JPH09264126A - Manufacture of exhaust emission controlling catalytic converter - Google Patents
Manufacture of exhaust emission controlling catalytic converterInfo
- Publication number
- JPH09264126A JPH09264126A JP8076614A JP7661496A JPH09264126A JP H09264126 A JPH09264126 A JP H09264126A JP 8076614 A JP8076614 A JP 8076614A JP 7661496 A JP7661496 A JP 7661496A JP H09264126 A JPH09264126 A JP H09264126A
- Authority
- JP
- Japan
- Prior art keywords
- insulating material
- heat insulating
- catalyst carrier
- metal shell
- catalytic converter
- 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 claims abstract description 32
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 16
- 239000011810 insulating material Substances 0.000 claims abstract description 71
- 229910052751 metal Inorganic materials 0.000 claims abstract description 47
- 239000002184 metal Substances 0.000 claims abstract description 47
- 238000004804 winding Methods 0.000 claims abstract description 7
- 238000003780 insertion Methods 0.000 claims abstract description 6
- 230000037431 insertion Effects 0.000 claims abstract description 6
- 230000006835 compression Effects 0.000 claims abstract description 3
- 238000007906 compression Methods 0.000 claims abstract description 3
- 239000003054 catalyst Substances 0.000 claims description 78
- 239000000835 fiber Substances 0.000 claims description 21
- 238000000034 method Methods 0.000 claims description 20
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 11
- 239000000919 ceramic Substances 0.000 claims description 11
- 229920003002 synthetic resin Polymers 0.000 claims description 3
- 239000000057 synthetic resin Substances 0.000 claims description 3
- 239000012943 hotmelt Substances 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- -1 polyethylene Polymers 0.000 description 5
- 239000004698 Polyethylene Substances 0.000 description 4
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 4
- 229920000573 polyethylene Polymers 0.000 description 4
- 229910052878 cordierite Inorganic materials 0.000 description 3
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 3
- 229920000915 polyvinyl chloride Polymers 0.000 description 3
- 239000004800 polyvinyl chloride Substances 0.000 description 3
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- 230000006866 deterioration Effects 0.000 description 2
- 229920000554 ionomer Polymers 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- 229910052697 platinum Inorganic materials 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000010687 lubricating oil Substances 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229910052902 vermiculite Inorganic materials 0.000 description 1
- 235000019354 vermiculite Nutrition 0.000 description 1
- 239000010455 vermiculite Substances 0.000 description 1
Landscapes
- Exhaust Gas After Treatment (AREA)
- Catalysts (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】この発明は、車両の排気系に
おいて、エキゾーストパイプの途中やエキゾーストマニ
ホールドに設けて、排気ガスの浄化をはかる触媒コンバ
ータの製造方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a catalytic converter in an exhaust system of a vehicle, which is provided in the middle of an exhaust pipe or in an exhaust manifold to purify exhaust gas.
【０００２】[0002]
【従来の技術】従来、排気ガス浄化用触媒コンバータ
（以下、触媒コンバータと示す）としては、白金等の触
媒が保持された触媒担体とこの触媒担体の外側を覆う筒
状の金属シェルとの間に断熱材を設けた構造のものが知
られている。なお、触媒担体には、その断面をハニカム
状に成形したコージェライト担体が一般に用いられてい
る。2. Description of the Related Art Conventionally, as an exhaust gas purifying catalytic converter (hereinafter referred to as a catalytic converter), a space between a catalyst carrier that holds a catalyst such as platinum and a cylindrical metal shell that covers the outside of the catalyst carrier is used. A structure having a heat insulating material is known. As a catalyst carrier, a cordierite carrier having a honeycomb cross section is generally used.
【０００３】この種の触媒コンバータは、触媒担体にシ
ート状のセラミックファイバーを巻き付けてから、触媒
担体を分割された金属シェルで挟んで組み付ける、いわ
ゆるクラムシェル方式にて製造するのが、一般的であ
る。例えば、特開平７−１８９６７８号公報には、シー
ト状のセラミックファイバーで覆われた触媒担体を、気
密性フィルムからなる気密袋に入れて、この気密袋を減
圧することによって、収縮した気密袋がセラミックファ
イバー層の厚みを減少し、触媒担体の金属シェルへの組
み付けを容易にする方法が提案されている。This type of catalytic converter is generally manufactured by a so-called clam shell method, in which a sheet-shaped ceramic fiber is wound around a catalyst carrier and then the catalyst carrier is sandwiched and assembled by divided metal shells. is there. For example, in Japanese Unexamined Patent Publication No. 7-189678, a catalyst carrier covered with a sheet-shaped ceramic fiber is placed in an airtight bag made of an airtight film, and the airtight bag is decompressed to obtain a contracted airtight bag. Methods have been proposed to reduce the thickness of the ceramic fiber layer to facilitate assembly of the catalyst support to the metal shell.
