JPH09144533A - Manufacture of catalyst support - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce the number of parts and joining mandays by inserting a catalyst support into an external cylinder from its one end side after the other end of an external cylinder is press-formed in a tapered shape, and an excessive thickness part is squeezed to form a diffuser. SOLUTION: A catalyst support 1 accommodated in a metallic external cylinder 3 is formed by piling a corrugated plate and a flat plate which are made of metal and winding them in a cylindrical shape, and the corrugated and flat plates are mutually joined by diffusive joining. The external cylinder 3 is unitedly formed with the diffuser 9 by press-forming the one end of a cylindrical pipe material in a tapered shape and squeezing an excessive thickness part 3a, and the catalyst support 1 is soldered to the inner periphery of a cylindrical part 3b of the external cylinder 3 excepting the part of diffuser 9 to compose a catalyst support 11. After catalyst support processing is carried out to the catalyst support, and the diffuser 9 is deposited on the one end side of the external cylinder 3, the above components are attached to a vehicle exhaust system through a flange to carry out the purification of exhaust gas as a catalyst converter.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a diffuser-integrated catalyst carrier used in a catalytic converter.

[0002]

2. Description of the Related Art Conventionally, for example, a vehicle exhaust system is equipped with a catalytic converter for purifying exhaust gas discharged from an engine. As a catalyst carrier used in the catalytic converter, a ceramic carrier formed of ceramics or a ceramic carrier has been conventionally used. A metal carrier made of a metal material is used.

The metal carrier is composed of a catalyst carrier formed by a metal corrugated plate and a flat plate, and an outer cylinder (shell) containing the catalyst carrier therein. The noble metal catalyst is carried on the catalyst carrier. After the treatment, a diffuser and a flange are joined to both ends of the outer cylinder to form a catalytic converter as disclosed in Japanese Utility Model Laid-Open No. 2-18610.

Further, in order to form a catalytic converter using a ceramics carrier, the ceramics carrier is subjected to a noble metal catalyst supporting treatment, and thereafter, as disclosed in Japanese Utility Model Publication No. 4-127829. After the diffuser is housed in a pair of half-split outer cylinders integrally formed with each other through a holding member and a foaming seal member (interram mat), flanges are attached to both ends of the outer cylinder.

[0005]

However, in order to manufacture a catalytic converter using a metal carrier as described above,
It has been pointed out that the diffuser has to be separately press-molded and then joined to both ends of the outer cylinder, respectively, so that the number of parts is large and the number of working steps is troublesome.

Further, when manufacturing a catalytic converter using a ceramics carrier, a pair of half-cracked outer cylinders having diffusers formed at both ends must be aligned and joined together. If it is not properly performed according to the shape of the ceramics carrier, there is a possibility that the housed ceramics carrier may rattle. The present invention has been devised in view of such circumstances, and an object of the present invention is to provide a method of manufacturing a catalyst carrier, which is mainly intended to reduce the number of parts and the number of joining steps in manufacturing a catalytic converter.

[0007]

In order to achieve such an object, in the method for producing a catalyst carrier according to claim 1, one end side of a cylindrical outer cylinder is press-molded into a taper shape, and a surplus portion is crushed. After forming the diffuser by processing, the catalyst carrier is inserted into the outer cylinder from the other end side of the outer cylinder.

According to the second aspect of the present invention, a catalyst carrier formed of a metal corrugated plate and a flat plate is inserted into a cylindrical outer cylinder, and the entire outer cylinder is squeezed to make the outer cylinder a catalyst. The method for producing a catalyst carrier according to claim 3, wherein the diffuser is formed by pressing one end side of the outer cylinder into a taper shape after press-contacting the outer periphery of the carrier and crushing the excess thickness portion to form a diffuser. A catalyst carrier formed by processing a cylindrical outer cylinder to form a large diameter portion on one end side and a small diameter portion on the other end side, and forming a metal corrugated plate and a flat plate from the end portion on the large diameter portion side. After press-fitting into the small diameter part,
The diffuser is characterized in that the large-diameter side end is press-formed into a taper shape and the surplus portion is crushed to form a diffuser.

