JPH07289917A - Method and apparatus for producing catalyst member - Google Patents

Abstract

PURPOSE:To eliminate the loss due to the adhesion of a slurry to a jig by alternately holding a metal base material by two jigs to raise and lower the same and dipping the held metal base material in the slurry within a dip tank to uniformly form a catalyst carrier or catalyst coating layer on the metal base material by one process. CONSTITUTION:At the time of the production of a catalyst member, at first, a current is applied to a first jig 2 by a control device 6 and a metal base material 1 is fixed to the jig 2. Next, the first jig 2 is allowed to fall to be immersed in a slurry 5. The supply of a current to the first jig 2 is cut off while a current is applied to a second jig 3 and the metal base material 1 is fixed to the second jig 3. Continuously, the second jig 3 is allowed to fall to immerse the whole of the metal base material 1 in the slurry 5. Further, the supply of a current to the second jig 3 is cut off while a current is applied to the first jig 2 and the metal base material 1 is fixed to the first jig 2. The first jig 2 is raised to be moved to a palette and the application of a current is cut off to separate the metal base material. Thereafter, the metal base material 1 is dried and baked to form a catalyst film.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a catalyst member having a metal substrate coated with a catalyst layer.

[0002]

2. Description of the Related Art As a catalytic combustion catalyst for mixing liquid fuel or gas fuel with air for catalytic combustion, or as a purifying catalyst used for detoxifying exhaust gas generated from various combustion equipment or automobiles, A metal base material such as a ferritic stainless steel containing aluminum on which a catalyst layer is formed is used.

This type of catalyst member is manufactured by immersing a metal substrate in a slurry containing inorganic heat-resistant particles having a high specific surface area and a noble metal salt, which serves as a catalyst carrier, and then drying and firing. Then, when the metal base material is immersed in the slurry, a method of holding the metal base material with a jig having an electromagnet has been used.

[0004]

As described above, when the metal base material is fixed with one jig and is immersed in the slurry layer to form the catalyst film on the entire surface of the metal base material, the slurry is formed on the jig. Therefore, extra slurry is required, resulting in high cost. Further, when the slurry is dried and the catalyst coating layer is formed on the jig, the slurry is sucked up by the catalyst coating layer due to the capillary phenomenon, so that a film is formed like a snowball. When the film is formed on the jig, the fixing of the metal base material becomes unstable during the repeated dipping process, and the dried slurry adheres to the metal base material, which is not desirable. Therefore, it is necessary to wipe off the slurry adhering to the jig, resulting in a high cost.
Further, when the metal base material is dipped in the slurry layer, it is not desirable to provide a portion where the slurry does not adhere on the top of the metal base material because the catalyst member becomes non-uniform. The present invention provides a method for solving the above-mentioned conventional drawbacks and obtaining a catalyst member having a uniform catalyst coating layer at a low cost in a series of working steps.

[0005]

A method for producing a catalyst member of the present invention is a method of immersing a metal base material in a slurry to form a catalyst carrier or a catalyst coating layer on the surface of the metal base material. A step of immersing the upper end of the metal base material in a slurry by supporting it with a first jig, a second jig before the first jig supporting the upper end of the metal base material is immersed in the slurry, A step of supporting the lower end of the metal base material with a jig and separating the first jig from the upper end of the metal base material, and then immersing the entire metal base material in the slurry, The step of pulling up the metal base material with the jig, and the upper end portion of the metal base material is supported by the first jig while the upper end portion of the metal base material is exposed from the liquid surface of the slurry, It includes a step of separating the jig and pulling up the metal base material.

Further, the catalyst member manufacturing apparatus of the present invention comprises a dip tank containing the catalyst slurry, a first jig that moves up and down by supporting the upper end of the metal base material above the dip tank,
And a second jig that supports the lower end of the metal base material and moves up and down in the dip tank, and coats the slurry on the entire metal base material by the cooperation of the first and second jigs. . Here, it is preferable to use a magnetic metal for the metal base material and use one having an electromagnet for the first and second jigs.

[0007]

According to the present invention, the catalyst carrier or the catalyst coating layer can be uniformly formed on the metal substrate in one step by the above means, and the loss due to the adhesion of the slurry to the jig is eliminated, so that the catalyst can be quickly and inexpensively manufactured. It is possible to provide a different catalyst member.
Further, when a magnetic metal is used for the metal base material, it is possible to fix the jig by using an electromagnet. As a result, remote operation is possible, and workability is significantly improved.
By applying water repellent treatment to the jig, the adhesion of the slurry to the jig is further suppressed.

