JPH0929104A - Metallic honeycomb body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the turbulent flow characteristics and purification characteristics for an exhaust gas and to extremely save the consumption of a base material by providing a corrugate belt like material and a flat belt like material, one of which has non-perforated rejected parts and recessed parts alternately in the exhaust gas flow direction at a wall face part, and constituting a cell. SOLUTION: The corrugated belt like material 1 constituting a metallic honeycomb body H is constituted so as to form alternately the non-perforated projected part 11 and the non-perforated recessed part 12 in the exhaust gas flow direction on the corrugated curved surface part, which has a desired pitch width and wave height and is between each higher part and each bottom part. The corrugated curved surface part between each high part and each bottom part constitutes the wall part of the cell 3 in cooperation with the flat belt like material 1. The corrugated belt like material having the recessed and projected parts 11, 12 is prepared by embossing the flat belt like material 2 into non-perforated state and corrugating. As a result, the exhaust gas flow is efficiently made turbulent inside the honeycomb body and the purification efficiency is improved.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a honeycomb body for carrying an exhaust gas purifying catalyst made of metal and having a honeycomb structure, which is a main component of a metal carrier used for purifying exhaust gas (hereinafter, simply It is called a metal honeycomb body.).

More specifically, the present invention comprises a metal honeycomb body using a corrugated strip material and / or a flat strip material having a specific structure and made of a thin metal plate. An economical metal honeycomb body is proposed which has excellent turbulence characteristics and exhaust gas purification characteristics, and can reduce the amount of band material used.

[0003]

2. Description of the Related Art An example of a conventional typical metal carrier for purifying exhaust gas is shown in FIGS. As shown in the figure, this type of metal carrier has (i) a corrugated strip material (1 ′) and a flat strip material (2 ′) made of a heat-resistant thin metal plate stacked on top of each other ( (See FIG. 10), which is a honeycomb structure manufactured by winding the same, and is a metal honeycomb body (H for supporting an exhaust gas purifying catalyst (catalyst system using Pt, Rh, Pd, etc.)). as well as
(ii) A metal casing (C) for accommodating and fixing the metal honeycomb body (H ′) therein. The metal carrier is referred to as a metal support or a metal substrate in the industry, and an abbreviation (MS) is used. In the present invention,
The abbreviation (MS) is used. Regarding the metal honeycomb body, the honeycomb structure (Honeycomb Structure
), The abbreviated symbol of the prior art is (H '), and that of the present invention is (H). Further, for metal casings, the abbreviation (C) is used due to the casing.

The metal honeycomb body (H ') which is a main constituent element of the above-mentioned conventional metal carrier (MS) is as follows:
Various structures have been proposed. 10 to FIG.
The metal honeycomb body (H ′) shown in FIG. 12 is formed by winding and laminating the corrugated strip material (1 ′) and the flat strip material (2 ′). It is called the time type. FIG. 10 is a perspective view of a pair of corrugated strips (1 ′) and flat strips (2 ′) which are constituent members of the wound type metal honeycomb body (H ′). 11
Is the conventional winding type metal honeycomb body (H
′) Is a perspective view of a metal carrier (MS) in which a metal casing (C) is fixed, and FIG. 12 is a front view of the conventional winding type metal honeycomb body (H ′) described above. The conventional metal honeycomb body (H ′) described above has, for example, 10
Corrugated strip (1 ′) and flat strip (2 ′) made of heat-resistant thin steel plate of 0 μm or less (preferably 50 μm or less)
And so on as to have mutually abutting portions, which are collectively spirally wound to have a large number of mesh-like vent holes (cells) (3) for exhaust gas passages in the axial direction. This is a honeycomb structure.

In addition, as the metal honeycomb body (H '), which is a main constituent element of the metal carrier (MS), in addition to the above-described wound type, a corrugated strip material and a flat strip material are used to form the metal honeycomb. Various types have been proposed depending on the difference in the method for producing the body (H ').

[0006] For example, both band members (corrugated plate member and flat plate member) are in contact with each other in a layered manner and are stacked on top of each other (see FIG. 13). 62-27
No. 3050, Japanese Patent Laid-Open No. 62-273051, Special Publication 3-
A radial type (see FIG. 14), an S-shaped type (see FIG. 15), a tongue-shaped type (see FIG. 16), and an X-type disclosed in Japanese Patent Laid-Open No. 502660, JP-A-4-227855 and the like.
There is known a metal honeycomb body (H ′) having a wrap type (see FIG. 17) shape structure.

