US20050115070A1 - Metal carrier - Google Patents
Metal carrier Download PDFInfo
- Publication number
- US20050115070A1 US20050115070A1 US10/995,346 US99534604A US2005115070A1 US 20050115070 A1 US20050115070 A1 US 20050115070A1 US 99534604 A US99534604 A US 99534604A US 2005115070 A1 US2005115070 A1 US 2005115070A1
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- United States
- Prior art keywords
- radius
- metal
- metal sheet
- crest
- catalyst
- 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.)
- Abandoned
Links
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 86
- 239000002184 metal Substances 0.000 title claims abstract description 86
- 239000003054 catalyst Substances 0.000 claims abstract description 34
- 230000003197 catalytic effect Effects 0.000 description 7
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 7
- 238000004140 cleaning Methods 0.000 description 6
- 239000011888 foil Substances 0.000 description 6
- 239000002699 waste material Substances 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 229910052697 platinum Inorganic materials 0.000 description 4
- 230000001603 reducing effect Effects 0.000 description 4
- 238000005219 brazing Methods 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 238000009792 diffusion process Methods 0.000 description 3
- 238000005304 joining Methods 0.000 description 3
- 239000012528 membrane Substances 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- QVQLCTNNEUAWMS-UHFFFAOYSA-N barium oxide Chemical compound [Ba]=O QVQLCTNNEUAWMS-UHFFFAOYSA-N 0.000 description 2
- 229910000420 cerium oxide Inorganic materials 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 description 2
- 229910002060 Fe-Cr-Al alloy Inorganic materials 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000011086 high cleaning Methods 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
Images
Classifications
-
- B01J35/56—
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
- F01N3/2807—Metal other than sintered metal
- F01N3/281—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49345—Catalytic device making
Definitions
- the present invention relates to a metal carrier for catalytic converter provided in an exhaust system of an internal combustion engine and the like.
- An exhaust system for an internal combustion engine or the like is provided with a catalytic converter which cleans emissions.
- This kind of catalytic converter generally uses metal carrier having metal sheet such as Fe—Cr—Al based ferrite stainless foil as the catalytic converter.
- metal sheet corrugated plates and metal sheet flat plates are alternately stacked on one another. These stacked plates are wound many times, forming a core having a honeycomb structure.
- the structure has a circular cross section and the like.
- a lower-corrugated plate having lower corrugation height than that of the corrugated plate may be used as the flat plate.
- a brazing foil material is wound around an outer periphery of the core, it is press-fitted into a metal outer cylinder, and this is heated in a vacuum. With this heating operation, crests of the corrugated plate and the flat plate are joined to each other using diffusion joining, and the outer cylinder and the core are brazed to each other.
- Catalyst such as platinum is added to the core, diffusers are welded to both ends of the outer cylinder, thereby forming a catalytic converter.
- wash coat solution containing catalyst is poured into the core, and a thin membrane containing the catalyst is formed on the surface of the core. See Japanese Patent Applications Laid-open Nos. 2000-61317 and No. 2003-334456.
- the metal carrier has a joint portion between the corrugated plate and the flat plate (or low-corrugated plate)
- the joint portion has a fillet (catalyst residue) produced from the wash coat solution under surface tension.
- This fillet is determined by the plate material, air (atmosphere), the surface tension of the solution and the like.
- the fillet is formed such as to draw an arc, and has large thickness. This prevents catalyst contained in the fillet from exhibiting the original performance, and the catalyst is waste.
- the first aspect of the invention provides the following metal carrier.
- the metal carrier Includes a core having a thinned film containing a metal catalyst.
- the core includes a first metal sheet corrugated and having a crest with a first radius.
- the core includes a second metal sheet flattened or corrugated smaller in corrugation height than the first metal sheet.
- the first and second metal sheets are stacked on each other and are wound up.
- the crest and second metal sheet are joined to each other, having a joint therebetween.
- a fillet of the catalyst is formed between the joint, the first metal sheet, and the second metal sheet, having an arced surface of a second radius extending between the first and second metal sheets.
- the first radius is set substantially equal to the second radius.
- the first radius may be an inner radius of the crest.
- the first radius may be 1.0 to 1.2 times of the second radius.
- the second aspect of the invention provides the following metal carrier.
- the metal carrier includes a core having a thinned film containing a metal catalyst.
- the core includes a first metal sheet corrugated and having a crest of a first radius.
- the core includes a second metal sheet flattened or corrugated smaller in corrugation height than the first metal sheet.
- the first and second metal sheets are stacked on each other and are wound up.
- the crest and second metal sheet are joined to each other, having a joint therebetween.
