JPH1066880A - Production of metallic catalyst carrier of catalyst convertor for vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To contrive reduction of production cost in comparison with the conventional practice by unnecessitating joining of a thin plate made of metal and performing continuous catalyst fitting and drying. SOLUTION: A long-sized beltlike metallic thin plate consisting of a flat plate is continuously supplied to a pair of corrugate working gears in which a plurality of gears are laminated to form pairs are engaged with one another. The metallic thin plate is formed into a corrugated shape consisting of a plurality of crest parts and trough parts so that the crest parts and the trough parts of the adjacent metallic thin plates 19 do not become the same phase at time of lamination. Thereafter, the metallic thin plate 19 is continuously supplied into a catalyst tank 29 to stick a catalyst on the front and the rear thereof. After the metallic thin plate 19 is continuously supplied into a drying furnace and burned, it is laminated in a multiplex state to form a core and the core is pressed into an outer cylinder made of metal.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a metal catalyst carrier used for a catalytic converter for a vehicle.

[0002]

2. Description of the Related Art Conventionally, a catalytic converter for purifying exhaust gas has been mounted in a vehicle exhaust system. Recently, as a catalyst carrier used for the catalytic converter, an Fe-Cr-Al ferrite stainless steel foil material (20Cr-5Al) has been used. -La-F
Metal catalyst supports made of a thin metal plate such as e) are widely used.

[0003] As a method for producing such a metal catalyst carrier, the following production method is conventionally known. First, in the first manufacturing method, a band-shaped corrugated sheet made of a thin metal plate and a flat plate are alternately stacked, and these are wound in multiple layers to form a core having a circular or elliptical cross section. Press into the outer cylinder, squeeze the entire outer cylinder with a die, etc., and diffuse between the outer periphery of the corrugated sheet and the flat plate and the core and the outer cylinder in a high temperature atmosphere to eliminate relative movement between the corrugated sheet and the flat plate. It is to join.

[0004] A catalytic converter is manufactured by subjecting the core to a treatment for supporting a noble metal catalyst and welding a diffuser to both ends of the outer cylinder. In addition, as a treatment for supporting the metal catalyst, a washcoat solution containing a metal catalyst such as platinum (for example, a solution containing γ-alumina, an additive and a metal catalyst as components) is poured into the core in the outer cylinder, and the corrugated sheet is formed. A method of forming a thin coating film called a washcoat layer on the surface of a flat plate is widely used.

In a second method for producing a metal catalyst carrier, a strip-shaped corrugated sheet made of a thin metal plate and a flat plate are cut to a fixed size.
These are alternately laminated to form a core, and the third manufacturing method is to squeeze a band-shaped corrugated sheet made of a thin metal plate while cutting a flat plate cut to a fixed size for each fold. In these manufacturing methods, the core is pressed into a metal outer cylinder, and the corrugated plate and the flat plate, and the outer periphery of the core and the outer cylinder are diffusion-bonded. After the core is subjected to a precious metal catalyst loading treatment, diffusers are welded to both ends of the outer cylinder to produce a catalytic converter.

[0006]

As described above, in the conventional metal catalyst carrier, a cell through which exhaust gas passes is formed by laminating a corrugated plate and a flat plate in multiple layers. The corrugated sheet is heavy and can absorb the thermal stress caused by the high temperature exhaust gas, but the flat plate does not easily absorb the thermal stress. .

[0007] It has also been pointed out that insufficient bonding between the corrugated sheet and the flat sheet may cause film-out and damage to the metal catalyst carrier. In the case of the metal catalyst carrier in which the corrugated plate and the flat plate are multiplexed as described above, the fillet 1 to which a large amount of the wash coat solution adheres due to the surface tension as shown in FIG. And the fillet 1 is 30 to 40% of the total applied amount.
However, this fillet 1 did not contribute to the improvement of the purification performance at all, and the fact was that the wash coat solution was wasted.

