Usui Kokusai Sangyo Kabushiki Kaisha, Ltd.

Usui Kokusai Sangyo Kaisha Limited

Haruo Serizawa

Masayoshi Usui

Yuzo Hitachi

Kazunori Takikawa

Yasushi Sakamoto

Yasuaki Hashimoto

The invention provides a metal honeycomb core body used as the principal structural element of an exhaust gas cleaning unit excellent in various performances and economy that is provided with a corrugated band member, that is a structural member of a metal honeycomb core body having a special waveform structure. The invention provides a metal honeycomb core body having honeycomb structure fabricated by bringing corrugated band members ( ) and planar band members ( ) made of thin-walled metal sheet alternately into contact. The corrugated band member ( ) has a waveform structure obtained by using a waveform of an imaginary corrugated sheet ( &prime;) having crests and troughs which are in contact with a planar band member ( ) and composed of a connected waveform having a desired waveheight (h) and one period length (&lgr;&prime;). A one period length (&lgr;) of a new waveform is formed comprising the area ( ) where the waveform of the imaginary corrugated sheet ( &prime;) is in contact with the planar band member ( ) on at least one pair of an adjacent crest and trough of a wave. The area ( ) which is not in contact with the planar band member ( ) is connected adjacently to the area ( ) which is in contact with the planar band member ( ). The area ( ) of at least one end of which is in contact with the planar band member ( ) and is connected adjacently to the noncontact area ( ). An area ( ) which is not in contact with the planar band member ( ) is formed so as to have a height of about one half ( &middot;h) of the waveheight (h) of the imaginary corrugated sheet ( &prime;). The new waveform is constituted by connecting the three areas ( , and ) to form a waveform of one period length (&lgr;) by use of the waveform of the imaginary corrugated sheet ( &prime;).

Metal honeycomb structure

An exhaust gas cleaning device is constructed of a metal casing and a honeycomb core body fixedly inserted in the metal casing. The honeycomb core body have been formed by superposing a planar band made of a metal sheet and a corrugated band made from another metal sheet one over the other in a contiguous relation, defines a number of network-patterned axial gas flow passages, and is adapted to carry an exhaust gas cleaning catalyst thereon. The metal casing defines a cavity compartment isolated from an exterior. Preferably, at least one rib or partition wall is arranged in the cavity compartment of the metal casing.

Exhaust gas cleaning device

A metal-made honeycomb carrier body is provided for carrying thereon an exhaust gas cleaning catalyst. The carrier body has been formed by superposing a planar metal band made of a metal sheet and a corrugated band made from another metal sheet one over the other in a contiguous relation and defines a number of network-patterned gas flow passages along a central axis thereof. At one of opposite axial ends of the honeycomb carrier body, one of the planar band and the corrugated band extends outwardly relative to the other band.

Metal-made honeycomb carrier body

An exhaust gas cleaning apparatus comprises one or more honeycomb core bodies for carrying an exhaust gas cleaning catalyst and fitted in a tubular metal casing. The metal casing has an outer wall which is axially expandable and contractible so as to follow the stress due to thermal strains acting on the honeycomb core bodies inside, thereby remarkably improving the apparatus in durability and vibration resistance.

Exhaust gas cleaning apparatus

A metal-made carrier body, for carrying thereon an exhaust gas cleaning catalyst, is in the form of a multi-layered composite body composed of at least sheet-like metal band and a corrugated metal band. The corrugated band has ridges and inter-ridge grooves, both in contact with the sheet-like band. The shape of the corrugated band is such that a unit part of the corrugated band between each of the ridges and an individual one of the grooves contiguous thereto is longer than a virtual sine curve.

Metal-made carrier body for exhaust gas

A metal-made carrier body, for carrying thereon an exhaust gas cleaning catalyst, comprises a multi-layered composite body in a spirally rolled form composed of a sheet-like band and a corrugated band, the multi-layered composite body being enclosed in and fixed to a tubular metal casing. The metal casing is composed of an outer casing, and at least one inner casing disposed in the outer casing, thus giving excellent durability to the carrier body.

Metal-made carrier body for exhaust gas cleaning catalyst

An exhaust gas cleaning device for a motor vehicle is constructed of a honeycomb core body formed by superposing a planar band made of a metal sheet and a corrugated band made from another metal sheet one over the other in a contiguous relationship and then rolling the thus-superposed bands into a multi-layered spiral form with at least one outermost layer thereof being formed of the planar band. The honeycomb core body defines a number of network-patterned axial gas flow passages and is adapted to carry an exhaust gas cleaning catalyst. At least one fin is fixed on an outer peripheral wall of the honeycomb core body.

