Nippon Steel Corporation

Toru Utsumi

Masayuki Kasuya

Kazutoshi Iwami

Mikio Yamanaka

Atsuhiko Imai

Tadayuki Otani

Tamio Noda

Hitoshi Ohta

Yoshikuni Tokunaga

Toshihiro Egami

Takeshi Shinoda

Fujio Shimizu

Atuhiko Imai

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

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

Toru Utsumi