JPH06277526A - Catalyst carrier for exhaust gas purifying device - Google Patents

Abstract

PURPOSE:To provide a catalyst carrier which relieves thermal stresses and is excellent in terms of cost and silencing performance by winding metallic foil materials in multiple layers in a positional relation of making corrugated sheet parts and spacing parts correspondent to each other and brazing these materials, thereby forming a honeycomb structure having a roll shape as a whole. CONSTITUTION:This catalyst carrier 6 for an exhaust gas purifying device is placed in a use environment where high-temp. exhaust gases pass and the heat generation by a catalytic reaction is observed. Plural sheets of the metallic foil materials 8 forming the walls of the cells 14 of the catalyst carrier 6 are alternately formed with the corrugated sheet parts 7 and the spacing parts A consisting of flat sheet parts 9, etc., and are formed of the same shape and the length of the first raw material and, therefore, the elongation rate at the time of high-temp. heating and the contraction rate at the time of ordinary temp. cooling are both common. Then, the respective foil materials 8, i.e., cell walls, elongate and contract evenly over the entire part and integrally correspond to the elongation and contraction and, therefore, thermal stresses are relieved. As a result, the thermal stress fatigue is averted and the damage near the brazing joint parts between the cell walls is prevented.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a catalyst carrier for an exhaust gas purification device. That is, the present invention relates to a catalyst carrier which is used in a catalytic converter for cleaning exhaust gas of an automobile engine and other various kinds of exhaust gas, and to which a catalytic substance is attached as a supporting base.

[0002]

2. Description of the Related Art FIG. 7 is a perspective view of a conventional example of this kind.
(1) Figure shows the corrugated sheet, (2) Figure shows the corrugated sheet, (3)
The figure shows the whole. As shown in the same figure, a conventional catalyst carrier 1 for an exhaust gas purifying apparatus has a corrugated plate 2 made of metal foil shown in (1) and a flat plate 3 made of metal foil shown in (2). A typical example is one in which and are wound and brazed in multiple layers so that they are alternately positioned. As shown in FIG. The cell walls were formed to form a honeycomb structure. (3)
In the figure, 4 indicates each cell of the catalyst carrier 1, and 5 indicates the catalyst carrier 1.
The outer cylinder of is shown. In the catalyst carrier 1, for example, during use such as driving an automobile, high-temperature exhaust gas containing harmful substances from the engine passes through the cells 4 and reacts with the attached catalyst substances to be cleaned. .

[0003]

By the way, the following problems have been pointed out in such a conventional example. That is, in a use environment in which high-temperature exhaust gas passes and heat is also generated due to a catalytic reaction, the coefficient of thermal expansion and contraction of the corrugated plate 2 and the flat plate 3 forming the cell wall of the catalyst carrier 1 due to the difference in shape. There is a difference in the amount of expansion when heated at high temperature and the amount of contraction when cooled at room temperature. That is, the corrugated plate 2 formed by bending the flat plate material as the raw material and continuously forming the corrugated unevenness and the flat plate 3 using the flat plate material as the raw material have different shapes and lengths of the raw material. Due to the difference, the amount of expansion during use, that is, during heating at high temperature, and the amount of contraction during non-use, that is, during cooling at room temperature are different, and the corrugated sheet 2 is much easier to expand and contract than the flat sheet 3. However, the conventional catalyst carrier 1
Then, the corrugated plate 2 and the flat plate 3 which are formed separately from each other and have a same size, size, and area are used, and the both are completely brazed and integrally regulated. Was there.

Therefore, in the conventional catalyst carrier 1, thermal stress acts due to the difference in expansion and contraction in the radial direction and the axial direction between the corrugated plate 2 and the flat plate 3 forming the cell wall, and when used for a long time. Repeated expansion and contraction due to thermal stress causes thermal stress fatigue,
Degradation, damage, cracks, breakage, etc. were likely to occur near the brazed joint between the cell walls formed by the corrugated plate 2 and the flat plate 3. As described above, in the conventional catalyst carrier 1 for an exhaust gas purifying apparatus, it is pointed out that the thermal stress fatigue is caused by the use environment,
There was a problem with durability.

In view of the above situation, the present invention has been made to solve the problems of the above-mentioned conventional example, and employs a foil material in which corrugated plate portions and gap portions are alternately formed, Further, by using the flat plate portion or the corrugated plate portion as the space portion, firstly the thermal stress is relieved, secondly the cost is excellent, and in addition to this, the flat plate portion is provided with holes or slits. Thirdly, it is an object of the present invention to propose a catalyst carrier for an exhaust gas purification device, which is also excellent in silencing performance.

