JP2834236B2 - Metal catalyst carrier for catalytic converter and method for producing the same - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a metal catalyst carrier used for a catalytic converter, and more particularly to a metal catalyst carrier capable of effectively preventing a film-out phenomenon and a method for producing the same.

[Conventional technology]

2. Description of the Related Art Generally, a catalytic converter as disclosed in Japanese Utility Model Application Laid-Open No. 62-158117 is disposed in an exhaust system of an automobile to purify exhaust gas.

FIG. 10 shows the details of the metal catalyst carrier of the catalytic converter. As shown in FIG. 11, the metal catalyst carrier has metal corrugated plates 11 and flat plates 13 alternately stacked on each other. After the temporary support 15 is formed by winding a plurality of layers around the core material in a circular shape to form a temporary support 15, the temporary catalyst 15 is crushed to form an elliptical metal catalyst support 17 as shown in FIG. Formed.

After such a metal catalyst carrier 17 has been subjected to a catalyst supporting treatment, for example, as shown in FIG. 12, caps 19 are fitted to both ends of the carrier 17, and are accommodated in a cylindrical container 21. Although it is used, if the corrugated plate 11 and the flat plate 13 are kept wound, the flow of the exhaust gas G into the metal catalyst carrier 17 causes the corrugated plate 11 located at the center of the metal catalyst carrier 17 to flow. And the flat plate 13 projects in the axial direction of the metal catalyst carrier 17, so-called film-out phenomenon occurs.
After the formation, the corrugated plate 11 and the flat plate 13 are fixed to each other by spot welding, brazing, or the like.

[Problems to be solved by the invention]

However, in such a conventional metal catalyst carrier,
Since the corrugated sheet 11 and the parallel plate 13 need to be fixed to each other by spot welding, brazing, or the like, there is a problem that productivity is poor and cost is increased.

Further, since the exhaust gas G flows only in the central portion of the metal catalyst carrier 17, it is difficult to obtain sufficient purification performance.

The present invention has been made in order to solve the above-described problems, and it is possible to reliably prevent a film-out phenomenon with a simple configuration and to surely disperse exhaust gas to an outer peripheral portion of a metal catalyst carrier. An object of the present invention is to provide a metal catalyst carrier for a catalytic converter that can be manufactured, and a method for manufacturing a metal catalyst carrier that can easily manufacture the metal catalyst carrier.

[Means for solving the problem]

The metal catalyst carrier of the catalytic converter according to the present invention, a metal corrugated sheet and a flat plate are stacked, and in the metal catalyst carrier of the catalytic converter obtained by winding these in multiple layers, the exhaust gas inflow side end face of the carrier, The carrier protrudes in a conical shape toward the exhaust gas inflow side, and the outer peripheral portion of the carrier on the exhaust gas outflow side is crushed flat.

Further, the method for producing a metal catalyst carrier of the present invention is such that a metal corrugated sheet and a flat plate are overlapped, and these are wrapped in multiples to form a temporary carrier, and the exhaust gas outflow side end face of the temporary carrier is pressed. By projecting the end face of the exhaust gas inflow side in a conical shape toward the exhaust gas inflow side, the outer peripheral portion of the temporary carrier on the exhaust gas outflow side is flattened by a jig, and heat treatment is performed in this state. Then, the corrugated plate and the flat plate are formed into a shape when pressed by the jig.

(Operation)

In the metal catalyst carrier of the catalytic converter of the present invention,
The end face of the exhaust gas inflow side of the metal catalyst carrier protrudes in a conical shape toward the exhaust gas inflow side, whereby the exhaust gas is dispersed on the outer peripheral portion of the metal catalyst carrier, while the exhaust gas outflow side of the metal catalyst carrier is Is crushed flat, thereby preventing relative movement between the flat plate and the corrugated plate.

Further, in the method for producing a metal catalyst support of the present invention, a temporary support is formed by laminating a metal corrugated sheet and a flat plate, and winding these multiple times to form a temporary support. By pressing the end face of the gas outflow side in a conical shape toward the exhaust gas inflow side, the outer peripheral portion of the temporary carrier on the exhaust gas outflow side is flattened by a jig, and heat treatment is performed in this state. Is performed, and the corrugated plate and the flat plate are formed into a shape when pressed by the jig.