Further, the above-mentioned conventional metal carrier (MS)
As the metal casing (C), a tubular body for accommodating and fixing the metal honeycomb body (H ′) therein is used. The front (cross-section) shape of the metal casing (C) is not limited to the circular shape shown in FIGS. 11 to 12, and a shape suitable for the front (cross-section) shape of the metal honeycomb body (H ′). For example, it may be an elliptical shape, an oval shape, a racetrack shape, a polygonal shape, or any other irregular shape.

Then, the conventional metal carrier (M
Since S) is used under severe thermal environmental conditions such as an exhaust gas system, the strip materials (corrugated strip material and flat strip material) that make up the metal honeycomb body (H ′) come into contact with each other. The parts are firmly fixed. This is because the metal honeycomb body (H ') and the metal casing (C), which are the main components of the metal carrier (MS), have a high temperature of the exhaust gas itself and an exothermic reaction between the exhaust gas and the exhaust gas purification catalyst. This is because it is exposed to the high temperature generated by the heat treatment and a large thermal stress is applied to each element under such a high temperature atmosphere. It is fixed.

That is, in the metal honeycomb body (H '), from the viewpoint of ensuring the durability under the above-mentioned severe use conditions, the contact portion between the corrugated strip material and the flat strip material, which are the constituent members, is , Fixed by various methods and methods. For example, a contact portion between a flat plate-shaped band member and a corrugated plate-shaped band member at a desired portion inside the metal honeycomb body is fixed by a fixing means such as brazing or welding (for example, JP-B-63-44466).
No., JP-A-2-218442).

On the other hand, the contact surfaces of the metal honeycomb body (H ') and the metal casing (C) are also firmly fixed from the viewpoint of preventing the separation of both elements. A large thermal stress is generated inside the metal honeycomb body (H '), which concentrates and accumulates on the contact surfaces of both elements and induces the separation of both elements, but absorbs and relaxes the above-mentioned thermal stress. Therefore, a method of fixing a specific portion of the contact surface has also been proposed (see, for example, Japanese Utility Model Application Laid-Open No. 62-19443).

As described above, the conventional metal carrier (M
Metal honeycomb body (H ') which is the main constituent of S)
In the above, the corrugated strip material and the flat strip material, which are the constituent members, have a structure in which they are fixed to each other at the peaks and valleys of the corrugated strip. Therefore, since the catalyst substance cannot be supported on the contact portion, the effective area ratio for supporting the catalyst on the entire surface of both strips is low. More specifically, a corrugated plate member and a flat plate member of this type having a thickness of 50
Heat-resistant stainless steel foil of less than μm is used,
The area of the abutting portion of the two strips is 10 to 30 of the total surface area.
%, The effective area ratio for the catalyst carrier is extremely low. In particular, the corrugated plate material having a rectangular wave or a trapezoidal wave has a low effective area ratio because of the firm fixation of both the band materials.

When this is evaluated from an economical point of view, the Fe-Cr 20% -Al used as both strip materials (corrugated strip material and flat strip material) for the metal honeycomb body (H ').
A heat-resistant steel foil with a thickness of 50 μm or less such as a 5% type is very expensive, about 5 times as expensive as the material of SUS304 having a thickness of about 1.5 mm, and is effective for carrying a catalyst by the contact portion. The decrease in area ratio is uneconomical. By the way, the ratio of the material cost of the heat-resistant steel foil to the total price of the metal carrier (MS) is as high as 50%, and it is necessary to increase the effective area ratio of the heat-resistant steel foil or to increase the effective area ratio of the predetermined effective area ratio. From the viewpoint of economy, there is a strong demand for improving the exhaust gas purifying ability and reducing the amount of heat-resistant steel foil used.

Furthermore, a point to be considered in the conventional metal carrier (MS) is the fixing means applied to the manufacture of the metal carrier (MS). As described above, in the production of the metal carrier (MS), both strip materials (corrugated strip material and flat strip material) constituting the metal honeycomb body (H ′).
From the viewpoint of durability, the abutting portion of the metal honeycomb body (H ') and the abutting portion of the metal casing (C) are fixed by applying fixing means such as brazing (welding) or welding. Is. In the brazing method generally used as the fixing means, the brazing filler metal used is an expensive one such as Ni-based or Ni-Cr-based because it is used under the high temperature atmosphere of the metal carrier. It is a brazing material for high temperature, and there is a strong demand for reduction of its usage from the economical viewpoint. Further, the point of reducing the amount of brazing material used is that the contact area of the contact portions of both strips (corrugated strip and flat strip) is large as described above, The amount of brazing filler metal used increases, which causes problems such as a decrease in heat resistance of both strips due to an alloying reaction between the brazing filler metal component and the metal components of both strips, and a diffusion reaction, as well as deactivation of the catalyst. From this viewpoint, there is a strong demand for reduction of the amount of brazing filler metal used.

