JP5614697B1 - Catalyzer and catalyst device - Google Patents

Abstract

Provided are a catalyzer and a catalyst device that can protect and easily hold a catalyzer body. Holding member 32 formed into a cylindrical or annular shape by knitting and compressing the wire, and fitted to the inner peripheral portion of this holding member 32, the metal catalyst is supported, knitted for each fiber material or wire, and made into a net shape, Further, the catalyzer main body 31 having a wire knit structure formed by winding these nets and having a predetermined outer shape, and the catalyzer main body disposed on the end surface of the holding member 32 to prevent the catalyzer main body 31 from coming out of the holding member 32. And a net member 34 having large eyes so as not to hinder the flow of exhaust gas flowing into 31.

Description

  The present invention relates to a catalyzer and a catalyst device in which a catalyzer body having a wire knit structure is held by a holding member.

The exhaust gas discharged from the engine contains hydrocarbons (HC), carbon monoxide (CO), nitrogen oxides (NOx), etc., and in order to remove these, for example, a metal catalyst such as platinum is used on the honeycomb carrier. In general, a catalyzer assembled with a carrier is used. As such a catalyzer, in addition to the above-described honeycomb carrier, a wire knit structure in which a metal wire is knitted to form a net, a metal catalyst is supported on the net, and the net is folded and overlapped. Is known (see, for example, Patent Document 1).
The catalyst element having the wire knit structure of Patent Document 1 is housed in a recess formed in a muffler partition plate and is pressed by a pressing member provided in the opening of the recess.

JP 2009-162070 A

In Patent Document 1, for example, when engine vibration is transmitted to the muffler, the vibration is transmitted directly from the partition plate to the catalyst element. As a result, the vibration of the catalyst element facilitates the formation of a gap between the partition plate and the catalyst element. When a gap is formed, the exhaust gas leaks from the gap and the exhaust gas is not purified. Therefore, it is necessary to protect the vibration by suppressing the vibration of the catalyst element. In addition, a recess is formed in the partition plate and a pressing member is attached to the opening edge of the partition plate in order to close the opening of the recess. However, in order to reduce the cost, the catalyst element has a simpler structure. It is desirable to hold.
The present invention has been made in view of the above-described circumstances, and an object thereof is to provide a catalyzer and a catalyst device that can protect the catalyzer body and can hold the catalyzer body with a simpler structure.

To solve the problems described above, the present invention includes a holding member formed in a cylindrical shape or a ring by compressing by weaving metal wire, fitted in the inner peripheral portion of the holding member, a metal wire to KNITTED And forming a flat wire mesh and a corrugated wire mesh formed into a corrugated shape by knitting a metal wire, and winding the flat wire mesh and the corrugated wire mesh with one type of metal catalyst, and a catalyzer body having the flat wire net and the crimped wire mesh another type of metal catalyst has been plated, is disposed on the end face of the holding member, and a net member for preventing the escape from the holding member of the catalyzer body , Provided.

According to this configuration, if the catalyzer body is accommodated in the cylinder constituting the exhaust pipe via the holding member, the catalyzer body can be buffered by the elastic force of the holding member, and the catalyzer body can be protected. it can.
In addition, while the catalyzer body is housed inside the holding member that acts as a buffer, the catalyzer body can be held so that it does not come out of the holding member with a simple structure that covers the end surface of the holding member with a net member, reducing costs. can do.

In the above structure, closing the radial gap between the holding member and the catalyzer body, yet good comprise a ring member formed in a cylindrical shape or a ring by compressing by knitting metal wires.
Further, in the above configuration, the net member may have a portion extending in a radial direction through a central portion of the catalyzer body. According to this configuration, the net member passes through the central portion of the catalyzer body, so that the catalyzer body can be effectively prevented from coming out even if the net member covers the catalyzer body. Can be suppressed.
Moreover, the said structure WHEREIN: The said catalyzer main body may be comprised by metal-plating a metal catalyst, after making it mesh shape. According to this structure, peeling of plating can be prevented and quality can be improved.

  Further, in the above configuration, a moisture trap body may be provided which has a catalyzer in an exhaust pipe provided in an exhaust system of the engine, is knitted with a wire material immediately upstream of the catalyzer, and carries a metal catalyst. According to this configuration, the moisture present in the exhaust gas at the time of engine cold start can be received by the moisture trap body so that it does not easily flow to the downstream side of the catalyzer. As a result, since moisture hardly adheres to the catalyzer, it is possible to suppress a decrease in the catalytic reaction of the catalyzer, and it is possible to purify the exhaust gas at an early stage when the engine is cold started.

The present invention includes a holding member formed into a cylindrical shape or an annular shape by knitting and compressing a wire, and fitted to the inner peripheral portion of the holding member, carrying a metal catalyst, and knitted for each fiber material or wire. Furthermore, the catalyzer main body having a wire knit structure formed by winding these nets and having a predetermined outer shape, and the catalyzer main body that is disposed on the end surface of the holding member to prevent the catalyzer main body from coming out of the holding member. And a net member having large eyes so as not to obstruct the flow of the exhaust gas. Therefore, if the catalyzer main body is accommodated in a cylinder constituting the exhaust pipe via the holding member, the catalyzer main body by the elastic force of the holding member Thus, the catalyzer body can be protected.
In addition, while the catalyzer body is housed inside the holding member that acts as a buffer, the catalyzer body can be held so that it does not come out of the holding member with a simple structure that covers the end surface of the holding member with a net member, reducing costs. can do.