(Operation) According to the invention of claim 1, one end side of the outer cylinder is press-molded into a taper shape, the excess portion is crushed to form a diffuser, and then the other end side of the outer cylinder is pressed. By inserting the catalyst carrier into the outer cylinder, the catalyst carrier is manufactured. Further, according to the invention of claim 2, after inserting the metal catalyst carrier into the outer cylinder, squeezing the entire outer cylinder and pressing the outer cylinder to the outer periphery of the catalyst carrier,
A catalyst carrier integrated with a diffuser is manufactured by press-forming one end side of the outer cylinder into a taper shape and crushing a surplus portion to form a diffuser.

Further, in the invention according to claim 3, the outer cylinder is processed to form a large diameter portion on one end side and a small diameter portion on the other end side, and a metal member is formed from the end portion on the large diameter portion side. The catalyst carrier is manufactured by press-fitting the catalyst carrier into the small diameter portion, press-forming the large diameter portion side end portion into a taper shape, and crushing the excess thickness portion to form a diffuser.

[0011]

Embodiments of the present invention will be described below in detail with reference to the drawings.

1 to 3 show a catalyst carrier manufactured by an embodiment of the method of the present invention according to claim 1, wherein 1 is a catalyst carrier which is housed in an outer cylinder 3 made of metal. so,
The catalyst carrier 1 has a corrugated plate 5 made of metal as shown in FIG.
And the flat plate 7 are overlapped, and these are wound in multiple layers to form a cylindrical shape. The catalyst carrier 1 has a structure in which the corrugated plate 5 and the flat plate 7 are joined to each other by diffusion joining.

As shown in FIGS. 2 and 3, the outer cylinder 3 is
A diffuser 9 is integrally formed by press-forming one end side of a cylindrical pipe material into a taper shape and crushing a surplus portion 3a thereof. Then, the catalyst carrier 1 is brazed to the inner periphery of the tubular portion 3b of the outer cylinder 3 excluding the diffuser 9 portion to form a catalyst carrier 11 composed of the catalyst carrier 1 and the outer cylinder 3.

In FIG. 3, numeral 13 is a cylindrical exhaust gas inlet connected to the diffuser 9, and the exhaust gas inlet 13 is press-formed at the same time as the diffuser 9 is formed. The catalyst carrier 11 in this embodiment is configured in this way, and the catalyst carrier 11 is manufactured as follows by an embodiment of the method of the invention according to claim 1. First, as shown in FIG. 4, the metal corrugated plate 5 and the flat plate 7 are overlapped,
After these are wound in multiple layers, the outer periphery of the corrugated plate 5 and the flat plate 7 are diffusion-bonded to each other and heat-treated in a vacuum furnace to manufacture the catalyst carrier 1.

On the other hand, apart from the production of the catalyst carrier 1, FIG.
The diffuser 9 is formed in the outer cylinder 3 in the steps (a) and (b). That is, first, as shown in FIG. 5 (a), in the metal outer cylinder 3 formed in a cylindrical shape, the diffuser 9, the exhaust gas inlet 13, and the tapered portion 15a and the cylindrical portion 15b, which are similar in shape, are The middle mold 15 formed on the side is inserted.

Thereafter, the outer cylinder 3 is press-molded by a pair of upper and lower molds (not shown). The cavities of the pair of upper and lower molds have the outer shape of the outer cylinder 3 of the catalyst carrier 11 shown in FIG. 3, and the outer cylinder 3 is press-molded with such a mold to crush the surplus portion 3a. By processing,
As shown in (b), the diffuser 9 and the exhaust gas inlet 13 are integrally formed on one end side of the outer cylinder 3.

Then, the middle mold 15 is removed from the outer cylinder 3,
After applying the brazing material to the inner periphery of the cylindrical portion 3b of the outer cylinder 3 excluding the diffuser 9 and the exhaust gas inlet 13, the catalyst carrier 1 is inserted into the outer cylinder 3 as shown in FIG. 5 (c). When heat treatment is performed in a brazing furnace in the leveraged state, the catalyst carrier 1 and the outer cylinder 3 are brazed, and the catalyst carrier 11 shown in FIG. 3 is manufactured.

