JP3206779B2 - Manufacturing method of catalytic converter - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a catalytic converter, and more particularly to a method for fixing a buffer member.

[0002]

2. Description of the Related Art In general, a catalytic converter is mounted in an exhaust system of an automobile to purify exhaust gas, and the catalytic converter removes unburned components such as a CO component and a HC component in the exhaust gas. Is done. In the catalytic converter, a catalyst carrier is accommodated in a cylindrical container. For example, a catalytic converter disclosed in Japanese Utility Model Laid-Open No. 58-108225 is known (shown in FIG. 3).

[0003] In the drawing, reference numeral 101 denotes a catalytic converter. The catalytic converter 101 is constituted by accommodating a catalyst carrier 103 in a cylindrical container 102.
A support cap 104 is fixed to one side at a position corresponding to the axial dimension of the catalyst carrier 103. A buffer member 105 made of a heat-expandable sealing material is mounted between the supporting cap 104 and the end surface 103A of the catalyst carrier 103.

In the catalytic converter 101 having such a structure,
For example, the cylindrical container 102 is composed of a pair of half cases. Similarly, in a state where the cap pieces similarly divided into half shapes are welded to both ends of one half case, the catalyst carrier 103,
The parts of the cushioning member 105 are provided in the cylindrical container 102 and the cylindrical container 1
02, while being positioned and accommodated between the cap pieces fixed to both ends, the other half case in which cap pieces are similarly welded to both ends is put on one half case, and the flanges of both half cases are placed. And the catalytic converter 101 is assembled.

[0005]

However, in the conventional method of manufacturing the catalytic converter 101, the supporting caps 104, 1 are adjusted in advance according to the design dimensions of the catalyst carrier 103.
04 is welded to the cylindrical container 102, so that the catalyst carrier 1
If there is a variation in the quality of the axial dimension 03, the support cap 104 cannot be reliably pressed onto the end surface 103A of the catalyst carrier 103 via the cushioning member 105, and the catalyst carrier 103 during assembly will not be pressed. May not be able to absorb the variation in the quality of the axial dimension of.

That is, when the axial dimension of the catalyst carrier 103 is large, the catalyst carrier 103 cannot be accommodated between the supporting caps 104, 104 welded to the cylindrical container 102. When the axial dimension of 103 is small, the gap between support cap 104 and end surface 103A of catalyst carrier 103 becomes large, and buffer member 10
5, the predetermined elastic force cannot be ensured, and therefore, the holding force of the catalyst carrier 103 is not sufficiently ensured, and there is a possibility that troubles such as chipping of the catalyst carrier 103 may occur. .

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to reduce the axial dimension of the catalyst carrier even if the quality of the axial dimension of the catalyst carrier varies. An object of the present invention is to provide a method of manufacturing a catalytic converter that absorbs variations in quality, secures a holding force of a catalyst carrier by a buffer member, and eliminates a risk of occurrence of a problem such as chipping of the catalyst carrier.

[0008]

According to the first aspect of the present invention,
In the cylindrical container, an annular cap having a cylindrical portion and an annular portion which is continuous with the cylindrical portion and faces the end surface of the catalyst carrier is set on both sides of the catalyst carrier via a buffer member, and the annular portions of the annular cap are formed. One pressing jig having an annular cap pressing surface that comes into contact with the catalyst cap and a catalyst carrier pressing surface that protrudes from the annular cap pressing surface by a predetermined step size and comes into contact with the center of the end surface of the catalyst carrier. An annular cap pressing surface that is arranged on one side of the carrier and contacts the annular portion of the annular cap, and protrudes from the annular cap pressing surface by the same dimension as the step size of one pressing jig and contacts the center of the end surface of the catalyst carrier. The other pressing jig configured with the catalyst carrier pressing surface to be arranged on the other side of the catalyst carrier, by pressing with both pressing jigs so that they are close to both annular caps, Annular surface of catalyst support edge and annular cap In a state that the buffer member was pressurized to between the cylindrical portion of the cylindrical container and the annular cap, characterized in that plug welding.