It is sectional drawing which shows the exhaust apparatus provided with the catalyst apparatus of 1st Embodiment which concerns on this invention. It is a perspective view which shows a catalyzer structure. It is a front view which shows a catalyzer structure. It is a disassembled perspective view which shows a catalyzer structure. It is a perspective view explaining the structure of a catalyzer. It is explanatory drawing which shows the structure of a catalyzer. It is explanatory drawing which shows the linear catalyzer which comprises each metal mesh of a catalyzer. It is explanatory drawing which shows the structure of the catalyzer of 2nd Embodiment. It is explanatory drawing which shows the structure of the catalyzer of 3rd Embodiment. It is explanatory drawing which shows the structure of the catalyzer of 4th Embodiment. It is explanatory drawing which shows the structure of the catalyzer of 5th Embodiment. It is explanatory drawing which shows the linear catalyzer of 6th Embodiment. It is explanatory drawing which shows the strand wire of 7th Embodiment. It is sectional drawing which shows the exhaust apparatus provided with the catalyst apparatus of 8th Embodiment. It is a 1st operation | movement figure which shows the effect | action of a catalyst apparatus. It is a 2nd operation | movement figure which shows the effect | action of a catalyst apparatus. It is sectional drawing which shows the exhaust apparatus provided with the catalyst apparatus of 9th Embodiment. It is sectional drawing which shows the exhaust apparatus provided with the catalyst apparatus of 10th Embodiment. It is a front view which shows the catalyzer structure of 11th Embodiment. It is explanatory drawing which shows the catalyzer structure of 12th Embodiment.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following description, “upstream” and “downstream” indicate upstream and downstream of the flow of exhaust gas.
<First Embodiment>
FIG. 1 is a cross-sectional view showing an exhaust device 10 including a catalyst device 11 according to a first embodiment of the present invention.
The exhaust device 10 is a component (exhaust pipe) including a catalyst device 11 for purifying exhaust gas discharged from the engine, and one end of the connection pipe 13 connected to the cylinder head of the engine is connected to the connection pipe 13. The upstream tapered tube 14, the catalyst device 11 connected to the other end of the upstream taper tube 14, and the downstream taper tube 16 connected to the downstream end of the catalyst device 11. The side taper pipe 16 is connected to, for example, another exhaust pipe, a silencer, or the like.

  The connecting pipe 13 includes a flange portion 21 in which bolt holes 21 a and 21 a are opened when the exhaust device 10 is attached to the cylinder head with a bolt, and a pipe portion 22 attached to the flange portion 21. The upstream taper pipe 14 includes a small-diameter pipe part 14a attached to the outer peripheral surface of the pipe part 22 of the connection pipe 13 and a large-diameter pipe part attached to the inner peripheral surface of the catalyst device 11 (specifically, the outer cylinder 25). 14b and a tapered portion 14c that integrally connects the small-diameter pipe portion 14a and the large-diameter pipe portion 14b.

  The catalyst device 11 includes an outer cylinder 25 and a catalyzer 26 disposed in the outer cylinder 25. The downstream taper pipe 16 includes a large-diameter pipe portion 16a attached to the inner peripheral surface of the outer cylinder 25, a small-diameter pipe section 16b formed with a smaller diameter than the large-diameter pipe section 16a, and these large-diameter pipe sections. 16a and the small diameter pipe part 16b are each comprised from the taper part 16c which connects integrally.

  The catalyzer 26 includes a catalyzer main body 31 in which catalyst layers made by separately knitting wires carrying platinum (Pt), rhodium (Rh), and palladium (Pd) as metal catalysts are stacked, and the catalyzer main body 31. A pair of ring members 33, 33 provided in the vicinity of the outer peripheral edge portions on both sides of the catalyzer main body 31 in order to close the radial gaps between the catalyzer main body 31 and the holding member 32, respectively. In order to keep the catalyzer main body 31 and the ring members 33, 33 in the holding member 32, they are composed of net members 34, 34 attached to both end faces of the holding member 32.

  The catalyzer body 31 is a three-way catalyst that removes HC, CO, and NOx in the exhaust gas. The outer periphery of the holding member 32 is attached to the outer cylinder 25. The holding member 32 and the ring member 33 are parts formed by knitting a stainless steel wire, the holding member 32 being compressed into a cylindrical shape, and the ring member 33 being compressed into an annular shape. The net member 34 is a wire net obtained by knitting a stainless steel wire rod having a relatively large wire diameter into a plain weave or the like.

2 is a perspective view showing the catalyzer 26, FIG. 3 is a front view showing the catalyzer 26, and FIG. 4 is an exploded perspective view showing the catalyzer 26.
The catalyzer main body 31 has a wire knit structure in which a metal material (platinum, rhodium, palladium) supported on a fiber material or wire material is knitted into a net shape, and these nets are wound to have a predetermined outer shape. By adopting such a structure, the surface area of the fiber material or wire is increased, and the surface area of the supported metal catalyst is also increased, so that the exhaust gas purification performance can be enhanced. Further, when a certain surface area necessary for purifying the exhaust gas is secured, the catalyzer main body 31 can be made smaller and the catalyzer 26 can be made smaller.

The holding member 32 and the ring member 33 are, for example, members formed in a cylindrical shape or an annular shape by knitting and compressing a stainless steel wire, and both have elasticity, and therefore absorb vibration transmitted from the engine. The catalyzer body 31 can be protected. The holding member 32 is fixed to the outer cylinder 25 (see FIG. 1) by, for example, brazing.
The net member 34 is, for example, a stainless steel wire mesh having large eyes so as not to hinder the flow of exhaust gas flowing into the catalyzer main body 31, and is fixed to the end surface of the holding member 32 by, for example, welding, brazing, or the like. . 3 denotes a central point that is a central portion of the catalyzer 26, and the net member 34 is disposed so that a part thereof overlaps the central point 26A in a front view.

FIG. 5 is a perspective view for explaining the structure of the catalyzer body 31.
The catalyzer main body 31 (see FIGS. 2 to 4) is composed of, for example, three catalyzer materials 41, 42, and 43. Hereinafter, the catalyzer materials 41, 42, and 43 will be described with reference to the same drawing.
The catalyzer material 41 includes a flat wire mesh 103 obtained by flatly forming a fiber material or wire material in which platinum is supported by electroplating, for example, by plain weaving or knitting, and a fiber material or wire material in which platinum is supported by electroplating. The corrugated wire mesh 104 is formed into a corrugated shape after being formed flat by plain weaving or knitting.

