JPH0372954A - Preparation of catalyst carrier - Google Patents

Abstract

PURPOSE:To enhance not only reaction efficiency but also engine efficiency and output by forming a catalyst capable of being brought near to the direct close part of an engine by baking a base material coated with a particulate metal to prepare a thin-wall pipe and incorporating said pipe in a frame body. CONSTITUTION:Ceramizol 888(R) or an acrylic resin is used as a base material and molded into a shape supposing a final shape. A metal such as an iron-Cr alloy or an iron-Ni alloy having a particle size of about 20mum or less, pref., about 10mum or less is applied to the molded one to be bonded thereto. Thereafter, this coated molded one is baked to form a pipe having an extremely thin wall thickness. When this catalyst structure is brought near to the direct close part of the engine in exhaust piping, a catalyst can be allowed to act at high exhaustion temp. and calalytic reaction efficiency is enhanced and, therefore, engine efficiency and output can be enhanced.

Description

【発明の詳細な説明】 ［産業上の利用分野］ 本発明は自動車用排気ガスのＮＯｘ、　ＳＯＸ処理用に
用いられる触媒を乗せるメタル担体の製造方法に関する
ものである。DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a method for manufacturing a metal carrier on which a catalyst used for treating NOx and SOx in automobile exhaust gas is mounted.

［従来の拉術］ 自動車の排気ガスの規制が実施されて１０年以上経過す
るが、現在の排気ガス対策はエンジンの改良と触媒によ
る排気ガスの浄化によって行われている。排気ガス浄化
用の触媒はコージオライト等のセラミックスハニカムの
一ヒに白金等の貴金属触媒を担持する構造のものが主流
を占めている。しかしこれらのセラミックスハニカムは
排気抵抗が相対的に高く、ハニカムの破壊を防止するた
めに外筒との間に挿入する緩衝用ステンレスメツシュの
耐熱性の１−１約などから、その使用温度を低くせざる
を得ない欠点がある。[Conventional techniques] It has been more than 10 years since automobile exhaust gas regulations were implemented, and current exhaust gas countermeasures are implemented by improving engines and purifying exhaust gas using catalysts. The mainstream catalysts for exhaust gas purification are those having a structure in which a precious metal catalyst such as platinum is supported on a ceramic honeycomb such as cordiolite. However, these ceramic honeycombs have relatively high exhaust resistance, and the temperature at which they are used must be adjusted due to the heat resistance of the buffer stainless steel mesh inserted between the honeycomb and the outer cylinder to prevent damage. There are drawbacks that force it to be lower.

これらの欠点を改善するものとして、近年ステンレス箔
からなる金属担体が注目されている。これらの金属担体
は当然反応中の高温かつ高速の排気ガスに耐える耐熱性
と激しい加熱、冷却サイクルに耐える耐熱疲労性か要求
される。In recent years, metal carriers made of stainless steel foil have been attracting attention as a means of improving these drawbacks. These metal supports are naturally required to have heat resistance to withstand the high temperature and high velocity exhaust gas during the reaction, and thermal fatigue resistance to withstand intense heating and cooling cycles.

第２図に示すように、一般にこの種の金属担体１は５０
μｍ前後のステンレス平箔とコルゲート加工したステン
レス波箔とを屯ねて円筒形または楕円桟状に巻き込みハ
ニカム体２を形成し、これを耐熱ステンレス製の外筒管
３に挿入して後、平箔〜波箔〜外筒管を相互にロウ付け
あるいは抵抗溶接等により接合製造される。As shown in FIG. 2, generally this type of metal carrier 1 has a
The honeycomb body 2 is formed by rolling stainless steel flat foil of around μm and corrugated stainless steel corrugated foil into a cylindrical or elliptical crosspiece shape, and inserting this into an outer tube 3 made of heat-resistant stainless steel. Foil, corrugated foil, and outer tube are bonded together by brazing or resistance welding.

［発明が解決しようとする課題］ 従来の方法では、内部の担体部の金属箔が薄いため、空
隙部が真っ直ぐな構造の担体しか製造できなかった。ま
た、製造した直管担体を曲げることは極めて困難で内部
の金属箔が破断し゛〔しまうために技術的には実用化の
〔１処が立っていない。[Problems to be Solved by the Invention] In the conventional method, since the metal foil of the internal carrier portion is thin, only a carrier having a straight cavity structure can be manufactured. Furthermore, it is extremely difficult to bend the manufactured straight pipe carrier and the metal foil inside would break, so there is no way to put it into practical use technically.

