JPH081013A - Metal carrier for catalyst device - Google Patents

Abstract

PURPOSE:To obtain such a honeycomb body to be used as a metal carrier for a catalyst device that has high heat-resistant strength with decreased thermal stress, is light in weight compared with a two-layer double structure of flat plates and can be produced at a low cost. CONSTITUTION:A flat plate 14 and a wavy plate 21 are laminated with a brazing material 31 interposed, while a wavy plate 22 and a flat plate 13 are laminated with a brazing material 32 interposed. These two laminated layers are stacked with a flat plate 12 interposed to obtain a first layer 10. The first layer 10 is wound into a roll to form the second layer 20 and succeedingly wound to obtain a roll-state honeycomb body. No brazing material is inserted between both sides of the flat plate 12 and between the first layer 10 and the second layer 20.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal carrier for a catalyst device used in an exhaust gas purifying device for an internal combustion engine, and more particularly to a metal carrier for a catalyst device forming a honeycomb body for reducing thermal stress.

[0002]

2. Description of the Related Art As shown in FIG. 3A, a metal carrier for a catalyst device used in a conventional exhaust gas purifying device has a brazing material 33 interposed between a thin metal flat plate material 31 and a corrugated plate material 32. Then, the flat plate member 31 and the corrugated plate member 32 are overlapped with each other, and as shown in FIG. 3B, the honeycomb member 34 is formed by winding the flat plate member 31 and the corrugated plate member 32 in a roll form from the center, and the brazing filler metal 33 is melted by using a high vacuum furnace. The joining was performed at the contact portion of the plate materials. A Ni-based brazing material was used as the brazing material, and a ferritic stainless steel material was used as the flat plate material and the corrugated plate material. The honeycomb body 34 thus formed is housed in a metal outer cylinder 35 and is known as a metal carrier 30 for a catalyst device (for example, JP-A-56-4373).

A catalyst supporting layer made of alumina or the like is formed on the surface of the honeycomb passages of the honeycomb body, and a noble metal catalyst is supported on the catalyst supporting layer and functions as an exhaust gas purifying catalyst. Then, it is arranged in the exhaust passage of the internal combustion engine to purify HC, CO, NO _x, etc. in the exhaust gas. Since it is necessary to secure as large a honeycomb passage area as possible in a limited volume, the thickness of the flat plate material and the corrugated plate material is as thin as possible within the range where the strength can be maintained.

[0004]

In the above-mentioned conventional metal carrier for a catalyst device, the flow velocity of the exhaust gas passing through the honeycomb body is higher from the outer layer portion to the inner layer portion of the honeycomb body, so that the temperature of the honeycomb body becomes higher. Due to contact with exhaust gas, heat generation due to catalytic reaction, and heat dissipation from the outer cylinder, a temperature distribution is generated in which the inner layer portion has a higher temperature and the outer layer portion has a lower temperature. Due to this temperature distribution, the expansion / contraction amount of the inner layer portion of the high temperature honeycomb body becomes larger than the expansion / contraction amount of the outer layer portion of the low temperature, so that thermal stress is generated between the inner layer portion and the outer layer portion. . This thermal stress is repeated each time the honeycomb body expands / contracts, but as shown in FIG. 3A, all flat plate materials 31 and corrugated plate materials 32 are integrally brazed through the brazing material 33. Therefore, the thermal stress cannot be released, and the flat plate member 31 and the corrugated plate member 32 can be used for a long period of time.
There is a drawback that the joint part with is broken.

In order to eliminate this drawback, FIG.
As shown in (B), there is disclosed a honeycomb body 34a in which two flat plate materials 31 are stacked in the range of two or more layers from the outside, and the two flat plates are simply stacked without being bonded. The two-layer double structure has the drawbacks of increased weight and high cost.

The object of the present invention is to improve the heat resistance strength by relaxing the thermal stress generated in the honeycomb body, and is lighter in weight and less in the amount of brazing material than the honeycomb body having a two-layer double structure, and therefore inexpensive. Another object of the present invention is to provide a metal carrier for a catalyst device that forms a simple honeycomb body.

