Nippon Steel Corporation

Kazutoshi Iwami

Masayuki Kasuya

Tadayuki Otani

Yasuo Takahashi

Mikio Yamanaka

Toru Utsumi

Shuji Nagasaki

Atsuhiko Imai

Tamio Noda

Hitoshi Ohta

Yoshikuni Tokunaga

Atuhiko Imai

Toshihiro Egami

Fujio Shimizu

Takeshi Shinoda

A honeycomb body, which is composed in such a manner that a strip of corrugated foil made of heat-resistant stainless steel containing aluminum and a strip of flat foil made of stainless steel are alternately wound or laminated on each other, is incorporated into an outer cylinder made of metal and integrated into one body by means of diffusion bonding, so that a diffusion bonded metallic catalyst carrier can be formed. Surface roughness of the strip of foil after the completion of diffusion bonding is 0.001 to 2.0 &#x3bc;m when it is expressed by center line average height Ra, and no sintered bridges are formed at both end portions of the diffusion bonded section in the longitudinal direction. The catalyst carrier is manufactured in a condition so that &#x3bb;b, which is defined by&#x3bb;=6.8&#xd7;10&#xd7;exp(15000/)&#xd7;,can be in a range from 8 to 20 where thickness of the strip of foil is &#x3b4;f (m), average roughness of the foil surface is Ra (m), back tension in the case of winding is F (kgf), contact width of the piece of flat foil with the piece of corrugated foil is b (m), heat treatment temperature is T (K), and degree of vacuum is Pout (Pa), under the condition that 7.52&#xd7;10&#xd7;exp(&#x2212;35000/T)&#x2267;8&#xd7;Pout.

Diffusion bonded metallic catalyst carrier and production thereof

The present invention provides a method of manufacturing a honeycomb body () formed by winding a flat metal foil () and a corrugated metal foil () in layers and brazing them, capable of reducing the equipment cost of honeycomb body manufacturing facilities and conforming to the countermeasure against an engine misfire problem of the honeycomb body, without causing insufficient or excessive application of adhesive which is seen in the cases of adhesive application methods using rolls; and relates to a method of manufacturing a honeycomb body characterized by: applying an adhesive to the portions to be brazed of the flat or corrugated foil corresponding to a bonding portion () which is located at one or both ends of the honeycomb body and/or a bonding portion () inside the honeycomb body over a cross section which is located away from one or both ends thereof in the axial direction; then, winding the flat and corrugated foils in layers to form a honeycomb body; then, making the portion of one or both end faces of the honeycomb body corresponding to the bonding portion () over the full axial length of the honeycomb body outer layers contact the surface of a liquid binder and having the binder sucked up along contact lines () of the flat and corrugated foils; and, then, feeding a brazing filler metal in powder to the honeycomb body so as to have it deposited at the portions where the adhesive and binder have been deposited.

Method of manufacturing honeycomb body

The present invention is: a metallic foil to be used for a metallic honeycomb for purifying exhaust gas of an automobile or the like, said metallic foil not causing cracks or ruptures to develop in the foil even when it undergoes corrugation work with more sharply bending corner portions of a trapezoidal shape; and a catalyst support for purifying exhaust gas of an automobile or the like, characterized in that said metallic foil, being rough surface finished and having good corrugation workability, is made of heat-resistant stainless steel and has surface roughness more than 2.0 and not more than 5.0 &mgr;m in R and, said metallic catalyst support for purifying exhaust gas has a structure comprising a honeycomb inserted in a jacket, wherein the honeycomb is composed of rough surface finished metallic foil having surface roughness more than 2.0 and not more than 5.0 &mgr;m in R and the jacket is made of heat-resistant stainless steel.

Rough surface finished metallic foil with good corrugation workability and catalyst support for exhaust gas purification

In order to improve solid phase diffusion bondability at contact portions between a metal flat foil and a metal corrugated foil together constituting a metal honeycomb body for a catalyst converter used for purifying an exhaust gas and to improve engine durability, the present invention comprises one or combination of the following structures; a structure wherein at least one of the metal foils has a foil thickness of less than 40 &mgr;m; a structure wherein an Al content after bonding is at least 3%; a structure wherein the surface condition of both metal foils in a width-wise direction has a predetermined surface coarseness or a predetermined surface shape and condition; and a structure wherein the width of contact portions between both metal foils is at least five times the thickness of the metal foils. In order to further improve engine durability, the present invention disposes an unbonded portion inside the honeycomb body having the construction described above, or disposes a shell on the outer periphery of the honeycomb body.

Metal honeycomb body for exhaust gas purification catalyst and method for producing the same

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Tokyo, Japan

Kazutoshi Iwami