JP2008173555A - Metal catalyst carrier - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a metal catalyst carrier which enhances the degree of freedom of thermal expansion and shrinkage of a honeycomb structure without the enlargement, weight increase and deterioration of purification performance of a metal catalyst carrier. <P>SOLUTION: The metal catalyst carrier is characterized by comprising a plurality of cells 13 formed by piling up a large corrugated plate 11 and a plate 12 made of a metal to wind them in a rolled state and integrated by bonding the junction of each pate 11, 12, the honeycomb structure 3 having a catalyst supported layer A3 coated on the surface of each cell 13, a tubular case 2 to store the honeycomb structure 3 and a pair of stopper members 6, 7 to hold the honeycomb structure 4, 5 that is fixed to the case 2 and brought in contact with the front-rear edge faces 4, 5 of the honeycomb structure 3 respectively and further characterized by forming a first reinforcement part 14 installed by means of a wax material A2 to the contact part 9 between at least stopper members 6, 7 in the front-rear edge faces 4, 5 of the honeycomb structure 3. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a metal catalyst carrier.

Conventionally, in order to increase the degree of freedom of thermal expansion / contraction of the honeycomb body of the metal catalyst carrier, an intermediate cylinder interposed between the honeycomb body and the case and joined only in a part of the case in the axial direction; A technique of a metal catalyst carrier that is held by the intermediate cylinder and includes a pair of stopper members that respectively contact the front and rear end surfaces of the honeycomb body is known (see Patent Document 1).
Japanese Patent Laid-Open No. 06-79182

  However, in the conventional invention, since a predetermined gap is required between the honeycomb body, the intermediate cylinder, and the case, the diameter of the case becomes large and the metal catalyst carrier becomes larger, or the predetermined gap There is a problem that the size of the honeycomb body that can be accommodated in the case of the diameter is reduced. In addition, the weight increases due to the intermediate cylinder.

  The present invention was made in order to solve the above-mentioned problems, and the purpose thereof is that the intermediate cylinder can be omitted without increasing the size of the metal catalyst carrier, increasing the weight, and degrading the purification performance. An object of the present invention is to provide a metal catalyst carrier capable of preventing buckling due to thermal expansion / contraction of a honeycomb body.

  According to the first aspect of the present invention, a metal large wave plate and a small wave plate or a flat plate are overlapped and wound into a roll shape to form a plurality of cells, and the joining portions of the plates are joined together. After the formation, the honeycomb body formed by coating the surface of each cell with a catalyst support layer, a cylindrical case that accommodates the honeycomb body, and fixed to the case, and on the front and rear end faces of the honeycomb body A first reinforcing portion provided with a brazing material after joining the plates to at least the contact portion with the stopper member on the front and rear end faces of the honeycomb body, each of which includes a pair of stopper members that contact and hold the honeycomb body Is formed.

  In the invention according to claim 1 of the present invention, a plurality of cells are formed by overlapping a metal corrugated plate and a corrugated plate or a flat plate and winding them into a roll shape, and joining the joining portions of the plates. And then integrally forming the honeycomb body formed by coating the surface of each cell with a catalyst support layer, a cylindrical case for housing the honeycomb body, and being fixed to the case, A pair of stopper members that respectively hold the honeycomb body in contact with the front and rear end faces, and at least a contact portion with the stopper member on the front and rear end faces of the honeycomb body is provided with a brazing material after joining the plates. Since one reinforcing portion is formed, the degree of freedom of thermal expansion and contraction of the honeycomb body can be increased without causing an increase in size, weight, and purification performance of the metal catalyst carrier.

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

Example 1 will be described below.
In the following description, the exhaust gas upstream side is the front and the exhaust gas downstream side is the rear.
1 is a side sectional view showing a metal catalyst carrier of Example 1 of the present invention, FIG. 2 is a sectional view taken along line S2-S2 in FIG. 1, FIG. 3 is a sectional view taken along line S3-S3 in FIG. FIG. 4 is a diagram for explaining the manufacture of the honeycomb body of the first embodiment.