- a fillet of the catalyst is formed between the Joint, the first metal sheet, and the second metal sheet, having an arced surface of a second average radius extending between the first and second metal sheets.
- the first radius is set to the second average radius with a standard deviation (a) or more.
- the first metal sheet has a vertical wall set to be substantially normal to the second metal sheet.
- the first metal sheet may have a corrugation height between a crest and a trough thereof and a corrugation pitch between neighboring crests.
- the corrugation height may be greater than the corrugation pitch.
- FIG. 1 is an illustrative view of a method of producing a metal carrier according to a first embodiment
- FIG. 2 is a perspective view of the metal carrier of the first embodiment
- FIG. 3 is an elevation view illustrating the benefit of the first embodiment
- FIG. 4 is a partial sectional view of a metal carrier of a comparative example
- FIG. 5 is a partial sectional view of a metal carrier according to a second embodiment
- FIGS. 6A and 5B are illustrative views of a concrete. design example according to the second embodiment.
- FIGS. 7A and 7B are illustrative views of catalyst-reduction effects obtained by a substantially normal corrugated foil vertical wall.
- a metal carrier 10 A includes a corrugated plate 1 A as a first metal sheet and a flat sheet 2 as a second metal sheet of a thinned metal plate in a band-shape.
- the corrugated plate 1 A and the flat plate 2 are composed with Al of around 5%, Cu of around 20%, in addition, minute amount of metal Mn, Mo and the like, and the remains of Fe.
- the thickness of plate 1 A or 2 is 20 to 50 ⁇ m.
- the corrugated plate 1 A and the flat plate 2 are alternately stacked on one another, forming a layered product.
- the layered product is wound many times, forming a core 3 having a honeycomb structure.
- the honeycomb structure has a circular cross section for example.
- a brazing foil material wound around the outer periphery of the core 3 This is press-fitted into a metal outer cylinder 4 as shown in FIG. 2 and heated in a vacuum. With this heating operation, the corrugated plate 1 A and the flat plate 2 are joined to each other using diffusion joining, and the outer cylinder 4 and the core 3 are brazed to each other for joint.
- Wash coat solution containing catalyst such as platinum is poured into the core 3 , forming a thin membrane containing the catalyst on the surface of the core 3 .
- the catalyst contains a main component of alumina (Al 2 O 3 ) with another minute amount of cerium oxide (CeO 2 ) or barium oxide or the like, which contains Pt, Pd, or Rh.
- Diffusers (not shown) are welded to both ends of the outer cylinder 4 , forming a catalytic converter.
- the corrugated plate 1 A has thickness of 30 ⁇ m, corrugation height H 1 of 2.0 mm, and corrugation pitch P 1 of 1.6 mm.
- the corrugation height is a distance between the trough and the crest of a corrugation.
- the corrugation pitch is a distance between neighboring crests or between neighboring troughs of a corrugation.
- the corrugated plate 1 A has crests 1 a, 1 b, and 1 c whose radii R 1 , R 2 , and R 3 are 0.2 mm, 0.3 mm and 0.4 mm, respectively.
- the cross section areas of fillets 5 a, 5 b, and 5 c are 55 , 65 , and 90 , respectively. These numeric values are comparative values when a cross section area of a fillet 103 of a comparative example shown in FIG. 4 is set to 100.
- the corrugated plate 101 is interposed between two flat plates 102 .
- the corrugated plate 101 has corrugation height H 2 of 1.2 mm, pitch P 2 of 2.56 mm, and crest radius R 4 of 0.55 mm.
- Each of the fillets 5 a, 5 b, and 5 c has radius r 1 of 0.25 mm.
- a crest la having radius R 1 of 0.2 mm produces a catalyst residue inside the crest 1 a.
- the crest 1 a having radius R 4 of 0.4 mm does not produce a catalyst residue inside of the crest 1 a.
- the fillet 5 c is greater in area than the fillet 5 a having the radius R 1 of 0.2 mm.
- the crest 1 b having radius R 2 of 0.3 mm produces little catalyst residue inside the crest 1 b.
- the fillet 5 b is smaller in area than the fillet 5 c in correspondence with radius R 3 , and greater than the fillet 5 a.
- the crest 1 b reduces a total amount of waste catalyst as compared with the crests 5 a and 5 c of radius R 1 and R 3 .
- the radii R 1 , R 2 , and R 3 are outer radii of the crests 1 a, 1 b, and 1 c, respectively.
- the inner radii of the crests 1 a, 1 b, and 1 c are smaller than the radii R 1 , R 2 , and R 3 .
