JPH094443A - Metallic catalytic carrier unit and its manufacture - Google Patents

Abstract

PURPOSE: To greatly increase a joining strength between an outer cylinder and a flat plate more than by a conventional diffusion joining method in a metallic catalytic carrier unit used for the metallic catalyst converter of an automobile, an industrial vehicle and the like and its manufacturing method. CONSTITUTION: A metallic catalytic carrier unit houses a metallic catalytic carrier 23 composed of a wavy plate and a flat plate, which are superposed on each other, wound in multi-layers and duffusively joined, in its outer cylinder 21, and this unit is constructed by diffusely joining the flat plate in the outer periphery of the metallic catalytic carrier 23 to a projection 33 formed in the inner peripheral surface 29 of the outer cylinder 21. The manufacturing method of the metallic catalyst carrier unit is composed in such a manner that after the metallic catalytic carrier 23 is inserted into the outer cylinder 21 having a number of projections 33 formed in its inner peripheral surface 29, the outer cylinder 21 and the metallic catalytic carrier 23 are subjected to heat treatments, the wavy plate and the flat plate are diffusely joined to each other and the flat plate of the outer periphery of the metallic catalytic carrier 23 is duffusively joined to the projection 33.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal catalyst carrier unit used in a metal catalyst converter mounted on an automobile, an industrial vehicle or the like for purifying exhaust gas, and a method for producing the same.

[0002]

2. Description of the Related Art In general, a catalytic converter is disposed in an exhaust system of an automobile for purifying exhaust gas. This catalytic converter is disclosed, for example, in Japanese Utility Model Laid-Open No. 4-53450 and Japanese Patent Publication No. 57-55886. A metal catalyst carrier unit as disclosed in a gazette or the like is used as a component.

FIGS. 13 and 14 show a metal catalyst carrier unit of this type. In the drawings, reference numeral 11 denotes a cylindrical outer cylinder made of metal. A metal catalyst carrier 13 is fitted in the outer cylinder 11. As shown in FIG. 15, the metal catalyst carrier 13 is formed by alternately stacking corrugated plates 15 and flat plates 17 made of metal and multiply winding these in a circular shape.

A throttle portion 19 is formed on the exhaust gas outflow side of the outer cylinder 11. The metal catalyst carrier unit described above includes the outer cylinder 11 in a state in which the throttle portion 19 is not formed.
After inserting the metal catalyst carrier 13 therein, one side of the outer cylinder 11 is drawn to form a narrowed portion 19, the diameter of the metal catalyst carrier 13 is reduced, and the corrugated plate 15 and the flat plate 17 are brought into contact with each other. After the pressure is increased and a brazing material is interposed in the reduced diameter portion in this state, heat treatment is performed in a vacuum furnace and the corrugated plate 15 and the flat plate 17 are brazed.

[0005] In addition, heat treatment is performed in a vacuum furnace without any brazing material, and the corrugated plate 15 and the flat plate 17 are diffusion-bonded. In the diffusion bonding of the method for manufacturing the metal catalyst carrier unit, the metal catalyst carrier 13 is reduced in diameter from the outside to increase the contact pressure between the corrugated plate 15 and the flat plate 17, and the corrugated plate 15 and the flat plate 17 are connected to each other. Since the diffusion bonding is performed, it is possible to improve the bonding strength by the diffusion bonding between the corrugated plate 15 and the flat plate 17.

[0006]

However, the conventional brazing method in the method for manufacturing the metal catalyst carrier unit has a problem that the brazing material is expensive and the cost is high, whereas the diffusion bonding method has a problem in that the outer cylinder 11 is used. Since the flat plate 17 is diffusion-bonded to the flat inner peripheral surface of the outer cylinder 11,
The contact area between the inner peripheral surface of the flat plate 17 and the inner peripheral surface of the
There is a problem in that the contact pressure between No. 1 and the flat plate 17 is limited, and it is difficult to secure sufficient bonding strength between the outer cylinder 11 and the flat plate 17.

The present invention has been made to solve the above-mentioned conventional problems, and provides a metal catalyst carrier unit capable of significantly increasing the bonding strength between an outer cylinder and a flat plate, and a method for manufacturing the same. The purpose is to

[0008]

A metal catalyst carrier unit according to a first aspect of the present invention is a metal catalyst carrier comprising a metal corrugated plate and a flat plate which are superposed and wound in a multiple manner and which are diffusion-bonded, and the metal catalyst carrier. It consists of a metal outer cylinder that houses
A plurality of projections formed on the inner peripheral surface of the outer cylinder are provided, and the metal catalyst carrier is fixed in the outer cylinder by diffusion bonding the projections and the flat plate on the outer circumference of the metal catalyst carrier. Is characterized by.