According to a second aspect of the present invention, in a cylindrical container having a reduced-diameter stepped portion formed on one side, a cylindrical portion and an end surface of one side of the catalyst carrier are continuously connected to the cylindrical portion. An annular cap having an annular portion is accommodated on one side of the catalyst carrier in a state of being in contact with the reduced-diameter step portion via a buffer member, while the cylindrical portion is continuous with the cylindrical portion in the cylindrical container. An annular cap having an annular portion facing the other edge surface of the other side of the catalyst carrier is set on the other side of the catalyst carrier via a cushioning member, and an annular cap pressing surface which contacts the annular portion of the annular cap; By pressing the annular cap with a pressing jig configured to have a catalyst carrier pressing surface that projects from the pressing surface by a predetermined step size and comes into contact with the center of the end surface of the catalyst carrier, With the cushioning member pressed between the edge surface and the annular portion of the annular cap, Method for producing a catalytic converter, characterized by plug welding tubular portion of the cap.

[0010]

According to the first aspect of the present invention, in the cylindrical container,
An annular cap having a cylindrical portion and an annular portion which is continuous with the end surface of the catalyst carrier and which is continuous with the cylindrical portion is set on both sides of the catalyst carrier via a buffer member, and the two caps are attached so that they come close to each other. The cylindrical container and the cylindrical portion of the annular cap are plug-welded while applying pressure to the buffer member between the end surface of the catalyst carrier and the annular portion of the annular cap.

In this case, there is provided an annular cap pressing surface which comes into contact with the annular portion of the annular cap, and a catalyst carrier pressing surface which projects from the annular cap pressing surface by a predetermined step size and contacts the center of the end surface of the catalyst carrier. One of the configured pressing jigs is disposed on one side of the annular cap, and the annular cap pressing surface that contacts the annular portion of the annular cap, and the same step size as the one pressing jig from the annular cap pressing surface. The other pressurizing jig having the catalyst carrier pressing surface that protrudes only and comes into contact with the center of the end face of the catalyst carrier is disposed on the other side of the annular cap, and pressurization is performed by both pressurizing jigs. .

According to the second aspect of the present invention, in a cylindrical container having a reduced-diameter stepped portion formed on one side, a cylindrical portion and an end surface on one side of the catalyst carrier are continuously connected to the cylindrical portion. An annular cap having an annular portion is accommodated on one side of the catalyst carrier in a state of being in contact with the reduced-diameter step portion via a buffer member, and the tubular portion and the catalyst are continuously connected to the tubular portion in the tubular container. An annular cap having an annular portion facing the other edge surface of the carrier is set on the other side of the catalyst carrier via a buffer member, and a pressure is applied to the annular cap to thereby form an edge of the catalyst carrier. With the buffer member pressurized between the annular portions of the annular cap, the tubular container and the tubular portion of the annular cap are plug-welded. In such a case, the annular cap pressing surface that comes into contact with the annular portion of the annular cap, and a catalyst carrier pressing surface that projects from the annular cap pressing surface by a predetermined step size and contacts the center of the end surface of the catalyst carrier. Pressurization is performed with a pressure jig.

[0013]

Embodiments of the present invention will be described below with reference to the drawings. A method for manufacturing a catalytic converter according to an embodiment of the present invention will be described with reference to FIG. 1 using a manifold catalytic converter as an example of a catalytic converter.

In FIG. 1, reference numeral 1 denotes a manifold catalytic converter according to an embodiment of the present invention. The manifold catalytic converter 1 is directly connected to an exhaust manifold of a multi-cylinder engine (not shown) and is disposed substantially perpendicular to an exhaust system. ing.

The cylindrical vessel 2 of the manifold catalytic converter 1 includes an upstream diffuser (not shown), a downstream diffuser (not shown), and a body 3 continuous between the upstream diffuser and the downstream diffuser. And The body 3 is formed by half-joining the half cases 3A, 3A, and a catalyst carrier 4 made of ceramic is accommodated in the body 3.