As a measure for improving the exhaust gas purifying ability of a metal carrier (MS) in the art, the following measures for improving the contact efficiency between the exhaust gas flow and the supported catalyst inside various metal honeycomb bodies have been proposed. There is. (1). Jitsukai Sho 62-90742: This is a condition that the hole diameter is 0.5 mm to 10 mm and the hole arrangement density is 1 to 10 holes / cm ^{3 in} the corrugated plate member and the flat plate member. In order to improve the contact time and contact efficiency between the exhaust gas and the catalyst, the exhaust gas is allowed to pass between the cells by forming a large number of holes that satisfy the requirements. As a similar technique of this kind, there is Jitsukaihei 4-53448. (2). Japanese Patent Laid-Open No. 63-258647: This is a base material (corrugated strip and flat strip) having small projecting holes to allow exhaust gas to cross-flow and to be formed on the projecting portion. It carries a catalyst. The formation of the small holes reduces the effective supporting area of the base material, but the protrusions compensate for this.
As a similar technique of this kind, there is Japanese Patent Laid-Open No. 5-33636. (3). Japanese Patent Publication No. 4-502880: This is to provide an opening in at least a part of the cell wall and to attach a flow surface extending to the cell wall at an angle to the opening. The flow surface guides the exhaust gas from the inner cell to the outer cell and equalizes the flow velocity distribution, thereby improving the exhaust gas purification ability.

[0015]

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention In the industry, as an attempt to improve the characteristics of a metal honeycomb body, the contact efficiency between the exhaust gas and the supported catalyst is determined by the base material (corrugated plate material and By devising the configuration of the flat plate-shaped strip), attempts have been made to make the exhaust gas turbulent or to make the flow rates uniform by communicating the cells, but this is still insufficient. That is, an attempt to form a hole in the base material (corrugated plate material and flat plate material), or to dispose a perforated protrusion is performed, for example, on the side of the corrugated material. In the method of arranging a hole or a hole-like protrusion, the corrugated structure is practically small, specifically, the corrugated structure has a small wave pitch of 2 to 5 mm and a wave height of 1 to 3 mm, In addition, it is difficult to form the holes because, as disclosed in Japanese Utility Model Laid-Open No. 62-90742, a hole having a minimum diameter of 0.5 mm is required to efficiently connect the cells. However, unless the large-diameter hole is formed, it is ineffective and the effective area of the base material must be small. When the hole has a small diameter, it is clogged when forming a wash coat layer for supporting a catalyst, when supporting a catalyst component, or when purifying exhaust gas (when using a metal carrier), The initial result cannot be achieved.

The present invention seeks to remedy the above-mentioned drawbacks of the prior art metal carriers (MS) and to meet expected needs. The present inventors diligently studied measures for improving a metal carrier (MS) from the above viewpoint. As a result, in the metal honeycomb body (H), which is a main constituent element of the metal carrier (MS), a hole portion having a small diameter or a hole portion having a small diameter with respect to the base material (corrugated plate member and flat plate member). Each cell (exhaust gas vent passage) rather than adopting the traditional approach of forming protrusions with
Adopts a technical structure that adopts a base material in which the non-perforated concave and convex portions are alternately arranged on the part of the wall section that divides the parts, depending on the exhaust gas inflow / outflow direction (exhaust gas passage direction) At that time, it was found that the exhaust gas flow can be efficiently turbulent.

Further, as a corrugated structure of the corrugated strip material, a triangular waveform (the former one) is used as compared with a generally employed substantially sinusoidal waveform and a trapezoidal waveform or a rectangular waveform for improving the fixing strength. Compared with the corrugated structure, the feature that the top of the wave is point-bonded to the flat strip is adopted.
It is possible to obtain the same weight ratio strength as that of the conventional one and to increase the effective area ratio for supporting the catalyst on the base material,
It was also found that when a corrugated plate material having the above-mentioned triangular waveform and the above-mentioned concavo-convex forming means are adopted, a large effect of saving the base material can be obtained.

