JPH09155202A - Metal carrier and method of manufacturing the same - Google Patents

Abstract

(57) An object of the present invention is to integrally form a cone portion with an outer cylinder of a metal carrier, thereby enabling a short-term production without the need for welding and assembling the cone portion, and at the same time, the inner surface of the cone portion and the honeycomb. (EN) Provided are an inexpensive metal carrier having excellent purification performance that allows a catalyst to be simultaneously supported on the body surface, and a method for producing the same. SOLUTION: A heat-resistant metal foil is provided with an outer cylinder made of a heat-resistant metal, and a cone having a connecting pipe connected to an exhaust gas system is integrally provided on at least one side of the exhaust gas inlet side and the exhaust gas side. A flat plate and a corrugated plate obtained by processing the flat plate into a corrugated plate, which are wound or laminated to form a honeycomb body, which is inserted and fixed to the outer cylinder, and a cone portion integrally formed. A catalyst is supported on the inner surface and the surface of the honeycomb body.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cone-integrated metal carrier to be installed in an engine exhaust gas system such as an automobile and a method for manufacturing the same.

[0002]

2. Description of the Related Art In order to remove nitrogen oxides and sulfur oxides contained in engine exhaust gas, a carrier carrying a catalyst is installed in the exhaust gas system. It's getting more and more.

This metal carrier is connected to an exhaust gas system (pipe) by combining several members, one example of which is shown in FIG. That is, in the figure, reference numeral 21 denotes a metal carrier, and a honeycomb body 22 formed by stacking a flat plate made of a heat-resistant metal foil and a corrugated plate processed into a corrugated shape and spirally winding the plate is inserted into an outer cylinder 23. It is fixed. Reference numerals 24 and 25 denote cone portions arranged in front of and behind the metal carrier 1, respectively, and connecting pipes 2 each having a predetermined diameter.
6, 27. Reference numerals 28 and 29 are flanges arranged so as to be located at the connecting portion with the exhaust gas pipe.

As shown in FIG. 7 (b), each of the above-mentioned members is welded to the catalyst-supporting metal carrier 21 with cones 24 and 25 arranged in front of and behind it, respectively.
Further, flanges 28 and 29 are joined and integrated with the tip ends of the connecting pipes 26 and 27 of the respective cones.

As described above, the metal carrier becomes the exhaust gas purifying device only after the catalyst is supported and then the cone and the flange are attached. However, a joining (welding) step is required to join and join the respective members, and further joining is performed. It takes time and cost to go through the adjustment process such as part inspection, and it is a big problem in terms of construction period and cost to carry out these post-processes by different manufacturers.

In order to improve these problems, there has been proposed a catalyst carrier having a structure in which a cone portion and a connecting pipe are integrally formed with a container (case) for accommodating a honeycomb body.

For example, Japanese Utility Model Laid-Open No. 61-110823 discloses a case of using a holding case (see FIG. 8) in which a tubular portion having the same diameter as the body portion 30 is left on one end side. Since a component (cushion material, cushion ring, etc.) for inserting and fixing the honeycomb body in the holding case is required, the dimensional tolerance with the body portion 30 required for the holding case must be strict. If the size is narrow, the fixed parts cannot be inserted, and if the size is wide, they are misaligned and the honeycomb body cannot be held. Alternatively, in order to obtain strict dimensional accuracy, the expanded cylindrical portion has to be “ironed”, which causes a great problem in manufacturing cost of the holding case.

Further, when the honeycomb body is ceramics,
If the body part 30 of the holding case is partially narrowed or the corner part 31 provided for locking the honeycomb body is deformed, the surface pressure locally rises, which may cause a honeycomb defect. is there.

Further, the converter (see FIG. 9) as disclosed in Japanese Utility Model Laid-Open No. 5-96427 discloses the above-mentioned Japanese Utility Model Laid-Open No. 61-11082 in which one end of a cylindrical tube is reduced in diameter.
After the holding case 32 as shown in Japanese Patent Publication No. 3 is made, the supporting body 34 for fixing the catalyst-supported honeycomb body 33 is put in and fixed to the holding case 32 by welding, and then the catalyst-supporting honeycomb body. This is a catalytic converter made by winding an elastic member 35 around 33, inserting it until it hits a support 34, fixing the other one again with a support 36, and then reducing the diameter of a cone portion 37 and a connecting portion 38.