【０００４】[0004]
【発明が解決しようとする課題】しかしながら、上記の
手法は、減圧することによりセラミックファイバー層の
厚みを減少しているが、その圧縮力は制限され、つまり
大気圧以上の圧縮力を与えることができないから、セラ
ミックファイバー層の嵩密度を0.1 〜0.25ｇ／cm 3 以上
にすることは難しい。そのために、触媒担体を金属シェ
ルに圧入して組み付けする際に、セラミックファイバー
層の先端部が擦れたり、ずれたりして、組み付け作業性
が阻害される。なお、セラミックファイバー層の充填密
度を0.3 ｇ／cm3 以上にできたとしても、減圧する気密
袋の嵩密度を高めることが難しいため、結果として、触
媒担体を筒状のシェルに挿入することはできない。従っ
て、触媒コンバータの製造はクラムシェル方式に限られ
て、コンバータの種類も制約を受けることになる。SUMMARY OF THE INVENTION
The technique is to depressurize the ceramic fiber layer
It has reduced thickness, but its compressive force is limited,
Since it is not possible to apply a compression force above atmospheric pressure,
The bulk density of the Mick fiber layer is 0.1-0.25g / cm Threethat's all
It's difficult to do. Therefore, the catalyst carrier is
Ceramic fiber when press-fitting and assembling
Assembly workability due to rubbing or misalignment of the tips of layers
Is hindered. In addition, the packing density of the ceramic fiber layer
0.3 g / cmThreeEven if you can do the above, airtight to reduce the pressure
As it is difficult to increase the bulk density of the bag,
The media carrier cannot be inserted into the tubular shell. Follow
Therefore, the production of catalytic converters is limited to the clamshell method.
Therefore, the type of converter will also be restricted.
【０００５】そこで、この発明は、触媒担体の金属シェ
ル内への挿入を容易にする方法について提案することを
目的とする。Therefore, the object of the present invention is to propose a method for facilitating the insertion of a catalyst carrier into a metal shell.
【０００６】[0006]
【課題を解決するための手段】この発明は、触媒が保持
された触媒担体の外側を断熱材で覆った後、この触媒担
体を筒状の金属シェルの内側に挿入するに当たり、該断
熱材で覆われた触媒担体の金属シェルに対する挿入先端
部の外径を、有機質シートの巻き付け圧縮によって、金
属シェルの内径よりも小さく保持し、その後触媒担体を
金属シェル内に挿入することを特徴とする触媒コンバー
タの製造方法である。According to the present invention, after covering the outside of a catalyst carrier holding a catalyst with a heat insulating material, the heat insulating material is used to insert the catalyst carrier into a cylindrical metal shell. A catalyst characterized in that the outer diameter of the insertion tip of the covered catalyst carrier with respect to the metal shell is kept smaller than the inner diameter of the metal shell by winding and compressing the organic sheet, and then the catalyst carrier is inserted into the metal shell. It is a converter manufacturing method.
【０００７】ここで、金属シェルに挿入前の触媒担体を
覆った断熱材の嵩密度は、有機質フィルムシートの巻き
付け部分が残りの部分の1.5 倍であること、具体的に
は、有機質フィルムシートの巻き付け部分を除く部分の
嵩密度が、0.10〜0.40ｇ／cm3であることが、実施に当
たり有利である。Here, the bulk density of the heat insulating material covering the catalyst carrier before being inserted into the metal shell is 1.5 times that of the remaining portion of the organic film sheet, specifically, the bulk density of the organic film sheet. It is advantageous in practice that the bulk density of the portion excluding the wound portion is 0.10 to 0.40 g / cm 3 .
【０００８】また、断熱材には、アルミナファイバーを
45重量％以上含有しているセラミックファイバーマット
が、そして有機質フィルムシートには、熱収縮性の有機
合成樹脂が、それぞれ有利に適合する。Alumina fiber is used as the heat insulating material.
Ceramic fiber mats containing 45% by weight or more and heat-shrinkable organic synthetic resins are suitable for the organic film sheet.
【０００９】なお、触媒担体には、例えばコージェライ
ト、アルミナまたはクロム系ステンレス等から成るハニ
カム状構造が、そして金属シェルには、ステンレス鋼例
えばSUS 409 ステンレス鋼から成る円筒が、それぞれ推
奨される。A honeycomb structure made of, for example, cordierite, alumina or chromium-based stainless steel is recommended for the catalyst carrier, and a cylinder made of stainless steel, for example, SUS 409 stainless steel is recommended for the metal shell.
【００１０】[0010]
【発明の実施の形態】さて、この発明の方法に従って得
られる触媒コンバータは、図１に示すように、白金など
の触媒が保持された触媒担体１と、この触媒担体１の外
側を覆う金属シェル２と、両者の間に配置した断熱材３
と、から成り、さらに断熱材３の一端には熱収縮性の有
機質フィルムシートによるリング４が嵌められている。BEST MODE FOR CARRYING OUT THE INVENTION A catalytic converter obtained according to the method of the present invention, as shown in FIG. 1, has a catalyst carrier 1 in which a catalyst such as platinum is held, and a metal shell which covers the outside of the catalyst carrier 1. 2 and heat insulating material 3 arranged between the two
And a ring 4 made of a heat-shrinkable organic film sheet is fitted to one end of the heat insulating material 3.