- the determination of inner radius of the crest 1 a as a reference eliminates the influence due to the thickness of the corrugated plate 1 , reducing the amount of the catalyst residue with higher accuracy.
- the inner radius of the crest 1 a may not be completely equal to the radius r 1 .
- the inner radius is 0.8 to 1.2 times of the radius r 1 .
- the inner radius may be 1.0 to 1.2 times of the radius r 1 .
- the stacked corrugated plates, flat plates, and metal carrier 10 A are described.
- the flat plate 2 may be replaced by a lower-corrugated plate with a lower corrugation height.
- the lower-corrugated plate and the corrugated plate 1 may be stacked on each other to form the core, which obtains the identical benefit.
- a metal carrier 10 B of a second embodiment will be described.
- the basic structure of the metal carrier 10 B is identical with that of the metal carrier 10 A in the first embodiment.
- Corrugated plate 1 B and flat plate 2 of band-shaped thinned metal plates are alternately stacked on one another, forming a layered product.
- the layered product is wound many times, forming a core 3 having a honeycomb structure.
- This honeycomb structure has a rectangular cross section.
- Brazing foil material is wound around the outer periphery of the core 3 (see FIG. 1 ). This is press-fitted into a metal outer cylinder 4 and heated in a vacuum. With this heating operation, the corrugated plate 1 B and the flat plate 2 are joined to each other using diffusion joining, and the outer cylinder 4 and the core 3 are brazed to each other for joint (see FIG. 2 ).
- Wash coat solution containing catalyst such as platinum is poured into the core 3 .
- Diffusers (not shown) are welded to both ends of the outer cylinder 4 , forming a catalytic converter.
- the corrugated plate 1 B has crests 1 d each having radius R 5 .
- Each of the crests 1 d has a fillet 5 d.
- the arc of the fillet 5 d is set equal to or greater than average radius r 2 + ⁇ ( ⁇ : standard deviation).
- the corrugated plate 1 B has a corrugated foil vertical wall 1 e.
- the vertical wall 1 e is set to be substantially normal (for example 88°, preferably 90°) relative to the flat plate 2 .
- the fillet 5 d has the arc having average value of 0.264 mm and radius r 2 having standard deviation of 0.024.
- radius R 5 of the crest 1 d is set to the average value +2.33 ⁇ of the radius r 2 of the arc of the fillet 5 d, e.g., to 0.32 mm for example.
- the density of a corrugated plate 1 is 600 cells, and its corrugation height H 3 is 1.91 mm.
- Corrugation pitch P 3 is 1.28 mm which is two times of the radius R 5 . With this, the height H 3 of the corrugated plate is greater than the corrugation pitch P 3 thereof.
- the corrugation pitch P 4 is 1.28 mm.
- the corrugation height H 4 is 1.35 mm.
- the corrugation pitch P 4 and the corrugation height H 4 are substantially equal to each other.
- the corrugated plate 1 B produces little catalyst residue Inside of the crest 1 d.
- radius R 5 of 0.32 mm does not produce the catalyst residue with a probability of 99%.
- the fillet 5 d is smaller in area than the fillet 5 c (see FIG. 3 ) with the radius R 3 of 0.4 mm, which reduces the total amount of waste catalyst.
- FIG. 7A shows a corrugated plate 101 of a comparative example with respect to FIG. 4 , and radius r of an arc of a fillet 103 is in contact with a straight line of the corrugated plate.
- the fillet 103 is formed in a range surrounded by contact points Rfa, Rfb, and Rla.
- the substantially normal corrugated vertical wall 1 b allows an arc of a fillet 5 with radius r 2 and the circle of the crest 1 a of the corrugated plate 1 B with radius R 5 to be in contact with each other.
- the area of the fillet 5 d is smaller than that of the fillet 5 shown in FIG. 7A .
- the radius R 5 of the crest 1 d of the corrugated plate 1 B is slightly greater than the radius r 2 of the arc of the fillet 5 .
- the corrugated plate 1 B has a corrugation-shape having a substantially normal corrugated vertical wall 1 d. This configuration minimizes the waste catalyst, reducing the production costs.
- the standard deviation is 2.33 in this embodiment, in order to obtain the benefit of this embodiment, the standard deviation may be at least 1 a.
- This relationship reduces the representative length (equivalent diameter) which controls the coefficient of heat transfer by the current corrugated plate.
- the reduction promotes heating of the carrier, which shortens period from start of an engine to activation of the catalyst.
- This relation enhances the cleaning performance in a cold region.
- This effect enhances the cleaning performance also in the corrugation shape of the first embodiment by increasing the value of H 1 /P 1 .
