JP2005313083A - Catalyst carrier made of metal - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a catalyst carrier made of a metal capable of enhancing an exhaust gas cleaning performance by enhancing the effect of aggressively causing a turbulence relatively to an exhaust gas passing in a cell passage. <P>SOLUTION: In the catalyst carrier A made of the metal, a large number of cell passages in which an exhaust gas passes between respective corrugated sheets 11 and flat plates 12 are formed by alternately and multiply superposing the corrugated sheets 11 and the flat plates 12 and a plurality of slit holes 11a, 12a are formed on the corrugated sheet 11 and the flat plate 12. Annular projections 6 projected from surfaces of the corrugated sheets 11 and the flat plates 12 are formed on opening edges of the slit holes 11a, 12a when the slit holes 11a, 12a are machined on the corrugated sheets 11 and the flat plates 12. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a metal catalyst carrier mounted on an exhaust system of an internal combustion engine or the like.

  As a conventional metal catalyst carrier, a large number of metal corrugated plates (large corrugated plates) and flat plates (or small corrugated plates) are alternately stacked and wound in multiple layers so that exhaust gas passes between the corrugated plates and the flat plates. A honeycomb structure having a cell passage is formed, and a plurality of slit holes are formed at predetermined intervals on at least one of the corrugated plate and the flat plate, thereby disturbing exhaust gas passing through the cell passage. There is a structure in which the flow is positively caused to increase the chance that the exhaust gas contacts the catalyst coated on the surface of the corrugated plate and the flat plate as much as possible, thereby improving the exhaust gas purification performance (for example, , See Patent Document 1).

JP 2002-143893 A (Page 2, Fig. 4-6)

  However, as in the prior art, there is a problem that the effect of positively causing turbulent flow to the exhaust gas passing through the cell passage is small if the slit holes are simply formed in the corrugated plate and the flat plate.

  The problem to be solved by the present invention is to provide a metal catalyst carrier capable of improving exhaust gas purification performance by enhancing the effect of positively causing turbulence to exhaust gas passing through the cell passage There is to do.

  In order to solve the above-mentioned problems, the metal catalyst carrier according to claim 1 is configured such that a thin plate corrugated plate and a corrugated plate or a flat plate are alternately stacked and an exhaust gas passes between the corrugated plate and the corrugated plate or the flat plate. In the metal catalyst carrier in which a plurality of slits are formed in at least one of the large wave plate and the small wave plate or the flat plate, the large wave plate and the small wave plate or the flat plate are provided with slit holes. An annular protrusion protruding from the surface of the large wave plate and the small wave plate or a flat plate is formed at the opening edge of the slit hole when processing.

  The metal catalyst carrier according to claim 2 is the metal catalyst carrier according to claim 1, wherein the opening of the slit hole is performed by a conical hole drilling tool having a sharp tip. An annular protrusion is formed by cutting the large wave plate and the small wave plate or a flat plate so as to protrude from the surface.

  The metal catalyst carrier according to claim 3 is the metal catalyst carrier according to claim 1, wherein a punch for punching is used at the opening of the slit hole, and a punching operation speed by the punch for punching is reduced. Thus, an annular protrusion protruding from the surface of the large wave plate and the small wave plate or the flat plate is formed at the opening edge of the slit hole.

  According to a fourth aspect of the present invention, there is provided the metal catalyst carrier according to the first aspect, wherein the slit hole is opened by a punch for punching a hole having a large clearance between the female and the male. An annular projection protruding from the surface of the large wave plate and the small wave plate or a flat plate is formed at the opening edge of the slit hole.

  In the metal catalyst carrier according to claim 1, as described above, when the slit hole is processed in the large wave plate and the small wave plate or the flat plate, the opening edge portion of the slit hole is formed from the surface of the large wave plate and the small wave plate or the flat plate. By adopting a configuration in which projecting annular projections are formed, the exhaust gas flowing in each cell passage directly hits the annular projection portion, and therefore the effect of positively causing turbulence to the exhaust gas passing through the cell passage As a result, the exhaust gas purification performance can be improved.

  In the metal catalyst carrier according to claim 2, by performing the opening of the slit hole with a conical hole drill having a sharp tip as described above, a large wave plate and a small wave plate or By adopting a configuration in which the annular protrusions that are cut open so as to protrude from the surface of the flat plate are formed, the annular protrusions can be greatly protruded, and the cost of the drilling tool is reduced and the durability is improved. Is possible.

  In the metal catalyst carrier according to claim 3, as described above, a punch for punching is used at the opening of the slit hole, and the opening edge of the slit hole is reduced by reducing a punching speed by the punch for punching the hole. Since the annular projections projecting from the surface of the large wave plate and the small wave plate or the flat plate are formed in the part, the conventional punch for punching can be used as it is as a tool for processing the conventional slit hole. The exhaust gas purification performance can be improved without increasing it.