According to a second aspect of the present invention, there is provided a method for manufacturing a metal catalyst carrier unit, in which a metal catalyst carrier formed by stacking a corrugated plate and a flat plate and winding them in multiple layers is provided in an outer cylinder having a large number of protrusions formed on its inner peripheral surface. After being inserted in a pressure state, the outer cylinder and the metal catalyst carrier are heat-treated, the corrugated plate and the flat plate are diffusion-bonded, and the flat plate on the outer periphery of the metal catalyst carrier is diffusion-bonded to the protrusion to form the metal catalyst carrier. Is fixed in the outer cylinder.

In the method for manufacturing a metal catalyst carrier unit according to a third aspect of the present invention, a large number of protrusions are formed on the inner peripheral surfaces of the first half outer cylinder and the second half outer cylinder, which are made of metal and have a matching shape of a cylinder. And a metal catalyst carrier formed by stacking and corrugating a corrugated plate and a flat plate in a pressurized state is sandwiched in these half outer cylinders, and the first half outer cylinder and the second half outer shell are formed. After forming the outer cylinder by fixing the matching end portion with the cylinder, the outer cylinder containing the metal catalyst carrier is heat-treated, the corrugated plate and the flat plate are diffusion-bonded, and the protrusion of the metal catalyst carrier is formed. The flat plate on the outer periphery is diffusion-bonded to fix the metal catalyst carrier in the outer cylinder.

According to a fourth aspect of the present invention, there is provided a method for manufacturing a metal catalyst carrier unit, wherein a plurality of protrusions are formed on the inner peripheral surfaces of the first half outer cylinder and the second half outer cylinder, which are made of metal and have a matching shape of a cylinder. And a metal catalyst carrier formed by stacking and corrugating a corrugated plate and a flat plate in multiple layers is sandwiched in a pressurized state, and the first half outer cylinder and the second half split outer cylinder are formed. The brazing filler metal is interposed at the matching end portion with the outer cylinder to align the two and heat-treat them to form the first
The outer cylinder is formed by brazing the half outer cylinder and the second half outer cylinder, and the corrugated plate and the flat plate are diffusion-bonded, and at the same time, the flat plate on the outer periphery of the metal catalyst carrier is diffusion-bonded to the protrusion. Then, the metal catalyst carrier is fixed in the outer cylinder.

According to a fifth aspect of the present invention, there is provided a method of manufacturing a metal catalyst carrier unit, wherein a metal catalyst carrier formed by stacking a corrugated plate and a flat plate in a metal outer cylinder and winding the metal catalyst carrier in multiple layers is brought into a pressurized state of at least a close contact state. After the insertion, the outer circumference of the outer cylinder is embossed to form a plurality of protrusions projecting to the inner circumference of the outer cylinder, and the flat plate forming the outermost periphery of the metal catalyst carrier is pressed by the plurality of projections. The metal catalyst carrier is fixed in the outer cylinder by heat-treating these and diffusively bonding the corrugated plate and the flat plate and diffusively bonding the protrusion and the flat plate.

[0013]

In the metal catalyst carrier unit of the first aspect, since the flat plate on the outer periphery of the metal catalyst carrier is brought into contact with a large number of projections formed on the inner peripheral surface of the outer cylinder, the contact between the projections and the flat plate is point contact. The contact pressure between the protrusion and the flat plate is increased, and the protrusion and the flat plate are firmly diffusion-bonded to each other at this contact portion.

In the method for manufacturing a metal catalyst carrier unit according to a second aspect, when the metal catalyst carrier is inserted into the outer cylinder, a large number of protrusions on the inner peripheral surface of the outer cylinder press the flat plate on the outer periphery of the metal catalyst carrier. The contact between the protrusion and the flat plate becomes close to a point contact, the contact pressure at the contact portion between the protrusion and the flat plate increases, and heat treatment in this state causes the protrusion and the flat plate to contact each other at the contact portion. Is strongly diffusion bonded.

Further, during the heat treatment, the corrugated plate and the flat plate are diffusion-bonded, but since the metal catalyst carrier is pressed in the radial direction by the protrusions, the contact pressure between the corrugated plate and the flat plate increases, and the corrugated plate and the flat plate become larger. And are firmly diffusion bonded. In the method for manufacturing a metal catalyst carrier unit according to claim 3, when the outer cylinder is formed by fixing the matching end portions of the first half-divided outer cylinder and the second half-divided outer cylinder, a large number of inner peripheral surfaces of the outer cylinder are formed. The flat plate on the outer periphery of the metal catalyst carrier is brought into contact with the projection in a pressurized state, the contact between the projection and the flat plate becomes close to point contact, and the contact pressure at the contact portion between the projection and the flat plate increases. By heat-treating, the protrusion and the flat plate are firmly diffusion bonded at the contact portion.

