JPH09300031A - Metal honeycomb catalyst and manufacturing method thereof - Google Patents

Abstract

(57) [PROBLEMS] To provide a metal honeycomb catalyst having improved purification efficiency and a simple structure, and a method for producing the same. SOLUTION: A flat plate 1 and a corrugated plate 2 made of metal are superposed on each other, and a winding shaft 3 in which end portions 1a and 2a thereof are engaged is rotated a plurality of times to rotate the flat plate 1 and the corrugated plate 3 on the winding shaft 3. The plate 2 is wound to form a spiral winding member 5. A metal honeycomb carrier 6 formed by pulling out the winding shaft 3 from the winding member 5.
The bent side edges 1b, 2b of the flat plate 1 and the corrugated plate 2 arranged in the radial direction of the passage 7 of the central winding portion of the deformed side edges 1a, 2a
Then, the passage 7 is completely closed to prevent the exhaust gas G from flowing through the passage 7. Alternatively, the passage 7 is closed with a gap, and the exhaust gas G passing through the gap is brought into contact with the catalyst body for purification. In the last step, the metal honeycomb carrier 6 is coated with a catalyst to form the metal honeycomb catalyst 8.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal honeycomb catalyst in which an exhaust gas passage formed in a central winding portion of a metal honeycomb carrier is closed or substantially closed, and a method for manufacturing the metal honeycomb catalyst.

[0002]

2. Description of the Related Art Exhaust gas from an automobile contains various harmful components (CO, HC, etc.). Therefore, a catalyst is used to reduce the harmful components to a certain level. The catalyst is mounted on the exhaust system of the engine, for example, directly below the exhaust manifold of the engine or in the middle of an exhaust pipe connected to the exhaust manifold. Further, the catalyst is housed and held in a catalyst case interposed in the exhaust system.

As a catalyst for purifying this exhaust gas, there is a metal honeycomb catalyst formed by coating an active component (hereinafter referred to as a catalyst body) on a honeycomb-shaped metal carrier formed of metal, or a honeycomb-shaped ceramic carrier formed of ceramics. There is a ceramic catalyst coated with a catalyst body.

The manufacture of the above metal honeycomb catalyst has hitherto been
It was done as follows. That is, as shown in FIG. 5, the flat plate 1 and the corrugated plate 2 made of metal are overlapped with each other, and the end portions 1a and 2a thereof are inserted into the slit 4 of the winding shaft 3 (see also FIG. 7), and then, As shown by the arrows in FIGS. 5 and 6, the winding shaft 3 is rotated so that the flat plate 1 and the corrugated plate 2 are attached to the winding shaft 3.
Is wound to form a spiral winding member 5.

After that, as shown in FIG. 7, the winding shaft 3 is pulled out from the spiral winding member 5 to form a metal honeycomb carrier 6. A space after the winding shaft 3 is located remains in the central winding portion of the metal honeycomb carrier 6. In this space, the flat portions 1a and 2a of the flat plate 1 and the corrugated plate 2 which are inserted into the slits 4 of the winding shaft 3 extend in the radial direction, so that the space portion has two substantially semicircular holes, that is, , Two passages 7 each having a substantially semicircular shape.

The diameter of the passage of the substantially semicircular passage 7 is equal to that of the corrugated plate 2.
It is considerably larger than the wave pitch of. After that, a catalyst body (not shown) is placed on the metal honeycomb carrier 6.
To form a metal honeycomb catalyst 8.
When this metal honeycomb catalyst 8 is attached to an exhaust pipe of an engine exhaust system, etc., the exhaust gas G, as shown by an arrow in FIG. Flowing through the passage 7 of the part, contacting the coated catalyst body, reacting, and purified.

As a catalytic converter, the actual converter
Some are disclosed in Japanese Patent No. 139321. What is disclosed in this publication is that a metal catalyst carrier integrally formed on the outer periphery of the pipe is housed in a tubular container having an exhaust inflow pipe at one end and an exhaust outflow pipe at the other end, An exhaust passage is formed in the cylindrical container, and an auxiliary metal catalyst carrier is provided in the exhaust outflow pipe so that exhaust gas passing through the metal catalyst carrier flows to the auxiliary metal catalyst carrier through the exhaust passage. It was done.