A gap 5 is formed between the inner wall surface 3B of the body 3 of the cylindrical container 2 and the side surface 4D of the catalyst carrier 4. The holding member 6 and the inflatable sealing material 7
(Product name: Intramat). The expandable sealing material 7 prevents exhaust gas from bypassing.

The annular caps 8, 9 are fixed to both sides of the catalyst carrier 4, respectively, and a washer wire is provided between the annular caps 8, 9 and the edge surfaces 4A, 4B of the catalyst carrier 4.
Buffer members 10 and 11 called a mesh are mounted.

The upstream annular cap 8 includes a cylindrical portion 8A fixed to the body 3 by plug welding S1 and an annular portion 8B which is continuous with the cylindrical portion 8A and faces the end surface 4A of the catalyst carrier 4. The downstream annular cap 9 has a cylindrical portion 9A fixed to the body portion 3 by plug welding S2, and an annular portion continuous with the cylindrical portion 9A and opposed to the edge surface 4B of the catalyst carrier 4. 9B. The buffer members 10 and 11 are in a compressed state and hold the edge surfaces 4A and 4B of the catalyst carrier 4.

In the manifold catalytic converter 1 configured as described above, the exhaust gas flows into the cylindrical container 2 and is purified while passing through the catalyst carrier 4. Then, the manifold catalytic converter 1 is manufactured as follows.

First, after setting one half case 3A on the lower side, the annular caps 8 and
9 are set on both sides of the catalyst carrier 4 via buffer members 10 and 11, respectively.
A, and the flanges of the half cases 3A, 3A are butt-welded.

In this state, pressing jigs J1 and J2
A pressing force is applied to the two annular caps 8 and 9 in the direction of the catalyst carrier 4 from the outside in the axial direction, and both end surfaces 4A and 4B of the catalyst carrier 4 and the annular portions 8B and 9B of the two annular caps 8 and 9 are formed.
The cylindrical container 2 and the cylindrical portions 8A and 9A of the annular caps 8 and 9 are plug-welded while the buffer members 10 and 11 are compressed by a predetermined amount.

The one pressing jig J1 has an annular cap pressing surface 21 which contacts the annular portion 8A of the annular cap 8.
And a catalyst carrier pressing surface 22 protruding from the annular cap pressing surface 21 by a predetermined step dimension L and contacting the center 4C of the end surface of the catalyst carrier 4, and is disposed on one side of the catalyst carrier 4. I have.

The other pressing jig J2 has an annular cap pressing surface 23 which contacts the annular portion 9A of the annular cap 9.
And a catalyst carrier pressing surface 24 protruding from the annular cap pressing surface 23 by the same dimension as the step size L of the one pressing jig J1 to come into contact with the center 4C of the end surface of the catalyst carrier 4. The two pressing jigs J1 and J
2, pressurization is performed as described above.

According to the above-described structure, the manifold catalytic converter 1 is assembled in a state where all the components of the catalyst carrier 4, the buffer members 10, 11 and the annular caps 8, 9 are accommodated in the cylindrical container 2, and the annular cap is assembled. 8 and 9 are cylindrical containers 2
Even if there is a variation in the quality of the catalyst carrier 4 in the axial direction, the end surfaces 4A and 4B of the catalyst carrier 4
By pressing both annular caps 8 and 9 via the buffer members 10 and 11, the variation in the quality of the catalyst carrier 4 in the axial direction can be absorbed.

That is, even when the axial dimension of the catalyst carrier 4 is large, the annular caps 8 and 9 can be assembled on both sides of the catalyst carrier 4. Even when the axial dimension of the catalyst carrier 4 is small, A predetermined elastic force can be ensured without reducing the elastic force of the cushioning members 10 and 11. Therefore, the holding force of the catalyst carrier 4 can be ensured by the buffer members 10 and 11, and the possibility of occurrence of a problem such as chipping of the catalyst carrier 4 can be eliminated.

Further, as the pressing means, pressing jigs J1 and J2 having a special structure are adopted, and the step size L of both pressing jigs J1 and J2 is the same. The distance from the caps 8 and 9 to the center 4C of the end surface of the catalyst carrier 4 of the buffer members 10 and 11 is regulated by the step size L, and the compression amounts of both buffer members 10 and 11 are made equal to each other.
1 can more reliably hold the catalyst carrier 4.