However, in the catalytic converter having such a structure, the inner diameter (body portion) 39 of the holding case and the corner portion 4 are
The dimension of 0 has a drawback that the corner portion 40, the end face of the honeycomb body 33, and the support body 34 cannot be fixed close to each other because the dimension variation occurs due to the influence of the diameter reduction processing. When the diameter of the case at the other end is reduced, the honeycomb body 33 is supported by the support body 36.
However, if the corner body 41 is too close to the honeycomb body, there is a problem that the honeycomb body is damaged due to the deformation due to the diameter reduction. The parallel portions that absorb the influence of deformation are required at the corner portions 40 and 41, and the exhaust gas purifying apparatus is upsized and the mounting size is restricted.

Further, in the case of the converter disclosed in Japanese Patent Laid-Open No. 64-60711 (see FIG. 10), the honeycomb body 43 carrying the catalyst is wrapped in the expandable mat 42 and placed in the holding case 44. A converter in which the central portion of the holding case is reduced in diameter 47, the honeycomb body is fixed, and further, both ends are reduced in diameter to form the cone portions 45 and 46, and a manufacturing method thereof. Since this method does not use a support for fixing the honeycomb body, it is not possible to use an actual flat plate with an opening of 5-964.
Although the problem as in Japanese Patent No. 27 is not caused, there is a drawback that the process is complicated and the cost is increased such that a diameter reducing process for holding the carrier is required and an inflatable mat 42 and its assembling work are required.

On the other hand, Japanese Patent Laid-Open No. 63-100220 discloses a honeycomb body 48 carrying a catalyst as shown in FIG.
An exhaust gas purifying apparatus having excellent purifying performance, in which the cone portion and the connecting portions 49 and 50 are welded together at the welding surface 51 and assembled, is presented. However, in the case of producing an exhaust gas purifying apparatus having excellent purification performance in which a cone portion and a connecting pipe portion are supported by a catalyst as described above, the catalyst supporting member 52 is previously provided on the cone portion, the cone portion and the connecting pipe component in addition to the honeycomb body. After that, a process of welding and assembling the both is required. Therefore, an increase in the number of parts of the cone portion, a step of separately supporting the catalyst before assembling them, and a step of joining (welding) them together require labor and cost, resulting in an expensive exhaust gas purifying apparatus.

[0013]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned problems of the prior art by assembling a casing and a cone portion without using a casing as in the case of loading a ceramic honeycomb body. An inexpensive and inexpensive molding that can be manufactured in a short period by integrally molding the outer cylinder and the cone part that are joined to the metal honeycomb body without forming parts, that is, by integrally molding the outer cylinder and the cone part (without welding). In addition to providing a metal carrier and a method for producing the same, by using the integrally formed metal carrier, an inexpensive exhaust gas having excellent purification performance that enables catalyst components to be simultaneously supported on the inner surface of the outer cylinder and the surface of the honeycomb body. It is an object of the present invention to provide a purification device and a manufacturing method thereof.

[0014]

