JP4239485B2 - Method for assembling catalyst reformer - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention provides a catalyst such as a catalytic converter for use in a purification apparatus for automobile exhaust gas or a hydrogen reformer for a fuel cell by incorporating a honeycomb ceramic catalyst having a holding mat wound around its outer peripheral surface in a metal case. The present invention relates to a method for assembling a reformer.
[0002]
[Prior art and prior art]
Conventionally, in order to remove harmful substances contained in the exhaust gas of an internal combustion engine such as an automobile, a honeycomb ceramic catalyst (hereinafter sometimes simply referred to as “catalyst”) is accommodated in the catalyst casing of the exhaust gas flow path. The purification device that has been used is used. For example, in a car, a muffler is used as a catalyst casing, and a catalyst is accommodated inside the muffler via a holding mat to form a purification device.
[0003]
Such a purification device, that is, a catalytic converter, includes a catalyst (honeycomb ceramic catalyst) carrying a catalyst such as a noble metal, a metal case for housing the catalyst and connecting it to a muffler, and the metal case It is mainly composed of three parts including a holding mat for fixing the catalyst to the catalyst.
[0004]
Conventionally, as a method for assembling a catalytic converter, a catalyst in which a holding mat is wound (hereinafter sometimes referred to as “catalyst-mat wound body”) is mounted in a half-divided metal case and divided in half. There are a clamshell method in which cases are integrated by welding, and a stuffing method in which a catalyst-mat wound body is press-fitted into a metal case slightly larger than the outer periphery of the catalyst. In particular, recently, the stuffing method is becoming mainstream because of the reduction in the number of parts or the number of assembly steps.
[0005]
In assembling the catalytic converter by the stuffing method, the catalyst-mat winding body is press-fitted into a metal case having an inner diameter smaller than the outer diameter of the catalyst-mat winding body (hereinafter referred to as “press-fit method”). And a method in which the outer diameter of the metal case is drawn after being inserted into a metal case having an inner diameter larger than the outer diameter of the catalyst-mat winding body. Productivity is excellent in that processing is unnecessary.
[0006]
By the way, the use temperature of the catalytic converter is usually 600 ° C. or higher, and it is necessary to use the catalyst converter at a higher temperature in order to obtain higher catalyst efficiency. Under such a high temperature, in the conventional holding mat mainly composed of ceramic fibers, there is a possibility that the fibers are thermally deteriorated and the holding capacity is lowered. Therefore, a method using a holding mat made of alumina fibers having higher heat resistance has attracted attention (JP-A-7-286514, JP-A-9-946, etc.). Among these, a mat that is a laminated sheet of alumina fibers, in which a part of the fibers is oriented in the penetrating direction with respect to the laminated surface by needle punching, is particularly excellent in its strength, resilience, and handleability.
[0007]
However, even in such a heat-resistant mat made of alumina fibers, in the assembled catalytic converter, if the holding mat and the catalyst are not uniformly contained in the metal case, good performance can be exhibited. Can not. In particular, in the assembly method using the press-fitting method, which has been the mainstream recently, there is a problem that it is difficult to press-in a bulky holding mat and even press-fitting is not possible. In order to solve these problems, a mat whose thickness is reduced by a vacuum pack made of a resin film and a mat whose thickness is suppressed by impregnating an organic binder and compressing in the thickness direction have been proposed. Furthermore, a proposal has been made to improve the assemblability (in particular, in the case of the press-fitting method, hereinafter referred to as “press-fit”) by covering the surface with a protective layer such as a protective film. Yes.
[0008]
However, in a holding mat containing an organic component such as an organic binder, these combustion gases are generated at the start of the catalytic converter and the working environment is deteriorated, and recently, the organic binder in the holding mat is reduced as much as possible. More preferably, a holding mat containing no organic binder is used, and a protective layer is used on the mat surface only during assembly.
[0009]
Usually, the holding mat contains about 10 to 20% by weight (content when the inorganic fiber of the mat base material is 100% by weight) as a vacuum packing material or an organic binder, and further includes the protective layer described above and the following. A few weight percent organic content is added with adhesive or double-sided tape. Therefore, reducing the organic content in the mat is very effective in reducing the organic content of the assembled catalytic converter itself.