〔Example〕

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

1 to 3 show a metal catalyst carrier and one embodiment of a catalytic converter according to the present invention. In these figures, reference numeral 31 indicates a metal catalyst carrier.

The metal catalyst carrier 31 is formed by stacking a metal corrugated plate 33 and a flat plate 35, and winding these over and over.

In this embodiment, the end face of the metal catalyst carrier 31 on the exhaust gas inflow side protrudes in a conical shape toward the exhaust gas inflow side to form a projection 37.

Note that the tip angle θ of the projecting portion 37 is
Although it depends on the shape, size, etc., an angle of about 40 to 60 degrees is desirable.

And, on the end face on the exhaust gas outflow side of the metal catalyst carrier 31,
A conical recess 39 corresponding to the protrusion 37 is formed.

Further, the outer peripheral portion of the metal catalyst carrier 31 on the exhaust gas outflow side is flattened to form a flat portion 41.

The metal catalyst carrier configured as described above is manufactured as described below.

That is, first, the corrugated plate 33 and the flat plate 35 are overlapped, and these are wound in multiple layers to form a columnar temporary carrier.

Thereafter, the central portion of the end surface of the temporary carrier on the exhaust gas outflow side is pressed toward the exhaust gas inflow side by a jig or the like, thereby forming a protrusion 37 on the exhaust gas inflow side end surface of the temporary carrier.

Then, as shown in FIGS. 4 and 5,
Between the angle members 43 arranged at predetermined intervals, the outer peripheral portion on the exhaust gas outflow side of the temporary carrier 32 is sandwiched, and a nut 47 screwed to a pair of bolts 45 connecting the angle member 31 is tightened, The elliptical flat portion 41 is formed by moving the angle member 43 toward the temporary carrier 32 and crushing the outer periphery of the temporary carrier 32 on the exhaust gas outflow side in a flat shape.

Note that the position where the angle member 43 contacts is preferably a position near the vertex of the concave portion 39 formed in the temporary carrier 32.

Thereafter, heat treatment is performed in a state of being pressed by the jig, and the corrugated plate 33 and the flat plate 35 are formed into a shape when pressed by the jig.

The heat treatment is performed, for example, by heating at an atmosphere temperature of 925 ° C. for 4 hours or at an atmosphere temperature of 1050 ° C. for 2 hours.

Thus, in the metal catalyst carrier of the catalytic converter configured as described above, the exhaust gas inflow side end face of the metal catalyst carrier 31 is protruded in a conical shape toward the exhaust gas inflow side to form a projection 37, and the metal Since the outer peripheral portion of the catalyst carrier 31 on the exhaust gas outflow side is flattened and the flat portion 41 is formed, the film-out phenomenon can be reliably prevented with a simple configuration, and at the same time, the exhaust gas is transferred to the metal catalyst carrier 31. Can be surely dispersed to the outer peripheral portion.

That is, in the metal catalyst carrier configured as described above, since the outer peripheral portion on the exhaust gas outflow side of the metal catalyst carrier 31 is crushed flat, the corrugated plate 33 and the flat plate 35 form the exhaust gas of the metal catalyst carrier 31. The movement to the outflow side is reliably prevented by the flat shape 41, so that the film-out phenomenon can be reliably prevented with a simple configuration.

Further, since the end face of the exhaust gas inflow side of the metal catalyst carrier 31 protrudes in a conical shape toward the exhaust gas inflow side, the flow of the exhaust gas G flowing into the metal catalyst carrier 31 is reduced as shown in FIG. It is dispersed in the outer peripheral direction, and the purification performance can be greatly improved as compared with the related art.

In the method for manufacturing a metal catalyst carrier described above, a corrugated metal plate 33 and a flat plate 35 are stacked, and these are wrapped in multiple layers to form a temporary carrier 32, and the exhaust gas inflow side of the temporary carrier 32 is formed. After projecting the end face in a conical shape toward the exhaust gas inflow side,
Since the outer peripheral portion of the temporary carrier 32 on the exhaust gas outflow side was flattened by a jig, heat treatment was performed in this state, and the corrugated plate 33 and the flat plate 35 were formed into a shape when pressed by the jig. The metal catalyst carrier 31 described above can be easily manufactured.