  Similarly, the catalyzer material 42 includes a flat wire mesh 105 and a corrugated wire mesh 106, and the catalyzer material 43 includes a flat wire mesh 107 and a corrugated wire mesh 108. The catalyzer materials 42 and 43 differ from the catalyzer material 41 only in the metal catalyst supported on the fiber material or wire by electroplating. The catalyzer material 42 carries rhodium and the catalyzer material 43 carries palladium.

FIG. 6 is an explanatory view showing the structure of the catalyzer main body 31. 6A is a side view showing the configuration of the catalyzer main body 31 (see FIG. 6B), and FIG. 6B is a side view showing the manufacturing process of the catalyzer main body 31. FIG.
As shown in FIG. 6A, a catalyzer material 102 as a material for manufacturing the catalyzer main body 31 includes a flat wire mesh 103, a corrugated wire mesh 104, a flat wire mesh 105, a corrugated wire mesh 106, a flat wire mesh 107, and a corrugated wire mesh 108. The

  As shown in FIG. 6B, the flat wire mesh 103, the corrugated wire mesh 104, the flat wire mesh 105, the corrugated wire mesh 106, the flat wire mesh 107, and the corrugated wire mesh 108 are sequentially stacked so that the flat wire mesh 103 is on the outermost side. The end of the winding is fixed to a portion wound by brazing or the like, and further cut into a predetermined width in a direction perpendicular to the winding direction (front and back direction on the paper surface) to form the catalyzer body 31.

FIG. 7 is an explanatory diagram showing the linear catalyzer main bodies 47, 173, and 174 that constitute each wire mesh of the catalyzer main body 31. 7A is a perspective view of the linear catalyzer bodies 47, 173, and 174, and FIG. 7B is a cross-sectional view of the linear catalyzer bodies 47, 173, and 174. 7B, the cross-sectional shape of the linear catalyzer main body 47, 173, 174 main body will be described using the same diagram.
As shown in FIG. 7A, the surface of a wire 45 made of stainless steel is electroplated with platinum as a metal catalyst 46 to form a linear catalyzer main body 47. Further, rhodium is electroplated as a metal catalyst 176 on the surface of the wire 45 to form a linear catalyzer main body 173 main body. Further, palladium is electroplated as a metal catalyst 177 on the surface of the wire 45 to form a linear catalyzer main body 174 main body.

  As the stainless steel used as the wire 45, a ferrite system having high heat resistance, an aluminum-containing ferrite system, an austenite system, and the like are suitable. The above-described wire may be a fiber material having a smaller diameter. The diameter of the wire material is preferably 0.1 to 1 mm, and the fiber material is preferably 1 to 100 μm.

As shown in FIG. 7B, in the linear catalyzer main body 47 (, 173, 174), a layer of the metal catalyst 46 (, 176, 177) is formed on the surface of the stainless steel wire 45 by electroplating. The film thickness of the layer of the metal catalyst 46 (, 176, 177) is formed more uniformly and thinner by selecting the electroplating process conditions according to the type of metal catalyst to be plated, the amount of wire, and the like. In addition, the film thickness of the metal catalyst 46 (176 or 177) can be easily set, and the film thickness can be easily managed. Therefore, electroplating can be said to be an effective means for reducing the amount of the metal catalyst 46 (, 176, 177), which is an expensive noble metal.
6 (A), (B) and FIGS. 7 (A), (B) above, the catalyzer main body 31 is provided with the linear catalyzer main bodies 47, 173, 174 based on the experimental data. Including. That is, it contains Pt, Rh, and Pd as a metal catalyst at a certain ratio.

Second Embodiment
FIG. 8 is an explanatory view showing the structure of the catalyzer main body 121 of the second embodiment. 8A is a side view showing the configuration of the catalyzer main body 121 (see FIG. 8B), and FIG. 8B is a side view showing the manufacturing process of the catalyzer main body 121.
As shown in FIG. 8A, the catalyzer material 122 as a material for manufacturing the catalyzer main body 121 includes a flat wire mesh 123, a corrugated wire mesh 124, a corrugated wire mesh 126, and a corrugated wire mesh 128.

The flat wire mesh 123 is a material obtained by flatly forming a fiber material or wire made of stainless steel by plain weaving or knitting.
The corrugated wire mesh 124, 126, 128 is a material formed into a corrugated shape after a fiber material or wire made of stainless steel is formed flat by plain weaving or knitting.
The corrugated wire mesh 124 is obtained by electroplating, for example, platinum as a metal catalyst on the surface of a fiber material or a wire material. The corrugated wire mesh 126 is obtained by electroplating, for example, rhodium as a metal catalyst on the surface of a fiber material or a wire material. The corrugated wire mesh 128 is obtained by electroplating, for example, palladium as a metal catalyst on the surface of a fiber material or a wire material. The flat wire mesh 123 is obtained by electroplating any one of platinum, rhodium, and palladium as a metal catalyst on the surface of a fiber material or a wire, or does not perform any electroplating.

  When manufacturing the catalyzer main body 121, first, the flat wire mesh 123, the corrugated wire mesh 124, the corrugated wire mesh 126, and the corrugated wire mesh 128 are sequentially stacked. At this time, the wave extending direction of the corrugated wire mesh 126 (left and right direction in the figure) and the wave extending direction of the corrugated wire meshes 124 and 128 (front and back direction on the paper surface) are set to be perpendicular to each other.