In this embodiment, the manifold catalytic converter 1 is described as an example of the catalytic converter, but the present invention is not limited to this, and the present invention can be applied to an underfloor type catalytic converter.

Further, in the present embodiment, a ceramic carrier is taken as an example of the catalyst carrier, but the catalyst carrier can be applied to a metal carrier. In the present embodiment, the body 3 of the cylindrical container 2 is formed by combining the half cases 3A, 3A, and one half case 3A is provided on the lower side.
Is set to cover the other half case 3A on the upper side, but the present invention can also be applied to a case where the body 3 is not formed in a half-shape but is formed in a cylindrical shape.

Further, the catalyst carrier 4 is accommodated in the cylindrical container 2 to which the one side annular cap 8 is fixedly attached to one side by sandwiching the one side buffer member 10 between the one side annular cap 8 and the annular cap 8. After that, the other-side annular cap 9 is set on the other side of the catalyst carrier 4 via the other-side buffer member 11 in the cylindrical container 2, and the pressing force is applied from the outside in the axial direction toward the catalyst carrier 4. By acting on both annular caps 8, 9, both end edges 4 A, 4 B of catalyst carrier 4 and annular portions 8 of both annular caps 8, 9 are formed.
With the buffer members 10 and 11 pressurized between B and 9B, the cylindrical portions 8A and 9A of the cylindrical container 2 and the other-side annular caps 8 and 9 are pressed.
Can also be plug welded.

The case where the structure of the catalytic converter is different will be described with reference to FIG. In the figure, a catalyst carrier 33 is accommodated in a cylindrical container 32 having a reduced diameter stepped portion 31A formed on one side, and a cylindrical portion 34A and a catalyst are continuously connected to the cylindrical portion 34A in the cylindrical container 32. An annular cap 34 having an annular portion 34B facing one end surface 33A of one side of the carrier 33 is set on one side of the catalyst carrier 33 via a buffer member 35, and the annular cap 34 comes into contact with the reduced diameter step portion 31A. ing.

An annular cap 3 having a cylindrical portion 36A and an annular portion 36B continuous with the cylindrical portion 36A and facing the other end surface 33B of the catalyst carrier 33 in the cylindrical container 32.
6 is set on the other side of the catalyst carrier 33 via a buffer member 37, and a pressing force is applied to the annular cap 36 by a pressing jig J3 to thereby form an end surface 33 </ b> B of the catalyst carrier 33 and the annular portion of the annular cap 36. With the buffer member 37 pressurized between 36B, the cylindrical container 32 and the cylindrical portion 36A of the annular cap 36 are pressed.
Is plug welded.

In this case, as shown in the figure, the pressing jig J3 includes an annular cap pressing surface 38 that contacts the annular portion 36B of the annular cap 36, and an annular cap pressing surface 38.
And a catalyst carrier pressing surface 39 which projects from the center of the catalyst carrier 33 by a predetermined step dimension L1 and comes into contact with the end surface center portion 33C of the catalyst carrier 33, and is pressurized by the pressing jig J3.

[0033]

As described above, according to the first aspect of the present invention, the catalyst carrier, the cushioning member, and the annular cap are all assembled in a cylindrical container, and the annular cap is attached to the cylindrical container. Even if there is a variation in the quality of the axial size of the catalyst carrier, both annular caps are pressed onto the edge surface of the catalyst carrier via the buffer member, so that the axial Variations in the quality of the dimension in the direction can be absorbed.

That is, even when the axial size of the catalyst carrier is large, the annular caps can be assembled on both sides of the catalyst carrier, and even when the axial size of the catalyst carrier is small, the elastic force of the cushioning member can be increased. The predetermined elastic force can be ensured without reducing. Therefore, the holding force of the catalyst carrier is ensured by the buffer member, and it is possible to eliminate the possibility of occurrence of a problem such as chipping of the catalyst carrier.