[0006]

The technical means of the present invention for achieving this object are as follows. First, claim 1
About: That is, the catalyst carrier for this exhaust gas purifying apparatus is composed of a plurality of metal foil materials each of which has a strip shape and in which longitudinal corrugated portions and interval portions are alternately formed in the longitudinal direction. And the space portion are wound in a multi-layer and brazed in a corresponding positional relationship so that the whole has a roll shape and a honeycomb structure. Next, claim 2 is as follows. That is, according to the second aspect, in the catalyst carrier for the exhaust gas purifying apparatus according to the first aspect, the space between the foil members is a flat plate portion. The claim 3 is as follows. That is, according to the third aspect of the present invention, in the catalyst carrier for an exhaust gas purifying apparatus according to the second aspect, the flat plate portion which is the gap portion of the foil material is perforated or slit. Further, claim 4 is as follows. That is, according to the fourth aspect of the present invention, in the catalyst carrier for an exhaust gas purifying apparatus according to the first aspect, the interval between the foil members is a small corrugated plate portion having a smaller pitch or height than the corrugated plate portion.

[0007]

Since the present invention comprises such means, it operates as follows. The catalyst carrier according to the first, second, third, and fourth aspects is used in a use environment in which high-temperature exhaust gas passes and heat generation due to a catalytic reaction is also observed. So first
In addition, a plurality of foil materials forming the cell wall of this catalyst carrier,
The corrugated plate and the space between the flat plate and the small corrugated plate are alternately formed. Since they have the same shape and the same length of raw material, the amount of expansion during high temperature heating and the amount of contraction during room temperature cooling are Have in common. Therefore, in this catalyst carrier, each foil material, that is, the cell wall can be uniformly expanded and contracted as a whole to integrally support expansion and contraction, so that the thermal stress is relieved. Therefore, expansion and contraction due to thermal stress is mitigated even after long-term use, and thermal stress fatigue is avoided.
Damage, cracks and fractures are prevented.

In addition to the above, in the catalyst carrier according to claim 4, since the cell wall, that is, the space between the foil members is composed of the small corrugated sheet portion, both the corrugated sheet portion and the small corrugated sheet portion which easily expand and contract during heating at high temperature or cooling at room temperature. The expansion and contraction of the materials are absorbed by and, respectively, so that the expansion and contraction can be performed smoothly and surely by uniformly expanding and contracting as a whole. Therefore, in particular, relaxation of thermal stress is promoted,
Deterioration, damage, cracks, breaks, etc. are prevented.

Secondly, these are easily realized by a simple structure such as a small number of constituent members. Thirdly, since the catalyst carrier according to claim 3 has holes or slits formed in the cell wall, that is, in the flat plate portion which is a gap portion of the foil material,
It also has excellent silencing performance.

[0010]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below based on the embodiments shown in the drawings. 1, FIG. 2, FIG. 3, and FIG. 4 are perspective views of foil materials in the first, second, third, and fourth embodiments of the present invention, respectively. Further, FIG. 5A is a front explanatory view of the foil material of the fourth embodiment, and FIG.
The front explanatory view of the foil material of the embodiment and FIG. 5 (3) are overall perspective views of the foil material of the sixth embodiment. FIG. 6 shows the first, second, and
It is a perspective view of a catalyst carrier of the 3rd and 6th examples.

First, in the catalyst carrier 6 for the exhaust gas purifying apparatus, a metal foil material 8 is used which has a band shape and in which longitudinal corrugated plate portions 7 and gap portions A are alternately formed. To describe these in detail, a strip-shaped stainless steel foil, for example, is used as the foil material 8 in each of the embodiments. Except for the outermost peripheral portion B (see FIG. 5 (3)), which will be described later, it is sequentially arranged in the longitudinal direction. The corrugated plate portions 7 and the interval portions A are alternately formed and are divided in parallel in the width direction at intervals. The corrugated plate portion 7 is formed by corrugating gears or corrugating racks only on the corresponding portions of the foil material 8 so that, for example, corrugated irregularities each having a predetermined pitch and height, such as triangular corrugations, are continuously bent in the longitudinal direction. It will be done.

In the foil material 8 of the first embodiment shown in FIG. 1, the spacing portions A where such corrugated plate portions 7 are not formed are each made of a flat plate portion 9 and are perforated. A large number of long holes 10 are formed. The foil material 8 of the second embodiment shown in FIG. 2 is similar to that of the first embodiment, except that the long hole 1
Instead of 0, a large number of round holes 11 are created by punching or other hole processing.
Are formed.