  Then, as shown in FIG. 8B, the flat wire mesh 123, the corrugated wire mesh 124, the corrugated wire mesh 126, and the corrugated wire mesh 128 are wound so that the flat wire mesh 123 is on the outermost peripheral side. The catalyzer main body 121 can be formed by being fixed to the wound portion and further cut to have a predetermined width in a direction orthogonal to the winding direction (front and back direction of the paper surface). The catalyzer main body 121 constitutes a three-way catalyst containing platinum, rhodium and palladium as a metal catalyst. In the catalyzer main body 121, the corrugated wire mesh 126 is arranged so that the wave direction of the corrugated wire mesh 126 is perpendicular to the wave direction of the corrugated wire meshes 124, 128, thereby reducing the number of flat wire meshes 123. A gap between 128 can be secured.

<Third Embodiment>
FIG. 9 is an explanatory view showing the structure of the catalyzer main body 131 of the third embodiment. 9A is a perspective view showing the configuration of the catalyzer main body 131 (see FIG. 9B), and FIG. 9B is a perspective view showing the catalyzer main body 131.
As shown in FIG. 9A, the catalyzer material 132 as a material for manufacturing the catalyzer main body 131 includes a plurality of corrugated wire meshes 133, a plurality of corrugated wire meshes 134, and a plurality of corrugated wire meshes 135.
The corrugated wire nets 133, 134, and 135 are materials in which a fiber material or wire made of stainless steel is formed into a corrugated shape after being flatly formed by plain weaving or knitting, and the outer shape is cut into a circular shape.

The corrugated wire mesh 133 is obtained by electroplating, for example, platinum as a metal catalyst on the surface of a fiber material or wire. The corrugated wire mesh 134 is obtained by electroplating, for example, rhodium as a metal catalyst on the surface of a fiber material or wire. The corrugated wire mesh 135 is obtained by electroplating, for example, palladium as a metal catalyst on the surface of a fiber material or a wire material.
When manufacturing the catalyzer main body 131, first, the corrugated wire nets 133, 134, and 135 are sequentially stacked. At this time, the direction in which the waves of the adjacent corrugated wire meshes 133, 134, 135 extend is preferably substantially perpendicular or not matched. As a result, the catalyzer main body 131 shown in FIG.

<Fourth embodiment>
FIG. 10 is an explanatory view showing the structure of the catalyzer main body 141 of the fourth embodiment. FIG. 10A is a perspective view showing the configuration of the catalyzer main body 141 (see FIG. 10B), and FIG. 10B is a perspective view showing the catalyzer main body 141.
As shown in FIGS. 10A and 10B, the catalyzer material 142 as a material for manufacturing the catalyzer body 141 is a flat wire mesh 143 with respect to the catalyzer material 132 of the third embodiment shown in FIG. 9B. Is different between the plurality of corrugated wire meshes 133, the plurality of corrugated wire meshes 134 and the plurality of corrugated wire meshes 135.
The flat wire mesh 143 is a material in which a fiber material or wire made of stainless steel is flatly formed by plain weaving or knitting, and the outer shape is cut into a circular shape.
Thus, by adding the flat wire mesh 143, the rigidity of the entire catalyzer main body 141 is improved and it is difficult to bend, and the assembly into the holding member 32 (see FIG. 4) becomes easy.

<Fifth Embodiment>
FIG. 11 is an explanatory view showing the structure of the catalyzer main body 151 of the fifth embodiment. 11A is a front view showing the material 152 of the catalyzer main body 151 (see FIG. 11B), FIG. 11B is a cross-sectional view taken along the line BB of FIG. 11A, and FIG. It is a side view which shows the catalyzer main body 151 comprised by the raw material 152,153,154.
As shown in FIG. 11A, a material 152 as a material for manufacturing the catalyzer main body 151 is formed into a corrugated shape after a fiber material or wire made of stainless steel is formed flat by plain weaving or knitting, etc. A plurality of recesses 152a are formed, and the outer shape is cut into a circle. For example, platinum is electroplated on the surface of the material 152 as a metal catalyst on the surface of the fiber or wire.
As shown in FIG. 11B, a plurality of recesses 152a formed in the material 152 are formed deeper than the corrugated valley.

  As shown in FIG. 11C, the catalyzer main body 151 can be formed by stacking a plurality of materials 153 and 154 that differ only in the material 152 and the metal catalyst supported on the material 152. The raw material 153 is electroplated with rhodium on the fiber material or wire, and the raw material 154 is electroplated with palladium on the fiber material or wire. By forming the recesses 152a, 153a, and 154a in the materials 152, 153, and 154 in this way, when these materials 152, 153, and 154 are stacked, the respective peaks and peaks of the waveforms of the materials 152, 153, and 154 are formed. The valleys can be prevented from overlapping with each other, and the gaps between the materials 152, 153, and 154 can be secured.

<Sixth Embodiment>
FIG. 12 is an explanatory view showing the linear catalyzer body 163 of the sixth embodiment. 12A is a perspective view of the linear catalyzer body 163, and FIG. 12B is a cross-sectional view of the linear catalyzer body 163.
As shown in FIG. 12A, the surface of the wire 161 made of stainless steel is roughened by etching. The wire 161 is electroplated with one of platinum, rhodium and palladium as the metal catalyst 162 to form the linear catalyzer body 163. The above-described wire may be replaced with a fiber material having a smaller diameter.

As shown in FIG. 12B, a metal catalyst 162 is formed as a layer on the surface of a stainless steel wire 161 by electroplating. Thus, by electroplating the metal catalyst 162 after making the surface of the wire 161 rough, the surface area of the metal catalyst 162 can be increased, and the catalytic reaction can be promoted.
As the above-mentioned linear catalyzer main body 163, those supporting platinum, rhodium or palladium are prepared, and the linear catalyzer main body for each metal catalyst is separately knitted to form a net material, and the net material for each metal catalyst is prepared. A three-way catalyst can be formed by overlapping and forming a catalyzer.