[0010]
However, the holding mat containing no organic binder is not only bulky, but also has a problem that the mat cannot be directly fixed to the catalyst surface because the connection between fibers is weak. That is, conventionally, when a mat (a flat plate provided with fitting portions, ie, uneven portions on both ends) is wound around a catalyst (generally a cylindrical shape), the catalyst and the mat are bonded with an adhesive or a double-sided tape. After fixing, it was generally fixed around the wound mat with a film or tape, but the mat without organic binder fuzzed the surface and gained adhesive strength with adhesive or tape. (The so-called “ineffective state”), there arises a problem that the mat is easily displaced from the catalyst when the catalyst-mat winding body is mounted on the metal case.
[0011]
A honeycomb ceramic catalyst housed in a metal case via a holding mat is not only a catalytic converter for an exhaust gas purification device, but also a fuel cell for reforming hydrocarbons to hydrogen by selecting a catalyst. The present invention is also applied to a catalytic reformer. In this reformer as well, it is desired to improve the assembling property of the catalyst-mat wound body.
[0012]
Conventionally, various techniques have been proposed for improving the assembly property of the catalyst-mat wound body as described below. However, these methods also use the above-described mats that do not contain an organic binder. The problem has not been solved.
(1) Japanese Patent No. 3246215: When assembling an exhaust gas purification device, first, a sealing material whose front and back surfaces or outer periphery is covered with a synthetic resin film is wound around the outer periphery of the ceramic monolith, and then this ceramic monolith is placed in the exhaust gas flue How to insert and fix. This method is considered to be an effective method basically, but the detailed description of the winding method is not described in the publication, and the problem has not been completely solved.
(2) Japanese Patent Application Laid-Open No. 9-228829: A method in which an inorganic fiber sheet is wound around the outer periphery of a catalyst holder, put into a bag of an airtight plastic film, and the inside of the bag is evacuated before being inserted into a metal pipe . In this method, the pressure is reduced in an airtight plastic film, the operability is poor, and it is difficult to maintain airtightness in all steps from the start of insertion to the completion. In addition, there is a problem that the thickness cannot be reduced by compressive force above atmospheric pressure, which is not practical.
(3) Japanese Patent Application Laid-Open No. 9-264126: After covering the outside of the catalyst carrier holding the catalyst with a heat insulating material, inserting the catalyst carrier into the inside of the cylindrical metal shell, the metal shell of the catalyst carrier A method in which the outer diameter of the insertion tip is kept smaller than the inner diameter of the metal shell by winding and compressing the organic sheet, and then the catalyst carrier is inserted into the metal shell. In this method, since only the front end portion of the mat insertion side is compressed so as to be smaller than the inner diameter of the metal shell (metal case), the mat in the other uncompressed portion may become a press-fit resistance and is practical. is not.
(4) Japanese Patent Laid-Open No. 09-317455: The bulk density is 0.1 g / cm using an organic sheet under tension on the outside of a crystalline alumina fiber mat provided with a fitting portion in advance.³After covering and fixing as described above, the end of the organic sheet is fixed on the end face side of the catalyst holding body, and then a funnel-shaped attachment jig is set on the end of the metal pipe and then press-fitted. Method. In this method, the front end of the mat insertion side is fixed to the catalyst. However, such partial adhesion of the end may also cause problems such as unburned soot at the time of combustion blocking the catalyst hole. Not practical.
[0013]
By the way, when the catalyst-mat wound body is press-fitted into the metal case by the press-fitting method, it is common to use a funnel-shaped press-fitting jig having an inner surface inclined. However, this press-fitting jig with a large inclination angle and shallow depth is suitable for mass production because the press-in distance is short and the cycle time can be shortened. Due to the reaction, the reintroduction side is greatly repelled, the wound outer diameter of the mat is enlarged, and the adhesion with the catalyst is deteriorated. Usually, the holding mat is partially fixed to the catalyst with an adhesive or a double-sided tape and used for press-fitting. If such a repulsion occurs, it will cause the bond to come off. If the press-fitting is performed with the adhesive remaining detached, the mat will be excessively displaced. In addition, if a jig with a very small inclination angle is used, the adhesion between the holding mat and the catalyst gradually increases, and relatively good press-fitting can be performed. However, if the press-fitting distance is too long, it is not suitable for mass production. . Further, when the moving distance becomes long, the surface condition deteriorates due to the contact between the holding mat and the jig and remains as a scratch, which may cause a problem in the durability of the mat.
