JP2016037871A - Carrier holding mat, and catalytic converter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a carrier holding mat to be used while being wound on a catalyst carrier and disposed for use in the main case of a catalytic converter, and capable of simplifying a manufacturing process and reducing the occurrence of an end material at a producing time.SOLUTION: A carrier holding mat 1 to be wound on the outer circumference of a catalyst carrier 3 disposed in an exhaust passage 14 of an internal combustion engine 9 is formed with: a recess 19 at the end of the upstream side of an exhaust gas flow in an exhaust passage 9; and a salient 21 of the same pattern as that of the recess 19 at the downstream side end.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a carrier holding mat and a catalytic converter, and more particularly to a carrier holding mat provided with a recess for trapping foreign matter.

  Conventionally, a carrier holding mat 301 having a “V” -shaped recess 303 for trapping foreign matter as shown in FIG. 7 is known (see, for example, Patent Document 1).

As shown in FIG. 5, the carrier holding mat 301 is used by being wound around a catalyst carrier 305. As shown in FIG. 4, the catalyst carrier 305 around which the carrier holding mat 301 is wound is installed and used in the main case 309 of the catalytic converter 307. And the exhaust gas which came out of the engine 311 flows through the catalytic converter 307. Thus, the recess 303 for purifying the exhaust gas coming out of the engine 311 is located on the upstream end surface of the carrier holding mat 301 wound around the catalyst carrier 305 in the exhaust gas flow direction.

  As a result, foreign matter is captured by the recess 303, and the catalyst carrier 305 is prevented from being damaged due to the movement of foreign matter such as welding spatter on the end surface of the catalyst carrier 305.

  Further, Patent Documents 2 and 3 can be listed as patent documents related to the conventional technology.

JP 2002-332834 A JP 2012-26074 A Japanese Patent No. 5089868

  By the way, for example, after the carrier holding mat 301 is cut out from the large plate-like material having the shape shown in FIG. 6 (the one not provided with the recess 303) 313, the semi-finished product 313 has a “V” shape. It is manufactured by providing a recess (notch) 303.

  Since the step of providing the “V” -shaped recess 303 is necessary, the manufacturing process of the catalyst carrier 305 becomes complicated, and there is a problem that the end material (the end material having the same shape as the recess 303) is generated. .

  The present invention has been made in view of the above problems, and can simplify the manufacturing process in a carrier holding mat that is wound around a catalyst carrier and used in the main case of the catalytic converter together with the catalyst carrier. At the same time, it is an object of the present invention to provide a product that can reduce the generation of mill ends during manufacturing.

  In the carrier holding mat wound around the outer periphery of the catalyst carrier provided in the exhaust passage of the internal combustion engine, the invention according to claim 1 is provided with a recess at the upstream end of the exhaust gas flow in the exhaust passage, The carrier holding mat is provided with a convex portion having the same pattern as the concave portion at an end on the downstream side.

  According to a second aspect of the present invention, the carrier holding mat according to the first aspect is obtained by cutting a plurality of sheets from one mat material, and the cutting is performed on all the carrier holding mats. It is a carrier holding mat formed in a form in which all the convex portions of the other one carrier holding mat are inserted into the concave portion.

  According to a third aspect of the present invention, in the carrier holding mat wound around the outer periphery of the catalyst carrier provided in the exhaust passage of the internal combustion engine, a recess is provided at an upstream end of the exhaust gas flow in the exhaust passage. A convex portion is provided at the downstream end, and the exhaust gas flow of the one carrier holding mat is arranged so that the convex portion of the other carrier holding mat is inserted into the concave portion of the one carrier holding mat. When the upstream end of the other carrier holding mat is brought into contact with the downstream end of the exhaust gas flow of the other carrier holding mat, the convex portion of the other carrier holding mat becomes the one carrier holding mat. The carrier holding mat is formed so as to enter the recess.

  The invention according to claim 4 is a catalytic converter having the carrier holding mat according to any one of claims 1 to 3.

  In the carrier holding mat that is wound around the catalyst carrier and installed in the main case of the catalytic converter together with the catalyst carrier, the production process can be simplified and the generation of scraps can be reduced during production. There is an effect.