Further, in any of the manufacturing methods, two kinds of metal thin plates, ie, a corrugated plate and a flat plate are required, and in the second lamination type manufacturing method, the corrugated plate and the flat plate are used. Dozens of sheets had to be cut to a fixed size, and in the case of the third metal catalyst carrier having a self-folding structure, a flat plate had to be inserted for each fold, so that the operation was complicated. in addition,
In these manufacturing methods, corrugation of a thin metal plate (forming of a corrugated sheet) → forming of a core (winding of a corrugated sheet and a flat plate, zigzag folding, etc.) → metal catalyst carrier assembly (insertion of a core into an outer cylinder) , Diffusion bonding) → catalyzing (processing of loading the precious metal catalyst on the core) → drying (firing) of the catalyst is required. Of course, catalyzing and drying must be performed for each metal catalyst carrier. For this reason, a large drying furnace (firing furnace) is required because of this, and there is a disadvantage that the number of steps is large and the production cost of the metal catalyst carrier is high.

Japanese Patent Application Laid-Open No. 5-138040 discloses that
In order to eliminate the necessity of joining the metal thin plates in the production of the metal catalyst carrier, a single metal thin plate is corrugated as shown in FIG. 12 to form a plurality of rows 9a, 9b, A method for manufacturing a metal catalyst carrier is disclosed in which a plurality of rows 9a, 9b, 9c, and 9d are formed while being sectioned, and the phases of the rows 9a, 9b, 9c, and 9d are shifted between adjacent ones.

[0010] In the metal catalyst carrier using the corrugated sheet 11, no flat plate is required, so that the weight of the entire metal catalyst carrier can be reduced, and as a result, the heat capacity becomes low and the temperature rises. In addition to being able to shorten the time, it is excellent in absorbing thermal stress and there is no possibility of causing breakage or falling off, and the ends of the laminated corrugations 7 mesh with each other to prevent the relative movement of the corrugated plate 11, so that the film-out phenomenon occurs. Nothing happens.

However, even in the method for manufacturing a metal catalyst carrier using the corrugated plate 11, the fact is that the supporting treatment and drying of the noble metal catalyst on the core are still performed for each metal catalyst carrier. The present invention has been devised in view of the above circumstances, and is a vehicle that eliminates the need for joining thin metal plates, and achieves a lower manufacturing cost compared to the conventional vehicle by performing continuous catalysting and drying. It is an object of the present invention to provide a method for producing a metal catalyst carrier of a catalytic converter for use.

[0012]

According to a first aspect of the present invention, there is provided a method for manufacturing a metal catalyst carrier for a catalytic converter for a vehicle, wherein a plurality of gears are stacked and a pair of gears mesh with each other. To a pair of corrugated processing gears, a long strip-shaped metal thin plate made of a flat plate was continuously supplied,
After forming the metal sheet into a corrugated shape including a plurality of peaks and valleys so that the peaks and valleys of adjacent metal sheets do not have the same phase during lamination, the metal sheet is catalyzed. After continuously supplying the inside of the tank and attaching the catalyst to the front and back thereof, and then continuously supplying such a thin metal plate to a drying furnace and firing it, laminating the multiple layers to form a circular cross section or a cross section A track-shaped core is formed, and the core is pressed into a metal outer cylinder.

The invention according to claim 2 is based on claim 1
In the method for producing a metal catalyst support according to the above aspect, the core is formed by folding a metal thin plate by staking and multiply laminating the core. The manufacturing method is characterized in that a metal thin plate is cut into a fixed size, and the laminated thin plates are sequentially laminated to form a core.

According to a fourth aspect of the present invention, in the method for producing a metal catalyst carrier according to the first aspect, a core is formed by winding multiple thin metal plates.

(Effects) According to the invention of each claim, a long band-shaped thin metal plate made of a flat plate is continuously supplied to a pair of corrugated gears, and the thin metal plate is formed into a plurality of peaks. And a valley, the metal sheet is continuously fed into the catalyst tank to attach the catalyst to the front and back, and then the metal sheet is continuously fed to a drying furnace. After supplying and firing, the core is formed by laminating the cores in multiple layers, and the core is pressed into an outer cylinder to produce a metal catalyst carrier.