Since the catalyst carrier 11 in this embodiment is constructed in this way, the catalyst carrier 1 is subjected to a catalyst carrier treatment, and a diffuser similar to the conventional one is welded to the other end of the outer cylinder 3. After that, if this is attached to the vehicle exhaust system via the flange, the exhaust gas will be purified as a catalytic converter. Thus, the catalyst carrier 1 according to the present embodiment
In the manufacturing method of No. 1, when manufacturing the catalyst carrier 11, one end side of the outer cylinder 3 is press-molded and the surplus portion 3a is crushed to integrally form the diffuser 9 on the outer cylinder 3. It is characterized by

Therefore, as described above, conventionally, in the metal carrier, the diffuser is joined to both ends of the outer cylinder containing the catalyst carrier to manufacture the catalytic converter. However, according to this embodiment, It is possible to reduce the number of parts of the diffuser as compared with the conventional one, and as a result, it is possible to reduce the number of parts and the number of joining steps in manufacturing the catalytic converter, and to reduce the cost.

In the above embodiment, a diffuser similar to the conventional one is welded to the other end side of the outer cylinder 3 of the manufactured catalyst carrier 11 to form a catalytic converter. However, instead of such a conventional diffuser, Other outer cylinders may be press-molded in the same process as in FIGS. 5A and 5B to form a diffuser on one end side thereof, and this may be welded to the outer cylinder 3. Thus, according to the present embodiment as well, similar to the above-described embodiments, the intended purpose can be achieved.

Further, the catalyst carrier 11 of the above-mentioned embodiment is one in which the metal catalyst carrier 1 is inserted into the outer cylinder 3,
By replacing the metal catalyst carrier 1 with the ceramic carrier by inserting a holding member and a foaming seal member into the outer cylinder 3 in which the diffuser 9 is press-molded as shown in FIG. 5B. It is also possible to produce a catalyst carrier.

Thus, according to this embodiment of the manufacturing method, it is not necessary to accurately join the pair of half-cracked outer cylinders having the diffusers formed at both ends with each other as in the conventional case. Work is easier than before. Further, in this embodiment, the corrugated plate 5 and the flat plate 7 of the catalyst carrier 1 are diffusion-bonded, and the diffuser 9 is press-molded on one end side of the outer cylinder 3, and then the catalyst carrier 1 is fixed to the outer cylinder 3. Tubular part 3
Although it was brazed to the inner circumference of b, as shown in FIG.
And a flat plate 7 are wound in multiple layers to form a cylindrical catalyst carrier 1, and a diffuser 9 is press-molded on one end side of the outer cylinder 3, and then the catalyst carrier 1 is cylindrically formed on the outer cylinder 3. 3b may be inserted and these may be diffusion-bonded in a vacuum furnace.

FIG. 6 relates to an embodiment of the method of the invention according to claim 2, and this embodiment will be described in detail below with reference to the drawings. First, as in the above embodiment, the metallic corrugated plate 5 and the flat plate 7 are overlapped as shown in FIG. 4, and these are wound in multiple layers to form the cylindrical catalyst carrier 1, and then shown in FIG. As described above, the catalyst carrier 1 is inserted into one end side of the outer cylinder 17 made of metal and formed into a cylindrical shape.

The outer cylinder 17 has an inner diameter slightly larger than that of the catalyst carrier 1 and is located between the inserted catalyst carrier 1 and the inner circumference of the outer cylinder 17 as shown in FIG. 6B. A slight gap is formed in the. Then, after inserting the catalyst carrier 1 into the outer cylinder 17 in this way, the entire outer cylinder 17 is squeezed with a die or the like, and is brought into pressure contact with the outer periphery of the catalyst carrier 1 as shown in FIG. 6C. .