- the embodiment with the substantially normal corrugated vertical wall 1 e has the maximum H 3 /P 3 value. This corrugation shape achieves the best cleaning performance.
- H 4 :P 4 is set to about 1:1. This relationship slightly reduces the cleaning performance in a cold region, while increases call density. This enhances the cleaning performance as a whole.
- a carrier with a corrugation height H 3 of 1.91 mm has 600 cells in FIG. 6A
- a carrier with a corrugation height H 4 of 1.35 mm has 900 cells in FIG. 6B .
- this embodiment provides products with a high cleaning performance and the reduced cost overall.
- the corrugated plate and the flat plate are stacked on each other.
- the flat plate may be replaced by a lower-corrugated plate that is lower in corrugation height than the corrugated plate.
- the lower-corrugated plate is stacked on the corrugated plate, forming the core, which provides the identical benefit.
Abstract
A metal carrier includes a core (3) having a thinned film containing a metal catalyst. The core includes a first metal sheet (1) corrugated and having a crest with a first radius (R). The core includes a second metal sheet (2) flattened or corrugated smaller in corrugation height than the first metal sheet, The first and second metal sheets are stacked on each other to be wound up. The crest and second metal sheet are joined to each other, having a joint therebetween. A fillet of the catalyst is formed between the joint, the first metal sheet, and the second metal sheet, having an arced surface of a second radius (r) extending between the first and second metal sheets. The first radius is set substantially equal to the second radius.
Description
- This application is based upon and claims the benefit of priorities from Japanese Patent Applications No. 2003-399384 filed on Nov. 28, 2003 and No. 2004-195606 filed on Jul. 1, 2004; the entire contents of which are incorporated herein by reference.
- The present invention relates to a metal carrier for catalytic converter provided in an exhaust system of an internal combustion engine and the like.
- An exhaust system for an internal combustion engine or the like is provided with a catalytic converter which cleans emissions. This kind of catalytic converter generally uses metal carrier having metal sheet such as Fe—Cr—Al based ferrite stainless foil as the catalytic converter.
- To produce a metal carrier of this kind, metal sheet corrugated plates and metal sheet flat plates are alternately stacked on one another. These stacked plates are wound many times, forming a core having a honeycomb structure. The structure has a circular cross section and the like. A lower-corrugated plate having lower corrugation height than that of the corrugated plate may be used as the flat plate. Then, a brazing foil material is wound around an outer periphery of the core, it is press-fitted into a metal outer cylinder, and this is heated in a vacuum. With this heating operation, crests of the corrugated plate and the flat plate are joined to each other using diffusion joining, and the outer cylinder and the core are brazed to each other.
- Catalyst such as platinum is added to the core, diffusers are welded to both ends of the outer cylinder, thereby forming a catalytic converter. In the catalyst-adding processing, wash coat solution containing catalyst is poured into the core, and a thin membrane containing the catalyst is formed on the surface of the core. See Japanese Patent Applications Laid-open Nos. 2000-61317 and No. 2003-334456.
- The metal carrier has a joint portion between the corrugated plate and the flat plate (or low-corrugated plate) The joint portion has a fillet (catalyst residue) produced from the wash coat solution under surface tension. This fillet is determined by the plate material, air (atmosphere), the surface tension of the solution and the like. The fillet is formed such as to draw an arc, and has large thickness. This prevents catalyst contained in the fillet from exhibiting the original performance, and the catalyst is waste.
- It is an object of the present invention to reduce the fillet produced in a joint between a flat plate or a corrugated plate forming a core, reducing an amount of waste catalyst.
- It is another object of the invention to enhance the cleaning performance.
- The first aspect of the invention provides the following metal carrier. The metal carrier Includes a core having a thinned film containing a metal catalyst. The core includes a first metal sheet corrugated and having a crest with a first radius. The core includes a second metal sheet flattened or corrugated smaller in corrugation height than the first metal sheet. The first and second metal sheets are stacked on each other and are wound up. The crest and second metal sheet are joined to each other, having a joint therebetween. A fillet of the catalyst is formed between the joint, the first metal sheet, and the second metal sheet, having an arced surface of a second radius extending between the first and second metal sheets. The first radius is set substantially equal to the second radius.
- The first radius may be an inner radius of the crest.
- The first radius may be 1.0 to 1.2 times of the second radius.
- The second aspect of the invention provides the following metal carrier. The metal carrier includes a core having a thinned film containing a metal catalyst.
