JPH1043605A - Metal honeycomb structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a metal honeycomb structure wherein a special waveform constitution is substituted for a corrugated-plate-form strip. SOLUTION: In reference to virtual corrugated plate 1' composed by connecting a waveform of a segment of one cycle length λ',(i) with a desired wave height(h) the corrugated-plate-form strip 1 is divided, (ii) for the corrugated platell', into a segment of one cycle length λ of newly resultant waveform having a region where the waveform of the (ii-1) invisible corrugated plate 1' in contrast with the corrugated plate 1' contacts a flat-plate-form strip 2 at crest portions and through portions of at least one set of proximate waves and a region of no contact with the flay-plate-form strip 2 connecting the region contacting the flat-plate-from strip 2, (ii-2) the region of no contact with the flat-plate-form strip 2 is divided so as to have about a half height on the wave height of the virtual corrugated plate 1', (iii) the waveform constitution of a segment of one cycle length λ divided on the virtual corrugated plate 1' is connected.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a honeycomb structure for supporting an exhaust gas purifying catalyst having a metal structure and a honeycomb structure (hereinafter, simply referred to as a metal honeycomb structure).

More specifically, the present invention relates to a novel structure of a metal honeycomb structure which is a main component of an exhaust gas purifying apparatus (metal carrier). More specifically, the present invention relates to a metal honeycomb structure, which is a main component of an exhaust gas purification apparatus (metal carrier), using a conventional flat band material (flat foil) and a corrugated sheet material (corrugated foil). The present invention relates to a novel metal honeycomb structure constituted by using a special corrugated structure as a corrugated band material, instead of the one formed by stacking.

[0003]

2. Description of the Related Art As described above, a metal honeycomb structure, which is an essential component of an exhaust gas purifying apparatus (metal carrier) of the present invention, is replaced with a corrugated strip having a conventional simple corrugated structure. Since it uses a corrugated strip having a special corrugated structure, it has a special structure. Hereinafter, in relation to the metal honeycomb structure having a special structure of the present invention described above,
The prior art will be described.

A typical example of a conventionally proposed metal honeycomb structure is shown in FIGS.
Is shown in As shown in the figure, a metal honeycomb structure (H ') of this type is made of a heat-resistant thin metal plate made of corrugated sheet material (corrugated foil) (1') and a flat band material (flat foil). (2
') Are alternately piled up (see Fig. 15), and this is wound and formed into a honeycomb structure (Figs. 16 to 17).
And an exhaust gas purifying catalyst (for example, Pt, R
h, Pd, etc.). The metal honeycomb structure (H ′) is housed in a metal casing, that is, a metal casing (C) as shown in FIGS. 16 and 17, and is fixed to be a metal carrier (MS). Things.

The above-mentioned metal carrier (MS) is called a metal support (MetalSupport) or a metal substrate (Metal Substrate) in the art, and the abbreviation (MS) is used. In this sense, FIGS. 16 to 17 also use the abbreviations (MS) described above. Further, in the metal honeycomb structure, the abbreviation (H) is used for the honeycomb structure. In order to distinguish the present invention from the prior art, those of the prior art are indicated by dashed symbols (H '). Further, corrugated foils and flat foils which are constituent members thereof are also indicated by symbols with dashes (1 ′, 2 ′). Further, in the metal casing, the abbreviation (C) is used for the casing (Casing).

Various types of metal honeycomb structures (H ') for supporting the above-mentioned conventional exhaust gas purifying catalyst have been proposed. The metal honeycomb structure (H ′) shown in FIGS.
') And the corrugated foil (2') are wound and laminated, and are commonly referred to in the art as the wound type. FIG. 15 is a perspective view of a set of corrugated foil (1 ′) and flat foil (2 ′), which are constituent members of the wound-type metal honeycomb structure (H ′), and FIG. FIG. 17 is a perspective view of a metal carrier (MS) manufactured by fixing a conventional wound-type metal honeycomb structure (H ′) in a metal casing (C), and FIG. 17 shows the metal carrier of FIG. (MS) shows the front view.

The above-mentioned conventional wound-type metal honeycomb structure (H ') is made of a corrugated foil (1) made of a heat-resistant thin steel plate of, for example, 100 μm or less (preferably 50 μm or less).
') And the flat foil (2') are stacked so as to alternately have an abutting portion, and are formed into a spiral shape so as to form a large number of mesh-shaped passages for the exhaust gas passage in the axial direction. Stomatal channel (cell) (3
′). In the present invention and the prior art, the cells have different shapes and structures due to the difference in the corrugated structure of the corrugated foil. Thus, in order to distinguish the present invention from the prior art, prior art cells are indicated by dashed symbols (3 ').

In addition, as a metal honeycomb structure (H ') for supporting an exhaust gas purifying catalyst, in addition to the above-mentioned wound type, a corrugated foil (1') and a flat foil (2 ') are used.
Various types of structures have been proposed depending on the difference in the method for manufacturing a honeycomb structure.

For example, a layer type (see FIG. 18) in which both foil members (1 ', 2') are stacked in a layered manner is known. Further, JP-A-62-273050 and JP-A-62-273050
No. 273051, JP-A-1-218637, Special Publication 3
Radial type (see FIG. 19), S-shaped type (see FIG. 20), Tomoe type (see FIG. 21), and X as disclosed in JP-A-502660 and JP-A-4-227855.
-A lap (swastika) type (see FIG. 22) metal honeycomb structure (H ') is known.

The conventional wound type metal honeycomb structure (H ') shown in FIGS. 16 to 17 as well as the conventional hierarchical type, radial type, and S-shape shown in FIGS. Type, Tomoe type, and X
-Various metal honeycomb structures (H ') such as a wrap (swastika) type have a structure in which the corrugated foil (1') is replaced with a corrugated foil (1) having a special structure of the present invention described later. It can be configured. That is, since the metal honeycomb structures (H ′) having the various structures described above have a deep relationship with the present invention, the metal honeycomb structures (H ′) having the various structures will be described in detail here.