  FIG. 5 is an enlarged cross-sectional view (only a part) illustrating the first reinforcing portion on the front and rear end faces of the honeycomb body of the first embodiment, and FIG. 6 is a cross-sectional view taken along line S6-S6 in FIG.

First, the overall configuration will be described.
As shown in FIGS. 1 to 3, the metal catalyst carrier 1 of the first embodiment corresponds to a cylindrical case 2, a columnar honeycomb body 3 accommodated in the case 2, and a honeycomb body 3. Ring-shaped stopper members 6 and 7 for holding the honeycomb body 3 in contact with the front and rear end surfaces 4 and 5 are provided.

  The case 2 is made of a metal made of stainless steel or the like and is formed in a cylindrical shape, and its front end 2a is connected to a connection pipe on the engine side (not shown), for example, a collecting portion of an exhaust manifold, while the rear end The part 2b is connected to a connecting pipe on the main muffler side not shown.

  The honeycomb body 3 is formed in a columnar shape, and front and rear end surfaces 4 and 5 thereof are held by stopper members 6 and 7 described later.

Each of the stopper members 6 and 7 is formed in a metal ring shape made of stainless steel or the like, and the contact surface 8 on the inner side thereof contacts the contact portion 9 of the honeycomb body 3 so that the honeycomb body 3 is The outer peripheral surface 10 is brazed and fixed to the inner peripheral surface 2 c of the case 2 in the held state.
The stopper members 6 and 7 and the case 2 may be fixed by welding.

Hereinafter, the honeycomb body 3 of Example 1 will be described in detail.
In order to manufacture the honeycomb body 3 of the first embodiment, first, as shown in FIG. 4, a large wave plate 11 and a flat plate 12 each made of stainless steel containing aluminum and the like are stacked, and the ends thereof are wound. A state in which the jig X is fitted into a rotating jig X, the jig X is wound in a roll shape by rotating it in the direction of the arrow in the figure, and then heat treated in a heating furnace not shown in the figure to produce the plates 11, 12 Are joined together by diffusion bonding or the like.
At this time, the honeycomb body 3 is formed with a plurality of cells 13 communicating in the axial direction.

  Next, after applying or immersing a brazing material over a range of a predetermined dimension L1 (see FIG. 1) on the front and rear end faces 4 and 5 of the honeycomb body 3 integrally formed by diffusion bonding or the like, heating outside the figure is again performed. By performing heat treatment in the furnace, the first reinforcing portion 14 provided by the brazing material A2 is formed on the surfaces of the plates 11 and 12 of the front and rear end faces 4 and 5 of the honeycomb body 3 (see FIGS. 5 and 6). The value of the predetermined dimension L1 can be set as appropriate.

  Finally, the surface of the cell 13 is coated with a catalyst supporting layer by a method such as immersing the honeycomb body 3 in a washcoat solution containing a catalyst such as platinum.

  Therefore, as shown in FIGS. 5 and 6, on the front and rear end faces 4 and 5 of the honeycomb body 3, the brazing material A2 and the catalyst support layer A3 are formed on the surface of the core material A1 of the plates 11 and 12, respectively. The first reinforcing portion 14 provided over the range of the dimension L1 is formed, whereby the surface rigidity of the front and rear end faces 4 and 5 of the honeycomb body 3 can be improved uniformly.

  In the first embodiment, each part of the honeycomb body 3 is securely bonded by diffusion bonding or the like in the first heat treatment, and the first reinforcement portion 14 is formed by the subsequent heat treatment. Therefore, the first reinforcement portion 14 is formed. It is also possible to change the type of brazing material used in the process and the temperature in the furnace, and the first reinforcing portion 14 can be easily formed.

Next, the operation will be described.
The thus configured metal catalyst carrier 1 is interposed in the middle of the exhaust system, and hot exhaust gas flowing from the front end portion 2a side of the case 2 passes through each cell 13 on the front end face 4 of the honeycomb body 3. Then, while being discharged from the rear end face 5, harmful substances (NOx, HC, etc.) contained in the exhaust gas are purified into non-hazardous substances (H ₂ O, CO ₂ , etc.) by catalytic action, and together with the exhaust gas, the case 2 Discharge to the rear end 2b side.