- The core includes a first metal sheet corrugated and having a crest of a first radius. The core includes a second metal sheet flattened or corrugated smaller in corrugation height than the first metal sheet. The first and second metal sheets are stacked on each other and are wound up. The crest and second metal sheet are joined to each other, having a joint therebetween. A fillet of the catalyst is formed between the Joint, the first metal sheet, and the second metal sheet, having an arced surface of a second average radius extending between the first and second metal sheets. The first radius is set to the second average radius with a standard deviation (a) or more. The first metal sheet has a vertical wall set to be substantially normal to the second metal sheet.
- The first metal sheet may have a corrugation height between a crest and a trough thereof and a corrugation pitch between neighboring crests.
- The corrugation height may be greater than the corrugation pitch.
-
FIG. 1 is an illustrative view of a method of producing a metal carrier according to a first embodiment; -
FIG. 2 is a perspective view of the metal carrier of the first embodiment; -
FIG. 3 is an elevation view illustrating the benefit of the first embodiment; -
FIG. 4 is a partial sectional view of a metal carrier of a comparative example; -
FIG. 5 is a partial sectional view of a metal carrier according to a second embodiment; -
FIGS. 6A and 5B are illustrative views of a concrete. design example according to the second embodiment; and -
FIGS. 7A and 7B are illustrative views of catalyst-reduction effects obtained by a substantially normal corrugated foil vertical wall. - Embodiments of the present invention will be described with reference to the drawings.
- With reference to
FIG. 1 , ametal carrier 10A includes acorrugated plate 1A as a first metal sheet and aflat sheet 2 as a second metal sheet of a thinned metal plate in a band-shape. Thecorrugated plate 1A and theflat plate 2 are composed with Al of around 5%, Cu of around 20%, in addition, minute amount of metal Mn, Mo and the like, and the remains of Fe. The thickness ofplate corrugated plate 1A and theflat plate 2 are alternately stacked on one another, forming a layered product. The layered product is wound many times, forming acore 3 having a honeycomb structure. The honeycomb structure has a circular cross section for example. A brazing foil material wound around the outer periphery of thecore 3. This is press-fitted into a metalouter cylinder 4 as shown inFIG. 2 and heated in a vacuum. With this heating operation, thecorrugated plate 1A and theflat plate 2 are joined to each other using diffusion joining, and theouter cylinder 4 and thecore 3 are brazed to each other for joint. - Wash coat solution containing catalyst such as platinum is poured into the
core 3, forming a thin membrane containing the catalyst on the surface of thecore 3. The catalyst contains a main component of alumina (Al2O3) with another minute amount of cerium oxide (CeO2) or barium oxide or the like, which contains Pt, Pd, or Rh. Diffusers (not shown) are welded to both ends of theouter cylinder 4, forming a catalytic converter. - With reference to
FIG. 3 , thecorrugated plate 1A has thickness of 30 μm, corrugation height H1 of 2.0 mm, and corrugation pitch P1 of 1.6 mm. The corrugation height is a distance between the trough and the crest of a corrugation. The corrugation pitch is a distance between neighboring crests or between neighboring troughs of a corrugation. Thecorrugated plate 1A hascrests fillets fillet 103 of a comparative example shown inFIG. 4 is set to 100. Thecorrugated plate 101 is interposed between twoflat plates 102. Thecorrugated plate 101 has corrugation height H2 of 1.2 mm, pitch P2 of 2.56 mm, and crest radius R4 of 0.55 mm. - Each of the
fillets crest 1 a. - The
crest 1 a having radius R4 of 0.4 mm does not produce a catalyst residue inside of thecrest 1 a. Thefillet 5 c is greater in area than thefillet 5 a having the radius R1 of 0.2 mm. - The
crest 1 b having radius R2 of 0.3 mm produces little catalyst residue inside thecrest 1 b. Thefillet 5 b is smaller in area than thefillet 5 c in correspondence with radius R3, and greater than thefillet 5 a. Thecrest 1 b reduces a total amount of waste catalyst as compared with thecrests - The radii R1, R2, and R3 are outer radii of the
crests crests fillet 5 b. - As this manner, the determination of inner radius of the
crest 1 a as a reference eliminates the influence due to the thickness of thecorrugated plate 1, reducing the amount of the catalyst residue with higher accuracy. - The inner radius of the
