JP3199151B2 - Corrugated sheet of metal honeycomb carrier and molding apparatus therefor - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a corrugated sheet of a metal honeycomb carrier in a catalytic converter of an automobile and an apparatus for forming the same.

[0002]

2. Description of the Related Art Generally, a catalytic converter is disposed in an exhaust system of an automobile to purify exhaust gas. The metal honeycomb carrier of the catalytic converter is configured by winding a metal flat plate and a corrugated plate alternately. When manufacturing a metal honeycomb carrier, its flat plate and corrugated plate are heated to a high temperature and integrated by diffusion bonding. During diffusion bonding, it is necessary to apply a predetermined pressure between the flat plate and the corrugated plate,
Various methods have been devised for applying pressure.

As a method of manufacturing a metal honeycomb carrier by applying pressure between a flat plate and a corrugated plate, for example, Japanese Patent Application Laid-Open No.
Japanese Patent Application Laid-Open No. 0839 is known. JP-A-4-
The method disclosed in Japanese Patent Publication No. 180839 is illustrated in FIG. 13, and illustrates a honeycomb body 101 made of a metal corrugated plate and a flat plate.
Has a large-diameter portion 101A formed in a part thereof, and has a different dimension in the width direction (vertical direction in the drawing).

The honeycomb body 101 has a large diameter portion 101A.
Is press-fitted into the outer cylinder 102 slightly smaller than the outer diameter of the honeycomb body 101, the large-diameter portion 101A is reduced in diameter to the outer cylinder 102, and the corrugated plate and the flat plate constituting the honeycomb body 101 are more closely adhered to each other, and the diffusion bonding is performed. The pressure increases. Such a honeycomb body 10
In forming one corrugated sheet, a corrugated sheet forming apparatus 103 shown in FIG. 14 is used in order to make the crest height of the corrugated sheet different in the width direction (vertical direction in the drawing).

[0005] The shaping device 103 comprises a crest gear device 104 comprising a pair of crest shaping gears 104A, 104A.
And a third gear device 106 including a pair of crest shaped gears 105A and 105A and a third crest device 106 including a pair of crest shaped gears 106A and 106A. Have been. When the flat material 107 is sent to the molding device 103, the crest portions 108 and the low wave portions 10 having the same pitch and different peak heights are applied to the flat material 107.
9. A corrugated plate 111 partitioned into crest portions 110 is formed.

There are various methods for dividing the corrugated sheet 111 into a wave low part and a wave high part along the longitudinal direction. However, as shown in FIG. 15, the gear units 112A and 112B can be arranged in two rows. In this case, the corrugated sheet 111 formed by the forming device 113 is divided into a crest 114 and a crest 115 having the same length and different peak heights.

[0007]

However, when forming into a corrugated sheet 111 partitioned into crests 114 and crests 115 as shown in FIG. 15, the state shown in FIG. 16 is obtained.
That is, the crest 114 and crest 115 have the same pitch but different crests, so that the crest 114 and crest 1
There is a possibility that the corrugated sheet 111 is broken at the boundary 116 because the elongation at the boundary 116 (FIGS. 15 and 16) is large.

Further, in order to make the elongation amounts at the crest 114 and crest 115 the same, the crest 114 and the crest 11
If the pitch of 5 is different, as shown in FIG. 17, when the corrugated sheet 111 is formed from the flat material 107 by the forming apparatus 113, the corrugated sheet 111 is bent in the traveling direction. The present invention has been made in order to solve the above-mentioned problems, and an object of the present invention is to form a corrugated sheet from a flat material without bending in the traveling direction, and also to increase the wave height and wave height of the corrugated sheet. An object of the present invention is to provide a corrugated sheet of a metal honeycomb carrier capable of preventing breakage of a boundary between portions, and a forming apparatus therefor.

[0009]

According to the first aspect of the present invention,
A crest portion formed along one side in the longitudinal direction, a crest portion formed along the other side in the longitudinal direction, formed lower than the crest portion, and a crest portion having the same length as the crest portion, a crest portion and a crest portion And a gradually changing portion formed between the low portions, wherein the crest portion and the low portion have the same curve length per pitch.

According to a second aspect of the present invention, there is provided a corrugated sheet of the metallic honeycomb carrier according to the first aspect, wherein the gear device for a crest portion includes a pair of crest shaped gears having a module of a predetermined size. , A module with the same length as the crest-shaped molded gear module, a curved length per pitch of the crest-shaped molded gear and a curve length per pitch having the same length, and a tooth height lower than the tooth height of the crest-shaped gear. And a gear unit for crests comprising a pair of gears for crests having a gear unit for crests and a gear unit for crests are arranged at predetermined intervals in the wave width direction. I do.

[0011]

According to the first aspect of the present invention, the crest portion and the crest portion of the corrugated sheet have the same pitch even if the crest height is different in the wave width direction. Since the curve length per pitch of the crest portion and crest portion is the same,
There is no significant difference in the amount of elongation between the crest portion and the crest portion of the corrugated sheet, and the corrugated sheet does not bend in the traveling direction when the corrugated sheet is formed from a flat material.

In the invention according to claim 2, the flat material is formed into the following corrugated sheet by the forming apparatus. The crest portion of the corrugated sheet is formed by a crest portion gear device including a pair of crest portion forming gears. At the same time, by the gear device for wave low part composed of a pair of gears for wave low part,
The crest of the corrugated sheet is formed.

