JPH09173861A - Electrothermal catalytic device - Google Patents
Electrothermal catalytic deviceInfo
- Publication number
- JPH09173861A JPH09173861A JP8260726A JP26072696A JPH09173861A JP H09173861 A JPH09173861 A JP H09173861A JP 8260726 A JP8260726 A JP 8260726A JP 26072696 A JP26072696 A JP 26072696A JP H09173861 A JPH09173861 A JP H09173861A
- Authority
- JP
- Japan
- Prior art keywords
- foil
- corrugated
- metal foil
- foils
- brazing material
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 230000003197 catalytic effect Effects 0.000 title abstract description 6
- 239000011888 foil Substances 0.000 claims abstract description 391
- 229910052751 metal Inorganic materials 0.000 claims abstract description 114
- 239000002184 metal Substances 0.000 claims abstract description 114
- 238000005219 brazing Methods 0.000 claims abstract description 101
- 239000003054 catalyst Substances 0.000 claims abstract description 60
- 238000010030 laminating Methods 0.000 claims abstract description 19
- 239000000463 material Substances 0.000 claims description 86
- 230000001603 reducing effect Effects 0.000 claims description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 12
- 229910052726 zirconium Inorganic materials 0.000 description 12
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 11
- 238000010586 diagram Methods 0.000 description 9
- 230000004913 activation Effects 0.000 description 7
- 238000010438 heat treatment Methods 0.000 description 7
- 239000007789 gas Substances 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- 229910052759 nickel Inorganic materials 0.000 description 5
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 4
- 239000002131 composite material Substances 0.000 description 4
- 230000005611 electricity Effects 0.000 description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 3
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 238000006555 catalytic reaction Methods 0.000 description 3
- 238000005485 electric heating Methods 0.000 description 3
- 238000007254 oxidation reaction Methods 0.000 description 3
- 230000002093 peripheral effect Effects 0.000 description 3
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 3
- 238000000746 purification Methods 0.000 description 3
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000000977 initiatory effect Effects 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 229910044991 metal oxide Inorganic materials 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 239000010948 rhodium Substances 0.000 description 2
- 230000008646 thermal stress Effects 0.000 description 2
- 229910001928 zirconium oxide Inorganic materials 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 230000000644 propagated effect Effects 0.000 description 1
- 229910052703 rhodium Inorganic materials 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Landscapes
- Exhaust Gas After Treatment (AREA)
- Exhaust Gas Treatment By Means Of Catalyst (AREA)
- Catalysts (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、金属箔を積層して
構成した触媒担体を有する電気加熱式触媒装置に関す
る。TECHNICAL FIELD The present invention relates to an electrically heated catalyst device having a catalyst carrier formed by laminating metal foils.
【０００２】[0002]
【従来の技術】内燃機関の排気通路に排気浄化触媒を設
け、排気中のＨＣ、ＣＯ、ＮＯX 等の有害成分を浄化す
る技術が知られている。しかし、排気浄化触媒は活性化
温度より低い温度では排気浄化能力が著しく低下するた
め、機関始動時等、触媒温度が低い間は機関から排出さ
れた上記有害成分、特にＨＣ、ＣＯ成分が触媒により浄
化されずそのまま大気に放出される問題が生じる。2. Description of the Related Art There is known a technique in which an exhaust gas purifying catalyst is provided in an exhaust passage of an internal combustion engine to purify harmful components such as HC, CO and NO x in the exhaust gas. However, the exhaust purification catalyst has a significantly reduced exhaust purification capability at a temperature lower than the activation temperature. Therefore, when the engine temperature is low such as when the engine is started, the above-mentioned harmful components, particularly HC and CO components, discharged from the engine, are absorbed by the catalyst. There is a problem that it is not purified but is released to the atmosphere as it is.
【０００３】この問題を解決するために、本願出願人は
既に、触媒担体に金属を使用し、機関始動時に担体に局
所的に電流を流すことにより担体を局所的に発熱させて
短時間で触媒温度を活性化温度まで上昇させるようにし
た電気加熱式触媒装置を提案している（特願平７−１３
２０８８号）。図１３は、上記電気加熱式触媒装置の触
媒担体の一部拡大断面図である。In order to solve this problem, the applicant of the present application has already used a metal for the catalyst carrier, and locally causes an electric current to flow through the carrier at the time of engine start, thereby locally generating heat in the carrier, so that the catalyst can be heated in a short time. An electric heating type catalyst device is proposed in which the temperature is raised to the activation temperature (Japanese Patent Application No. 7-13).
No. 2088). FIG. 13 is a partially enlarged cross-sectional view of the catalyst carrier of the electrically heated catalyst device.
【０００４】図１３に示すように、この触媒担体は平板
状金属箔（平箔）１０と波板状金属箔（波箔）２０とを
交互に積層した金属箔積層体として形成され、金属箔積
層体の積層方向両端部に通電用電極（図示せず）を接続
した構成とされている。また、平箔１０または波箔２０
の表面には絶縁被膜が形成されており、平箔１０と波箔
２０とは上記絶縁被膜の絶縁を破壊して金属箔相互を導
通可能に接合できるロウ材箔１３４１ににより局所的に
接合される。As shown in FIG. 13, this catalyst carrier is formed as a metal foil laminate in which flat metal foils (flat foils) 10 and corrugated metal foils (corrugated foils) 20 are alternately laminated. The structure is such that energizing electrodes (not shown) are connected to both ends of the stack in the stacking direction. In addition, flat foil 10 or corrugated foil 20
An insulating coating is formed on the surface of the metal foil, and the flat foil 10 and the corrugated foil 20 are locally bonded to each other by a brazing material foil 1341 capable of destroying the insulation of the insulating coating and bonding the metal foils to each other so as to be able to conduct each other. It
【０００５】更に、図１３に示すように、波箔２０を挟
んで隣接する２つのロウ材箔（例えば図１３、１３４１
ａと１３４１ｂ、及び１３４１ｃと１３４１ｄ）は金属
箔積層方向から見てその一部のみが重なるように互いに
金属箔に沿ってずらして配置されている。このように、
波箔２０の両側のロウ材箔を一部のみが重なるように配
置することにより、電極間に通電すると電流はロウ材箔
の重なり部分近傍（図１３に斜線で示した部分）の波箔
２０を通って層間を流れることになり、重なり部分近傍
の波箔２０に電流が集中して流れ、この部分の波箔が局
所的に発熱することになる。このように、比較的小さな
局所的発熱部（図１３斜線部分）に電流を集中して流す
ことにより、通電電流を全体として低く抑え、バッテリ
の負担を軽減しながら短時間で局所的発熱部を触媒活性
化温度まで昇温させることが可能となる。局所的発熱部
の温度が触媒活性化温度に到達すると、この部分に担持
された触媒では触媒により排気ガス中のＨＣ、ＣＯ成分
の酸化反応が開始される。また、この反応により発生し
た熱は発熱部周囲に伝播され、発熱部を中心として高温
領域が広がるため、発熱部周囲の触媒も活性化温度に到
達して触媒によるＨＣ、ＣＯ成分の酸化反応が開始され
て反応熱が発生する。このため、上記発熱部は、いわば
触媒反応を開始させる火種として機能することになり、
発熱部に通電後短時間で触媒担体全体が触媒活性化温度
に到達し、担体全体で触媒による酸化反応が開始される
ようになる。Further, as shown in FIG. 13, two brazing material foils adjacent to each other with the corrugated foil 20 interposed therebetween (for example, FIG. 13, 1341).
a and 1341b, and 1341c and 1341d) are displaced from each other along the metal foil so that only a part thereof overlaps when viewed from the metal foil stacking direction. in this way,
By arranging the brazing material foils on both sides of the corrugated foil 20 so that only a part thereof overlaps with each other, when a current is applied between the electrodes, a current flows in the vicinity of the overlapping portion of the brazing material foils (the hatched portion in FIG. 13). Therefore, the electric current concentrates on the corrugated foil 20 in the vicinity of the overlapping portion, and the corrugated foil in this portion locally generates heat. In this way, by concentrating the current in the relatively small local heat generating portion (hatched portion in FIG. 13), the energizing current is suppressed as a whole, and the load on the battery is reduced, and the local heat generating portion can be operated in a short time. It is possible to raise the temperature to the catalyst activation temperature. When the temperature of the local heat generating portion reaches the catalyst activation temperature, the catalyst loaded on this portion starts the oxidation reaction of HC and CO components in the exhaust gas by the catalyst. In addition, the heat generated by this reaction is propagated to the periphery of the heat generating portion, and the high temperature region spreads around the heat generating portion. Therefore, the catalyst around the heat generating portion also reaches the activation temperature and the oxidation reaction of the HC and CO components by the catalyst occurs. When it is started, heat of reaction is generated. Therefore, the heat generating portion functions as a kind of spark for initiating the catalytic reaction, so to speak.