In the metal catalyst carrier thus manufactured, the ends of the ridges and valleys of the laminated metal thin plates mesh with each other to prevent relative movement between the metal thin plates.

[0017]

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

FIG. 1 shows a metal catalyst carrier of a vehicular catalytic converter manufactured according to one embodiment of the invention according to claims 1 and 2. The metal catalyst carrier 13 is made of a metal having a track-shaped cross section. A cylinder 15 and a core 17 pressed into the outer cylinder 15, and the core 17 is made of Fe—Cr—
FIG. 2 shows a strip-shaped metal thin plate 19 made of an Al alloy or the like.
And the layers are sequentially laminated in the horizontal direction.

As shown in FIG. 3, a plurality of peaks 21 and valleys 23 having the same length L are formed in the metal thin plate 19 by louver corrugation as shown in FIG. Are formed in a waveform shape that is sequentially shifted and shifted by 1/2 L in the diagonal direction, and in the present embodiment, the plurality of peaks 21 and valleys 23 are formed in a predetermined regularity in the diagonal direction. 4, the metal thin plates 19 are folded in a zigzag as shown in FIG.
The valleys 23 and the valleys 23 do not have the same phase, and the opposing ridges 21 are in contact with each other so that the cells are not blinded.

As shown in FIG. 4, the peaks 21 and the valleys 23 are formed to have the same length L, and are shifted by 1/2 L obliquely to the flow direction of the exhaust gas G. Almost half of the ridges 21 ′ and valleys 23 ′ arranged at both ends of the metal thin plate 19 are
The length of the valley 23 is 1 / 2L. In addition, in FIG. 3, a thick line portion indicated by reference numeral 25 is a peak portion 21 or a valley portion 2.
3 is a flat part.

The metal catalyst carrier 13 in the present embodiment is configured as described above. The metal catalyst carrier 13 is manufactured as follows by one embodiment of the method according to the first and second aspects of the present invention. You. Although not shown, first, a long band-like thin metal plate made of a flat plate is continuously supplied to a pair of corrugated gears in which a plurality of gears are stacked and a pair of gears mesh with each other. The corrugated metal thin plates 19 described in 3 are sequentially formed.

Next, as shown in FIG. 5, the metal thin plate 19 is continuously passed through a catalyst tank 29 in which a conventionally known wash coat solution 27 containing a metal catalyst such as platinum is stored. The washcoat solution 27 is attached to the front and back of the substrate 19. In FIG. 5, 31 and 33 are guide rollers for the metal thin plate 19, and the metal thin plate 19 is guided by the guide rollers 31 and 33 so as to pass through the washcoat solution 27 in about 3 seconds. .

After that, wash coat solution 27
By continuously supplying the metal thin plate 19 to which the metal is adhered to the drying furnace and firing it, as shown in FIG.
9, a thin washcoat layer 35 is formed on the front and back.
Then, the metal thin plate 19 is folded in a zigzag as shown in FIG. 2, and the metal thin plate 19 is cut into a predetermined size while sequentially laminating the metal thin plates 19 to sequentially form the core 17 having a track-shaped cross section. . Then, each of the molded cores 17 is press-fitted into the outer cylinder 15 made of metal, whereby the metal catalyst carrier 13 as shown in FIG. 1 is manufactured.

Thereafter, a diffuser is welded to both ends of the outer cylinder 15 to produce a catalytic converter. However, the diffusers 39 and 41 are provided in the outer cylinder 15 as in a catalytic converter 37 shown in FIG. Inserted and welded, and the exhaust gas inflow side end 1 of the core 17 is formed with the thickness of the insertion side end 39a, 41a.
7a and the peripheral edge of the exhaust gas outflow end 17b, respectively, or alternatively, as shown in FIG. The core 17 can be positioned with respect to the outer cylinder 15 by holding the peripheral edge of the exhaust gas outflow end 17 b of the core 17.