Further, during the heat treatment, the corrugated plate and the flat plate are diffusion-bonded, but since the metal catalyst carrier is pressed in the radial direction by the protrusions, the contact pressure between the corrugated plate and the flat plate increases, and the corrugated plate and the flat plate become larger. And are firmly diffusion bonded. In the method for manufacturing a metal catalyst carrier unit according to claim 4, when the metal catalyst carrier is sandwiched between the first half outer cylinder and the second half outer cylinder in a pressurized state,
The flat plate on the outer periphery of the metal catalyst carrier is brought into contact with a large number of protrusions on the inner peripheral surface of the half-divided outer cylinder in a pressurized state, and the contact between the protrusions and the flat plate becomes close to point contact. The contact pressure of the contact portion increases, and heat treatment is performed in this state, so that the protrusion and the flat plate are firmly diffusion bonded at the contact portion.
At the same time, the matching end portions of the first half-divided outer cylinder and the second half-divided outer cylinder are brazed to form the outer cylinder.

Further, the corrugated plate and the flat plate are diffusion-bonded during the heat treatment, but since the metal catalyst carrier is pressed in the radial direction by the projection, the contact pressure between the corrugated plate and the flat plate increases,
The corrugated plate and the flat plate are firmly diffusion-bonded. In the method for manufacturing a metal catalyst carrier unit according to claim 5, when the outer circumference of the outer cylinder is embossed to form a plurality of protrusions on the inner peripheral surface of the outer cylinder, a flat plate on the outer circumference of the metal catalyst carrier inserted into the outer cylinder. In, the protrusion is abutted in a pressed state, the contact pressure of the contact portion between the protrusion and the flat plate increases, by heat treatment in this state,
At the contact portion, the protrusion and the flat plate are firmly diffusion bonded.

Further, during the heat treatment, the corrugated plate and the flat plate are diffusion-bonded, but since the metal catalyst carrier is pressed in the radial direction by the protrusions, the contact pressure between the corrugated plate and the flat plate increases, and the corrugated plate and the flat plate are increased. And are firmly diffusion bonded.

[0019]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The details of the present invention will be described below with reference to the drawings.

1 and 2 show a first embodiment of a metal catalyst carrier unit according to the present invention, which is denoted by reference numeral 2 in the drawings.
Reference numeral 1 denotes a racing track-shaped outer cylinder made of metal. A metal catalyst carrier 23 is fitted in the outer cylinder 21. The metal catalyst carrier 23 is formed by alternately stacking a corrugated plate 25 and a flat plate 27 made of metal, and winding these in multiple layers in a racing track.

In this embodiment, the outer cylinder 21 and the corrugated plate 2 are used.
5 and the flat plate 27 are made of 20% Cr-5% Al ferritic stainless steel. On the exhaust gas outflow side of the inner peripheral surface 29 of the outer cylinder 21, a ring-shaped protrusion 31 having a predetermined length in the axial direction is formed.
It is composed of a large number of protrusions 33 formed on.

These protrusions 33 are previously formed on the outer cylinder 21.
Is formed by embossing. The corrugated plate 25 and the flat plate 27 are joined to each other by diffusion joining,
In addition, the protrusion 33 and the outermost flat plate 27 of the metal catalyst carrier 23.
And are joined by diffusion joining. In this way, in this metal catalyst carrier unit, the metal catalyst carrier 23 is fixed to the outer cylinder 21.

The metal catalyst carrier unit described above is manufactured as described below. First, a racing track-shaped outer cylinder 21 is formed. Next, in the vicinity of one end of the outer cylinder 21, embossing is performed from the outer circumference to the entire circumference to a predetermined length in the axial direction. As a result, a ring-shaped protrusion 31 having a large number of protrusions 33 formed on its inner peripheral surface is formed.

Next, as shown in FIGS. 3 and 4, a honeycomb-shaped metal catalyst carrier 23 formed by winding a corrugated plate 25 and a flat plate 27 and temporarily fixing only the ends by spot welding.
One side is compressed by the compression jig 35 and is inserted into one end of the outer cylinder 21. The compression jig 35
Is a metal strip plate 37 wound around the outer circumference of the metal catalyst carrier 23, bolts 39 inserted into both ends of the strip plate 37, and a nut 41 screwed to the tip of the bolt 39.
And by tightening the nut 41, the strip plate 3
7 is strongly clamped to the outer periphery of the metal catalyst carrier 23, and the metal catalyst carrier 23 is compressed.

The tightening position by the compression jig 35 is
The tip of the metal catalyst carrier 23 is located at a position slightly separated from the insertion tip of the metal catalyst carrier 23 so that it can be inserted into one end of the outer cylinder 21. In addition, the compression jig 35
Is approximately equal to or larger than the width of the protrusion 31.

As a result, the compressed portion of the metal catalyst carrier 23 corresponding to the protruding portion 31 is slightly plastically deformed to have a small diameter as compared with the other portions, and this portion is protruded during pressing as described later. Even when it reaches, it does not become difficult to insert. Then, one side of the metal catalyst carrier 23 is attached to the outer cylinder 2.
1 is inserted into the compression jig 35 from the metal catalyst carrier 23.
Is removed and the other side of the metal catalyst carrier 23 is pressed, whereby the metal catalyst carrier 23 is completely housed in the outer cylinder 21.