The entire catalyst carrier reaches the catalyst activation temperature in a short time after energizing the heat generating part, and the oxidation reaction by the catalyst is started in the entire carrier.
【０００６】[0006]
【発明が解決しようとする課題】上記特願平７−１３２
０８８号で本出願人が提案した電気加熱式触媒装置で
は、波箔の両側のロウ材箔を互いにその一部のみ重なる
ように配置して波箔と平箔とを接合することにより、ロ
ウ材箔の重なり部分に局所的発熱部を形成している。と
ころが、このように重なり部分を設けて局所的発熱部を
形成した場合には必ずしも局所的発熱部の電流路断面積
を充分に小さくすることができない場合が生じる。以
下、図１４を用いてこの問題を説明する。[Patent Document 1] Japanese Patent Application No. 7-132
In the electrically heated catalyst device proposed by the applicant of the present invention in No. 088, the brazing material foil is arranged by joining the brazing material foils on both sides of the corrugated foil so that only a part thereof overlaps with each other and joining the corrugated foil and the flat foil. A local heat generating part is formed in the overlapping part of the foil. However, in the case where the local heating portion is formed by providing the overlapping portion in this way, there are cases where the current path cross-sectional area of the local heating portion cannot always be made sufficiently small. Hereinafter, this problem will be described with reference to FIG.
【０００７】図１４は、図１３の局所的発熱部（図１３
斜線部分）を更に拡大して示した図である。図１４にお
いて、波箔２０の両側のロウ材箔１３４１ｃと１３４１
ｄとにより重なり部分（図１４にＯＬで示す部分）が形
成されている。通電時、電流はこの重なり部分ＯＬに含
まれる波箔を通って中心電極側の平箔１０ａから外周側
の平箔１０ｂに向けて流れることになる。すなわち、重
なり部分に含まれる波箔により局所的発熱部が形成され
ることになる。ところが、図１４の場合には、重なり部
分ＯＬ内でロウ材箔１３４１ｄは波箔２０の一方の側の
１つの波頂部２０Ａと接合され、ロウ材箔１３４１ｃは
波箔２０の他方の側の２つの波頂部２０ａ、２０ｂと接
合されている。この場合には、通電時に電流は、波箔２
０を通って、ロウ材箔１３４１ｃの側の２つの波頂部２
０ａ、２０ｂからロウ材箔１３４１ｄの側の波頂部２０
Ａに向かう２つの経路ＲA 、ＲB と、ロウ材箔１３４１
ｃの側の波頂部２０ｂからロウ材箔１３４１ｄの側の２
０Ａの隣の波頂部２０Ｂに向かう経路ＲC との計３つの
並列電流路を通って流れることになる。この並列電流路
の数はロウ材箔の重なり部ＯＬ内に含まれる波箔の両側
の波頂部の数が多くなる程増大する。FIG. 14 shows the local heat generating portion (FIG. 13) of FIG.
It is the figure which expanded and showed the (shaded part). In FIG. 14, brazing material foils 1341c and 1341 on both sides of the corrugated foil 20 are shown.
An overlapping portion (a portion indicated by OL in FIG. 14) is formed by d. When energized, a current flows from the flat foil 10a on the center electrode side to the flat foil 10b on the outer peripheral side through the corrugated foil included in the overlapping portion OL. That is, the corrugated foil included in the overlapping portion forms the local heat generating portion. However, in the case of FIG. 14, the brazing material foil 1341d is joined to one corrugated portion 20A on one side of the corrugated foil 20, and the brazing material foil 1341c is disposed on the other side of the corrugated foil 20 in the overlapping portion OL. It is joined to the two wave crests 20a and 20b. In this case, the current when energized is the corrugated foil 2.
0 through two wave crests 2 on the side of the brazing foil 1341c.
0a, 20b to the wave crest 20 on the side of the brazing material foil 1341d
Two paths R A towards A, and R B, the brazing material foil 1341
2 from the wave crest 20b on the c side to the brazing material foil 1341d side
It will flow through a total of three parallel current paths with the path R C toward the wave crest 20B next to 0A. The number of the parallel current paths increases as the number of wave crests on both sides of the corrugated foil included in the overlapping portion OL of the brazing material foil increases.
【０００８】電流路ＲA 、ＲB 、ＲC の抵抗値は同一で
あるため、形成される電流路の数が多くなるほどロウ材
箔の重なり部分を流れる電流は分散されてしまい、発熱
部をを流れる電流の密度は小さくなることになる。この
ため、各電流路ＲA 、ＲB 、ＲC の発熱量は相対的に小
さくなり、発熱部の昇温速度を充分に早く設定できない
場合が生じてしまう。Since the current paths R A , R B , and R C have the same resistance value, the larger the number of current paths formed, the more the current flowing through the overlapping portion of the brazing material foil is dispersed, and the heat generating portions are separated. The density of the electric current flowing through will decrease. For this reason, the amount of heat generated in each of the current paths R A , R B , and R C becomes relatively small, and the temperature rising rate of the heat generating portion may not be set sufficiently fast in some cases.
【０００９】また、図１４の場合、局所的発熱部ＯＬ内
に複数の並列電流路が形成されるため、局所的発熱部の
電気抵抗が小さくなり、全体として通電時の電流値が増
大してしまう。このため、上記電気加熱式触媒装置では
全体として通電時の電流値を充分に低減することができ
ず、バッテリの負荷低減効果を充分に得ることができな
い問題が生じるのである。Further, in the case of FIG. 14, since a plurality of parallel current paths are formed in the local heat generating portion OL, the electric resistance of the local heat generating portion becomes small, and the current value during energization increases as a whole. I will end up. Therefore, the electric heating type catalyst device as a whole cannot sufficiently reduce the current value at the time of energization, which causes a problem that the load reduction effect of the battery cannot be sufficiently obtained.
【００１０】さらに、前述のように局所的発熱部は触媒
反応を開始させる火種としての役割を果たすため、触媒
担体全体として触媒作用を早期に開始させるためには、
担体内に局所的発熱部をできるだけ多く設けることが好
ましい。ところが、図１４のように個々の局所的発熱部
の抵抗を充分に大きくできない場合には、担体内に局所
的発熱部を多数設けると、担体全体としての抵抗値が大
幅に低下してしまい、電気加熱式触媒装置通電時に大電
流が流れてしまうようになる。このため、触媒担体内に
局所的発熱部の数を多くとることができない問題が生じ
る。Further, as described above, the local heat generating portion plays a role of a spark for initiating the catalytic reaction. Therefore, in order to early initiate the catalytic action of the catalyst carrier as a whole,
It is preferable to provide as many local heating portions as possible in the carrier. However, if the resistance of each local heat generating portion cannot be made sufficiently large as shown in FIG. 14, if a large number of local heat generating portions are provided in the carrier, the resistance value of the carrier as a whole is significantly reduced, A large current will flow when the electrically heated catalyst device is energized. Therefore, there arises a problem that the number of local heat generating parts cannot be increased in the catalyst carrier.
【００１１】本発明は上記問題に鑑み、局所的発熱部内
に形成される電流路の数を最小にして発熱部の昇温速度
を増大することを可能にするとともに、担体内に形成す
る局所的発熱部の数を増大させることが可能な電気加熱
式触媒装置を提供することを目的としている。In view of the above problems, the present invention makes it possible to minimize the number of current paths formed in the local heat generating portion to increase the rate of temperature rise of the heat generating portion, and to form the local heat generating portion in the carrier. An object of the present invention is to provide an electrically heated catalyst device capable of increasing the number of heat generating parts.