[0014]
The present applicant has solved the problem of such a conventional press-fitting jig, and when the catalyst-mat winding body is press-fitted into a metal case to assemble a catalytic converter, the catalyst is not lost. As shown in FIG. 2, an inner hole 10S is provided as a press-fitting guide jig that can be smoothly press-fitted without deteriorating or damaging the holding mat wound around the holding mat and preventing the holding mat from shifting or protruding. Has been proposed (Japanese Patent Application No. 2002-100142, hereinafter referred to as “prior application”), in which the inner peripheral surface has different taper angles at the introduction portion 10a, the holding portion 10b, and the press-fit portion 10c. . According to this press-fitting guide jig 10, it is possible to prevent the holding mat 2 from slipping out or protruding with a relatively short press-fitting distance, without impairing productivity, without deteriorating or damaging the holding mat 2. The honeycomb ceramic catalyst 1 around which the holding mat 2 is wound can be smoothly pressed into the metal case 3. In FIG. 2, 10 </ b> A is a concave step portion for fitting the metal case 3.
[0015]
The above-mentioned press-fitting jig 10 can solve the above-mentioned problem. However, even if such a jig is used, in the case of a mat that does not contain an organic binder, which is the subject of the present invention, The problem that the adhesive and tape become so-called “ineffective” due to fluffing and the mat easily deviates from the catalyst at the time of press-fitting still remains.
[0016]
[Problems to be solved by the invention]
The present invention solves the above-mentioned conventional problems, and even in the case where a holding mat consisting only of inorganic fibers not containing an organic binder is used, the catalyst-mat wound body is placed in a metal case with a good assembly property. It is an object of the present invention to provide a method for assembling a catalyst reformer that can be attached to a vehicle.
[0017]
[Means for Solving the Problems]
  The assembly method of the catalyst reformer of the present invention includes a honeycomb-shaped ceramic catalyst, a holding mat wound around the outer peripheral surface of the honeycomb-shaped ceramic catalyst, and surrounding the outer periphery of the holding mat. In a method of assembling a catalyst reformer having a step of mounting a catalyst-mat winding body having a holding layer in close contact with the outer peripheral surface of a ceramic catalyst in a metal case, the honeycomb ceramic catalyst On the other hand, the holding mat is wound while being compressed, and the holding mat is 0.5 kg / cm against the outer peripheral surface of the honeycomb ceramic catalyst.²Adhere to the above even pressure, and then perform the mounting processA catalyst reformer assembling method, wherein the catalyst-mat winding body is mounted by press-fitting into a cylindrical metal case, and the holding mat of the catalyst-mat winding body is , Not fixed to the honeycomb ceramic catalyst with adhesive or double-sided tapeIt is characterized by that.
[0018]
According to the present invention, the holding mat is wound around the honeycomb-shaped ceramic catalyst while being compressed, and the holding layer is applied to the outer peripheral surface of the honeycomb-shaped ceramic catalyst by the holding layer at 0.5 kg / cm.²By attaching to the metal case in close contact with the above even pressure, even if the holding mat does not contain an organic binder, the holding mat does not cause a deviation from the catalyst, and against the metal case. It can be easily attached.
[0019]
  In the present invention, the holding mat is preferably composed of substantially inorganic fibers not containing an organic binder, and needle-punched alumina fiber mats are particularly preferable.In the present invention,The holding mat is not fixed to the honeycomb ceramic catalyst with an adhesive or double-sided tape.Yes.
[0020]
As the holding layer for bringing such a holding mat into close contact with the honeycomb-shaped ceramic catalyst, a resin film, a nonwoven fabric, a net, a cold chill, a thread, a string, or the like can be used.
[0021]
  BookinventionInIs a catalyst-mat wound bodyIsPress fit into a cylindrical metal caseBe done.
[0022]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of an assembly method for a catalyst reformer according to the present invention will be described below in detail with reference to the drawings.
[0023]
First, the method for winding the holding mat in the present invention will be described with reference to FIG. FIG. 1 is a schematic sectional view showing an example of a holding mat winding method suitable for the present invention.
