeated in another radial direction. Characterized in that the secondary catalyst carrier is cut out.
[0013]
The invention according to claim 6 is the method for producing a catalyst carrier according to any one of claims 1 to 5, wherein the primary catalyst carrier has a length relative to the length of the secondary catalyst carrier. It is characterized in that it has a length that is an integral multiple.
[0014]
The invention according to claim 7 is the method for producing a catalyst carrier according to claim 6, wherein the primary catalyst carrier is cut by wire discharge cutting to the length of the secondary catalyst carrier.
[0015]
【The invention's effect】
According to the first aspect of the present invention, the primary catalyst carrier is manufactured by cutting out an area having carrier cells of substantially the same area without using the core trace area of the primary catalyst carrier. Therefore, it is possible to produce a catalyst carrier having a catalyst purification performance, which is provided with a carrier cell having a substantially uniform spatial area. In particular, when the secondary catalyst carrier is small, it is possible to exhibit extremely excellent catalyst purification performance as compared with a conventional one having a core area. In addition, the secondary catalyst carrier finally used as a product can be easily produced having a desired shape.
[0016]
According to the second aspect of the invention, in addition to the effects of the first aspect, when the primary catalyst carrier is press-fitted into the outer cylinder, an area which may be deformed when the first catalyst carrier is press-fitted into the outer cylinder is avoided. Thus, a secondary catalyst carrier can be produced. Therefore, even when the primary catalyst carrier is press-fitted into the outer cylinder, a catalyst carrier having excellent catalyst purification performance can be manufactured.
[0017]
According to the third aspect of the invention, in addition to the effects of the first and second aspects of the invention, the circumference of the primary catalyst carrier can be obtained without using the core trace area and the outer peripheral end area. A plurality of catalyst supports can be produced along the direction. Therefore, a catalyst carrier having a target size can be efficiently produced.
[0018]
According to the fourth aspect of the present invention, in addition to the effects of the first to third aspects of the present invention, the primary catalyst carrier can be cut with as little processing strain as possible. Therefore, a change in the shape of each carrier cell during cutting can be minimized.
[0019]
According to the fifth aspect of the invention, in addition to the effects of the fourth aspect, the cutting operation can be performed while minimizing damage to the primary catalyst carrier. Therefore, the quality of the secondary catalyst carrier of the target size can be improved. For example, even when the carrier cells of the primary catalyst carrier are large and the joining strength is low, a catalyst carrier of a target size can be produced without causing trouble such as deformation of the carrier cells.
[0020]
According to the sixth aspect of the invention, in addition to the effects of the first to fifth aspects, the primary catalyst carrier having the same length as the secondary catalyst carrier can be efficiently produced.
[0021]
According to the seventh aspect of the present invention, in addition to the effect of the sixth aspect of the present invention, since the lengthwise processing and cutting of the primary catalyst carrier are performed by the same wire discharge cutting, the efficiency of production equipment can be improved. Cost reduction can be achieved.
[0022]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, details of a method for producing a catalyst carrier according to the present invention will be described based on an embodiment shown in the drawings.
[0023]
(First Embodiment)
1 to 4 show a first embodiment of the present invention. 1A is a side view of the first metal catalyst carrier 2, FIG. 1B is a front view of the first metal catalyst carrier 2, and FIG. 2 is a first metal catalyst carrier for explaining a cutting procedure. 2, FIG. 3 is a perspective view of a secondary metal catalyst carrier 1 of a target size as a secondary catalyst carrier, and FIG. 4 is a diagram illustrating the size of the primary metal catalyst carrier 2.
[0024]
As shown in FIG. 3, the secondary metal catalyst carrier 1 having the target size has a columnar shape, a diameter R1 (for example, about 30 mm or less), and a length L1 (for example, about 20 mm). A method for producing the secondary metal catalyst carrier 1 having the target size will be described below.
[0025]
First, the first metal catalyst carrier 2 shown in FIGS. 1A and 1B is manufactured. The first metal catalyst carrier 2 is wound in a state in which a strip-shaped corrugated plate 5 (shown in FIG. 3) and a strip-shaped flat plate 6 (shown in FIG. 3) are overlapped to form a honeycomb structure 3. The honeycomb structure 3 is press-fitted into the outer cylinder 4 and heat-treated to produce the first metal catalyst carrier 2. This primary metal catalyst carrier 2 is manufactured using a known method.