The present invention has been completed on the basis of the above-mentioned findings. The present invention has excellent turbulence characteristics of exhaust gas and purification characteristics of exhaust gas, and at the same time, has a significantly large base material (corrugated plate-shaped band). Material and metal plate for flat exhaust gas, which is economical and can reduce the amount of exhaust gas used (M
A metal honeycomb body (H) which is a main constituent of S) is provided.

[0019]

The present invention will be summarized as follows.
The present invention has a honeycomb having a large number of cells that are manufactured by stacking corrugated strips made of a thin metal plate having a desired corrugated structure and flat plate strips made of a thin metal plate so as to be in contact with each other. In the metal honeycomb body for supporting the exhaust gas purifying catalyst having a structure, at least one of the corrugated strip member and the flat strip member is alternately arranged in the wall surface portion of the cell as viewed in the exhaust gas flow direction. The present invention relates to a metal honeycomb body characterized by having a perforated concave-convex portion.

Hereinafter, the technical constitution and embodiments of the present invention will be described in detail with reference to the drawings. It goes without saying that the present invention is not limited to the illustrated one.
Further, a wound type is described below as the metal honeycomb body (H), but the present invention is not limited to this.

1 to 3 are views for explaining a metal honeycomb body (H) according to the first embodiment of the present invention. FIG. 1 is a diagram for explaining a corrugated strip material (1) that constitutes the metal honeycomb body (H) of the first embodiment, and FIG. 1 (1) is a perspective view,
FIG. 1B is a sectional view taken along the line I-I of FIG. FIG.
[Fig. 2] is a diagram for explaining the flat strip (2) that constitutes the metal honeycomb body (H) of the first embodiment. Fig. 2 (1) is a perspective view and Fig. 2 (2) is Fig. 2 (1). 11 is a sectional view taken along line II-II of FIG. FIG. 3 is a partially front enlarged view of a metal honeycomb body (H) configured by using the corrugated strip material (1) and the flat strip material (2).

The features of the corrugated strip (1) constituting the metal honeycomb body (H) of the first embodiment of the present invention are shown in FIG. As shown in FIG. 1 (1), the corrugated strip material (1) of the present invention has a desired pitch width (p) and wave height (h), and each crest (or trough) and trough. A corrugated curved surface portion between (or peak portions) is alternately formed with a non-perforated convex portion (11) and a non-perforated concave portion (12) when viewed in the exhaust gas flow direction (F). It is characterized in that it is composed of. In addition, as is clear from FIG.
The corrugated curved surface portion between each peak (or valley) and the valley (or peak) cooperates with the flat strip (1) to form the cell (3).
It constitutes the wall portion of. In FIG. 1 (1), the concavo-convex portion of the corrugated curved surface portion on the opposite side to the corrugated curved surface portion having the concavo-convex portion (11, 12) is shown in a transparent state by a dotted circle.

The specific sizes of the non-perforated concave-convex portions (11, 12) are as follows. The wave height (h) and wave pitch (wave amplitude) (p) of the corrugated plate material (1) for the metal honeycomb body (H) are substantially the same as those applied to this type of application. You may For example, h =
The one having 1 to 3 mm and p = 2h (2 to 6 mm) is adopted. In relation to the corrugated structure described above, for example, the convex portion (11) and the concave portion (12) shown in FIG.
The distance (1) between them is 1 to 10 mm, and the height (h1) of the uneven portions (11, 12) shown in FIG. 1 (2) may be set to 0.1 to 1.0 mm. As will be described later, the corrugated strip material (1) of this type is generally composed of a heat-resistant steel foil of a Fe—Cr 20% —Al 5% system and having a thickness of 50 μm or less. Since it is a material having a low degree of elongation (elongation), in other words, breakage easily occurs due to embossing (unevenness) processing, the above-mentioned non-perforated unevenness portion, especially its height (h1) is realistic. Is.

The corrugated strip material (1) having the above-mentioned concavo-convex portions (11, 12) is formed by first embossing (concavo-convex) the flat strip material (2) into a non-perforated shape, and then forming a desired corrugated structure. Can be prepared by corrugating. The corrugated structure of the corrugated strip (1) is compared with that of the corrugated corrugated strip (see FIG. 4) having a triangular corrugation applied to the metal honeycomb body (H) of the second embodiment described later. , Has a waveform structure of a substantially sinusoidal waveform.