[0024]
In the present invention, first, as the catalyst-mat wound body to be mounted on the metal case, the holding mat is wound around the honeycomb ceramic catalyst while being compressed, and the holding mat is wound around the outer peripheral surface of the honeycomb ceramic catalyst. 0.5kg / cm²What was stuck by the above equal surface pressure is produced.
[0025]
Conventionally, the holding mat is usually partially fixed to the catalyst with an adhesive or double-sided tape and subjected to press-fitting, but as described above, if the holding mat does not contain an organic binder, the mat becomes fluffy, Adhesives and tapes are in a so-called “ineffective state”, and even if bonding is performed, it has no substantial meaning. In addition, adhesives and double-sided tapes contain a large amount of organic components as pressure-sensitive adhesives, and the use of such materials impairs the effect of using a holding mat that does not contain an organic binder.
[0026]
In order to adhere the holding mat to the catalyst without using an adhesive or a double-sided tape for fixing the holding mat to the catalyst, the present invention uses a holding layer and a pair of fastenings as shown in FIG. Using a winding device having rollers 6A, 6B and a belt 7, the holding layer 4 is disposed on the outer peripheral surface side of the holding mat 2, and the holding mat 2 is compressed by the rollers 6A, 6B and the belt 7 and wound around the catalyst 1. Turn to close.
[0027]
That is, first, as shown in FIG. 1A, the holding mat 2 is laminated on the holding layer 4, and the honeycomb ceramic catalyst 1 is placed thereon. The holding layer 4 is longer than the holding mat 2 by a length W, and one end of the holding layer 4 is an overlap margin 4A extending from the holding mat 4 by the length W. It is desirable that an adhesive is attached to the upper surface (in the figure).
[0028]
Next, as shown in FIGS. 1B and 1C in this state, the roller 6A is placed on the belt 7 between the rollers 6A, 6B, and the rollers 6A, 6B are brought close to each other with a predetermined tension applied to the belt 7. The holding mat 2 and the holding layer 4 are wound around the catalyst 1.
[0029]
Thereafter, as shown in FIG. 1 (d), the belt 7 is pulled and moved to the left in the figure, and the overlap margin 4A of the holding layer 4 is adhered to the wound body to obtain a catalyst-mat wound body.
[0030]
As the holding layer 4, a resin film, a nonwoven fabric, a net, a cold chill, a thread, a string, or the like can be used, and these may be used alone or in combination of two or more. The holding layer 4 needs to have sufficient strength to bring the mat 2 into close contact with the catalyst 1 with a necessary compressive force, and is appropriately selected and used depending on the required strength.
[0031]
With the winding method as shown in FIG. 1, the adhesiveness of the wound mat 2 can be easily adjusted by changing the tension of the belt 7. Usually, the tension of the belt 7 can be obtained by applying (multiplying) a necessary pressure to the projected area of the mat 2 wound around the catalyst 1. That is, when the catalyst 1 having a diameter of 100 mm is wound around the mat 2 having a width of 100 mm, the projected area is 100 cm.²It is. Therefore, tentatively 0.5 kg / cm²If the mat 2 is brought into close contact with the pressure of 50 kgf (= 100 cm)²× 0.5kg / cm²) Will be wound with tension. In addition, the relationship between the thickness when compressing an actual mat and the required compression pressure is obtained in advance, and the contact pressure applied to the mat that is in close contact can be estimated from the compressed mat thickness after winding. it can.
[0032]
Further, the holding layer 4 such as a resin film can be selected based on the tension thus obtained. That is, the holding layer 4 has a sufficient strength to maintain the compressed state of the mat 2 and, in the case of the press-fitting method, it is necessary to select from those having good slipperiness with the press-fitting jig at the time of press-fitting. It is preferable to select the holding layer 4 made of a material that can withstand a predetermined tension. According to the present invention, the entire outer periphery of the holding mat is 0.5 kg / cm.²By tightening while compressing evenly, the honeycomb ceramic catalyst is wound and closely attached, and the surroundings are maintained in a close contact state with a holding layer, and then attached to a metal case by press fitting or the like, thereby including an organic binder. Even when a holding mat is not used, it can be mounted relatively easily. Note that the method of winding the holding mat around the catalyst is not limited to the method shown in FIG. 1, and in the present invention, the holding mat is compressed to 0.5 kg / cm with respect to the outer peripheral surface of the catalyst.²Any method may be used as long as it can be brought into close contact with the above uniform pressure.