[0026]
The primary metal catalyst carrier 2 has a length L2 (for example, about 40 mm) as shown in FIG. 1A, and a diameter R2 (for example, about 60 mm) as shown in FIG. 1B. To make. In this embodiment, the length L2 of the primary metal catalyst carrier 2 is set in advance to twice the length L1 (see FIG. 3) of the secondary metal catalyst carrier 1 described later. The diameter R2 of the primary metal catalyst carrier 2 is R2 ≧ 2 × (r1 + R1 + h), where r1 is the radius of the core trace area (see FIG. 4) and h is the height of the corrugated plate 5 (not shown). Is set to The winding core trace area is an area where there is a possibility of being deformed in the vicinity of the winding core trace when manufacturing the honeycomb structure 3 by the corrugated plate 5 and the flat plate 6 and the vicinity thereof. The value is r1 ≧ 5 mm or more, and a specific numerical value is determined by, for example, accumulation of measured data. The outermost peripheral area corresponding to the height of the corrugated sheet 5 is an area that may be deformed when the honeycomb structure 3 is pressed into the outer cylinder 4.
[0027]
Next, as shown in FIG. 1A, the primary metal catalyst carrier 2 is cut along the auxiliary line A so as to make the length L1. This cutting is performed by a wire discharge cutting method. In the wire discharge cutting method, a wire (not shown) is caused to travel along a cut surface of the primary metal catalyst carrier 2 placed in water, and a discharge is generated between the two to cut the wire in a jigsaw manner. As a result, two primary metal catalyst carriers 2 having a length of L1 are produced.
[0028]
Next, the primary metal catalyst carrier 2 having a length L1 is partially cut out of the space excluding the core trace area and the outermost peripheral area corresponding to the height of the corrugated sheet 5 to perform cutting of the target metal of the target size. The secondary metal catalyst carrier 1 is manufactured. This cutting is performed by a wire discharge cutting method in the same manner as the cutting of the primary metal catalyst carrier 2 described above. The cutting procedure is performed in the order of the numbered arrows in FIG.
[0029]
Describing the cutting procedure specifically, the center C of the first metal catalyst carrier 2 is set as a wire entry start point. After inserting the wire into the hole from which the core of the center C has been removed, the wire is moved outward in the radial direction to cut the secondary metal catalyst carrier 1 of the target size, and the wire is moved in the radial direction along the same path. The wire is returned to the center C of the primary metal catalyst carrier 2 by moving inward, and such a cutting path is sequentially repeated in another radial direction, so that the secondary metal catalyst carrier 1 having the target size can be moved, for example. Cut out 5 pieces. Thus, the secondary metal catalyst carrier 1 having the target size as shown in FIG. 3 is manufactured.
[0030]
According to such a manufacturing method, the area having the carrier cell 7 of substantially the same area without using the core trace area in which the carrier cell 7 has a different size and shape from other parts in the primary metal catalyst carrier 2 is used. Cut out and made. FIG. 3 shows a carrier cell 7 having a desired shape. Thus, the secondary metal catalyst carrier 1 having the carrier cells 7 having substantially the same area and having excellent catalyst purification performance can be manufactured. In particular, when the secondary catalyst carrier 1 of the target size is small (having a diameter of about 30 mm or less), a catalyst exhibiting an extremely excellent catalyst purification performance as compared with the related art can be manufactured. Further, since the secondary catalyst carrier 1 having a desired size is produced by cutting out the primary metal catalyst carrier 2, the catalyst carrier 1 having a desired shape can be easily produced.
[0031]
In the above-described embodiment, since the cutting of the primary metal catalyst carrier 2 is performed except for the outermost peripheral area corresponding to the height of the corrugated sheet 5, the honeycomb structure is attached to the outer cylinder 4 as the primary metal catalyst carrier 2. Even when a press-fitted portion 3 is used, a portion that may be deformed when press-fitted into the outer cylinder 4 is not used. Therefore, even when the first metal catalyst carrier 2 press-fitted into the outer cylinder 4 is used, the second metal catalyst carrier 1 having excellent catalyst purification performance can be manufactured.
