JP5022176B2 - Honeycomb shaped catalyst carrier - Google Patents

Description

  The present invention relates to a honeycomb-shaped catalyst carrier in which corrugated sheets are stacked on a flat plate and wound in multiple layers to carry a catalyst component.

For example, when an automobile engine is operated, exhaust gas is discharged from the engine portion. A catalyst is used to convert harmful components in the exhaust gas into harmless substances.
As one form of this catalyst, a honeycomb-shaped catalyst carrier is known.

FIG. 9 is a diagram for explaining a conventional honeycomb-shaped catalyst carrier. A catalyst carrier 100 is formed by laminating corrugated plates 101 on a flat plate (not shown) and winding them in multiple layers to carry catalyst components.
By the way, when such a catalyst carrier 100 is used in an automobile, exhaust gas is discharged from an automobile engine as indicated by an arrow. The catalyst carrier 100 is subjected to wind pressure due to exhaust gas.

  When the wind pressure of the exhaust gas is applied, the flat plate and the corrugated plate 101 are pushed out in the axial direction from a location near the shaft core portion 102 indicated by an imaginary line. When the flat plate and the corrugated plate 101 are pushed out, the catalyst carrier 100 is deformed. If the catalyst carrier 100 is deformed, the function of the catalyst is lowered, which is not preferable.

Conventionally, a catalyst metal honeycomb has been known as a honeycomb-shaped catalyst carrier that prevents the flat plate and the corrugated sheet from slipping in the axial direction (see, for example, Patent Document 1).
Japanese Patent Laid-Open No. 10-28873 (FIG. 3)

Patent document 1 is demonstrated based on the following figure.
FIG. 10 is a diagram for explaining the basic configuration of the prior art. The catalyst metal honeycomb 110 includes a flat plate 111, a flat plate protrusion 112 that is a protrusion provided on the flat plate 111, a corrugated plate 113, and the corrugated plate 113. A top protrusion 115 provided on the top 114 of the ridge and a trough protrusion 117 provided on the trough 116.

The bottom surface of the valley projection 117 is overlaid on the flat plate projection 112 and wound. The top protrusion 115 is fitted to the lower surface of the rolled flat protrusion 112.
According to such a catalyst metal honeycomb 110, since the flat plate projection 112, the valley projection 117, and the top projection 115 are fitted, the axis of the flat plate and the corrugated plate can be obtained without welding or brazing. Sliding in the direction can be prevented.

  However, the protrusions 112, 115, and 117 of the catalyst metal honeycomb 110 are lower than the heights of the top portion 114 and the trough portion 116 (paragraph number [0009] in Patent Document 1). When the exhaust gas has a high wind pressure or when vibration is generated by this wind pressure, the use of such a catalyst metal honeycomb 110 causes the projections 112, 115 and 117 to be separated by the wind pressure and vibration, resulting in a flat plate and a corrugated plate. 113 slips in the axial direction.

  On the other hand, when the respective protrusions 112, 115, and 117 are enlarged, the stress for bending the flat plate 111 is reduced. When the stress for bending is reduced, it is difficult to reduce the size of the catalyst metal honeycomb.

  It is desired to provide a honeycomb-shaped catalyst carrier that can be downsized and that can effectively prevent the flat plate and the corrugated plate from slipping in the axial direction.

  An object of the present invention is to provide a honeycomb-shaped catalyst carrier that can be downsized and can effectively prevent the flat plate and the corrugated plate from slipping in the axial direction.

The invention according to claim 1 is a honeycomb-shaped catalyst carrier in which corrugated plates are stacked on a flat plate and wound in multiple layers to carry a catalyst component.
An upper cut-and-raised portion projecting upward and a lower cut-and-raised portion projecting downward are formed on the flat plate, and the upper and lower raised portions are inserted into the corrugated plate. the cut-and-raised portion insertion hole that can be provided,
The upper cut-and-raised portion is composed of a rising portion that extends vertically upward from the flat plate and an upper horizontal portion that extends in parallel to the flat plate from the tip of the rising portion, and the lower cut-and-raised portion is formed from the flat plate. A falling portion extending vertically downward, and a lower horizontal portion extending in parallel to the flat plate from the tip of the falling portion,
The lengths of the upper horizontal portion and the lower horizontal portion are longer than the wavelength of the corrugated plate .