曲げ加工に耐える物にするには、内部の金属箔をＪ’Ｘ
めの金属板にする必要かあり、空隙率、比表向ｉＩ″ｔ
が低下して触媒担体としての機能が大幅に劣化する問題
点がある。To make it resistant to bending, use the J'X internal metal foil.
Is it necessary to use a metal plate with a porosity and specific surface direction?
There is a problem that the function as a catalyst carrier is significantly deteriorated due to a decrease in

本発明はこの従来技４４ｒの問題点を解消し、良好な機
能を介する触媒担体として大川化可能なものを提供し得
ることを［」的とする。It is an object of the present invention to solve the problems of the prior art 44r and to provide a catalyst carrier with good functionality that can be used extensively.

［課題を解決するためのｆ段］ この［１的を達成するための本発明の要旨は、基材に微
粉末金属を塗着し、１該３．Ｂ材を焼成することにより
薄肉パイプを製造し、該薄肉パイプを枠体に組込むこと
を特徴とする触媒担体の製造方法である。[Step F for Solving the Problems] The gist of the present invention for achieving object 1 is to apply fine powder metal to a base material, and to apply 1.3. This method of manufacturing a catalyst carrier is characterized by manufacturing a thin-walled pipe by firing material B, and incorporating the thin-walled pipe into a frame.

本発明の方法では、粉末冶金技術を応用して予め最終的
に枠体に組み込んだ時の形状を計算して超薄肉厚のパイ
プを製造しておき、それを枠体を構成する通常肉厚管で
包む方式で製造することにより、軽量で曲管部にも装肴
可能な触媒担体を製造できるようにしたものである。In the method of the present invention, an ultra-thin-walled pipe is manufactured by applying powder metallurgy technology to calculate in advance the shape of the pipe when it will be finally assembled into the frame, and then the pipe is manufactured using the normal pipes that make up the frame. By manufacturing the catalyst by wrapping it in a thick tube, it is possible to manufacture a catalyst carrier that is lightweight and can be placed in curved tubes.

１１体的には、まずウレタンゴムや発泡スチレン等の可
塑性の樹脂を基材として用い、最終形状を想定した形状
に成形する。基材は金属微粉末の整形体形状を維持する
ための材料であり、昇温段階で大きな体積変化を起こさ
ず金属微粉末の接着を破壊しない物で、かつ、焼結反応
か終γするまでに気化する材料であれば採用できる。基
材が液化または気化し初めて形状の支持機能を失っても
金属微粉末が元の形状を保つためには、金属微粉末同士
の焼結がある程度進行する温度まで接着効力を保つ接着
剤が必要である。例えばセラミゾール８８８、アクリル
樹脂粉末等が使用できる。11 First, a plastic resin such as urethane rubber or expanded styrene is used as a base material, and is molded into a shape assuming the final shape. The base material is a material that maintains the shape of the fine metal powder, and it is a material that does not cause a large volume change during the heating stage and does not destroy the adhesion of the fine metal powder until the sintering reaction is completed. Any material that vaporizes can be used. In order for fine metal powder to maintain its original shape even when the base material liquefies or vaporizes and loses its ability to support its shape, an adhesive is required that maintains its adhesive effect up to a temperature at which sintering of the fine metal powders progresses to some extent. It is. For example, Ceramisol 888, acrylic resin powder, etc. can be used.

準４Ｔする金属微粉末の粒度は、塗布表面を滑らかに仕
」二げ、厚みを均一にし、焼結反応速度をあげるために
できるだけ粒度の細かいものが好ましい。１５さが５０
１ＪＩ１１程度の超薄肉厚のパイプを製造するには、原
料の金属粉末粒度は平均で２０μｍ以下にする必要があ
り、できれば１０μｍ以下が望ましい。The particle size of the metal fine powder for quasi-4T is preferably as fine as possible in order to finish the coated surface smoothly, make the thickness uniform, and increase the sintering reaction rate. 15 is 50
In order to manufacture a pipe with an ultra-thin wall thickness of about 1JI11, the average particle size of the raw metal powder must be 20 μm or less, preferably 10 μm or less.