[0008]

In the prior art described above, the exhaust gas G is contacted with the catalyst body coated on the metal honeycomb carrier 6 to react and be purified. Is formed with a space portion after the winding shaft 3 is pulled out, that is, two substantially semicircular passages 7. The passage 7 has a passage diameter of, as shown in FIGS. Since the wave pitch is considerably larger than the wave pitch of, the part of the exhaust gas G passing through the passage 7 cannot pass through the catalyst body coated on the passage 7 and passes through it. There was a problem that purification was insufficient. Therefore, there is a problem that the purification efficiency of the metal honeycomb catalyst 8 as a whole decreases.

In the catalytic converter disclosed in Japanese Utility Model Laid-Open No. 2-139321, the exhaust gas entering from the exhaust inflow pipe on one end side passes through the metal catalyst carrier contained in the tubular container, and Although it passes through the exhaust passage formed in the cylindrical container and passes through the auxiliary metal catalyst carrier provided in the exhaust outflow pipe on the other end side, there is a problem that the structure and manufacturing become complicated.

The present invention has been made in order to solve the above-mentioned conventional problems, and the passage formed in the central winding portion of the metal honeycomb carrier has a flat plate and an end of a corrugated plate extending radially in the passage. It is an object of the present invention to provide a metal honeycomb catalyst having a simplified structure and a method for manufacturing the same, which is closed at a deformed portion near the portion, thereby improving the purification efficiency.

[0011]

According to the first aspect of the present invention,
A flat plate and a corrugated plate made of a metal are superposed and wound to form a spiral metal honeycomb carrier in which the flat plate and the corrugated plate are alternately arranged, and the spirally formed metal honeycomb carrier is formed in a central winding portion. The passage is arranged in the radial direction of the passage and is closed or substantially closed by the flat plate and the corrugated plate that divide the passage into two substantially semicircular passages.

As described above, the flat plate and the corrugated plate made of metal are superposed and wound a plurality of times, and the flat plate and the corrugated plate are alternately arranged. The relatively large passage having the relatively large diameter is closed or substantially closed near the ends of the flat plate and the corrugated plate that extend in the radial direction of the passage and divide the passage into two substantially semicircular passages. That is, the passage is closed or substantially closed at the deformed bent side edge portion near the end portion.

When the passage is closed, the passage is completely closed so that the exhaust gas does not pass through the passage to prevent the exhaust gas from passing through without coming into contact with the catalyst body. Further, when the passage is substantially closed, the passage is closed with a gap, and when exhaust gas flows through the gap, the exhaust gas always comes into contact with the catalyst body to ensure the purification.

According to a second aspect of the present invention, one half of the inlet side of the passage formed in the central winding portion of the metal honeycomb carrier is arranged in the radial direction of the passage, and the passage has a substantially semicircular shape. The flat plate and the corrugated plate which are divided into two passages are closed at a deformed portion in the vicinity of the ends thereof, and the other half of the outlet side of the passage is arranged in the radial direction of the flat plate and the corrugated plate. It is characterized in that it is closed or substantially closed at a deformed portion near the end.

In this way, one half of the opening on the inlet side of the passage formed in the central winding portion of the metal honeycomb carrier extends in the radial direction of the passage and the passage is divided into two substantially semicircular passages. The flat plate and the corrugated plate end portions are closed or substantially closed by a deformed bent side edge part, and the other half of the opening on the outlet side of the passage is provided near the end parts of the flat plate and the corrugated plate. It is closed or almost closed at the deformed bent side edge.

Also in this case, when the passage is closed, the passage is completely closed so that the exhaust gas does not pass through the passage to prevent the exhaust gas from passing through without coming into contact with the catalyst body. When the passage is to be closed, the passage should be closed with a gap, and when exhaust gas passes through the gap,
Ensure contact with the catalytic body to ensure purification.