At this time, although the metal catalyst carrier 23 is slightly plastically deformed, it is generally elastically deformed by the displacement of the corrugated plate 25 and accommodated in the outer cylinder 21. In this state, the metal catalyst carrier 23 exerts a pressure outward due to its elasticity, and the contact pressure of the contact portion of the flat plate 27 with the protrusion 33 of the outer cylinder 21 and the contact pressure between the corrugated plate 25 and the flat plate 27 are extremely high. Is getting bigger.

Then, in this state, the outer cylinder 21 accommodating the metal catalyst carrier 23 is accommodated in a vacuum furnace and heat-treated at a predetermined temperature, whereby the contact portion between the protrusion 33 and the flat plate 27 and the corrugated plate 25. The contact portion between the flat plate 27 and the flat plate 27 is diffusion-bonded. In this way, the metal catalyst carrier 23 is attached to the outer cylinder 21.
It is firmly fixed inside and the metal catalyst carrier unit is completed.

Although the metal catalyst carrier 23 is partially tightened by the compression jig 35 in the above-mentioned embodiment, the present invention is not limited to this, but this metal catalyst carrier is excluded except for a slight insertion margin on the insertion side. The entire carrier 23 may be tightened. In this case, insertion is easier than in the case described above. Thus, in the metal catalyst carrier unit described above, a large number of protrusions 33 formed on the inner peripheral surface 29 of the outer cylinder 21.
Since the flat plate 27 on the outer periphery of the metal catalyst carrier 23 is brought into contact with the flat plate 27, the contact between the projection 33 and the flat plate 27 becomes close to a point contact, and the contact pressure at the contact portion between the projection 33 and the flat plate 27 increases. At this contact portion, the protrusion 33 and the flat plate 27 are firmly diffusion-bonded to each other, so that the bonding strength between the outer cylinder 21 and the flat plate 27 can be significantly increased as compared with the conventional case.

Further, during heat treatment, the corrugated plate 25 and the flat plate 27 are diffusion-bonded, but since the metal catalyst carrier 23 is pressed in the radial direction by the projection 33, the contact pressure between the corrugated plate 25 and the flat plate 27 increases. The corrugated plate 25 and the flat plate 27 can be firmly diffusion-bonded. Furthermore, since the corrugated plate 25 and the flat plate 27 and the outer cylinder 21 and the flat plate 27 can be diffusion-bonded by the same heat treatment, the number of heat treatment steps can be reduced.

In the above embodiment, the compression catalyst 35 is used to store the metal catalyst carrier 23 in the pressurized state in the outer cylinder 21, but the present invention is not limited to this. Alternatively, the metal catalyst carrier 23 may be pressed and inserted after being flared. Next, a second embodiment of the present invention will be described. The second embodiment is different in the outer cylinder structure from the first embodiment described above.

Therefore, only the differences from the first embodiment will be described, duplicated explanation will be avoided, and common parts will be explained using the same numbers. FIG. 5 is a perspective view of the metal catalyst carrier unit of this embodiment. Outer cylinder 21 of this metal catalyst carrier unit
Is a metal first half outer cylinder 21a and a second half outer cylinder 21b.
By aligning with, the whole is in the form of a racing track.

The matching end portions 21c and 21c of the first outer half tube 21a and the second outer half tube 21b are fixed by welding. Then, similarly to the first embodiment, this outer cylinder 2
A large number of protrusions 33 are formed on the inner peripheral surface 29 near one end of the first.
(See FIG. 1), the protrusions 31 are formed, and each protrusion 33 is the outermost flat plate 27 of the metal catalyst carrier 23.
The metal catalyst carrier 23 is fixed to the outer cylinder 21 in the metal catalyst carrier unit of this embodiment.

This metal catalyst carrier unit is manufactured as follows. The outer circumferences of the first half-divided outer cylinder 21a and the second half-divided outer cylinder 21b are embossed to form the protrusions 33 on the aforementioned portions. Then, the metal catalyst carrier 23 in a state in which the corrugated plate 25 and the flat plate 27 are simply wound or in a state in which the ends are temporarily fixed is separated from the first half-split outer cylinder 21a and the second half-split outer cylinder 21b. The metal catalyst carrier 2 is placed between the first and second half outer cylinders 21a and 21b and pressed from the outer circumference.
Hold 3 under pressure.