[0033]
The holding mat is 0.5 kg / cm with respect to the catalyst.²It is sufficient if the pressure is evenly adhered as described above. However, if this pressure is excessively high, the fibers constituting the mat are crushed and the repulsive force is lost, so that the holding performance is lowered. Therefore, this pressure is 2 kg / cm.²The following is preferable.
[0034]
As mentioned above, the holding mat has been generally made by mixing amorphous alumina silica fiber with a heat-expandable ore (generally vermiculite). From the viewpoint of increasing the temperature, the catalyst position is moved closer to the engine to increase the temperature, and the catalyst carrier (honeycomb structure mainly made of cordierite) is becoming thinner. However, the conventional heat-expandable holding mat has a problem that the heat resistance of the material itself is low, and a thin catalyst carrier may be destroyed by the “expansion pressure” of the expansion material that occurs in the initial stage of heating. Due to such changes in market demand, holding mats using crystalline alumina silica fibers (often collectively referred to as alumina fibers) that have higher heat resistance and stable elasticity from low temperature to high temperature are becoming mainstream. .
[0035]
Alumina fibers are composed of short fibers having a fiber diameter of 3 to 5 μm and a length of several millimeters to several hundreds of millimeters, and are supplied to the market in the form of bulk (fiber lump) or blanket.
[0036]
Mats can be manufactured by the so-called papermaking method (generally also called papermaking method) using various binders, or organically on a blanket in which some of the fibers are oriented vertically with respect to the laminated surface by needle punching. A material impregnated with a binder is common. The organic binder not only protects the fibers but also improves the handling properties during use, such as keeping the thickness of the holding mat uniform, but sometimes it does not allow good press-fitting because it inhibits sliding with the jig during press-fitting. Often causes. In addition, the organic binder is necessary when the catalytic converter is assembled, but it is unnecessary after that. As described above, recently, there is a movement to dislike the organic combustion gas due to the deterioration of the working environment at the time of starting the catalytic converter. For this reason, it is preferable to reduce the organic binder in the mat as much as possible and use a holding layer on the mat surface during assembly.
[0037]
Generally, as the holding mat, the amount of alumina fiber is 1000 to 2000 g / m.², Bulk density 0.1-0.2 g / cm³In the present invention, an organic binder resin amount of 3 to 30% by weight and a thickness of about 5 to 10 mm is used. However, in the present invention, such an organic binder is not included, and the alumina fiber amount is 1000 to 2000 g / m.², Bulk density 0.08-0.2 g / cm³It is preferable to use an alumina fiber mat having a thickness of about 5 to 12.5 mm, preferably needle punched.
[0038]
In the present invention, the catalyst and the metal case are not particularly limited, and those generally used conventionally for the production of a catalyst reformer can be used.
[0039]
In the present invention, there is no particular limitation on the mounting method itself when assembling the catalyst reformer by mounting the catalyst-mat winding body on a metal case, and any of the aforementioned clamshell method and stuffing method may be used. In particular, the present invention is effective when the catalyst-mat wound body is mounted on a metal case by a press-fitting method.
[0040]
That is, as described above, the mat 2 usually has a bulk density of 0.1 to 0.2 g / cm.³And the thickness is 5 to 10 mm. Further, the gap (the distance between the inner peripheral surface of the metal case 3 and the outer peripheral surface of the catalyst 1 of the catalyst-mat wound body 5 in a state where the catalyst-mat wound body 5 is press-fitted into the metal case 3: FIG. Since (G) of (c) is usually 3 to 4 mm, it is press-fitted while compressing the thickness of the holding mat to a thickness of 1/2 to 1/3. The standard of gap filling density (hereinafter referred to as “GBD”) is usually 0.3 to 0.4 g / cm.³The pressure required for compression to this density (hereinafter referred to as “compression surface pressure”) is 2 to 5 kg / cm for a general holding mat.²It is. However, if the fiber weight tolerance of the mat is further considered in addition to the inner dimension tolerance of the catalyst-mat winding body and the outer dimension tolerance of the catalyst, 0.5 g / cm when the GBD is the highest.³This may be reached. There, 1/4 of the initial thickness of the holding mat, the compression surface pressure is 8 kg / cm²It also becomes. If stable press-fitting is not possible under these conditions, the holding mat will not be uniformly present around the catalyst, so the catalyst holding will not be stable, and the mat will be partially scattered by exhaust gas (wind erosion). Therefore, it is necessary to perform good press-fitting even under such high compression conditions.