【００１１】また、触媒担体１の周面を覆う断熱材３
は、その周面を例えばポリエチレン製の気密シート５で
覆うことが、圧入組付けをする際に、シェルと断熱材と
のこすれによる組付作業悪化の防止および剪断力による
断熱材の損傷を阻止する点で好ましいが、気密シート５
は、例えば有機質フィルムを触媒担体１の全周に巻いて
しまえば機密シートとして同様の効果がある為、省略す
ることも可能である。Further, the heat insulating material 3 covering the peripheral surface of the catalyst carrier 1
Covering the peripheral surface with an airtight sheet 5 made of polyethylene, for example, prevents deterioration of the assembling work due to rubbing between the shell and the heat insulating material during press fitting and prevents damage to the heat insulating material due to shearing force. Airtight sheet 5 is preferable in terms of
Can be omitted because, for example, if an organic film is wrapped around the entire circumference of the catalyst carrier 1, it has the same effect as a confidential sheet.
【００１２】次に、上記した触媒コンバータの製造手順
について、図面を参照して説明する。図２は、触媒担体
１を金属シェル２に挿入するに先立って触媒担体１に取
り付ける各部品などを示したものであり、同図(A) に断
熱材３、同図(B) に２枚の気密シート5a,5b および同図
(C) にリング４をそれぞれ示す。断熱材３は、端部に凹
状係合部31およびこれと噛み合う凸状係合部32を有す
る。そして、リング４は、有機質シートを金属シェル２
の外径よりも小さい径に加工したものである。Next, a procedure for manufacturing the above-mentioned catalytic converter will be described with reference to the drawings. FIG. 2 shows parts and the like attached to the catalyst carrier 1 prior to inserting the catalyst carrier 1 into the metal shell 2. The heat insulating material 3 is shown in FIG. 2 (A), and two pieces are shown in FIG. 2 (B). Airtight sheets 5a, 5b and the same figure
Rings 4 are shown in (C). The heat insulating material 3 has a concave engaging portion 31 and a convex engaging portion 32 that meshes with the concave engaging portion 31 at the end. And, the ring 4 is made of the organic sheet and the metal shell 2
The outer diameter is smaller than the outer diameter.
【００１３】以上の各部品類を使用して、まず、図３
(A) に示すように、触媒担体１を断熱材３上に載置し、
その後同図(B) に示すように、断熱材３を触媒担体１の
周囲に巻き回して断熱材３の凹状係合部31内に凸状係合
部32を嵌めて断熱材３で触媒担体１を被覆する。なお、
33は断熱材３の凹状係合部31と凸状係合部32との嵌め合
わせによって生じた綱ぎ目である。さらに、同図(c) に
示すように、触媒担体１を覆う断熱材３の外側に、２枚
の気密シート5a,5b を挟む如く巻き付けるとともに、両
端部をテープ等で仮止めしておくことによって気密シー
ト5a,5b の内部を減圧してから、断熱材３の周囲に密着
させた、気密シート5a,5b をホットメルトにより貼り合
わせて接合し、断熱材３を被覆した触媒担体１を所定の
外径に保持する。なお、50は気密シート5a,5b の接合部
である。First, referring to FIG.
As shown in (A), the catalyst carrier 1 is placed on the heat insulating material 3,
After that, as shown in FIG. 3B, the heat insulating material 3 is wound around the catalyst carrier 1 and the convex engaging portion 32 is fitted into the concave engaging portion 31 of the heat insulating material 3 so that the heat insulating material 3 is used as the catalyst carrier. Coat 1. In addition,
33 is a seam formed by fitting the concave engaging portion 31 and the convex engaging portion 32 of the heat insulating material 3. Further, as shown in FIG. 3C, the two airtight sheets 5a and 5b should be wound so as to sandwich the heat insulating material 3 covering the catalyst carrier 1, and both ends should be temporarily fixed with tape or the like. After decompressing the inside of the airtight sheets 5a, 5b by the method, the airtight sheets 5a, 5b adhered to the periphery of the heat insulating material 3 are pasted and joined by hot melt, and the catalyst carrier 1 coated with the heat insulating material 3 is predetermined. To the outer diameter of. Incidentally, 50 is a joint portion of the airtight sheets 5a and 5b.
【００１４】かくして得られた触媒担体１は、図４(A)
に示すように、周囲の断熱材３の先端部に熱収縮性の有
機質シートからなるリング４を嵌めて、その後加圧雰囲
気下で上記気密シート5a,5b の軟化温度よりも低い温度
に加熱することにより、リング４を熱収縮させて、断熱
材３の先端部分の嵩密度を増加して厚みを減少すること
によって、この先端部の外径のみを金属シェル２の内径
より小さくする。The catalyst carrier 1 thus obtained is shown in FIG. 4 (A).
As shown in FIG. 5, a ring 4 made of a heat-shrinkable organic sheet is fitted to the tip of the surrounding heat insulating material 3, and then heated under a pressure atmosphere to a temperature lower than the softening temperature of the airtight sheets 5a and 5b. As a result, the ring 4 is heat-shrunk to increase the bulk density and reduce the thickness of the tip portion of the heat insulating material 3, so that only the outer diameter of this tip portion is smaller than the inner diameter of the metal shell 2.