[0007]

MEANS FOR SOLVING THE PROBLEMS A metal carrier for a catalytic device according to the present invention is a flat metal plate made of a thin strip-shaped thin metal plate and a thin metal strip formed by continuously bending corrugations. A corrugated sheet made of a plate and a layer formed by abutting against each other and stacking at least two layers and being wound into a roll form a honeycomb body having a large number of mesh-like ventilation passages. In the metal carrier for a catalyst device, the corrugated sheet material in at least one of the stacked layers is formed so as to be joined to the flat sheet material on one side and not joined to the flat sheet material on the other side.

Further, a flat plate member made of a thin metal plate having a flat band shape and a corrugated plate member made of a thin metal plate having a band shape in which corrugated irregularities are continuously bent and formed are brought into contact with each other and overlapped. At least two layers formed by stacking the stacked layers, and stacking the stacked layers in a metal carrier for a catalyst device forming a honeycomb body having a large number of mesh-like ventilation passages. The corrugated sheet material in at least one of the layers is formed such that it is joined to the flat sheet material on one side and not to the flat sheet material on the other side.

It is preferable that the flat plate member to be joined with the corrugated plate member in at least one of the stacked layers of the metal carrier for a catalyst device is formed of metals having different thicknesses.

[0010]

The layer formed by laminating the flat plate material and the corrugated plate material forming the honeycomb body on each other is stacked at least two layers and wound in a roll shape or further laminated, and at least one layer of them is formed. Since the corrugated sheet material is joined to the flat sheet material on one side and is not joined to the flat sheet material on the other side and simply abuts, there is a degree of freedom between expansion and contraction due to heat between the two layers at the non-joined portion. Thermal stress can be relaxed.

[0011]

Embodiments of the present invention will now be described with reference to the drawings. FIG. 1 is a schematic partial cross-sectional view perpendicular to the axis of an embodiment of the metal carrier for a catalyst device of the present invention.

In FIG. 1A, the first layer 10 is a flat layer.
Plate material 1₁ And corrugated sheet material 2₁ Brazing material 3 ₁ Overlaid through
Set layer and corrugated sheet material 2₂ And flat plate material 1₃ Brazing material 3₂ Through
The two layers, which are the layer that has been overlapped with each other, are flat plate materials 1₂ Fucked through
It is formed by overlapping. This first layer 10 is low
The second layer 20 is further formed by winding the film in a roll shape, and sequentially.
It is wound to form a roll-shaped honeycomb body. First
Two corrugated sheet materials 2 forming the layer 10₁ Two₂ Respectively
Flat plate material 1 on one side₁ Or 1₃ Brazing material 3₁ Well
Or 3₂ Are joined together and also on the other side
Flat plate material 1 without brazing material₂ Is in contact with
Only Further between the first layer 10 and the second layer 20
Since no brazing material is interposed between the first layer 10 and the second layer,
Only in contact with the layer 20. Therefore,
At these points of contact, expansion due to heat
Since it has the freedom to shrink, the thermal stress between layers
Will be alleviated. In addition, a double structure of flat plate material is provided every two layers.
Therefore, it is provided for each layer as shown in the conventional example of FIG.
The weight is reduced compared to the flat plate double structure.

In FIG. 1B, the first layer 11 is a flat layer.
Plate material 1₁ And corrugated sheet material 2₁ Brazing material 3 ₁ Overlaid through
Set layer and flat plate material 1₂ And corrugated sheet material 2₂ Brazing material 3₂ Through
And the layers that have been stacked on top of each other without using brazing material
Has been formed. This first layer 11 is wound into a roll
Then, the second layer 21 is formed, and the second layer 21 is sequentially wound.
A rolled honeycomb body is formed. First layer 11 and second
A brazing material is not interposed between the layers 21 of. Accordingly
And corrugated sheet material 2₁ Two₂ Is a plate on each side
Material 1₁ 1₂ Joined with but flat on the other side
It is not joined to the material, but just abuts. This
Expansion and contraction due to heat at the point of contact
The thermal stress between layers is relaxed because
You. Furthermore, since the double structure of flat plate material is not provided, the weight is increased.
Do not join.

