JP2023034799A - Exhaust purification device and its manufacturing method - Google Patents

Exhaust purification device and its manufacturing method Download PDF

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JP2023034799A
JP2023034799A JP2021141215A JP2021141215A JP2023034799A JP 2023034799 A JP2023034799 A JP 2023034799A JP 2021141215 A JP2021141215 A JP 2021141215A JP 2021141215 A JP2021141215 A JP 2021141215A JP 2023034799 A JP2023034799 A JP 2023034799A
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exhaust gas
catalyst structure
laminate
papermaking
reinforcing member
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恵太 冨松
Keita Tomimatsu
裕也 井田
Yuya Ida
達也 秋山
Tatsuya Akiyama
涼 鈴木
Ryo Suzuki
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FCC Co Ltd
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FCC Co Ltd
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Priority to PCT/JP2022/032251 priority patent/WO2023032857A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/86—Catalytic processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/86—Catalytic processes
    • B01D53/88—Handling or mounting catalysts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/54—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
    • B01J23/56—Platinum group metals
    • B01J23/63—Platinum group metals with rare earths or actinides
    • B01J35/56—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/08—Heat treatment

Abstract

To provide an exhaust purification device capable of attempting light-weight of a catalyst structure and capable of suppressing generation of cracks even in the catalyst structure of a rectangular column and its manufacturing method.SOLUTION: An exhaust purification device comprises: a catalyst structure 2 capable of circulating an exhaust gas; a metal catalyst 3 carried on the catalyst structure 2 and capable of reacting with the exhaust gas circulating through the catalyst structure 2 to purify the exhaust gas; and a housing case 4 housing the catalyst structure 2 and attachable to an exhaust gas flow path through which the exhaust gas circulates. The catalyst structure 2 has a laminate E in which paper sheets folded into a corrugated shape are laminated into a plurality of stages, and formed into a rectangular columnar shape imitating a shape of an inner peripheral shape of the housing case 4, and a notch A is formed in a laminate direction side surface α located in a laminate direction G of at least paper sheets E1, E2 of a rectangular columnar shaped side surfaces.SELECTED DRAWING: Figure 7

Description

本発明は、排ガスを流通可能な触媒構造体と、触媒構造体に担持され、当該触媒構造体を流通する排ガスと反応して浄化し得る金属触媒と、触媒構造体を収容するとともに、排ガスが流通する排ガス流路に取り付け可能な収容ケースとを具備した排ガス浄化装置及びその製造方法に関するものである。 The present invention contains a catalyst structure through which an exhaust gas can flow, a metal catalyst supported on the catalyst structure and capable of reacting with the exhaust gas flowing through the catalyst structure to purify the exhaust gas, and a catalyst structure. The present invention relates to an exhaust gas purifying apparatus having a storage case that can be attached to a flowing exhaust gas flow path, and a manufacturing method thereof.

薪ストーブは、金属製の密閉された箱型の本体内で薪を燃焼させて放熱させることにより室内を暖めるための暖房器から成り、輻射熱と室内空気の対流との相乗効果により、穏やかな暖かさの室内空間を作り出すことができるとされている。この薪ストーブは、通常、屋外まで延設された煙突を具備するとともに、薪の燃焼空間と煙突との間の排ガス流路には、排ガス浄化装置が配設されている。 A wood-burning stove consists of a heater that heats the room by burning firewood inside a closed metal box-shaped body and dissipating heat. It is said that it is possible to create a large indoor space. This wood stove usually has a chimney that extends to the outside, and an exhaust gas purifying device is arranged in the exhaust gas flow path between the firewood combustion space and the chimney.

従来の排ガス浄化装置は、薪の燃焼により発生する排ガスを浄化するもので、排ガスを流通可能な触媒構造体と、触媒構造体に担持され、例えば灰の微粒子であるＰＭ（Particulate Matter）や不完全燃焼により生じるＣＯ（一酸化炭素）と反応して浄化し得る金属触媒と、触媒構造体を収容するとともに、排ガスが流通する排ガス流路に取り付け可能な収容ケースとを有している。なお、特許文献１に薪ストーブの一般的構造について開示されている。 A conventional exhaust gas purifying device purifies exhaust gas generated by burning firewood, and includes a catalyst structure through which the exhaust gas can flow, and PM (Particulate Matter), which is fine particles of ash and impurities, which are supported by the catalyst structure. It has a metal catalyst that can react with and purify CO (carbon monoxide) generated by complete combustion, and a storage case that houses the catalyst structure and can be attached to an exhaust gas flow path through which the exhaust gas flows. Note that Patent Document 1 discloses a general structure of a wood-burning stove.

特開２０１４－２０５７３号公報JP 2014-20573 A

上記従来の排ガス浄化装置においては、金属触媒を担持するハニカム構造（触媒構造体）が比較的重くなってしまい、装置全体の軽量化を図るのが困難となっていた。そこで、本出願人は、例えば湿式抄造法によって得られた抄造シートを波型形状に折り曲げ、その折り曲げられた抄造シートを複数段に積層して積層体を構成するとともに、当該積層体を乾燥及び焼成することにより、軽量化された触媒構造体を得ることを検討するに至った。 In the above conventional exhaust gas purifier, the honeycomb structure (catalyst structure) that supports the metal catalyst is relatively heavy, making it difficult to reduce the weight of the entire device. Therefore, the present applicant folds a paper-made sheet obtained by, for example, a wet paper-making method into a corrugated shape, and laminates the folded paper-made sheets in a plurality of stages to form a laminate, and the laminate is dried and dried. We have come to consider obtaining a lightweight catalyst structure by calcination.

しかるに、排ガス流路の形状に応じて排ガス浄化装置の触媒構造体を角柱形状とした場合、角柱形状の側面のうち抄造シートの積層方向に位置する積層方向側面にクラックが発生してしまう虞があった。すなわち、角柱形状（断面矩形状）の触媒構造体は、角部より中心部の方が排ガスを通過させ易いため、中心部と角部との間で大きな温度差が生じ、熱応力による熱衝撃によって角部にクラック（亀裂）が生じ易くなっているのである。 However, when the catalyst structure of the exhaust gas purifier is shaped like a prism in accordance with the shape of the exhaust gas flow path, there is a risk that cracks may occur on the stacking direction side surface of the prismatic shape located in the stacking direction of the papermaking sheets. there were. That is, in a prismatic (rectangular cross-section) catalyst structure, exhaust gases are more likely to pass through the center than at the corners. Therefore, cracks are likely to occur at the corners.

本発明は、このような事情に鑑みてなされたもので、触媒構造体の軽量化を図ることができるとともに、角柱形状の触媒構造体であってもクラックの発生を抑制することができる排ガス浄化装置及びその製造方法を提供することにある。 SUMMARY OF THE INVENTION The present invention has been made in view of such circumstances. An object of the present invention is to provide an apparatus and a manufacturing method thereof.

請求項１記載の発明は、排ガスを流通可能な触媒構造体と、前記触媒構造体に担持され、当該触媒構造体を流通する前記排ガスと反応して浄化し得る金属触媒と、前記触媒構造体を収容するとともに、排ガスが流通する排ガス流路に取り付け可能な収容ケースとを具備した排ガス浄化装置であって、前記触媒構造体は、波型形状に折り曲げられた抄造シートが複数段に積層された積層体を有するとともに、前記収容ケースの内周面の形状に倣った角柱形状に形成され、且つ、前記角柱形状の側面のうち少なくとも前記抄造シートの積層方向に位置する積層方向側面に切り欠きが形成されたことを特徴とする。 A first aspect of the present invention provides a catalyst structure through which an exhaust gas can flow, a metal catalyst carried on the catalyst structure and capable of reacting with and purifying the exhaust gas flowing through the catalyst structure, and the catalyst structure. and a storage case that can be attached to an exhaust gas flow path through which the exhaust gas flows, wherein the catalyst structure is formed by stacking a plurality of layers of paper-made sheets folded in a corrugated shape. and is formed in a prismatic shape that follows the shape of the inner peripheral surface of the storage case, and has a notch in at least one side surface of the prismatic shape in the stacking direction that is positioned in the stacking direction of the papermaking sheets. is formed.

請求項２記載の発明は、請求項１記載の排ガス浄化装置において、前記触媒構造体は、断面が長辺及び短辺を有した長方形とされるとともに、前記積層方向側面は当該長方形の長辺に位置することを特徴とする。 According to a second aspect of the invention, in the exhaust gas purifying apparatus of the first aspect, the catalyst structure has a rectangular cross section with long sides and short sides, and the side surfaces in the stacking direction are the long sides of the rectangle. characterized by being located in

請求項３記載の発明は、請求項２記載の排ガス浄化装置において、前記切り欠きは、前記長辺の中央の位置に形成されたことを特徴とする。 The invention according to claim 3 is characterized in that, in the exhaust gas purifying apparatus according to claim 2, the notch is formed at a central position of the long side.

請求項４記載の発明は、請求項１～３の何れか１つに記載の排ガス浄化装置において、前記積層体の外周面には、前記収容ケースの内周面に沿って延設された補強部材が形成されるとともに、当該補強部材に前記切り欠きが形成されたことを特徴とする。 The invention according to claim 4 is the exhaust gas purifying apparatus according to any one of claims 1 to 3, wherein a reinforcement extending along the inner peripheral surface of the storage case is provided on the outer peripheral surface of the laminate. A member is formed, and the notch is formed in the reinforcing member.

請求項５記載の発明は、請求項４記載の排ガス浄化装置において、前記補強部材は、前記触媒構造体における前記角柱形状の側面に沿った複数のシート状部材で構成され、当該シート状部材のうち前記積層方向側面に位置するシート状部材に前記切り欠きが形成されたことを特徴とする。 The invention according to claim 5 is the exhaust gas purifier according to claim 4, wherein the reinforcing member is composed of a plurality of sheet-like members along the side surfaces of the prismatic shape of the catalyst structure, and the sheet-like members are The notch is formed in the sheet-like member positioned on the side surface in the stacking direction.

請求項６記載の発明は、請求項１～５の何れか１つに記載の排ガス浄化装置において、薪を燃焼させて放熱可能とされるとともに当該薪の燃焼により発生する排ガスを外部に排出可能な薪ストーブに取り付けられることを特徴とする。 The invention according to claim 6 is the exhaust gas purifying apparatus according to any one of claims 1 to 5, in which heat can be released by burning firewood and exhaust gas generated by burning the firewood can be discharged to the outside. It is characterized by being attached to a simple wood stove.

請求項７記載の発明は、排ガスを流通可能な触媒構造体と、前記触媒構造体に担持され、当該触媒構造体を流通する前記排ガスと反応して浄化し得る金属触媒と、前記触媒構造体を収容するとともに、排ガスが流通する排ガス流路に取り付け可能な収容ケースとを具備した排ガス浄化装置の製造方法であって、前記触媒構造体は、波型形状に折り曲げられた抄造シートが複数段に積層された積層体を有するとともに、前記収容ケースの内周面の形状に倣った角柱形状に形成され、且つ、前記角柱形状の側面のうち少なくとも前記抄造シートの積層方向に位置する積層方向側面に切り欠きを形成することを特徴とする。 A seventh aspect of the present invention provides a catalyst structure through which an exhaust gas can flow, a metal catalyst supported on the catalyst structure and capable of reacting with and purifying the exhaust gas flowing through the catalyst structure, and the catalyst structure. and a storage case that can be attached to an exhaust gas flow path through which exhaust gas flows, wherein the catalyst structure comprises a plurality of stages of paper-made sheets folded into a corrugated shape. and is formed in a prismatic shape following the shape of the inner peripheral surface of the storage case, and is positioned in at least the stacking direction of the papermaking sheets among the side faces of the prismatic shape in the stacking direction characterized by forming a notch in the

請求項８記載の発明は、請求項７記載の排ガス浄化装置の製造方法において、前記触媒構造体は、断面が長辺及び短辺を有した長方形とされるとともに、前記積層方向側面は当該長方形の長辺に位置することを特徴とする。 According to an eighth aspect of the invention, in the method for manufacturing an exhaust gas purifying apparatus according to the seventh aspect, the catalyst structure has a rectangular cross-section having long sides and short sides, and the side surface in the stacking direction is rectangular. is located on the long side of

請求項９記載の発明は、請求項８記載の排ガス浄化装置の製造方法において、前記切り欠きは、前記長辺の中央の位置に形成されたことを特徴とする。 According to a ninth aspect of the invention, in the method for manufacturing an exhaust gas purifying device according to the eighth aspect, the notch is formed at a central position of the long side.