The inventions according to claims 3 and 4 relate to a method for producing a metal honeycomb catalyst which can be understood from the above-mentioned claims 1 and 2. That is, according to the invention of claim 3, a step of superposing a metal flat plate and a corrugated plate and engaging the vicinity of the end with a slit of the winding shaft, and rotating the winding shaft a plurality of times. A step of winding the flat plate and the corrugated plate in a spiral shape so that the flat plate and the corrugated plate are alternately located on the winding shaft; and a metal honeycomb by pulling out the winding shaft from the spiral winding member. A step of forming a carrier, and a step of closing or substantially closing the passage with a deformed portion near the ends of the flat plate and the corrugated plate arranged in the radial direction of the passage of the central winding portion of the metal honeycomb carrier. And a step of coating a metal honeycomb carrier having the passages closed or substantially closed with a catalyst body.

As described above, the flat plate and the corrugated plate made of metal are superposed on each other, and the vicinity of the end is engaged with the slit of the winding shaft, whereby the flat plate and the corrugated plate can be held by the winding shaft. Then, in the next step, by rotating the winding shaft a plurality of times, the flat plate and the corrugated plate can be wound around the winding shaft from the end, and the flat plate and the corrugated plate are alternately positioned to form a spiral shape. A winding member can be formed.

Then, in the next step, by pulling out the winding shaft from the spiral winding member, a metal honeycomb carrier having a passage for exhaust gas can be formed in the central winding portion. A deformed bent side edge portion in the vicinity of the end portion of the flat plate and the corrugated plate that extends in the radial direction of the passage provided in the central winding portion of the metal honeycomb carrier and divides the passage into two substantially semicircular passages The passage can be closed or substantially closed.

When the passage is closed, the passage is completely closed so that the exhaust gas does not pass through the passage and the passage of the exhaust gas is eliminated. If you want to close the passage, close the passage with a gap,
When the exhaust gas flows through the gap, the exhaust gas always comes into contact with the catalyst body to ensure the purification. Then, in the final step, the metal honeycomb carrier having the passages closed or substantially closed is coated with a catalyst to form a metal honeycomb catalyst.

According to a fourth aspect of the invention, in the invention of the third aspect, the catalyst is coated immediately after the step of forming the metal honeycomb carrier and before the step of closing the passage. It was done. That is,
A step of superposing a metal flat plate and a corrugated plate and engaging the vicinity of the end thereof with a slit of the winding shaft; and rotating the winding shaft a plurality of times so that the flat plate and the corrugated plate are attached to the winding shaft. A step of winding the flat plate and the corrugated plate in a spiral shape so that the plates are alternately positioned; a step of extracting the winding shaft from the spiral winding member to form a metal honeycomb carrier; and the metal honeycomb A step of coating the catalyst body on the carrier, and closing the passage with a deformed portion near the end of the flat plate and the corrugated plate arranged in the radial direction of the passage of the central winding portion of the coated metal honeycomb carrier; And a step of substantially closing.

As described above, the flat plate and the corrugated plate made of metal are overlapped with each other, and the vicinity of the end is engaged with the slit of the winding shaft, so that the flat plate and the corrugated plate can be held by the winding shaft. Then, in the next step, by rotating the winding shaft a plurality of times, the flat plate and the corrugated plate can be wound around the winding shaft from the end portion, and the flat plate and the corrugated plate are alternately positioned in a spiral shape. The winding member can be formed.

Then, in the next step, by pulling out the winding shaft from the spiral winding member, the metal honeycomb carrier having the exhaust gas passage formed in the central winding portion can be formed.

Further, in the next step, the metal honeycomb carrier is coated with the catalyst, and then the coated metal honeycomb carrier near the ends of the flat plate and the corrugated plate arranged in the radial direction of the passage of the central winding section. The deformed bent-side edge can close or substantially close the passage.