  Here, the honeycomb body 3 has a temperature distribution due to contact with a high-temperature exhaust gas, heat generation due to a catalytic reaction, release of heat from the case 2 to the outside, a difference in heat capacity between the honeycomb body 3 and the case 2, and the like. As a result, the honeycomb body 3 mainly thermally expands and contracts in the axial direction, and the contact portion 9 with the stopper members 6 and 7 may buckle due to thermal stress.

  On the other hand, in the first embodiment, as described above, the first reinforcing portion 14 significantly improves the surface rigidity of the front and rear end faces 4 and 5 of the honeycomb body 3, so that the thermal expansion and contraction of the honeycomb body 3 is achieved. Thus, buckling due to thermal stress on the contact portion 9 can be prevented.

  Further, it is possible to prevent the contact portion 9 of the honeycomb body 3 from buckling even when the honeycomb body 3 swings in the front-rear direction due to exhaust gas pulsation or vehicle body vibration.

  In the first embodiment, the brazing material A2 is provided on each of the plates 11 and 12 over the entire front and rear end faces 4 and 5 of the honeycomb body 3, but it can also be provided only on the contact portion 9, in this case. Before the honeycomb body 3 is formed into a roll shape, a portion of the brazing material A2 corresponding to the contact portion 9 of each of the plates 11 and 12 is provided with a width of a predetermined dimension L1 more than other portions.

Next, the effect will be described.
As described above, in the metal catalyst carrier 1 of the first embodiment, a plurality of cells 13 are formed by overlapping a metal corrugated plate 11 and a flat plate 12 and winding them in a roll shape, After the joined portions of the plates 11 and 12 are integrally formed by diffusion bonding or the like, the honeycomb body 3 formed by coating the surface of each cell 13 with the catalyst supporting layer A3 and the honeycomb body 3 are accommodated. A cylindrical case 2 that is fixed to the case 2 and a pair of stopper members 6 and 7 that hold the honeycomb bodies 4 and 5 in contact with the front and rear end faces 4 and 5 of the honeycomb body 3 respectively. Since the first reinforcing portion 14 provided by the brazing material A2 is formed after joining the plates 11 and 12 to at least the contact portion 9 with the stopper members 6 and 7 on the front and rear end surfaces 4 and 5 of the body 3, the metal catalyst carrier Honeycomb without increasing body size, increasing weight, and degrading purification performance Buckling due to thermal stress on the body 3 can be prevented.

Example 2 will be described below.
In the second embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, the description thereof will be omitted, and only differences will be described in detail.

  FIG. 7 is a view (only a part) illustrating the second reinforcing portion on the front and rear end faces of the honeycomb body according to the second embodiment of the present invention.

  As shown in FIG. 7, in Example 2, the second reinforcing part 21 configured by winding the flat plate 12 and the corrugated plate 20 is formed on the contact part 9 of the honeycomb body 3 as in Example 1. Different.

  Therefore, the surface rigidity of the outer peripheral surface 9 of the honeycomb body 3 can be easily improved, and the effect that the buckling of the contact portion 9 of the honeycomb body 3 can be prevented similarly to the first embodiment can be obtained.

  The second reinforcing portion 21 may be formed by winding only the flat plate 12 or the corrugated plate 20.

Example 3 will be described below.
In the third embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, the description thereof will be omitted, and only differences will be described in detail.

  FIG. 8 is an enlarged cross-sectional view (only a part) illustrating the third reinforcing portion on the front and rear end faces of the honeycomb body of the third embodiment, and FIG. 9 is a cross-sectional view taken along line S9-S9 in FIG.