FIG. 2 shows the features of the flat strip (2) constituting the metal honeycomb body (H) of the first embodiment of the present invention. As shown in FIG. 2 (1), the flat strip (2) of the present invention has a non-perforated convex portion (21) and a concave portion (22) that alternate in the exhaust gas flow direction (F). It is characterized in that it is configured by the one formed in. In the present invention, the concavo-convex rows viewed in the exhaust gas flow direction (F) are desired at desired intervals in the longitudinal direction of the flat strip (2), that is, in the direction orthogonal to the exhaust gas flow direction (F). Rows are formed. As is apparent from FIG. 3, the flat strip (2) cooperates with the corrugated strip (1) to form the cell (3).
Of the flat strip (2) while constituting the wall of
The set of concave and convex rows (21, 22) is arranged so as to exist on the wall portion of the cell (3). In the flat strip (2), the height (h2) of the non-perforated irregularities (21, 22) and the interval (l) between the non-perforated irregularities (21, 22) are It may be configured in the same manner as the non-perforated uneven portions (11, 12) of the corrugated strip (1).

The corrugated strip material (1) having the non-perforated uneven portions (11, 12) and the non-perforated uneven portion (2)
When the metal honeycomb body (H) is constructed by using the flat strip (2) having (1, 22) as a constituent member, each cell (3 ...
.), The exhaust gas is efficiently turbulent, the contact reaction with the supported catalyst is improved, and the exhaust gas purification performance can be improved. That is, as seen in the exhaust gas flow direction (F),
Since the concave portions and the convex portions are alternately arranged on all the wall portions of each cell, the turbulent flow promoting means according to the present invention is extremely efficient as compared with the conventional turbulent flow promoting means. . By the way, since the exhaust gas purification performance is significantly improved by the configuration of the non-perforated uneven portion, the amount of the base material (corrugated strip material and flat strip material) used is reduced by 10% to 15%. can do. This saving effect is extremely large in view of the base material price. Since the non-perforated concave-convex portion of the present invention is not a conventional perforated type, a perforated portion (hole portion)
It is possible to eliminate defects such as reduction of the effective surface area of the base material due to the above and clogging of the hole.

The corrugated strip material (1) and the flat strip material (2) constituting the metal honeycomb body (H) of the present invention are used for producing a conventional metal monolith type honeycomb body (H '). You can use the one that has been used. More specifically, chrome steel (chrome 13% to 25%), Fe-Cr2
A band material having a thickness of about 0.03 to 0.1 mm, such as heat resistant stainless steel such as 0% -Al 5%, may be used. It is to be noted that the strip material (1, 2) containing Al,
Alternatively, a material having an Al layer formed on the surface thereof is heat-treated, and whisker-like or mushroom-like alumina (Al ₂ O ₃ ) is deposited on the surface thereof. The whisker-like alumina is preferable because it can firmly hold the washcoat layer for carrying the exhaust gas purifying catalyst such as Pt, Pd, and Rh.

The metal honeycomb body (H) of the present invention has a metal casing (C) similar to that shown in FIG.
Metal carrier (M
S). As a material used to manufacture the metal casing (C) that constitutes the metal carrier (MS), heat-resistant steel of the same kind as the strip materials (1 and 2) that constitute the metal honeycomb body (H) is used. May be used.
Alternatively, a double-structured metal casing (C) having a double structure with high heat and corrosion resistance, specifically, a ferritic stainless steel for the inner part and an austenitic stainless steel for the outer part, is used. Good.

On the metal carrier (MS), the catalyst for purifying the exhaust gas may be carried by a conventional method.
That is, the surface of the corrugated strip material (1) and the flat strip material (2), which are the constituent members of the metal honeycomb body (H), has a wash coat (washco) as a support for the exhaust gas purifying catalyst.
at) layer, and more specifically, coated with a large surface area γ-Al ₂ O ₃ that enhances catalytic activity, and then P
An exhaust gas purifying catalyst such as a t, Pd or Rh-based redox catalyst may be supported.

Various modifications of the metal honeycomb body (H) of the present invention are possible. For example, although not shown in the drawings, the following are modifications of the first embodiment.

(1). Corrugated strip (1) and flat strip (2)
Of these, one of the strips may be formed with the non-perforated uneven portion. (2). As shown in FIG. 4, the concave and convex rows formed on the base material (corrugated plate member and flat plate member), for example, the flat plate member (2), that is, the exhaust gas flow direction ( In the concavo-convex rows that are alternately arranged as seen in F), the non-perforated convex portions and concave portions may not be formed so as to be aligned. That is, the non-perforated convex portion and the concave portion may be out of phase with respect to the exhaust gas flow direction (F).