  In the invention according to claim 1, an upper cut-and-raised portion protruding upward and a lower cut-and-raised portion protruding downward are formed on the flat plate, and the upper cut-and-raised portion and the lower cut-off portion are formed on the corrugated plate. A cut-and-raised portion insertion hole into which the raised portion can be inserted is provided. The upper cut and raised portion and the lower cut and raised portion are inserted into the cut and raised portion insertion hole. When each cut-and-raised portion comes into contact with the cut-and-raised portion insertion hole, the flat plate and the corrugated plate can be prevented from slipping in the axial direction.

  In addition, the upper cut-and-raised part and the lower cut-and-raised part are shaped by cutting and raising the flat plate. Since the flat plate is cut and raised, the stress for bending the flat plate is not reduced. Since the bending stress of the flat plate is not weakened, the honeycomb-shaped catalyst carrier can be downsized.

In addition, in the invention according to claim 1 , the lengths of the upper and lower horizontal portions are longer than the wavelength of the corrugated plate. If it is longer than the wavelength of the corrugated plate, the horizontal part is always cut and raised and comes into contact with the insertion hole. By reliably cutting and raising the horizontal part and bringing it into contact with the part insertion hole, it is possible to more reliably prevent the flat plate and the corrugated sheet from slipping in the axial direction.

The best mode for carrying out the present invention will be described below with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.
FIG. 1 is a perspective view of a honeycomb-shaped catalyst carrier according to the present invention. A honeycomb-shaped catalyst carrier 10 includes a corrugated corrugated plate 11 and a flat plate 13 that is superimposed on the axial core portion 12 side of the corrugated plate 11. Consists of multiple windings.

  FIG. 2 is a perspective view of a flat plate used for the honeycomb-shaped catalyst carrier according to the present invention. The flat plate 13 protrudes upward at predetermined intervals and has an L-shaped upper cut and raised portion 15 and protrudes downward. The lower cut-and-raised portions 16 having an L shape are alternately provided.

The upper cut-and-raised portion 15 includes a rising portion 17 having a height H that extends vertically upward from the flat plate 13 and an upper horizontal portion 18 that extends from the tip of the rising portion 17 in parallel to the flat plate 13 by L1.
The lower cut-and-raised part 16 includes a falling part 21 having a height H extending vertically downward from the flat plate 13 and a lower horizontal part 22 extending from the tip of the falling part 21 by L1 in parallel to the flat plate 13. The
The width of the upper and lower horizontal portions 18 and 22 is B1.

The upper cut and raised portion 15 can be formed by applying an L-shaped mold to the lower surface 23 of the flat plate 13 and punching it from the upper surface 24 side of the flat plate 13.
The lower cut-and-raised portion 16 can be formed by applying an L-shaped mold to the upper surface 24 of the flat plate 13 and punching it from the lower surface 23 side of the flat plate 13.

  The cut and raised portions 15 and 16 can be easily formed by applying a die and punching. If the respective cut-and-raised portions 15 and 16 can be easily formed, a honeycomb-shaped catalyst carrier can be produced in a short time, which is beneficial.

  The upper cut-and-raised portions 15 and the lower cut-and-raised portions 16 do not have to be provided alternately. For example, two upper cut-and-raised portions 15 are continuously arranged, and two lower cut-and-raised portions 16 are continuously arranged. The same effect can be obtained even with such an arrangement.

  That is, the arrangement of the upper cut and raised portion 15 and the lower cut and raised portion 16 is not limited to these.