【００１５】ここで、断熱材３のリング４を嵌めた先端
部分の嵩密度は、触媒担体の金属シェルへの挿入組み付
け作業を容易に行うために、残りの部分の嵩密度より大
きく、具体的には1.5 倍程度にすることが好ましい。と
りわけ、断熱材３の先端部分で0.15〜0.45ｇ／cm3 およ
び残りの部分で0.10〜0.40ｇ／cm3 の嵩密度とするとよ
い。なぜなら、断熱材３の先端部分の嵩密度が0.15ｇ／
cm3 未満であると、断熱材層の復元力が弱く、自動車の
エンジン振動または走行振動によって触媒担体ががたつ
いて、断熱材が粉化したり摩滅するばかりでなく、排気
ガスが断熱材を貫通する可能性がある。一方、嵩密度が
0.45ｇ／cm3 をこえると、断熱材自体が圧壊したり、触
媒担体が、破損または変形してしまうからである。Here, the bulk density of the tip end portion of the heat insulating material 3 into which the ring 4 is fitted is larger than the bulk density of the remaining portion in order to easily insert and assemble the catalyst carrier into the metal shell. It is preferable to set it to about 1.5 times. Particularly, it is preferable that the tip portion of the heat insulating material 3 has a bulk density of 0.15 to 0.45 g / cm 3 and the remaining portion has a bulk density of 0.10 to 0.40 g / cm 3 . Because the bulk density of the tip of the heat insulating material 3 is 0.15 g /
When it is less than 3 cm3, the restoring force of the heat insulating material layer is weak, and the catalyst carrier rattles due to the engine vibration or running vibration of the car, which not only causes the heat insulating material to be powdered or abraded but also exhaust gas to penetrate the heat insulating material. there's a possibility that. On the other hand, the bulk density is
If it exceeds 0.45 g / cm 3 , the heat insulating material itself will be crushed and the catalyst carrier will be damaged or deformed.
【００１６】なお、先端部分以外の嵩密度を0.10〜0.40
ｇ／cm3 程度とするのは、熱収縮リングを嵌めた後に嵩
密度が1.5 杯程度大きくなることを想定したためであ
り、熱収縮リングを嵌める前に、上記嵩密度にしておく
ことによって、嵩密度が0.15ｇ／cm3 未満及び0.45ｇ／
cm3 を越えることにより起こる、上記不具合を防止して
いる。The bulk density other than the tip portion is set to 0.10 to 0.40.
The reason for setting g / cm 3 is that it is assumed that the bulk density increases after fitting the heat shrink ring by about 1.5 cups. Density less than 0.15g / cm 3 and 0.45g /
The above problems caused by exceeding cm 3 are prevented.
【００１７】次に、先端部の外径が金属シェル２の内径
より小さくなった触媒担体１を、図５に示すように、金
属シェル２の内部に挿入する。このとき、触媒担体１の
先端部が金属シェル２の内径より小さいため、断熱材３
に損傷を与えることなく、触媒担体１および断熱材３を
容易に金属シェル２内に案内できる。そして、この先端
部さえ金属シェル２内に挿入されれば、触媒担体１およ
び断熱材３の径が、触媒担体１金属シェル２内に圧入す
る過程で縮小可能であるから、残る部分の挿入は容易で
ある。Next, the catalyst carrier 1 having the outer diameter of the tip portion smaller than the inner diameter of the metal shell 2 is inserted into the metal shell 2 as shown in FIG. At this time, since the tip of the catalyst carrier 1 is smaller than the inner diameter of the metal shell 2, the heat insulating material 3
The catalyst carrier 1 and the heat insulating material 3 can be easily guided into the metal shell 2 without damaging the. If even this tip portion is inserted into the metal shell 2, the diameters of the catalyst carrier 1 and the heat insulating material 3 can be reduced in the process of press-fitting into the catalyst carrier 1 metal shell 2, so that the remaining part is not inserted. It's easy.
【００１８】すなわち、触媒担体１および断熱材３を金
属シェル２内に圧入組み付けすることが容易であり、か
つ圧入組み付け時に、断熱材と触媒担体との間にずれが
生じることもない。また、かくして得られた触媒コンバ
ータは、その取り扱い輸送時においても触媒担体が金属
シェル内で動いたり、破損したりすることがない。従っ
て、金属シェルと触媒担体とのクリアランスに影響され
ず、どのような構造のコンバータに対しても組み付ける
ことができる。That is, it is easy to press-fit and assemble the catalyst carrier 1 and the heat insulating material 3 into the metal shell 2, and there is no deviation between the heat insulating material and the catalyst carrier during press-fitting and assembling. Further, in the thus obtained catalytic converter, the catalyst carrier does not move or break in the metal shell even during its handling and transportation. Therefore, the converter is not affected by the clearance between the metal shell and the catalyst carrier, and can be assembled to a converter of any structure.