According to the metal catalyst carrier 13 manufactured as described above, the peaks 2 of each of the laminated metal thin plates 19 are formed.
1 and the ends of the valleys 23 are engaged with each other,
9 Prevent relative movement of each other. In addition, the metal catalyst carrier 1
7, the insertion-side ends 39a, 41a of the diffusers 39, 41 abut against both ends 17a, 17b of the core 17, respectively.
Of the core 17 as a whole and the laminated metal sheet 19
Mutual displacement is prevented.

As described above, in the method for manufacturing the metal catalyst carrier according to the present embodiment, the metal catalyst carrier 13 is manufactured by louver corrugating a long strip-shaped metal thin plate made of a metal plate as shown in FIG. The thin plate 19 is continuously formed and then continuously supplied to the catalyst tank 29 as shown in FIG. 5 to perform catalysis. Thereafter, the cell 17 is formed and pressed into the outer cylinder 15. In the manufacturing process, metal thin plates 19 and outer cylinder 15
The diffusion bonding between the core 17 and the core 17 becomes unnecessary, and the number of steps is reduced. In addition, the catalyst can be continuously applied to the thin metal plate 19 before the core 17 is formed, and the noble metal catalyst can be supported on the core. Compared to the conventional example where the treatment was performed for each metal catalyst carrier,
It becomes possible to manufacture the metal catalyst carrier 13 at extremely low cost.

Conventionally, in order to form a metal catalyst carrier by folding a single corrugated sheet, a flat plate must be inserted at each fold to form a cell. When winding or laminating with a single sheet, there are parts where the peaks and valleys of the corrugated sheet have the same phase, so the peaks and valleys overlap and the blindness and surface area of the cell decrease, There is a drawback that the ventilation resistance and the exhaust gas purifying action of the catalyst are significantly deteriorated.

As a countermeasure, it is necessary to wind two corrugated sheets together in the opposite direction, or to turn the two corrugated sheets upside down so that one sheet is in opposite phase. According to this, the core 17 can be manufactured by simply folding a single metal thin plate 19, and needless to say, it is not necessary to insert a flat plate for each fold to form cells as in the conventional case, The produced metal catalyst carrier 13 does not suffer from blinding of cells, nor does the fillet 1 as shown in FIG. 11 be formed.

Since the metal catalyst carrier 13 is reduced in weight by eliminating the need for such a flat plate, the catalytic converter 37 using the metal catalyst carrier 13 has a low heat capacity, can reduce the time required for temperature rise, and can reduce the thermal stress. The metal catalyst carrier 13 is excellent in absorption and there is no danger of breaking or falling off, and the metal catalyst carrier 13 is prevented from moving relative to the metal thin plate 19 because the ends of the peaks 21 and the valleys 23 of the stacked metal thin plates 19 mesh with each other. Therefore, the film-out phenomenon does not occur.

As described above, in the present embodiment, the metal thin plate 19 provided with the washcoat layer 35 on the front and back is folded in a zigzag as shown in FIG. 2, so that the peeling of the washcoat layer 35 slightly occurs at the fold. There is a fear. However, in the case of the metal catalyst carrier 13 of this type, since the catalytic action at such a portion is not so expected, any peeling of the wash coat layer 35 at the fold portion does not cause any exhaust gas of the catalytic converter 37. There is no hindrance to purification performance.

In the above-described embodiment, the core 17 is formed by folding the thin metal plate 19 to which the catalyst has been applied, as shown in FIG. 2, but according to the first and third embodiments shown in FIG. As described above, the metal thin plate 19 after the catalyzing shown in FIG. 5 is cut into a fixed length, and these are sequentially laminated to form the core 17. As in the embodiment of item 4, the core may be formed by winding the metal thin plate 19 having been catalyzed as shown in FIG. 5 in multiple layers, and the intended purpose may be achieved by each of these embodiments. It is possible to achieve.

Further, the metal sheet for forming the metal catalyst carrier is not limited to the above-mentioned metal sheet 19, and a long strip-shaped metal sheet made of a flat plate is continuously supplied to the corrugating gear. As shown in FIG. 10, a ridge portion 49 having the same length M is successively adjacent to each valley portion 47 in a diagonal direction to the flow direction of the exhaust gas G like a metal thin plate 45 shown in FIG. It may be formed into a corrugated shape so that the opposed metal peaks 49 of the laminated metal thin plates 45 do not come into contact with each other so that the cells are not blinded. It is also possible to use a conventional metal thin plate 11 shown in FIG.