そのようにして、基材に金属微粉末を塗布、接着せしめ
た整形体をＮ２ガス、ＣＯガス、真空等の非酸化性雰囲
気ドて焼成する。鉄とＣｒの合金の場合テ１３００℃×
２時間、鉄とＮｉ）場合テ１２００”Ｃｘ　２時間の焼
結時間を確保することにより、超薄肉厚のパイプが焼成
できる。In this manner, the shaped body with fine metal powder applied and bonded to the base material is fired in a non-oxidizing atmosphere such as N2 gas, CO gas, vacuum, or the like. For alloys of iron and Cr, the temperature is 1300℃×
By ensuring a sintering time of 2 hours, in the case of iron and Ni) Te 1200''Cx, a pipe with an ultra-thin wall thickness can be fired.

次に第１図により本発明の触媒担体の製造フローを説明
する。Next, the manufacturing flow of the catalyst carrier of the present invention will be explained with reference to FIG.

例えば」耳甲性樹脂からなる共材４を微粉末鉄粉と水を
混合したスラリー中に浸消させ微粉末鉄粉５を塗着させ
る（第１図（ａ）（ｂｌ照）。スラリー中にはＪ、（材
４に微粉末鉄粉５が接着しゃすいようにバインダーとし
て接着剤、微粉末鉄粉５がスラリー中に沈降しないよう
に活＋１：刑、あるいはスラリー中に泡が発生して鉄粉
５が基材４に均一にゆ着しないのを防止する消泡剤等を
添加する。For example, a co-material 4 made of auricular resin is immersed in a slurry of a mixture of fine powdered iron powder and water, and finely powdered iron powder 5 is applied (Fig. 1(a) (bl)). J, (adhesive as a binder so that the fine powdered iron powder 5 does not adhere to the material 4, active +1 to prevent the fine powdered iron powder 5 from settling in the slurry, or bubbles are generated in the slurry. Then, an antifoaming agent or the like is added to prevent the iron powder 5 from being uniformly deposited on the base material 4.

このようにして基材４に微粉末鉄粉５を塗着したら、次
に基材４を加熱して焼成する（第１図（Ｃ））。この時
、基材４は焼失し、基材４に塗着した微粉末鉄粉５のみ
が残り、薄肉パイプロが製造される。After applying the fine iron powder 5 to the base material 4 in this manner, the base material 4 is then heated and fired (FIG. 1(C)). At this time, the base material 4 is burned away, only the fine powdered iron powder 5 coated on the base material 4 remains, and a thin-walled pipe is manufactured.

この薄肉パイプロを複数個集め（第１図（ｄ））、例え
ば第１図（ｃ）に示すように半割りパイプの枠体７に複
数個の薄肉パイプロを組込み溶接して（第１図（ｆ））
触媒担体８を製造する。本発明は特に曲管タイプの触媒
担体８を製造するに打利であり、そのために第１図に示
す基材４を曲管にしておけばよい。Collect a plurality of these thin-walled pipes (Fig. 1(d)), and as shown in Fig. 1(c), for example, incorporate and weld the plurality of thin-walled pipes into the frame 7 of the half-split pipe (Fig. 1(c)). f))
A catalyst carrier 8 is manufactured. The present invention is particularly advantageous for producing a curved tube type catalyst carrier 8, and for this purpose, the base material 4 shown in FIG. 1 may be formed into a curved tube.

尚、薄肉パイプロは丸形、角形等、種々の形状が考えら
れ、その形状は特に限定されるものでない。Note that the thin-walled pipe may have various shapes such as a round shape and a square shape, and the shape is not particularly limited.

［実施例］ 次に本発明の実施例について述べる。[Example] Next, examples of the present invention will be described.

（実施例１） 表１に示した成分、粒度の鉄粉粉末を使い、同じく表２
に示した３種類の薬品を水と混合してスラリーを作り、
発泡スチレンに塗布した。それを室温で２４時間乾燥し
た後、乾燥機に入れて１００℃で１時間乾燥し、窒素雰
囲気下で１２００℃×３時間焼成して超薄肉厚の曲管を
製作して、２分割にした通常肉厚のパイプにくるんで一
体構造体を製作した。焼成後の成品寸法を表５に、１ｆ
ｉｌｌ　ｆｌｌ１１定結果を表６に示す。(Example 1) Using iron powder powder with the ingredients and particle size shown in Table 1,
Mix the three types of chemicals shown in water with water to make a slurry.
Applied to expanded styrene. After drying it at room temperature for 24 hours, put it in a dryer and dry it at 100℃ for 1 hour, and then bake it in a nitrogen atmosphere at 1200℃ for 3 hours to make an ultra-thin curved tube and divide it into two parts. An integrated structure was fabricated by wrapping it in a normally thick pipe. The dimensions of the finished product after firing are shown in Table 5.
Table 6 shows the ill full11 results.