(3). As shown in FIG. 5, the flat strip (2) has a flat strip (2) in addition to the non-perforated uneven portions (21, 22). The grooved groove and the grooved groove (2a) may be formed in the width direction (the same direction as the exhaust gas flow direction F). In addition, the uneven groove (2a)
May be alternately formed at desired intervals in the longitudinal direction of the flat strip (2) (direction orthogonal to the exhaust gas flow direction F). The uneven groove grooves (2a,
The distance between 2a) is preferably set such that the wave crests (the ridgeline of the wave crests) of the corrugated strip (1) are arranged between the pair of corrugated grooves. The uneven groove (2a, 2
The a) has a function of effectively absorbing and relaxing the thermal stress generated inside the metal honeycomb body (H). (4). As shown in FIG. 6, the flat strip (2) has a small wave height (2) in the same direction as the exhaust gas flow direction (F).
b) formed, in other words, formed by forming a waveform (2b) having a relatively small wave height in a direction orthogonal to the traveling direction of the large waveform of the corrugated strip (1). You may. In this case, the small corrugations (2
Also in part b), the exhaust gas can be made turbulent, so that the exhaust gas purification performance can be further improved.

(5). As shown in FIG. 7, in addition to the waveform (2b) shown in FIG. 6, the flat strip (2) has a direction orthogonal to the exhaust gas flow direction (F), that is, , The corrugated strip (1) in the same direction as the corrugated traveling direction of the corrugated strip (1)
May be formed by forming a waveform (microcorrugation) (2c) having a relatively small wave height with respect to a waveform having a large wave height. The waveform of the small wave height (microcorrugation) (2c) effectively absorbs the thermal stress generated inside the metal honeycomb body (H), similarly to the uneven groove (2a, 2a) shown in FIG. Has a function of relaxing. (6). The corrugated structure of the corrugated strip (1) is not limited to the substantially sinusoidal waveform. That is, in addition to the substantially sine shape, a trapezoidal waveform or a rectangular waveform may be used. When the corrugated structure is a triangular corrugated structure, it has an important meaning in the effect of saving the base material in the present invention, and therefore will be described below as a second embodiment.

FIG. 8 is a view for explaining the metal honeycomb body (H) of the second embodiment of the present invention. FIG. 8 is a partially front enlarged view of the metal honeycomb body (H) according to the second embodiment of the present invention, and is a view corresponding to FIG. 3 according to the first embodiment. As is clear from FIG. 8, the characteristic point in the metal honeycomb body (H) of the second embodiment is that the corrugated plate material (1
The point a) is configured so as to have a triangular wave waveform in which a triangular shape with an acute angle is retained as the structure of the crest (and valley) of the wave. The other technical structure, that is, the disposition of the non-perforated uneven portion is exactly the same as that of the first embodiment.

FIG. 9 is a view for explaining the brazing mode of the metal honeycomb body (H) according to the second embodiment of the present invention. FIG. 9 (1) shows a brazing mode of the metal honeycomb body (H) (see FIG. 8) of the second embodiment of the present invention.
(2) is the metal honeycomb body (H) of the first embodiment
4 shows a brazing mode (see FIG. 3). As shown in the figure, the corrugated strip (1a) is formed at the front end and the rear end of the metal honeycomb body (H) as seen in the exhaust gas flow direction (F).
Alternatively, the desired depth of the contact portion between 1) and the flat strip (2) is brazed.

FIGS. 9 (1) and 9 (2) show new findings in the brazing mode of the metal honeycomb body (H) of this type. FIG. 9 (1) shows a brazing mode of the metal honeycomb body (see FIG. 8) of the second embodiment, in which the corrugated strip (1a) has a triangular corrugated structure. The brazing portion at the contact portion with the flat strip (2) is shown as a straight line as shown. On the other hand, FIG. 9 (2) shows a brazing mode of the metal honeycomb body (see FIG. 3) of the first embodiment, in which the corrugated plate material (1) has a substantially sinusoidal corrugated structure, Since the wave crest is deformed into a trapezoidal shape or a rectangular shape due to the processing stress at the time of roll forming, the brazing joint portion at the contact portion with the flat plate-shaped strip (2) is shown as a plane as shown in the drawing. . In the brazing mode, that is, in the modes of FIG. 9 (1) and FIG. 9 (2), it is expected that the latter surface bonding mode will provide stronger bond strength. It was confirmed that they are almost the same. That is, when the weight specific strength, more specifically, a predetermined load was applied from one end surface of the metal honeycomb body (H) and the peeling resistance strength of the contact portion was tested, no difference was observed between the two.