crest 1 a may not be completely equal to the radius r1. The inner radius is 0.8 to 1.2 times of the radius r1. The inner radius may be 1.0 to 1.2 times of the radius r1. - In the above embodiment, the stacked corrugated plates, flat plates, and
metal carrier 10A are described. Theflat plate 2 may be replaced by a lower-corrugated plate with a lower corrugation height. The lower-corrugated plate and thecorrugated plate 1 may be stacked on each other to form the core, which obtains the identical benefit. - With reference to
FIG. 5 , ametal carrier 10B of a second embodiment will be described. The basic structure of themetal carrier 10B is identical with that of themetal carrier 10A in the first embodiment.Corrugated plate 1B andflat plate 2 of band-shaped thinned metal plates are alternately stacked on one another, forming a layered product. The layered product is wound many times, forming acore 3 having a honeycomb structure. This honeycomb structure has a rectangular cross section. Brazing foil material is wound around the outer periphery of the core 3 (seeFIG. 1 ). This is press-fitted into a metalouter cylinder 4 and heated in a vacuum. With this heating operation, thecorrugated plate 1B and theflat plate 2 are joined to each other using diffusion joining, and theouter cylinder 4 and thecore 3 are brazed to each other for joint (seeFIG. 2 ). - Wash coat solution containing catalyst such as platinum is poured into the
core 3. This forms a thin membrane containing the catalyst on the surface of thecore 3. Diffusers (not shown) are welded to both ends of theouter cylinder 4, forming a catalytic converter. - With reference to
FIG. 5 , thecorrugated plate 1B hascrests 1 d each having radius R5. Each of thecrests 1 d has afillet 5 d. The arc of thefillet 5 d is set equal to or greater than average radius r2+σ (σ: standard deviation). Thecorrugated plate 1B has a corrugated foilvertical wall 1 e. Thevertical wall 1 e is set to be substantially normal (for example 88°, preferably 90°) relative to theflat plate 2. - In
FIGS. 6A and 6B , a concrete design example of the second embodiment using the wash coat solution will be described. Thefillet 5 d has the arc having average value of 0.264 mm and radius r2 having standard deviation of 0.024. Here, in order to reduce the production probability of filling of a catalyst into thecrests 1 d, radius R5 of thecrest 1 d is set to the average value +2.33σ of the radius r2 of the arc of thefillet 5 d, e.g., to 0.32 mm for example. In the design example shown inFIG. 6A , the density of acorrugated plate 1 is 600 cells, and its corrugation height H3 is 1.91 mm. Corrugation pitch P3 is 1.28 mm which is two times of the radius R5. With this, the height H3 of the corrugated plate is greater than the corrugation pitch P3 thereof. InFIG. 6B , the corrugation pitch P4 is 1.28 mm. The corrugation height H4 is 1.35 mm. The corrugation pitch P4 and the corrugation height H4 are substantially equal to each other. - Like the first embodiment, the
corrugated plate 1B produces little catalyst residue Inside of thecrest 1 d. For example, as shown inFIGS. 6A and 6B , radius R5 of 0.32 mm does not produce the catalyst residue with a probability of 99%. Thefillet 5 d is smaller in area than thefillet 5 c (seeFIG. 3 ) with the radius R3 of 0.4 mm, which reduces the total amount of waste catalyst. - The corrugated
vertical wall 1 e of thecorrugated plate 1B is substantially normal to theflat plate 2. With reference toFIGS. 7A and 7B , the following describes a catalyst reducing effect obtained by the substantially normal corrugatedvertical wall 1 e.FIG. 7A shows acorrugated plate 101 of a comparative example with respect toFIG. 4 , and radius r of an arc of afillet 103 is in contact with a straight line of the corrugated plate. Thefillet 103 is formed in a range surrounded by contact points Rfa, Rfb, and Rla. InFIG. 7B , the substantially normal corrugatedvertical wall 1 b allows an arc of a fillet 5 with radius r2 and the circle of thecrest 1 a of thecorrugated plate 1B with radius R5 to be in contact with each other. Geometrically, the area of thefillet 5 d is smaller than that of the fillet 5 shown inFIG. 7A . - As described above, the radius R5 of the
crest 1 d of thecorrugated plate 1B is slightly greater than the radius r2 of the arc of the fillet 5. Thecorrugated plate 1B has a corrugation-shape having a substantially normal corrugatedvertical wall 1 d. This configuration minimizes the waste catalyst, reducing the production costs. - While the standard deviation is 2.33 in this embodiment, in order to obtain the benefit of this embodiment, the standard deviation may be at least 1 a.