請求項１０記載の発明は、請求項７～９の何れか１つに記載の排ガス浄化装置の製造方法において、抄造法により抄造シートを生成する抄造シート生成工程と、前記抄造シート生成工程で生成された抄造シートを波型形状に折り曲げるとともに、その波型形状に折り曲げられた抄造シートを複数段に積層して積層体を得る積層体生成工程と、前記抄造シート生成工程で生成された抄造シートにコート材を塗布して焼成することにより補強部材を得る補強部材生成工程と、前記積層体生成工程で得られた前記積層体の外周面に前記補強部材生成工程で得られた前記補強部材を取り付けた状態として焼成することにより前記触媒構造体を得る触媒構造体生成工程と、前記触媒構造体生成工程で得られた前記触媒構造体に前記金属触媒を担持させる担持工程とを有することを特徴とする。 The invention according to claim 10 is the method for manufacturing an exhaust gas purifier according to any one of claims 7 to 9, wherein the papermaking sheet is produced by a papermaking sheet producing step of producing a papermaking sheet by a papermaking method, and the papermaking sheet producing step. a laminate producing step of bending the folded papermaking sheet into a corrugated shape and laminating the papermaking sheets bent into the corrugated shape in a plurality of stages to obtain a laminated body; A reinforcing member generating step of obtaining a reinforcing member by applying a coating material to the surface and baking it, and applying the reinforcing member obtained in the reinforcing member generating step to the outer peripheral surface of the laminate obtained in the laminate generating step. The method is characterized by comprising a catalyst structure generating step of obtaining the catalyst structure by sintering it in an attached state, and a supporting step of supporting the metal catalyst on the catalyst structure obtained in the catalyst structure generating step. and

請求項１１記載の発明は、請求項１０記載の排ガス浄化装置の製造方法において、前記補強部材生成工程で得られる補強部材は、焼成により消滅する連結部材により連結されて成り、前記触媒構造体生成工程における焼成により前記連結部材が消滅して前記切り欠きが形成されることを特徴とする。 According to an eleventh aspect of the invention, in the method for manufacturing an exhaust gas purifying apparatus according to the tenth aspect, the reinforcing member obtained in the reinforcing member forming step is connected by a connecting member that disappears by firing, and the catalyst structure is formed. It is characterized in that the notch is formed by annihilating the connecting member by firing in the process.

請求項１２記載の発明は、請求項１１記載の排ガス浄化装置の製造方法において、前記触媒構造体生成工程は、前記積層体生成工程で得られた前記積層体の外周面に前記補強部材生成工程で得られた前記補強部材を取り付けるとともに、当該補強部材の外周面に前記抄造シート生成工程で得られた抄造シートを巻き付けて固定した状態で焼成されることを特徴とする。 According to a twelfth aspect of the invention, there is provided the method for manufacturing an exhaust gas purifying apparatus according to the eleventh aspect, wherein the step of forming a reinforcing member is applied to the outer peripheral surface of the laminated body obtained in the step of forming a laminated body. The reinforcing member obtained in step 1 is attached, and the papermaking sheet obtained in the papermaking sheet producing step is wound around the outer peripheral surface of the reinforcing member and fixed.

請求項１、７の発明によれば、触媒構造体は、波型形状に折り曲げられた抄造シートが複数段に積層された積層体を有するとともに、収容ケースの内周面の形状に倣った角柱形状に形成され、且つ、角柱形状の側面のうち少なくとも抄造シートの積層方向に位置する積層方向側面に切り欠きが形成されたので、触媒構造体の軽量化を図ることができるとともに、角柱形状の触媒構造体であってもクラックの発生を抑制することができる。 According to the inventions of claims 1 and 7, the catalyst structure has a layered body in which paper-made sheets folded in a corrugated shape are layered in a plurality of stages, and the prismatic structure follows the shape of the inner peripheral surface of the storage case. In addition, the notch is formed at least in the stacking direction side surface of the prismatic sheet located in the stacking direction of the paper-making sheets. It is possible to suppress the occurrence of cracks even in the catalyst structure.

請求項２、８の発明によれば、触媒構造体は、断面が長辺及び短辺を有した長方形とされるとともに、積層方向側面は当該長方形の長辺に位置するので、積層体における抄造シートの積層段数を低減させることができ、製造過程の作業性を向上させることができる。 According to the inventions of claims 2 and 8, the catalyst structure has a rectangular cross section with long sides and short sides, and the side surfaces in the stacking direction are located on the long sides of the rectangle. The number of stacked layers of sheets can be reduced, and the workability of the manufacturing process can be improved.

請求項３、９の発明によれば、切り欠きは、長辺の中央の位置に形成されたので、断面が長辺及び短辺を有した長方形の積層体におけるクラックの発生をより効果的に抑制することができる。 According to the inventions of claims 3 and 9, since the notch is formed at the center of the long side, cracks can be more effectively prevented from occurring in a rectangular laminate having a long side and a short side in cross section. can be suppressed.

請求項４の発明によれば、積層体の外周面には、収容ケースの内周面に沿って延設された補強部材が形成されるとともに、当該補強部材に切り欠きが形成されたので、補強部材により製造過程における積層体の変形を防止することができるとともに、その補強部材に形成された切り欠きによりクラックの発生を抑制することができる。 According to the fourth aspect of the invention, the reinforcing member extending along the inner peripheral surface of the storage case is formed on the outer peripheral surface of the laminate, and the reinforcing member is formed with the notch. The reinforcing member can prevent deformation of the laminate during the manufacturing process, and the notches formed in the reinforcing member can suppress the occurrence of cracks.

請求項５の発明によれば、補強部材は、触媒構造体における角柱形状の側面に沿った複数のシート状部材で構成され、当該シート状部材のうち積層方向側面に位置するシート状部材に切り欠きが形成されたので、収容ケースが排ガス流路の形状に倣った矩形形状（長方形等）であっても、触媒構造体を収容ケースの内周面に合致させて収容することができるとともに、補強部材に形成された切り欠きによりクラックの発生を抑制することができる。 According to the invention of claim 5, the reinforcing member is composed of a plurality of sheet-like members along the side surfaces of the prismatic shape of the catalyst structure, and among the sheet-like members, the sheet-like members are cut into the sheet-like members positioned on the side surfaces in the stacking direction. Since the notch is formed, even if the storage case has a rectangular shape (rectangular or the like) that follows the shape of the exhaust gas flow path, the catalyst structure can be accommodated in conformity with the inner peripheral surface of the storage case. The notches formed in the reinforcing member can suppress the occurrence of cracks.

請求項６の発明によれば、薪を燃焼させて放熱可能とされるとともに当該薪の燃焼により発生する排ガスを外部に排出可能な薪ストーブに取り付けられるので、薪ストーブから排出される排ガスを確実に浄化することができる。 According to the invention of claim 6, since it is possible to burn firewood and dissipate heat, and it is attached to a wood stove that can discharge the exhaust gas generated by burning the firewood to the outside, the exhaust gas emitted from the firewood stove is ensured. can be purified to

請求項１０の発明によれば、抄造法により抄造シートを生成する抄造シート生成工程と、抄造シート生成工程で生成された抄造シートを波型形状に折り曲げるとともに、その波型形状に折り曲げられた抄造シートを複数段に積層して積層体を得る積層体生成工程と、抄造シート生成工程で生成された抄造シートにコート材を塗布して焼成することにより補強部材を得る補強部材生成工程と、積層体生成工程で得られた積層体の外周面に補強部材生成工程で得られた補強部材を取り付けた状態として焼成することにより前記触媒構造体を得る触媒構造体生成工程と、触媒構造体生成工程で得られた前記触媒構造体に前記金属触媒を担持させる担持工程とを有するので、焼成工程時のクラックの発生を抑制し、且つ、積層体の変形を確実に防止しつつ軽量化された排ガス浄化装置を円滑に製造することができる。 According to the invention of claim 10, the papermaking sheet producing step of producing a papermaking sheet by a papermaking method, the papermaking sheet produced in the papermaking sheet producing step is folded into a wavy shape, and the papermaking is performed by folding into the wavy shape. A laminate production step of laminating sheets in a plurality of stages to obtain a laminate, a reinforcing member production step of applying a coating material to the papermaking sheet produced in the papermaking sheet production step and baking it to obtain a reinforcing member, and lamination a catalyst structure generating step for obtaining the catalyst structure by sintering the laminated body obtained in the body generating step in a state in which the reinforcing member obtained in the reinforcing member generating step is attached to the outer peripheral surface of the laminate; and a catalyst structure generating step. Since it has a supporting step of supporting the metal catalyst on the catalyst structure obtained in 1., the occurrence of cracks during the firing step is suppressed, and the deformation of the laminate is reliably prevented, and the weight of the exhaust gas is reduced. The purification device can be manufactured smoothly.

請求項１１の発明によれば、補強部材生成工程で得られる補強部材は、焼成により消滅する連結部材により連結されて成り、触媒構造体生成工程における焼成により連結部材が消滅して切り欠きが形成されるので、補強部材が連結部材で連結されて仮止めされることにより製造過程における作業性を向上することができるとともに、焼成により連結部材が消滅することにより切り欠きを容易且つ確実に形成することができる。 According to the eleventh aspect of the invention, the reinforcing member obtained in the reinforcing member forming step is connected by a connecting member that disappears by firing, and the connecting member disappears by firing in the catalyst structure forming step to form a notch. Therefore, the reinforcing members are connected and temporarily fixed by the connecting member, so that the workability in the manufacturing process can be improved, and the connecting member disappears by firing, so that the notch can be easily and reliably formed. be able to.

請求項１２の発明によれば、触媒構造体生成工程は、積層体生成工程で得られた積層体の外周面に補強部材生成工程で得られた補強部材を取り付けるとともに、当該補強部材の外周面に抄造シート生成工程で得られた抄造シートを巻き付けて固定した状態で焼成されるので、焼成前の製造過程における作業性をより一層向上させることができる。 According to the twelfth aspect of the invention, in the catalyst structure generating step, the reinforcing member obtained in the reinforcing member generating step is attached to the outer peripheral surface of the laminate obtained in the laminate generating step, and the outer peripheral surface of the reinforcing member is attached. Since the paper-made sheet obtained in the paper-made sheet production step is wrapped around the sheet and fixed, the workability in the manufacturing process before baking can be further improved.