When the passage is closed, the passage is completely closed so that the exhaust gas does not pass through the passage and the passage of the exhaust gas is eliminated. If you want to close the passage, close the passage with a gap,
When the exhaust gas flows through the gap, the exhaust gas must be in contact with the catalyst body to ensure the purification.

[0026]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention understood from the description of claim 1 is, as shown in FIGS. 1 and 2, a flat plate 1 made of metal.
The corrugated plate 2 is superposed and wound to form a spiral metal honeycomb carrier 6 in which the flat plates 1 and the corrugated plates 2 are alternately arranged. A flat plate 1 in which a passage 7 formed in a central winding portion of the metal honeycomb carrier 6 is arranged in a radial direction of the passage 7 and divides the passage 7 into two substantially semicircular passages 7.
And the bent side edge 1 of the corrugated plate 2 near the ends 1a, 2a
Completely close with b, 2b, or close it with a gap.

The present invention grasped from the description of claim 2 is
As shown in FIGS. 1 and 2, one half of the inlet side 7a of the passage 7 formed in the central winding portion of the metal honeycomb carrier 6 is
It is arranged in the radial direction of the passage 7 and is divided by the deformed bent side edges 1b, 2b near the end portions 1a, 2a of the flat plate 1 and the corrugated plate 2 which divide the passage 7 into two substantially semicircular passages 7. Or close it with a gap. Furthermore, the exit side of passage 7
The other half of 7b is a bent side edge 1b obtained by deforming the vicinity 1a of the flat plate 1 and the corrugated plate 2 arranged in the radial direction of the passage 7 and 2a.
Completely close it with 2b, or close it with a gap.

The present invention grasped from the description of claim 3 is
As shown in FIGS. 1 and 2, the flat plate 1 and the corrugated plate 2 made of metal are overlapped with each other, and the end portions 1a and 2a thereof are engaged with the slits 4 of the winding shaft 3, and in the next step, the winding process is performed. By rotating the take-up shaft 3 a plurality of times, the flat plate 1 and the corrugated plate 2 are taken up so that the flat plate 1 and the corrugated plate 2 are alternately located on the take-up shaft 3, and the spiral winding member 5 is formed. To do. In the next step, the winding shaft 3 is pulled out from the wound spiral winding member 5 to form the metal honeycomb carrier 6. Further, in the next step, the bent side edges 1b of the deformed bent side edges 1a, 2a of the flat plate 1 and the corrugated plate 2 arranged in the radial direction of the passage 7 of the central winding portion of the metal honeycomb carrier 6 are formed. , 2b, one half of the opening on the inlet side 7a of the passage 7 and the other half of the opening on the outlet side 7b are completely closed or with a gap. Then, in the last step, the metal honeycomb catalyst 6 is formed by coating the metal honeycomb carrier 6 which has completely closed the passages 7 or which has closed the gaps with a catalyst.

The present invention grasped from the description of claim 4 is
In the invention according to claim 3, the coating of the catalyst body is not performed last but is performed in a step immediately after the step of forming the metal honeycomb carrier 6. That is, as shown in FIGS. 1 and 2, the flat plate 1 and the corrugated plate 2 made of metal are overlapped with each other, and the end portions 1a and 2a thereof are engaged with the slits 4 of the winding shaft 3, and in the next step, , The winding shaft 3 is rotated a plurality of times, and the flat plate 1 and the corrugated plate 2 are wound so that the flat plate 1 and the corrugated plate 2 are alternately positioned on the winding shaft 3 to form a spiral winding member 5. To form. Then, in the next step, the winding shaft 3 is pulled out from the spiral winding member 5 to form the metal honeycomb carrier 6. Further, in the next step, the metal honeycomb carrier 6 is coated with the catalyst body. Then, in the last step, the flat plate 1 arranged in the radial direction of the passage 7 of the central winding portion of the coated metal honeycomb carrier 6.
And the bent side edge 1 of the corrugated plate 2 near the ends 1a, 2a
In b and 2b, one half of the opening on the inlet side 7a of the passage 7 and the other half of the opening on the outlet side 7b are completely closed, or are closed with a gap to form the metal honeycomb catalyst 8. .