The significance of what has been described above is extremely great. That is, when a corrugated strip (1a) having a corrugated structure having a triangular corrugation is used (see the second embodiment), the effective area ratio for carrying the catalyst of the corrugated strip (1a) is , Substantially sine wave, trapezoidal wave and rectangular wave. This means that it is possible to reduce the amount of the expensive base material for the metal honeycomb body (corrugated plate member and flat plate member) used. It has been found that the saving rate of the substrate is as high as 10 to 15%. Therefore, the metal honeycomb body (H) of the second embodiment, that is, the metal honeycomb body (H) using the corrugated plate material (1a) having a triangular corrugation and having a specific uneven portion provided on the base material
Is a conventional metal honeycomb body (H ') (see, for example, FIGS.
Compared with the conventional wound type metal honeycomb body of FIG. 12, the usage rate of the base material can be reduced by 15 to 25%. As for the saving effect of the above-mentioned base material, as described above, the contribution ratio by the former technical configuration (the technical configuration of arranging a specific uneven portion) is 10 to 15%, and the latter technical configuration (triangular waveform). It is estimated that the contribution rate due to the technical constitution of using a corrugated plate material having a corrugated structure) is 5 to 10%.

In the metal honeycomb body (H) of the second embodiment of the present invention, the flat strip (2) applied as a constituent member thereof is the same as that shown in FIGS. 8 and 9 (1). Not limited. For example, as the flat strip (2),
It goes without saying that various structures shown in FIGS. 4 to 7 described in the first embodiment are used.

[0039]

The metal honeycomb body (H) having a honeycomb structure (cell structure), which is a main constituent element of the metal carrier (MS) of the present invention, has a corrugated plate material as its constituent member (base material). Divide each cell (exhaust gas vent passage) without adopting the conventional approach of using a flat strip with a small-diameter hole or a protruding part having a small-diameter hole. A characteristic point is that the structure is formed by using a specific uneven portion formed on the wall portion. That is, the present invention is characterized in that, as the base material, a material having non-perforated concave-convex portions which are alternately seen in the exhaust gas inflow direction (passing direction) is used at the site of the wall portion dividing each cell. There is.
Due to the features of the present invention, the exhaust gas flow is efficiently turbulent inside the metal honeycomb body, the contact between the exhaust gas flow and the supported catalyst is improved, and the purification efficiency can be significantly improved.

Further, in the metal honeycomb body (H) of the present invention, in addition to the technical constitution of forming the non-perforated concave and convex portion, a corrugated plate material having a corrugated structure with a triangular waveform is particularly preferable. When the technical constitution of using is added, the effective area for supporting the catalyst on the base material can be increased without lowering the weight specific strength (in particular, the brazing strength between the base materials). This has the advantage that the purification efficiency can be greatly improved. Therefore,
The metal honeycomb body (H) of the aspect of the present invention has the same purification characteristics as those of the conventional metal honeycomb body.
It can be miniaturized. This is extremely important in view of the fact that the constituent members (corrugated plate member and flat plate member) of the metal honeycomb body (H) are extremely expensive.

As described above, according to the present invention, the characteristics of turbulence of exhaust gas and the characteristics of purifying exhaust gas are excellent, and the amount of the base material (corrugated strip material and flat strip material) used is significantly reduced. There is provided an economical metal honeycomb body (H) that can be manufactured. That is, the present invention provides an economical metal carrier (MS) having the metal honeycomb body (H) as a main constituent element.

[Brief description of drawings]

FIG. 1 is a diagram illustrating a corrugated strip material applied to a metal honeycomb body (H) of a first embodiment of the present invention,
FIG. 1A is a perspective view, and FIG. 2B is a sectional view taken along line I-I of FIG. 1A.

[Fig. 2] Fig. 2 is a view for explaining a flat strip material applied to the metal honeycomb body (H) of the first embodiment of the present invention,
(1) is a perspective view, (2) is a II-I in the above (1).
It is an I line sectional view.

FIG. 3 is a partial front enlarged view of the metal honeycomb body (H) of the first embodiment of the present invention.