Next, in the foil material 8 of the third embodiment of FIG. 3, the corrugated plate portion 7 is first bent in a so-called helical shape unlike the other embodiments. That is, in the corrugated sheet portion 7 of each of the other embodiments, the corrugations are formed in parallel with each other along the width direction of the strip-shaped foil material 8, that is, at right angles to the sides of the strip-shaped foil material 8 in the longitudinal direction. However, the corrugated plate portion 7 of the third embodiment
Has a corrugated shape that is slightly inclined with respect to the width direction and does not form a right angle with respect to the strip-shaped sides, and is continuously bent and formed in parallel with each other. Note that the helical shape of this illustrated example is formed symmetrically in the middle with the center line (imaginary one) along the longitudinal direction as a fold, but of course such a fold exists. Alternatively, a helical shape in which all the directions are the same may be considered. Further, in the foil material 8 of the third embodiment, the gap portions A where such corrugated plate portions 7 are not formed are flat plate portions 9 respectively.
And slit processing is performed to form a large number of slits 12.

The slit 12 in the third embodiment and the elongated hole 1 in the first and second embodiments described above are used.
The size, position, arrangement, direction, number, etc. of 0 and round holes 11 are not limited to those shown in the drawings, and various other modes are possible. Further, the elongated hole 10, the round hole 11, the slit 12 and the like are not limited, and a large number of triangles, squares and other various shapes may be formed by hole processing or slit processing.

Next, in the foil material 8 of the fourth embodiment shown in FIGS. 4 and 5 (1), the interval A between the corrugated plate portions 7 is smaller in pitch and height than the corrugated plate portions 7. It consists of a small corrugated plate portion 13. That is, the small corrugated sheet portion 13 has the same corrugated shape as the corrugated sheet portion 7, and the corrugated sheet portion 7 has the same pitch and height.
It is set smaller, and the number of waveforms is larger than that of the corrugated plate portion 7. In the fourth embodiment, since the corrugated sheet portion 8 has a triangular corrugated shape, the small corrugated sheet portion 13 also has a triangular corrugated shape. Also, the fifth of FIG.
The foil material 8 of the embodiment is similar to that of the fourth embodiment,
In the fifth embodiment, since the corrugated plate portion 8 has a trapezoidal wave shape, the small wave plate portion 13 also has a trapezoidal wave shape.

In the foil material 8 of the sixth embodiment shown in FIG. 5 (3), the gap portions A where the corrugated plate portions 7 are not formed are made of flat plate portions 9, respectively. Unlike the first, second and third embodiments, the long hole 10 and the round hole 1
1, the slit 12 and the like are not formed. By the way, B in FIG. 5 (3) is an outermost peripheral portion which is one end portion of the strip-shaped foil material 8, and such an outermost peripheral portion B is generally the same in other embodiments as well. Is not a corrugated plate portion 7 or the like but a flat plate portion 9 and is used for brazing to the outer cylinder 5 (see FIG. 6) as described later.

In the present invention, as shown in each of the above-described first to sixth embodiments, the corrugated plate portion 7 and the gap portion A composed of the flat plate portion 9 and the small corrugated plate portion 13 are sequentially arranged in the longitudinal direction. The metal foil material 8 having a predetermined length and formed alternately is used. And, the catalyst carrier 6 for this exhaust gas purification device is
In each embodiment, two pieces of such foil material 8 are used, and the corrugated plate portion 7 and the gap portion A are wound in multiple layers and brazed in a corresponding positional relationship with each other, and the whole is roll-shaped. And a honeycomb structure.

These will be described in detail. The two strip-shaped foil members 8 have a central portion C (FIG. 5) of an end which is a winding start portion.
(See FIG. 3)), and each corrugated plate portion 7 and flat plate portion 9
And the interval portion A of the corrugated plate portion 13 and the like, based on the corresponding positional relationship (see the drawings of the respective examples of FIG. 1, FIG. 2, FIG. 3, FIG. 4, and FIG. 5 (3)), In other words, under the positional relationship in which the corrugated plate portions 7 are displaced from each other, a brazing filler metal (not shown) is interposed,
The layers are alternately superposed from the central portion C and wound into multiple layers. The outermost peripheral portion B of the end portion, which is the last winding portion, of both foil materials 8 is aligned, and all or a part of the contact portions between the two foil materials 8 are brazed with the brazing material that has been interposed. The catalyst carrier 6 having a perfect circular roll shape in cross section is molded (see FIG. 6). The catalyst carrier 6
In addition to this, various other forms are possible, for example, one in which three or more foil materials 8 are bundled and wound, or a perfect circular roll shape is slightly crushed, The cross-sectional shape of which is a substantially elliptical track field shape, and the like are conceivable.