It is a figure which shows the carrier holding mat which concerns on embodiment of this invention. It is a figure which shows the manufacturing method of the carrier holding mat which concerns on embodiment of this invention. It is a figure which shows the state by which the support | carrier holding mat which concerns on embodiment of this invention was wound around the catalyst support | carrier. It is a figure which shows the use condition of a carrier holding mat. It is a figure which shows the state by which the conventional support | carrier holding mat was wound around the catalyst support | carrier. It is a figure which shows the manufacturing method of the conventional carrier holding mat. It is a figure which shows the conventional carrier holding mat.

  The carrier holding mat 1 according to the embodiment of the present invention is used by being wound around the outer periphery of the catalyst carrier 3 as shown in FIG. The catalyst carrier 3 around which the carrier holding mat 1 is wound is installed in the main case 7 of the catalytic converter 5 as shown in FIG.

  More specifically, a catalytic converter 5 is provided immediately below a collective portion of an exhaust manifold 11 connected and fixed to a cylinder head of an engine (internal combustion engine) 9. An exhaust pipe (front tube) is provided at the outlet side of the catalytic converter 5. ) 13 is connected.

  The case of the catalytic converter 5 constitutes a part of the exhaust passage 14, and includes a cylindrical main case 7, and substantially conical diffusers 15 and 17 connected to the inlet side and the outlet side thereof by welding, respectively. Become.

  The catalyst carrier 3 is accommodated in the main case 7 via a carrier holding mat 1 wound around the outer periphery. As a result, the carrier holding mat 1 is installed and used in the exhaust passage 14 of the internal combustion engine together with the catalyst carrier 3. The catalyst carrier 3 is a ceramic monolith catalyst carrier having a honeycomb structure having a cylindrical outer shape, and a catalyst is coated on the surface of the carrier.

  The carrier holding mat 1 is provided with a concave portion 19 and a convex portion 21 having the same pattern as the concave portion 19 (the convex portion having the same shape and the same shape as the concave portion 19). The concave portion 19 is provided at the upstream end of the exhaust gas flow in the exhaust passage 14 of the carrier holding mat 1, and the convex portion 21 is provided on the downstream side of the exhaust gas flow in the exhaust passage 14 of the carrier holding mat 1. It is provided at the end.

  The carrier holding mat 1 is a non-expandable interlam mat made of, for example, ceramic fiber, alumina fiber, vermiculite or the like. Further, as shown in a development view in FIG. 1, the carrier holding mat 1 has a length L corresponding to the outer peripheral length when wound around the catalyst carrier 3 and a width W corresponding to the length of the catalyst carrier 3 in the exhaust flow direction. And have.

  However, in the state where the carrier holding mat 1 is wound around the outer periphery of the catalyst carrier 3, the upstream end surface of the catalyst carrier 3 and the upstream end surface of the carrier holding mat 1 are not flush with each other, as shown in FIG. Furthermore, it is desirable that the carrier holding mat 1 is lower (becomes downstream) so that an annular groove is formed around the catalyst carrier 3. Further, a rectangular convex portion 23 is formed at one end portion of the both ends of the carrier holding mat 1 in the winding direction in the exhaust flow direction, and the convex portion 23 is formed at the other end portion. A rectangular recess 25 is formed at a position corresponding to.

  When the carrier holding mat 1 is wound around the outer periphery of the catalyst carrier 3 as shown in FIG. 3, the convex portion 23 at one end and the concave portion 25 at the other end are fitted together, The exhaust is prevented from escaping from the mating part.

  Here, the concave portion 19 provided on the end surface of the carrier holding mat 1 on the upstream side in the exhaust flow direction acts as a foreign matter trap. The recess 19 is formed in a V shape, for example. Further, on the end face of the carrier holding mat 1 on the downstream side in the exhaust flow direction, for example, a convex portion 21 formed in a V shape is formed corresponding to the concave portion 19.

  The number of the recesses 19 may be one, but here, in order to increase trapping efficiency, a plurality of recesses 19 are formed so as to have a constant interval in the wound state. Accordingly, a plurality of convex portions 21 are also formed. In addition, a round (R) is attached to the intersection of the V-shape so as not to avoid the mat.