FIG. 4 is a diagram illustrating a first modified example of the flat strip (2) applied to the first embodiment of the present invention, and is a partial perspective view of the flat strip (2).

FIG. 5 is a diagram illustrating a second modification of the flat strip (2) applied to the first embodiment of the present invention, and is a partial perspective view of the flat strip (2).

FIG. 6 is a diagram illustrating a third modified example of the flat strip (2) applied to the first embodiment of the present invention, and is a partial perspective view of the flat strip (2).

FIG. 7 is a diagram illustrating a fourth modification of the flat strip (2) applied to the first embodiment of the present invention, and is a partial perspective view of the flat strip (2).

FIG. 8 is a partial front enlarged view of the metal honeycomb body (H) according to the second embodiment of the present invention, and is a view corresponding to FIG. 3.

FIG. 9 is a view for explaining a brazing mode of the metal honeycomb body (H) of the present invention, (1) FIG. 9 shows a brazing mode of the metal honeycomb body (FIG. 4) of the second embodiment, and (2) )
The figure shows a brazing mode of the metal honeycomb body (FIG. 3) of the first embodiment.

FIG. 10 A conventional winding type metal honeycomb body (H
It is a figure explaining the corrugated plate-shaped strip material (1 ') and flat plate-shaped strip material (2') used for manufacture of ′ '.

FIG. 11 A conventional winding type metal honeycomb body (H
It is a perspective view of a metal carrier (MS) using ′ ′.

FIG. 12 is a front view of the conventional wound type metal honeycomb body (H ′) shown in FIG. 11.

FIG. 13: Conventional laminated type metal honeycomb body (H
It is a front view of ′).

FIG. 14 is a front view of a conventional radial type metal honeycomb body (H ′).

FIG. 15 is a front view of a conventional S-shaped metal honeycomb body (H ′).

FIG. 16: Conventional Tomoe type metal honeycomb body (H
It is a front view of ′).

FIG. 17 is a front view of a conventional X-wrap (swastika) type metal honeycomb body (H ′).

[Explanation of symbols]

 MS: Metal carrier H: Metal honeycomb body H'of the present invention H ': Conventional metal honeycomb body C: Metal casing 1, 1a ... Corrugated strip material (present invention) 11 ...... Convex portion of corrugated strip material 12 ………… Concave portion of corrugated strip material 2 ………… Flat plate material (present invention) 21 ………… Convex portion of flat strip material 22 ………… Plate shape Concave part 2a of the strip ……… Concave / convex groove 2b ………… Small wave height waveform 2c ………… Micro corrugation 3 ………… Cell h ………… Wave height of the corrugated strip p ………… Corrugated strip Pitch width h1, h2 ……… Height of uneven parts l ……… Distance between uneven parts

Claims (10)

[Claims] 1. A large number of cells manufactured by stacking corrugated strips made of a thin metal plate having a desired corrugated structure and flat strips made of a thin metal plate so as to be in contact with each other. In a metal honeycomb body for supporting an exhaust gas purifying catalyst having a honeycomb structure, at least one of the corrugated strip material and the flat strip material is, in a wall surface portion that constitutes a cell, viewed alternately in the exhaust gas flow direction. It has a non-perforated uneven portion,
Metal honeycomb body characterized by. 2. The metal honeycomb body according to claim 1, wherein the corrugated plate-shaped strip material is configured to have a non-perforated uneven portion. 3. The metal honeycomb body according to claim 1, wherein the flat plate-shaped strip material is configured to have a non-perforated uneven portion. 4. The metal honeycomb body according to claim 1, wherein both the corrugated strip material and the flat strip material are configured to have a non-perforated uneven portion. 5. A corrugated strip material is prepared by first forming non-perforated uneven portions on a flat strip material first, and then corrugating a desired corrugated structure. Item 2. The metal honeycomb body according to item 1. 6. The metal honeycomb body according to claim 5, wherein the corrugated strip material has a substantially sine waveform, a trapezoidal wave, and a rectangular wave. 7. The corrugated strip material has a triangular wave.
The metal honeycomb body according to 1. 8. The metal honeycomb body according to claim 1, wherein the corrugated structure of the corrugated strip has a wave height (h) of 0.5 to 3.5 mm and a wave pitch (amplitude) (p) of 2 h. 9. The distance (l) between the non-perforated uneven portions.
Is 1 to 10 mm, the metal honeycomb body according to claim 1. 10. The metal honeycomb body according to claim 1, wherein the non-perforated uneven portion is formed by embossing (unevenness) processing.