本発明の実施形態に係る薪ストーブ用排ガス浄化装置の外観を示す斜視図BRIEF DESCRIPTION OF THE DRAWINGS The perspective view which shows the external appearance of the exhaust gas purification apparatus for wood stoves which concerns on embodiment of this invention. 同薪ストーブ用排ガス浄化装置を示す４面図Four views showing the exhaust gas purifier for the same wood-burning stove 図２におけるＩＩＩ－ＩＩＩ線断面図III-III line sectional view in FIG. 図２におけるＩＶ－ＩＶ線断面図IV-IV line sectional view in FIG. 同薪ストーブ用排ガス浄化装置における触媒構造体を構成する抄造シートを示す斜視図The perspective view which shows the paper-making sheet|seat which comprises the catalyst structure in the exhaust gas purification apparatus for wood stoves. 同抄造シートを積層した積層体を示す斜視図A perspective view showing a laminate obtained by laminating the same papermaking sheets. 同積層体の側面に補強部材を取り付けた状態の触媒構造体を示す斜視図A perspective view showing a catalyst structure with a reinforcing member attached to the side surface of the laminate. 同補強部材（積層方向側面に取り付けられる補強部材）を示す平面図及び側面図A plan view and a side view showing the same reinforcing member (reinforcing member attached to the side surface in the stacking direction) 同補強部材（積層方向側面とは異なる側面に取り付けられる補強部材）を示す平面図及び側面図A plan view and a side view showing the same reinforcing member (reinforcing member attached to a side surface different from the side surface in the stacking direction) 同積層体の側面に取り付けられた補強部材の周囲を抄造シートで巻いて取り付けた状態の触媒構造体を示す斜視図A perspective view showing a catalyst structure in which a reinforcing member attached to a side surface of the laminate is wrapped with a paper-making sheet and attached. 同触媒構造体の側面に保持部材を取り付けた状態を示す斜視図A perspective view showing a state in which a holding member is attached to a side surface of the same catalyst structure. 同保持部材（触媒構造体への取付前）を示す全体模式図Overall schematic diagram showing the holding member (before attachment to the catalyst structure) 同薪ストーブ用排ガス浄化装置における収容ケースを示す３面図A three-sided view showing a housing case in the exhaust gas purifier for the same wood-burning stove. 本実施形態に適用される薪ストーブを示す模式図Schematic diagram showing a wood stove applied to this embodiment 本実施形態に係る薪ストーブ用排ガス浄化装置の製造工程を示すフローチャートFlowchart showing the manufacturing process of the exhaust gas purifier for a wood stove according to the present embodiment 本実施形態に係る薪ストーブ用排ガス浄化装置の製造過程における補強部材（連結部材で連結された補強部材）を示す平面図及び側面図The top view and side view which show the reinforcement member (reinforcement member connected with the connection member) in the manufacturing process of the exhaust gas purification apparatus for wood stoves which concerns on this embodiment. 同補強部材における連結部を示す拡大断面図Enlarged cross-sectional view showing a connecting portion of the reinforcing member 本実施形態に係る薪ストーブ用排ガス浄化装置の製造過程における補強部材（連結された補強部材）の内部に抄造シートを積層させた状態を示す断面模式図Schematic cross-sectional view showing a state in which a papermaking sheet is laminated inside a reinforcing member (connected reinforcing member) in the manufacturing process of the exhaust gas purification apparatus for a wood stove according to the present embodiment. 同抄造シートを積層させた後、補強部材で覆った状態を示す断面模式図Schematic cross-sectional view showing a state in which the paper-made sheets are laminated and then covered with a reinforcing member. 本実施形態に係る薪ストーブ用排ガス浄化装置の触媒構造体に担持された金属触媒による技術的効果を示すグラフGraph showing the technical effect of the metal catalyst supported on the catalyst structure of the exhaust gas purifier for wood stove according to the present embodiment

以下、本発明の実施形態について図面を参照しながら具体的に説明する。
本実施形態に係る排ガス浄化装置は、薪を燃焼させて放熱可能とされるとともに当該薪の燃焼により発生する排ガスを外部に排出可能な薪ストーブに取り付けられ、排ガスを浄化するための薪ストーブ用排ガス浄化装置に適用されたものである。 Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
The exhaust gas purifying apparatus according to the present embodiment is attached to a wood stove that can burn firewood to dissipate heat and can discharge the exhaust gas generated by burning the firewood to the outside, and is for purifying the exhaust gas. It is applied to an exhaust gas purifier.

本実施形態に適用される薪ストーブＷは、図１４に示すように、薪Ｍを燃焼させて放熱可能な燃焼室Ｗ２が形成された箱型の金属製本体Ｗ１と、薪Ｍの燃焼により発生した排ガスを外部に排出可能な煙突Ｗ３とを有して構成されており、金属製本体Ｗ１の前面には、燃焼室Ｗ２に薪Ｍを投入又は燃焼室Ｗ２内の灰を回収する際に開閉可能なガラス製の前扉Ｄが取り付けられている。 As shown in FIG. 14, the wood stove W applied to this embodiment includes a box-shaped metal main body W1 in which a combustion chamber W2 capable of radiating heat by burning firewood M is formed, and a and a chimney W3 capable of discharging the discharged exhaust gas to the outside, and the front surface of the metal main body W1 is opened and closed when throwing firewood M into the combustion chamber W2 or collecting ash in the combustion chamber W2. A possible glass front door D is installed.

また、燃焼室Ｗ２と煙突Ｗ３との間には、燃焼室Ｗ２で発生した排ガスを流通させ得る２つの排ガス流路Ｎ１、Ｎ２が形成されている。一方の排ガス流路Ｎ１は、本排ガス浄化装置１が取り付けられるとともに、他方の排ガス流路Ｎ２は、流路を開閉可能なダンパＢが取り付けられている。ダンパＢは、操作者が任意に操作可能とされており、排ガス流路Ｎ２を任意タイミングで開閉可能とされている。 Two exhaust gas passages N1 and N2 are formed between the combustion chamber W2 and the chimney W3, through which the exhaust gas generated in the combustion chamber W2 can flow. The exhaust gas purifier 1 is attached to one exhaust gas passage N1, and a damper B capable of opening and closing the passage is attached to the other exhaust gas passage N2. The damper B is arbitrarily operable by an operator, and can open and close the exhaust gas flow path N2 at arbitrary timing.

そして、薪Ｍを燃焼させて排ガスの温度が低いとき、ダンパＢを閉状態とすることにより、排ガスａが他方の排ガス流路Ｎ２を流通して煙突Ｗ３から外部に排出されるとともに、排ガスの温度が高くなると、ダンパＢを閉状態とすることにより、排ガスｂが一方の排ガス流路Ｎ１を流通する過程で排ガス浄化装置１にて浄化され、煙突Ｗ３から外部に排出されることとなる。 When the firewood M is burned and the temperature of the exhaust gas is low, the damper B is closed so that the exhaust gas a flows through the other exhaust gas passage N2 and is discharged to the outside from the chimney W3. When the temperature rises, by closing the damper B, the exhaust gas b is purified by the exhaust gas purifier 1 while flowing through one of the exhaust gas passages N1, and is discharged to the outside from the chimney W3.

排ガス浄化装置１は、薪ストーブＷの排ガス流路Ｎ１に取り付け可能とされたもので、図１～３に示すように、排ガスを流通可能な触媒構造体２と、触媒構造体２に担持され、当該触媒構造体２を流通する排ガスと反応して浄化し得る金属触媒３と、触媒構造体２を収容するとともに、排ガスが流通する排ガス流路Ｎ１に取り付け可能な収容ケース４と、触媒構造体２と収容ケース４との間に介装されて収容ケース４に触媒構造体２を保持させる保持部材５とを有して構成されている。 The exhaust gas purification device 1 can be attached to the exhaust gas flow path N1 of the wood stove W, and as shown in FIGS. a metal catalyst 3 capable of reacting with and purifying exhaust gas flowing through the catalyst structure 2; a housing case 4 housing the catalyst structure 2 and capable of being attached to an exhaust gas flow path N1 through which the exhaust gas flows; and a catalyst structure. A holding member 5 is interposed between the body 2 and the housing case 4 to hold the catalyst structure 2 in the housing case 4 .

本実施形態に係る触媒構造体２は、図５、６に示すように、波型形状に折り曲げられた抄造シートＥ１及び抄造シートＥ２が複数段に積層された積層体Ｅを有するものである。抄造シートＥ１及び抄造シートＥ２は、湿式抄造法（抄紙法）により得られた無機質材料を主材とするシート状部材（可撓性ペーパー状部材）から成り、図５に示すように、抄造シートＥ１は、折り曲げ加工により波型形状に折り曲げられるとともに、抄造シートＥ２は、両端部が屈曲形成されている。 As shown in FIGS. 5 and 6, the catalyst structure 2 according to the present embodiment has a laminate E in which papermaking sheets E1 and papermaking sheets E2 folded into a corrugated shape are laminated in multiple stages. The papermaking sheet E1 and the papermaking sheet E2 are made of a sheet-like member (flexible paper-like member) mainly composed of an inorganic material obtained by a wet papermaking method (papermaking method). E1 is bent into a corrugated shape by a bending process, and both ends of the papermaking sheet E2 are bent.

そして、抄造シートＥ２の表面に抄造シートＥ１を重ね合わせることにより、図５で示す抄造シート対を得るとともに、この抄造シート対を複数段に積層することにより、図６に示す積層体Ｅが構成されている。これにより、波型形状に折り曲げられた抄造シートＥ１とシート状の抄造シートＥ２との間が所謂ハニカム形状となり、排ガスを流通し得るようになっている。 Then, the papermaking sheet pair shown in FIG. 5 is obtained by superposing the papermaking sheet E1 on the surface of the papermaking sheet E2, and the laminate E shown in FIG. It is As a result, a so-called honeycomb shape is formed between the paper-made sheet E1 folded into a corrugated shape and the sheet-like paper-made sheet E2, so that the exhaust gas can flow.

また、本実施形態に係る触媒構造体２は、図７～９に示すように、積層体Ｅの外周面に補強部材Ｆ１、Ｆ２が取り付けられている。かかる補強部材Ｆ１、Ｆ２は、収容ケース４の内周面に沿って延設されたシート状の部材から成り、積層体Ｅを構成する抄造シート（Ｅ１、Ｅ２）と同一材質から成るとともに、少なくとも積層体Ｅを構成する抄造シート（Ｅ１、Ｅ２）より大きい厚さ寸法のシート状部材から成る。 Further, in the catalyst structure 2 according to the present embodiment, reinforcing members F1 and F2 are attached to the outer peripheral surface of the laminate E, as shown in FIGS. The reinforcing members F1 and F2 are sheet-like members extending along the inner peripheral surface of the storage case 4, and are made of the same material as the papermaking sheets (E1 and E2) constituting the laminate E, and at least It consists of a sheet-like member having a thickness larger than that of the papermaking sheets (E1, E2) constituting the laminate E.

より具体的には、補強部材Ｆ１、Ｆ２は、積層体Ｅを構成する抄造シート（Ｅ１、Ｅ２）より大きい厚さ寸法の抄造シートから成り、コート材を含侵させた後、乾燥及び焼成することにより硬化された剛性の高い部材とされている。コート材は、積層体Ｅを焼成する前に塗布される液体状塗布剤から成り、乾燥及び焼成により硬化する性質を有するものとされている。 More specifically, the reinforcing members F1 and F2 are made of papermaking sheets having a thickness larger than the papermaking sheets (E1 and E2) constituting the laminate E, and are impregnated with a coating material, then dried and baked. It is considered as a member with high rigidity hardened by this. The coating material is made of a liquid coating agent that is applied before firing the laminate E, and has the property of being cured by drying and firing.

このように、本実施形態に係る触媒構造体２は、積層体Ｅ及び補強部材Ｆ１、Ｆ２にて構成されており、全体形状が収容ケース４の内周面の形状に倣った角柱形状（断面矩形のブロック形状）に形成されている。このように、補強部材Ｆ１、Ｆ２は、触媒構造体２における角柱形状の側面に沿った複数のシート状部材で構成されており、それぞれの表面が角柱形状の側面（α、β）を成している。 As described above, the catalyst structure 2 according to the present embodiment is composed of the laminate E and the reinforcing members F1 and F2, and has a prismatic shape (cross-section rectangular block shape). In this manner, the reinforcing members F1 and F2 are composed of a plurality of sheet-like members along the side surfaces of the prismatic shape of the catalyst structure 2, and the respective surfaces form the side surfaces (α, β) of the prismatic shape. ing.