【００１２】[0012]
【課題を解決するための手段】請求項１に記載の発明に
よれば、波板状金属箔と平板状金属箔とを第１の金属の
酸化物からなる絶縁層を介して交互に積層して金属箔積
層体を形成し、前記第１の金属より還元作用の大きい第
２の金属を含むロウ材箔を金属箔の層間に局所的に配置
し、該ロウ材箔により波板状金属箔と平板状金属箔とを
前記絶縁層を介して導通可能に接合した触媒担体を有す
る電気加熱式触媒装置において、各波板状金属箔を挟ん
で互いに隣接する位置に配置された２つのロウ材箔は、
該２つのロウ材箔間に挟まれる波板状金属箔中に、該２
つのロウ材箔を結ぶ単一の電流路を形成するように配置
されたことを特徴とする電気加熱式触媒装置が提供され
る。すなわち、請求項１の発明では波板状金属箔の両側
に配置されたロウ材箔は、波板状金属箔中に、単一の電
流路を形成するように配置されている。このため、局所
的発熱部では波板状金属箔中に電流路が複数形成される
ことがなく、常に局所的発熱部の抵抗を大きく維持する
ことが可能となる。請求項２に記載の発明によれば、前
記波板状金属箔を挟んで互いに隣接する２つのロウ材箔
の一方は前記波板状金属箔の一方の側の少なくとも１つ
以上の波頂部を平板状金属箔に接合し、前記２つのロウ
材箔の他方は前記波板状ロウ材箔の他方の側の少なくと
も１つ以上の波頂部を平板状金属箔に接続し、前記一方
の金属箔により平板状金属箔に接合される波頂部のグル
ープと前記他方のロウ材箔により平板状金属箔に接合さ
れる波頂部のグループとは、金属箔積層方向から見て、
重なることなく互いに連続している請求項１に記載の電
気加熱式触媒装置が提供される。すなわち、請求項２の
発明では波板状金属箔の両側に配置された２つのロウ材
箔は、波板状金属箔のそれぞれの側の１つ以上の波頂部
を平板状金属箔に接合する。また、波板状金属箔の一方
の側のロウ材箔により接合される波頂部のグループと他
方の側のロウ材箔により接合される波頂部のグループと
は、金属箔積層方向から見て重なることなく互いに連続
しているため、両方の波頂部のグループ間では、各グル
ープの端部に位置する波頂部の間の波板状金属箔部分を
通じてのみ電流が流れるようになる。このため、波板状
金属箔中には両側の平板状金属箔との接合部間に必ず単
一の電流路が形成されるようになる。この場合、両側の
ロウ材箔により平板状金属箔に接続される波頂部グルー
プが上記の構成になっていれば、両側のロウ材箔自体は
金属箔積層方向から見て互いに重なり部分を有していて
も良く、重なり部分を有さなくても良い。According to the present invention, the corrugated metal foil and the flat metal foil are alternately laminated with the insulating layer made of the oxide of the first metal interposed therebetween. To form a metal foil laminate, and locally dispose a brazing material foil containing a second metal having a reduction action larger than that of the first metal between the layers of the metal foil, and the corrugated metal foil is formed by the brazing material foil. In an electrically heated catalyst device having a catalyst carrier in which a flat metal foil and a flat metal foil are conductively joined via the insulating layer, two brazing materials arranged adjacent to each other with each corrugated metal foil sandwiched therebetween. Foil
In the corrugated metal foil sandwiched between the two brazing foils, the
An electrically heated catalytic device is provided which is arranged to form a single current path connecting two brazing foils. That is, in the invention of claim 1, the brazing material foils arranged on both sides of the corrugated metal foil are arranged so as to form a single current path in the corrugated metal foil. For this reason, a plurality of current paths are not formed in the corrugated metal foil in the local heat generating portion, and it is possible to always maintain a large resistance of the local heat generating portion. According to the invention of claim 2, one of the two brazing material foils adjacent to each other with the corrugated plate-shaped metal foil sandwiched therebetween has at least one or more wave crests on one side of the corrugated plate-shaped metal foil. The other of the two brazing material foils is joined to a flat metal foil, and at least one or more wave crests on the other side of the corrugated brazing foil are connected to the flat metal foil, and the one metal foil is joined. With the group of wave crests joined to the flat metal foil and the group of wave crests joined to the flat metal foil by the other brazing material foil, viewed from the metal foil laminating direction,
An electrically heated catalytic device according to claim 1 is provided which is continuous with each other without overlapping. That is, in the invention of claim 2, the two brazing material foils arranged on both sides of the corrugated metal foil join one or more wave crests on each side of the corrugated metal foil to the flat metal foil. . In addition, the group of corrugations joined by the brazing foil on one side of the corrugated metal foil and the group of corrugations joined by the brazing foil on the other side overlap when viewed from the metal foil laminating direction. Since they are not continuous with each other, current flows between the groups of both crests only through the corrugated metal foil portion between the crests located at the ends of each group. Therefore, in the corrugated metal foil, a single current path is always formed between the joints with the flat metal foils on both sides. In this case, if the wave crest groups connected to the flat metal foil by the brazing material foils on both sides have the above-mentioned configuration, the brazing material foils on both sides have overlapping portions when viewed from the metal foil laminating direction. It does not have to have an overlapping part.
【００１３】[0013]
【発明の実施の形態】以下、添付図面を用いて本発明の
実施形態について説明する。以下に説明する各実施形態
は全て、金属製の平箔と波箔とを重ねて中心電極回りに
巻回して円筒状の金属箔積層体からなる触媒担体を形成
し、その外周部にもう一方の電極を接続した形式の電気
加熱式触媒装置に本発明を適用した場合を例にとって説
明している。そこで、それぞれの実施形態の説明に入る
前に、図１から図３を用いて先ず、これらの実施形態に
共通する円筒状積層体構造の電気加熱式触媒装置につい
て説明する。なお、以下に説明する全実施形態におい
て、共通する構成要素には同一の参照符号を付して説明
する。Embodiments of the present invention will be described below with reference to the accompanying drawings. In each of the embodiments described below, a metal flat foil and a corrugated foil are overlapped and wound around a center electrode to form a catalyst carrier made of a cylindrical metal foil laminate, and the other end is formed on the outer periphery thereof. The case where the present invention is applied to an electrically heated catalyst device of the type in which the electrodes are connected will be described as an example. Therefore, before entering the description of each embodiment, first, an electrically heated catalyst device having a cylindrical laminated body structure common to these embodiments will be described with reference to FIGS. 1 to 3. In all the embodiments described below, common constituent elements will be described with the same reference numerals.
【００１４】図１は円筒状金属箔積層体構造の電気加熱
式触媒装置の軸線に沿った断面図を示す、図１において
１は電気加熱式触媒装置の全体、２は後述する円筒状金
属箔積層体からなる触媒担体、１０、２０はそれぞれ円
筒状金属箔積層体２を構成する帯状の平箔と波箔とを示
している。また、３は円筒状金属箔積層体の中心に設け
られ、平箔と波箔とに通電可能に接続された棒状の中心
電極（プラス極）、５は金属箔積層体２を収容する円筒
状のケーシングであり、ケーシング５は積層体２の外周
と通電可能に接続され、外部電極（マイナス極）として
の機能を果たしている。従って、中心電極３とケーシン
グ（外部電極）５との間に電圧を印加することにより円
筒状金属箔積層体の平箔１０と波箔２０とに通電するこ
とが可能となっている。FIG. 1 is a sectional view taken along the axis of an electrically heated catalyst device having a cylindrical metal foil laminate structure. In FIG. 1, 1 is the whole electrically heated catalyst device, and 2 is a cylindrical metal foil described later. The catalyst carriers 10 and 20 each composed of a laminated body are a strip-shaped flat foil and a corrugated foil which constitute the cylindrical metal foil laminated body 2. Further, 3 is a rod-shaped center electrode (plus electrode) which is provided at the center of the cylindrical metal foil laminated body and electrically connected to the flat foil and the corrugated foil, and 5 is a cylindrical shape for accommodating the metal foil laminated body 2. The casing 5 is connected to the outer periphery of the laminate 2 so as to be able to conduct electricity, and functions as an external electrode (minus electrode). Therefore, it is possible to energize the flat foil 10 and the corrugated foil 20 of the cylindrical metal foil laminate by applying a voltage between the center electrode 3 and the casing (external electrode) 5.
【００１５】図２、図３は、図１の円筒状金属箔積層体
２の構造を説明する図である。図２に示すように、円筒
状金属箔積層体２は平箔１０と波箔２０とを重ねてそれ
ぞれの長手方向端部を中心電極３に接合した後、平箔１
０と波箔２０とを重ねた状態のまま中心電極３の周りに
巻回した構成とされる。図３は上記により構成された円
筒状金属箔積層体２の、図１のIII-III 線に沿った断面
を示す。上記のように平箔１０と波箔２０とを重ねて中
心電極周りに巻回した結果、円筒状積層体２は、図３に
示すように平箔１０と波箔２０との間の空隙により形成
された軸線方向の通路６が中心電極３の周りに渦巻き状
に配列した構成となっている。また、後述のように、平
箔１０と波箔２０との表面には排気浄化触媒が担持され
ており、触媒装置１のケーシング５を内燃機関の排気系
に接続して排気を上記軸線方向通路６を通して流すこと
により、排気中の有害成分が触媒によって浄化される。2 and 3 are views for explaining the structure of the cylindrical metal foil laminate 2 of FIG. As shown in FIG. 2, the cylindrical metal foil laminate 2 is obtained by stacking the flat foil 10 and the corrugated foil 20 and bonding the longitudinal end portions of the flat foil 10 and the corrugated foil 20 to the center electrode 3 and then forming the flat foil 1.
0 and the corrugated foil 20 are wound around the center electrode 3 in a stacked state. FIG. 3 shows a cross section of the cylindrical metal foil laminate 2 constructed as described above, taken along line III-III in FIG. As a result of stacking the flat foil 10 and the corrugated foil 20 and winding them around the center electrode as described above, the cylindrical laminated body 2 has a gap between the flat foil 10 and the corrugated foil 20 as shown in FIG. The formed axial passages 6 are arranged spirally around the center electrode 3. Further, as will be described later, an exhaust purification catalyst is carried on the surfaces of the flat foil 10 and the corrugated foil 20, and the casing 5 of the catalyst device 1 is connected to the exhaust system of the internal combustion engine to exhaust the exhaust gas in the axial passage. By flowing through 6, the harmful components in the exhaust gas are purified by the catalyst.