[0030]

EXAMPLE An example of the metal honeycomb catalyst according to the present invention will be described below with reference to FIG. In the structure shown in FIG. 1, a flat plate 1 and a corrugated plate 2 are superposed and wound on a winding shaft 3 (see FIG. 5) in a multiple manner to form a spiral metal honeycomb carrier 6 on which a catalyst body (shown in the figure). None) is a metal honeycomb catalyst 8 coated with.

In the central winding portion of the metal honeycomb catalyst 8,
When forming the metal honeycomb carrier 6, the flat plate 1 and the corrugated plate 2
After the end portions 1a and 2a near the end are inserted into the slit 4 provided in the winding shaft 3 and wound up, and then the winding shaft 3 is pulled out, a space remains.

In this space, the end portions 1a and 2a of the flat plate 1 and the corrugated plate 2 which are engaged with the slits 4 of the winding shaft 3 are arranged so as to extend in a substantially radial direction. By these end portions 1a and 2a, two substantially semicircular passages 7 and 7 are formed in the central winding portion.

Therefore, as shown in FIGS. 1 and 2, one half of the opening on the inlet side 7a into which the exhaust gas G of these passages 7 and 7 flows is located near the end portions 1a of the flat plate 1 and the corrugated plate 2. , 2a are closed by the bent side edge portions 1b and 2b (indicated by the one-dot chain line in FIG. 1) that are deformed by crushing the side edges (the arrow in FIG. 1 indicates the bending direction). That is, the entrance side of the passage 7
One half of the opening of 7a is completely closed by the bent side edges 1b and 2b.

Furthermore, the other half of the opening on the outlet side 7b of the passage 7 is formed by bending the side edges of the end portions 1a, 2a of the flat plate 1 and the corrugated plate 2 and crushing the bent side edge portion 1b, Closed by 2b. That is, the other half of the opening on the outlet side 7b of the passage 7 is also completely closed by the bent side edges 1b and 2b (FIG. 2).
reference).

As described above, since one half of the opening on the inlet side 7a of the passage 7 and the other half of the opening on the outlet side 7b are completely closed, the passage 7 is no longer communicated and the diameter of the passage is reduced. Even in the relatively large passage 7, the exhaust gas G does not flow through this passage 7.

The one shown in FIG. 3 is one in which the metal honeycomb catalyst 8 is housed in a catalyst case 9 interposed in the middle of an exhaust pipe (not shown), and FIG.
Shown in Fig. 8 is the metal honeycomb catalyst 8 in the catalyst case 9.
2 is a cross-sectional view of the metal honeycomb catalyst 8. One half of the opening on the inlet side 7a of the passage 7 of the central winding portion of the metal honeycomb catalyst 8 is closed by the bent side edges 1b and 2b.

It is to be noted that one half of the opening on the inlet side 7a and the other half of the opening on the outlet side 7b of the passage 7 of the metal honeycomb catalyst 8 are completely closed by the bent side edges 1b and 2b to form a passage. 7
To prevent the exhaust gas G from flowing, but without doing so, the passage 7 is substantially closed by the bent side edges 1b and 2b so that the exhaust gas G slightly flows in the passage 7. You may do it. That is, the passage may be closed with a gap.

In this way, the exhaust gas G comes to pass through the narrow passage 7, and when passing, the exhaust gas G comes into contact with the catalyst body coated on the passage 7 to be purified, and the purification at the passage 7 As a result, the purification efficiency of the metal honeycomb catalyst 8 as a whole can be improved.

Further, one half of the opening on the inlet side 7a and the other half of the opening on the outlet side 7b of the passage 7 of the metal honeycomb catalyst 8 are completely closed by the bent side edges 1b and 2b, or Although it is configured to be closed with a gap, the entire opening on the inlet side 7a of the passage 7 is completely closed by the bent side edge portions 1b and 2b of the flat plate 1 and the corrugated plate 2 without doing so. Further, it may be closed with a gap. Alternatively, the entire opening on the outlet side 7b of the passage 7 may be completely closed by the bent side edges 1b and 2b of the flat plate 1 and the corrugated plate 2, or may be closed with a gap.