- Specifically as shown in
FIG. 6A , the relationship between the corrugation height H3 and the corrugation pitch P3 is H3/P3=1.5. This relationship reduces the representative length (equivalent diameter) which controls the coefficient of heat transfer by the current corrugated plate. The reduction promotes heating of the carrier, which shortens period from start of an engine to activation of the catalyst. This relation enhances the cleaning performance in a cold region. This effect enhances the cleaning performance also in the corrugation shape of the first embodiment by increasing the value of H1/P1. The embodiment with the substantially normal corrugatedvertical wall 1 e has the maximum H3/P3 value. This corrugation shape achieves the best cleaning performance. - As shown in
FIG. 6B , in the relation of corrugation height H4>corrugation pitch P4, H4:P4 is set to about 1:1. This relationship slightly reduces the cleaning performance in a cold region, while increases call density. This enhances the cleaning performance as a whole. Where a carrier with a corrugation height H3 of 1.91 mm has 600 cells inFIG. 6A , a carrier with a corrugation height H4 of 1.35 mm has 900 cells inFIG. 6B . - As described above, this embodiment provides products with a high cleaning performance and the reduced cost overall.
- In this embodiment, the corrugated plate and the flat plate are stacked on each other. The flat plate may be replaced by a lower-corrugated plate that is lower in corrugation height than the corrugated plate. The lower-corrugated plate is stacked on the corrugated plate, forming the core, which provides the identical benefit.
- Although the Invention has been described above by reference to certain embodiments of the invention, the invention is not limited to the embodiments described above. Modifications and variations of the embodiments described above will occur to those skilled in the art, in light of the above teachings. The scope of the invention is defined with reference to the following claims.
Claims (5)
1. A metal carrier comprising
a core having a thinned film containing a metal catalyst,
the core comprising:
a first metal sheet corrugated and having a crest with a first radius; and
a second metal sheet flattened or corrugated smaller in corrugation height than the first metal sheet,
wherein the first and second metal sheets are stacked on each other and are wound up,
wherein the crest and second metal sheet are joined to each other, having a joint therebetween,
wherein a fillet of the catalyst is formed between the joint, the first metal sheet, and the second metal sheet, having an arced surface of a second radius extending between the first and second metal sheets,
wherein the first radius is set substantially equal to the second radius.
2. The metal carrier according to claim 1 , wherein the first radius is an inner radius of the crest.
3. The metal carrier according to claim 2 , wherein the first radius is 1.0 to 1.2 times of the second radius.
4. The metal carrier comprising:
a core having a thinned film containing a metal catalyst,
the core comprising;
a first metal sheet corrugated and having a crest with a first radius; and
a second metal sheet flattened or corrugated smaller in corrugation height than the first metal sheet,
wherein the first and second metal sheets are stacked on each other and are wound up,
wherein the crest and second metal sheet are joined to each other, having a joint therebetween,
wherein a fillet of the catalyst is formed between the joint, the first metal sheet, and the second metal sheet, having an arced surface of a second average radius extending between the first and second metal sheets,
wherein the first radius is set to the second average radius with a standard deviation (σ) or more,
wherein the first metal sheet has a vertical wall set to be substantially normal to the second metal sheet.
5. The metal carrier according to claim 4 , wherein the first metal sheet has a corrugation height between a crest and a trough thereof and a corrugation pitch between neighboring crests,
wherein the corrugation height is greater than the corrugation patch.
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2003399384 | 2003-11-28 | ||
JP2003-399384 | 2003-11-28 | ||
JP2004195606A JP2005177736A (en) | 2003-11-28 | 2004-07-01 | Metal carrier |
JP2004-195606 | 2004-07-01 |
Publications (1)
Publication Number | Publication Date |
---|---|
US20050115070A1 true US20050115070A1 (en) | 2005-06-02 |
Family
ID=34467830
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/995,346 Abandoned US20050115070A1 (en) | 2003-11-28 | 2004-11-24 | Metal carrier |
Country Status (4)
Country | Link |
---|---|
US (1) | US20050115070A1 (en) |