【００１６】平箔１０、波箔２０は、本実施形態ではと
もにアルミニウムを含有する鉄系合金等（例えば、２０
％Ｃｒ−５％Ａｌ−７５％Ｆｅ）の金属の、厚さ５０ミ
クロン程度の箔材から構成される。また、以下に説明す
る実施形態では、これら平箔１０、波箔２０のいずれか
一方、又は両方の表面には必要に応じて予め、例えばア
ルミナ（Ａｌ2 Ｏ3 ）等の金属酸化物からなる厚さ１ミ
クロン程度の電気的絶縁層が形成されている。このアル
ミナ層は、例えば酸素雰囲気下で上記金属箔を加熱して
金属箔表面に母材中のアルミニウムの酸化被膜を形成す
ることにより容易に得ることができる。また、金属箔上
に触媒を担持させるため、上記絶縁層を形成した箔（以
下「絶縁箔」という）ではアルミナ絶縁層上に、絶縁層
を形成していない金属箔（以下「生箔」という）では金
属箔の母材上に、それぞれ触媒担持用の厚さ３０ミクロ
ン程度のウォッシュコート層を形成し、このウォッシュ
コート層に含浸等により白金Ｐｔ、ロジウムＲｈ、パラ
ジウムＰｄ等の触媒成分を担持させている。In this embodiment, the flat foil 10 and the corrugated foil 20 are both iron-based alloys containing aluminum (for example, 20
% Cr-5% Al-75% Fe) metal foil material with a thickness of about 50 microns. In the embodiments described below, one or both surfaces of the flat foil 10 and the corrugated foil 20 are made of a metal oxide such as alumina (Al 2 O 3 ) in advance, if necessary. An electrically insulating layer having a thickness of about 1 micron is formed. This alumina layer can be easily obtained, for example, by heating the metal foil in an oxygen atmosphere to form an oxide film of aluminum in the base material on the surface of the metal foil. Further, in order to support the catalyst on the metal foil, the above-mentioned insulating layer-formed foil (hereinafter referred to as “insulating foil”) does not have an insulating layer formed on the alumina insulating layer (hereinafter referred to as “raw foil”). ), A washcoat layer having a thickness of about 30 μm for supporting a catalyst is formed on a base material of a metal foil, and a catalyst component such as platinum Pt, rhodium Rh, or palladium Pd is supported by impregnating the washcoat layer. I am letting you.
【００１７】本発明の電気加熱式触媒装置は、機関始動
時に中心電極３と外部電極５との間に電圧を印加して、
触媒を担持する平箔１０と波箔２０とに電流を流し箔１
０、２０の発熱により短時間で触媒を活性化温度（例え
ば３００度Ｃから４００度Ｃ程度）まで昇温する。本発
明ではこのために各層の金属箔を局所的に通電可能に接
合して金属箔積層方向に比較的狭い断面積の電流路を形
成し、上記接合部を通して金属箔積層方向に集中して電
流を流すようにしている。このように、局所的に狭い断
面積の電流路を設けることにより、電流路部分（すなわ
ち発熱部分）の体積が低減されて発熱部の熱容量が低く
なるため、通電により発熱部の急速な温度上昇を得るこ
とができる。また、電流路の断面積を比較的狭く設定す
ることにより、電極間の抵抗をを比較的高く維持できる
ため、通電時の合計電流量を低く抑えたままで電流路を
流れる電流密度を高く設定して電流路単位体積当たりの
発熱量を増加させることが可能となる。In the electrically heated catalyst device of the present invention, a voltage is applied between the center electrode 3 and the outer electrode 5 when the engine is started,
An electric current is passed between the flat foil 10 carrying the catalyst and the corrugated foil 20.
Due to the heat generation of 0 and 20, the temperature of the catalyst is raised to the activation temperature (for example, about 300 to 400 degrees C) in a short time. For this reason, in the present invention, the metal foils of the respective layers are locally joined so as to be able to conduct electricity to form a current path having a relatively narrow cross-sectional area in the metal foil laminating direction, and the current is concentrated through the joint portion in the metal foil laminating direction. I am trying to flush. In this way, by providing a current path with a locally narrow cross-sectional area, the volume of the current path part (that is, the heat generating part) is reduced and the heat capacity of the heat generating part is reduced, so that the temperature of the heat generating part rapidly rises due to energization. Can be obtained. Also, by setting the cross-sectional area of the current path relatively narrow, the resistance between the electrodes can be kept relatively high, so the current density flowing through the current path can be set high while keeping the total current amount during energization low. As a result, it is possible to increase the amount of heat generated per unit volume of the current path.
【００１８】以下に説明する本発明の実施形態では、波
箔２０に絶縁箔（表面に絶縁層を形成した金属箔）を、
平箔１０として生箔（表面に絶縁層を形成していない金
属箔）をそれぞれ使用して、この平箔１０と波箔２０と
を中心電極３周りに巻回して図１に示したような円筒状
金属箔積層体を形成するとともに、局所的に波箔２０の
絶縁層の絶縁性を破壊して平箔１０と接合することによ
り中心電極３と外部電極４とを接続する金属箔積層方向
の電流路を形成している。In the embodiments of the present invention described below, the corrugated foil 20 is provided with an insulating foil (a metal foil having an insulating layer formed on its surface).
Raw foil (metal foil having no insulating layer formed on the surface) is used as the flat foil 10, and the flat foil 10 and the corrugated foil 20 are wound around the center electrode 3 as shown in FIG. A metal foil laminating direction for connecting the center electrode 3 and the external electrode 4 by forming a cylindrical metal foil laminated body and locally destroying the insulating property of the insulating layer of the corrugated foil 20 and joining it to the flat foil 10. Forming a current path of.
【００１９】図４は平箔１０と波箔２０とを通電可能に
接合する接合方法を示す図である。本実施形態では、平
箔１０と波箔２０とを重ねて中心電極３周りに巻回す際
に、通電可能な接合部を形成する部分の平箔１０と波箔
２０との間に、波箔２０の絶縁層を形成する金属酸化物
（本実施形態ではＡｌ2 Ｏ3 ）より還元性の大きい金属
（例えばジルコニウムＺｒ）を含む所定の幅ｄのロウ材
箔４１を挟んで平箔１０と波箔２０とを巻回し、円筒状
積層体を形成している。このように積層体を形成した
後、積層体全体を加熱することにより、これらの部分に
絶縁層の絶縁性を破壊した接合部が形成される。すなわ
ち、平箔１０と波箔２０との間に介挿されるロウ材箔に
は絶縁層を形成する金属（アルミニウム）より還元性が
高い金属（ジルコニウムＺｒ）が含まれるため、加熱に
よりロウ材が溶融すると、ロウ材中のジルコニウムは絶
縁層のアルミナから酸素を奪い酸化ジルコニウムを形成
する。この形成された酸化ジルコニウムは接合部に分散
するため通電可能な接合部が形成される。FIG. 4 is a view showing a joining method for joining the flat foil 10 and the corrugated foil 20 so that they can be electrically conducted. In the present embodiment, when the flat foil 10 and the corrugated foil 20 are overlapped and wound around the center electrode 3, a corrugated foil is formed between the flat foil 10 and the corrugated foil 20 in a portion that forms an energizable joint. 20 of the metal oxide forming the insulating layer (Al 2 O 3 in the present embodiment) having a metal (for example, zirconium Zr) having a greater reducibility is sandwiched with the brazing material foil 41 having a predetermined width d and waved with the flat foil 10. It is wound with the foil 20 to form a cylindrical laminated body. After the laminated body is formed in this manner, the entire laminated body is heated to form a joint portion in which the insulating property of the insulating layer is destroyed in these portions. That is, since the brazing material foil interposed between the flat foil 10 and the corrugated foil 20 contains a metal (zirconium Zr) having a higher reducing property than the metal (aluminum) forming the insulating layer, the brazing material is heated by heating. When melted, zirconium in the brazing material deprives alumina of the insulating layer of oxygen to form zirconium oxide. The zirconium oxide thus formed is dispersed in the joint, so that a joint capable of conducting electricity is formed.