<Seventh embodiment>
FIG. 13 is an explanatory view showing a stranded wire 171 of the seventh embodiment. 13A is a perspective view of the stranded wire 171, and FIG. 13B is a cross-sectional view of the stranded wire 171.
As shown in FIG. 13A, the stranded wire 171 is formed by twisting three linear catalyzer bodies 47, 173, and 174. A three-way catalyst can be obtained by replacing the braided wire 171 with the catalyzer body 31 shown in FIG. The linear catalyzer bodies 47, 173, and 174 may be formed from a fiber material.
As shown in FIG. 13B, layers of metal catalysts 46, 176, and 177 are formed on the surfaces of stainless steel wires 45, 45, and 45 by electroplating.
Thus, by forming the catalyzer from the stranded wire 171, for example, it becomes possible to omit a process of making a catalyzer main body by stacking a plurality of nets knitted for each wire carrying each metal catalyst. , Productivity can be improved.

<Eighth Embodiment>
FIG. 14 is a cross-sectional view showing an exhaust device 180 including the catalyst device 181 of the eighth embodiment. The same components as those in the first embodiment shown in FIG.
The catalyst device 181 includes an outer cylinder 156, a catalyzer 26 disposed on the upstream side in the outer cylinder 156, and a catalyzer 27 disposed on the downstream side of the catalyzer 26 in the outer cylinder 156. Reference numeral 28 denotes an inter-catalyst space surrounded by the outer cylinder 156, the catalyzer 26, and the catalyzer 27.

The catalyzer 27 includes a catalyzer main body 37 as a three-way catalyst supporting platinum, rhodium and palladium as metal catalysts, and a holding body 38 for holding the catalyzer main body 37 with respect to the outer cylinder 156. The catalyzer main body 37 is supported on a ceramic or metal honeycomb carrier in which a large number of pores extending in the axial direction are formed in a cylindrical shape inside the cylindrical shape, and on the inner wall of each pore of the honeycomb carrier. A ceramic honeycomb catalyst or a metal honeycomb catalyst comprising platinum, rhodium and palladium as a metal catalyst for purifying exhaust gas components. Note that L in the figure is the distance between the catalyzer body 31 of the catalyzer 26 and the catalyzer body 37 of the catalyzer 27.
As described above, the catalyst device 181 purifies the exhaust gas with the catalyzer main bodies 31 and 37 including the two catalyzers 26 and 27. In the catalyst device 181, the catalyzer 26 and the catalyzer 27 are arranged at a predetermined interval L in the same outer cylinder 156, so it can be said that the catalyzer 26 is arranged immediately upstream of the catalyzer 27.

Next, the operation of the catalyst device 181 described above will be described.
FIG. 15 is a first action diagram showing the action of the catalyst device 181.
When exhaust gas flows into the exhaust device 180 as indicated by arrow A from the cylinder head side of the engine, the exhaust gas first passes through the catalyzer 26 of the catalyst device 181 as indicated by arrow B. At this time, exhaust gas contacts with the metal catalyst while passing through the reticulated catalyzer main body 31 while causing disturbance of the flow in the catalyzer main body 31, so that the catalytic reaction by the metal catalyst is promoted and the exhaust gas purification performance is improved. Enhanced. Further, even after the exhaust gas passes through the catalyzer body 31, as shown by the arrow C, the turbulent flow of the exhaust gas continues to occur in the inter-catalyst space 28 between the catalyzer 26 and the catalyzer 27. Then, as shown by an arrow D, the exhaust gas contacts the metal catalyst while passing through a large number of pores formed along the axis 180a of the exhaust device 180 in the catalyzer 27, and the exhaust gas is purified. And as shown by the arrow E, it exhausts outside from the exhaust apparatus 180 through an exhaust pipe, a silencer, etc.

FIG. 16 is a second operation diagram showing the operation of the catalyst device 181. The operation described in FIG. 15 will be described in detail.
When the exhaust gas passes through the catalyzer 26 as indicated by arrows F1 and F2, it passes through the mesh-like catalyzer body 31 so that the linear catalyzer bodies 47, 173, 174 (about the linear catalyzer bodies 173, 174). 7A) is bent in all directions in the catalyzer body 31, the cross-sections of the linear catalyzer bodies 47, 173, and 174 are circular, and the linear catalyzer bodies 47, 173, and 174 are Due to the denseness, turbulent flow is generated in the exhaust gas, and the exhaust gas is more easily brought into contact with the metal catalyst of the catalyzer main body 31, and the catalytic reaction is further promoted to improve the exhaust gas purification performance.

  Further, when the engine is started in a cold state, the temperature of the exhaust device 180 (see FIG. 15) including the catalyzer body 31 is low, so moisture contained in the exhaust gas is likely to condense in the catalyzer body 31. The water drops 48 adhere to the linear catalyzer bodies 47, 173, and 174 of the catalyzer body 31. Further, in the inter-catalyst space 28, as shown by the arrow G, a turbulent flow is generated in the exhaust gas. Therefore, a part of the scattered water droplets 48 from the catalyzer main body 31 side diverges as shown by the white arrow H. Therefore, it becomes difficult to reach the catalyzer 27.

  As a result, when the exhaust gas proceeds from the inter-catalyst space 28 into the plurality of pores 27a formed along the axis 180a (see FIG. 15) from the inter-catalyst space 28 to the catalyzer body 37, as indicated by an arrow J. In addition, moisture is reduced in the exhaust gas, and water droplets are less likely to adhere to the surface of the metal catalyst supported on the inner surface of the pores 27a. Therefore, the contact of the exhaust gas with the metal catalyst of the catalyzer body 37 is not hindered by the water droplets, so that the catalytic reaction is promoted and the exhaust gas purification performance can be enhanced.

  Eventually, when the temperature of the catalyzer body 31 rises to the catalyst activation temperature as the engine warms up, it becomes difficult for water droplets to condense on the linear catalyzer bodies 47, 173, and 174, and the evaporation of the attached water droplets is also promoted. Therefore, the surface of the metal catalyst in the linear catalyzer body 47 can easily come into contact with the exhaust gas, so that the exhaust gas purification performance can be improved and the exhaust gas purification can be performed in both the catalyzer bodies 31 and 37.