Among the various structural metal honeycomb structures (H ') described above, the laminated (layer) type metal honeycomb structure (H') shown in FIG. 18 is a corrugated foil (1 ') made of a thin metal plate. And the flat foil (2 ') are laminated (stacked) in a hierarchical manner so as to abut each other.

The radial type metal honeycomb structure (H ') shown in FIG. 19 has a corrugated foil (1') and a flat foil (2 ').
The purification element is manufactured by fixing one end of the purification element to a fixed shaft (central axis) and extending (radiating) each purification element from the fixed shaft, using a desired number of purification elements composed of: It should be noted that only some purification elements are shown for clarity.

The S-shaped or Tomoe type metal honeycomb structure (H ') shown in FIGS. 20 to 21 is manufactured as follows. That is, a rectangular corrugated foil (1 ') and a flat foil (2') having a desired length and width are alternately laminated in a desired number of stages to form a stack, and the desired number of the stacks is used. It is manufactured. For example, in the case of the S-shaped type (see FIG. 20), a rod-shaped jig for winding is disposed substantially at the center of the upper and lower outermost surfaces of one stack, and the jig for winding is provided. It is manufactured by winding in the same direction at the same time. The S-shaped and tom-shaped metal honeycomb structures (H ') of this type are loaded and fixed in the metal casing (C) when both foil members (1', 2) forming the stack are fixed. ′) Has a structure in which both end portions are in contact with the inner wall surface of the metal casing (C) to be wrapped. For this reason, the thermal stress (thermal deformation force) generated inside the metal honeycomb structure (H ′) at the portion can be absorbed and reduced, and thus, this kind of S-shaped metal honeycomb structure (H ′) is used. ') Is excellent in durability.

In the above-mentioned manufacturing method, when one stack is used, as shown in FIG. 20, a metal honeycomb structure (H ') of an S-shaped type whose constituent members are curved in an S-shape at a central portion. Is manufactured. When three stacks are used, as shown in FIG. 21, there is obtained a tom type in which the three stacks have a three-toe shape at the central portion. In addition, only a part of corrugated foil (1 ') and flat foil (2') are shown for clarity of the figure.

An X-wrap type metal honeycomb structure (H ') shown in FIG. 22 has a corrugated foil (1') and a flat foil (2 ').
') Are alternately stacked in a desired number of stages to form a stack (s
and four stacks (X _{1 to} X ₄ ) are used, and the stacks are brought into contact with each other at one contact end and wound and formed in the same direction around the contact end. Things. When this kind of X-wrap type metal honeycomb structure (H ') is loaded and fixed in the metal casing (C), one end of the corrugated foil (1') and the flat foil (2 ') of each stack is provided. The structure is such that the portion comes into contact with the inner wall surface of the outer metal casing (C). In the manufacturing method described above,
As shown in FIG. 22, a metal honeycomb structure (H ′)
Since the stack is assembled in an X-shaped (cross-shaped) shape at the center portion of the metal honeycomb structure and wound and formed around the center portion, this kind of metal honeycomb structure (H) is known in the art as an X-wrap type. It is commonly called. In addition, in order to make a figure clear, some corrugated foil (1 ') and flat foil (2')
Only shown.

The above-described conventional metal honeycomb structures (H ') having various structures are loaded and fixed in a metal casing (C) to manufacture a metal carrier (MS).
As the metal casing (C), which is a component of the metal carrier (MS), a metal tubular body for housing and fixing the metal honeycomb structure (H ′) therein is used. Front view (cross section) of the metal casing (C)
The shape is not limited to the circular shape shown in FIGS. 16 to 17, but may be a shape suitable for the front (cross-sectional) shape of the metal honeycomb structure (H ′), for example, an elliptical shape, an oval shape, a race track shape , Polygons and other irregular shapes.

The metal carrier (M ') having the above-described conventional metal honeycomb structure (H') of various structures as a main component is used.
S) is used under severe thermal environmental conditions of an exhaust gas system. For this reason, first, at the site of the metal honeycomb structure (H '), the contact portions of the two foil materials (corrugated foil and flat foil) (1', 2 '), which are the constituent members, are firmly fixed. . This is a metal honeycomb structure (H ')
Is exposed to high temperature due to the high temperature of the exhaust gas itself and the exothermic reaction between the exhaust gas and the supported exhaust gas purifying catalyst, which generates a large thermal stress in such a high temperature atmosphere. The contact portion is firmly fixed by a fixing method such as brazing or welding so as to withstand the thermal stress. For example, in consideration of absorption / relaxation of thermal stress, the contact portion between the flat foil (1 ′) and the corrugated foil (2 ′) at a desired portion inside the honeycomb structure (H ′) is fixed by brazing or welding. It is fixed by means.

Second, a metal honeycomb structure (H
') And the contact surface of the metal casing (C) are also firmly fixed from the viewpoint of preventing separation of the two components due to the thermal stress and vibration. Note that a large thermal stress is generated inside the metal honeycomb structure (H ′), which concentrates and accumulates on the contact surface of both components, and induces separation of both components. In order to absorb and relax, a method has been proposed in which a specific portion of the contact surface of both components is fixed by brazing or the like.

As described above, a conventional metal carrier (M
Metal honeycomb structure (H) which is a main component of S)
′), The corrugated foil (1 ′) and the flat foil (2 ′)
They are fixed to each other at the peaks and valleys of the corrugated foil (1 '). Therefore, since the contact portion cannot carry a catalyst substance for purifying exhaust gas, both foil materials (1
', 2'), the effective area ratio for supporting the catalyst with respect to the total surface area is low.