【００２０】図５は、本実施形態の円筒状金属箔積層体
２の排気入口側端面２ｄ上に上記により形成した金属箔
層間の接合部の配置を示している。本実施形態では、各
金属箔層間の通電可能な接合部は、金属箔積層体２の排
気入口側端面２ｄ上に図５に示すように二重の渦巻のパ
ターン５１ａ、５１ｂを描くように配置されている。ま
た、上記接合部は、端面２ｄから積層体軸線方向に所定
の深さにわたって形成されている。この端面からの接合
部の深さは、図４のロウ材箔４１の幅（図４にｄで示
す）により決定され、本実施形態では、この深さは例え
ば０．５ｍｍ〜３ｍｍ程度の範囲とされる。また、図５
において、２ａ、２ｂで示した部分は、それぞれ中心電
極周りと外周部とに形成された、金属箔層間の接合領域
である。接合領域２ａ、２ｂでは平箔１０と波箔２０と
は全面が通電可能に接合されており、この領域では通電
時の抵抗は極めて低くなっている。FIG. 5 shows the arrangement of the joints between the metal foil layers formed as described above on the exhaust inlet side end surface 2d of the cylindrical metal foil laminate 2 of this embodiment. In the present embodiment, the energizable joints between the metal foil layers are arranged on the exhaust inlet side end surface 2d of the metal foil laminate 2 so as to draw double spiral patterns 51a and 51b as shown in FIG. Has been done. Further, the joint portion is formed from the end face 2d to a predetermined depth in the axial direction of the laminated body. The depth of the bonded portion from this end face is determined by the width of the brazing material foil 41 (shown by d in FIG. 4) in FIG. 4, and in this embodiment, this depth is in the range of, for example, about 0.5 mm to 3 mm. It is said that FIG.
In the above, the portions indicated by 2a and 2b are joint regions between the metal foil layers formed around the center electrode and the outer peripheral portion, respectively. In the joining regions 2a and 2b, the entire surface of the flat foil 10 and the corrugated foil 20 are joined so that they can be energized, and the resistance when energized is extremely low in this region.
【００２１】図６は、図５のVI-VI 線に沿った積層体２
の軸線方向断面図である。図６において、斜線で示す領
域は金属箔相互間が通電可能に接合された部分を示す。
図６から判るように、中心電極３近傍の領域２ａと外周
近傍の領域２ｂでは、波箔と平箔とは数層にわたって全
面的に接合されているが、領域２ａと２ｂとの中間の領
域では、端面２ｄから所定深さのみ（本実施形態では、
例えば０．５ｍｍ〜３ｍｍ程度）が局所的に接合され、
これらの局所的接合部により上記領域２ａ、２ｂを接続
する渦巻状の小さな断面積の電流路５１ａ、５１ｂ（図
５）が形成されている。FIG. 6 shows a laminated body 2 taken along line VI-VI of FIG.
FIG. 4 is a sectional view in the axial direction of FIG. In FIG. 6, a hatched region indicates a portion where metal foils are joined so as to be able to conduct electricity.
As can be seen from FIG. 6, in the area 2a near the center electrode 3 and the area 2b near the outer circumference, the corrugated foil and the flat foil are entirely bonded over several layers, but the area between the areas 2a and 2b is intermediate. Then, only a predetermined depth from the end face 2d (in the present embodiment,
(For example, about 0.5 mm to 3 mm) is locally bonded,
These local joints form spiral current paths 51a and 51b (FIG. 5) having a small cross-sectional area that connect the regions 2a and 2b.
【００２２】なお、中心部及び外周部の接合領域２ａ、
２ｂは、電流路５１ａ、５１ｂと同様にジルコニウムＺ
ｒを含むロウ材箔を用いて接合しても良いが、本実施形
態では、図７に示す方法で接合領域２ａ、２ｂを形成し
ている。すなわち、本実施形態では波箔２０として、絶
縁箔２０ａの長手方向両側に生箔２０ｂ、２０ｃを接続
した構成の複合箔が使用される。この複合波箔は、図７
に示すように生箔２０ｂ側を中心電極３に接合して、平
箔１０（生箔）と重ねた状態で中心電極３周りに巻回さ
れ、金属箔積層体２が形成される。この際、波箔２０の
うち生箔２０ｂ、２０ｃ部分には、ニッケルＮｉを含む
ロウ材を塗布して平箔１０と重ねて巻回す。これによ
り、形成された金属箔積層体２では領域２ａ、２ｃ部分
はニッケル系のロウ材を介してそれぞれ生箔の状態の平
箔と波箔とが接触することになり、この状態で加熱、ロ
ウ付けを行うことにより平箔１０と波箔２０とが絶縁層
を介さずに通電可能に接合される。このように、生箔相
互を直接ロウ付け接合することにより、絶縁箔と生箔と
を、ジルコニウムロウ材箔を用いて絶縁層を介して接合
した場合に較べて高い接合強度を得ることができる。The central and outer peripheral joint regions 2a,
2b is zirconium Z, like the current paths 51a and 51b.
The brazing material foil containing r may be used for joining, but in the present embodiment, the joining regions 2a, 2b are formed by the method shown in FIG. That is, in the present embodiment, as the corrugated foil 20, a composite foil having a configuration in which the raw foils 20b and 20c are connected to both sides of the insulating foil 20a in the longitudinal direction is used. This composite corrugated foil is shown in FIG.
As shown in, the raw foil 20b side is joined to the center electrode 3 and wound around the center electrode 3 in a state of being overlapped with the flat foil 10 (raw foil) to form the metal foil laminate 2. At this time, a brazing material containing nickel Ni is applied to the raw foils 20b and 20c of the corrugated foil 20, and the raw foils 20b and 20c are overlapped with the flat foil 10 and wound. As a result, in the formed metal foil laminate 2, the flat foil and the corrugated foil in the raw foil state come into contact with each other in the regions 2a and 2c through the nickel-based brazing material. By brazing, the flat foil 10 and the corrugated foil 20 are electrically connected to each other without an insulating layer. By directly brazing and joining the raw foils to each other in this manner, it is possible to obtain a higher joining strength than in the case where the insulating foil and the raw foil are joined via the insulating layer using the zirconium brazing material foil. .
【００２３】また、本実施形態では電流路５１ａ、５１
ｂ部分は図４に示したように平箔（生箔）１０と波箔
（絶縁箔）２０とをジルコニウムロウ材箔（図４、４
１）のみを介して接合しているが、ニッケルを含むロウ
材箔は生箔と良好な接合性を示すため、ジルコニウムを
含むロウ材箔とニッケルを含むロウ材箔とを重ねた複合
箔を用いて平箔１０と波箔２０とを接合するようにして
もよい。この場合、ニッケルロウ材箔は平箔（生箔）１
０側に、ジルコニウムロウ材箔は波箔（絶縁箔）２０側
に接するように上記複合箔を配置して接合を行う。これ
により、ジルコニウムロウ材箔のみを用いて接合を行っ
た場合に較べて接合強度が向上する利点がある。Further, in this embodiment, the current paths 51a, 51a
As shown in FIG. 4, the portion b includes a flat foil (raw foil) 10 and a corrugated foil (insulating foil) 20 which are zirconium brazing material foils (see FIGS.
Although bonded only through 1), since the brazing material foil containing nickel shows good bonding properties to the raw foil, a composite foil obtained by stacking a brazing material foil containing zirconium and a brazing material foil containing nickel was laminated. You may make it join the flat foil 10 and the corrugated foil 20 using it. In this case, the nickel brazing material foil is flat foil (raw foil) 1
On the 0 side, the zirconium brazing material foil is placed so as to be in contact with the corrugated foil (insulating foil) 20 side, and the composite foil is joined. Thereby, there is an advantage that the bonding strength is improved as compared with the case where the bonding is performed using only the zirconium brazing material foil.
【００２４】次に、図８を用いて、本実施形態の電流路
５１ａ、５１ｂの形状の詳細について説明する。図８
は、図５の電流路５１ａのVIIIで示した部分の拡大図で
ある。図８において、８１０ａ〜８１０ｃは積層された
平箔の一部を、８２０ａ、８２０ｂは平箔８１０ａ〜８
１０ｃの間に配置された波箔を示す。また、それぞれの
平箔と波箔との間には、ジルコニウムロウ材箔８４１ａ
〜８４１ｄが介挿されている。ジルコニウムロウ材箔８
４１ａ〜８４１ｄは、それぞれ幅（図８の紙面に直角な
方向、すなわち円筒状金属箔積層体の軸線方向寸法）が
０．５ｍｍ〜３ｍｍ程度の長方形とされている。Next, the shape of the current paths 51a and 51b of this embodiment will be described in detail with reference to FIG. FIG.
FIG. 8 is an enlarged view of a portion indicated by VIII of the current path 51a in FIG. In FIG. 8, 810a to 810c are part of the laminated flat foils, and 820a and 820b are flat foils 810a to 810.
Figure 10 shows a corrugated foil placed between 10c. Further, a zirconium brazing material foil 841a is provided between each flat foil and the corrugated foil.
~ 841d is inserted. Zirconium brazing foil 8
Each of 41a to 841d is a rectangle having a width (direction perpendicular to the paper surface of FIG. 8, that is, axial dimension of the cylindrical metal foil laminate) of about 0.5 mm to 3 mm.