【００１９】ここで、触媒担体１の周囲に設ける断熱材
３の厚みを、触媒担体１および金属シェル２のクリアラ
ンスの1.0 〜2.5 倍にすることが好ましい。なぜなら、
断熱材３の厚みが、クリアランスの1.0 倍未満になる
と、組立てられた触媒コンバータの取り扱い輸送時に、
触媒担体の位置がずれてしまったり、とりわけセラミッ
ク製の触媒担体では破損する場合があるからである。一
方、2.5 倍をこえると、組立て作業性が極めて悪くなる
のに加えて、断熱材が崩れてしまうからである。Here, the thickness of the heat insulating material 3 provided around the catalyst carrier 1 is preferably 1.0 to 2.5 times the clearance between the catalyst carrier 1 and the metal shell 2. Because
If the thickness of the heat insulating material 3 is less than 1.0 times the clearance, it will be
This is because the position of the catalyst carrier may be misaligned, and in particular, the catalyst carrier made of ceramic may be damaged. On the other hand, if it exceeds 2.5 times, not only the assembly workability becomes extremely poor, but also the heat insulating material collapses.
【００２０】なお、図示例では、有機質シートとしてリ
ング状に加工したものを断熱材の先端部に嵌めたが、例
えばリボン状の有機質シートを断熱材の先端部に巻き回
して取り付けることを可能である。また、断熱材３の先
端部に取り付けた有機質シートは、エンジンの運転に伴
う高温度の排気ガスによって焼失するか、あるいは触媒
コンバータを排気ガスパイプに接続する前に焼失させれ
ば良い。In the illustrated example, the ring-shaped organic sheet is fitted to the tip of the heat insulating material. However, for example, a ribbon-shaped organic sheet can be wound around and attached to the tip of the heat insulating material. is there. Further, the organic sheet attached to the tip of the heat insulating material 3 may be burned out by the exhaust gas of high temperature accompanying the operation of the engine, or may be burned out before connecting the catalytic converter to the exhaust gas pipe.
【００２１】また、図３に示した、触媒担体１に断熱材
３および気密シート5a,5b を順に巻き付ける工程に代え
て、図６に示すように、断熱材３を２枚の気密シート5
a,5bで挟んで内部を減圧した後、気密シートの周囲をホ
ットメルトにより貼り合わせた真空パックマット６を作
製しておき、この真空パックマット６を触媒担体１の外
周部に巻き付けて、テープ７で固定することも可能であ
る。その後は、図４に示した手順でリング４を先端部に
嵌めて、図５に示した手順で触媒担体１を金属シェル２
内に挿入すればよい。Further, instead of the step of winding the heat insulating material 3 and the airtight sheets 5a and 5b around the catalyst carrier 1 shown in FIG. 3 in order, as shown in FIG.
After depressurizing the inside by sandwiching it with a and 5b, a vacuum pack mat 6 in which the periphery of an airtight sheet is pasted by hot melt is prepared, and this vacuum pack mat 6 is wrapped around the outer periphery of the catalyst carrier 1 to form a tape. It is also possible to fix with 7. After that, the ring 4 is fitted to the tip portion by the procedure shown in FIG. 4, and the catalyst carrier 1 is attached to the metal shell 2 by the procedure shown in FIG.
You just have to insert it inside.
【００２２】さらに、図３に示した工程に代えて、図７
に示すように、断熱材３で覆った触媒担体１の外側に、
１枚の気密シート８を巻いて締め付けることによって、
断熱材３の嵩密度を増加して厚みを減少することも可能
である。その後、図４に示した手順でリング４を先端部
に嵌めて、図５に示した手順で触媒担体１を金属シェル
２内に挿入することは、同様である。Further, instead of the steps shown in FIG. 3, FIG.
As shown in, outside the catalyst carrier 1 covered with the heat insulating material 3,
By winding and tightening one airtight sheet 8,
It is also possible to increase the bulk density of the heat insulating material 3 and reduce its thickness. After that, the ring 4 is fitted to the tip portion in the procedure shown in FIG. 4, and the catalyst carrier 1 is inserted into the metal shell 2 in the procedure shown in FIG.
【００２３】ここに、断熱材としては、アルミナファイ
バーマット、とりわけアルミナ繊維またはシリカ−アル
ミナ繊維の不織布から選ばれる素材によるアルミナファ
イバーマットが好ましい。これらはいずれも耐熱性に優
れた物質であり、排気ガス、特に高温のリーンバーン排
気ガスに曝されても、従来のバーミキュライト等による
熱膨張性緩衝シール材のように、膨張圧力の低下による
変形、品質の劣化を起こすことがないので有利である。
さらに、セラミックファイバーマットは、高温になる触
媒担体側に高価ではあるがより耐熱性に優れたアルミナ
繊維を配し、その外側の低温側に若干耐熱性に劣るが安
価なシリカ−アルミナ繊維を配する等の２層構造とする
ことが、材料コストを低減する上で有利である。Here, the heat insulating material is preferably an alumina fiber mat, particularly an alumina fiber mat made of a material selected from a non-woven fabric of alumina fibers or silica-alumina fibers. All of these are substances with excellent heat resistance, and even when exposed to exhaust gas, especially high-temperature lean burn exhaust gas, they deform due to a decrease in expansion pressure, like the conventional heat-expandable buffer seal materials such as vermiculite. This is advantageous because it does not cause quality deterioration.