More specifically, a heat-resistant Fe—Cr 20% -Al 5% system having a thickness of 50 μm or less and used as a corrugated foil (1 ′) and a flat foil (2 ′) of this type is used. For steel foil, SU with a weight basis of about 1.5 mm thick
It is extremely expensive, about 5 times the material of S304,
The reduction of the effective area ratio for supporting the catalyst by the contact portion is uneconomical. By the way, metal carrier (M
S) The ratio of the material cost of the heat-resistant steel foil (1 ', 2') to the total cost is as high as 50%, and the catalyst for purifying the exhaust gas of the heat-resistant steel foil (1 ', 2') is supported. In order to improve the exhaust gas purifying ability under a predetermined effective area ratio, the heat-resistant steel foil (1
', 2') is strongly demanded from the viewpoint of economy.

Further, what must be considered in the conventional metal carrier (MS) is the fixing means applied to the production of the metal carrier (MS). As described above, in the production of the metal carrier (MS), both foil materials (corrugated foil and flat foil) (1 ′, 2) constituting the metal honeycomb structure (H ′)
(A) and the contact surface between the metal honeycomb structure (H ') and the metal casing (C) are fixed by applying fixing means such as brazing or brazing from the viewpoint of durability. Is what is done.

As the fixing means, a brazing method is generally adopted from the viewpoint of productivity and uniformity of fixing strength. However, in the brazing method, the brazing material used is, for example, Ni, because of the conditions under which the metal carrier (MS) is used in a high-temperature atmosphere.
And high-temperature brazing materials such as Ni-Cr-based alloys. From the viewpoint of economy, reduction in the amount of use is strongly demanded. In addition, the point of reducing the amount of the brazing material used is that the contact area between both foil materials (corrugated foil and flat foil) (1 ′, 2 ′) is large as described above. The amount of brazing material increases, and as a result, the heat resistance of both foil materials decreases due to the alloying reaction and diffusion reaction between the brazing material components and the metal components of both foil materials,
Further, problems such as activation of the catalyst are induced, and from this aspect, it is strongly demanded to reduce the amount of the brazing filler metal used.

[0023]

SUMMARY OF THE INVENTION The present invention has been made in view of the limitations of the above-mentioned conventional metal honeycomb structure (H ') for supporting an exhaust gas purifying catalyst. The present inventors have eagerly studied a metal honeycomb structure having a new structure.

As a result, the present inventors changed the corrugated structure of the corrugated foil (1 ') to a special corrugated foil (1') in the conventional metal honeycomb structure (H '). By doing so, the contact loss between both foil materials (1 ', 2') is greatly reduced, and the back pressure resistance (ventilation resistance of exhaust gas), which has a great influence on the efficiency of the internal combustion engine, is greatly reduced. Furthermore, it has been found that excellent operational effects can be obtained, such as saving of expensive foil materials based on drastic reduction of contact loss between both foil materials (1 ', 2').

That is, the present inventors changed the corrugated foil (1 ′) of the conventional metal honeycomb structure (H ′) to (i).
And (ii) the flat foil (2)
(A) has a non-contact area (b) that is not in contact with the flat foil (2 ′) connected to the area (a) that is in contact with the area (a), and (iii) the waveform of the non-contact area (b). Wave height of conventional wave foil (1 ')
(Iv) having a wavefront substantially half of the wave height of the flat foil and substantially parallel to the flat foil (2 ′).
(A) and the non-contact area (b) as a repeating unit having one cycle length, the knowledge that the above-mentioned excellent characteristics can be exhibited. Was.

The present invention has been completed based on the above findings. According to the present invention, there is provided a metal honeycomb structure (H) which is a main component of an exhaust gas purifying metal carrier (MS) which is economical and has excellent characteristics.

[0027]

SUMMARY OF THE INVENTION In summary, the present invention is made by alternately abutting corrugated strips (1) and flat strips (2) made of a thin metal plate. In a metal honeycomb structure for supporting an exhaust gas purifying catalyst having a honeycomb structure, the corrugated band-like material (1) includes: (i) a one-cycle length (λ ′) having a desired wave height (h); (Ii). With respect to the virtual corrugated sheet (1 '), (ii) -1. The virtual corrugated sheet (1') A region where at least one set of adjacent peaks and valleys of adjacent waves is in contact with the plate-shaped band (2), and a plate-shaped band connected to the region in contact with the plate-shaped band (2) (2) dividing the period of the new waveform having a non-contact area (λ) into (2), and (ii) -2. , The virtual corrugated sheet (1) ′) Are divided so as to have a height of approximately half (approximately ・ · h) of the wave height (h) of (iii). (Iii). The one period divided on the virtual corrugated sheet (1 ′) The present invention relates to a metal honeycomb structure in which a corrugated structure (1) is formed by connecting a long (λ) corrugated structure.

[0028]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The technical constitution and embodiments of the present invention will be described below in detail with reference to the drawings. It goes without saying that the present invention is not limited to the illustrated one.

FIGS. 1 and 2 are views for explaining the configuration of the metal honeycomb structure (H) according to the first embodiment of the present invention.
FIG. 1 is a diagram illustrating a corrugated strip (1) having a special corrugated structure, which is a constituent member of the metal honeycomb structure (H). FIG. 1 is an enlarged front view of the corrugated band material (1). FIG. 2 shows a metal honeycomb structure (1) of the first embodiment of the present invention manufactured using the corrugated strip (1) shown in FIG. 1 and a flat strip (2) as another component. It is a partial enlarged front view of H). FIG. 2 corresponds to a partially enlarged view of the front view of the conventional metal honeycomb structure (H ′) shown in FIG.

As shown in FIGS. 1 and 2, in the metal honeycomb structure (H) according to the first embodiment of the present invention, the largest characteristic point is the point of the corrugated structure of the corrugated strip (1). It is in.

The corrugated structure of the corrugated strip (1) of the present invention is as follows:
Particularly, as shown in FIG. 1, it has the following configuration. The uniqueness of the corrugated structure of the corrugated strip (1) of the present invention is the corresponding conventional corrugated strip (1 ') (see FIG. 15).
Can be easily understood in comparison with. For this reason, in FIG. 1, the conventional corrugated strip (1 ′) is replaced with the virtual corrugated sheet (1 ′).
'). In the figure, the corrugated strip (1) of the present invention is indicated by a solid line, while the conventional corrugated strip (1 '), that is, the virtual corrugated sheet (1') of the present invention. The non-contact area (1b) described later in the solid line portion of the corrugated strip (1)
And the dotted line.