【００２５】また、本実施形態では、それぞれの波箔
（８２０ａ、８２０ｂ）を挟んで両側に配置されるロウ
材箔は、互いに円筒状金属箔積層体の円周方向にずらし
て配置されており、波箔（８２０ａ、８２０ｂ）の一方
の側のロウ材箔（８４１ｂ、８４１ｄ）により平箔（８
１０ｂ、８１０ｃ）に接合される波箔の波頂部のグルー
プ（例えば、波箔８２０ａ、８２０ｂの波頂部Ａ１、Ａ
２、Ａ３）と、上記波箔（８２０ａ、８２０ｂ）の他方
の側のロウ材箔（８４１ａ、８４１ｃ）により平箔（８
１０ａ、８１０ｂ）に接合される波箔の波頂部のグルー
プ（例えば、波箔８２０ａ、８２０ｂの波頂部Ｂ１、Ｂ
２、Ｂ３）とが、金属箔積層方向（図８に矢印Ｙで示し
た方向）から見て互いに重なっておらず、しかも互いに
連続している。すなわち、波箔８２０ａを例にとると、
波箔８２０の上側の波頂部グループＡ１、Ａ２、Ａ３と
下側の波頂部グループＢ１、Ｂ２、Ｂ３（波頂部Ｂ３は
図示を省略している）とは、Ｙ方向から見て重なってお
らず、かつ各グループの互いに最も近接した波頂部Ａ１
とＢ１とは互いに連続している（すなわち、波頂部Ａ１
とＢ１との間には他の波頂部が存在しない）。この波頂
部の関係は波箔８２０ｂの波頂部Ａ１、Ａ２、Ａ３（波
頂部Ｂ３は図示を省略している）についても全く同様に
成立している。In the present embodiment, the brazing material foils arranged on both sides of the corrugated foils (820a, 820b) are arranged so as to be offset from each other in the circumferential direction of the cylindrical metal foil laminate. , The flat foil (8) by the brazing material foil (841b, 841d) on one side of the corrugated foil (820a, 820b).
10b, 810c) a group of corrugated crests of corrugated foil (eg, corrugated crests A1, A of corrugated foils 820a, 820b).
2, A3) and the brazing material foil (841a, 841c) on the other side of the corrugated foil (820a, 820b).
10a, 810b) a group of corrugated crests of corrugated foil (eg corrugated crests B1, B of corrugated foils 820a, 820b).
2 and B3) do not overlap each other when viewed from the metal foil laminating direction (direction shown by arrow Y in FIG. 8), and are continuous with each other. That is, taking the corrugated foil 820a as an example,
The upper crest groups A1, A2, A3 of the corrugated foil 820 and the lower crest groups B1, B2, B3 (the crest B3 is not shown) do not overlap when viewed from the Y direction. , And the crests A1 closest to each other in each group
And B1 are continuous with each other (ie, the crest A1
There is no other crest between B1 and B1). The relationship of the wave crests is completely the same for the wave crests A1, A2, A3 (the wave crest B3 is not shown) of the corrugated foil 820b.
【００２６】上記のように波箔（８２０ａ、８２０ｂ）
の両側のロウ材箔（８４１ａと８４１ｂ、８４１ｃと８
４１ｄ）を配置することにより、各局所的発熱部の波箔
中に単一の電流路が形成されることになる。例えば、図
８に示すように、波箔８２０ａ両側のロウ材箔（８４１
ａと８４１ｂ）は、波頂部Ａ１と波頂部Ｂ１との間の波
箔部分によって形成される単一の電流ＲA のみによって
結ばれ、波箔８２０ｂ両側のロウ材箔（８４１ｃと８４
１ｄ）は、波頂部Ａ１と波頂部Ｂ１との間の波箔部分に
よって形成される単一の電流ＲA のみによって結ばれて
いる。また、図示していない他の波箔においても、両側
のロウ材箔も上記と同様に波箔中の単一の電流路によっ
て結ばれることになる。上述のように、本実施形態によ
れば各局所的発熱部の波箔には単一の電流路のみが形成
され、複数の電流路が並列に形成されることがないた
め、局所的発熱部の電流路断面積を極めて小さく設定す
ることが可能となる。このため、局所的発熱部での電流
密度が大幅に増大し、電流値を増大させることなく短時
間で発熱部の温度を上昇させることが可能となる。Corrugated foil (820a, 820b) as described above
On both sides of the brazing foil (841a and 841b, 841c and 8)
By arranging 41d), a single current path is formed in the corrugated foil of each local heating element. For example, as shown in FIG. 8, the brazing material foil (841
a and 841b) are connected only by a single current R A formed by the corrugated foil portion between the corrugated portions A1 and B1 and the brazing material foils (841c and 841c and 841c and 841c on both sides of the corrugated foil 820b).
1d) is connected only by a single current R A formed by the corrugated foil portion between the crests A1 and B1. Also, in other corrugated foils (not shown), the brazing material foils on both sides are also connected by a single current path in the corrugated foil as described above. As described above, according to the present embodiment, only a single current path is formed in the corrugated foil of each local heat generating portion, and a plurality of current paths are not formed in parallel. It is possible to set the current path cross-sectional area of 1 to be extremely small. For this reason, the current density in the local heat generating part is significantly increased, and the temperature of the heat generating part can be raised in a short time without increasing the current value.
【００２７】また、波箔の局所的発熱部を単一の電流路
で形成したことにより、各発熱部の電気抵抗が大きくな
ることから、発熱部の数を多く設定した場合でも触媒担
体全体の抵抗値はあまり低下しない。このため、全体と
しての電流値を増大させることなく局所的発熱部の数を
増加させることが可能となり、触媒反応開始のための火
種の数を増大し短時間で触媒担体全体を昇温することが
可能となる。図１０は、図８の実施形態における波箔の
両側のロウ材箔（８４１ａと８４１ｂ、８４１ｃと８４
１ｄ）の配置を説明する模式図である。図８の実施形態
では、波箔の両側のロウ材箔（８４１ａと８４１ｂ、８
４１ｃと８４１ｄ）は図８、図１０にＯＬで示すよう
に、金属箔積層方向Ｙから見て互いに重なった部分を有
している。しかし、上記説明から明らかなように、本発
明は波箔両側のロウ材箔が金属箔積層方向から見て互い
に全く重なる部分を有さない場合にも適用することがで
きる。図１１は、波箔両側のロウ材箔が金属箔積層方向
から見て全く重なる部分を有さない場合の本発明の実施
形態を示している。図１１において、波箔の両側に配置
されたロウ材箔（８４１ａと８４１ｂ、８４１ｃと８４
１ｄ）は、金属箔積層方向Ｙから見て互いに間隔をあけ
て配置されており、互いに重なりあう部分を有していな
い。しかし、波箔（８２０ａ、８２０ｂ）の一方の側の
ロウ材箔（８４１ｂ、８４１ｄ）により平箔（８１０
ｂ、８１０ｃ）に接合される波箔の波頂部のグループ
（例えば、波箔８２０ａ、８２０ｂの波頂部Ａ１、Ａ
２、Ａ３）と、波箔（８２０ａ、８２０ｂ）の他方の側
のロウ材箔（８４１ａ、８４１ｃ）により平箔（８１０
ａ、８１０ｂ）に接合される波箔の波頂部のグループ
（例えば、波箔８２０ａ、８２０ｂの波頂部Ｂ１、Ｂ
２、Ｂ３）とは、金属箔積層方向（図８に矢印Ｙで示し
た方向）から見て互いに重なっておらず、しかも互いに
連続している。従って、この場合も波箔（８２０ａ、８
２０ｂ）の両側に配置されたロウ材箔（８４１ａと８４
１ｂ、８４１ｃと８４１ｄ）は、それぞれ波頂部Ａ１と
Ｂ１との間の波箔部分を通る単一の電流路のみによって
結ばれることになる。Further, since the local heat generating portion of the corrugated foil is formed by a single current path, the electric resistance of each heat generating portion increases, so that even if a large number of heat generating portions are set, the entire catalyst carrier is The resistance does not decrease much. Therefore, it is possible to increase the number of local heat generating parts without increasing the current value as a whole, increase the number of sparks for starting the catalytic reaction, and raise the temperature of the entire catalyst carrier in a short time. Is possible. FIG. 10 shows brazing material foils (841a and 841b, 841c and 84) on both sides of the corrugated foil in the embodiment of FIG.
It is a schematic diagram explaining arrangement | positioning of 1d). In the embodiment of FIG. 8, the brazing foils (841a and 841b, 8) on both sides of the corrugated foil are used.
