Exhaust gas purifying catalyst device

Abstract

An exhaust gas purifying catalyst device, which can have high durability against vibration and high temperatures, can be configured to suppress the peeling of the catalyst layer from the catalyst carrier member during use. Additionally, the metallic catalyst can be easily recovered after use. According to the present disclosure, an exhaust gas purifying catalyst device can comprise a catalyst carrier member on which metallic catalyst for exhaust gas purification can be carried characterized in that the catalyst carrier member can be formed of a sheet-like catalyst carrier made by a wet paper-making method, and that the metallic catalyst can be carried as a catalyst layer on surfaces of the sheet-like catalyst carrier after the sheet-like catalyst carrier has been baked.

What is claimed is: 
     
         1 . An exhaust gas purifying catalyst device comprising:
 a catalyst carrier member on which metallic catalyst for exhaust gas purification is carried;   wherein the catalyst carrier member is formed of a sheet-like catalyst carrier made by a wet paper-making method; and   wherein the metallic catalyst is carried as a catalyst layer on surfaces of the sheet-like catalyst carrier after the sheet-like catalyst carrier has been baked.   
     
     
         2 . An exhaust gas purifying catalyst device of  claim 1 , wherein the sheet-like catalyst carrier comprises ceramic powder and alumina-silica fibers. 
     
     
         3 . An exhaust gas purifying catalyst device of  claim 1 , wherein the ceramic powder comprises alumina. 
     
     
         4 . An exhaust gas purifying catalyst device of  claim 3 , wherein the weight ratio of the alumina-silica fibers to the ceramic powder of alumina is within a range of 0.2-2.5. 
     
     
         5 . An exhaust gas purifying catalyst device  claim 1 , wherein the baking temperature is within a range of 1450-1550° C. 
     
     
         6 . An exhaust gas purifying catalyst device of  claim 1 , wherein the catalyst carrier member is manufactured through a sheet making step for paper-making the sheet-like catalyst carrier from flock formed by adding flocculant into slurry of predetermined amount of water mingled with predetermined fibers and binder; a baking step for baking the sheet-like catalyst carrier obtained in the sheet making step; and a metallic catalyst applying step for applying the metallic catalyst onto the surfaces of the catalyst carrier member obtained in the baking step. 
     
     
         7 . An exhaust gas purifying catalyst device of  claim 1 , wherein the catalyst carrier member has a honeycomb structure formed by adhering a corrugated sheet-like catalyst carrier onto at least one surface of a flat sheet-like catalyst carrier and by winding them to a roll. 
     
     
         8 . A method for forming an exhaust gas purifying catalyst device comprising:
 manufacturing a sheet-like catalyst carrier from flock through a wet paper-making step;   baking the sheet-like catalyst carrier; and   applying a metallic catalyst to the surface of the baked sheet-like catalyst carrier.   
     
     
         9 . A method of  claim 8 , wherein the sheet-like catalyst carrier comprises ceramic powder and alumina-silica fibers. 
     
     
         10 . A method of  claim 9 , wherein the ceramic powder comprises alumina. 
     
     
         11 . An exhaust gas purifying catalyst device of  claim 10 , wherein the weight ratio of the alumina-silica fibers to the ceramic powder of alumina is within a range of 0.2-2.5. 
     
     
         12 . A method of  claim 8 , wherein the baking temperature is within a range of 1450-1550° C.