FIG. 7 shows another embodiment of the metal catalyst carrier of the catalytic converter of the present invention. In this embodiment, the center of the metal catalyst carrier 51 is directed toward the exhaust gas outflow side of the metal catalyst carrier 51. The plug 53 to be tapered is inserted.

In addition, this metal catalyst carrier is formed by winding a corrugated plate 33 and a flat plate 35 around the outer periphery of a winding core, removing the winding core, forming a protruding portion 55, and forming the protrusion at the center as shown in FIG. Insert the plug 53 into the space, and as shown in FIG.
It is formed by crushing the exhaust gas outflow side of 51.

With the metal catalyst carrier of the catalytic converter configured as described above, substantially the same effects as in the embodiment shown in FIG. 1 can be obtained.

In the above-described embodiments, an example in which the present invention is applied to a metal catalyst carrier having a circular cross section has been described.However, the present invention is not limited to such embodiments.
It goes without saying that the metal catalyst carrier having an elliptical cross section may be crushed and formed.

〔The invention's effect〕

As described above, in the metal catalyst carrier of the catalytic converter of the present invention, the end face of the exhaust gas inflow side of the metal catalyst carrier is projected in a conical shape toward the exhaust gas inflow side,
Since the outer peripheral portion on the exhaust gas outflow side of the metal catalyst carrier is flattened, the film-out phenomenon can be reliably prevented with a simple configuration, and the exhaust gas is reliably dispersed on the outer peripheral portion of the metal catalyst carrier. be able to.

In the method for manufacturing a metal catalyst carrier described above, a metal corrugated sheet and a flat plate are stacked, and these are wrapped in multiple layers to form a temporary carrier, and the end face of the temporary carrier on the exhaust gas outflow side is pressed. By projecting the end face of the exhaust gas inflow side in a conical shape toward the exhaust gas inflow side, the outer peripheral portion of the temporary carrier on the exhaust gas outflow side is flattened by a jig, and heat treatment is performed in this state. In this case, since the corrugated plate and the flat plate are formed into a shape when pressed by the jig, there is an advantage that the metal catalyst carrier of the present invention can be easily manufactured.

[Brief description of the drawings]

FIG. 1 is a perspective view showing one embodiment of the metal catalyst carrier of the catalytic converter of the present invention. FIG. 2 is a top view of the metal catalyst carrier of FIG. FIG. 3 is a bottom view of the metal catalyst carrier of FIG. FIG. 4 and FIG. 5 are explanatory views showing a state where the metal catalyst carrier is crushed. FIG. 6 is an explanatory diagram showing dispersion of exhaust gas in the metal catalyst carrier of FIG. FIG. 7 is an explanatory view showing another embodiment of the metal catalyst carrier of the present invention. 8 and 9 are explanatory views showing a method for producing the metal catalyst carrier of FIG. FIG. 10 is a perspective view showing a conventional metal catalyst carrier. FIG. 11 is a perspective view showing a state in which a corrugated plate and a flat plate are wound. FIG. 12 is an explanatory view showing a film-out phenomenon. [Description of Signs of Main Parts] 31 Metal catalyst carrier 33 Corrugated plate 35 Flat plate 37 Projecting portion 41 Flat portion.

Claims (2)

(57) [Claims] 1. A metal catalyst carrier of a catalytic converter comprising a metal corrugated plate and a flat plate superimposed on each other and wound in multiple layers, with the exhaust gas inflow side end face of the carrier facing the exhaust gas inflow side. A metal catalyst carrier for a catalytic converter, wherein the metal catalyst carrier protrudes in a conical shape and the outer peripheral portion of the carrier on the exhaust gas outflow side is flattened. 2. A temporary carrier is formed by laminating a metal corrugated plate and a flat plate, and winding these multiple times to form a temporary carrier, and pressing the exhaust gas outflow side end surface of the temporary carrier to form an exhaust gas inflow side end surface. After projecting in a conical shape toward the exhaust gas inflow side,
A catalyst wherein the outer peripheral portion of the temporary carrier on the exhaust gas outflow side is crushed flat by a jig, heat treatment is performed in this state, and the corrugated plate and the flat plate are formed into a shape when pressed by the jig. A method for producing a metal catalyst carrier for a converter.