In order to achieve the above object, the gist of the present invention is that (1) at least one of the inlet and outlet of exhaust gas is provided in an outer cylinder made of heat-resistant metal. On the side, a cone for connecting to the exhaust gas system or a cone with a connecting pipe is integrally provided, and a flat plate made of a heat-resistant metal foil and a corrugated plate obtained by processing this flat plate are overlapped and wound or laminated. The honeycomb body formed by the above, a metal carrier characterized by being inserted and fixed to the outer cylinder, and (2) carrying the catalyst component on the honeycomb body surface and the inner surface of the cone portion and the connecting pipe portion. An exhaust gas purifying apparatus using the metal carrier according to (1), and (3) an outer cylinder integrally formed with a brim portion extending to at least one side of the exhaust gas inlet side and outlet side. A flat plate made of heat-resistant metal foil and Insert and fix the honeycomb body formed by winding or laminating the corrugated sheet processed in the above, and pressing the collar portion of the outer cylinder with a press or a die to form a cone portion or a connecting pipe of a desired diameter. A method of manufacturing a metal carrier, characterized by joining a honeycomb part and an outer cylinder with a cone after integrally molding a cone part having the same, and (4) extending to at least one side which is an inlet side and an outlet side of exhaust gas. An outer cylinder integrally formed with a brim portion, a flat plate made of a heat-resistant metal foil, and a corrugated plate obtained by processing the flat plate into a corrugated plate, or wound, or insert a honeycomb body formed by stacking, Manufacture of a metal carrier characterized by forming a cone part or a cone part having a connecting pipe of a desired diameter by drawing the flange part of the outer cylinder with a press or a die after joining the outer cylinder. Method,
And (5) Exhaust gas purification, characterized in that the metal carrier produced by the method described in (3) or (4) above, simultaneously carries a catalyst component on the inner surface of the cone-shaped outer cylinder and the surface of the honeycomb body. Device manufacturing method, and (6) a flat plate made of a heat-resistant metal foil, and this flat plate on an outer cylinder integrally formed with a brim portion extending to at least one side that is an inlet side and an outlet side of exhaust gas. A corrugated plate processed into a corrugated shape is wound in a laminated manner, or a honeycomb body formed by stacking is inserted, and after being joined to an outer cylinder, a catalyst component is simultaneously carried on the inner surface of the outer cylinder and the surface of the honeycomb body, and thereafter. A method of manufacturing an exhaust gas purifying apparatus, comprising forming a cone portion or a cone portion having a connecting pipe having a desired diameter by performing a pressing process or a die process on the flange portion of the outer cylinder.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail based on an embodiment shown in the drawings. FIG. 1 (a) is an example of the material of the metal carrier 1 of the present invention, and shows a state in which the honeycomb body 3 is housed and fixed in the central portion of the elongated outer cylinder 2. That is, the outer cylinder 2 is integrally provided with both brim portions 2a and 2b forming a space portion at the front end portion and the rear end portion in the axial direction of the honeycomb body 3. An adhesive material is applied to the honeycomb body 3 in advance at a portion where both flat plates and corrugated plates come into contact when they are wound, and a plate wax is attached to the outer periphery of the honeycomb body 3 to form a cylindrical outer cylinder 2 Then, the honeycomb body 3 is slidingly charged. After that, a long-sized honeycomb body obtained by feeding and adhering powdery brazing filler metal from the end face side of the honeycomb body through the brim portion is inserted into a vacuum heating furnace, and the necessary portions are joined together. The joining method is not limited to the above method, and the brazing material supplying step is not required as long as a diffusion joining method or a joining method using high-density energy can be adopted.

Next, as shown in FIG. 1B, the brim portion 2
The a and 2b are processed to form the cone portions 4 and 5 having the connecting pipes 4a and 5a. The method for processing the cone portion may be either a pressing method using a die or a drawing method as described later, or another method may be adopted. Connection pipe 4
The diameters of a and 5a can be arbitrarily changed at the time of processing, and for example, the diameters of 4a and 5a can be changed to reduce the pressure loss of the exhaust gas to be treated.

FIG. 2 shows another example of the present invention, which is a metal carrier 11 having a single brim structure in which the integral brim 2c of the outer cylinder 2 is present only on one side. The method of processing the integral brim 2c to form the cone portion 6 having the connecting pipe 6a is the same as that in FIG. In this way, in the present invention, the metal carrier having the integrated cone portion can be manufactured in a reduced number of steps.

[0018]

【Example】

Example 1 A heat-resistant metal flat plate having a thickness of 50 μm and a corrugated plate corrugated on the flat plate were used, and these were stacked and spirally wound to form a honeycomb body having a diameter φ62 mm and a length 80 mm. This thickness 1.5mm, diameter φ65mm, length 240
mm heat-resistant metal outer cylinder is press-fitted into the central part to form the brim portions 2a and 2b on both sides of the outer cylinder as shown in FIG. 3 (a), and both brim integrated metal so that each brim portion is 80 mm. Carrier 1 was prepared. This carrier 1 is loaded into a vacuum heating furnace, and the flat body of the honeycomb body 3 is joined to the corrugated plate, and the honeycomb body 3 and the outer cylinder 2 are joined together.
The contact part of the was diffusion-bonded. As shown in FIG. 3 (b), the carrier 1 is placed on a press pedestal 7, and a cone forming jig (press die) 8 having a connecting pipe pressing portion 8a is arranged above the carrier 1 to As shown in (c), the upper brim portion 2a was pressed with a press die 8 to apply a load of 2 tons to form the cone portion 4 having the connecting pipe 4a. Next, the carrier 1 is reversed, the formed cone portion 4 is mounted on the press pedestal 9 having the cone portion supporting hole 9a, and the brim portion 2a is pressed with a press die 8 from above to press the cone portion 2a, The part 5 was molded (FIG. 3D).
reference).

FIG. 3 (e) shows a molded product, in which the tip of each connecting pipe of the cone portion is molded and further loaded with a catalyst, and then a flange 10 is attached thereto as shown in FIG. It can be attached to the system. The taper angle of the cone parts 4 and 5 of the above product is 15 °, the connecting pipe 4a,
The diameter of the parallel portion of 5a was 40 mm in diameter and 20 mm in length.