  In the metal catalyst carrier according to claim 4, as described above, the opening of the slit hole is performed by a punch for punching with a large clearance between the female and the male, so that the opening edge of the slit hole is formed. By adopting a structure in which an annular protrusion protruding from the surface of the large wave plate and the small wave plate or flat plate is formed, the wear resistance of the punch for punching holes can be improved, and the durability can be improved. Setup time can be shortened.

  Embodiments of the present invention will be described below with reference to the drawings.

The metal catalyst carrier of Example 1 corresponds to the inventions described in claims 1 and 2.
First, the metal catalyst carrier of Example 1 will be described with reference to the drawings.
FIG. 1 is a partially cutaway perspective view showing a metal catalyst carrier of the first embodiment, FIG. 2 is a perspective view showing a honeycomb structure constituting the metal catalyst carrier, and FIG. FIG. 4 is an explanatory view showing a slit hole processed state, and FIG. 5 is an enlarged cross-sectional view of a main part of a metal catalyst carrier.

The metal catalyst carrier A of Example 1 is composed of a honeycomb structure 1, a raw foil material 2, and an outer cylinder 3.
As shown in FIGS. 2 and 3, the honeycomb structure 1 is formed by alternately laminating corrugated plates (large corrugated plates) 11 and flat plates (small corrugated plates or flat plates) 12 made of metal of several tens of microns. Formed in the form of a honeycomb wound outwardly in multiple layers, a catalyst carrier layer made of alumina or the like is formed on the surface of the honeycomb passage (cell passage), and catalyst components are supported on the catalyst carrier layer. The exhaust gas purifying catalyst is disposed in the exhaust path of the internal combustion engine to purify HC, CO, NOx, etc. (reactive substances) in the exhaust gas by a catalytic reaction, and the generated substances (H ₂ O, CO ₂ , N ₂ ).

  The corrugated plate 11 is formed with a plurality of slit holes 11a with a predetermined length and a predetermined length before being formed into a wave shape, while the flat plate 12 also has a plurality of slit holes with a predetermined interval. 12a is formed.

  That is, in the metal catalyst carrier A, in order to improve the exhaust gas purification performance, turbulent flow is actively caused to the exhaust gas passing through the honeycomb passage (cell passage), and the exhaust gas contacts the catalyst. It is effective to increase as many opportunities as possible. For this reason, the corrugated plate 11 and the flat plate 12 are partitioned by the corrugated plate 11 and the flat plate 12 by opening a large number of slit holes 11a and 12a extending in a direction perpendicular to the cell passage. The flow between the cell passages is made possible, and the exhaust gas purification performance is improved by making the exhaust gas flow in the honeycomb passages more turbulent in the width direction.

  And in this Example 1, as shown in FIG. 4, as a tool for opening the slit holes 11a, 12a in the corrugated plate 11 and the flat plate 12, by using a conical hole drilling tool 4 with a sharp tip, As shown in FIG. 5, annular projections 6 that are cut open so as to protrude from the surfaces of the corrugated plate 11 and the flat plate 12 are formed at the opening edges of the slit holes 11 a and 12 a, respectively.

  As shown in FIG. 1, the raw foil material 2 is wound around the outer peripheral surface on the downstream side of the honeycomb structure 1 before the honeycomb structure 1 is press-fitted to the outer cylinder 3. In Example 1, the raw foil material 2 is partially wound around a midway portion near the end portion on the exhaust gas outflow side (left side in the figure) of the honeycomb structure 1.

  The outer cylinder 3 is formed in a cylindrical shape with a SUS430 ferritic stainless steel plate or the like having a thickness of 1 to 2 mm, and the honeycomb structure 1 is press-fitted into the outer cylinder 3.

  Then, the metal catalyst carrier A assembled in the above state is heated to the diffusion bonding temperature in a furnace in a non-oxidizing atmosphere, thereby diffusion bonding between the corrugated sheet 11 and the flat plate 12 and the honeycomb structure. The body 1 and the outer cylinder 3 are joined by the raw foil material 2.

Next, functions and effects of the metal catalyst carrier of Example 1 will be described.
In the metal catalyst carrier A of Example 1, as described above, when the slit holes 11a and 12a are processed in the corrugated plate 11 and the flat plate 12, a large wave plate and a small wave are formed at the opening edges of the slit holes 11a and 12a. By adopting a configuration in which the annular protrusion 6 protruding from the surface of the plate or the flat plate is formed, the exhaust gas flowing in each cell passage directly hits the annular protrusion 6 portion, and thus the conventional example in which the annular protrusion 6 is not formed. As compared with the above, the effect of positively causing turbulent flow with respect to the exhaust gas passing through the cell passage is enhanced, thereby obtaining the effect that the exhaust gas purification performance can be improved.

  Further, by opening the slit holes 11a and 12a with the conical hole drilling tool 4 having a sharp tip, the slits 11a and 12a are projected from the surfaces of the corrugated plate 11 and the flat plate 12 to the opening edges. By adopting a configuration in which the cut-out annular protrusion 6 is formed, the annular protrusion 6 can be made to protrude greatly, and the cost of the drilling tool is reduced as compared with the conventionally used drilling punch. And durability can be improved.