すなわち、本実施形態に係る触媒構造体２は、図７に示すように、積層体Ｅの外周面に複数の補強部材Ｆ１、Ｆ２が取り付けられることによって、抄造シート（積層体Ｅを構成する抄造シートＥ１、Ｅ２）の積層方向Ｇに位置する積層方向側面α（図７の上下の面）と、その他の側面β（図７の左右の面）とを有した角柱形状（ブロック形状）とされている。また、本実施形態に係る触媒構造体２の角柱形状は、断面が長辺及び短辺を有した長方形とされており、積層方向側面αが長方形の長辺に位置するとともに、その他の側面βが長方形の短辺に位置するようになっている。 That is, the catalyst structure 2 according to the present embodiment, as shown in FIG. It has a prismatic shape (block shape) having stacking direction side surfaces α (upper and lower surfaces in FIG. 7) located in the stacking direction G of the sheets E1 and E2) and other side surfaces β (left and right surfaces in FIG. 7). ing. Further, the prismatic shape of the catalyst structure 2 according to the present embodiment has a rectangular cross section with long sides and short sides, and the side surface α in the stacking direction is located on the long side of the rectangle, and the other side surface β are located on the short sides of the rectangle.

さらに、本実施形態に係る触媒構造体２は、図７に示すように、積層方向側面αに切り欠きＡが形成されている。かかる切り欠きＡは、触媒構造体２の断面形状（長方形）のうち長辺の中央の位置に形成されており、本実施形態においては、隣接する補強部材Ｆ１の間に形成された隙間から成る。なお、切り欠きＡの寸法は、触媒構造体２の形状及び大きさによって種々設定されるものであり、所謂スリットと称されるものも含む。 Furthermore, as shown in FIG. 7, the catalyst structure 2 according to the present embodiment has a notch A formed on the side surface α in the stacking direction. The notch A is formed at the center position of the long side of the cross-sectional shape (rectangular) of the catalyst structure 2, and in this embodiment, it is formed by the gap formed between the adjacent reinforcing members F1. . The dimensions of the notch A are variously set according to the shape and size of the catalyst structure 2, and include so-called slits.

またさらに、触媒構造体２は、図１０に示すように、補強部材Ｆ１、Ｆ２の外周面に抄造シートＥ３が巻き付けられている。この抄造シートＥ３は、積層体Ｅを構成する抄造シートＥ１，Ｅ２と同一材質から成るとともに、積層体Ｅを構成する抄造シートＥ１，Ｅ２より小さい厚さ寸法のシート状部材とされており、補強部材Ｆ１、Ｆ２の外周に巻き付けられて、製造過程において、これら補強部材Ｆ１、Ｆ２を積層体Ｅに固定可能とされている。 Further, in the catalyst structure 2, as shown in FIG. 10, a papermaking sheet E3 is wound around the outer peripheral surfaces of the reinforcing members F1 and F2. The papermaking sheet E3 is made of the same material as the papermaking sheets E1 and E2 constituting the laminate E, and is a sheet member having a thickness smaller than that of the papermaking sheets E1 and E2 constituting the laminate E. The reinforcing members F1 and F2 can be fixed to the laminate E during the manufacturing process by being wound around the outer circumferences of the members F1 and F2.

上記の如く抄造シートＥ３が外周面に巻き付けられた触媒構造体２は、図１１に示すように、当該抄造シートＥ３のさらに外周面に対して保持部材５が巻き付けられている。この保持部材５は、アルミナ繊維から成るシート状部材から成り、図２～４に示すように、触媒構造体２と収容ケース４との間に介装されて収容ケース４に触媒構造体２を保持させるものである。 As shown in FIG. 11, the catalyst structure 2 having the papermaking sheet E3 wound around the outer peripheral surface thereof as described above has a holding member 5 further wound around the outer peripheral surface of the papermaking sheet E3. The holding member 5 is made of a sheet-like member made of alumina fibers, and is interposed between the catalyst structure 2 and the housing case 4 to hold the catalyst structure 2 in the housing case 4 as shown in FIGS. It is intended to be retained.

より具体的には、保持部材５は、Ａｌ２Ｏ３：ＳｉＯ２が重量比で７２：２８とされた結晶質アルミナ繊維から成り、熱膨張し難くい材質とされている。また、本実施形態に係る保持部材５は、図１２で示すように、一端が端面５ａ、５ｂを有した段形状とされるとともに他端が端面５ｃ、５ｄを有した段形状とされており、端面５ａと端面５ｃ、及び端面５ｂと端面５ｄをそれぞれ合致させて触媒構造体２の外周面に巻き付けられるようになっている。 More specifically, the holding member 5 is made of crystalline alumina fiber in which the weight ratio of Al 2 O 3 :SiO 2 is 72:28, and is a material that is difficult to thermally expand. As shown in FIG. 12, the holding member 5 according to this embodiment has a stepped shape with end faces 5a and 5b at one end and a stepped shape with end faces 5c and 5d at the other end. , the end faces 5a and 5c, and the end faces 5b and 5d, respectively.

収容ケース４は、触媒構造体２を収容するとともに、薪ストーブＷに形成された排ガス流路Ｎ１（図１４参照）に取り付け可能な金属製プレス加工部品から成り、図１３に示すように、触媒構造体２を収容する収容空間４ａと、補強のため開口縁部に形成された折り返し部４ｂとを有して構成されている。すなわち、触媒構造体２は、収容ケース４の内周面の形状に倣った角柱形状に形成されており、本実施形態においては、収容ケース４内に複数（２つ）隣接して収容されるとともに、それぞれの触媒構造体２の外周面に保持部材５が形成されている。 The housing case 4 houses the catalyst structure 2 and is made of a metal pressed part that can be attached to the exhaust gas flow path N1 (see FIG. 14) formed in the wood stove W. As shown in FIG. It has a housing space 4a for housing the structure 2 and a folded portion 4b formed at the edge of the opening for reinforcement. That is, the catalyst structures 2 are formed in a prismatic shape following the shape of the inner peripheral surface of the housing case 4, and in this embodiment, a plurality (two) of the catalyst structures 2 are housed adjacently in the housing case 4. In addition, a holding member 5 is formed on the outer peripheral surface of each catalyst structure 2 .

しかるに、本実施形態に係る収容ケース４は、既述の如く開口縁部に補強のための折り返し部４ｂが形成されており、当該折り返し部４ｂにて保持部材５を抜け止め可能とされている。具体的には、触媒構造体２を収容ケース４に収容した状態において、図３に示すように、保持部材５は、触媒構造体２と収容ケース４の内周面との間に介装するとともに、側面が折り返し部４ｂと対峙して抜け止めされているのである。 However, in the storage case 4 according to the present embodiment, the folded portion 4b for reinforcement is formed at the opening edge portion as described above, and the holding member 5 can be retained by the folded portion 4b. . Specifically, with the catalyst structure 2 housed in the housing case 4, the holding member 5 is interposed between the catalyst structure 2 and the inner peripheral surface of the housing case 4, as shown in FIG. At the same time, the side surface faces the folded portion 4b and is prevented from coming off.

金属触媒３は、触媒構造体２の積層体Ｅに担持された金属（図６の符号３にて模式的に示す金属）から成り、本実施形態においては、金属触媒３として、銀（Ａｇ）及びパラジウム（Ｐｄ）を有している。一方、触媒構造体２（抄造シートＥ１、Ｅ２の材質）は、アルミナ（Ａｌ２Ｏ３）及びジルコニア（ＺｒＯ２）から成るとともに、ジルコニア（ＺｒＯ２）に対する前記アルミナ（Ａｌ２Ｏ３）の重量比率が６０～９０％とされている。 The metal catalyst 3 is made of a metal (schematically indicated by reference numeral 3 in FIG. 6) supported on the laminate E of the catalyst structure 2. In this embodiment, the metal catalyst 3 is silver (Ag). and palladium (Pd). On the other hand, the catalyst structure 2 (the material of the papermaking sheets E1 and E2) is made of alumina (Al 2 O 3 ) and zirconia (ZrO 2 ), and the weight of the alumina (Al 2 O 3 ) to the zirconia (ZrO 2 ) is The ratio is said to be 60 to 90%.

ここで、本実施形態に係る金属触媒３は、パラジウム（Ｐｄ）に対する銀（Ａｇ）の重量比率が５０～８０％とされている。以下に、パラジウム（Ｐｄ）に対する銀（Ａｇ）の重量比率（Ａｇ比（％））が５０～８０％であることによる技術的優位性について、表１及び図２０のグラフに基づいて説明する。 Here, in the metal catalyst 3 according to this embodiment, the weight ratio of silver (Ag) to palladium (Pd) is 50 to 80%. The technical advantages of having a weight ratio of silver (Ag) to palladium (Pd) of 50 to 80% (Ag ratio (%)) will be described below with reference to Table 1 and the graphs of FIG.

セリウム（Ｃｅ）及びジルコニア（ＺｒＯ２）が５：５及び８：２の重量比率で構成される触媒構造体２、及びアルミナ（Ａｌ２Ｏ３）及びジルコニア（ＺｒＯ２）が５：５、６：４、７：３、８：２、９：１の重量比率で構成される触媒構造体２の２種類を用意した。そして、セリウム（Ｃｅ）及びジルコニア（ＺｒＯ２）が５：５及び８：２の重量比率で構成される触媒構造体２においては、金属触媒３としてパラジウム（Ｐｄ）に対する銀（Ａｇ）の重量比率（Ａｇ比）が１００％（銀のみ）、８０％、７０％、６０％、５０％、２０％、０％（パラジウムのみ）で担持されたものを用意した。 Catalyst structure 2 composed of cerium (Ce) and zirconia ( ZrO2 ) in weight ratios of 5:5 and 8 :2 and alumina ( Al2O3 ) and zirconia ( ZrO2 ) in weight ratios of 5:5,6 : 4, 7:3, 8:2 and 9:1. In the catalyst structure 2 composed of cerium (Ce) and zirconia (ZrO 2 ) at weight ratios of 5:5 and 8:2, the weight ratio of silver (Ag) to palladium (Pd) as the metal catalyst 3 (Ag ratio) of 100% (silver only), 80%, 70%, 60%, 50%, 20% and 0% (palladium only) were prepared.

同様に、アルミナ（Ａｌ２Ｏ３）及びジルコニア（ＺｒＯ２）が８：２の重量比率で構成される触媒構造体２において、金属触媒３としてパラジウム（Ｐｄ）に対する銀（Ａｇ）の重量比率（Ａｇ比）が１００％（銀のみ）、８０％、７０％、６０％、５０％、２０％、０％（パラジウムのみ）で担持されものを複数用意した。これら触媒構造体２をそれぞれ加熱して反応開始温度（℃）（金属触媒３が反応して排ガスを浄化可能な温度）を計測したところ、表１で示すような結果となった。 Similarly, in the catalyst structure 2 composed of alumina (Al 2 O 3 ) and zirconia (ZrO 2 ) at a weight ratio of 8:2, the weight ratio of silver (Ag) to palladium (Pd) as the metal catalyst 3 ( A plurality of supports having Ag ratios of 100% (only silver), 80%, 70%, 60%, 50%, 20%, and 0% (only palladium) were prepared. When each of these catalyst structures 2 was heated and the reaction initiation temperature (° C.) (the temperature at which the metal catalyst 3 reacted to purify the exhaust gas) was measured, the results shown in Table 1 were obtained.