[0032]
Further, in the above-described embodiment, the secondary metal catalyst carrier 1 of the target size is a cylindrical body having a diameter R1, and the diameter R2 of the primary catalyst carrier 2 produced in this case is determined by the radius of the core trace area. Is set to be r1 and the height of the corrugated plate 5 is set to h, so that R2 ≧ 2 × (r1 + R1 + h). Therefore, the size of the carrier cell 7 in the primary metal catalyst carrier 2 is different from other portions. A plurality of metal catalyst carriers 1 of a desired size can be produced along the circumferential direction of the primary metal catalyst carrier 2 without using the winding core trace area and the outer peripheral end area which are shaped. Therefore, the secondary metal catalyst carrier 1 of the target size can be efficiently produced.
[0033]
Further, in the above-described embodiment, since the cutting of the primary metal catalyst carrier 2 is performed by wire electric discharge cutting, the cutting can be performed with as little machining strain on the primary metal catalyst carrier 2 as possible. Therefore, the shape change of each carrier cell 7 at the time of cutting can be minimized.
[0034]
Further, in the above-described embodiment, the center C of the primary metal catalyst carrier 2 is set as the entry start point of the wire, and the wire is moved outward in the radial direction to cut the metal catalyst carrier 1 of the target size. The wire is returned to the center C of the primary metal catalyst carrier 2 by moving the wire inward in the radial direction along the same route, and then such a cutting route is sequentially repeated in another radial direction to obtain a plurality of objectives. A metal catalyst carrier 1 having a size is cut out. By taking such a cutting path, a cutting operation can be performed while minimizing damage to the primary metal catalyst carrier 2. Therefore, the quality of the secondary metal catalyst carrier 1 of the target size can be improved. In particular, even when the carrier cell 7 of the primary metal catalyst carrier 2 is large and the joining strength is low, the secondary metal catalyst carrier 1 of the target size can be manufactured without causing trouble such as deformation of the carrier cell 7.
[0035]
Further, in the above-described embodiment, the primary metal catalyst carrier 2 has a length twice as long as the target secondary metal catalyst carrier 1, so that the metal catalyst carrier 2 The first metal catalyst carrier 2 having the same length as the first metal catalyst carrier 2 can be produced efficiently. In the above-described embodiment, the primary metal catalyst carrier 2 may have a length that is an integral multiple of 2 or more with respect to the length of the metal catalyst carrier 1.
[0036]
In the above-described embodiment, the primary metal catalyst carrier 2 is cut by wire discharge cutting to the same length as the length of the secondary metal catalyst carrier 1 of the target size. Therefore, since the processing and the cutting process in the length direction of the primary metal catalyst carrier 2 are performed by the same wire discharge cutting, the efficiency of the production equipment can be improved.
[0037]
(Second embodiment)
FIG. 5 is a front view illustrating a cutting procedure according to the second embodiment of the present invention. The diameter R2 of the primary metal catalyst carrier 10 is as follows: R1 is the diameter of the secondary metal catalyst carrier 1 of the target size, r1 is the radius of the core trace area, and h is the height of the corrugated plate (not shown). It satisfies the condition of R2 ≧ 2 × (r1 + R1 + h) and is set slightly larger than the value of 2 × (r1 + 2 × R1 + h). Then, in the same manner as in the first embodiment described above, the space excluding the core trace area and the outermost peripheral area corresponding to the height of the corrugated plate of the primary metal catalyst carrier 10 is removed by a wire discharge cutting method. The metal catalyst carrier 1 having the target size is manufactured by cutting a part of the metal catalyst carrier 1 in the order of the numbered arrows in FIG.
[0038]
In the second embodiment, in the outer peripheral area near the winding core trace area, five target metal secondary metal carriers 1 are placed in the outer peripheral area farther from the winding core trace area, and the ten target size second metal catalyst carriers 1 are removed. Cutting for cutting out the next metal catalyst carrier 1 is performed. In other words, in the first embodiment shown in FIG. 2, one row is provided in the circumferential direction, but in the second embodiment, the cutting for cutting out the secondary metal catalyst carrier 1 having the target size in two rows in the circumferential direction is performed. Is going. The other manufacturing procedures and the like are the same as those in the above-described first embodiment, and a description thereof will not be repeated.
[0039]
Also in the second embodiment, similarly to the above-described first embodiment, a metal catalyst carrier 1 having uniform carrier cells of substantially the same area and having excellent catalyst purification performance can be manufactured.