If the entire opening on the inlet side 7a or the entire opening on the outlet side 7b of the passage 7 is completely closed in this way, the passage 7 cannot be communicated completely, and the exhaust gas G cannot pass through the passage 7. The exhaust gas G does not flow through the passage 7 having a relatively large passage diameter of the metal honeycomb catalyst. As a result, the exhaust gas G passing directly through the passage 7 can be eliminated without coming into contact with the catalyst body.

Also in this case, the opening on the inlet side 7a and the opening on the outlet side 7b of the passage 7 may not be completely closed but may be closed with a gap. If the exhaust gas G that has flowed into the passage 7 and stagnates gradually flows out through the space by closing it with a gap in this way, the exhaust gas G comes into contact with the catalyst when flowing out. The exhaust gas is purified, and the purification efficiency can be improved.

Next, a method for manufacturing the metal honeycomb catalyst 8 will be described. First, the flat plate 1 and the corrugated plate 2 made of metal are overlapped, and the ends 1a and 2a near the ends thereof are engaged with the slits 4 of the winding shaft 3, so that the flat plate 1 and the corrugated plate 2 can be wound up. It can be held on the shaft 3.

Then, when the winding shaft 3 is rotated a plurality of times in the next step, the flat plate 1 and the corrugated plate 2 are attached to the winding shaft 3 and the flat plate 1 is rotated.
The corrugated plates 2 can be alternately positioned and wound in a spiral shape. Furthermore, in the next step, the winding shaft 3 is pulled out from the spirally wound winding member 5 (see FIG. 6), so that a passage 7 for the exhaust gas G is provided in the central winding portion. The carrier 7 can be formed.

Then, in the next step, the inlet side 7a of the passage 7 is formed by the bent side edges 1b and 2b of the flat plate 1 and the corrugated plate 2 extending in the radial direction of the passage 7 and the deformed side edges 1a and 2a. The one half of the opening and the other half of the opening on the outlet side 7b are closed. That is, the passage 7 is completely blocked by the bent side edge portions 1b and 2b.

Further, in the last step, the metal honeycomb catalyst 6 is formed by coating the metal honeycomb carrier 6 with the passages 7 completely closed with the catalyst. When the metal honeycomb catalyst 8 is arranged in the exhaust pipe of the exhaust system, the exhaust gas G does not pass through the passage 7, and the exhaust gas G does not pass through the passage 7 having a relatively large passage diameter. There is no exhaust gas G that passes through without contacting the medium.

The one half of the opening on the inlet side 7a of the passage 7 and the other half of the opening on the outlet side 7b are bent side edges 1b and 2b.
However, instead of doing so, one half of the opening on the inlet side 7a and the other half of the opening on the outlet side 7b of the passage 7 may be closed with a gap. .

In this way, when the exhaust gas G passes through the gap, the exhaust gas G comes into contact with the catalyst body and the exhaust gas G is sufficiently purified even in the passage, so that the purification efficiency of the entire metal honeycomb catalyst 8 is improved. Can be improved.

In the method for producing the metal honeycomb catalyst 8 described above, the opening of the passage 7 is completely closed by the bent side edge portions 1b and 2b, or is closed with a gap. Although the carrier 6 is coated with the catalyst body, the catalyst body is coated on the metal honeycomb carrier 6 without doing so, and then the opening and the outlet of the coated metal honeycomb carrier 6 on the inlet side 7a of the passage 7 are formed. The opening on the side 7b may be completely closed by the bent side edges 1b and 2b, or may be closed with a gap. Note that the operation is the same as the above method, and therefore will be omitted.

[0049]

According to the first aspect of the invention, the center of the spiral metal honeycomb carrier is formed by stacking and winding metal flat plates and corrugated plates, and alternately arranging the flat plates and corrugated plates. Since the passage having a relatively large passage diameter located in the winding portion is closed at the ends of the flat plate and the corrugated plate that extend in the radial direction of the passage and divide the passage into two substantially semicircular passages,
Exhaust gas does not flow through the passage and does not come into contact with the catalyst body as in the conventional case, so that exhaust gas passing through the passage can be eliminated.