[0008]

Embodiments of the present invention will be described below with reference to the accompanying drawings. As shown in FIGS. 2 and 3, Fe is used for the metal substrate 1.
A compact having a height of about 55 mm and a width of about 35 mm obtained by bending a —Cr—Al-based metal thin body (thickness 50 μm) was used. The first jig 2 and the second jig 3 can fix the metal base material by an electromagnet, and the base material can be arbitrarily attached and detached by the control device. BaO ・ Al ₂ O ₃・ in the dip tank 4
1000 g of CeO ₂ powder (specific surface area 120 m ² / g), 85 g of aluminum nitrate nonahydrate, 1300 g of water and 5 g of dinitrodiammineplatinum aqueous solution (5 g in terms of Pt) were added to the slurry 5 and the slurry 5 was always kept constant by overflowing. The water level is maintained.

Next, the manufacturing method will be described with reference to FIG. First, when the metal base material 1 is positioned below the jig 2, the jig 2
When a current is applied to the metal base material, the metal base material is fixed to the jig 2 (a). The jig 2 is lowered by 100 mm at a speed of 2 mm / sec and immersed in the slurry 5. When the water surface of the slurry reaches the upper end 10 mm of the metal base material, the electric current is cut off from the electromagnet of the jig 2, and at the same time, the electric current enters the jig 3, and the metal base material is separated from the jig 2 and fixed to the jig 3. (B). After that, the jig 3 is subsequently lowered by 20 mm at 2 mm / sec and then held for 5 seconds to immerse the entire metal base material in the slurry (c). Then, the jig 3 is raised by 20 mm at 1 mm / sec, and then the current is cut off. At the same time, the jig 2 is energized and the metal base material is fixed to the jig 2 (d). After that, the jig 2 moves up by 100 mm (e), then moves onto the pallet, and the current is cut off to separate the metal base material.
The metal substrate 1 to which the catalyst slurry had adhered was irradiated with far infrared rays, dried, and then baked at 500 ° C. for 30 minutes to form a catalyst film.

According to this method, the adhesion of the slurry to the jig during the formation of the catalyst film is extremely small, the wiping is not required at the time of repetition, the loss of the slurry can be reduced, and the immersion is performed once. A uniform film was formed. As a comparative example, when the entire metal base material is immersed in the slurry with only a single jig, the slurry accumulates between the metal base material and the jig, and when the jig and the base material are separated, the slurry is treated with the base material. A large amount of slurry adhered to both of the ingredients, which made the workability poor.
The jigs 2 and 3 and the dip device will be more effective if they are subjected to water repellent treatment.

In the above embodiments, an example in which a metal substrate is coated with a slurry containing a catalyst carrier and a catalyst metal salt has been shown. However, the present invention uses a slurry containing a catalyst carrier to form a catalyst carrier on a metal substrate. It can also be applied to a method of forming a coating layer. In this case, a step of adding a catalyst to the catalyst carrier coating layer later is required.

[0012]

According to the manufacturing method of the present invention, since the adhesion of the slurry to the jig is reduced, the labor of wiping the adhered slurry is saved and the loss of the slurry is reduced. Therefore, a uniform catalyst film can be formed on the entire surface of the metal substrate by one dipping, so that the cost can be reduced.

[Brief description of drawings]

FIG. 1 shows a process of manufacturing a catalyst member according to an embodiment of the present invention.

FIG. 2 is a front view of a metal base material used in the same example.

FIG. 3 is a cross-sectional view of the same metal substrate.

[Explanation of symbols]

 1 Metal Base Material 2 First Jig 3 Second Jig 4 Dip Tank 5 Slurry 6 Control Device

Claims (3)

[Claims] 1. A method for forming a catalyst carrier or a catalyst coating layer on the surface of a metal substrate by immersing the metal substrate in a slurry, wherein the upper end of the metal substrate is supported by a first jig. In the slurry, the first jig supporting the upper end of the metal base material is immersed in the slurry before the first jig supports the lower end part of the metal base material by the second jig. After separating the first jig from the upper end of the material, the step of immersing the entire metal base material in the slurry, the step of pulling up the metal base material with the second jig supporting the lower end, and the upper end of the metal base material The step of supporting the upper end of the metal base material with the first jig in a state where the part is exposed from the liquid surface of the slurry and pulling up the metal base material by separating the second jig from the lower end portion of the metal base material. A method for manufacturing a characteristic catalyst member. 2. The method for producing a catalyst member according to claim 1, wherein the metal base material is made of magnetic metal, and the first and second jigs have electromagnets. 3. A dip tank accommodating the catalyst slurry, a first jig for supporting the upper end of the metal base material above and below the dip tank, and a lower end of the metal base material for supporting the lower end in the dip tank. An apparatus for manufacturing a catalyst member, comprising: a second jig, which coats the entire metal base material with the slurry by cooperation of the first and second jigs.