[0040]
Although the first and second embodiments have been described above, the present invention is not limited to these, and various design changes accompanying the gist of the configuration are possible.
[0041]
For example, in each of the above embodiments, the secondary metal catalyst carrier 1 of the target size has a cylindrical shape, but the shape is not limited to this. According to the present invention, an arbitrary shape can be manufactured by cutting the primary catalyst carrier 2.
[0042]
In the first and second embodiments, the corrugated plate 5 is an offset corrugated plate in which the carrier cells 7 arranged along the gas flow direction are offset from each other in a direction orthogonal to the gas flow direction. However, the carrier cell 7 arranged along the gas flow direction may be a corrugated corrugated corrugated sheet having a straight corrugated shape that is not offset in the direction orthogonal to the gas flow direction, and any other corrugated corrugated sheet may be used in the present invention. Is applicable. Further, in the present invention, the flat plate 6 includes one having a slight wavy shape. In the present invention, known processing means such as laser processing and water jet can be used in addition to the wire discharge described above.
[Brief description of the drawings]
FIG. 1 (a) is a side view of a primary metal catalyst carrier showing a first embodiment of the present invention, and FIG. 1 (b) is a front view of the primary metal catalyst carrier.
FIG. 2 is a front view of the primary metal catalyst carrier for explaining a cutting procedure according to the first embodiment of the present invention.
FIG. 3 is a perspective view of a secondary metal catalyst carrier showing the first embodiment of the present invention.
FIG. 4 is a diagram illustrating the size of a primary metal catalyst carrier according to the first embodiment of the present invention.
FIG. 5 is a front view of a primary metal catalyst carrier for explaining a cutting procedure according to a second embodiment of the present invention.
FIGS. 6 (a) to (e) are diagrams showing each production process of a conventional catalyst carrier.
7A is a front view showing a conventional example, in which an initial winding body is set for winding, and FIG. 7B is a side view thereof.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Secondary metal catalyst carrier 2, 10 Primary metal catalyst carrier 5 Corrugated plate 6 Flat plate 7 Carrier cell

Claims (7)

The belt-shaped corrugated plate (5) and the band-shaped flat plate (6) are wound in a state of being overlapped to produce primary catalyst carriers (2) and (10) larger than the target outer diameter size. A catalyst carrier characterized in that the secondary catalyst carrier (2), (10) is cut to partially cut out an area excluding the core trace area to produce a secondary catalyst carrier (1) having a target diameter. The manufacturing method of (1). It is a manufacturing method of the catalyst support (1) of Claim 1, Comprising:
The method for producing a catalyst carrier (1), wherein the cutting of the primary catalyst carriers (2) and (10) is performed except for the outermost peripheral area corresponding to the height of the corrugated plate (5). A method for producing a catalyst carrier (1) according to claim 1 or claim 2,
When the secondary catalyst carrier (1) is a cylindrical body having a diameter R1, the diameter R2 of the primary catalyst carriers (2) and (10) is such that the radius of the core trace area is r1, and the corrugated sheet ( 5. The method for producing a catalyst carrier (1), wherein the height of (5) is set to h and R2 ≧ 2 × (r1 + R1 + h). A method for producing a catalyst carrier (1) according to any one of claims 1 to 3, wherein:
The method for producing a catalyst carrier (1), wherein the cutting of the primary catalyst carriers (2) and (10) is performed by wire discharge cutting. It is a manufacturing method of the catalyst support (1) of Claim 4, Comprising:
The center of the primary catalyst carriers (2) and (10) is defined as the entry point of the wire, and the wire is moved radially outward to cut the secondary catalyst carrier (1).
The wire is moved radially inward through the same path that cut the secondary catalyst carrier (1) to return the wire to the center of the primary catalyst carriers (2) and (10),
A method for producing a catalyst carrier (1), wherein a plurality of the secondary catalyst carriers (1) are cut out by sequentially repeating a cutting path in another radial direction. A method for producing a catalyst carrier (1) according to any one of claims 1 to 5,
A method for producing a catalyst carrier (1), wherein the length of the primary catalyst carrier (2) is an integral multiple of the length of the secondary catalyst carrier (1). It is a manufacturing method of the catalyst support (1) of Claim 6, Comprising:
A method for producing a catalyst carrier (1), characterized in that the primary catalyst carrier (2) is cut by wire discharge cutting to the length of the secondary catalyst carrier (1).

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