Thus, by pressing the outer cylinder 17 as a whole and bringing it into pressure contact with the catalyst carrier 1, the entire outer cylinder 17 is reduced in diameter and the corrugated plate 5 and the flat plate 7 of the catalyst carrier 1 come into contact with each other. The pressure will increase. Then, in this state, the catalyst carrier 1 and the outer cylinder 17 are heat-treated in a vacuum furnace, so that the corrugated plate 5 and the flat plate 7 of the catalyst carrier 11 and the catalyst carrier 11 and the outer cylinder 17 are diffusion-bonded.

Thereafter, the outer cylinder 17 is press-molded by the above-mentioned pair of upper and lower molds, and the surplus portion 17a is crushed as shown in FIG. 6 (d). The catalyst carrier 23 in which the diffuser 19 and the exhaust gas inlet 21 are integrally molded is manufactured. The catalyst carrier 23 in the present embodiment is manufactured in this way, and after the catalyst carrier 1 is subjected to the catalyst carrier treatment and the diffuser similar to the conventional one is welded to the other end side of the outer cylinder 17, the catalyst carrier 23 is inserted through the flange. If it is installed in the vehicle exhaust system, the exhaust gas will be purified as a catalytic converter.

Thus, the catalyst carrier 23 according to this embodiment
In manufacturing the catalyst carrier 23 as well, the diffuser 19 is integrally molded with the outer cylinder 17 by press-molding one end of the outer cylinder 17 and crushing the surplus portion 17a. Is characterized by. Therefore,
Also according to this embodiment, it is possible to reduce the number of parts of the diffuser as compared with the related art, and as a result, it is possible to reduce the number of parts and the number of joining steps in manufacturing the catalytic converter, and to reduce the cost.

Even in the present embodiment, instead of the conventional diffuser, another outer cylinder is press-molded by a pair of molds to mold the diffuser on one end side of the outer cylinder, and the diffuser is molded as described above. Of course, it may be welded to the outer cylinder 17. FIG. 7 shows an embodiment of the method according to claim 3, and in this embodiment as well, first, as shown in FIG. Is subjected to clamping pressure with a pressure jig and heat-treated in a vacuum furnace to manufacture the catalyst carrier 1 in which the corrugated plate 5 and the flat plate 7 are diffusion-bonded.

Separately from the production of the catalyst carrier 1, FIG.
As shown in FIG. 7 (a), one end side of a cylindrical metal outer cylinder 25 is drawn with a die or the like to form a small diameter portion (drawing portion) 27 at that portion as shown in FIG. 7 (b). To do. Then, after the brazing material is applied to the inner circumference of the small diameter portion 27, as shown in FIG.
As shown in FIG. 7C, when the catalyst carrier 1 is pressed into the small diameter portion 27 from the end of the outer cylinder 25 on the large diameter portion 29 side and heat-treated in a brazing furnace, as shown in FIG. 7D. The catalyst carrier 1 is brazed to the inner circumference of the small diameter portion 27 of the outer cylinder 25.

Thereafter, the outer cylinder 25 is press-molded by the above-mentioned pair of upper and lower molds, and the excess thickness portion 25a is crushed as shown in FIG. 7 (e). Thus, the catalyst carrier 35 in which the diffuser 31 and the exhaust gas inlet 33 are integrally formed at the end portion on the 29 side is manufactured.
The catalyst carrier 35 in the present embodiment is manufactured in this way, and after the catalyst carrier 1 is subjected to the catalyst carrier treatment and the diffuser is welded to the other end of the outer cylinder 35, the catalyst carrier 35 is exhausted through the flange. If it is installed in the system, it will purify the exhaust gas as a catalytic converter.