Further, in the ceramic fiber mat, an alumina fiber, which is expensive but more excellent in heat resistance, is arranged on the side of the catalyst carrier which becomes high temperature, and a silica-alumina fiber, which is slightly inferior in heat resistance but is inexpensive, is arranged on the outer side thereof at a low temperature. It is advantageous to reduce the material cost by adopting a two-layer structure such as.
【００２４】次に、有機質シートは、シリコン樹脂、ポ
リ塩化ビニル、ポリエチレンまたはイオノマー樹脂等の
熱収縮性の有機合成樹脂を用いることが、好ましい。特
に、金属シェル内への挿入をより容易にするためには、
有機質シートの表面が良好な潤滑性を有すること、すな
わち有機質シートに表面の摩擦係数の低い材料を用いる
ことが好ましい。かかる点から、ポリ塩化ビニル、ポリ
エチレンおよびイオノマー樹脂が推奨されるのである。
さらに、有機質シートの外面や金属シェルの内面に潤滑
油等をコーティングし、潤滑性を増加させることも有効
な手段である。Next, for the organic sheet, it is preferable to use a heat-shrinkable organic synthetic resin such as silicone resin, polyvinyl chloride, polyethylene or ionomer resin. In particular, for easier insertion into the metal shell,
It is preferable that the surface of the organic sheet has good lubricity, that is, a material having a low surface friction coefficient is used for the organic sheet. From this point of view, polyvinyl chloride, polyethylene and ionomer resins are recommended.
Further, it is also an effective means to coat the outer surface of the organic sheet and the inner surface of the metal shell with lubricating oil or the like to increase the lubricity.
【００２５】[0025]
実施例１ 図３に示したところに従って、コージェライトよりな
る、外径：130 mmの円柱状の触媒担体１に、触媒担体内
側がアルミナ繊維および外側がシリカ−アルミナ繊維の
２層構造のセラミックファイバーマットによる、幅：10
0 mm、長さ：415mm、厚み：20mmおよび嵩密度：0.10ｇ
／cm3 の断熱材３を巻き付けた後、ポリエチレン製の気
密シート5a,5b を挟む如く巻き付けるとともに、気密シ
ート5a,5bの内部を減圧してから、断熱材３の周囲に密
着させた、気密シート5a,5b をホットメルトにより貼り
合わせて接合し、断熱材３を厚み８mmおよび嵩密度0.25
ｇ／cm3 とした。Example 1 As shown in FIG. 3, a cylindrical catalyst carrier 1 made of cordierite and having an outer diameter of 130 mm was used, and a ceramic fiber having a two-layer structure of an alumina fiber inside and a silica-alumina fiber outside. Width by mat: 10
0 mm, length: 415 mm, thickness: 20 mm and bulk density: 0.10 g
/ Cm 3 of the heat insulating material 3 is wrapped, then the polyethylene airtight sheets 5a, 5b are wrapped so as to sandwich it, and the inside of the airtight sheets 5a, 5b is depressurized and then adhered to the periphery of the heat insulating material 3 The sheets 5a and 5b are pasted and joined by hot melt, and the heat insulating material 3 is 8 mm thick and has a bulk density of 0.25
It was set to g / cm 3 .
【００２６】かくして得られた触媒担体１を、図４に示
したところに従って、周囲の断熱材３の先端部に、ポリ
塩化ビニル製の有機質シートからなるリング４を嵌め
て、その後加圧室内に触媒を配置し、４kgf ／cm2 の圧
縮空気の加圧雰囲気下で上記気密シート5a,5b の軟化温
度よりも低い温度（120 ℃）に加熱することにより、リ
ング４を熱収縮させて、断熱材３の先端部分の厚み：5.
5 mmおよび嵩密度：0.364 ｇ／cm3 とし、この先端部の
外径のみを金属シェル２の内径（142 mm）より小さくし
た。As shown in FIG. 4, the catalyst carrier 1 thus obtained is fitted with a ring 4 made of an organic sheet made of polyvinyl chloride at the tip of the surrounding heat insulating material 3, and then placed in a pressure chamber. By placing a catalyst and heating it to a temperature (120 ° C.) lower than the softening temperature of the airtight sheets 5a and 5b under a pressurized atmosphere of 4 kgf / cm 2 of compressed air, the ring 4 is thermally shrunk to perform heat insulation. Thickness of the tip of material 3: 5.
5 mm and bulk density: 0.364 g / cm 3, and only the outer diameter of this tip portion was made smaller than the inner diameter (142 mm) of the metal shell 2.
【００２７】次に、図５に示したところに従って、触媒
担体１を金属シェル２の内部に挿入したところ、触媒担
体１と金属シェル２との間の６mmのクリアランスに断熱
材３が均等に充填された、触媒コンバータを、断熱材３
に損傷を与えることなしに、作製できた。Next, as shown in FIG. 5, when the catalyst carrier 1 was inserted into the metal shell 2, the clearance of 6 mm between the catalyst carrier 1 and the metal shell 2 was uniformly filled with the heat insulating material 3. Installed catalytic converter, heat insulating material 3
Could be produced without damaging the.