  As shown in FIGS. 8 and 9, in Example 3, the catalyst supporting layer A3 of each of the plates 11 and 12 is placed in other parts over the range of the predetermined dimension L2 of the front and rear end faces 4 and 5 of the honeycomb body 3. The point which formed the 3rd reinforcement part 30 provided many compared with differs from Example 1. FIG.

  Therefore, the surface rigidity of the front and rear end faces 4 and 5 of the honeycomb body 3 can be improved by the brazing material A2 and the catalyst supporting layer A3, and the effect that the buckling of the contact portion 9 of the honeycomb body 3 can be prevented as in the first embodiment. Can be obtained.

  In Example 3, the surface rigidity of the front and rear end faces 4 and 5 of the honeycomb body 3 is improved by the brazing material A2 and the catalyst support layer A3. However, the brazing material A2 can be reduced according to the required surface rigidity. It can be omitted.

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 first embodiment, the stopper members 6 and 7 are ring-shaped, but as shown in FIG. 10, a stopper member 41 in which a cross-shaped column portion 40 is added inside the stopper member 6 (7) described above. May be employed to improve the retention of the honeycomb body 3.

Moreover, the dimension of the mutual thickness of core material A1, brazing material A2, and catalyst support layer A3 can be set suitably.
In addition, the thickness and material of the case 2 and the stopper members 6 and 7, the dimensions of the predetermined dimensions L1 and L2, and the like can be set as appropriate.

  Further, a gap may be formed between the case 2 and the honeycomb body 3 as necessary.

It is a sectional side view which shows the metal catalyst carrier of Example 1 of this invention. It is sectional drawing in the S2-S2 line | wire of FIG. It is sectional drawing in the S3-S3 line | wire of FIG. It is a figure explaining manufacture of the honeycomb body of Example 1. FIG. 3 is an enlarged cross-sectional view (only a part) illustrating a first reinforcing portion on the front and rear end faces of the honeycomb body of the first embodiment. It is sectional drawing in the S6-S6 line of FIG. It is an expanded sectional view (only a part) explaining the 2nd reinforcement part in the front-and-back end surface of the honeycomb body of Example 2 of the present invention. FIG. 10 is an enlarged cross-sectional view (only a part) for explaining a second reinforcing portion on the front and rear end faces of a honeycomb body of Example 3. It is sectional drawing in the S9-S9 line | wire of FIG. It is a figure explaining the stopper member of other Examples.

Explanation of symbols

A1 Core material A2 Brazing material A3 Catalyst support layer O Gap X Jig 1 Metal catalyst carrier 2 Case 2a Front end 2b Rear end 2c Inner peripheral surface 3 Honeycomb body 4 Front end surface 5 Rear end surface 6, 7 Stopper member 8 Contact surface 9 Contact portion 10 Outer peripheral surface 11 Large wave plate 12 Flat plate 13 Cell 14 First reinforcing portion 20 Small wave plate 21 Second reinforcing portion 30 Third reinforcing portion 40 Column portion 41 Stopper member

Claims (3)

A metal large wave plate and a small wave plate or flat plate are overlapped and wound into a roll shape to form a plurality of cells. After joining and integrally forming a joint portion between the plates, the surface of each cell is formed. A honeycomb body formed by coating a catalyst support layer;
A cylindrical case for housing the honeycomb body;
A pair of stopper members fixed to the case and holding the honeycomb body in contact with the front and rear end faces of the honeycomb body,
A metal catalyst carrier, wherein a first reinforcing portion provided with a brazing material after joining the plates is formed at least in contact portions with the stopper member on the front and rear end faces of the honeycomb body. The metal catalyst carrier according to claim 1,
The stopper member is formed in a ring shape,
A metal catalyst carrier characterized in that a second reinforcing portion formed by winding a corrugated plate or a flat plate is formed at least in contact with the stopper member on the front and rear end faces of the honeycomb body. In the metal catalyst carrier according to claim 1 or 2,
A metal catalyst carrier characterized in that a third reinforcing portion provided with more catalyst support layers than other portions is formed at least in contact portions with front and rear end faces of the honeycomb body with stopper members.

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