[0033]

As described above, according to the method for manufacturing a metal catalyst carrier according to each claim, it is not necessary to join the metal thin plates forming the core, and the number of steps is reduced. The catalyst can be continuously applied to the thin metal plate before core molding and drying, so the metal catalyst carrier is manufactured at extremely low cost compared to the conventional case where the processing of loading the noble metal catalyst on the core is performed for each metal catalyst carrier. It became possible to do.

[Brief description of the drawings]

FIG. 1 is an overall perspective view of a metal catalyst carrier manufactured by one embodiment of a manufacturing method according to claims 1 and 2.

FIG. 2 is a process chart of the method for producing the metal catalyst carrier shown in FIG.

FIG. 3 is a partial perspective view of a metal thin plate used for manufacturing the metal catalyst carrier shown in FIG.

FIG. 4 is an explanatory diagram showing a state of lamination of metal thin plates at the time of manufacturing the metal catalyst carrier of FIG. 1;

FIG. 5 is a process chart of the method for producing the metal catalyst carrier shown in FIG.

FIG. 6 is a process chart of the method for producing the metal catalyst carrier shown in FIG.

FIG. 7 is a sectional view of a main part of a catalytic converter using the metal catalyst carrier shown in FIG.

8 is an enlarged sectional view of a main part of a modified example of the catalytic converter using the metal catalyst carrier shown in FIG.

FIG. 9 is a process chart of one embodiment of the manufacturing method according to claims 1 and 3;

FIG. 10 is a partial perspective view of a modified example of a metal thin plate.

FIG. 11 is a sectional view of a main part of a conventional metal catalyst carrier.

FIG. 12 is a partial perspective view of a conventional metal thin plate.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 13 Metal catalyst carrier 15 Outer cylinder 17 Core 19, 45 Metal thin plate 21, 21 ', 49 Mountain part 23, 23', 47 Valley part 27 Wash coat solution 29 Catalyst tank 35 Wash coat layer 37 Catalytic converter 39, 41 Diffuser 43 Flange

──────────────────────────────────────────────────の Continuation of the front page (51) Int.Cl. ⁶ Identification number Office reference number FI Technical display location B21D 47/00 B21D 47/00 C F01N 3/28 301 F01N 3/28 301P

Claims (4)

[Claims] An elongated strip-shaped thin metal plate made of a flat plate is continuously supplied to a pair of corrugated gears in which a plurality of gears are stacked and a pair of gears mesh with each other. When laminating, the adjacent metal sheet (19,
45) peaks (21, 21 ', 49) and valleys (2)
3, 23 ', 47) and a plurality of peaks (21, 21', 49) and valleys (23, 23 ', 4) so that they do not have the same phase.
7), the metal thin plates (19, 45) are continuously supplied into the catalyst tank (29) to attach the catalyst to the front and back surfaces thereof, and then the metal thin plates (19, 45) are formed. (19, 45) is continuously supplied to a drying furnace and fired, and then laminated in multiple layers to form a core (17) having a circular or track-shaped cross section, and the core (17) is made of metal. A method for manufacturing a metal catalyst carrier for a catalytic converter for a vehicle, wherein the metal catalyst carrier is press-fitted into an outer cylinder (15). 2. The core (17) is made of a metal sheet (19, 4).
5. The method for manufacturing a metal catalyst carrier of a catalytic converter for a vehicle according to claim 1, wherein the metal catalyst carrier is formed by folding and severing 5). 3. The core (17) is made of a metal sheet (19, 4).
5. The method for producing a metal catalyst carrier for a catalytic converter for a vehicle according to claim 1, wherein 5) is cut into a fixed size, and is sequentially laminated and molded. 4. The core (17) is made of a metal sheet (19, 4).
5. The method for producing a metal catalyst carrier of a catalytic converter for a vehicle according to claim 1, wherein 5) is formed by winding multiple times.