As shown in the figure, a conventional corrugated strip (1)
′), That is, the virtual corrugated sheet (1 ′) has a wave height of (h) and is constituted by a series of triangular waveforms having one wavelength (one cycle length) of (λ ′). The waveform structure of the conventional corrugated strip (1 '), that is, the virtual corrugated sheet (1') is not limited to the triangular waveform described above, but may be a desired shape such as a substantially sinusoidal waveform or a trapezoidal waveform. It is needless to say that there is no problem. Therefore, the corrugated structure of the region of the corrugated strip (1) of the present invention in contact with the flat strip (2) is, by definition, divided on the virtual corrugated sheet (1 '). As can be seen from the above, the present invention is not limited to the above triangular waveform.

As shown in FIG. 1, the corrugated sheet material (1) of the present invention is constituted as follows. That is, the corrugated strip material (1) having a special structure according to the present invention includes: (i) a virtual corrugated sheet formed by connecting triangular waveforms having a desired wave height (h) and corresponding to one cycle length (λ ′); (1 ′), in other words, with reference to the corrugated band material (1 ′) (see FIG. 15) of the conventional simple structure employed in the prior art, (ii). In contrast to (ii), (ii) -1. A region (1a) where a pair of adjacent peaks and valleys of the waveform of the virtual corrugated sheet (1 ') abuts on the flat strip material (2); And a non-contact area (1b) of the flat strip material (2) connected to the contact area (1a) is divided into one cycle length (λ), and ( ii) -2. The area (1b) that is not in contact with the flat strip (2) is set to a height that is approximately half (approximately 1/2 · h) of the wave height (h) of the virtual corrugated sheet (1 ′). (Iii). Dividing the sheet so as to have a wavefront substantially parallel to the flat strip material (2). Way virtual wave plate (1 ') articulating the sectioning has been the one period length (lambda) worth of corrugations on it, is composed by.

In FIG. 1, an area (1c) is shown in addition to the areas (1a, 1b). This area (1c)
Is to be understood as a complementary region for completing a waveform of one period length (one unit length) (λ). In the present invention, the region (1c) is, as shown in FIG. 7 described later, a region (1a) in contact with a desired number of flat strips different from the regions (1a, 1b), and a region (1a) not in contact with the band member. 1
b). In this case, it goes without saying that the areas (1a, 1b) and the area (1c) together constitute one cycle length (λ).

In the present invention, in the contact area (a), the adjacent peaks and valleys of the triangular waveform abut on the flat strip material (2). It is to be understood that the present invention is not limited to the mode of contacting the flat strip material (2), and may be, for example, two sets as shown in FIG. It is. Furthermore, it should be understood in a broad sense that the wavefront of the non-contact area (1b) is substantially parallel to the flat strip (2). For example, non-parallel relationships due to deformations in the manufacture of the corrugated strip (1) should be interpreted as acceptable.

As described above, the virtual corrugated sheet (1) of the present invention is used.
'), The corrugated strip (1) formed (referenced) has a wave height (h) and a wavelength (λ) of a desired size.
Is something that can have In general, when the non-contact area (1b) of the corrugated sheet material (1) is large, the processing rigidity is reduced when the corrugated sheet material (1) is wound and formed with the flat sheet material (2). The corrugated structure of the material (1) is easily deformed. In order to improve this point, as will be described in detail later, the corrugated band material (1) of the present invention has another corrugated structure in addition to the corrugated structure as shown in FIG. It may be configured. In the corrugated band material (1) of the present invention,
The magnitude of the wave height (h) and one wavelength (λ) may be set as desired. For example, the wave height (h) is 1.0 mm to 2.5
mm and one wavelength (wave pitch) (λ) may be set to 2 mm to 10 mm. In the conventional wound-type metal honeycomb structure (H ′) (see FIGS. 16 to 17), the diameter is 90 mm.
mm, wave height (h) is 1.4 mm, and pitch width is 3.2 (3
00 cpsi).

The metal honeycomb structure (H) according to the first embodiment of the present invention has the above-mentioned special corrugated structure.
As shown in FIG. 2, the contact loss between the two band members (1, 2) can be significantly reduced as compared with the related art as shown in FIG. This results in an improvement in the effective surface area ratio for supporting the exhaust gas purifying catalyst and a reduction in the amount of both band members (1, 2) used. For example, the amount of material used can be reduced by about 20% or more compared to the related art. In addition,
As an additional effect, it is possible to reduce the contact portion between the two strips (1, 2), so that the expensive high-temperature brazing material used for fixing the contact portion between the two strips (1, 2) can be reduced. The amount used can be reduced.

Further, as shown in FIG. 2, due to the corrugated structure of the corrugated strip material (1) of the present invention, the exhaust gas vent hole (cell) (3) has the conventional cell (3). ') (See FIG. 17). For this reason, the metal honeycomb structure (H) of the present invention can significantly reduce the back pressure resistance (ventilation resistance), which greatly affects the efficiency of the internal combustion engine, without lowering the exhaust gas purification ability than before. . For example, the back pressure resistance (ventilation resistance) is about 15%
The above can be reduced. In addition, the thermal deformation force generated inside the metal honeycomb structure (H) is effectively absorbed and absorbed under the corrugated structure of the non-contact area (1b) not in contact with the flat strip (2). Can be relaxed.