The catalyst carrier 6 has a honeycomb structure (see FIG. 6). That is, the foil material 8 having the corrugated plate portion 7 and the interval portion A forms a cell wall, and has a substantially triangular shape, a substantially square shape,
It is formed of a planar aggregate of a large number of hollow column-shaped cells 14 each having a substantially trapezoidal shape, a substantially half-hexagonal shape, and other various shapes, each of which is divided into independent spaces. Since the catalyst carrier 6 has a honeycomb structure as described above, it has excellent weight ratio strength, lightness, and high rigidity and strength, like a general honeycomb core.
Also, it has excellent rectification effect, plane accuracy, heat retention, sound insulation, etc.
It is known to have various characteristics such as easy molding and excellent cost. Further, because the surface area per unit volume is large, that is, the surface area of the cell wall formed by the foil material 8 is large, it is used for a catalytic converter for cleaning exhaust gas of an automobile engine or the like, for example. As a base material, the catalytic material is coated and adhered to the surface of the foil material 8, that is, the cell wall. In other words, it removes various harmful substances in exhaust gas by reaction.
A catalytic material such as a noble metal for redox is coated and adhered to the surface via a supporting layer such as alumina. The catalyst carrier 6 is coaxially housed in the outer cylinder 5 which is a case made of stainless steel or the like, and the outermost peripheral portion B (see (3) of FIG. 5) and the outer cylinder 5 are brazed. To be done.

The present invention is constructed as described above. Then it becomes as follows. In the catalyst carrier 6 for this exhaust gas purifying apparatus, a foil material 8 in which corrugated plate portions 7 and spacing portions A are alternately formed in the longitudinal direction is adopted, and further, FIGS. 5 (3) and the like, and in the first, second, third and sixth embodiments shown in FIG. 6, the flat plate portion 9 is used as the spacing portion A, and FIGS. 2) In the fourth and fifth embodiments of the figure, the small corrugated plate portion 13 is used as the spacing portion A. Then, a plurality of such foil materials 8 such as two are wound in a roll shape and brazed in such a positional relationship that the corrugated plate portion 7 and the interval portion A correspond to each other to form a cell wall. To form a honeycomb structure (see FIG. 6). Exhaust gas containing harmful substances passes from the engine through the cells 14 of the catalyst carrier 6 during use, for example, when driving a vehicle, and the harmful substances come into contact with and react with the attached catalyst. Are removed and cleaned.
In this way, the catalyst carrier 6 is used under a use environment in which high-temperature exhaust gas passes and heat is also generated by the catalytic reaction.
Used. Then, the following first, second, and third become.

First, the two foil materials 8 forming the cell walls of the catalyst carrier 6 are both corrugated plate portions 7 and flat plate portions 9 and small corrugated sheet portions necessary for forming a honeycomb structure. Interval portions A such as 13 are continuously and alternately formed. As described above, the two foil materials 8 are used by shifting the same one, so that they have the same size, size, and area, and also have the same shape and the same length of raw material. The shrinkage coefficients are the same, and the amount of expansion during high temperature heating and the amount of shrinkage during normal temperature cooling are common. Therefore, in this catalyst carrier 6,
Since both foil members 8, that is, the cell walls, expand and contract uniformly under the same conditions as a whole and can accommodate expansion and contraction as a whole, the expansion and contraction difference between them is eliminated, and the thermal stress is relieved. Therefore, even if it is used for a long period of time, expansion and contraction due to thermal stress is alleviated, and the occurrence of thermal stress fatigue due to repeated thermal stress is avoided, as pointed out in the catalyst carrier 1 of this type of related art shown in FIG. It Therefore, in this catalyst carrier 6, deterioration, damage, cracks, breakage, etc. from both foil materials 8, that is, the vicinity of the brazed joint between the cell walls, can be reliably prevented.

In addition to the above, FIG.
(2) In the catalyst carrier 6 of the fourth and fifth embodiments shown in the figure, since the interval portion A of the foil material 8 forming the cell wall is composed of the corrugated plate portion 13, both expand and contract during high temperature heating and normal temperature cooling. The corrugated sheet portion 7 and the small corrugated sheet portion 13, which are easy to perform, absorb the expansion and contraction of the material. Therefore, both foil members 8, that is, the cell walls, can be smoothly and surely expanded and contracted uniformly and integrally as a whole, so that the expansion and contraction of thermal stress is promoted, and deterioration and
Damage, cracks, breaks, etc. are reliably prevented.