Further, since the step sizes of the two pressing jigs are the same, the distance from the annular caps on both sides to the edge surface of the catalyst carrier of the buffer member is regulated by the step size, and the both buffer members are formed. And the amount of compression can be made the same, and an effect that the holding of the catalyst carrier by the buffer member can be more reliably achieved.

According to the second aspect of the present invention, the same effects as those of the first aspect of the invention can be obtained.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view showing a method for manufacturing a catalytic converter according to an embodiment of the present invention.

FIG. 2 is a longitudinal sectional view showing another method for manufacturing a catalytic converter according to an embodiment of the present invention.

FIG. 3 is a longitudinal sectional view showing a conventional catalytic converter.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Manifold catalytic converter 2 Cylindrical container 4 Catalyst carrier 4A End surface 4B End surface 4C End surface central portion 8 Annular cap 8A Cylindrical portion 8B Annular portion 9 Annular cap 9A Cylindrical portion 9B Annular portion 10 Buffer member 11 Buffer member 21 Annular cap Pressing surface 22 Catalyst carrier pressing surface 23 Annular cap pressing surface 24 Catalyst carrier pressing surface J1 Pressing jig J2 Pressing jig

Continuation of the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) F01N 3/28 B01J 35/04 B01D 53/36 B23P 21/00

Claims (2)

(57) [Claims] 1. A cylindrical portion (8A, 9) is provided in a cylindrical container (2).
A) and the cylindrical portion (8A, 9A) and the annular portion (8) facing the edge surface (4A, 4B) of the catalyst carrier (4).
B, 9B) are set on both sides of the catalyst carrier (4) via the cushioning members (10, 11), and the annular cap (8) is brought into contact with the annular portion (8B) of the annular cap (8). Cap pressing surface (21) and annular cap pressing surface (21)
From the catalyst carrier (4) by a predetermined step size (L).
The catalyst carrier pressing surface (2) contacting the center (4C) of the end surface of the
2) is disposed on one side of the catalyst carrier (4), and the annular cap pressing surface is in contact with the annular portion (9B) of the annular cap (9). (23) and an annular cap pressing surface (23)
And a catalyst carrier pressing surface (24) protruding from the same by the same dimension as the step size (L) of one pressing jig (J1) and contacting the center (4C) of the end surface of the catalyst carrier (4). The other pressurizing jig (J2) is placed on the other side of the catalyst carrier (4), and the two pressurizing jigs (J1, J2) are used so that they are close to the two annular caps (8, 9). By applying pressure, the cushioning member (1) is placed between the edge surfaces (4A, 4B) of the catalyst carrier (4) and the annular portions (8B, 9B) of the annular caps (8, 9).
A method for producing a catalytic converter, comprising: plug welding a tubular container (2) and a tubular portion (8A, 9A) of an annular cap (8, 9) while pressurizing (0, 11). 2. A cylindrical part (34A) and a cylindrical part (3A) in a cylindrical container (32) having a reduced diameter step (31A) formed on one side.
4A), the edge surface (3) on one side of the catalyst carrier (33).
An annular cap (34) having an annular portion (34B) opposed to 3A) is provided on one side of the catalyst carrier (33) with a cushioning member (3).
5), and is accommodated in a state of being in contact with the reduced diameter step portion (31A). On the other hand, in the tubular container (32), the catalyst is continuously connected to the tubular portion (36A) and the tubular portion (36A). An annular cap (36) having an annular portion (36B) facing the other edge surface (33B) of the support (33) is set on the other side of the catalyst support (33) via a buffer member (37), An annular cap pressing surface (38) contacting the annular portion (36B) of the annular cap (36);
8) a pressing jig (J3) configured to have a catalyst carrier pressing surface (39) that protrudes from the catalyst carrier (33) by a predetermined step size (L1) and comes into contact with the center (33C) of the end surface of the catalyst carrier (33). ,
By applying pressure to the annular cap (36), the buffer member (37) is pressurized between the edge surface (33B) of the catalyst carrier (33) and the annular portion (36B) of the annular cap (36). , Cylindrical container (32) and annular cap (3
6) A method for producing a catalytic converter, wherein the cylindrical portion (36A) is plug-welded.