  As described above, in the catalyst device 181 (see FIG. 15), by providing the catalyzer 26 on the upstream side of the catalyzer 27 via the inter-catalyst space 28, particularly when the engine is cold, water drops in the exhaust gas by the catalyzer 26. As a result, the exhaust gas can be easily brought into contact with the metal catalyst of the catalyzer main body 37 of the catalyzer 27, and the exhaust gas purification performance can be improved at an early stage when the engine is started. Further, if the temperature of the catalyzer main body 31 of the catalyzer 26 rises, the original exhaust gas purification performance of the catalyzer main body 31 can be exhibited. Furthermore, since the water droplets are diverged by the inter-catalyst space 28 to make it difficult to reach the catalyzer 27, the exhaust gas purification performance by the catalyzer 27 can be further enhanced.

<Ninth Embodiment>
FIG. 17 is a cross-sectional view showing an exhaust device 70 provided with the catalyst device 71 of the ninth embodiment.
The same components as those in the embodiment shown in FIG.
The exhaust device 70 is a component (exhaust pipe) provided with a catalyst device 71 that purifies exhaust gas discharged from the engine, and includes a connection pipe 13, an upstream taper pipe 14, and the other end of the upstream taper pipe 14. And a downstream taper pipe 16 connected to the downstream end of the catalyst device 71.

The catalyst device 71 includes an outer cylinder 73 and catalyzers 26, 55, and 56 disposed in this outer cylinder 73 in order from the upstream side to the downstream side, and the catalyzer 55 is located away from the catalyzer 26 on the downstream side. The catalyzer 56 is provided adjacent to the catalyzer 55.
The catalyzer 55 and 56 differ from the catalyzer 26 only in the supported metal catalyst.
That is, the catalyzer 55 includes a catalyzer main body 61 in which, for example, rhodium is supported on a fiber material or a wire, and the catalyzer 56 includes a catalyzer main body 62 in which, for example, palladium is supported on a fiber material or a wire.

  The catalyzer body 31 carries platinum, the catalyzer body 61 carries rhodium, the catalyzer body 62 carries palladium, and these catalyzer bodies 31, 61, 62 constitute a three-way catalyst. In the figure, L1 is the distance between the catalyzer body 31 of the catalyzer 26 and the catalyzer body 61 of the catalyzer 55, W1 is the width of the catalyzer body 31, W2 is the width of the catalyzer body 61, W3 is the width of the catalyzer body 62, W1 = W2 = W3, but the widths W1, W2, and W3 may be different from each other.

  Thus, it is also possible to adjust the loading amount of each metal catalyst by making the widths W1, W2, and W3 different. Further, since the exhaust gas having a low temperature first hits the most upstream catalyzer body 31 when the engine is cold-started, for example, the catalyzer bodies 31, 61, In 62, a metal catalyst that is activated at a lower temperature may be carried on the upstream side, or a metal catalyst that is activated at the lowest temperature may be carried on the catalyzer body 31.

<Tenth Embodiment>
FIG. 18 is a cross-sectional view showing an exhaust device 50 including the catalyst device 51 of the tenth embodiment. The same components as those in the embodiment shown in FIG. 1 and the embodiment shown in FIG.
The exhaust device 50 is a component (exhaust pipe) including a catalyst device 51 for purifying exhaust gas discharged from the engine. The connection pipe 13, the upstream taper pipe 14, and the other end of the upstream taper pipe 14. And a downstream taper pipe 16 connected to the downstream end of the catalyst device 51.
The catalyst device 51 includes an outer cylinder 53 and catalyzers 26, 55, and 56 disposed in the outer cylinder 53 so as to be adjacent to each other in order from the upstream side to the downstream side. In this way, by making the catalyzers 26, 55, and 56 next to each other, the overall length of the catalyst device 51, and thus the exhaust device 50, can be shortened.

<Eleventh embodiment>
FIG. 19 is a front view showing the catalyzer 190 of the eleventh embodiment.
The catalyzer 190 includes a catalyzer main body 31, a holding member 32 that holds the catalyzer main body 31, and net members 191 and 191 that are attached to both end surfaces of the holding member 32 in order to keep the catalyzer main body 31 in the holding member 32. (Only the net member 191 on the near side is shown). The net member 191 is composed of two wire rods 192 and 192 that pass through a center point 26A (which is also the center portion of the catalyzer 190) which is the center portion of the catalyzer body 31. As the material of the wire 192, stainless steel is suitable.

<Twelfth embodiment>
FIG. 20 is an explanatory view showing a catalyzer 195 of the twelfth embodiment. 20A is a front view, and FIG. 20B is a cross-sectional view taken along line BB in FIG. 20A.
As shown in FIG. 20A, the catalyzer 195 includes a catalyzer main body 31, a holding member 32 that holds the catalyzer main body 31, and both ends of the holding member 32 to keep the catalyzer main body 31 in the holding member 32. It comprises net members 196 and 196 (only the front net member 196 is shown) attached to the surface. The net member 196 is a member formed by press molding, and a cross-shaped portion 196a passing through a center point 26A (which is also the central portion of the catalyzer 195) that is the central portion of the catalyzer main body 31, and the cross-shaped portion 196a. An annular portion 196b that connects the outer peripheral side ends is integrally formed. The cross-shaped portion 196a includes four arm portions 196c. As a material of the net member 196, stainless steel is suitable.

  As shown in FIG. 20B, the arm portion 196c of the net member 196 is formed in a U-shaped cross section, and has a flat base portion 196d and a bent portion 196e bent almost at right angles from both edges of the base portion 196d. , 196e. Thus, by making the arm part 196c have a U-shaped cross section, the rigidity of the arm part 196c can be improved, and the catalyzer 26 can be reliably prevented from coming out of the holding member 32 shown in FIG. be able to.