While maintaining this state, the first half outer cylinder 2
Aligning end portions 21c and 21c of 1a and the second outer half tube 21b
Are welded to form the outer cylinder 21. As a result, the metal catalyst carrier 23 is housed in the outer cylinder 21 while maintaining the pressurized state. Then, as in the first embodiment, heat treatment is performed in a vacuum furnace, and each protrusion 33 is joined to the outermost peripheral flat plate 27 of the metal catalyst carrier 23 by diffusion bonding, and at the same time, the contact portion between the corrugated plate 25 and the flat plate 27 is formed. Diffusion bonded.

As a result, the metal catalyst carrier 23 becomes the outer cylinder 2
It is fixed in 1 and the unit for metal catalyst carrier is completed. The second embodiment requires a welding process for forming the outer cylinder 21, but in addition to the same operation and effect as those of the above-described first embodiment, the metal catalyst carrier 23 is attached to the outer cylinder 21. It has the effect of being easy to store.

Next, a third embodiment of the present invention will be described. The third embodiment differs from the above-described second embodiment only in the method of joining the matching end portions 21c, 21c of the outer cylinder 21 and is otherwise the same. That is, in the third embodiment,
The metal catalyst carrier 23 in a state in which the corrugated plate 25 and the flat plate 27 are simply wound or in a state in which the ends are temporarily fixed is placed between the first half outer cylinder 21a and the second half outer cylinder 21b. At the same time, a brazing material is interposed between the matching end portions 21c, 21c of the first and second half-divided outer cylinders 21a, 21b, and thereafter, the first and second half-divided outer cylinders 21a, 21b are pressed from the outer circumference. Then, the matching end portions 21c, 21c and the metal catalyst carrier 23 are held in a pressurized state.

Then, while maintaining this state, these are heat-treated in a vacuum furnace, and the first half split outer cylinder 21a and the second half outer cylinder 21a.
The outer cylinder 21 is formed by brazing the matching end portions 21c and 21c with the half outer cylinder 21b, and the respective projections 33 are formed.
Is bonded to the outermost flat plate 27 of the metal catalyst carrier 23 by diffusion bonding, and at the same time, the contact portion between the corrugated plate 25 and the flat plate 27 is diffusion bonded.

As a result, the metal catalyst carrier 23 becomes the outer cylinder 2
It is fixed in 1 and the metal catalyst carrier unit is completed. In the third embodiment, the welding process for forming the outer cylinder 21 is not necessary, and the same operation and effect as those of the first embodiment described above can be obtained. It has an excellent effect that it is easy to store.

In this embodiment, when forming the outer cylinder 21, the matching end portions 21c and 21c of the first half outer cylinder 21a and the second half outer cylinder 21b are butt-brazed together. Not limited to this, as shown in FIG. 6, the matching end portions 21c, 21c of the first and second half outer cylinders 21a, 21b.
May have a first flange portion 21d and a second flange portion 21e.

In this structure, since the brazing allowance is large, the brazing work is easy and the strength thereof is large. Although not shown, the matching end portions 21c, 2
One of the 1c may be a hinge stopper, and the other may be abutting or bridging brazing as described above.
Next, a fourth embodiment of the present invention will be described.

In the fourth embodiment, as shown in FIG. 7, a metal catalyst carrier 23 is housed in a cylindrical outer cylinder 21, and the outer cylinder 21 and the metal catalyst carrier 23 are the outermost flat plates. 27 and the plurality of protrusions 33 are fixed by diffusion bonding. The fourth embodiment is manufactured as follows. As shown in FIG. 8, a cylindrical honeycomb-shaped metal catalyst carrier 23 is pressed into an outer cylinder 21 having an inner diameter substantially equal to the outer diameter.

That is, the metal catalyst carrier 23 is the outer cylinder 21.
It is stored with a slight interference fit. The metal catalyst carrier 23 is formed by winding the corrugated plate 25 and the flat plate 27 in advance and temporarily fixing the ends. Then
As shown in FIG. 7, the outer circumference of the outer cylinder 21 is embossed to form a large number of protrusions 33 on the inner peripheral surface 29.

These projections 33 are provided in the vicinity of one end of the outer cylinder 21 so as to project over the entire circumference, and form a ring-shaped projection 31. Then, the metal catalyst carrier 23
The protrusions 33 are housed in the outer cylinder 21 in a state where the outermost flat plate 27 of the metal catalyst carrier 23 is partially pressed.

The outer cylinder 21 in this state is heat-treated in a vacuum furnace. As a result, these protrusions 33 and the metal catalyst carrier 23
The outermost flat plate 27 is diffusion-bonded to the metal catalyst carrier 23.
Is firmly fixed in the outer cylinder 21, and at the same time, the contact portion between the corrugated plate 25 and the flat plate 27 is diffusion-bonded to complete the metal catalyst carrier unit. In the present embodiment, the outer cylinder 2 of the metal catalyst carrier 23
In addition to being easy to press fit into 1, the pressure of the protrusion 33 for pressing the flat plate 27 becomes uniform, so that the diffusion bonding can be made uniform.