  As shown in FIG. 2, a plurality of the carrier holding mats 1 are cut out from one mat material 27, and this cutting is performed on all the concave portions 19 of one carrier holding mat 1 (1A). It is made in a form in which all the convex portions 21 of the other one carrier holding mat 1 (1B) are inserted.

  More specifically, the carrier holding mat 1 (the carrier holding mat immediately after being cut out) 1 before being wound around the outer periphery of the catalyst carrier 3 is formed in a rectangular shape having a predetermined thickness.

  That is, when the carrier holding mat 1 is viewed from this thickness direction, it is formed in a rectangular shape as shown in FIG. 1, and the concave portion 19 is formed in, for example, a “V” shape as described above. In addition, it is recessed from one long side (upper side in FIG. 1) of a pair of long sides of the rectangle to the central side (inside; lower side in FIG. 1) of the rectangle. Each recess 19 is provided at a predetermined interval (at a predetermined pitch) in the extending direction (left and right direction in FIG. 1) of one long side of the pair of long sides of the rectangle.

  Further, when the carrier holding mat 1 is viewed from the thickness direction, the convex portion 21 is formed in a “V” shape that is the same shape as the concave portion 19, and the other long side of the pair of long sides of the rectangle ( It protrudes from the side of the lower side of FIG. 1 to the outside of the rectangle (the lower side of FIG. 1).

  Moreover, the convex part 21 is provided in the same number as the recessed part 19, and each convex part 21 is each extending | stretching direction (left-right direction of FIG. 1) of the other long side among a pair of long sides of a rectangle, and each recessed part. 19 is provided at the same predetermined interval as that of 19. That is, each concave portion 19 and each convex portion 21 have the same position in the extending direction of the long side of the rectangle.

  As shown in FIG. 2, the carrier holding mat 1 is manufactured by making a predetermined shape cut through the thickness direction in one mat material 27 having a predetermined thickness and a predetermined shape (for example, a large rectangular shape). That is done. The predetermined-shaped cut is formed in such a manner that a plurality of carrier holding mats 1 are generated from one mat material 27, and no end material is generated between the carrier holding mats adjacent to each other. It is like that. That is, the predetermined shape of the cut has a shape in which the convex portion 21 of the other carrier holding mat 1B enters the one concave portion 19 of the carrier holding mat 1A adjacent to each other and is continuously connected without a gap.

  Further, the cut is made by penetrating the blade having the predetermined shape (the blade whose blade thickness dimension can be ignored) in the thickness direction of the mat material 27. One mat material 27 is generated, for example, by appropriately cutting a long material roll-shaped material called a raw material into a length. In the form shown in FIG. 2, when a plurality of carrier holding mats 1 are cut out from one mat material 27, a “B” -shaped end material 29 remains at the end of the mat material 27.

  In addition, if the pitch of each recessed part 19 and the pitch of each convex part 21 are mutually equal, in the rectangular longitudinal direction (horizontal direction of FIG. 1 and FIG. 2), each of each recessed part 19 and each convex part 21 are provided. The position of each may be shifted.

  Moreover, although it is the shape of the recessed part 19, it does not necessarily need to be "V" shape. Other shapes may be used as long as the foreign matter is trapped. For example, in the “V” shape, the width of the concave portion is reduced in proportion to the depth of the concave portion 19, but the proportion of the width of the concave portion is reduced in proportion to the depth of the concave portion 19. It may be in a shape (a shape in which two line segments of “V” shape are arcuate and projecting inside the recess). Furthermore, the shape of each recessed part 19 may differ. Further, a plurality of recesses 19 may be provided continuously rather than intermittently. Thus, when the shape of the concave portion 19 is changed, the shape of the convex portion 21 is also changed in accordance with the change of the concave portion 19.