  As shown in FIGS. 2 to 4 above, the holding member 32 formed into a cylindrical shape or an annular shape by knitting and compressing the wire, and the inner periphery of the holding member 32 are fitted, and the metal catalyst is supported. Each of the fiber material or the wire material is knitted into a net-like shape, and is further arranged on the end face of the catalyzer main body 31 having a wire knit structure formed by winding these nets into a predetermined outer shape and the holding member 32. And a net member 34 having large eyes so as not to hinder the flow of exhaust gas flowing into the catalyzer main body 31 to prevent the holding member 32 from coming out.

According to this configuration, if the catalyzer main body 31 is accommodated in the outer cylinder 25 constituting the exhaust device 10 as an exhaust pipe via the holding member 32, the catalyzer main body 31 is buffered by the elastic force of the holding member 32. The catalyzer body 31 can be protected.
In addition, while the catalyzer body 31 is accommodated inside the holding member 32 that performs a buffering action, the end surface of the holding member 32 is closed by the net member 34, so that the catalyzer body 31 is held by the holding member 32. In addition, the catalyzer body 31 can be held by the net member 34 so as not to come out of the holding member 32, the number of parts can be reduced, and the cost of the catalyzer 26 can be reduced.
Further, by fitting the catalyzer body 31 made of a fiber material or a wire to the inner peripheral part of the holding member 32 made of a wire material that is a similar material, the adhesion of the fitting part between the catalyzer body 31 and the holding member 32 is improved. And the gap can be made smaller or eliminated.

Further, since the net member 34 is fixed to the end surface of the holding member 32 by welding, the net member 34 can be easily fixed to the holding member 32.
Further, as shown in FIG. 3, the net member 34 has a portion extending in the radial direction through the central portion (center point 26 </ b> A) of the catalyzer main body 31. Even if the area covering 31 is small, it is possible to effectively prevent the catalyzer main body 31 from being pulled out, to suppress the weight and cost of the net member 34, and to reduce the weight and cost of the catalyzer 26.
Moreover, as shown in FIGS. 2-4, the catalyzer main body 31 may be comprised by carrying out the metal-plating process after making it mesh-shaped. Thereby, peeling of plating can be prevented and quality can be improved.

  Further, as shown in FIGS. 14 and 17, a catalyzer 27 is provided in an exhaust device 180 as an exhaust pipe provided in an exhaust system of an engine, and a wire is knitted immediately upstream of the catalyzer 27. The catalyst has a catalyzer 26 as a moisture trap body, and also has a catalyzer 55 and 56 in an exhaust device 70 as an exhaust pipe provided in an exhaust system of the engine, immediately upstream of the catalyzer 55 and 56. Since the catalyzer 26 as a moisture trap body carrying a metal catalyst is provided, the moisture present in the exhaust gas when the engine is cold started is received by the catalyzer 26 (specifically, the catalyzer body 31). It is possible to make it difficult to flow to the downstream side of the catalyzer 27, 55, 56. As a result, moisture hardly adheres to the catalyzers 27, 55, and 56. Therefore, it is possible to suppress a decrease in the catalytic reaction of the catalyzers 27, 55, and 56, and to purify the exhaust gas at an early stage when the engine is cold started. it can.

As shown in FIGS. 6 and 7, the linear catalyzer body 47 as the first wire plated with platinum, the linear catalyzer body 173 as the second wire plated with rhodium, and palladium. The flat metal mesh 103, 105, 107 as a plurality of catalyst layers formed by knitting the linear catalyzer main body 174 as the third wire rod plated with the above, separately or by knitting two or more wire rods, corrugated Wire meshes 104, 106, 108 were provided, and each flat wire mesh 103, 105, 107 and corrugated wire mesh 104, 106, 108 were overlapped.
According to this configuration, each of the linear catalyzer main bodies 47, 173, and 174 is plated with a metal catalyst and then knitted, and the flat wire nets 103, 105, and 107 and the corrugated wire nets 104, 106, and 108 are overlapped. The original catalyst can be easily produced. In addition, by plating each linear catalyzer body 47, 173, 174, the metal catalyst can be uniformly and thinly coated with the wire 45, and the film thickness can be easily controlled. The cost can be reduced while ensuring the above.

Further, since the flat wire nets 103, 105, 107 and the corrugated wire nets 104, 106, 108 are formed by winding them in a solid state, the catalyzer body 31 can be manufactured more easily and the productivity is improved. Can do.
Moreover, in FIG.1 and FIG.2, since the flat metal net 103,105,107, the corrugated metal net 104,106,108, ie, the catalyzer main body 31, is hold | maintained inside the holding member 32 which hardened the metal wire rod to the cylinder shape, The catalyzer main body 31 can be easily held by the cylindrical holding member 32, and the cylindrical holding member 32 can be easily attached to the outer cylinder 25 as a cylindrical body.
Moreover, since the catalyzer main body 31 is disposed in the outer cylinder 25 provided in the exhaust system of the engine, the exhaust gas discharged from the engine can be purified by the three-way catalyst.

  In addition, the catalyzer main body 31 is also arranged as a moisture trap in the outer cylinder 25 provided in the exhaust system of the engine, and the catalyzer main body 37 as a honeycomb three-way catalyst is arranged downstream of the catalyzer main body 31. Moisture present in the exhaust gas at the time of the intermediate start can be received by the catalyzer main body 31 and can be made difficult to flow to the downstream catalyzer main body 37 side. As a result, moisture hardly adheres to the catalyzer main body 37, so that a decrease in the catalytic reaction of the catalyzer main body 37 can be suppressed, and the exhaust gas can be purified from an early stage when the engine is cold started.

The above-described embodiment is merely an aspect of the present invention, and can be arbitrarily modified and applied without departing from the gist of the present invention.
For example, in the above embodiment, as shown in FIGS. 6A and 6B and FIGS. 7A and 7B, three types of linear catalyzer bodies 47, 173, and 174 are separately knitted to form a net-like shape. These nets are superposed to form a three-way catalyst. However, the present invention is not limited to this, and any two types of linear catalyzer main bodies 47, 173, and 174 are separately knitted to form a net, A three-way catalyst may be obtained by overlapping the nets.