[0041]
Moreover, as described above, the catalyst-mat wound body using the holding mat that does not contain an organic binder is good even when the improved press-fitting guide jig is used for press-fitting the catalyst-mat wound body. It was difficult to perform press-fitting in a stable state.
[0042]
Therefore, the present invention is effective for the press-fitting method in which it is particularly difficult to mount the catalyst-mat wound body using the holding mat that does not contain an organic binder.
[0043]
When the catalyst-mat winding body is mounted by this press-fitting method, it is preferable to use the press-fitting guide jig 10 of the prior application shown in FIG.
[0044]
By using such a press-fitting guide jig 10, as shown in FIGS. 3A to 3C, the catalyst-mat winding body 5 is moved from the introduction part 10 a to the holding part 10 b of the press-fitting guide jig 10. It is possible to smoothly press-fit the metal case 3 through the press-fit portion 10c.
[0045]
【Example】
Hereinafter, the present invention will be described more specifically with reference to Examples and Comparative Examples.
[0046]
In the following examples and comparative examples, the width of the holding mat (M in FIG. 2) is made 10 mm shorter than the length of the catalyst in consideration of the extension of the mat when press-fitted in preparation of the catalyst-mat winding body (ie, , M = 10 mm in FIG. 2), press-fitted into the metal case in a state of being wound in alignment with the catalyst end face in the press-fitting direction, and whether or not the end face of the mat after press-fitting protrudes from the end face of the catalyst. We decided to judge good and bad. If the press-fit property is poor and the mat is not press-fitted well, this amount of protrusion increases.
[0047]
Example 1
The catalytic converter was assembled using the press-fitting guide jig 10 of the prior application shown in FIG.
[0048]
The press-fitting guide jig 10 has a substantially cylindrical shape with the following specifications (the shape of the horizontal cross section of the inner hole is circular).
[Specifications for press-fitting guide jig 10]
Introduction part 10a: inner diameter D of the inlet end₁= 121mm
Inner diameter D of boundary₂= 112mm
Length L₁= 10mm
Taper angle θ₁= 24.2 °
Holding part 10b: inner diameter D of upper boundary part₂= 112mm
Inner diameter D of lower boundary₃= 108.5mm
Length L₂= 115mm
Taper angle θ₂= 0.9 °
Press-fit portion 10c: inner diameter D of the boundary portion₃: 108.5mm
Outer end D₄: 106.5mm
Length L₃= 25mm
Taper angle θ₃= 2.3 °
[0049]
As the holding mat, a needle punched alumina fiber mat for holding mat (trade name “Maftech Blanket MLS-2”, manufactured by Mitsubishi Chemical Corporation) without an organic binder was prepared. The amount of fibers per unit area of the holding mat is 1320 g / m.², Bulk density 0.13 g / cm³The amount of resin is 0% by weight, the thickness is 10.2 mm, the width is 114 mm, and the length is 338 mm. The surface pressure required to compress this holding mat to a thickness of 8.3 mm, 6.8 mm, and 5.8 mm is 0.2kg / cm each²0.4 kg / cm²And 0.6 kg / cm²It is. The thickness is 2.6 mm, that is, 0.5 g / cm in GBD.³8kg / cm when compressed to²The compression surface pressure was required. This holding mat has a length of 124 mm and an outer diameter (d in FIG.₁) To a 101.5 mm honeycomb ceramic catalyst, aligned on the end face of the catalyst in the press-fitting direction, and as a holding layer, a commercially available carton tape (manufactured by Nitto Denko Co., Ltd .: trade name “Holding Tape No. 3800A”: substrate thickness 0 0.038 mm), and the whole surface was covered and wound while being compressed by the method shown in FIG.
[0050]
The outer diameter of the resulting catalyst-mat winding (d in FIG. 2)₂) Was approximately 113 mm, the thickness of the holding mat at this point was 5.8 mm (= (113-101.5) / 2), and the holding mat was about 0.6 kg / cm.²Thus, it was estimated that the catalyst was tightly fixed to the catalyst.