Therefore, the bonding between the metal catalyst carrier 23 and the outer cylinder 21 becomes uniform, and a stable product can be obtained. In addition,
In the present embodiment, the metal catalyst carrier 23 and the outer cylinder 21 are fitted in an interference fit state, but the invention is not limited to this, and the metal catalyst carrier 23 and the outer cylinder 21 may be fit in a slight clearance fit within the height of the protrusion 33. You can also

In this case, the protrusion 33 for pressing the flat plate 27
Since the pressure of is slightly weakened, the diffusion bonding strength is reduced, but since the insertion of the metal catalyst carrier 23 into the outer cylinder 21 is weightless, the manufacturing is extremely easy. Therefore, it is most suitable for applications where strength is not required so much. Table 1 below shows
The joint strength of the outer cylinder 21 and the flat plate 27 in the prototypes 1 to 8 of the metal catalyst carrier unit of the present invention is shown. In this table, each dimension is shown in FIGS. 9 and 10.

Here, L ₁ is the length of the outer cylinder 21 in the axial direction, L ₂ is the length of the protrusion 31 in the axial direction, L ₃ is the length of the metal catalyst carrier 23 in the axial direction, and P is P. ₁ is the processing pitch of the protrusion 33, D ₁ is the length of the outer cylinder 21 in the minor axis direction, and H ₁ is the protrusion 3
The protrusion height of 3 and t ₁ is the thickness of the outer cylinder 21.

[Table 1] It should be noted that, as shown in FIG. 11, the bonding strength is measured by using a mold 4 similar to the metal catalyst carrier 23 on the end face of the metal catalyst carrier 23.
3 was pressed and the load when the flat plate 27 started to slide with respect to the outer cylinder 21 was measured.

From Table 1, it can be seen that the joint strengths of prototypes 5 and 6 are as large as 4000 kg or more. Here, the reason why the pressure is set to 4000 kg or more is that the measurement becomes impossible because the metal catalyst carrier 23 buckled and fractured under the load of 4000 kg. Also, from Table 1, L ₂ is 30 mm
As described above, it is preferable that H ₁ is 1.3 mm or more and P ₁ is 1 mm or less.

Incidentally, L ₂ of 30 mm or more means L
It is shown that the length of ₂ should be 17% or more of the total length L ₁ of the outer cylinder 21. The position of the protruding portion 31 formed on the outer cylinder 21 is not limited to the above-described embodiment, and, for example, as shown in FIGS. It may be on the inflow side or in the center, and further, as shown in (c) and (d), the protrusion 31 is divided into a plurality of parts, and the total length of these is the total length L of the outer cylinder 21.
It may be 17% or more of ₁ .

In the first to third embodiments described above, an example in which the present invention is applied to a racing track-shaped metal catalyst carrier unit has been described, but the present invention is limited to such embodiments. Instead, it can be applied to a metal catalyst carrier unit having a circular shape, for example.

[0052]

As described above, in the metal catalyst carrier unit of claim 1, since the flat plate on the outer periphery of the metal catalyst carrier is brought into contact with the many protrusions formed on the inner peripheral surface of the outer cylinder, And the flat plate become close to point contact, the contact pressure between the projection and the flat plate increases, and the projection and the flat plate are firmly diffusion-bonded at this contact part. It is possible to obtain a metal catalyst carrier unit having a high bonding strength with.

In the method for manufacturing a metal catalyst carrier unit according to a second aspect, when the metal catalyst carrier is inserted into the outer cylinder, a large number of protrusions on the inner peripheral surface of the outer cylinder press the flat plate on the outer periphery of the metal catalyst carrier. The contact between the protrusion and the flat plate becomes close to a point contact, the contact pressure at the contact portion between the protrusion and the flat plate increases, and heat treatment in this state causes the protrusion and the flat plate to contact each other at the contact portion. Is strongly diffusion-bonded, the bonding strength between the outer cylinder and the flat plate can be significantly increased as compared with the conventional case.

Further, during the heat treatment, the corrugated plate and the flat plate are diffusion-bonded, but since the metal catalyst carrier is pressed in the radial direction by the projections, the contact pressure between the corrugated plate and the flat plate increases, and the corrugated plate and the flat plate become larger. And can be firmly diffusion-bonded. Furthermore, since the corrugated plate and the flat plate and the outer cylinder and the flat plate can be diffusion-bonded by the same heat treatment, the number of heat treatment steps can be reduced.

In the method for manufacturing a metal catalyst carrier unit according to a third aspect of the present invention, when the outer cylinder is formed by fixing the matching end portions of the first half outer cylinder and the second half outer cylinder, the inner peripheral surface of the outer cylinder is formed. The flat plate on the outer periphery of the metal catalyst carrier is brought into contact with a large number of projections of
The contact between the protrusion and the flat plate becomes close to a point contact, the contact pressure at the contact portion between the protrusion and the flat plate increases, and by heat treatment in this state, the protrusion and the flat plate are firmly diffusion bonded at the contact portion. Therefore, the joint strength between the outer cylinder and the flat plate can be significantly increased as compared with the conventional case.