41c and 841d), as indicated by OL in FIGS. 8 and 10, have portions overlapping each other when viewed from the metal foil laminating direction Y. However, as is clear from the above description, the present invention can also be applied to the case where the brazing material foils on both sides of the corrugated foil do not have any portions which overlap each other when viewed from the metal foil laminating direction. FIG. 11 shows an embodiment of the present invention in which the brazing material foils on both sides of the corrugated foil do not have any overlapping portions when viewed from the metal foil laminating direction. In FIG. 11, brazing material foils (841a and 841b, 841c and 84) arranged on both sides of the corrugated foil.
1d) are arranged at a distance from each other when viewed from the metal foil laminating direction Y, and have no overlapping portions. However, the flat foil (810) is formed by the brazing material foil (841b, 841d) on one side of the corrugated foil (820a, 820b).
b, 810c) a group of corrugated crests of corrugated foil (eg, corrugated crests A1, A of corrugated foils 820a, 820b).
2, A3) and the brazing material foil (841a, 841c) on the other side of the corrugated foil (820a, 820b).
a, 810b) a group of corrugated crests of corrugated foil (eg corrugated crests B1, B of corrugated foils 820a, 820b).
2, B3) do not overlap each other when viewed from the metal foil stacking direction (direction shown by arrow Y in FIG. 8), and are continuous with each other. Therefore, in this case also, the corrugated foil (820a, 8
20b) on both sides of the brazing material foil (841a and 841a and 84b).
1b, 841c and 841d) will be connected only by a single current path through the corrugated foil portion between the crests A1 and B1, respectively.
【００２８】なお、図８、図１１の実施形態では平箔を
挟んで配置されるロウ材箔相互（例えば８４１ｂと８４
１ｃ）も金属箔積層方向Ｙから見て重なりを有している
が、図８、図１１の説明から明らかなように平箔を挟ん
で対向するロウ材箔相互（例えば、図８、図１１の８４
１ｂと８４１ｃ）は必ずしも重なり部分を有している必
要はない。このため、例えば、図９に示すように、平箔
（８１０ｂ）を挟んで対向するロウ材箔（８４１ｂと８
４１ｃ）相互が金属箔積層方向Ｙから見て重なりを有さ
ないように適宜な間隔（図９、Ｇ）をあけて配置するよ
うにしても良い。この場合も、ロウ材箔間の部分Ｇでは
電流は平箔（８１０ｂ）を通ってロウ材箔８４１ｂと８
４１ｃとの間を流れる。このため、図９のようにロウ材
箔を配置することにより、図８、図１１のロウ材箔配置
の場合と同様に、通電時の電流を比較的小さく抑えなが
ら発熱部に電流を集中させて効率的に発熱部温度を上昇
させることが可能となる。図１２は、本発明の別の実施
形態を示す。上述の各実施形態では、波箔両側に配置さ
れたロウ材箔は、それぞれ波箔の２つ以上の波頂部をそ
れぞれの側の平箔に接合していた。しかし、本実施形態
では、波箔両側のロウ材箔がそれぞれ波箔の１つの波頂
部のみをそれぞれの側の平箔に接合するようにしてい
る。In the embodiments shown in FIGS. 8 and 11, the brazing material foils (eg, 841b and 841) are arranged with the flat foils sandwiched therebetween.
1c) also has an overlap when viewed from the metal foil laminating direction Y, but as is clear from the description of FIGS. 8 and 11, the brazing material foils facing each other with the flat foil interposed therebetween (for example, FIGS. 8 and 11). Of 84
1b and 841c) do not necessarily have to have overlapping portions. Therefore, for example, as shown in FIG. 9, the brazing material foils (841b and 841b and 810b) facing each other with the flat foil (810b) interposed therebetween are provided.
41c) The metal foils may be arranged at appropriate intervals (FIG. 9, G) so that they do not overlap each other when viewed from the metal foil laminating direction Y. Also in this case, in the portion G between the brazing material foils, the current passes through the flat foil (810b) and the brazing material foils 841b and 841b.
It flows between 41c. Therefore, by arranging the brazing material foil as shown in FIG. 9, as in the case of the brazing material foil arrangement shown in FIGS. 8 and 11, the current is concentrated at the heat generating portion while the current during energization is kept relatively small. It is possible to efficiently raise the temperature of the heat generating part. FIG. 12 shows another embodiment of the present invention. In each of the above-described embodiments, the brazing material foils arranged on both sides of the corrugated foil are such that two or more wave crests of the corrugated foil are joined to the flat foils on the respective sides. However, in the present embodiment, the brazing material foils on both sides of the corrugated foil respectively bond only one wave crest of the corrugated foil to the flat foil on each side.
【００２９】すなわち、本実施形態では、図１２に示す
ように波箔８２０ａ、８２０ｂの両側に配置されたロウ
材箔８４１ａと８４１ｂ及び８４１ｃと８４１ｄは、そ
れぞれ波箔の１つの波頂部（Ａ１、Ｂ１）のみを平箔
（８１０ａ、８１０ｂ、８１０ｃ）に接合している。こ
の場合も、波箔の両側のロウ材箔はそれぞれ波頂部Ａ１
と波頂部Ｂ１との間の波箔部分を通る単一の電流路のみ
によって結ばれることになり、複数の電流路が波箔中に
並列に形成されることがない。図１２のように、波箔の
両側のロウ材箔がそれぞれ波箔の単一の波頂部のみを平
箔に接合するようにした場合には、前述の実施形態のよ
うに１つのロウ材箔が２つ以上の波頂部を平箔に接合す
るようにした場合に較べて波箔の耐久性が向上する利点
がある。すなわち、１つのロウ材箔が波箔の２つ以上の
波頂部を平箔に接合している場合には、触媒担体が高温
になると、接合されている波頂部間の波箔部分が熱膨張
するために波箔に熱応力が生じる場合がある。このた
め、機関の運転、停止が繰り返されると、接合された波
頂部間の波箔部分が繰り返し応力により破断する可能性
がある。That is, in the present embodiment, as shown in FIG. 12, the brazing material foils 841a and 841b and 841c and 841d arranged on both sides of the corrugated foil 820a and 820b respectively have one wave crest (A1, Only B1) is joined to the flat foil (810a, 810b, 810c). Also in this case, the brazing material foils on both sides of the corrugated foil are respectively crest portions A1.
And the wave crest B1 are connected by only a single current path passing through the corrugated foil portion, and a plurality of current paths are not formed in parallel in the corrugated foil. As shown in FIG. 12, when the brazing foils on both sides of the corrugated foil are joined to the flat foil only at the single wave crests of the corrugated foil, one brazing foil is used as in the above-described embodiment. Has an advantage that the durability of the corrugated foil is improved as compared with the case where two or more corrugated portions are joined to the flat foil. That is, in the case where one brazing material foil joins two or more wave crests of a corrugated foil to a flat foil, when the temperature of the catalyst carrier becomes high, the corrugated foil part between the wave crests being joined thermally expands. Therefore, thermal stress may occur in the corrugated foil. Therefore, when the engine is repeatedly operated and stopped, the corrugated foil portion between the joined wave crests may be repeatedly broken due to stress.
【００３０】一方、図１２の実施形態では、各ロウ材箔
は波箔の１つの波頂部のみを平箔に接合する構成である
ため、運転中波箔が高温になった場合でも接合部近傍の
波箔に熱応力が生じることがない。このため、本実施形
態によれば、上述の各実施形態と同様に、局所的発熱部
の波箔に複数の電流路が形成されることを防止し、しか
も触媒担体の耐久性を向上することが可能となってい
る。なお、図１２では、波箔両側のロウ材箔（８４１ａ
と８４１ｂ、及び８４１ｃと８４１ｄ）が金属箔積層方
向Ｙから見て互いに重なり部分を有する場合を示してい
るが、本実施形態においても、波箔両側のロウ材箔は重
なり部分を有さないように配置しても良いことはいうま
でもない。On the other hand, in the embodiment of FIG. 12, each brazing foil has a structure in which only one wave crest of the corrugated foil is bonded to the flat foil, so that even when the corrugated foil becomes hot during operation, the vicinity of the bonded portion No thermal stress is generated on the corrugated foil. Therefore, according to the present embodiment, as in each of the above-described embodiments, it is possible to prevent a plurality of current paths from being formed in the corrugated foil of the local heating portion, and improve the durability of the catalyst carrier. Is possible. In FIG. 12, the brazing material foil (841a) on both sides of the corrugated foil is used.
And 841b and 841c and 841d) have overlapping portions when viewed from the metal foil laminating direction Y, but also in this embodiment, the brazing material foils on both sides of the corrugated foil do not have overlapping portions. It goes without saying that it may be arranged in the.
【００３１】[0031]
【発明の効果】各請求項に記載の発明によれば、波箔の
両側のロウ材箔を接続する単一の電流路を波箔内に形成
するようにしたことにより、通電電流の増加を防止しつ
つ短時間で触媒の昇温が可能となり、しかも触媒担体内
に形成する局所的発熱部の数を増大させることが可能と
なるという共通の効果を奏する。According to the invention described in each claim, a single current path for connecting the brazing material foils on both sides of the corrugated foil is formed in the corrugated foil, thereby increasing the energizing current. There is a common effect that the temperature of the catalyst can be raised in a short time while preventing it, and the number of local heat generating parts formed in the catalyst carrier can be increased.