【００２８】実施例２ 実施例１と同様の触媒担体１、断熱材３および気密シー
ト5a,5b を用いて、図６に示すところに従って、断熱材
３を２枚の気密シート5a,5b で挟んで内部を減圧した
後、気密シートの周囲をホットメルトにより貼り合わせ
ることによって、厚み：８mmおよび嵩密度：0.25ｇ／cm
3 の真空パックマット６を作製し、次いでこの真空パッ
クマット６を触媒担体１の外周部に巻き付けて、テープ
７で固定した後、実施例１と同様に、図４に示した手順
でリング４を先端部に嵌めて、図５に示した手順で触媒
担体１を金属シェル２内に挿入したところ、断熱材３に
損傷を与えることなしに、触媒コンバータを作製でき
た。Example 2 Using the same catalyst carrier 1, heat insulating material 3 and airtight sheets 5a and 5b as in Example 1, the heat insulating material 3 is sandwiched between two airtight sheets 5a and 5b as shown in FIG. After decompressing the inside with a hot melt, the periphery of the airtight sheet is pasted with hot melt to give a thickness of 8 mm and a bulk density of 0.25 g / cm.
The vacuum pack mat 6 of No. 3 was prepared, and then the vacuum pack mat 6 was wound around the outer periphery of the catalyst carrier 1 and fixed with the tape 7, and then the ring 4 was prepared by the procedure shown in FIG. When the catalyst carrier 1 was inserted into the metal shell 2 according to the procedure shown in FIG. 5, the catalytic converter could be manufactured without damaging the heat insulating material 3.
【００２９】実施例３ 実施例１と同様の触媒担体１および断熱材３を用いて、
図７に示すところに従って、断熱材３で覆った触媒担体
１の外側に、ポリプロピレン製で厚み：0.050mmの気密
シート８を巻いて締め付けることによって、断熱材３の
嵩密度を0.25ｇ／cm3 に増加して厚みを８mmまで減少し
た後、実施例１と同様に、図４に示した手順でリング４
を先端部に嵌めて、図５に示した手順で触媒担体１を金
属シェル２内に挿入したところ、断熱材３に損傷を与え
ることなしに、触媒コンバータを作製できた。Example 3 Using the same catalyst carrier 1 and heat insulating material 3 as in Example 1,
As shown in FIG. 7, the bulk density of the heat insulating material 3 is 0.25 g / cm 3 by winding and tightening the airtight sheet 8 made of polypropylene and having a thickness of 0.050 mm on the outside of the catalyst carrier 1 covered with the heat insulating material 3. And the thickness is reduced to 8 mm, the ring 4 is subjected to the procedure shown in FIG.
When the catalyst carrier 1 was fitted to the tip and the catalyst carrier 1 was inserted into the metal shell 2 according to the procedure shown in FIG. 5, a catalytic converter could be manufactured without damaging the heat insulating material 3.
【００３０】[0030]
【発明の効果】この発明によれば、触媒担体をその周囲
の断熱材を損傷することなしに、金属シェル内へ挿入す
ることができ、高歩留りかつ安価に触媒コンバータを製
造し得る。また、触媒担体を金属シェル内へ確実に案内
できるから、両者の組み付け時に断熱材と触媒担体との
間にずれが生じることもなく、さらに触媒コンバータの
取り扱い輸送時においても触媒担体が金属シェル内で動
いたり、破損したりすることがない。従って、金属シェ
ルと触媒担体とのクリアランスに影響されず、どのよう
な構造のコンバータに対しても組み付ける手法を提供で
きるのである。According to the present invention, the catalyst carrier can be inserted into the metal shell without damaging the heat insulating material around the catalyst carrier, and the catalytic converter can be manufactured at a high yield and at a low cost. In addition, since the catalyst carrier can be reliably guided into the metal shell, there is no gap between the heat insulating material and the catalyst carrier when the two are assembled, and the catalyst carrier is kept inside the metal shell during handling and transportation of the catalytic converter. It does not move or get damaged. Therefore, it is possible to provide a method of assembling to a converter of any structure, without being affected by the clearance between the metal shell and the catalyst carrier.
【図１】この発明により製造される触媒コンバータの一
部を断面とした斜視図である。FIG. 1 is a perspective view showing a cross section of a part of a catalytic converter manufactured according to the present invention.
【図２】触媒コンバータの製造に供する部品類を示す模
式図である。FIG. 2 is a schematic diagram showing components used for manufacturing a catalytic converter.
【図３】触媒コンバータの製造手順を示す説明図であ
る。FIG. 3 is an explanatory view showing a manufacturing procedure of the catalytic converter.
【図４】触媒コンバータの製造手順を示す説明図であ
る。FIG. 4 is an explanatory view showing a manufacturing procedure of the catalytic converter.
【図５】触媒コンバータの製造手順を示す説明図であ
る。FIG. 5 is an explanatory view showing the manufacturing procedure of the catalytic converter.