In the present invention, the corrugated strip (1) having the special corrugated structure is, for example, a conventional corrugated strip (1 ') applied to a metal honeycomb structure of this kind. ) May be made of a thin metal plate made of heat-resistant steel of the same type as in (1). The corrugated strip (1) of the present invention may be manufactured by corrugating a flat strip. As this flat strip, a normal metal monolith type metal honeycomb structure is used. Strips used for manufacturing, for example, chromium steel (chromium 13% to 25%), Fe-Cr20% -Al
5% thick heat-resistant stainless steel or a heat-resistant stainless steel to which a rare earth metal (REM such as Ce or Y) is added to improve high-temperature oxidation resistance.
A band of about 0 μm to 100 μm is used. In particular, a plate-shaped strip containing Al or an Al layer provided on the surface thereof is subjected to heat treatment, and whisker-like or mushroom-like alumina (Al
Those in which ₂ O ₃ ) is precipitated are preferred. The whisker-like alumina layer is preferable because it can firmly hold a washcoat layer for supporting an exhaust gas purifying catalyst such as Pt, Pd, and Rh.

In the metal honeycomb structure (H) of the present invention, the corrugated strip (1), which is an essential component thereof, is not limited to the above-described one, and various modifications are possible.
Hereinafter, a modified example of the corrugated strip (1) of the present invention and a production example of the corrugated strip (1) of the present invention will be described.

FIGS. 3 and 4 show a corrugated strip (1) of the present invention.
It is a figure explaining the 1st modification of. 3 and 4
FIG. 3 is a view corresponding to FIGS. 1 and 2 relating to a corrugated strip (1) applied to the metal honeycomb structure (H) of the first embodiment. The corrugated band material (1) of the first modified example shown in FIGS. 3 and 4 has a flat wavefront having a height of ・ · h formed in the non-contact area (1b) ( This is the point that the width in the traveling direction of the waveform) is set to one wavelength (λ ′) of the virtual corrugated plate (1 ′). The corrugated strip (1) shown in FIGS. 1 and 2 has a width corresponding to a half wavelength (1/2 · λ).

FIG. 5 is a view for explaining a second modification of the corrugated strip material (1) of the present invention, and is a view corresponding to FIG. FIG. 6 is a view for explaining a third modification of the corrugated strip material (1) of the present invention, and is a view corresponding to FIG. FIG.
FIG. 4 is a view for explaining a fourth modification of the corrugated strip material (1) of the present invention, and is a view corresponding to FIG.

As shown in FIGS. 5 to 7, in the corrugated structure of the corrugated sheet material (1) according to the present invention, "a pair of adjacent peaks and valleys having a triangular waveform have a flat sheet material. (2) a condition in which an area (1a) in contact with the contact area (1a) and a non-contact area (1b) in the flat strip material (2) connected to the contact area (1a) ”are essential requirements. It is understood that the present invention is not limited to this. The manner in which a pair of adjacent peaks and valleys of the triangular waveform abuts on the flat band material (2) is shown in FIGS. FIG. 6 shows a mode in which two sets of adjacent peaks and valleys of a triangular waveform abut on the flat band material (2).

As shown in FIGS. 5 to 7, in the corrugated strip material (1) of the present invention, one period length (λ) is
It can be seen that, in addition to the regions (1a, 1b), a region (1c) connected to the region (1b) for forming a waveform structure having one cycle length (λ) exists. And it turns out that the said area | region (1c) may have a site | part which contacts a flat strip | belt-shaped strip (2), and a part which does not touch a flat strip | belt-shaped strip (2). One period length (λ) of the corrugated strip material (1) of the present invention is constituted by the above-mentioned regions (1a, 1b, 1c).

In the corrugated structure of the area (1c), the area not in contact with the flat strip (2) is the virtual corrugated sheet (1 ').
Has a wavefront that is half (1/2 · h) of the height of the sheet and substantially parallel to the flat strip material (2), and the length of the wavefront is the wavelength (λ ′) of the virtual corrugated sheet (1 ′). ), Or may be an integral multiple of 2 or more of the half wavelength (1/2 · λ ′). Further, in the corrugated structure of the region (1c), the number of the portions that come into contact with the flat strip material (2) and the portions that do not come into contact with the flat strip material (2) may be as desired. It is.

FIGS. 8 and 9 show a corrugated strip (1) of the present invention.
It is a figure explaining the 5th modification of. FIG. 8 is a view corresponding to FIG. FIG. 9 shows one example of a wound-type metal honeycomb structure (H) manufactured using the corrugated sheet material (1) and the flat sheet material (2) of the fifth modified example shown in FIG. It is a front view which omitted a part, and is a figure explaining especially the structure of the central part (winding center part) field and the peripheral part field of a metal honeycomb structure (H).

As shown in FIG. 8, the corrugated band material (1) of the fifth modification is (i) a corrugated plate of the second modification (see FIG. 3) having a wave height of (h). While using the strip (1), (i
i). A triangular waveform area (A) having the same wave height (h) and one cycle length (λ ″) is arranged at one end thereof. The corrugated band material (1) of the fifth modified example having the above-described corrugated structure is important for manufacturing a wound-type metal honeycomb structure (H). That is, the corrugated band material (1) of the fifth modified example has the triangular waveform region (A).
Is wound and formed together with a flat band material (2) as another component so as to be disposed at the winding center and the vicinity thereof, and is used when manufacturing a winding type metal honeycomb structure (H). Is done.

Winding type metal honeycomb structure (H)
When manufacturing a corrugated sheet material (1) of the present invention,
When the triangular waveform region (A) does not exist, the number of abutting portions per unit volume of the corrugated strip (1) with respect to the flat strip (2) is determined by the conventional corrugated strip (1). '), The corrugated portion tends to be deformed by the processing stress during the winding forming. In particular, since a large processing stress is applied to the central portion of the roll forming and the vicinity thereof, the corrugated band material (1) of the fifth modified example is formed of a rolled metal honeycomb structure (H). Important in manufacturing. FIG. 9 shows that a triangular corrugated portion (A) is arranged at the center of the winding and a portion in the vicinity thereof, so that a uniform triangular cell structure can be obtained at this portion, and the wave of the second modified example can be obtained at other portions. This shows that the advantages of the plate-shaped strip (1) can be enjoyed.