Example 2 A heat-resistant metal flat plate having a thickness of 50 μm and a corrugated plate corrugated on this flat plate were used, and these were stacked and spirally wound to form a honeycomb body having a diameter of 77 mm and a length of 80 mm. Created. This is wall thickness 1.5mm, diameter φ80
mm and length 150 mm, the heat-resistant metal outer cylinder is press-fitted into one side to form the brim 2c only on the other side of the outer cylinder as shown in FIG. 4 (a), and the brim length of the brim 2c is 65 mm. A single brim-integrated metal carrier 1 was prepared so that As shown in FIG. 4 (b), this carrier 1 is placed on the press pedestal 7 with the brim portion 2c facing upward, and the connecting pipe pressing portion 8a is placed upward.
A cone forming jig (press die) 8 having the above is arranged, and the press die 8 is used to press the collar portion 2c with a load of 2 tons as shown in FIG. 4 (c).
As shown in (d), the cone portion 6 having the connecting pipe 6a was integrally molded. After that, the carrier shown in FIG. 4 (d) was loaded into a vacuum heating furnace, and the joining portion between the flat plate and the corrugated plate of the honeycomb body 3 and the contact portion between the honeycomb body 3 and the outer cylinder 2 were diffusion-bonded. The cone angle of the cone portion 6 of this product was 30 °, and the diameter of the parallel portion of the connecting pipe 6a was 40 mm in diameter and 20 mm in length.

[Embodiment 3] As shown in FIG.
The same metal carrier 1 as described above is used, and a cone forming jig (die) 18 while rotating one of the brim portions 2a of the carrier 1.
Is formed into a cone portion 4 having a connecting pipe 4a (see FIG. 7A), and then, while the collar portion 2b on the opposite side is rotated, similarly drawn by a die 18 to have the connecting pipe 4a. It was molded into the cone portion 4 (see FIG. 2B). As a result, a product similar to that of Example 1 was obtained.

In the present invention, since the press or drawing degree can be changed by changing the die, the diameter of the connecting pipe can be selectively manufactured according to the diameter of the exhaust gas pipe to be connected. Further, although the above-mentioned embodiment describes the metal carrier using a single honeycomb body, it can also be applied to a tandem-type metal carrier which stores a plurality of honeycomb bodies in series as shown in FIG.

[Example 4] A heat-resistant metal flat plate having a thickness of 50 µm and a corrugated plate corrugated on the flat plate were used, and these were stacked and spirally wound to form a honeycomb body having a diameter of 62 mm and a length of 80 mm. Created. This has a wall thickness of 1.5 mm and a diameter of φ65.
mm, 140 mm in length, a heat-resistant metal outer cylinder was press-fitted into one end to form a flange 2c on one side of the outer cylinder as shown in FIG. 2 (a). The flat plate of the body 3 and the corrugated plate were joined by diffusion, and the honeycomb body 3 and the outer tube 2 were joined by diffusion. This carrier is placed on a press pedestal 7 as shown in FIG. 4, and a cone molding jig (press die) 8 having a connecting pipe press portion 8a is arranged above the carrier 1 and is then placed as shown in FIG. 4 (c). Press die 8 on the upper brim 2c
Pressing with a load of 2 tons is performed by connecting pipe 6a
The cone portion 6 having the above was molded.

Next, the operation of immersing the above metal carrier in the γ-alumina slurry and drying it is repeated twice, and further 6 times.
It was heated at 50 ° C. for 2 hours to deposit a γ-alumina layer. Then, the metal carrier was immersed in a chloroplatinic acid solution and a rhodium chloride solution and dried to support Pt-Rh.

For comparison, a honeycomb body was prepared in the same manner as above, and was press-fitted into an outer cylinder having a wall thickness of 1.5 mm, a diameter of 65 mm and a length of 80 mm, and diffusion bonding was performed in a vacuum heating furnace to form a brimless metal. The carrier was manufactured. On the other hand, a cone part having a connecting pipe was manufactured separately. Next, a γ-alumina layer is separately attached to the cone portion having the metal carrier and the connecting pipe, and then P
Supporting t-Rh. The method of supporting the γ-alumina layer and Pt-Rh was the same as in the above-mentioned example, and the amounts were the same.
In this case, when welding the outer cylinder and the cone, welding failure occurred due to the alumina layer adhering to the welded portion. In the present embodiment, welding of the outer cylinder and the cone is not required, the above-mentioned inconvenience does not occur at all, and the manufacturing cost can be reduced by about 20% as compared with the comparative example, and the manufacturing cost can be reduced. I was able to.