Since the metal catalyst carrier is sandwiched between the first half-divided outer cylinder and the second half-divided outer cylinder, the outer periphery of the metal catalyst carrier is attached to a large number of protrusions on the inner peripheral surface of the outer cylinder. The flat plate can be easily and surely brought into contact under pressure. Further, the corrugated plate and the flat plate are diffusion-bonded during the heat treatment, but since the metal catalyst carrier is pressed in the radial direction by the protrusion, the contact pressure between the corrugated plate and the flat plate becomes large, and the corrugated plate and the flat plate are firmly bonded. Can be diffusion bonded.

Further, by the same heat treatment, a corrugated plate and a flat plate,
And since the outer cylinder and the flat plate can be diffusion-bonded,
The number of heat treatment steps can be reduced. In the method for manufacturing a metal catalyst carrier unit according to claim 4, when the metal catalyst carrier is sandwiched between the first half outer cylinder and the second half outer cylinder in a pressurized state,
The flat plate on the outer periphery of the metal catalyst carrier is brought into contact with a large number of protrusions on the inner peripheral surface of the half-divided outer cylinder in a pressurized state, and the contact between the protrusions and the flat plate becomes close to point contact. The contact pressure of the contact part becomes large, and by heat-treating in this state, the protrusion and the flat plate are strongly diffusion-bonded at the contact part, so that the bonding strength between the outer cylinder and the flat plate is significantly increased compared to the conventional case. You can

Since the metal catalyst carrier is sandwiched between the first half-divided outer cylinder and the second half-divided outer cylinder, the outer periphery of the metal catalyst carrier is attached to a large number of protrusions on the inner peripheral surface of the outer cylinder. The flat plate can be easily and surely brought into contact under pressure. Further, the corrugated plate and the flat plate are diffusion-bonded during the heat treatment, but since the metal catalyst carrier is pressed in the radial direction by the protrusion, the contact pressure between the corrugated plate and the flat plate becomes large, and the corrugated plate and the flat plate are firmly bonded. Can be diffusion bonded.

Further, by the same heat treatment, a corrugated plate and a flat plate,
Since the outer cylinder and the flat plate can be diffusion-bonded and the matching end portions of the first half-divided outer cylinder and the second half-divided outer cylinder can be brazed at the same time, the number of heat treatment steps can be reduced. Claim 5
In the method for manufacturing a metal catalyst carrier unit of, when a plurality of protrusions are formed on the inner peripheral surface of the outer cylinder by embossing the outer circumference of the outer cylinder, a flat plate on the outer circumference of the metal catalyst carrier inserted into the outer cylinder,
When the protrusion is brought into contact with the pressed state, the contact pressure of the contact portion between the protrusion and the flat plate increases, and by heat treatment in this state, the protrusion and the flat plate are firmly diffusion-bonded at the contact portion. The joining strength between the cylinder and the flat plate can be significantly increased as compared with the conventional case.

Further, by the embossing, the projection can be easily and surely brought into contact with the flat plate on the outer periphery of the metal catalyst carrier inserted into the outer cylinder in a pressed state. Further, the corrugated plate and the flat plate are diffusion-bonded during the heat treatment, but since the metal catalyst carrier is pressed in the radial direction by the protrusion, the contact pressure between the corrugated plate and the flat plate becomes large, and the corrugated plate and the flat plate are firmly fixed. Can be diffusion bonded. Further, since the corrugated plate and the flat plate and the outer cylinder and the flat plate can be diffusion-bonded by the same heat treatment, the number of heat treatment steps can be reduced.

[Brief description of drawings]

FIG. 1 is a vertical sectional view showing a first embodiment of a metal catalyst carrier unit of the present invention.

FIG. 2 is a cross-sectional view showing the metal catalyst carrier unit of FIG.

FIG. 3 is an explanatory view showing a compression method of the metal catalyst carrier of FIG.

FIG. 4 is an explanatory view showing a method of inserting the metal catalyst carrier of FIG. 1 into an outer cylinder.

FIG. 5 is a perspective view showing a second embodiment of the metal catalyst carrier unit of the present invention.

FIG. 6 is an explanatory view showing an example in which a flange portion is formed on the first and second half outer cylinders.

FIG. 7 is a perspective view showing a fourth embodiment of the metal catalyst carrier unit of the present invention.

FIG. 8 is an explanatory view showing a method of inserting the metal catalyst carrier of FIG. 7 into an outer cylinder.

FIG. 9 is an explanatory diagram showing dimensions of a prototype of the metal catalyst carrier unit of the present invention.

FIG. 10 is an explanatory diagram showing dimensions of a prototype of the metal catalyst carrier unit of the present invention.