In the present invention, the size of the triangular waveform area (A), that is, the length (l _A ) of the triangular waveform area (A) shown in FIG. 8 may be set as desired. For example, in the case of a metal honeycomb structure (H) having a diameter of 100 mm, the length (l _A ) may be set so that the triangular waveform region exists within a range of a radius of 15 mm to 30 mm from the winding center. In the present invention, various modifications can be made to the structure of the triangular waveform region (A). For example,
Modifications such as that the waveform shape is not limited to a triangular waveform and that the wave height (h) may be the same as or different from the corrugated band material (1) are possible.

FIG. 10 is a view for explaining a sixth modification of the corrugated band material (1) of the present invention. FIG. 10 shows an S-shaped metal honeycomb structure manufactured by winding and forming a stack composed of a corrugated strip (1) and a flat strip (2) according to a sixth modification of the present invention. It is a figure which shows the winding center area | region of the body (H) (refer FIG. 20). This type of S-shaped type metal honeycomb structure (H) is formed by stacking a desired number of rectangular strips (1, 2) having a desired length and width in a desired number of steps. Then, a jig for bar-shaped winding forming is disposed at a substantially intermediate portion between the upper and lower outermost layers, and the jig for winding forming is wound in the same direction. Therefore, a large processing stress is applied to the substantially middle portion of the corrugated strip (1) during the winding forming. For this reason, in the corrugated band material (1) of the sixth modified example, the triangular waveform region (A) is disposed at an intermediate portion thereof.

As is apparent from the above description, only the arrangement portion of the triangular waveform area (A) is different.
The corrugated strip (1) of the sixth modification shown in FIG. 9 and the corrugated strip (1) of the fifth modification shown in FIG. 9 have basically the same structure. As is apparent from FIG.
When manufacturing a metal-shaped honeycomb structure (H) in the shape of a letter, the processing stress is applied almost at the center of the stack and to the upper and lower outermost layers and the adjacent layers. In the corrugated band material (1) to be formed, a triangular waveform region (A) may be arranged in the corrugated band material (1) located at the relevant portion (upper and lowermost layers and its neighboring layers),
Alternatively, a triangular waveform area (A) may be provided on all corrugated strips (1) as shown in the figure.

In the present invention, the corrugated band material (1) (see FIGS. 8 and 10) of the fifth and sixth modifications is itself provided.
That is, the corrugated sheet material (1) having the triangular waveform area (A) in at least a part of the area is manufactured by corrugating one continuous flat sheet material. Alternatively, the region (A) having the triangular waveform may be formed of a separate member, which is fixed to the corrugated band material having the above-described special corrugated structure of the present invention by a desired fixing means. It may be. As the fixing means, a desired fixing means such as welding, caulking, mechanical engagement, or temporary fixing may be adopted.

In the present invention, a metal honeycomb structure (H) of the type shown in FIG. 9 is, for example, a corrugated sheet material according to the fifth to sixth modifications described above. It is not limited to the method in which the sheet material is piled up so as to abut on the sheet material, and the sheet material is wound all together. In addition, first, the center portion is manufactured from a corrugated strip having a triangular waveform and a flat strip, and the corrugated strip (1) having the special corrugated structure according to the present invention and the flat strip are formed. The metal honeycomb structure (H) may be manufactured by fixing the material (2) to each of the mating members and subsequently winding and forming the same.

Next, a method of manufacturing the corrugated strip (1) having the above-described various special corrugated structures applied to the manufacture of the metal honeycomb structure (H) of the present invention will be described.

The corrugated strip (1) having the special corrugated structure of the present invention can be efficiently and economically manufactured by using, for example, a pair of upper and lower corrugated gears.

FIG. 11 shows a corrugated strip (1) (FIG. 1) applied to the metal honeycomb structure (H) of the first embodiment.
FIG. 7 is a diagram for explaining a forming gear for manufacturing the same. The corrugated strip (1) having the corrugated structure shown in FIG. 1 is efficiently and economically manufactured by a pair of upper and lower forming gears of a first gear (G1) and a second gear (G2) shown. can do. In the figure, first to first
A drive gear for accurately driving the gear feed of the second gear (G1, G2) is omitted. Further, in FIG. 11 and FIGS.
The toothed black portions of the gear (G1) and the second gear (G2)
This indicates that the tooth shape is half-mountain.

In order to manufacture the corrugated strip (1) having the corrugated structure shown in FIG. 1, (i).
The first gear (G1) is configured to have a tooth shape in which every other tooth has a half-mountain, and (ii) the second gear (G2) has a tooth shape in which all the teeth have a full-mountain. It is composed of things. The first gear (G1) and the second gear (G2) are arranged in the arrangement shown in the figure. In the present invention, a half-mountain tooth refers to a tooth obtained by removing half of the tooth. In addition, the tooth of the whole mountain means a tooth having a completely corrugated tooth. The half-peaked teeth are the remaining ones obtained by removing almost half of all the peaks (from the tooth tips), and the peaks of the half-ridged teeth may be substantially flat.

FIG. 12 is a view for explaining a forming gear for manufacturing the corrugated strip (1) (see FIG. 3) of the first modification. In order to manufacture the corrugated strip (1) having the corrugated structure shown in FIG. 3, as shown, (i). The first gear (G1) has every other tooth in a half-mountain. (Ii) the second gear (G
2) is also configured with a tooth shape in which every other tooth is a half-mountain. Then, the first gear (G1) and the second gear (G
2) is arranged in the arrangement shown in the figure.

FIG. 13 is a view for explaining a forming gear for producing the corrugated strip (1) (see FIG. 5) of the second modification. In order to manufacture the corrugated strip (1) having the corrugated structure shown in FIG. 5, as shown in the figure, (i). The first gear (G1) is formed by setting every third tooth to a half-mountain. (Ii) the second gear (G
2) is also configured with a tooth shape in which every third tooth is a half mountain. Then, the first gear (G1) and the second gear (G
2) is arranged in the arrangement shown in the figure.