Figure 2023034799000002
Figure 2023034799000002

しかるに、表１で示される結果について、図２０に示すように、横軸をＡｇ比（％）、縦軸を反応開始温度（℃）としたグラフにプロットしたところ、同図中符号Ｈで示す範囲のものについて、反応開始温度（℃）が低く、浄化性能が高いことが分かった。すなわち、触媒構造体２がアルミナ（Ａｌ２Ｏ３）及びジルコニア（ＺｒＯ２）から成るとともに、触媒構造体２に担持される金属触媒がパラジウム（Ｐｄ）に対する銀（Ａｇ）の重量比率が５０～８０％とされたものは浄化性能が高く、そのうち、ジルコニア（ＺｒＯ２）に対するアルミナ（Ａｌ２Ｏ３）の重量比率が６０～９０％とされた触媒構造体２とすれば、浄化性能が特に高く好ましい。 However, as shown in FIG. 20, the results shown in Table 1 were plotted on a graph with the Ag ratio (%) on the horizontal axis and the reaction initiation temperature (° C.) on the vertical axis. It was found that those within the range had a low reaction start temperature (°C) and high purification performance. That is, the catalyst structure 2 is made of alumina (Al 2 O 3 ) and zirconia (ZrO 2 ), and the metal catalyst supported on the catalyst structure 2 has a weight ratio of silver (Ag) to palladium (Pd) of 50 to 50. 80 % has a high purification performance . highly desirable.

次に、本実施形態に係る薪ストーブ用排ガス浄化装置１の製造方法について、図１５のフローチャートを用いて説明する。
本実施形態に係る薪ストーブ用排ガス浄化装置１は、抄造法により抄造シートを生成する抄造シート生成工程Ｓ１と、抄造シート生成工程Ｓ１で生成された抄造シートを波型形状に折り曲げるとともに、その波型形状に折り曲げられた抄造シートを複数段に積層して積層体Ｅを得る積層体生成工程Ｓ２と、抄造シート生成工程Ｓ１で生成された抄造シートにコート材を塗布して焼成することにより補強部材Ｆ１、Ｆ２を得る補強部材生成工程Ｓ３と、積層体生成工程Ｓ２で得られた積層体Ｅの外周面に補強部材生成工程Ｓ３で得られた補強部材Ｆ１、Ｆ２を取り付けた状態として焼成することにより触媒構造体２を得る触媒構造体生成工程（Ｓ４～Ｓ７）と、触媒構造体生成工程（Ｓ４～Ｓ７）で得られた触媒構造体２に金属触媒３を担持させる担持工程Ｓ８とを経ることにより製造される。 Next, a method for manufacturing the exhaust gas purifier 1 for a wood stove according to this embodiment will be described with reference to the flowchart of FIG. 15 .
The exhaust gas purifying apparatus 1 for a wood stove according to the present embodiment includes a papermaking sheet production step S1 for producing a papermaking sheet by a papermaking method, and the papermaking sheet produced in the papermaking sheet production step S1 is folded into a wavy shape and the waves Laminate production step S2 in which a laminated body E is obtained by laminating the papermaking sheets folded into a mold shape in a plurality of stages, and the papermaking sheet produced in the papermaking sheet production step S1 is reinforced by applying a coating material and baking it. A reinforcing member producing step S3 for obtaining the members F1 and F2, and firing in a state in which the reinforcing members F1 and F2 obtained in the reinforcing member producing step S3 are attached to the outer peripheral surface of the laminate E obtained in the laminate producing step S2. a catalyst structure generating step (S4 to S7) for obtaining a catalyst structure 2 by means of the above-mentioned process; and a supporting step S8 for supporting the metal catalyst 3 on the catalyst structure 2 obtained in the catalyst structure generating step (S4 to S7). It is manufactured by going through.

より具体的には、先ず、抄造シートを抄造法により生成する（抄造シート生成工程Ｓ１）。本実施形態に適用される抄造法は、湿式抄造法とされており、例えば所定量の水に対してアルミナ（Ａｌ２Ｏ３）やジルコニア（ＺｒＯ２）等を含む所定量の繊維及び無機バインダ等を投入して水溶液を作製し、これら含有物を均一に分散させたスラリーの作製、及びそのスラリーに凝集剤を添加したフロックの生成を経た後、当該フロックを抄紙してペーパー状の抄造シートＥ１、Ｅ２を得る。 More specifically, first, a papermaking sheet is produced by a papermaking method (papermaking sheet producing step S1). The papermaking method applied to this embodiment is a wet papermaking method. etc. to prepare an aqueous solution, prepare a slurry in which these contents are uniformly dispersed, and generate flocs by adding a flocculant to the slurry, and then make the flocs to make a paper-like sheet. E1 and E2 are obtained.

また、抄造シート生成工程Ｓ１においては、抄造シートＥ１、Ｅ２に加え、これら抄造シートＥ１、Ｅ２より大きい厚さ寸法の抄造シート（補強部材Ｆ１、Ｆ２）、及び抄造シートＥ１、Ｅ２より小さい厚さ寸法の抄造シートＥ３を生成する。そして、抄造シートＥ１を折り曲げ加工した後、抄造シートＥ２を組み合わせ、図５で示す波型形状に折り曲げられた抄造シートを形成するとともに、これら波型形状に折り曲げられた抄造シートを複数段に積層し、図６に示す積層体Ｅを生成する（積層体生成工程Ｓ２）。 In the papermaking sheet production step S1, in addition to the papermaking sheets E1 and E2, the papermaking sheets (reinforcing members F1 and F2) having a thickness larger than the papermaking sheets E1 and E2, and the papermaking sheets E1 and E2 having a thickness smaller than that of the papermaking sheets E1 and E2. A sized papermaking sheet E3 is produced. After the papermaking sheet E1 is folded, it is combined with the papermaking sheet E2 to form a papermaking sheet folded into a wavy shape shown in FIG. Then, a laminate E shown in FIG. 6 is produced (laminate producing step S2).

一方、抄造シート生成工程Ｓ１で生成された抄造シートＥ１、Ｅ２より大きい厚さ寸法の抄造シートは、液体状塗布剤から成るコート材が含侵された後、乾燥及び焼成することにより硬化された剛性の高い補強部材Ｆ１、Ｆ２とされる（補強部材生成工程Ｓ３）。かかる補強部材生成工程Ｓ３においては、例えばコート材に抄造シートを浸漬させつつ減圧することにより、抄造シートの表面に加え内部にまでコート材を含侵させることができる。なお、コート材は、粘着性を有するとともに、焼成により硬化する材質とされている。 On the other hand, the paper-made sheets having a thickness greater than the paper-made sheets E1 and E2 produced in the paper-made sheet producing step S1 were hardened by drying and baking after being impregnated with a coating material made of a liquid coating agent. Reinforcing members F1 and F2 having high rigidity are formed (reinforcing member producing step S3). In the reinforcing member producing step S3, for example, by reducing the pressure while immersing the paper-processed sheet in the coating material, not only the surface of the paper-processed sheet but also the interior of the paper-processed sheet can be impregnated with the coating material. The coating material is made of a material that is sticky and hardens by baking.

ここで、本実施形態において、補強部材生成工程Ｓ３で得られる補強部材Ｆ１は、図１６、１７に示すように、焼成工程Ｓ７の焼成により消滅する連結部材６により連結されて成り、触媒構造体生成工程（Ｓ４～Ｓ７）における焼成（焼成工程Ｓ７の焼成）により連結部材６が消滅して切り欠きＡ（図７参照）が形成されるようになっている。かかる連結部材６は、図１７に示すように、隣接する補強部材Ｆ１の対向する端面間に介在する切り欠き形成シール６ａと、この切り欠き形成シール６ａを含む範囲に貼着されて隣接する２枚の補強部材Ｆ１を連結する連結シール６ｂとを有して構成されており、焼成により、これら切り欠き形成シール６ａ及び連結シール６ｂが消失するとともに、切り欠き形成シール６ａの消失により、切り欠きＡが形成されるのである。 Here, in the present embodiment, as shown in FIGS. 16 and 17, the reinforcing member F1 obtained in the reinforcing member producing step S3 is connected by a connecting member 6 that disappears when fired in the firing step S7 to form a catalyst structure. The connecting member 6 is extinguished by firing (firing in the firing step S7) in the production steps (S4 to S7) to form the notch A (see FIG. 7). As shown in FIG. 17, such a connecting member 6 includes a notch forming seal 6a interposed between the opposing end surfaces of the adjacent reinforcing members F1, and a range including the notch forming seal 6a. The notch-forming seal 6a and the connecting seal 6b disappear by firing, and the notch-forming seal 6a disappears to form a notch. A is formed.

その後、図７に示すように、積層体Ｅの外周面に補強部材Ｆ１、Ｆ２を取り付けるとともに、図１０に示すように、抄造シートＥ３を外周面に巻き付けて固定することにより組付けた後、その組付けた全体をＳ３で用いたものと同様のコート材に浸漬することにより当該コート材を含侵させる（組付・全体コート工程Ｓ４）。具体的には、図１８に示すように、連結部材６で連結された補強部材Ｆ１を底面に設置するとともに、その両端に補強部材Ｆ２をそれぞれ設置した状態とし、これら補強部材Ｆ１、Ｆ２の内部空間に波型形状に折り曲げられた抄造シートＥ１、Ｅ２を所定段に積層して積層体Ｅを構成する。 After that, as shown in FIG. 7, reinforcing members F1 and F2 are attached to the outer peripheral surface of the laminate E, and as shown in FIG. The assembled whole is immersed in the same coating material as that used in S3 to impregnate the coating material (assembly/overall coating step S4). Specifically, as shown in FIG. 18, the reinforcing member F1 connected by the connecting member 6 is installed on the bottom surface, and the reinforcing members F2 are installed on both ends of the reinforcing member F1. A laminated body E is constructed by laminating the papermaking sheets E1 and E2 folded into a corrugated shape in a space in a predetermined stage.

こうして積層体Ｅが構成された後、上面に連結部材６で連結された補強部材Ｆ１を取り付けることにより、図７に示すように、補強部材Ｆ１、Ｆ２が取り付けられた積層体Ｅを得ることができる。そして、抄造シートＥ３を外周面に巻き付けて固定した状態の積層体Ｅをコート材に浸漬して含侵させることにより、組付・全体コート工程Ｓ４が行われることとなる。 After the laminated body E is constructed in this way, the reinforcing member F1 connected by the connecting member 6 is attached to the upper surface, thereby obtaining the laminated body E to which the reinforcing members F1 and F2 are attached as shown in FIG. can. Then, the assembly/overall coating step S4 is performed by immersing and impregnating the laminate E in which the papermaking sheet E3 is wrapped around the outer peripheral surface and fixed in the coating material.

そして、コート材が含侵された積層体Ｅに対して、乾燥工程Ｓ５及び脱脂工程Ｓ６（低温加熱工程）を施した後、所定温度で焼成（高温加熱による焼成）することにより硬化した触媒構造体２を得ることができる。なお、組付・全体コート工程Ｓ４、乾燥工程Ｓ５、脱脂工程Ｓ６及び焼成工程Ｓ７は、本発明の触媒構造体生成工程を構成する各工程とされている。 Then, the laminate E impregnated with the coating material is subjected to a drying step S5 and a degreasing step S6 (low-temperature heating step), and then baked at a predetermined temperature (baked by high-temperature heating) to harden the catalyst structure. You can get Body 2. The assembling/overall coating step S4, the drying step S5, the degreasing step S6, and the firing step S7 constitute the steps of the catalyst structure forming step of the present invention.