EP (2) | EP1536112B1 (en) |
JP (1) | JP2005177736A (en) |
DE (1) | DE602004005949T2 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20050274012A1 (en) * | 2003-02-06 | 2005-12-15 | Emitec Gesellschaft Fur Emisionstechnologie Mbh | Method and tool for producing structured sheet metal layers, method for producing a metal honeycomb body, and catalyst carrier body |
US20070185430A1 (en) * | 2001-07-12 | 2007-08-09 | Nxstage Medical, Inc. | Fluid, circuits, systems, and processes for extracorporeal blood processing |
US20140367512A1 (en) * | 2013-06-17 | 2014-12-18 | The Boeing Company | Honeycomb cores with splice joints and methods of assembling honeycomb cores |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP6275933B2 (en) * | 2016-01-08 | 2018-02-07 | 新日鉄住金マテリアルズ株式会社 | Honeycomb body and catalytic converter |
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US5050790A (en) * | 1987-12-28 | 1991-09-24 | Usui Kokusai Sangyo Kabushiki Kaisha | Process for the fabrication of metal-made carrier body for exhaust gas cleaning catalyst |
US5103641A (en) * | 1987-10-02 | 1992-04-14 | Emitec Gesellschaft Fur Emissionstechnologie Mbh | Catalyst arrangement with flow guide body |
US5620666A (en) * | 1994-07-11 | 1997-04-15 | Usui Kokusai Sangyo Kabushiki Kaisha, Ltd. | Exhaust gas cleaning metallic substrate |
US20030012708A1 (en) * | 1996-08-05 | 2003-01-16 | Yasushi Sakamoto | Metal honeycomb structure |
Family Cites Families (3)
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JPH08224444A (en) * | 1995-02-17 | 1996-09-03 | Mitsubishi Motors Corp | Electric heating catalyst device |
JP3350499B2 (en) * | 2000-01-20 | 2002-11-25 | 新日本製鐵株式会社 | Rough surface finish metal foil with good corrugation and catalyst carrier for exhaust gas purification |
JP2005052743A (en) * | 2003-08-04 | 2005-03-03 | Calsonic Kansei Corp | Metal carrier |
-
2004
- 2004-07-01 JP JP2004195606A patent/JP2005177736A/en not_active Withdrawn
- 2004-11-24 US US10/995,346 patent/US20050115070A1/en not_active Abandoned
- 2004-11-25 EP EP04028016A patent/EP1536112B1/en not_active Expired - Fee Related
- 2004-11-25 EP EP06011311A patent/EP1710410A3/en not_active Withdrawn
- 2004-11-25 DE DE602004005949T patent/DE602004005949T2/en not_active Expired - Fee Related
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
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US5103641A (en) * | 1987-10-02 | 1992-04-14 | Emitec Gesellschaft Fur Emissionstechnologie Mbh | Catalyst arrangement with flow guide body |
US5050790A (en) * | 1987-12-28 | 1991-09-24 | Usui Kokusai Sangyo Kabushiki Kaisha | Process for the fabrication of metal-made carrier body for exhaust gas cleaning catalyst |
US5620666A (en) * | 1994-07-11 | 1997-04-15 | Usui Kokusai Sangyo Kabushiki Kaisha, Ltd. | Exhaust gas cleaning metallic substrate |
US20030012708A1 (en) * | 1996-08-05 | 2003-01-16 | Yasushi Sakamoto | Metal honeycomb structure |
US6602477B2 (en) * | 1996-08-05 | 2003-08-05 | Usui Kokusai Sangyo Kaisha, Ltd. | Metal honeycomb structure |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20070185430A1 (en) * | 2001-07-12 | 2007-08-09 | Nxstage Medical, Inc. | Fluid, circuits, systems, and processes for extracorporeal blood processing |
US7419597B2 (en) | 2001-07-12 | 2008-09-02 | Nxstage Medical Inc. | Fluid, circuits, systems, and processes for extracorporeal blood processing |
US20050274012A1 (en) * | 2003-02-06 | 2005-12-15 | Emitec Gesellschaft Fur Emisionstechnologie Mbh | Method and tool for producing structured sheet metal layers, method for producing a metal honeycomb body, and catalyst carrier body |
US8336176B2 (en) * | 2003-02-06 | 2012-12-25 | Emitec Gesellschaft Fuer Emissionstechnologie Mbh | Method and tool for producing structured sheet metal layers, method for producing a metal honeycomb body, and catalyst carrier body |
US20140367512A1 (en) * | 2013-06-17 | 2014-12-18 | The Boeing Company | Honeycomb cores with splice joints and methods of assembling honeycomb cores |
US8985513B2 (en) * | 2013-06-17 | 2015-03-24 | The Boeing Company | Honeycomb cores with splice joints and methods of assembling honeycomb cores |
Also Published As
Publication number | Publication date |
---|---|
EP1710410A3 (en) | 2006-10-18 |
EP1710410A2 (en) | 2006-10-11 |
DE602004005949D1 (en) | 2007-05-31 |
JP2005177736A (en) | 2005-07-07 |
DE602004005949T2 (en) | 2007-08-30 |
EP1536112A1 (en) | 2005-06-01 |
EP1536112B1 (en) | 2007-04-18 |
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Owner name: CALSONIC KANSEI CORPORATION, JAPAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SUGIMOTO, TAMOTSU;MASHIKO, SEIJI;INOUE, KATSUFUMI;AND OTHERS;REEL/FRAME:016034/0693 Effective date: 20041118 |
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