FIG. 14 is a view for explaining a forming gear for producing the corrugated strip (1) (see FIG. 6) of the third modification. In order to produce a corrugated strip (1) having the corrugated structure shown in FIG.
(i) The first gear (G1) is configured to have a tooth shape in which every third tooth is a half-mountain, and (ii). the second gear (G2).
Also, it is configured with a tooth shape in which every third tooth is a half-mountain. Then, the first gear (G1) and the second gear (G2)
Are arranged in the arrangement shown in the figure.

[0061]

The metal honeycomb structure (H), which is a main component of the exhaust gas purifying metal carrier (MS) of the present invention, is a conventional simple corrugated corrugated strip (1 ').
And a metal honeycomb structure (H ′) manufactured using the flat band material (2 ′) are a novel structure having a completely different structure.

In particular, the metal honeycomb structure (H) of the present invention has a corrugated sheet material (1) having a special corrugated structure instead of a conventional simple corrugated structure.
And a flat band material (2). In particular, the corrugated strip (1) refers to (i) a virtual corrugated sheet (1 ′) formed by connecting a waveform of one period length (λ ′) having a desired wave height (h). (Ii). With respect to the virtual corrugated sheet (1 '), (ii) -1. The waveform of the virtual corrugated sheet (1') is flat at at least one set of adjacent wave peaks and valleys. One period of a new waveform having a region in contact with the band-shaped band (2) and a region not in contact with the plate-shaped band (2) connected to the region in contact with the plate-shaped band (2). (Ii) -2. The area that is not in contact with the flat strip material (2) is substantially half of the wave height (h) of the virtual corrugated sheet (1 ′) ( (Iii). The waveform structure corresponding to the one period length (λ) divided on the virtual corrugated plate (1 ′) is connected. The corrugated sheet material (1) is constituted. It is.

The metal honeycomb structure (H) of the present invention
Due to the special corrugated structure of the corrugated band material (1), which is a constituent member of the metal honeycomb structure (H), it is possible to have the following unprecedented excellent effects.

The corrugated strip (1) and the flat strip (2), which are the components of the metal honeycomb structure (H) of the present invention,
Due to the corrugated structure of the corrugated strip (1), both strips (1,
The contact loss of 2) can be significantly reduced as compared with the related art. This increases the effective surface area ratio of the expensive strip (1, 2) for supporting the exhaust gas purifying catalyst. In addition, the reduction of the contact loss between the two strips (1, 2) can be achieved by reducing the amount of expensive strips (1, 2) used and by reducing the size and size of the metal honeycomb structure (H). To guide.

Further, as an incidental effect of reducing the contact loss between the two strips (1, 2), an expensive high-temperature solder used for fixing the contact portions of the two strips (1, 2). The amount of material used can be reduced.

Due to the special corrugated structure of the corrugated strip material (1) of the present invention, the exhaust gas vent holes (cells) of the metal honeycomb structure (H) are larger than those of the conventional one. Can be set. For this reason, in the metal honeycomb structure (H) of the present invention, the back pressure resistance (air flow resistance), which greatly affects the efficiency of the internal combustion engine, can be set to be significantly smaller than before without reducing the exhaust gas purification ability. it can.

In the present invention, the heat deformation force generated inside the metal honeycomb structure (H) is a corrugated sheet material (1).
Is effectively absorbed and relaxed in a region where the metal honeycomb structure does not come into contact with the flat band material (2), and thus the metal honeycomb structure (H) of the present invention has excellent durability.

[Brief description of the drawings]

FIG. 1 is a partially enlarged front view of a corrugated strip (1) applied to a metal honeycomb structure (H) according to a first embodiment of the present invention.

FIG. 2 is a corrugated strip (1) and a flat strip (2) of FIG.
The honeycomb structure (H) according to the first embodiment composed of
FIG. 3 is a partially enlarged front view of FIG.

FIG. 3 is a partially enlarged front view of a corrugated strip (1) of a first modified example.

FIG. 4 is a partially enlarged front view of a metal honeycomb structure (H) according to a second embodiment composed of a corrugated strip (1) and a flat strip (2) of the first modified example of FIG. 3; is there.

FIG. 5 is a partially enlarged front view of a corrugated band material (1) of a second modified example.

FIG. 6 is a partially enlarged front view of a corrugated strip (1) of a third modified example.

FIG. 7 is a partially enlarged front view of a corrugated strip (1) of a fourth modified example.

FIG. 8 is a partially enlarged front view of a corrugated strip (1) of a fifth modified example.

FIG. 9 is a front view of a third embodiment of the metal honeycomb structure (H) according to the third embodiment, which is constituted by a corrugated strip (1) and a flat strip (2) of FIG. FIG.

FIG. 10 is a winding center portion of an S-shaped metal honeycomb structure (H) according to a fourth embodiment composed of a corrugated strip (1) and a flat strip (2) of a sixth modification. FIG. 3 is a partially enlarged front view of FIG.

FIG. 11 is a view for explaining a forming gear for manufacturing the corrugated band material (1) shown in FIG.

12 is a diagram illustrating a forming gear for manufacturing the corrugated strip (1) shown in FIG.

FIG. 13 is a diagram illustrating a forming gear for manufacturing the corrugated band material (1) shown in FIG.

FIG. 14 is a diagram illustrating a forming gear for manufacturing the corrugated band material (1) shown in FIG.

FIG. 15 is a perspective view of a corrugated strip (1 ′) and a flat strip (2 ′) used for manufacturing a conventional wound-type metal honeycomb structure (H ′).

FIG. 16 is a perspective view of a metal carrier (MS) including a conventional wound-type metal honeycomb structure (H ′) and a metal casing (C).

FIG. 17 is a front view of the conventional metal carrier (MS) of FIG.