その後、上記焼成工程Ｓ７を経て得られた触媒構造体２に金属触媒３としての銀（Ａｇ）及びパラジウム（Ｐｄ）を担持させた後、再びコート材を含侵させ、乾燥工程Ｓ５と同様の乾燥、脱脂工程Ｓ６と同様の脱脂、及び焼成工程Ｓ７と同様の焼成を施すことにより、金属触媒３を担持した触媒構造体２を得ることができる（担持工程Ｓ８）。次に、このようにして得られた触媒構造体２の外周面に保持部材５を巻き付けて取り付ける（保持部材取付工程Ｓ９）とともに、保持部材５が巻き付けられた触媒構造体２を収容ケース４内に収容して組み立てることにより、薪ストーブ用排ガス浄化装置１を得ることができる（組立て工程Ｓ１０）。組立て工程Ｓ１０においては、触媒構造体２と収容ケース４との間に保持部材５を介装して組付け、収容ケース４に触媒構造体２を保持させるようになっている。 After that, after carrying silver (Ag) and palladium (Pd) as the metal catalyst 3 on the catalyst structure 2 obtained through the firing step S7, the coating material is impregnated again, and the same as the drying step S5 is performed. By performing drying and degreasing similar to the degreasing step S6 and firing similar to the firing step S7, the catalyst structure 2 supporting the metal catalyst 3 can be obtained (supporting step S8). Next, the holding member 5 is wound around the outer peripheral surface of the catalyst structure 2 thus obtained (holding member mounting step S9), and the catalyst structure 2 around which the holding member 5 is wound is placed in the housing case 4. The exhaust gas purifying device 1 for a wood-burning stove can be obtained by housing and assembling in (assembling step S10). In the assembling step S10, the holding member 5 is interposed between the catalyst structure 2 and the housing case 4, and the catalyst structure 2 is held by the housing case 4. As shown in FIG.

本実施形態によれば、金属触媒３は、銀（Ａｇ）及びパラジウム（Ｐｄ）を有するので、白金（Ｐｔ）等の高価な貴金属に代えて安価な銀（Ａｇ）とすることができ、安価な金属を金属触媒として用いることにより製造コストを低下させることができるとともに、金属触媒３の反応開始温度を低下させることができる。 According to the present embodiment, since the metal catalyst 3 contains silver (Ag) and palladium (Pd), inexpensive silver (Ag) can be used in place of expensive precious metals such as platinum (Pt). By using such a metal as the metal catalyst, the production cost can be reduced, and the reaction initiation temperature of the metal catalyst 3 can be lowered.

また、本実施形態に係る触媒構造体２は、アルミナ（Ａｌ２Ｏ３）及びジルコニア（ＺｒＯ２）から成るとともに、触媒構造体２に担持される金属触媒３は、パラジウム（Ｐｄ）に対する銀（Ａｇ）の重量比率が５０～８０％とされたので、金属触媒３の反応開始温度をより低下させつつ浄化性能を向上させることができる。特に、ジルコニア（ＺｒＯ２）に対するアルミナ（Ａｌ２Ｏ３）の重量比率が６０～９０％の触媒構造体２を用いることにより、金属触媒３の反応開始温度をより一層低下させつつ浄化性能を向上させることができる。 In addition, the catalyst structure 2 according to the present embodiment is made of alumina (Al 2 O 3 ) and zirconia (ZrO 2 ), and the metal catalyst 3 supported on the catalyst structure 2 is silver ( Since the weight ratio of Ag) is set to 50 to 80%, the purification performance can be improved while further lowering the reaction initiation temperature of the metal catalyst 3 . In particular, by using the catalyst structure 2 in which the weight ratio of alumina (Al 2 O 3 ) to zirconia (ZrO 2 ) is 60 to 90%, the reaction start temperature of the metal catalyst 3 is further lowered while the purification performance is improved. can be made

さらに、本実施形態に係る触媒構造体２は、波型形状に折り曲げられた抄造シートＥ１、Ｅ２が複数段に積層された積層体Ｅを有するので、触媒構造体２の軽量化を図りつつ浄化性能を維持することができる。しかるに、本実施形態によれば、薪ストーブＷの排ガス流路Ｎ１に合致させて排ガス浄化装置１を取り付けることができ、排ガスの流通漏れを防止して効果的に排ガスの浄化を図ることができる。 Furthermore, since the catalyst structure 2 according to the present embodiment has the laminate E in which the papermaking sheets E1 and E2 folded into a corrugated shape are laminated in a plurality of stages, the weight of the catalyst structure 2 can be reduced while purifying. performance can be maintained. However, according to the present embodiment, the exhaust gas purifying device 1 can be attached so as to match the exhaust gas flow path N1 of the wood stove W, and it is possible to effectively purify the exhaust gas by preventing flow leakage of the exhaust gas. .

またさらに、抄造法により抄造シートを生成する抄造シート生成工程Ｓ１と、抄造シート生成工程Ｓ１で生成された抄造シートを波型形状に折り曲げるとともに、その波型形状に折り曲げられた抄造シートを複数段に積層して積層体Ｅを得る積層体生成工程Ｓ２と、積層体生成工程Ｓ２で得られた積層体Ｅを焼成して触媒構造体２を得る触媒構造体生成工程（Ｓ４～Ｓ７）と、触媒構造体生成工程（Ｓ４～Ｓ７）で得られた触媒構造体２に金属触媒３としての銀（Ａｇ）及びパラジウム（Ｐｄ）を担持させる担持工程Ｓ８とを有するので、製造コストの低下及び金属触媒３の反応開始温度の低下を図りつつ軽量化された排ガス浄化装置を円滑に製造することができる。 Furthermore, a papermaking sheet producing step S1 for producing a papermaking sheet by a papermaking method, and the papermaking sheet produced in the papermaking sheet producing step S1 is folded into a wavy shape, and the papermaking sheet folded into the wavy shape is folded into a plurality of stages. A laminate generation step S2 in which a laminate E is obtained by laminating a layered body E, and a catalyst structure generation step (S4 to S7) in which a catalyst structure 2 is obtained by firing the laminate E obtained in the laminate generation step S2, Since it has a supporting step S8 of supporting silver (Ag) and palladium (Pd) as the metal catalyst 3 on the catalyst structure 2 obtained in the catalyst structure generating step (S4 to S7), the production cost can be reduced and the metal It is possible to smoothly manufacture a lightweight exhaust gas purifying device while reducing the reaction start temperature of the catalyst 3 .

加えて、本実施形態によれば、触媒構造体２は、波型形状に折り曲げられた抄造シートＥ１、Ｅ２が複数段に積層された積層体Ｅを有するとともに、積層体Ｅの外周面には、収容ケース４の内周面に沿って延設された補強部材Ｆ１、Ｆ２が形成されたので、触媒構造体２の軽量化を図ることができるとともに、製造過程における積層体２の変形を防止して触媒構造体２と収容ケース４との間に隙間が生じてしまうのを抑制することができる。 In addition, according to the present embodiment, the catalyst structure 2 has the laminate E in which the papermaking sheets E1 and E2 folded into a corrugated shape are laminated in multiple stages, and the outer peripheral surface of the laminate E has Since the reinforcing members F1 and F2 are formed along the inner peripheral surface of the housing case 4, the weight of the catalyst structure 2 can be reduced and deformation of the laminate 2 during the manufacturing process can be prevented. As a result, the formation of a gap between the catalyst structure 2 and the housing case 4 can be suppressed.

また、触媒構造体２は、収容ケース４の内周面の形状に倣った角柱形状に形成され、且つ、補強部材Ｆ１、Ｆ２は、触媒構造体２における角柱形状の側面に沿った複数のシート状部材で構成されたので、収容ケース４が排ガス流路Ｎ１の形状に倣った矩形形状（長方形等）であっても、触媒構造体２を収容ケース４の内周面に合致させて収容することができる。 The catalyst structure 2 is formed in a prismatic shape that follows the shape of the inner peripheral surface of the storage case 4, and the reinforcing members F1 and F2 are formed of a plurality of sheets along the sides of the prismatic shape in the catalyst structure 2. Therefore, even if the housing case 4 has a rectangular shape (rectangular or the like) following the shape of the exhaust gas flow path N1, the catalyst structure 2 can be accommodated in conformity with the inner peripheral surface of the housing case 4. be able to.

さらに、補強部材Ｆ１、Ｆ２は、積層体Ｅを構成する抄造シートＥ１、Ｅ２と同一材質から成るとともに、少なくとも積層体Ｅを構成する抄造シートＥ１、Ｅ２より大きい厚さ寸法のシート状部材から成るので、厚さ寸法が異なる抄造シートを積層体Ｅ及び補強部材Ｆ１、Ｆ２のそれぞれに流用することができるとともに、厚さ寸法が大きく剛性が高い補強部材Ｆ１、Ｆ２によって、製造過程における積層体Ｅの変形を確実に防止することができる。 Further, the reinforcing members F1 and F2 are made of the same material as the papermaking sheets E1 and E2 that constitute the laminate E, and are made of sheet-like members that are at least thicker than the papermaking sheets E1 and E2 that constitute the laminate E. Therefore, paper-made sheets having different thickness dimensions can be used for the laminate E and the reinforcing members F1 and F2, respectively. deformation can be reliably prevented.

しかるに、薪を燃焼させて放熱可能とされるとともに当該薪の燃焼により発生する排ガスを外部に排出可能な薪ストーブＷに取り付けられるので、薪ストーブＷから排出される排ガスを確実に浄化することができる。 However, since it is attached to the wood stove W, which can burn firewood to dissipate heat and can discharge the exhaust gas generated by burning the firewood to the outside, the exhaust gas emitted from the wood stove W can be reliably purified. can.

またさらに、抄造法により抄造シートを生成する抄造シート生成工程Ｓ１と、抄造シート生成工程Ｓ１で生成された抄造シートを波型形状に折り曲げるとともに、その波型形状に折り曲げられた抄造シートを複数段に積層して積層体Ｅを得る積層体生成工程Ｓ２と、抄造シート生成工程Ｓ１で生成された抄造シートにコート材を塗布して焼成することにより補強部材Ｆ１，Ｆ２を得る補強部材生成工程Ｓ３と、積層体生成工程Ｓ２で得られた積層体Ｅの外周面に補強部材生成工程Ｓ３で得られた補強部材Ｆ１、Ｆ２を取り付けた状態として焼成することにより触媒構造体Ｅを得る触媒構造体生成工程（Ｓ４～Ｓ７）と、触媒構造体生成工程（Ｓ４～Ｓ７）で得られた触媒構造体２に金属触媒３を担持させる担持工程Ｓ８とを有するので、製造過程における積層体Ｅの変形を確実に防止しつつ軽量化された排ガス浄化装置１を円滑に製造することができる。 Furthermore, a papermaking sheet producing step S1 for producing a papermaking sheet by a papermaking method, and the papermaking sheet produced in the papermaking sheet producing step S1 is folded into a wavy shape, and the papermaking sheet folded into the wavy shape is folded into a plurality of stages. and a reinforcing member producing step S3 in which the reinforcing members F1 and F2 are obtained by applying a coating material to the papermaking sheets produced in the papermaking sheet producing step S1 and baking the papermaking sheets. Then, the reinforcing members F1 and F2 obtained in the reinforcing member generating step S3 are attached to the outer peripheral surface of the laminated body E obtained in the laminated body generating step S2, and the catalyst structure is fired to obtain the catalyst structure E. Since there are the production step (S4 to S7) and the carrying step S8 of carrying the metal catalyst 3 on the catalyst structure 2 obtained in the catalyst structure production step (S4 to S7), deformation of the laminate E during the production process It is possible to smoothly manufacture the exhaust gas purifier 1 that is reduced in weight while reliably preventing the

加えて、触媒構造体２は、波型形状に折り曲げられた抄造シートＥ１、Ｅ２が複数段に積層された積層体Ｅを有するとともに、収容ケース４の内周面の形状に倣った角柱形状に形成され、且つ、角柱形状の側面のうち少なくとも抄造シートＥ１、Ｅ２の積層方向Ｇに位置する積層方向側面αに切り欠きＡが形成されたので、触媒構造体２の軽量化を図ることができるとともに、角柱形状の触媒構造体２であってもクラックの発生を抑制することができる。 In addition, the catalyst structure 2 has a laminate E in which paper-made sheets E1 and E2 folded in a corrugated shape are laminated in multiple stages, and has a prismatic shape following the shape of the inner peripheral surface of the storage case 4. and the notch A is formed at least in the stacking direction side surface α located in the stacking direction G of the papermaking sheets E1 and E2 among the side surfaces of the prismatic shape, so that the weight of the catalyst structure 2 can be reduced. In addition, cracks can be suppressed even in the prismatic catalyst structure 2 .