  6A and 6B, after a metal catalyst is supported on a fiber material or wire, a flat wire mesh 103, a corrugated wire mesh 104, a flat wire mesh 105, a corrugated wire mesh 106, a flat wire mesh 107, and a corrugated wire mesh 108 are formed. However, the present invention is not limited to this. After each flat wire mesh and each corrugated wire mesh are formed, each flat wire mesh and each corrugated wire mesh are electroplated to carry a metal catalyst, and three different types of metal catalysts (Pt, Rh) , Pd) may be laminated to form a three-way catalyst. Such a three-way catalyst contains Pt, Rh, and Pd at a constant ratio determined based on experimental data.

Further, after winding each flat wire mesh and each corrugated wire mesh, a catalyzer may be manufactured by supporting any one kind of metal catalyst such as Pt, Rh, Pd by electroplating. In this case, the end of winding may be held by a jig without being fixed, and electroplating may be performed in that state.
If the plated material is inserted into the holding member as it is, the shape of the catalyzer can be maintained without fixing the winding end, and the cost can be reduced. Further, since the catalyzer and the holding member are the same material (wire material or fiber material), the adhesion between the catalyzer and the holding member can be improved by the unevenness of the contact portions, and the radial gap between the catalyzer and the holding member can be improved. Can be made smaller or eliminated.
Therefore, the two ring members 33 shown in FIGS. 2 to 4 can be omitted.

  6A and 6B, the catalyzer material 41 carrying platinum, the catalyzer material 42 carrying rhodium, the catalyzer material 43 carrying palladium, the catalyzer material 43 being the innermost, the catalyzer material Although 42 wound between the catalyzer materials 41 and 43 and the catalyzer material 41 is on the outermost side, it is not limited thereto. Similarly, in FIGS. 8A and 8B, a flat wire mesh 123 carrying platinum, a corrugated wire mesh 124, a corrugated wire mesh 126 carrying rhodium, and a corrugated wire mesh 128 carrying palladium are shown. Although the wire mesh 128 is wound so that it is the innermost side, the flat wire mesh 123 and the corrugated wire mesh 124 are the outermost surfaces, and the corrugated wire mesh 126 is between the corrugated wire meshes 124 and 128, this is not restrictive.

Further, in FIGS. 9A and 9B and FIGS. 10A and 10B, the corrugated wire nets 133, 134, and 135 are arranged in this order, but this is not restrictive. In FIGS. 10A and 10B, the flat wire mesh 143 is not limited to the position shown in the figure, and may be arranged between any adjacent corrugated wire meshes.
In addition, in FIG. 11C, the order in which the materials 152, 153, and 154 are stacked is not limited to the order shown.

In FIG. 13A, the stranded wire 171 is formed by twisting the three linear catalyzer bodies 47, 173, 174. However, the present invention is not limited to this, and the linear catalyzer bodies 47, 173, 174 are integrated. It may be bundled into a single string, or it may be braided into a single string.
Alternatively, any two of the three linear catalyzer bodies 47, 173, and 174 may be twisted and knitted to form a net, and the net may be overlapped to form a three-way catalyst.

Further, as shown in FIG. 14, the catalyzer 26 including the catalyzer main body 31 is disposed on the upstream side of the catalyzer 27. However, the present invention is not limited thereto, and a fiber or wire material is knitted on the upstream side of the catalyzer 27 to form a net shape. A wire knit member in which a plurality of the net-like members are stacked, that is, a member that does not carry a metal catalyst on the fiber material or the wire material in the catalyzer main body 31 may be disposed. Thereby, the wire knit member (moisture trap body) which has a water | moisture-content trap function is made, and since the metal catalyst is not used, cost can be held down.
In FIG. 17, a catalyzer 26 carrying platinum, a catalyzer 55 carrying rhodium, and a catalyzer 56 carrying palladium are arranged in this order from the upstream side, but the order is not limited.

Moreover, in FIG.19 and FIG.20, although the net member was comprised with the wire or the press molding material, you may employ | adopt not only this but a punching metal as a net member.
In each of the above embodiments, the metal catalyst is supported by electroplating. However, the present invention is not limited thereto, and the metal catalyst is supported by a plating process different from electroplating or a coating process different from the plating process. You may make it do.

10, 50, 70, 180 Exhaust device (exhaust pipe)
11, 51, 71, 181 Catalytic device 26, 27, 55, 56, 190, 195 Catalyzer 31, 61, 62, 121, 131, 141, 151 Catalyzer main body 32 Holding member 34, 191, 196 Net member

Claims (5)

A holding member formed into a cylindrical shape or an annular shape by knitting and compressing a metal wire, and
A flat wire mesh that is fitted into the inner periphery of the holding member and formed by knitting a metal wire, and a corrugated wire mesh that is formed by corrugating the metal wire and forming a corrugated shape. And the corrugated wire mesh is plated with one type of metal catalyst, and another type of metal catalyst is plated with the flat wire mesh and the catalyzer body having the corrugated wire mesh ,
A net member disposed on an end surface of the holding member to prevent the catalyzer body from coming out of the holding member;
A catalyzer characterized by comprising: 2. The ring member according to claim 1, further comprising a ring member formed in a cylindrical shape or an annular shape by closing a radial gap between the holding member and the catalyzer body, and knitting and compressing a metal wire . Catalyzer.   The catalyzer according to claim 1, wherein the net member has a portion extending in a radial direction through a central portion of the catalyzer main body.   The catalyzer according to any one of claims 1 to 3, wherein the catalyzer body is formed by plating a metal catalyst after forming a mesh.   An exhaust pipe provided in an exhaust system of an engine has a catalyzer according to any one of claims 1 to 4 and is configured by knitting a wire immediately upstream of the catalyzer, and a moisture trap body carrying a metal catalyst. An exhaust pipe catalyst device characterized by that.

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