In FIG. 1C, the first layer 12 is a layer in which the brazing material 3 ₁ is inserted between the flat plate material 1 ₁ and the corrugated plate material 2 ₁ and is stacked, and the flat plate material 1 ₂ and the corrugated material are The layer which is simply brought into contact with 2 ₂ is formed by overlapping with the brazing material 3 ₂ . This first layer 12 is rolled into a second
A layer 22 of a first layer 12 and a second layer 22.
A brazing filler metal 3 ₃ is inserted between them. The two layers thus stacked are sequentially wound to form a roll-shaped honeycomb body. The flat plate material 1 of the first layer 12 and the second layer 22
_{Since the two} and the corrugated sheet 2 ₂ are merely in contact with each other without a brazing filler metal, there is a degree of freedom for expansion and contraction due to heat in this portion, and thermal stress between layers is relaxed. It

[0015] In FIG. 1 (D), the first layer 13, sandwiching the wave plate 2 ₁ between the flat plate 1 ₁ and 1 _2, between the wave plate 2 ₁ and the flat plate ₁ 1, 1 ₂ A layer in which the brazing materials 3 ₁ and 3 ₂ are interposed and a layer in which the corrugated sheet materials 2 ₂ and 2 ₃ are arranged above and below the flat plate material 1 ₃ through the brazing materials 3 ₃ and 3 ₄ are brazing materials It is formed without being stacked. The first layer 13 is wound into a roll to form the second layer 23, and no brazing material is inserted between the first layer 13 and the second layer 23.
In this way, the first layer 13 including the three flat plate members and the three corrugated plate members is sequentially wound to form a roll-shaped honeycomb body. In this case, in the first layer 13 and the second layer 23, no brazing material is interposed between the flat plate material 1 ₂ and the corrugated sheet material 2 ₂ , and the corrugated sheet material 2 ₃ and the second corrugated sheet material of the first layer 13 are not provided. The brazing material is not inserted between the flat plate materials 1 ₁ of the layers, and they are merely in contact with each other. Therefore, the honeycomb body has a degree of freedom for expansion and contraction due to heat between the layers that do not sandwich the brazing material, so that the thermal stress between the layers is relaxed. Further, since the flat plate material does not have a double structure, the weight does not increase.

FIG. 2 shows a second metal carrier for a catalytic device according to the present invention.
FIG. 7 is a schematic partial cross-sectional view perpendicular to the axis of the embodiment of FIG. 7, in which flat plate materials having different thicknesses are partially used.

FIG. 2 (A) shows the honeycomb body of FIG. 1 (A).
Flat plate material to be formed 1₁ 1₃ A thicker plate material
1₁₁1₃₁It is the figure replaced by. The first layer 14 is flat
Plate material 1₁₁And corrugated sheet material 2₁ Brazing material 3₁ Overlaid through
Set layer and corrugated sheet material 2₂ And flat plate material 1 ₃₁Brazing material 3₂ Through
The two layers, which are the layer that has been overlapped with each other, are flat plate materials 1₂ Fucked through
It is formed by overlapping. This first layer 14 is low
The second layer 24 is further formed by winding the film in a roll shape, and sequentially.
It is wound to form a roll-shaped honeycomb body. First
Two corrugated sheet materials 2 forming the layer 14₁ Two₂ Respectively
Flat plate material 1 on one side₁₁Or 1₃₁Brazing material 3₁ Well
Or 3₂ Are joined together and also on the other side
Flat plate material 1 without brazing material₂ Is in contact with
Only Further between the first layer 14 and the second layer 24
Since no brazing material is interposed between the first layer 14 and the second layer
Only in contact with the layer 24. Therefore,
At these points of contact, expansion due to heat
Since it has the freedom to shrink, the thermal stress between layers
Will be alleviated. Thicker plate material 1₁₁1₃₁ To use
As a result, the heat resistance strength of the honeycomb body is improved.

FIG. 2B is a view in which the flat plate material 1 ₁ forming the honeycomb body of FIG. 1B is replaced with a thick flat plate material ₁₁ 1. The first layer 15 consists of a thick flat plate material ₁₁ 1 and a corrugated plate material 2 _1.
And a layer having the brazing material 3 ₁ sandwiched between them and a layer having the brazing material 3 ₂ sandwiched between the flat plate material 1 ₂ and the corrugated sheet material 2 ₂ . The first layer 15 is wound into a roll to further form a second layer 25, the first layer 15 and the second layer 25 being formed together.
The brazing material is not inserted between the layer 25 and the layer 25. 2 like this
The stacked layers are sequentially wound to form a roll-shaped honeycomb body. In this case, since the brazing material is not sandwiched between the two stacked layers, and the brazing material is not sandwiched between the wound first and second layers, the honeycomb body is formed.
Between the layers that do not sandwich the brazing material, there is a degree of freedom with respect to thermal expansion and contraction, so that the thermal stress between the layers is relaxed, and a thick flat plate material ₁₁ is used as a part of the plate material. This improves the heat resistance strength of the honeycomb body.