また、触媒構造体２は、断面が長辺及び短辺を有した長方形とされるとともに、積層方向側面αは当該長方形の長辺に位置するので、積層体Ｅにおける抄造シートＥ１、Ｅ２の積層段数を低減させることができ、製造過程の作業性を向上させることができる。特に、切り欠きＡは、長辺の中央の位置に形成されたので、断面が長辺及び短辺を有した長方形の積層体Ｅにおけるクラックの発生をより効果的に抑制することができる。 In addition, the catalyst structure 2 has a rectangular cross section with long sides and short sides, and the side surface α in the stacking direction is located on the long side of the rectangle. The number of stages can be reduced, and the workability of the manufacturing process can be improved. In particular, since the notch A is formed at the center position of the long side, it is possible to more effectively suppress the occurrence of cracks in the rectangular laminate E having the long side and the short side in cross section.

さらに、積層体Ｅの外周面には、収容ケース４の内周面に沿って延設された補強部材Ｆ１、Ｆ２が形成されるとともに、当該補強部材Ｆ１に切り欠きが形成されたので、補強部材Ｆ１、Ｆ２により製造過程における積層体Ｅの変形を防止することができるとともに、その補強部材Ｆ１に形成された切り欠きＡによりクラックの発生を抑制することができる。 Furthermore, the reinforcing members F1 and F2 extending along the inner peripheral surface of the storage case 4 are formed on the outer peripheral surface of the laminate E, and the reinforcing member F1 is provided with a notch, so that the reinforcing member F1 can be reinforced. The members F1 and F2 can prevent the laminate E from being deformed during the manufacturing process, and the notch A formed in the reinforcing member F1 can suppress the occurrence of cracks.

特に、補強部材Ｆ１、Ｆ２は、触媒構造体２における角柱形状の側面に沿った複数のシート状部材で構成され、当該シート状部材のうち積層方向側面αに位置するシート状部材に切り欠きＡが形成されたので、収容ケース４が排ガス流路Ｎ１の形状に倣った矩形形状（長方形等）であっても、触媒構造体２を収容ケース４の内周面に合致させて収容することができるとともに、補強部材Ｆ１に形成された切り欠きＡによりクラックの発生を抑制することができる。 In particular, the reinforcing members F1 and F2 are composed of a plurality of sheet-like members along the side surfaces of the prismatic shape of the catalyst structure 2. Among the sheet-like members, the sheet-like member positioned on the side surface α in the stacking direction has a notch A. is formed, even if the housing case 4 has a rectangular shape (rectangular or the like) following the shape of the exhaust gas flow path N1, the catalyst structure 2 can be housed in conformity with the inner peripheral surface of the housing case 4. In addition, the notch A formed in the reinforcing member F1 can suppress the occurrence of cracks.

また、抄造法により抄造シートを生成する抄造シート生成工程Ｓ１と、抄造シート生成工程Ｓ１で生成された抄造シートを波型形状に折り曲げるとともに、その波型形状に折り曲げられた抄造シートを複数段に積層して積層体Ｅを得る積層体生成工程Ｓ２と、抄造シート生成工程Ｓ１で生成された抄造シートにコート材を塗布して焼成することにより補強部材Ｆ１、Ｆ２を得る補強部材生成工程Ｓ３と、積層体生成工程Ｓ２で得られた積層体Ｅの外周面に補強部材生成工程Ｓ３で得られた補強部材Ｆ１、Ｆ２を取り付けた状態として焼成することにより触媒構造体２を得る触媒構造体生成工程（Ｓ４～Ｓ７）と、触媒構造体生成工程（Ｓ４～Ｓ７）で得られた触媒構造体２に金属触媒３を担持させる担持工程Ｓ８とを有するので、焼成工程Ｓ７時のクラックの発生を抑制し、且つ、積層体Ｅの変形を確実に防止しつつ軽量化された排ガス浄化装置１を円滑に製造することができる。 In addition, a papermaking sheet producing step S1 for producing a papermaking sheet by a papermaking method, the papermaking sheet produced in the papermaking sheet producing step S1 is folded into a wavy shape, and the papermaking sheet folded into the wavy shape is divided into a plurality of stages. A laminate production step S2 for laminating to obtain a laminate E, and a reinforcing member production step S3 for obtaining reinforcing members F1 and F2 by applying a coating material to the papermaking sheets produced in the papermaking sheet production step S1 and baking the sheets. Catalyst structure generation to obtain a catalyst structure 2 by sintering the laminate E obtained in the laminate generation step S2 with the reinforcing members F1 and F2 obtained in the reinforcement member generation step S3 attached to the outer peripheral surface of the laminate E. Since there are the steps (S4 to S7) and the carrying step S8 of carrying the metal catalyst 3 on the catalyst structure 2 obtained in the catalyst structure producing step (S4 to S7), the occurrence of cracks during the firing step S7 can be prevented. It is possible to smoothly manufacture the exhaust gas purifier 1 that is reduced in weight while suppressing and reliably preventing the deformation of the laminate E.

さらに、補強部材生成工程Ｓ３で得られる補強部材Ｆ１は、焼成により消滅する連結部材６により連結されて成り、触媒構造体生成工程（焼成工程Ｓ７）における焼成により連結部材６が消滅して切り欠きＡが形成されるので、補強部材Ｆ１が連結部材６で連結されて仮止めされることにより製造過程における作業性を向上することができるとともに、焼成により連結部材６が消滅することにより切り欠きＡを容易且つ確実に形成することができる。 Further, the reinforcing member F1 obtained in the reinforcing member producing step S3 is connected by the connecting member 6 that disappears by firing, and the connecting member 6 disappears by firing in the catalyst structure producing step (firing step S7) to form a notch. Since A is formed, workability in the manufacturing process can be improved by connecting and temporarily fixing the reinforcing member F1 with the connecting member 6, and the connecting member 6 disappears by firing to form the notch A. can be easily and reliably formed.

またさらに、触媒構造体生成工程（Ｓ４～Ｓ７）は、積層体生成工程Ｓ２で得られた積層体Ｅの外周面に補強部材生成工程Ｓ３で得られた補強部材Ｆ１、Ｆ２を取り付けるとともに、当該補強部材Ｆ１、Ｆ２の外周面に抄造シート生成工程Ｓ１で得られた抄造シートＥ３を巻き付けて固定した状態で焼成されるので、焼成前の製造過程における作業性をより一層向上させることができる。 Furthermore, in the catalyst structure generation step (S4 to S7), the reinforcing members F1 and F2 obtained in the reinforcement member generation step S3 are attached to the outer peripheral surface of the laminate E obtained in the laminate generation step S2, and the Since the papermaking sheet E3 obtained in the papermaking sheet producing step S1 is wrapped around the outer peripheral surfaces of the reinforcing members F1 and F2 and fixed, the workability in the manufacturing process before firing can be further improved.

加えて、本実施形態によれば、アルミナ繊維から成るシート状部材から成り、触媒構造体２と収容ケース４との間に介装されて収容ケース４に触媒構造体２を保持させる保持部材５を具備し、収容ケース４は、開口縁部に補強のための折り返し部４ｂが形成されるとともに、当該折り返し部４ｂにて保持部材５を抜け止め可能とされたので、保持部材５の熱膨張による折り返し部４ｂの変形を防止することができ、折り返し部４ｂによる収容ケース４の補強機能及び保持部材５の抜け止め機能を維持することができる。 In addition, according to this embodiment, the holding member 5 is made of a sheet-like member made of alumina fibers and is interposed between the catalyst structure 2 and the housing case 4 to hold the catalyst structure 2 in the housing case 4. The storage case 4 is formed with a folded portion 4b for reinforcement at the opening edge, and the holding member 5 can be retained by the folded portion 4b, so that the holding member 5 thermally expands Therefore, it is possible to maintain the function of reinforcing the storage case 4 and the function of retaining the holding member 5 by the folded portion 4b.

また、触媒構造体２は、収容ケース４内に複数（本実施形態においては２つ）隣接して収容されるとともに、それぞれの触媒構造体２の外周面に保持部材５が形成されたので、収容ケース４に隣接して収容された触媒構造体２の保持部材５がそれぞれ熱膨張して互いに押し合い、それぞれの触媒構造体２を変形又は破損させてしまうのを防止することができる。 In addition, since a plurality of (two in this embodiment) adjacent catalyst structures 2 are housed in the housing case 4, and the holding member 5 is formed on the outer peripheral surface of each catalyst structure 2, It is possible to prevent the holding members 5 of the catalyst structures 2 accommodated adjacent to the accommodation case 4 from thermally expanding and pressing against each other, thereby deforming or damaging the respective catalyst structures 2 .

さらに、抄造法により抄造シートを生成する抄造シート生成工程Ｓ１と、抄造シート生成工程Ｓ１で生成された抄造シートを波型形状に折り曲げるとともに、その波型形状に折り曲げられた抄造シートを複数段に積層して積層体Ｅを得る積層体生成工程Ｓ２と、抄造シート生成工程Ｓ１で生成された抄造シートにコート材を塗布して焼成することにより補強部材Ｆ１、Ｆ２を得る補強部材生成工程Ｓ３と、積層体生成工程Ｓ２で得られた積層体Ｅの外周面に補強部材生成工程Ｓ３で得られた補強部材Ｆ１、Ｆ２を取り付けた状態として焼成することにより触媒構造体２を得る触媒構造体生成工程（Ｓ４～Ｓ７））と、触媒構造体生成工程（Ｓ４～Ｓ７）で得られた触媒構造体２に金属触媒３を担持させる担持工程Ｓ８と、触媒構造体２と収容ケース４との間に保持部材５を介装して組付け、収容ケース４に触媒構造体２を保持させる組立て工程Ｓ１０とを有するので、保持部材５の側面と収容ケース４の折り返し部４ｂとを確実に対峙させた状態とすることができ、保持部材５の熱膨張による折り返し部４ｂの変形を防止することができとともに、軽量化された排ガス浄化装置１を円滑に製造することができる。 Further, a papermaking sheet producing step S1 for producing a papermaking sheet by a papermaking method, the papermaking sheet produced in the papermaking sheet producing step S1 is folded into a wavy shape, and the papermaking sheet folded into the wavy shape is divided into a plurality of stages. A laminate production step S2 for laminating to obtain a laminate E, and a reinforcing member production step S3 for obtaining reinforcing members F1 and F2 by applying a coating material to the papermaking sheets produced in the papermaking sheet production step S1 and baking the sheets. Catalyst structure generation to obtain a catalyst structure 2 by sintering the laminate E obtained in the laminate generation step S2 with the reinforcing members F1 and F2 obtained in the reinforcement member generation step S3 attached to the outer peripheral surface of the laminate E. step (S4 to S7)), a supporting step S8 of supporting the metal catalyst 3 on the catalyst structure 2 obtained in the catalyst structure producing step (S4 to S7), and between the catalyst structure 2 and the housing case 4 assembling step S10 in which the holding member 5 is interposed and assembled, and the catalyst structure 2 is held in the storage case 4. Therefore, the side surface of the holding member 5 and the folded portion 4b of the storage case 4 are reliably opposed to each other. It is possible to prevent deformation of the folded portion 4b due to thermal expansion of the holding member 5, and to smoothly manufacture the exhaust gas purifier 1 having a reduced weight.