[0026]

As described above, according to the present invention, the cone portion necessary for connecting the metal carrier to the exhaust gas piping is
It can be processed into an integral structure with the outer cylinder as shown in each example, rather than being an assembled part, and therefore the joining process such as welding can be omitted, providing a very inexpensive metal carrier in a short construction period. it can.

[Brief description of the drawings]

FIG. 1 is a conceptual sectional view of a metal carrier of the present invention, (a)
Shows before cone processing, and (b) and (c) show after cone processing.

FIG. 2 is a conceptual cross-sectional view of another example of the metal carrier of the present invention, (a) showing a cross section before cone processing, and (b) and (c) showing cross sections after cone processing.

3 (a) to 3 (f) are explanatory views showing a production example of the metal carrier of the present invention.

4 (a) to 4 (d) are explanatory views showing another production example of the metal carrier of the present invention.

5 (a) and 5 (b) are explanatory views showing another production example of the metal carrier of the present invention.

6A and 6B are explanatory views showing a conventional metal carrier, in which FIG. 6A is a component before assembly and FIG. 6B is a diagram after assembly and joining.

FIG. 7 is another embodiment of the present invention, showing a tandem-type metal carrier in which a plurality of processing carriers are arranged and fixed in series in an outer cylinder.

FIG. 8 is a view showing a conventional holding case.

FIG. 9 is a view showing a conventional catalytic converter using an integrated case.

FIG. 10 is a diagram showing another example of a conventional catalytic converter using a cone-integrated case.

FIG. 11 is a diagram showing a part of the structure of an exhaust gas purifying apparatus in another conventional example.

[Explanation of symbols]

 1, 11: Metal carrier 2: Outer cylinder 2a, 2b, 2c: Collar part 3: Honeycomb body 4, 5, 6: Cone part 4a, 5a, 6a: Connection pipe 7: Press pedestal 8, 18: Molding cure Tool 9: Press stand 10: Flange

Claims (6)

[Claims] 1. A heat-resistant metal outer cylinder is integrally provided with a cone connected to an exhaust gas system or a cone having a connecting pipe on at least one of the exhaust gas inlet and outlet sides thereof. A metal carrier, comprising: a flat plate made of a flexible metal foil; and a corrugated plate obtained by processing the flat plate in a corrugated shape, which are stacked and wound or laminated to join the outer cylinder. 2. The metal carrier according to claim 1, wherein a catalyst component is supported on the surface of the honeycomb body and the inner surfaces of the cone portion and the connecting pipe portion. 3. An outer cylinder integrally formed with a brim portion extending to at least one side that is an inlet side and an outlet side of exhaust gas, a flat plate made of heat-resistant metal foil, and a wave obtained by processing the flat plate into a corrugated shape. Insert and fix the honeycomb body formed by stacking and winding the plate and stacking or laminating, and press or squeeze the brim portion of the outer cylinder to form a cone portion or a cone portion having a connecting pipe of a desired diameter. A method of manufacturing a metal carrier, which comprises forming a honeycomb and an outer cylinder with a cone after they are integrally molded. 4. An outer cylinder integrally formed with a brim portion extending to at least one side that is an inlet side and an outlet side of exhaust gas, a flat plate made of heat-resistant metal foil, and a wave formed by corrugating the flat plate. A plate is overlapped and wound, or a honeycomb body formed by stacking is inserted, and after being joined to the outer cylinder, the brim portion of the outer cylinder is subjected to a drawing process by pressing or a die to obtain a cone portion or a desired diameter. A method of manufacturing a metal carrier, comprising forming a cone portion having a connecting pipe. 5. A method for producing a metal carrier, wherein the catalyst component is simultaneously supported on the inner surface of the cone-shaped outer cylinder and the surface of the honeycomb body on the metal carrier produced by the method according to claim 3 or 4. 6. A flat plate made of heat-resistant metal foil, and a wave formed by corrugating the flat plate in an outer cylinder integrally formed with a brim portion extending to at least one side that is an inlet side and an exhaust side of exhaust gas. Plates are stacked and wound, or a honeycomb body formed by stacking is inserted, and after being joined to the outer cylinder, a catalyst component is simultaneously supported on the inner surface of the outer cylinder and the surface of the honeycomb body, and then the outer cylinder A method for producing a metal carrier, which comprises forming a cone portion or a cone portion having a connecting pipe of a desired diameter by performing a pressing process on a brim portion by a press or a die.