An exhaust gas cleaning device is constructed of a honeycomb core body. The honeycomb core body has been formed by superposing a planar band made of a metal sheet and a corrugated band made from another metal sheet one over the other in a contiguous relationship and then rolling the thus-superposed bands into a multi-layered spiral form. The honeycomb core body defines a number of network-patterned axial gas flow passages and is adapted to carry an exhaust gas cleaning catalyst. The honeycomb core body is divided into a central honeycomb core section of a smaller diameter and an outer honeycomb core section of a larger diameter. A separator is interposed between an outer peripheral wall of the central honeycomb core section and an inner peripheral wall of the outer honeycomb core section. The outer honeycomb core section may be divided further into plural honeycomb core sub-sections having different diameters and a additional separator may be interposed between each two adjacent core sub-sections.

An exhaust gas cleaning device is constructed of a honeycomb core body formed by superposing in a contiguous relation a planar band made of a metal sheet and a corrugated band made from another metal sheet one over the other. The honeycomb core body defines a number of network-patterned axial gas flow passages and is adapted to carry an exhaust gas cleaning catalyst thereon. The planar band has alternating rugged sections and flat sections of desired lengths.

In an exhaust gas cleaning apparatus, at least two honeycomb core bodies each as an exhaust gas cleaning catalyst are arranged, with at least one axial space therebetween, in a metal casing. Each core body is composed of a sheet-like band and a corrugated band. The outer peripheral surfaces of the core bodies are fixed to the inner surface of the casing so that each core body is expandable and contractible axially. The axial space effectively absorbs and relaxes the stress due to large thermal strains acting on the individual core bodies, thus causing an improved durability.

An exhaust gas cleaning device is constructed of a honeycomb core body. The honeycomb core body is formed by superposing a planar band made of a metal sheet and a corrugated band made from another metal sheet, one over the other in a contiguous relationship, and then rolling the thus-superposed planar band and corrugated band together into a multilayered spiral form, defines a number of network-patterned axial gas flow passages, and is further processed to carry an exhaust gas cleaning catalyst thereon. The honeycomb core body defines, along the central axis of rolling thereof, an open cylindrical hollow space of a diameter .phi..sub.2 satisfying the following formula: ##EQU1## wherein .phi..sub.1 is the outer diameter of the honeycomb core body, and

A nickel coating and an aluminum layer are formed in this order on an inexpensive thin steel sheet made of a low-carbon steel, a low-chromium steel or a low-nickel steel. Then the nickel- and aluminum-plated thin steel sheet is subjected to a diffusion penetration treatment to form a mutually diffused layer over the entire surface of the thin steel sheet, thus providing a thin steel band which is excellent in heat-resistance, corrosion-proofness at high temperature and rigidity.

Substantially flat and thin steel band

In an exhaust gas cleaning apparatus, at least two honeycomb core bodies each carrying a cleaning catalyst are arranged, with at least one axial space therebetween, in a metal casing having an enlarged-diameter portion. The outer peripheral surfaces of the core bodies are fixed to the inner surface of the casing so that each core body is expandable and contractible axially. The result is that separation between each core body and the casing can be prevented, thus improving the durability. Further, an excellent cleaning performance can be achieved not only due to the heat insulating effect as well as the gas stirring effect by the enlarged-diameter casing portion, but also due to the gas turbulent effect by the inter-body space.

An exhaust gas cleaning device for a motor vehicle is constructed of a metal casing open at both ends thereof and a honeycomb core body fixedly enclosed within the metal casing. The honeycomb core body has been formed by superposing a planar band made of a metal sheet and a corrugated band made from another metal sheet one over the other in a contiguous relationship. The honeycomb core body defines a number of network-patterned axial gas flow passages and is adapted to carry an exhaust gas cleaning catalyst. At least one fin is fixed on an outer peripheral wall of the metal casing.

A metal-made carrier body, for carrying thereon an exhaust gas cleaning catalyst, comprises a honeycomb core structure composed of a sheet-like metal band and a corrugated metal band. As each of the metal bands, an inexpensive thin steel band which is plated with nickel and then with an aluminum coating and further processed by diffusive penetration treatment, is used. The metal-made carrier body is inexpensive and is excellently heat-resistant and corrosion-proof.

Growing community of inventors

Shizuoka, Japan

Haruo Serizawa