Further, since the passage is substantially closed by the end portions of the flat plate and the corrugated plate, the passage is narrowed and the exhaust gas passing through the passage can be brought into contact with the catalyst. By these,
It is possible to improve the purification in the passage of the central winding portion of the metal honeycomb catalyst, and it is possible to improve the purification efficiency of the metal honeycomb catalyst as a whole.

According to the second aspect of the present invention, one half of the opening on the inlet side of the passage formed in the central winding portion of the metal honeycomb carrier extends in the radial direction of the passage, and the passage is formed substantially in half. The flat plate and the corrugated plate that are divided into two circular passages are closed by a deformed portion near the end, and the other half of the opening on the outlet side of the passage is close to the flat plate and the corrugated plate. Since the gas is closed at the deformed portion, the exhaust gas does not flow through the passage, and the exhaust gas passing through the passage can be eliminated without contacting the catalyst body as in the conventional case.

Further, since the passage is substantially closed by the deformed portions near the end portions of the flat plate and the corrugated plate, the passage becomes narrow, and the exhaust gas easily comes into contact with the catalyst. As a result, it is possible to improve the purification in the passage of the central winding portion of the metal honeycomb catalyst, and it is possible to improve the purification efficiency of the metal honeycomb catalyst as a whole.

In the third aspect of the present invention, the metal flat plate and the corrugated plate are overlapped with each other, and the vicinity of the end is engaged with the slit of the winding shaft. It is possible to reliably hold the vicinity of the part. Then, in the next step, since the winding shaft was rotated a plurality of times, the flat plate and the corrugated plate can be wound around the winding shaft, and the flat plate and the corrugated plate are alternately positioned on the winding shaft. A winding member can be formed.

Further, in the next step, since the winding shaft is pulled out from the spiral winding member, it is possible to form the metal honeycomb carrier having the exhaust gas passage in the central winding portion. Then, in the next step, the vicinity of the end portions of the flat plate and the corrugated plate, which extend in the radial direction of the passage provided in the central winding portion of the metal honeycomb carrier and divide the passage into two substantially semicircular passages, are deformed. , The passage can be closed by the deformed part. As a result, the exhaust gas can be prevented from passing through the passage, and the exhaust gas can be prevented from passing through.

Further, by substantially closing the passage, the passage can be narrowed, and the exhaust gas can be brought into contact with the catalyst when the exhaust gas flows through the narrow gap.

Thus, the metal honeycomb catalyst can be formed by coating the catalyst body on the metal honeycomb carrier after closing or substantially closing the passage of the central winding portion of the metal honeycomb carrier. By mounting this metal honeycomb catalyst on the exhaust system of an automobile, the purification of the passage of the metal honeycomb catalyst can be improved and the purification efficiency of the entire metal honeycomb catalyst can be improved.

According to the fourth aspect of the present invention, since the flat plate and the corrugated plate made of metal are overlapped with each other and the vicinity of the end thereof is engaged with the slit of the winding shaft, the end of the flat plate and the corrugated plate is attached to the winding shaft. It is possible to reliably hold the vicinity of the part. Then, in the next step, since the winding shaft was rotated a plurality of times, the flat plate and the corrugated plate can be wound around the winding shaft, and the spiral winding member in which the flat plate and the corrugated plate are alternately positioned is provided. Can be formed.

Then, in the next step, by pulling out the winding shaft from the spiral member, it is possible to form a metal honeycomb carrier having a passage for exhaust gas in the central winding portion. Further, in the next step, after the catalyst body was coated on the metal honeycomb carrier, the vicinity of the ends of the flat plate and the corrugated plate arranged in the radial direction of the passage of the central winding portion of the coated metal honeycomb carrier was deformed. , Which allows the passage to be closed. As a result, the exhaust gas can be prevented from passing through the passage, and the exhaust gas can be prevented from passing through.