以上、本実施形態について説明したが、本発明はこれに限定されず、例えば積層体Ｅの外周面に補強部材Ｆ１、Ｆ２が取り付けられず、抄造シートＥ３による巻き付け固定がなされないもの、他の金属触媒が担持されたもの、他の材料から成る保持部材５を具備したもの等であってもよい。また、薪ストーブＷに適用されるものに限定されず、排ガスを排出する他の器具等に適用するものであってもよい。なお、触媒構造体２は、断面矩形の角柱形状の他、円柱形状等、他の形状であってもよい。 Although the present embodiment has been described above, the present invention is not limited to this. It may be one in which a metal catalyst is carried, or one provided with a holding member 5 made of another material. Further, the present invention is not limited to being applied to the wood stove W, and may be applied to other appliances that discharge exhaust gas. Note that the catalyst structure 2 may have a prismatic shape with a rectangular cross section, or may have another shape such as a cylindrical shape.

触媒構造体は、波型形状に折り曲げられた抄造シートが複数段に積層された積層体を有するとともに、収容ケースの内周面の形状に倣った角柱形状に形成され、且つ、角柱形状の側面のうち少なくとも抄造シートの積層方向に位置する積層方向側面に切り欠きが形成された排ガス浄化装置であれば、外観形状が異なるもの或いは他の機能が付加されたもの等にも適用することができる。 The catalyst structure has a laminate in which paper-made sheets folded in a corrugated shape are laminated in a plurality of stages, is formed into a prismatic shape following the shape of the inner peripheral surface of the storage case, and has a prismatic side surface. Of these, as long as the exhaust gas purifying device has a notch formed at least on the side surface in the stacking direction of the papermaking sheet, it can be applied to a device having a different external shape or having other functions added. .

１ 排ガス浄化装置
２ 触媒構造体
３ 金属触媒
４ 収容ケース
４ａ 収容空間
４ｂ 折り返し部
５ 保持部材
６ 連結部材
６ａ 切り欠き形成シール
６ｂ 連結シール
Ｓ 薪ストーブ
Ｗ１ 金属製本体
Ｗ２ 燃焼室
Ｗ３ 煙突
Ｎ１ 排ガス流路
Ｎ２ バイパス流路
Ｂ ダンパ
Ｍ 薪
Ｄ 前扉
Ｅ 積層構造体
Ｅ１ 抄造シート
Ｅ２ 抄造シート
Ｅ３ 抄造シート
Ｆ１ 補強部材
Ｆ２ 補強部材
Ａ 切り欠き
α 積層方向側面
β その他の側面
Ｇ 積層方向 1 Exhaust gas purification device 2 Catalyst structure 3 Metal catalyst 4 Storage case 4a Storage space 4b Folding part 5 Holding member 6 Connecting member 6a Notch forming seal 6b Connecting seal S Wood stove W1 Metal main body W2 Combustion chamber W3 Chimney N1 Exhaust gas flow path N2 Bypass channel B Damper M Firewood D Front door E Laminated structure E1 Paper-made sheet E2 Paper-made sheet E3 Paper-made sheet F1 Reinforcement member F2 Reinforcement member A Notch α Lamination direction side β Other side G Lamination direction

Claims (12)

排ガスを流通可能な触媒構造体と、
前記触媒構造体に担持され、当該触媒構造体を流通する前記排ガスと反応して浄化し得る金属触媒と、
前記触媒構造体を収容するとともに、排ガスが流通する排ガス流路に取り付け可能な収容ケースと、
を具備した排ガス浄化装置であって、
前記触媒構造体は、波型形状に折り曲げられた抄造シートが複数段に積層された積層体を有するとともに、前記収容ケースの内周面の形状に倣った角柱形状に形成され、且つ、前記角柱形状の側面のうち少なくとも前記抄造シートの積層方向に位置する積層方向側面に切り欠きが形成されたことを特徴とする排ガス浄化装置。 a catalyst structure through which exhaust gas can flow;
a metal catalyst supported on the catalyst structure and capable of reacting with and purifying the exhaust gas flowing through the catalyst structure;
a storage case that stores the catalyst structure and is attachable to an exhaust gas flow path through which exhaust gas flows;
An exhaust gas purification device comprising
The catalyst structure has a laminated body in which paper-made sheets folded in a corrugated shape are laminated in a plurality of stages, and is formed into a prismatic shape following the shape of the inner peripheral surface of the storage case, and An exhaust gas purifying device, wherein a notch is formed at least in a stacking direction side surface positioned in the stacking direction of the papermaking sheet among side surfaces of the shape. 前記触媒構造体は、断面が長辺及び短辺を有した長方形とされるとともに、前記積層方向側面は当該長方形の長辺に位置することを特徴とする請求項１記載の排ガス浄化装置。 2. An exhaust gas purifying apparatus according to claim 1, wherein said catalyst structure has a rectangular cross section with long sides and short sides, and said stacking direction side surfaces are positioned on the long sides of said rectangle. 前記切り欠きは、前記長辺の中央の位置に形成されたことを特徴とする請求項２記載の排ガス浄化装置。 3. An exhaust gas purifier according to claim 2, wherein said notch is formed at a central position of said long side. 前記積層体の外周面には、前記収容ケースの内周面に沿って延設された補強部材が形成されるとともに、当該補強部材に前記切り欠きが形成されたことを特徴とする請求項１～３の何れか１つに記載の排ガス浄化装置。 2. A reinforcing member extending along the inner peripheral surface of the storage case is formed on the outer peripheral surface of the laminate, and the notch is formed in the reinforcing member. 4. The exhaust gas purifier according to any one of 1 to 3. 前記補強部材は、前記触媒構造体における前記角柱形状の側面に沿った複数のシート状部材で構成され、当該シート状部材のうち前記積層方向側面に位置するシート状部材に前記切り欠きが形成されたことを特徴とする請求項４記載の排ガス浄化装置。 The reinforcing member is composed of a plurality of sheet-like members along the side surfaces of the prismatic shape of the catalyst structure, and the notch is formed in the sheet-like member positioned on the side surface in the stacking direction among the sheet-like members. 5. An exhaust gas purifier according to claim 4, characterized in that: 薪を燃焼させて放熱可能とされるとともに当該薪の燃焼により発生する排ガスを外部に排出可能な薪ストーブに取り付けられることを特徴とする請求項１～５の何れか１つに記載の排ガス浄化装置。 The exhaust gas purification according to any one of claims 1 to 5, characterized in that it is attached to a wood stove capable of burning firewood to dissipate heat and discharging the exhaust gas generated by burning the firewood to the outside. Device. 排ガスを流通可能な触媒構造体と、
前記触媒構造体に担持され、当該触媒構造体を流通する前記排ガスと反応して浄化し得る金属触媒と、
前記触媒構造体を収容するとともに、排ガスが流通する排ガス流路に取り付け可能な収容ケースと、
を具備した排ガス浄化装置の製造方法であって、
前記触媒構造体は、波型形状に折り曲げられた抄造シートが複数段に積層された積層体を有するとともに、前記収容ケースの内周面の形状に倣った角柱形状に形成され、且つ、前記角柱形状の側面のうち少なくとも前記抄造シートの積層方向に位置する積層方向側面に切り欠きを形成することを特徴とする排ガス浄化装置の製造方法。 a catalyst structure through which exhaust gas can flow;
a metal catalyst supported on the catalyst structure and capable of reacting with and purifying the exhaust gas flowing through the catalyst structure;
a storage case that stores the catalyst structure and is attachable to an exhaust gas flow path through which exhaust gas flows;
A method for manufacturing an exhaust gas purifier comprising
The catalyst structure has a laminated body in which paper-made sheets folded in a corrugated shape are laminated in a plurality of stages, and is formed into a prismatic shape following the shape of the inner peripheral surface of the storage case, and A method for manufacturing an exhaust gas purifying device, wherein a notch is formed at least in a stacking direction side surface positioned in the stacking direction of the papermaking sheet among side surfaces of the shape. 前記触媒構造体は、断面が長辺及び短辺を有した長方形とされるとともに、前記積層方向側面は当該長方形の長辺に位置することを特徴とする請求項７記載の排ガス浄化装置の製造方法。 8. The manufacturing of an exhaust gas purifier according to claim 7, wherein the catalyst structure has a rectangular cross section with long sides and short sides, and the side surfaces in the stacking direction are located on the long sides of the rectangle. Method. 前記切り欠きは、前記長辺の中央の位置に形成されたことを特徴とする請求項８記載の排ガス浄化装置の製造方法。 9. The method of manufacturing an exhaust gas purifier according to claim 8, wherein the notch is formed at a central position of the long side. 抄造法により抄造シートを生成する抄造シート生成工程と、
前記抄造シート生成工程で生成された抄造シートを波型形状に折り曲げるとともに、その波型形状に折り曲げられた抄造シートを複数段に積層して積層体を得る積層体生成工程と、
前記抄造シート生成工程で生成された抄造シートにコート材を塗布して焼成することにより補強部材を得る補強部材生成工程と、
前記積層体生成工程で得られた前記積層体の外周面に前記補強部材生成工程で得られた前記補強部材を取り付けた状態として焼成することにより前記触媒構造体を得る触媒構造体生成工程と、
前記触媒構造体生成工程で得られた前記触媒構造体に前記金属触媒を担持させる担持工程と、
を有することを特徴とする請求項７～９の何れか１つに記載の排ガス浄化装置の製造方法。 A papermaking sheet producing step of producing a papermaking sheet by a papermaking method;
a laminate producing step of bending the papermaking sheet produced in the papermaking sheet producing step into a wavy shape, and laminating the papermaking sheets folded into the wavy shape in a plurality of stages to obtain a laminate;
A reinforcing member producing step for obtaining a reinforcing member by applying a coating material to the papermaking sheet produced in the papermaking sheet producing step and baking the papermaking sheet;
a catalyst structure generating step of obtaining the catalyst structure by firing the laminate with the reinforcing member obtained in the reinforcing member generating step attached to the outer peripheral surface of the laminate obtained in the laminate generating step;
a supporting step of supporting the metal catalyst on the catalyst structure obtained in the catalyst structure generating step;
The method for manufacturing an exhaust gas purifier according to any one of claims 7 to 9, characterized by comprising: 前記補強部材生成工程で得られる補強部材は、焼成により消滅する連結部材により連結されて成り、前記触媒構造体生成工程における焼成により前記連結部材が消滅して前記切り欠きが形成されることを特徴とする請求項１０記載の排ガス浄化装置の製造方法。 The reinforcing member obtained in the reinforcing member forming step is connected by a connecting member that disappears by firing, and the connecting member disappears by firing in the catalyst structure forming step to form the notch. 11. The method for manufacturing an exhaust gas purifier according to claim 10. 前記触媒構造体生成工程は、前記積層体生成工程で得られた前記積層体の外周面に前記補強部材生成工程で得られた前記補強部材を取り付けるとともに、当該補強部材の外周面に前記抄造シート生成工程で得られた抄造シートを巻き付けて固定した状態で焼成されることを特徴とする請求項１１記載の排ガス浄化装置の製造方法。 In the catalyst structure generating step, the reinforcing member obtained in the reinforcing member generating step is attached to the outer peripheral surface of the laminate obtained in the laminate generating step, and the papermaking sheet is attached to the outer peripheral surface of the reinforcing member. 12. The method of manufacturing an exhaust gas purifying device according to claim 11, wherein the papermaking sheet obtained in the production step is wrapped and fixed in a state of being sintered.
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