[0051]
As shown in FIG. 3, the press-fitting guide jig 10 was fixed to the upper part of the metal case 3, and the catalyst-mat wound body 5 was press-fitted. The metal case 3 used had an inner diameter (D in FIG.₅) 106.7mmφ cylindrical shape (the shape of the horizontal cross section of the inner hole is circular), the gap G after press-fitting is 2.6mm (= (106.7-101.5) / 2), GBD Is 0.508 g / cm³However, there was no deviation or protrusion of the press-fitted holding mat, and good press-fitting could be performed.
[0052]
Comparative Example 1
A catalyst-mat wound body was produced in the same manner except that the holding mat was manually wound around a catalyst that was as tight as possible without using the winding device as shown in FIG. Since the outer diameter of the catalyst-mat winding body was approximately 118 mm, the mat thickness at this point was 8.3 mm (= (118-101.5) / 2), and the holding mat was approximately 0.00 mm. 2kg / cm²It was estimated that it was fixed to the catalyst.
[0053]
The catalyst-mat wound body was pressed into a metal case in the same manner as in Example 1, but the holding mat was displaced from the catalyst and did not enter the jig itself.
[0054]
Comparative Example 2
The holding mat was wound around the honeycomb-shaped ceramic catalyst in the same manner as in Example 1. However, the catalyst-mat wound body was produced by winding more gently than in the case of Example 1. Since the outer diameter of the catalyst-mat winding body was approximately 115 mm, the mat thickness at this point was 6.8 mm (= (115-101.5) / 2), and the holding mat was about 0.4 kg. / Cm²It was estimated that it was fixed to the catalyst.
[0055]
When this catalyst-mat wound body was press-fitted into a metal case in the same manner as in Example 1, although the press-fitting could be performed, a displacement of the holding mat of about 30 mm occurred.
[0056]
【The invention's effect】
As described above in detail, according to the method for assembling the catalyst reformer of the present invention, even if the holding mat does not contain an organic binder, the metal case can be prevented from being displaced between the holding mat and the catalyst. It can be easily attached. ADVANTAGE OF THE INVENTION According to this invention, the assembly of the catalyst reformer using the holding mat which does not contain an organic binder is attained, and the catalyst reformer suitable for maintenance of a working environment is provided.
[Brief description of the drawings]
FIG. 1 is a schematic cross-sectional view showing an example of a method of winding a holding mat suitable for the present invention.
FIG. 2 is a cross-sectional view showing a press-fitting guide jig, a catalyst-mat wound body, and a metal case according to the prior application.
FIG. 3 is a cross-sectional view showing an assembling method in the embodiment.
[Explanation of symbols]
1 Honeycomb ceramic catalyst
2 holding mat
3 Metal case
4 Retaining layer
5 Catalyst-mat roll
6A, 6B Roller
7 Belt

Claims (4)

A honeycomb ceramic catalyst;
A holding mat wound around the outer peripheral surface of the honeycomb-shaped ceramic catalyst;
A step of mounting a catalyst-mat wound body having a holding layer surrounding the outer periphery of the holding mat and holding the holding mat in close contact with the outer peripheral surface of the honeycomb ceramic catalyst in a metal case; In the assembly method of the catalyst reformer,
The holding mat is wound around the honeycomb ceramic catalyst while being compressed, and the holding mat is brought into close contact with the outer peripheral surface of the honeycomb ceramic catalyst with an equal pressure of 0.5 kg / cm ² or more. Thereafter, a method of assembling the catalyst reformer for performing the mounting step ,
The catalyst-mat winding body is mounted by press-fitting into a cylindrical metal case,
A method for assembling a catalyst reformer, wherein the holding mat of the catalyst-mat wound body is not fixed to the honeycomb-shaped ceramic catalyst using an adhesive or a double-sided tape .   2. The method of assembling a catalyst reformer according to claim 1, wherein the holding mat is a holding mat that is substantially composed of inorganic fibers and does not contain an organic binder.   3. The method of assembling a catalyst reformer according to claim 2, wherein the holding mat is a needle punched alumina fiber mat. The assembly of the catalyst reformer according to any one of claims 1 to 3 , wherein the holding layer is one or more of a resin film, a non-woven fabric, a net, a cold water bottle, a thread, and a string. Method.

Images