【図６】触媒コンバータの他の製造手順を示す説明図で
ある。FIG. 6 is an explanatory view showing another manufacturing procedure of the catalytic converter.
【図７】触媒コンバータの別の製造手順を示す説明図で
ある。FIG. 7 is an explanatory view showing another manufacturing procedure of the catalytic converter.
１ 触媒担体 ２ 金属シェル ３ 断熱材 ４ リング 5a,5b 気密シート ６ 真空パックマット ７ テープ ８ 気密シート 1 catalyst carrier 2 metal shell 3 heat insulating material 4 ring 5a, 5b airtight sheet 6 vacuum pack mat 7 tape 8 airtight sheet
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.6 識別記号 庁内整理番号 ＦＩ 技術表示箇所 Ｆ０１Ｎ 3/28 ３１１ Ｆ０１Ｎ 3/28 ３１１Ｒ ─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. 6 Identification code Internal reference number FI Technical display area F01N 3/28 311 F01N 3/28 311R
Claims (5)
材で覆った後、この触媒担体を筒状の金属シェルの内側
に挿入するに当たり、該断熱材で覆われた触媒担体の金
属シェルに対する挿入先端部の外径を、有機質シートの
巻き付け圧縮によって、金属シェルの内径よりも小さく
保持し、その後触媒担体を金属シェル内に挿入すること
を特徴とする排気ガス浄化用触媒コンバータの製造方
法。1. A metal shell of a catalyst carrier covered with a heat insulating material when the catalyst carrier holding the catalyst is covered with a heat insulating material and then the catalyst carrier is inserted into a cylindrical metal shell. The outer diameter of the insertion tip portion with respect to, by the winding compression of the organic sheet, is kept smaller than the inner diameter of the metal shell, and then the catalyst carrier is inserted into the metal shell, a method for manufacturing an exhaust gas purifying catalytic converter .
断熱材の嵩密度は、有機質フィルムシートの巻き付け部
分が残りの部分の1.5 倍である請求項１に記載の製造方
法。2. The production method according to claim 1, wherein the bulk density of the heat insulating material covering the catalyst carrier before being inserted into the metal shell is 1.5 times as large as that of the remaining portion of the organic film sheet.
の嵩密度が、0.10〜0.40ｇ／cm3 である請求項２に記載
の製造方法。3. The production method according to claim 2, wherein the bulk density of the portion excluding the winding portion of the organic sheet is 0.10 to 0.40 g / cm 3 .
％以上含有しているセラミックファイバーマットである
請求項１、２または３に記載の製造方法。4. The method according to claim 1, wherein the heat insulating material is a ceramic fiber mat containing 45% by weight or more of alumina fibers.
脂である請求項１、２、３または４に記載の製造方法。5. The manufacturing method according to claim 1, wherein the organic sheet is a heat-shrinkable organic synthetic resin.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP07661496A JP3759230B2 (en) | 1996-03-29 | 1996-03-29 | Exhaust gas purification catalytic converter and method for manufacturing the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP07661496A JP3759230B2 (en) | 1996-03-29 | 1996-03-29 | Exhaust gas purification catalytic converter and method for manufacturing the same |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH09264126A true JPH09264126A (en) | 1997-10-07 |
| JP3759230B2 JP3759230B2 (en) | 2006-03-22 |
Family
ID=13610234
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP07661496A Expired - Lifetime JP3759230B2 (en) | 1996-03-29 | 1996-03-29 | Exhaust gas purification catalytic converter and method for manufacturing the same |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3759230B2 (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2002147231A (en) * | 2000-11-10 | 2002-05-22 | Ibiden Co Ltd | Catalytic converter and holding sealant for the same |
| EP1548244A1 (en) * | 2003-12-26 | 2005-06-29 | Calsonic Kansei Corporation | Assembly device of support mat and for ceramic catalyst carrier |
| GB2425073A (en) * | 2005-04-12 | 2006-10-18 | Delphi Tech Inc | Catalytic converter and method |
| US7575727B2 (en) * | 2000-11-10 | 2009-08-18 | Ibiden Co., Ltd. | Catalytic converter and method for manufacturing the same |
-
1996
- 1996-03-29 JP JP07661496A patent/JP3759230B2/en not_active Expired - Lifetime
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2002147231A (en) * | 2000-11-10 | 2002-05-22 | Ibiden Co Ltd | Catalytic converter and holding sealant for the same |
| US7575727B2 (en) * | 2000-11-10 | 2009-08-18 | Ibiden Co., Ltd. | Catalytic converter and method for manufacturing the same |
| EP1548244A1 (en) * | 2003-12-26 | 2005-06-29 | Calsonic Kansei Corporation | Assembly device of support mat and for ceramic catalyst carrier |
| US7441333B2 (en) | 2003-12-26 | 2008-10-28 | Calsonic Kansei Corporation | Assembly device of support mat for ceramic catalyst carrier |
| GB2425073A (en) * | 2005-04-12 | 2006-10-18 | Delphi Tech Inc | Catalytic converter and method |
Also Published As
| Publication number | Publication date |
|---|---|
| JP3759230B2 (en) | 2006-03-22 |
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