Metal substrate for catalytic converter and catalyst carrier

Patent metadata

Field	Value
Publication number	US-10458305-B2
Application number	US-201615736659-A
Country	US
Kind code	B2
Filing date	Oct 4, 2016
Priority date	Oct 6, 2015
Publication date	Oct 29, 2019
Grant date	Oct 29, 2019

Abstract

A base for supporting a catalyst for exhaust gas purification, the base including a honeycomb structure obtained by superposing a metallic flat foil and a metallic wavy foil, characterized in that the wavy foil has offset portions where any adjoining two of the wave phases arranged in the axial direction of the honeycomb structure are offset from each other. The base is further characterized in that an oxide coating film has been formed in a given range of these offset portions which includes exposed edge surfaces that are exposed on the gas-inlet side, that the oxide coating film includes 30-99.9 mass % first alumina, with the remainder comprising at least one of second aluminas, Fe oxides, and Cr oxides, that the first alumina comprises α-alumina, that the second aluminas comprise one or more of γ-, θ-, χ-, δ-, η-, and κ-aluminas.

First claim

The invention claimed is:

1. A metal substrate for catalytic converter for purifying exhaust gas, the metal substrate comprising a honeycomb core including a flat metal foil and a corrugated metal foil, the flat metal foil and the corrugated metal foil being layered, wherein
the corrugated foil has an offset part having different wave phases between front and rear in an axial direction of the honeycomb core,
the offset part has an oxide film formed on an exposed end surface that is exposed toward at least a gas inlet side,
the oxide film contains 30% by mass or more and 99.9% by mass or less of a first alumina with the balance comprising at least one of a second alumina, a Fe oxide, and a Cr oxide,
the first alumina comprises α-alumina, and
the second alumina comprises at least one or more of γ, θ, χ, δ, η, and κ aluminas.

2. The metal substrate for catalytic converter according to claim 1 , wherein a content of Fe contained in the oxide film is 0.1% by mass or more and 7% by mass or less.

3. The metal substrate for catalytic converter according to claim 2 , wherein a content of Cr contained in the oxide film is 0.1% by mass or more and 4% by mass or less.

4. The metal substrate for catalytic converter according to claim 3 , wherein the oxide film has a thickness of 100 nm or more and 10 μm or less.

5. The metal substrate for catalytic converter according to claim 4 , wherein
the honeycomb core is formed from a stainless foil, and contains at least Fe, Cr, and Al,
a total amount of Cr contained in the stainless foil and the oxide film of the honeycomb core is 9% by mass or more and 30% by mass or less, and
a total amount of Al contained in the stainless foil and the oxide film of the honeycomb core is 1.5% by mass or more and 13% by mass or less.

6. The metal substrate for catalytic converter according to claim 3 , wherein
the honeycomb core is formed from a stainless foil, and contains at least Fe, Cr, and Al,
a total amount of Cr contained in the stainless foil and the oxide film of the honeycomb core is 9% by mass or more and 30% by mass or less, and
a total amount of Al contained in the stainless foil and the oxide film of the honeycomb core is 1.5% by mass or more and 13% by mass or less.

7. The metal substrate for catalytic converter according to claim 2 , wherein the oxide film has a thickness of 100 nm or more and 10 μm or less.

8. The metal substrate for catalytic converter according to claim 7 , wherein
the honeycomb core is formed from a stainless foil, and contains at least Fe, Cr, and Al,
a total amount of Cr contained in the stainless foil and the oxide film of the honeycomb core is 9% by mass or more and 30% by mass or less, and
a total amount of Al contained in the stainless foil and the oxide film of the honeycomb core is 1.5% by mass or more and 13% by mass or less.

9. The metal substrate for catalytic converter according to claim 2 , wherein
the honeycomb core is formed from a stainless foil, and contains at least Fe, Cr, and Al,
a total amount of Cr contained in the stainless foil and the oxide film of the honeycomb core is 9% by mass or more and 30% by mass or less, and
a total amount of Al contained in the stainless foil and the oxide film of the honeycomb core is 1.5% by mass or more and 13% by mass or less.

10. A catalyst carrier comprising:
the metal substrate for catalytic converter according to claim 2 ; and
a catalyst carried on the flat foil and the corrugated foil.

11. The metal substrate for catalytic converter according to claim 1 , wherein a content of Cr contained in the oxide film is 0.1% by mass or more and 4% by mass or less.

12. The metal substrate for catalytic converter according to claim 11 , wherein the oxide film has a thickness of 100 nm or more and 10 μm or less.

13. The metal substrate for catalytic converter according to claim 12 , wherein
the honeycomb core is formed from a stainless foil, and contains at least Fe, Cr, and Al,
a total amount of Cr contained in the stainless foil and the oxide film of the honeycomb core is 9% by mass or more and 30% by mass or less, and
a total amount of Al contained in the stainless foil and the oxide film of the honeycomb core is 1.5% by mass or more and 13% by mass or less.

14. The metal substrate for catalytic converter according to claim 11 , wherein
the honeycomb core is formed from a stainless foil, and contains at least Fe, Cr, and Al,
a total amount of Cr contained in the stainless foil and the oxide film of the honeycomb core is 9% by mass or more and 30% by mass or less, and
a total amount of Al contained in the stainless foil and the oxide film of the honeycomb core is 1.5% by mass or more and 13% by mass or less.

15. The metal substrate for catalytic converter according to claim 1 , wherein the oxide film has a thickness of 100 nm or more and 10 μm or less.

16. The metal substrate for catalytic converter according to claim 15 , wherein
the honeycomb core is formed from a stainless foil, and contains at least Fe, Cr, and Al,
a total amount of Cr contained in the stainless foil and the oxide film of the honeycomb core is 9% by mass or more and 30% by mass or less, and
a total amount of Al contained in the stainless foil and the oxide film of the honeycomb core is 1.5% by mass or more and 13% by mass or less.

17. The metal substrate for catalytic converter according to claim 1 , wherein
the honeycomb core is formed from a stainless foil, and contains at least Fe, Cr, and Al,
a total amount of Cr contained in the stainless foil and the oxide film of the honeycomb core is 9% by mass or more and 30% by mass or less, and
a total amount of Al contained in the stainless foil and the oxide film of the honeycomb core is 1.5% by mass or more and 13% by mass or less.

18. A catalyst carrier comprising:
the metal substrate for catalytic converter according to claim 1 ; and
a catalyst carried on the flat foil and the corrugated foil.

19. The catalyst carrier according to claim 18 , used for a purification device for purifying diesel exhaust gas.

20. The catalyst carrier according to claim 18 , used for a purification device for purifying exhaust gas from combustion of gasoline.

Assignees

• Nippon Steel & Sumikin Mat Co
• Nippon Steel Chemical & Mat Co Ltd

Inventors

• Inaguma Tooru
• Kawasoe Shinji
• Tsumura Yasuhiro
• Konya Shogo
• Kasuya Masayuki
• Omizu Masafumi

Classifications

• F01N2330/02

  Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal · CPC title

• B01D53/94

  by catalytic processes · CPC title

• F01N2370/02

  used in catalytic reactors · CPC title

• B01J23/86

  Chromium · CPC title

• B01D53/9418

  for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas · CPC title