（実施例２） 表３に示した成分、粒度の合金粉末を使い、同しく表４
に示した１神類の熱硬化樹脂薬品を混合して、接着材を
塗Ｉｎシたウレタンゴムに粉体塗装機で吹きつけた。そ
れを乾燥機に入れて１５０℃×１５分放置し、樹脂を硬
化させた後、雰ｌ用気調整炉に入れ窒素雰囲気下で１１
５０℃×１時間焼成した。(Example 2) Using alloy powder with the ingredients and particle size shown in Table 3,
The thermosetting resin chemicals shown in Figure 1 were mixed and sprayed on urethane rubber coated with adhesive using a powder coating machine. Put it in a dryer and leave it at 150°C for 15 minutes to harden the resin, then put it in an air conditioning oven and dry it for 11 minutes at 150℃ under a nitrogen atmosphere.
It was baked at 50°C for 1 hour.

Ｅｌ−冷却した後、更に真空釘】で１３００℃×３時間
焼成して冷却して製作した。焼成後の成品寸法を表５に
、圧損測定結果を火６に示す。After cooling with El-1, it was further baked in a vacuum nail at 1300°C for 3 hours and cooled. Table 5 shows the dimensions of the finished product after firing, and Table 6 shows the pressure drop measurement results.

表１ 表２ 実施例１の焼成前の原料性状と焼成後の成品成分実施例
１の粉体塗着基材とバインター配合比表４ 実施例２の粉体塗着基材とバインダー配合比表５ 灯り戊＾り旬ａ町未Ｗ１−豹牙Ｔ１７去表６ 圧Ｈ１沖淀結果例 ［発明の効果］ 本発明により、従来のメタル担体ては技術的に不可能で
あった距離まで、触媒構造体を排気配管内のエンジン直
近部まで近づけることができる。Table 1 Table 2 Raw material properties before firing and product components after firing in Example 1 Powder coating base material and binder blending ratio Table 4 Table of powder coating base material and binder blending ratio in Example 2 5 Lighting Shun a Town Mi W1-Leopard Fang T17 Table 6 Pressure H1 Okiyodo Result Example [Effects of the Invention] With the present invention, the catalyst can be transferred to a distance that was technically impossible with conventional metal carriers. The structure can be brought close to the engine in the exhaust pipe.

それにより、排気温度がより高いまま触媒を作用させる
ことができるので、触媒反応効率か上がり、エンジンの
効率、出力の向−Ｌを図ることができる。As a result, the catalyst can be operated while the exhaust gas temperature is still higher, so that the catalytic reaction efficiency can be increased, and the efficiency and output of the engine can be improved.

【図面の簡単な説明】[Brief explanation of drawings]

第１図は本発明の触媒担体の製造フローを示す説明図、
第２図は従来の金属担体の説明図である。 １・・・金属担体、２・・・ハニカム体、３・・・外筒
、４・・・基材、５・・・微粉末鉄粉、６・・・薄肉パ
イプ、７・・・枠体、８・・・触媒担体。 特許出頭上　代理人FIG. 1 is an explanatory diagram showing the manufacturing flow of the catalyst carrier of the present invention,
FIG. 2 is an explanatory diagram of a conventional metal carrier. DESCRIPTION OF SYMBOLS 1... Metal carrier, 2... Honeycomb body, 3... Outer cylinder, 4... Base material, 5... Fine powder iron powder, 6... Thin wall pipe, 7... Frame body , 8...Catalyst carrier. Patent filing agent

Claims (1)

【特許請求の範囲】[Claims] １、基材に微粉末金属を塗着し、該基材を焼成すること
により薄肉パイプを製造し、該薄肉パイプを枠体に組込
むことを特徴とする触媒担体の製造方法。1. A method for producing a catalyst carrier, which comprises applying fine powder metal to a base material, baking the base material to produce a thin-walled pipe, and incorporating the thin-walled pipe into a frame.