【図１】電気加熱式触媒装置の全体構造を示す図であ
る。FIG. 1 is a diagram showing an overall structure of an electrically heated catalyst device.
【図２】円筒状金属箔積層体の構造を説明する図であ
る。FIG. 2 is a diagram illustrating a structure of a cylindrical metal foil laminate.
【図３】図１のIII-III 線に沿った断面図である。FIG. 3 is a sectional view taken along line III-III in FIG.
【図４】絶縁箔と生箔との接合方法を説明する図であ
る。FIG. 4 is a diagram illustrating a method of joining an insulating foil and a raw foil.
【図５】本発明の一実施形態の電流路の形状を示す図で
ある。FIG. 5 is a diagram showing a shape of a current path according to an embodiment of the present invention.
【図６】図５のVI-VI 線に沿った断面図である。6 is a sectional view taken along line VI-VI of FIG.
【図７】図５の中心電極近傍と外周の接合領域の形成方
法を説明する図である。FIG. 7 is a diagram illustrating a method of forming a bonding region near the center electrode and the outer periphery of FIG.
【図８】本発明の一実施形態を示す図である。FIG. 8 is a diagram showing an embodiment of the present invention.
【図９】本発明の別の実施形態を示す図である。FIG. 9 is a diagram showing another embodiment of the present invention.
【図１０】本発明のロウ材箔の配置の１例を示す図であ
る。FIG. 10 is a diagram showing an example of the arrangement of the brazing material foil of the present invention.
【図１１】本発明の更に別の実施形態を示す図である。FIG. 11 is a view showing still another embodiment of the present invention.
【図１２】本発明の更に別の実施形態を示す図である。FIG. 12 is a view showing still another embodiment of the present invention.
【図１３】従来のロウ材箔と波箔との接合部の配置を示
す図である。FIG. 13 is a view showing an arrangement of a joint portion between a conventional brazing material foil and a corrugated foil.
【図１４】図１３の一部拡大図である。FIG. 14 is a partially enlarged view of FIG.
１…電気加熱式触媒装置全体 ２…円筒状金属箔積層体全体 ３…中心電極 ５…ケーシング（外部電極） １０…平箔 ２０…波箔 ４１…ジルコニウムロウ材箔 DESCRIPTION OF SYMBOLS 1 ... Electric heating type catalyst device whole 2 ... Cylindrical metal foil laminated body 3 ... Central electrode 5 ... Casing (external electrode) 10 ... Flat foil 20 ... Corrugated foil 41 ... Zirconium brazing material foil
───────────────────────────────────────────────────── フロントページの続き (72)発明者 紺谷 省吾 神奈川県川崎市中原区井田1618番地 新日 本製鐵株式会社技術開発本部内 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Shogo Kontani 1618 Ida, Nakahara-ku, Kawasaki-shi, Kanagawa Nippon Steel Corporation Technology Development Division
Claims (4)
金属の酸化物からなる絶縁層を介して交互に積層して金
属箔積層体を形成し、前記第１の金属より還元作用の大
きい第２の金属を含むロウ材箔を金属箔の層間に局所的
に配置し、該ロウ材箔により波板状金属箔と平板状金属
箔とを前記絶縁層を介して導通可能に接合した触媒担体
を有する電気加熱式触媒装置において、 各波板状金属箔を挟んで互いに隣接する位置に配置され
た２つのロウ材箔は、該２つのロウ材箔間に挟まれる波
板状金属箔中に、該２つのロウ材箔を結ぶ単一の電流路
を形成するように配置されたことを特徴とする電気加熱
式触媒装置。1. A metal foil laminate is formed by alternately laminating corrugated plate-shaped metal foils and flat plate-shaped metal foils with an insulating layer made of an oxide of a first metal interposed between the first metal. A brazing material foil containing a second metal having a large reducing action is locally arranged between the layers of the metal foil, and the corrugated metal foil and the flat metal foil can be electrically conducted through the insulating layer by the brazing material foil. In an electrically heated catalyst device having a catalyst carrier bonded to each other, two brazing material foils arranged at positions adjacent to each other with each corrugated metal foil sandwiched are corrugated sheets sandwiched between the two brazing material foils. An electrically heated catalyst device, wherein the electrically heated catalyst device is arranged in a strip-shaped metal foil so as to form a single current path connecting the two brazing material foils.
る２つのロウ材箔の一方は前記波板状金属箔の一方の側
の少なくとも１つ以上の波頂部を平板状金属箔に接合
し、前記２つのロウ材箔の他方は前記波板状ロウ材箔の
他方の側の少なくとも１つ以上の波頂部を平板状金属箔
に接続し、前記一方の金属箔により平板状金属箔に接合
される波頂部のグループと前記他方のロウ材箔により平
板状金属箔に接合される波頂部のグループとは、金属箔
積層方向から見て、重なることなく互いに連続している
請求項１に記載の電気加熱式触媒装置。2. One of two brazing material foils adjacent to each other with the corrugated plate-shaped metal foil sandwiched therebetween has at least one wave crest portion on one side of the corrugated plate-shaped metal foil joined to a flat plate-shaped metal foil. Then, the other of the two brazing material foils has at least one wave crest on the other side of the corrugated brazing material foil connected to a flat metal foil, and the one metal foil forms a flat metal foil. The group of wave crests to be joined and the group of wave crests to be joined to the flat metal foil by the other brazing material foil are continuous with each other without overlapping when viewed from the metal foil laminating direction. The electrically heated catalyst device described.
る２つのロウ材箔は、金属箔積層方向から見て互いに重
なる部分を有する請求項２に記載の電気加熱式触媒装
置。3. The electrically heated catalyst device according to claim 2, wherein the two brazing material foils that are adjacent to each other with the corrugated metal foil sandwiched therebetween have portions that overlap each other when viewed in the metal foil laminating direction.
る２つのロウ材箔は、金属箔積層方向から見て互いに重
なる部分を有さない請求項２に記載の電気加熱式触媒装
置。4. The electrically heated catalyst device according to claim 2, wherein the two brazing material foils that are adjacent to each other with the corrugated metal foil interposed therebetween do not have portions that overlap each other when viewed in the metal foil stacking direction.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP26072696A JP3337612B2 (en) | 1995-10-02 | 1996-10-01 | Electric heating type catalyst device |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP7-255377 | 1995-10-02 | ||
| JP25537795 | 1995-10-02 | ||
| JP26072696A JP3337612B2 (en) | 1995-10-02 | 1996-10-01 | Electric heating type catalyst device |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH09173861A true JPH09173861A (en) | 1997-07-08 |
| JP3337612B2 JP3337612B2 (en) | 2002-10-21 |
Family
ID=26542176
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP26072696A Expired - Fee Related JP3337612B2 (en) | 1995-10-02 | 1996-10-01 | Electric heating type catalyst device |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3337612B2 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2008521616A (en) * | 2004-12-02 | 2008-06-26 | エミテック ゲゼルシヤフト フユア エミツシオンス テクノロギー ミツト ベシユレンクテル ハフツング | Bonding material for positioning solder material, honeycomb body manufacturing process, and corresponding honeycomb body |
| JP2011513044A (en) * | 2008-02-27 | 2011-04-28 | エミテック ゲゼルシヤフト フユア エミツシオンス テクノロギー ミツト ベシユレンクテル ハフツング | Cellular components with flexible connection points |
| JP4860864B2 (en) * | 1999-09-14 | 2012-01-25 | エミテック ゲゼルシヤフト フユア エミツシオンス テクノロギー ミツト ベシユレンクテル ハフツング | End face side joining and bonding method and apparatus for carrier body of honeycomb body |
-
1996
- 1996-10-01 JP JP26072696A patent/JP3337612B2/en not_active Expired - Fee Related
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4860864B2 (en) * | 1999-09-14 | 2012-01-25 | エミテック ゲゼルシヤフト フユア エミツシオンス テクノロギー ミツト ベシユレンクテル ハフツング | End face side joining and bonding method and apparatus for carrier body of honeycomb body |
| JP2008521616A (en) * | 2004-12-02 | 2008-06-26 | エミテック ゲゼルシヤフト フユア エミツシオンス テクノロギー ミツト ベシユレンクテル ハフツング | Bonding material for positioning solder material, honeycomb body manufacturing process, and corresponding honeycomb body |
| JP2011513044A (en) * | 2008-02-27 | 2011-04-28 | エミテック ゲゼルシヤフト フユア エミツシオンス テクノロギー ミツト ベシユレンクテル ハフツング | Cellular components with flexible connection points |
Also Published As
| Publication number | Publication date |
|---|---|
| JP3337612B2 (en) | 2002-10-21 |
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