  According to the carrier holding mat 1, welding spatter when the exhaust manifold 11 is formed by pipe welding or the like in the manufacturing stage, residual casting sand in the case of casting, metal chips generated during processing, and metal generated during the operation of the internal combustion engine Even if foreign matters such as oxides fall due to vibration or thermal fatigue and reach the catalyst support 3 of the catalytic converter 5, if they fall on the end face of the support holding mat 1, they are V-shaped while moving on the end face. Once inside the recess 19, it is trapped, and once inside the recess 19, it is V-shaped and tapered, so that it does not jump out and is trapped reliably.

  Therefore, foreign matters such as welding spatter can be reliably trapped and damage to the catalyst carrier 3 can be prevented without causing a decrease in the holding power of the catalyst carrier 3 or exhaust exhaust.

  Further, according to the carrier holding mat 1, the concave portion 19 is provided at the upstream end of the exhaust gas flow in the exhaust passage 14, and the convex portion 21 having the same pattern as the concave portion 19 is provided at the downstream end. Yes. Thus, when a plurality of carrier holding mats 1 are cut out from one mat material 27, the other carrier holding mat is placed in the recess 19 of one carrier holding mat 1 of the carrier holding mats 1 adjacent to each other. By combining the one convex portion 21, the manufacturing process of the carrier holding mat 1 can be simplified, and the generation of the end material (the end material for providing the concave portion) can be eliminated when the carrier holding mat 1 is manufactured. . And the manufacturing cost of the carrier holding mat 1 can be reduced.

  By the way, in the above description, the shape of the concave portion 19 and the shape of the convex portion 21 coincide with each other, and when the convex portion 21 is overlapped with the concave portion 19, all the convex portions 21 and all the concave portions 19 are mutually connected. However, it is not always necessary that all the convex portions 21 and all the concave portions 19 overlap each other.

  That is, the upstream end of the exhaust gas flow of the one carrier holding mat is placed on the other carrier in order to insert the convex portion of the other carrier holding mat into the concave portion of one carrier holding mat. Even if it is formed so that the convex portion of the other carrier holding mat enters the concave portion of the one carrier holding mat when it is brought into contact with the downstream end of the exhaust gas flow of the holding mat. Good.

  For example, the convex portion may be smaller than the concave portion, and the convex portion may be positioned inside the concave portion when the concave portion is stacked on the convex portion. In addition, when a plurality of concave portions and convex portions are provided, the pitch of each concave portion and the pitch of each convex portion may coincide with each other, the convex portions are thinned, and the pitch of each convex portion is It may be an integral multiple of the pitch of each recess.

  If it does in this way, generation | occurrence | production of an end material cannot be eliminated when forming a recessed part, but the quantity of the generated end material will decrease compared with the case where it manufactures through processes like FIG. 6, FIG.

DESCRIPTION OF SYMBOLS 1 Carrier holding mat 3 Catalyst carrier 5 Catalytic converter 9 Internal combustion engine 14 Exhaust passage 19 Concave part 21 Convex part 27 Mat material

Claims (4)

In the carrier holding mat wound around the outer periphery of the catalyst carrier provided in the exhaust passage of the internal combustion engine,
A carrier holding mat, wherein a concave portion is provided at an upstream end of the exhaust gas flow in the exhaust passage, and a convex portion having the same pattern as the concave portion is provided at a downstream end.   The carrier holding mat according to claim 1, wherein a plurality of sheets are cut out from one mat material, and the cut out is formed in all the concave portions of one piece of the carrier holding mat and the other one piece of the above. A carrier holding mat characterized in that all the convex portions of the carrier holding mat are inserted. In the carrier holding mat wound around the outer periphery of the catalyst carrier provided in the exhaust passage of the internal combustion engine,
A concave portion is provided at the upstream end of the exhaust gas flow in the exhaust passage, and a convex portion is provided at the downstream end,
In order to insert the convex portion of the other carrier holding mat into the concave portion of the carrier holding mat, the upstream end of the exhaust gas flow of the one carrier holding mat is the other carrier. The convex part of the other carrier holding mat is formed so as to enter the concave part of the one carrier holding mat when it is brought into contact with the downstream end of the exhaust gas flow of the holding mat. A carrier holding mat. A catalytic converter comprising the carrier holding mat according to any one of claims 1 to 3.

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