FIG. 3 is a plan view of a corrugated plate used for the honeycomb-shaped catalyst carrier according to the present invention. The corrugated plate 11 includes a top portion 27 disposed outside the axial core portion, and the top portion 27. A trough portion 28 arranged on the shaft core side is repeatedly arranged at predetermined intervals, and an upper cut-up portion and a lower cut-up portion (the upper cut-up portion 15 and the lower cut-up portion in FIG. 2) in the center. A rectangular cut-and-raised portion insertion hole 29 having a length L2 and a width B2 into which the ridge portion 16) can be inserted is disposed.
The cut-and-raised portion insertion hole 29 can be formed by notch molding.

4 is a cross-sectional view taken along line 4-4 of FIG. 3, and a vertical portion 31 is disposed between the top portion 27 and the valley portion 28. FIG.
The length from the right surface of the vertical portion 31 to the right surface of the right vertical portion 31 is defined as a wavelength λ, and the length from the upper surface of the valley portion 28 to the upper surface of the top portion 27 is defined as an amplitude L3.

  In addition, the wave shape of the corrugated plate 11 is applicable as long as it repeats the same shape even if it is a semicircular shape or a V-shape in addition to the square shape shown in the drawing. That is, it is not limited to a square shape.

  FIG. 5 is a plan view in the case where a flat plate and a corrugated plate used for the honeycomb-shaped catalyst carrier according to the present invention are overlapped, and the corrugated plate 11 is overlapped on the upper surface 24 of the flat plate 13. The width B2 of the cut and raised portion insertion hole 29 is configured to satisfy B1 <B2 with respect to the width B1 of the upper horizontal portion 18 so that the upper cut and raised portion 15 can be inserted.

  The honeycomb-shaped catalyst is obtained by overlapping the corrugated plate 11 on the flat plate 13 and winding it in multiple layers. The width of the lower horizontal portion 22 is B1 which is the same as the width of the upper horizontal portion. By winding the corrugated plate 11 on the flat plate 13 and winding it in multiple layers, the lower horizontal portion 22 is inserted into the cut-and-raised portion insertion hole 29 of the corrugated plate 11 disposed on the axial core side.

  The upper cut and raised portion 15 and the lower cut and raised portion 16 are inserted into the cut and raised portion insertion hole 29. When the cut-and-raised portions 15 and 16 come into contact with the cut-and-raised portion insertion hole 29, the flat plate 13 and the corrugated plate 11 can be prevented from slipping in the axial direction (the vertical direction in the drawing).

6 is a cross-sectional view taken along the line 6-6 in FIG. 5, and the length L1 of the upper and lower horizontal portions 18 and 22 is longer than the wavelength λ of the corrugated plate 11. FIG. That is, L1> λ.
Further, the height H of the rising portion 17 and the falling portion 21 is lower than the amplitude L3 of the corrugated plate 11. That is, H <L3.

  When the length L1 of the upper and lower horizontal portions 18 and 22 is longer than the wavelength λ of the corrugated plate 11, the upper and lower horizontal portions 18 and 22 always come into contact with the corrugated plate 11. By reliably bringing the upper and lower horizontal portions 18 and 22 into contact with the corrugated plate 11, it is possible to more reliably prevent the flat plate 13 and the corrugated plate 11 from slipping in the axial direction (the front and back of the drawing).

  The upper cut-and-raised portion 15 and the lower cut-and-raised portion 16 have a shape obtained by cutting and raising the flat plate 13. Since the flat plate 13 is cut and raised, it is not necessary to weaken the stress with respect to the bending of the flat plate 13. Since the bending stress of the flat plate 13 is not weakened, the honeycomb-shaped catalyst carrier can be downsized.

  FIG. 7 is a flowchart of a method for manufacturing a honeycomb-shaped catalyst carrier according to the present invention. In step (hereinafter referred to as ST) 01, an upper cut-up portion and a lower cut-up portion are provided on a flat plate.

