Chemical apparatus and process disinfecting – deodorizing – preser – Chemical reactor – Waste gas purifier
Reexamination Certificate
1998-08-11
2001-09-11
Tran, Hien (Department: 1764)
Chemical apparatus and process disinfecting, deodorizing, preser
Chemical reactor
Waste gas purifier
C422S177000, C422S222000, C428S116000, C428S593000, C428S597000, C502S439000, C502S527210, C502S527220
Reexamination Certificate
active
06287523
ABSTRACT:
TECHNICAL FIELD
The present invention relates to a metal sheet for metallic catalyst carrier and a metallic catalyst converter using the same.
BACKGROUND ART
In an exhaust system of a vehicle such as automobile, etc., a catalyst converter for purifying an exhaust gas being exhausted from an engine is incorporated. As the catalyst carrier used in the catalyst converter, as shown in
FIG. 18
, a metallic catalyst carrier
23
having a honeycomb structure, in which a corrugated sheet
21
formed by applying corrugation process to a strip-like metal sheet base and a flat sheet
22
are superposed and then they are wound several times, has been widely employed (see Patent Application Publication (KOKOKU) Hei 8-11195).
Upon manufacturing the metallic catalyst carrier
23
, a film-out phenomenon must be prevented by eliminating relative movement between the corrugated sheet
21
and the flat sheet
22
. As a method of preventing such film-out phenomenon, methods have been adopted such that connected areas between the corrugated sheet
21
and the flat sheet
22
are jointed by welding or brazing, the metallic catalyst carrier
23
is fastened/pressurized by pressurizing jig such as a die and then is heated in a vacuum state to diffuse/joint the corrugated sheet
21
and the flat sheet
22
integrally, etc.
However, in the above metallic catalyst carrier
23
, a weight becomes heavier by the presence of the flat sheet
22
. In addition, since the corrugated sheet
21
can absorb thermal stress due to the high temperature exhaust gas but the flat sheet
22
is hard to absorb such thermal stress, stress strain occurs at the junction points between the corrugated sheet
21
and the flat sheet
22
to thus cause breaking and disconnection.
Therefore, in Patent Application Publication (KOKAI) Hei 5-138040, as shown in
FIG. 19
, the metal sheet
27
for metallic catalyst carrier has been disclosed wherein the corrugated sheet
24
is divided into a plurality of columns
25
a
,
25
b
,
25
c
,
25
d
along the winding direction, then a corrugate shape
26
is formed continuously in respective columns
25
a
,
25
b
,
25
c
,
25
d
at a predetermined pitch, and then phases of respective columns
25
a
,
25
b
,
25
c
,
25
d
are shifted between adjacent columns mutually and then wounded several times.
In the metallic catalyst carrier using such metal sheet
27
, a weight of the metallic catalyst carrier can be made lighter as a whole because the flat sheet can be omitted. As a result, heat capacity of the metallic catalyst carrier can be made smaller so that a temperature rising time can be shortened, and the metallic catalyst carrier is excellent in absorption of thermal stress, and there is no possibility that breaking of the metal sheet
27
and disconnection of the metal sheet
27
due to such breaking are caused. In addition, since end portions of superposed the corrugate shape
26
of the metal sheet
27
are engaged with each other, relative movement of the metal sheet
27
can be prevented. Therefore, so-called film-out phenomenon in which superposed layers of the metal sheet
27
are displaced to thus project like bamboo sprout (like a spiral shape) never occurs.
DISCLOSURE OF INVENTION
However, in the above metal sheet
27
, as shown in a front view in
FIG. 20
, respective columns
25
a
,
25
b
,
25
c
,
25
d
are coupled mutually only at intersection points P between crest portion
26
a
and trough portions
26
b
of the corrugate shape
26
. Hence, if difference in coefficients of thermal expansion is caused because of temperature change in the columns
25
a
,
25
b
,
25
c
,
25
d
generated when the exhaust gas flows thereinto, it is possible that mutual coupling portions between respective columns
25
a
,
25
b
,
25
c
,
25
d
at the above intersection points P are broken off.
Therefore, it is a first object of the present invention to provide a metal sheet for metallic catalyst carrier which is capable of enhancing breaking endurance rigidity of a metal sheet per se formed in a corrugate shape, constructing a honeycomb carrier in which cells are formed in superposed portions by superposing only the corrugated metal sheets, and avoiding mutual fittings of the metal sheets even when adjacent superposed metal sheets are displaced in a corrugation direction or a fold direction of a corrugate shape.
Further, in the metallic catalyst converter of this type, as shown in
FIG.21
, a honeycomb carrier
30
in which a number of cells are formed by superposing the above corrugated metal sheets
27
is formed, and then a core body is formed by providing this honeycomb carrier
30
onto a not shown outer cylinder.
As shown in
FIG.22
, the honeycomb carrier
30
can be formed by folding/superposing sequentially the above corrugated metal sheets
27
along the corrugation direction to form S-shapes, or by superposing several sheets of the above metal sheets
27
each having a predetermined length.
However, since such superposed metal sheets
27
are not secured mutually, there is a possibility that a so-called aperture opening phenomenon occurs, i.e., the metal sheets
27
are extended by the pressure of the entering exhaust gas in the upstream side of the exhaust gas, as shown in
FIG.23
in the former case and as shown in
FIG.24
in the latter case.
Therefore, it is a second object of the present invention to provide a metallic catalyst converter capable of preventing the aperture opening phenomenon in use effectively.
In order to achieve the above objects, according to the first aspect, there is provided a metal sheet for metallic catalyst carrier comprising a plurality of first convex portions; a plurality of second convex portions; and a plurality of rack portions; wherein the first convex portions are folded to protrude to one surface side of the metal sheet and extended in a first direction, the second convex portions are folded to protrude to other surface side of the metal sheet and extended in the first direction, the first convex portions and the second convex portions are arranged alternatively in parallel along a second direction intersecting with the first direction to form a corrugate shape, the rack portions are arranged between the first convex portions and the second convex portions and extend along the first direction and connect adjacent first convex portions and second convex portions, the first convex portions have third convex portions which are divided by two cuttings separated in the first direction and are folded to protrude partially to the other surface side of the metal sheet, and the second convex portions have fourth convex portions which are divided by two cuttings separated in the first direction and are folded to protrude partially to the one surface side of the metal sheet.
According to the second aspect, in the metal sheet for metallic catalyst carrier of the first aspect, end portions of the cuttings for dividing the third convex portions are positioned on boundary portions between the first convex portions and the rack portions, the third convex portions are folded from the boundary portions between the first convex portions and the rack portions, end portions of the cuttings for dividing the fourth convex portions are positioned on boundary portions between the second convex portions and the rack portions, and the fourth convex portions are folded from the boundary portions between the second convex portions and the rack portions.
According to the third aspect, in the metal sheet for metallic catalyst carrier of the first aspect, the third convex portions and the fourth convex portions are provided respectively along the first direction in plural.
According to the fourth aspect, in the metal sheet for metallic catalyst carrier of the third aspect, the third convex portions and the fourth convex portions are arranged based on predetermined regularity. More particularly, lengths of the third convex portions along the first direction and distances between the adjacent third convex portions are set based on a predetermined regularity in the same firs
Hirohashi Junichiroh
Katoh Humihiko
Mita Yasuhiro
Nagai Tadashi
Noda Masakazu
Berkowitz Marvin C.
Calsonic Kansei Corporation
Nath Gary M.
Nath & Associates PLLC
Tran Hien
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