Further, since the passage is substantially closed, the passage can be narrowed and the exhaust gas can be brought into contact with the catalyst when the exhaust gas flows through the narrow passage.

As described above, by closing or substantially closing the passage of the central winding portion of the metal honeycomb catalyst, the purification of the passage of the metal honeycomb catalyst can be improved, and at the same time, the entire metal honeycomb catalyst can be improved. The purification efficiency can be improved.

[Brief description of drawings]

FIG. 1 is a side view showing an embodiment of the present invention.

FIG. 2 is a diagram schematically showing a cross section taken along the central winding portion of the one shown in FIG.

3 is a cross-sectional view showing a state where the catalyst of FIG. 1 is mounted in a catalyst case.

FIG. 4 is a sectional view taken along line AA of FIG.

[Fig. 5] Fig. 5 is a diagram for explaining the production of the metal honeycomb carrier, and is a perspective view showing a flat plate and a corrugated plate that are overlapped with each other and engaged with the slit of the winding shaft.

FIG. 6 is a perspective view showing a state where the winding shaft of FIG. 5 is rotated to form a metal honeycomb carrier.

FIG. 7 is a perspective view showing a state where a winding shaft is pulled out from that of FIG. 6 to form a metal honeycomb carrier.

FIG. 8 is a diagram schematically showing a cross section taken along the central winding portion of the one shown in FIG. 7;

[Explanation of symbols]

 1 flat plate 2 corrugated plate 1a near the end 2a near the end 3 winding shaft 4 slit 6 metal honeycomb carrier 7 passage 7a inlet side 7b outlet side 5 winding member 8 metal honeycomb catalyst

Claims (4)

[Claims] 1. A flat plate and a corrugated plate made of metal are superposed and wound to form a spiral metal honeycomb carrier in which the flat plate and the corrugated plate are alternately arranged, and the center winding of the metal honeycomb carrier is performed. A metal honeycomb catalyst characterized in that a passage formed in a portion is closed or substantially closed by the flat plate and the corrugated plate which are arranged in a radial direction of the passage and divide the passage into two substantially semicircular passages. 2. The one half on the inlet side of the passage formed in the central winding portion of the metal honeycomb carrier is arranged in the radial direction of the passage to divide the passage into two substantially semicircular passages. Closed at the deformed portion near the ends of the flat plate and the corrugated plate, and deforming the other half of the outlet side of the passage near the end of the flat plate and the corrugated plate arranged in the radial direction of the passage. 2. It is closed or substantially closed by
The described metal honeycomb catalyst. 3. A metal flat plate and a corrugated plate are superposed on each other,
Engaging the slit of the winding shaft in the vicinity of the end thereof, and rotating the winding shaft a plurality of times so that the flat plate and the corrugated plate are alternately positioned on the winding shaft. A step of winding the corrugated plate in a spiral shape; a step of forming the metal honeycomb carrier by pulling out the winding shaft from the spiral winding member; and a radial direction of a passage of a central winding part of the metal honeycomb carrier. Closing or substantially closing the passage at a deformed portion near the ends of the arranged flat plate and corrugated plate, and coating the metal honeycomb carrier having the passage closed or substantially closed with a catalyst body, 1. A method for manufacturing a metal honeycomb catalyst comprising: 4. A metal flat plate and a corrugated plate are overlapped,
Engaging the slit of the winding shaft in the vicinity of the end thereof, and rotating the winding shaft a plurality of times so that the flat plate and the corrugated plate are alternately positioned on the winding shaft. A step of winding the corrugated plate in a spiral shape; a step of extracting the winding shaft from the spiral winding member to form a metal honeycomb carrier; a step of coating the metal honeycomb carrier with a catalyst body; A step of closing or substantially closing the passage at a deformed portion near the ends of the flat plate and the corrugated plate arranged in the radial direction of the passage of the central winding portion of the formed metal honeycomb carrier. Method for producing a metal honeycomb catalyst.