  The corrugated plate is cut and raised to provide an insertion hole (ST02). A corrugated sheet is stacked on the upper surface of the flat plate so that the upper cut and raised portion is inserted into the cut and raised portion insertion hole (ST03), and a combined plate of the flat plate and the corrugated plate is wound in multiple layers (ST04).

Note that the order of ST01 and ST02 may be reversed, or may be performed simultaneously in different places.
In ST03, a corrugated plate can be stacked on the lower surface of the flat plate. At this time, the corrugated plate is placed on the lower surface of the flat plate so that the lower cut-and-raised portion is cut and raised and inserted into the insertion hole.

The operation of the honeycomb-shaped catalyst carrier having the above configuration will be described below.
FIG. 8 is a diagram for explaining the operation of the honeycomb-shaped catalyst carrier according to the present invention, and the wind pressure of exhaust gas or the like indicated by the white arrow may be applied to the honeycomb-shaped catalyst carrier 10.

  At this time, force is applied to the flat plate 13 and the corrugated plate 11 in the axial direction (the front and back of the drawing). The upper cut-and-raised portion 15 and the lower cut-and-raised portion 16 prevent the flat plate 13 and the corrugated plate 11 from slipping in the axial direction by contacting the top portion 27, the valley portion 28, and the vertical portion 31.

In addition, this invention can also be set as the structure which puts a corrugated sheet between a flat plate other than the structure which piles up one corrugated sheet with respect to one flat plate.
In addition, the manufacturing method and apparatus are not limited to those described in the present invention, as long as the upper and lower cut-and-raised portions are inserted into the cut-and-raised portion insertion holes to prevent slipping.

  The honeycomb-shaped catalyst carrier of the present invention is suitable for a catalyst carrier used in an automobile.

1 is a perspective view of a honeycomb-shaped catalyst carrier according to the present invention. It is a perspective view of the flat plate used for the honeycomb-shaped catalyst carrier which concerns on this invention. It is a top view of the corrugated sheet used for the honeycomb-shaped catalyst carrier according to the present invention. FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. It is a top view at the time of laminating | stacking the flat plate and corrugated sheet used for the honeycomb-shaped catalyst support | carrier which concerns on this invention. FIG. 6 is a sectional view taken along line 6-6 of FIG. FIG. 3 is a flowchart of a method for manufacturing a honeycomb-shaped catalyst carrier according to the present invention. It is a figure explaining the effect | action of the honeycomb-shaped catalyst carrier which concerns on this invention. It is a figure explaining the conventional honeycomb-shaped catalyst carrier. It is a figure explaining the basic composition of the conventional technology.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Honeycomb-shaped catalyst carrier, 11 ... Corrugated plate, 13 ... Flat plate, 15 ... Upper cut-and-raised part, 16 ... Lower cut-and-raised part, 17 ... Rising part, 18 ... Upper horizontal part, 21 ... Falling part, 22 ... lower horizontal part, 29 ... cut-and-raised part insertion hole, L1 ... length of horizontal part, λ ... wavelength of corrugated plate.

Claims (1)

In a honeycomb-shaped catalyst carrier in which corrugated plates are stacked and wound in multiple layers to carry a catalyst component,
On the flat plate, an upward cut-and-raised part protruding upward and a downward cut-and-raised part protruding downward are formed,
The corrugated plate is provided with a cut and raised portion insertion hole into which the upper cut and raised portion and the lower cut and raised portion can be inserted .
The upper cut-and-raised portion is composed of a rising portion that extends vertically upward from the flat plate and an upper horizontal portion that extends in parallel to the flat plate from the tip of the rising portion, and the lower cut-and-raised portion is formed from the flat plate. A falling portion extending vertically downward, and a lower horizontal portion extending in parallel to the flat plate from the tip of the falling portion,
A honeycomb-shaped catalyst carrier , wherein the length of the upper horizontal portion and the lower horizontal portion is longer than the wavelength of the corrugated plate .

Images