  Next, another embodiment will be described. In the description of the other embodiments, the same components as those of the first embodiment are not shown, or the same reference numerals are given and the description thereof is omitted, and only the differences are described.

The metal catalyst carrier A of Example 2 corresponds to the inventions described in claims 1 and 3.
That is, as shown in FIG. 6, the metal catalyst carrier A of Example 2 uses a hole punching punch 5 having a female 5a and a male 5b at the openings of the slit holes 11a and 12a. The embodiment described above is that the annular punching projecting from the surfaces of the corrugated plate 11 and the flat plate 12 is formed at the opening edge of the slit holes 11a and 12a by slowing the punching speed by the punch 5 for use. This is different from 1.

  Therefore, according to the second embodiment, the conventional hole punching punch 5 can be used as it is as a tool for processing the conventional slit holes 11a and 12a, so that the exhaust gas purification performance can be improved without increasing the cost. become able to.

The metal catalyst carrier A of Example 3 corresponds to the inventions described in claims 1 and 4.
That is, as shown in FIG. 7, the metal catalyst carrier A of Example 3 is a hole processing punch 5 in which the openings of the slit holes 11a and 12a are formed with a large clearance h between the female 5a and the male 5b. This is different from the first embodiment in that the annular protrusion 6 protruding from the surface of the corrugated plate 11 and the flat plate 12 is formed at the opening edge of the slit holes 11a and 12a. .

  Therefore, according to the second embodiment, since the clearance h between the female 5a and the male 5b is formed larger, the wear resistance of the hole punching punch 5 is improved, thereby improving the durability. As a result, the setup time can be shortened.

Although the present embodiment has been described above, the present invention is not limited to the above-described embodiment, and design changes and the like within a scope not departing from the gist of the present invention are included in the present invention.
For example, in the embodiment, the metal catalyst carrier A has a structure in which the corrugated plates 11 and the flat plates 12 are alternately wound in multiple layers. However, the specific configuration of the metal catalyst carrier A is arbitrary. For example, the metal catalyst carrier A may be formed by alternately overlapping a large wave plate and a small wave plate.

  In the embodiment, the slit holes 11a and 12a are formed in both the corrugated plate 11 and the flat plate 12, but only one of them may be used.

1 is a partially cutaway perspective view showing a metal catalyst carrier of Example 1. FIG. 1 is a perspective view showing a honeycomb structure to which a metal catalyst carrier of Example 1 is applied. It is a perspective view which shows the state in the middle of winding up the corrugated sheet and flat plate in the metal catalyst carrier of Example 1. FIG. 3 is a process explanatory view showing a slit hole processed state in the metal catalyst carrier of Example 1. 2 is an enlarged cross-sectional view of a main part of a metal catalyst carrier of Example 1. FIG. FIG. 5 is a process explanatory view showing a slit hole processed state in the metal catalyst carrier of Example 2. FIG. 6 is a process explanatory view showing a slit hole processed state in the metal catalyst carrier of Example 3.

Explanation of symbols

A Metal catalyst carrier
h Clearance 1 Honeycomb structure 11 Corrugated sheet (large corrugated sheet)
11a slit hole 12 flat plate (wave plate or flat plate)
12a Slit hole 2 Raw foil material 3 Outer cylinder 4 Conical hole drilling tool 5 Hole punch 5a Female 5b Male 6 Annular projection

Claims (4)

A plurality of thin corrugated plates and corrugated plates or flat plates are alternately stacked to form a plurality of cell passages through which exhaust gas passes between the corrugated plates and the corrugated plates or flat plates. In a metal catalyst carrier having a plurality of slit holes formed in at least one of them,
An annular protrusion protruding from the surface of the large wave plate and the small wave plate or the flat plate is formed at an opening edge of the slit hole when the slit hole is processed in the large wave plate and the small wave plate or the flat plate. Catalyst carrier.   2. The metal catalyst carrier according to claim 1, wherein the slit hole is opened with a conical hole drill having a sharp tip, and the surface of the large wave plate and the small wave plate or the flat plate is formed at an opening edge of the slit hole. A metal catalyst carrier characterized in that an annular protrusion is formed that is cut open so as to project from the metal catalyst carrier.   2. The metal catalyst carrier according to claim 1, wherein the slit hole is opened with a punch for punching with a large clearance between the female and the male, and the large wave plate is formed at an opening edge of the slit hole. An annular protrusion protruding from a surface of a corrugated plate or a flat plate is formed. In the metal catalyst carrier according to claim 1, a hole processing punch is used for opening the slit hole,
An annular protrusion protruding from the surface of the large wave plate and the small wave plate or the flat plate is formed at the opening edge of the slit hole by slowing down a drilling operation speed by the punch for punching the hole. Catalyst carrier.

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