Further, also in the embodiment shown in FIGS. 1C and 1D, as in the embodiment shown in FIGS. 2A and 2B, a part of the flat plate material is replaced with a thick flat plate material. be able to.

While the roll-shaped honeycomb body has been described in the embodiments shown in FIGS. 1 and 2, the explanation is the same for the laminated body formed by further laminating the stacked layers. Therefore, the description thereof will not be repeated here.

[0021]

As described above, according to the present invention, at least two layers in which a flat plate material and a corrugated plate material are in contact with each other are stacked and wound in a roll shape or further stacked to form a honeycomb. In the metal carrier forming the body,
By forming the honeycomb body in which the corrugated sheet material in at least one of the stacked layers is not joined to the flat sheet material on one side, there is an effect that thermal stress generated in the honeycomb body is relaxed. Also, by using a flat plate material that is thicker than others as part of the flat plate material that is joined to the corrugated plate material, there is an effect that the heat resistance strength is improved. 2 layers of flat plate material
Since it does not have a heavy structure, there is no increase in weight, and the use of brazing material is reduced.

[Brief description of drawings]

FIG. 1 is a schematic partial cross-sectional view perpendicular to the axis of an embodiment of a metal carrier for a catalyst device of the present invention.

FIG. 2 is a schematic partial cross-sectional view perpendicular to the axis of another embodiment of the present invention.

3 is a schematic view of a metal carrier for a catalyst device according to the prior art, FIG. 3 (A) is a schematic cross-sectional view perpendicular to the axis of FIG. 3 (B), and FIG. 3 (B) is a perspective view of a roll-shaped honeycomb body. It is a figure.

4 is a schematic view of another conventional metal carrier for a catalyst device, FIG. 4 (A) is a schematic partial sectional view perpendicular to the axis of FIG. 4 (B), and FIG. 4 (B) is a roll-shaped honeycomb It is a perspective view of a body.

[Explanation of symbols]

1 ₁ , 1 ₂ , 1 ₃ , 1 ₁₁ , 1 ₃₁ , 31 Flat plate material 2 ₁ , 2 ₂ , 2 ₃ , 32 Corrugated plate material 3 ₁ , 3 ₂ , 3 ₃ , 3 ₄ , 33 Brazing material 10, 11, 12 , 13, 14, 15 First layer 20, 21, 22, 23, 24, 25 Second layer 30 Metal carrier 34, 34a Honeycomb body 35 Outer cylinder

Claims (3)

[Claims] 1. A flat plate member made of a thin metal plate having a flat band shape and a corrugated plate member made of a thin metal plate having a band shape in which corrugated irregularities are continuously bent and formed are abutted against each other and stacked. In a metal carrier for a catalyst device, which is a honeycomb body having a large number of mesh-like ventilation passages and is formed by stacking at least two layers formed by stacking the formed layers, The corrugated sheet material in at least one layer of is joined to the flat sheet material on one side,
A metal carrier for a catalyst device, which is not joined to the flat plate material on the other side. 2. A flat plate member made of a thin metal plate having a flat band shape and a corrugated plate member made of a thin metal plate having a band shape in which corrugated irregularities are continuously bent and formed are abutted against each other and stacked. A layer formed by stacking at least two layers, and further stacking the stacked layers,
In a metal carrier for a catalyst device forming a honeycomb body having a large number of mesh-like ventilation paths, the corrugated sheet material in at least one layer of the stacked layers is joined to the flat sheet material on one side,
A metal carrier for a catalyst device, which is not joined to the flat plate material on the other side. 3. The metal for a catalytic device according to claim 1, wherein the flat plate material to be joined with the corrugated plate material in at least one layer of the stacked layers is a metal plate having a different thickness. Carrier.