Thus, the catalyst carrier 35 according to the present embodiment
In manufacturing the catalyst carrier 35, the diffuser 31 is integrally formed with the outer cylinder 25 by press-molding one end side of the outer cylinder 25 and crushing the surplus portion 25a. Is characterized by. Therefore, according to the present embodiment as well, it is possible to reduce the number of parts of the diffuser as compared with the related art, and as a result, it is possible to reduce the number of parts and the number of joining steps in manufacturing the catalytic converter, and to reduce the cost. It was

In this embodiment, the corrugated plate 5 of the catalyst carrier 1 is used.
And the flat plate 7 are diffusion-bonded, and then the catalyst carrier 1 is attached to the outer cylinder 2
5 was brazed to the inner circumference of the small diameter portion 27, the metal corrugated plate 5 and the flat plate 7 were overlapped as shown in FIG. 4, and these were multiply wound to form a cylindrical catalyst carrier 1. Support 1
It is also possible to press fit the small diameter portion 27 from the end portion on the large diameter portion 29 side and diffuse and bond them to each other in a vacuum furnace, and then press-mold the diffuser 31 on the end portion on the large diameter portion 29 side of the outer cylinder 25.

In the present embodiment, one end of the outer cylinder 25 is drawn by a die or the like to form the small diameter portion 27 and the large diameter portion 29 on the outer cylinder 25. The small diameter portion 27 and the large diameter portion 29 may be formed on the outer cylinder 25 by expanding with a molding die, and the intended purpose can be achieved by the manufacturing method like the above embodiment. Is. Further, although the outer cylinders 3, 17 and 25 of each of the above-mentioned embodiments are all tubular members having a circular cross section, it is also possible to use a tubular member having an elliptical cross section for the outer barrel.

[0034]

As described above, according to the method for manufacturing a catalyst carrier according to each claim, it becomes possible to reduce the number of parts of the diffuser as compared with the conventional method, and as a result, in manufacturing the catalytic converter. The number of parts and the number of joining steps can be reduced, and the cost can be reduced.

Further, according to the method of the present invention as set forth in claim 1, when a ceramic carrier is used as the catalyst carrier, a pair of half-cracked outer cylinders having diffusers formed at both ends as in the prior art are placed in the middle. Since it is not necessary to join these with high precision, the work becomes easier than in the past.

[Brief description of the drawings]

FIG. 1 is a side view of a catalyst carrier manufactured by an embodiment of a manufacturing method according to claim 1.

FIG. 2 is a sectional view taken along line II-II of FIG.

FIG. 3 is a perspective view of the catalyst carrier shown in FIG.

FIG. 4 is an explanatory diagram showing steps of a method for producing a catalyst carrier.

FIG. 5 is an explanatory diagram showing steps of an embodiment of the method for producing a catalyst carrier according to claim 1.

FIG. 6 is an explanatory diagram showing a step of an embodiment of a method for producing a catalyst carrier according to claim 2.

FIG. 7 is an explanatory diagram showing a step of an embodiment of a method for producing a catalyst carrier according to claim 3.

[Explanation of symbols]

 1 Catalyst Carrier 3,17,25 Outer Cylinder 9,19,31 Diffuser 11,23,35 Catalyst Carrier 27 Small Diameter Part 29 Large Diameter Part

Claims (3)

[Claims] 1. A cylindrical outer cylinder (3) is press-formed at one end thereof into a taper shape, and a surplus portion (3a) is crushed to form a diffuser (9), and then the outer cylinder (3) is formed. A method for producing a catalyst carrier, characterized in that the catalyst carrier (1) is inserted into the outer cylinder (3) from the other end side. 2. A catalyst carrier (1) formed of a metal corrugated plate (5) and a flat plate (7) is inserted into a cylindrical outer cylinder (17), and the entire outer cylinder (17) is inserted. After squeezing the outer cylinder (17) into pressure contact with the outer periphery of the catalyst carrier (1), one end of the outer cylinder (17) is press-molded into a taper shape to form a surplus portion (17a).
A process for producing a catalyst carrier, which comprises crushing to form a diffuser (19). 3. A cylindrical outer cylinder (25) is processed to form a large diameter portion (29) on one end side and a small diameter portion (27) on the other end side, and the large diameter portion (29) side end. Corrugated sheet made of metal (5)
After press-fitting the catalyst carrier (1) formed by the flat plate (7) into the small diameter portion (27), the large diameter portion (29) side end portion is press-formed into a taper shape, and the surplus portion (25a) is formed. A method for producing a catalyst carrier, comprising crushing to form a diffuser (31).