FIG. 18 is a front view of a conventional hierarchical type metal honeycomb structure (H ′).

FIG. 19 is a front view in which a part of a conventional radial type metal honeycomb structure (H ′) is omitted.

FIG. 20 is a front view in which a part of a conventional S-shaped metal honeycomb structure (H ′) is omitted.

FIG. 21 is a front view in which a part of a conventional tom-shaped metal honeycomb structure (H ′) is omitted.

FIG. 22 is a front view in which a part of a conventional X-wrap (swastika) type metal honeycomb structure (H ′) is omitted.

[Explanation of symbols]

MS: Metal carrier H: Metal honeycomb structure C of the present invention C: Metal casing 1: Corrugated sheet material 1a: Contact area 1b to flat sheet material (2) 1b: ... Non-contact area with respect to the flat strip material (2) h... Wave height λ... One wavelength (one cycle length) A... ... A flat strip 3 for the metal honeycomb structure (H) of the present invention 3... Exhaust gas vent holes (cells) 1 ′ of the metal honeycomb structure (H) of the present invention 1 ′. (Conventional corrugated sheet material) 2 '.... Plate material for conventional metal honeycomb structure (H') 3 '... Exhaust gas vent hole of conventional metal honeycomb structure (H) (cell)

Claims (13)

[Claims] 1. A metal honeycomb for supporting an exhaust gas purifying catalyst having a honeycomb structure manufactured by alternately abutting corrugated strips (1) and flat strips (2) made of a thin metal plate. In the structure, the corrugated strip (1) comprises: (i) a virtual corrugated sheet (1 ′) formed by connecting a waveform of one period length (λ ′) having a desired wave height (h); (Ii). For the virtual corrugated sheet (1 '), (ii) -1. The waveform of the virtual corrugated sheet (1') has at least one pair of peaks and valleys of adjacent waves. In the portion, a new waveform having an area that abuts on the flat strip (2) and an area that is not in contact with the flat strip (2) connected to the area that abuts the flat strip (2). (Ii) -2. The area not in contact with the flat strip material (2) is defined as the wave height (h) of the virtual corrugated sheet (1 '). Half (approximately 1 / 2h) height (Iii) A corrugated structure (1) is formed by connecting the waveform structures corresponding to the one period length (λ) divided on the virtual corrugated sheet (1 ′). A metal honeycomb structure, characterized in that: 2. The non-contact area (1b) of the corrugated strip (1) with respect to the flat strip (2) is substantially half (substantially 1/1) of the wave height (h) of the virtual corrugated sheet (1 ′). 2. The metal honeycomb structure according to claim 1, wherein the metal honeycomb structure has a wave front substantially parallel to the flat strip material (2). 3. A non-contact area (1b) of a corrugated strip (1).
The size of the wavefront (width in the traveling direction of the waveform) substantially parallel to the flat band material (2) is the same as the size of approximately half the wavelength (approximately １ ／ · λ ′) of the virtual corrugated sheet (1 ′) The metal honeycomb structure according to claim 2, wherein 4. The non-contact area (1b) of the corrugated strip (1).
The size of the wavefront substantially parallel to the flat band material (2) in
3. The metal honeycomb structure according to claim 2, wherein the metal honeycomb structure has a size that is an integer multiple of 2 or more of a half wavelength (１ ／ · λ ′) of the virtual corrugated plate (1 ′). 4. 5. The corrugated strip (1) has a half wavelength (substantially ・ λ ′) of the virtual corrugated sheet (1 ′) per one cycle length (λ).
The metal honeycomb structure according to claim 2, wherein the metal honeycomb structure has a non-contact area (1b) having a size of (1). 6. The corrugated strip (1) has a half wavelength (1/2 · λ ′) of the virtual corrugated sheet (1 ′) per one cycle length (λ).
The metal honeycomb structure according to claim 2, wherein the metal honeycomb structure has a non-contact area (1b) having a size of an integral multiple of the above. 7. The corrugated sheet material (1) is substantially half wavelength (approximately 1 / 2λ ′) of the virtual corrugated sheet (1 ′) per one cycle length (λ).
And a non-contact portion region (1b) having an integral multiple of two or more half wavelengths (1/2 · λ ′) of the virtual corrugated plate (1 ′). The metal honeycomb structure according to claim 2, which is shared. 8. A corrugated strip (1) in a contact area (1a) of the corrugated strip (1) with respect to the flat strip (2).
2. The metal honeycomb structure according to claim 1, wherein the corrugated shape of the portion abutting the flat strip material (2) is a desired shape. 9. The metal honeycomb structure according to claim 8, wherein the waveform shape is selected from a substantially sinusoidal waveform, a triangular waveform, and a rectangular waveform. 10. A corrugated sheet material (1) is formed at a desired portion and over a desired width (width viewed in a traveling direction of a waveform).
2. The metal honeycomb structure according to claim 1, wherein the metal honeycomb structure has a waveform region (A) formed by connecting waveforms of one cycle length (λ ″) having a desired wave height (h). 11. A corrugated area (A) of a corrugated strip (1).
Is one end of the corrugated strip (1), and the corrugated strip (1) and the flat strip (2) are wound and formed to produce a wound-type metal honeycomb structure. The metal honeycomb structure according to claim 10, wherein the metal honeycomb structure is disposed in a winding center region at the time. 12. A corrugated region (A) of a corrugated strip (1).
Is a substantially middle portion of the corrugated strip (1) having a desired width, and the corrugated strip (1) and the flat strip (about 1) having substantially the same width as the corrugated strip (1). 2) The desired number of sheets are alternately stacked to form a stack, and the stack is wound and formed to be disposed in a winding center region when an S-shaped or tom-shaped metal honeycomb structure is manufactured. Claim 10
3. The metal honeycomb structure according to item 1. 13. A corrugated strip (1) of a desired width and a desired number of corrugated strips (1), at least a part of which has a corrugated region (A). 12
3. The metal honeycomb structure according to item 1.