Secondly, these are easily realized with a simple structure such as a small number of constituent members. That is, this catalyst carrier 6 does not need to separately prepare two pieces of two kinds of members, that is, the corrugated plate 2 and the flat plate 3 as in the above-mentioned conventional example of this kind (see FIG. 7), and the corrugated plate portion 7 and the same foil material 8 in which the flat portion 9 and the interval portion A such as the small corrugated plate portion 13 are partitioned and formed may be used, and the number of constituent members is small, and the above-described simple structure is easily adopted. Point 1 is realized.

Thirdly, in the catalyst carriers 6 of the first, second and third embodiments shown in FIGS. 1, 2 and 3, the flat plate portion 9 which is the space A of the foil material 8 forming the cell wall is used. A large number of long holes 10, round holes 11, slits 12 and the like are formed. Therefore, in the catalyst carriers 6 of the first, second, and third embodiments, in addition to the above-mentioned first and second, the exhaust gas passing therethrough has a large number of such long holes 10, round holes 11, slits. Since it is diffused between the cells 14 at 12, etc., it also has excellent sound deadening performance, and noise due to passing exhaust gas is reduced.

[0025]

As described above, the catalyst carrier for the exhaust gas purifying apparatus according to the first, second, third, and fourth aspects of the present invention is as follows.
Adopted a foil material in which the corrugated plate portion and the interval portion are formed alternately,
Further, by using the flat plate portion or the corrugated plate portion as the spacing portion, the following effects are exhibited.

First, the thermal stress is relieved. Therefore, this catalyst carrier avoids thermal stress fatigue even after long-term use,
Deterioration, damage, cracks, breakage, etc. from the vicinity of the brazed joint of the cell wall formed of the foil material are prevented, and the durability is improved. Secondly, this is easily realized with a simple structure such as a small number of constituent members, is inexpensive, and is excellent in cost.

Further, in the catalyst carrier for the exhaust gas purifying apparatus according to the third aspect of the present invention, the flat plate portions which are the spacing portions are perforated or slitted. Therefore, in addition to the above, thirdly, the sound deadening performance is excellent, and the noise caused by the passing exhaust gas is reduced. As described above, the effects of the present invention are remarkably large, such as the problems existing in this type of conventional example are eliminated.

[Brief description of drawings]

FIG. 1 is a perspective view of two foil materials showing a first embodiment of a catalyst carrier for an exhaust gas purifying apparatus according to the present invention.

FIG. 2 shows a second embodiment of the present invention and is a perspective view of the two foil materials.

FIG. 3 shows a third embodiment of the present invention and is a perspective view of the two foil materials.

FIG. 4 is a perspective view of the two foil materials showing the fourth embodiment of the present invention.

FIG. 5 (1) is a front explanatory view of a foil material of a fourth embodiment of the present invention, and (2) FIG. 5 is a front explanatory view of a foil material of the fifth embodiment of the present invention, (3) FIG. 6 is an overall perspective view of two foil materials of the sixth embodiment of the present invention.

FIG. 6 is a perspective view of catalyst carriers of first, second, third and sixth embodiments of the present invention.

7A and 7B are perspective views of a catalyst carrier for an exhaust gas purifying apparatus according to a conventional example, where FIG. 1A is a corrugated plate, and FIG. 2B is a flat plate.
(3) The figure shows the whole.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 catalyst carrier (conventional example) 2 corrugated plate 3 flat plate 4 cell 5 outer cylinder 6 catalyst carrier (of the present invention) 7 corrugated plate part 8 foil material 9 flat plate part 10 long hole 11 round hole 12 slit 13 small corrugated plate part 14 cells (of the present invention) A spacing portion B outermost peripheral portion C central portion

Claims (4)

[Claims] 1. A plurality of metal foil materials, each of which has a band shape and in which longitudinal corrugated plate portions and gap portions are alternately formed in the longitudinal direction, and the corrugated plate portions and gap portions correspond to each other. In relation to the above, the catalyst carrier for an exhaust gas purifying device is characterized in that it is wound in multiple layers and brazed, and the whole has a roll shape and a honeycomb structure. 2. The catalyst carrier for an exhaust gas purifying apparatus according to claim 1, wherein the space between the foil members is a flat plate portion,
A catalyst carrier for an exhaust gas purifying device, comprising: 3. The exhaust gas purifying apparatus according to claim 2, wherein the flat plate portion, which is a gap portion of the foil material, is perforated or slitted in the catalyst carrier for the exhaust gas purifying apparatus. Catalyst carrier. 4. The exhaust gas purifying apparatus catalyst carrier according to claim 1, wherein the space between the foil members is a small corrugated plate portion having a pitch or height smaller than that of the corrugated plate portion. Catalyst carrier for gas purification equipment.