FIG. 11 is an explanatory diagram showing a method for measuring bonding strength.

FIG. 12 is an explanatory view showing another example of the metal catalyst carrier unit of the present invention.

FIG. 13 is a cross-sectional view showing a metal catalyst carrier unit manufactured by a conventional method for manufacturing a metal catalyst carrier unit.

FIG. 14 is a side view showing the metal catalyst carrier unit of FIG.

FIG. 15 is a perspective view showing a state in which a corrugated plate and a flat plate are wound.

[Explanation of symbols]

 21 outer cylinder 21a first half outer cylinder 21b second half outer cylinder 21c matching end 23 metal catalyst carrier 25 corrugated plate 27 flat plate 29 inner peripheral surface 31 protrusion 33 protrusion

Claims (5)

[Claims] 1. A metal catalyst carrier (23) comprising a metal corrugated plate (25) and a flat plate (27) which are superposed and wound in multiple layers and are diffusion-bonded to each other, and the metal catalyst carrier (23) is accommodated. And a large number of projections (3) formed on the inner peripheral surface (29) of the outer cylinder (21).
3), the protrusion (33) and the metal catalyst carrier (2)
A metal catalyst carrier unit, characterized in that the metal catalyst carrier (23) is fixed in the outer cylinder (21) by diffusion bonding with a flat plate (27) on the outer periphery of 3). 2. A corrugated plate (25) and a flat plate (2) in an outer cylinder (21) having a large number of protrusions (33) formed on an inner peripheral surface (29).
Metal catalyst carrier (23) formed by stacking and
After being inserted in a pressurized state, the outer cylinder (21) and the metal catalyst carrier (23) are heat-treated to diffusion-bond the corrugated plate (25) and the flat plate (27), and the protrusion (33).
A flat plate (27) on the outer periphery of the metal catalyst carrier (23) is diffusion-bonded to the metal catalyst carrier (23) to attach the metal catalyst carrier (23) to the outer cylinder (2).
1) A method for producing a metal catalyst carrier unit, characterized in that the metal catalyst carrier unit is fixed inside. 3. A large number of protrusions (33) on the inner peripheral surface (29) of each of the first half outer cylinder (21a) and the second half outer cylinder (21b) which are made of metal and whose matching shape is a cylinder. ) Is formed, and a metal catalyst carrier (23) formed by superposing and corrugating a corrugated plate (25) and a flat plate (27) in these half split outer cylinders (21a, 21b) is sandwiched under pressure. Then, the first half split outer cylinder (21
a) and the matching end portion (21c, 21c) of the second half outer cylinder (21b).
21c) is fixed to form the outer cylinder (21), and then the outer cylinder (21) accommodating the metal catalyst carrier (23) is heat-treated to diffusion-bond the corrugated plate (25) and the flat plate (27). In addition, the metal catalyst carrier (2
3) A method for manufacturing a metal catalyst carrier unit, characterized in that the flat plate (27) on the outer periphery of (3) is diffusion bonded to fix the metal catalyst carrier (23) in the outer cylinder (21). 4. A large number of projections (33) are formed on the inner peripheral surface (29) of each of the first half outer cylinder (21a) and the second half outer cylinder (21b), which are made of metal and whose matching shape is a cylinder. ) Is formed, and a metal catalyst carrier (23) formed by superposing and corrugating a corrugated plate (25) and a flat plate (27) in these half split outer cylinders (21a, 21b) is sandwiched under pressure. At the same time, a brazing filler metal is interposed at the matching end portions (21c, 21c) of the first half outer cylinder (21a) and the second half outer cylinder (21b) to align the two,
By heat-treating these, the first half outer cylinder (21a) and the second half
The outer cylinder (21) is formed by brazing the half-split outer cylinder (21b), and the corrugated plate (25) and the flat plate (27) are diffusion-bonded to each other, and at the same time, the metal catalyst is attached to the protrusion (33). A method for manufacturing a metal catalyst carrier unit, characterized in that a flat plate (27) on the outer periphery of the carrier (23) is diffusion-bonded to fix the metal catalyst carrier (23) in the outer cylinder (21). 5. A corrugated plate (2) is provided in a metal outer cylinder (21).
5) and a flat plate (27) are superposed and wound in a multiplex manner, after inserting the metal catalyst carrier (23) into a pressurized state of at least a close contact state, the outer periphery of the outer cylinder (21) is embossed, A plurality of protrusions (33) projecting on the inner periphery of the outer cylinder (21) are formed, and a flat plate (27) forming the outermost periphery of the metal catalyst carrier (23) is pressed by the plurality of protrusions (33). , These are heat-treated, and the corrugated plate (25) and the flat plate (2
7) is diffusion-bonded and the projection (33) and the flat plate (27) are diffusion-bonded, whereby the metal catalyst carrier (23) is fixed in the outer cylinder (21). Method for manufacturing metal catalyst carrier unit.