At this time, the module of the crest-shaped formed gear and the crest-shaped formed gear have the same curve length per pitch, and the tooth height of the crest-shaped formed gear is Since it is lower than the tooth height of the formed gear, the corrugated sheet according to the first aspect of the present invention is manufactured. That is, the crest portion of the corrugated sheet formed by the gear device for crest portions and the crest portion formed by the gear device for crest portions have different peak heights in the wave width direction and the same pitch, and , The crest of the corrugated sheet,
The curve length per pitch in the longitudinal direction of the crest portion is the same.

The gradually changing portion between the crest portion and the crest portion is
Although it is not formed by the external force of the first and second crest gear devices, it is forcibly formed as the crest and crest are formed. At this time, the change in the curved surface from the crest portion to the crest portion of the corrugated sheet is moderated by the gradually changing portion.

[0015]

Embodiments of the present invention will be described below with reference to the drawings. 1 to 6 show a metal honeycomb carrier according to an embodiment of the present invention. 4 to 6, reference numeral 1 denotes a metal honeycomb carrier according to the present embodiment,
The metal honeycomb carrier 1 includes a honeycomb body 2 and an outer cylinder 3 into which the honeycomb body 2 is inserted. A diffuser (not shown) is connected to both ends of the metal honeycomb carrier 1 to constitute a catalytic converter (not shown).

The honeycomb body 2 is formed by winding a metal flat plate 4 and a corrugated plate 5 alternately, and is formed in a columnar shape. The flat plate 4 and the corrugated plate 5 are made of an alloy made of a ferritic stainless steel alloy, and contain Cr 10% to 40% and Al (aluminum) 1% to 7%. Its thickness is 30μ
m to 80 μm. For example, Cr 20%, Al
Ferritic stainless steel alloy containing 5% (aluminum) or 18% Cr, Al (aluminum)
Used as ferritic stainless steel alloy containing 3%. The diameter D of the honeycomb body 2 is 100 mm, and the total length L of the honeycomb body 2 is 80 mm.

The outer cylinder 3 is formed in a cylindrical shape.
It is made of an alloy made of a ferritic stainless steel alloy such as S430, and has a thickness of about 0.8 mm or more.
2.0 mm. Next, the shape of the corrugated sheet 5 will be described with reference to FIGS. The corrugated sheet 5 is composed of a crest portion 6, a crest portion 7, and a gradually changing portion 8 formed between the crest portion 6 and the crest portion 7.

The crest portion 6 has a sine curve in cross section, the pitch is P, and the length of the curve per pitch is L ₁ . The cross section of the crest portion 7 is formed by a curve having a trapezoidal shape with one peak, the pitch is P, and the curve length per pitch is L ₂ . The curve lengths L ₁ and L ₂ are the same. Accordingly, the total length of the crest 6 and the crest 7 of the corrugated sheet are also the same. The peak height H ₁ of the crest portion 6 is larger than the peak height H ₂ of the crest portion 7. That is, the crest portion 6 and the crest portion 7 have different peak heights in the wave width direction, and have the same pitch P.

Due to the gradual change portion 8, even if the crest portions 6 and 7 have different peak heights, there is no sudden surface change, and the crest portions 6 and 6 do not change.
This makes it possible to make the crest 7 continuous with a gentle surface change. According to the corrugated plate 5 of the honeycomb carrier 2 having the above-described configuration, the crest portions 6 and the corrugated portions 7 of the corrugated plate 5 have the same pitch even if the crest heights are different in the wave width direction, Also, since the curve length per pitch of the crest portion 6 and the crest portion 7 of the corrugated plate 5 are the same, there is a large difference in the elongation amount of the crest portion 6 and the crest portion 7 of the corrugated plate 5. Therefore, it is possible to prevent breakage due to elongation in the gradually changing portion 8 of the corrugated sheet 5, and
When the corrugated sheet 5 is formed from the flat sheet material 12 by a forming device 9 described later, the corrugated sheet 5 can be formed linearly without bending in the traveling direction.

In this embodiment, the corrugated plate 6, the crest 6, the crest 7, and the gradually changing part 8 are formed on the corrugated plate 5. However, the corrugated plate is composed of one or more crests and one or more crests. , One or more gradually changing parts. For example, one corrugated portion and two crest portions on both sides thereof may be formed on the corrugated sheet, and a gradually changing portion may be formed between each corrugated portion and the two crest portions. Alternatively, one crest portion and two crest portions may be formed on both sides of the corrugated sheet, and a gradually changing portion may be formed between one crest portion and the two crest portions.

Next, an apparatus 9 for forming a corrugated sheet 5 of a metal honeycomb carrier 1 according to an embodiment of the present invention will be described with reference to FIGS. In the figure, a corrugated sheet forming device 9 of a metal honeycomb carrier is provided with a crest gear device 10.
And a gear device 11 for wave crests. The crest section gear device 10 includes a pair of crest section forming gears 10A, 10A forming the crest section 6 of the corrugated plate 5. The module of the crest shaped gear 10A is M ₁ , and the number of teeth is Z ₁ , 1
Curve length per pitch is L _1. The width of the crest shaped gears 10A, 10A is the same as the crest 6 of the corrugated plate 5.

The crest gear device 11 comprises a pair of crest shaping gears 11A, 11A forming the crest 7 of the corrugated plate. The module of the formed gear 11A is M ₂ , the number of teeth thereof is Z ₂ , and the curve length per pitch is L ₂ .
The width of the crest forming gears 11A, 11A is the same as the crest 7 of the corrugated plate 5. A module M ₁ of the crest portion for molding the gear 10A, the module M ₂ waves lower portion for molding the gear 11A are the same length.

The number of teeth Z ₁ of the crest portion for molding the gear 10A, the number of teeth Z ₂ waves lower portion for molding the gear 11A is equal, therefore, it has a diameter also become the same length. The curve length L ₁ per pitch of the crest portion for molding the gear 10A is a curve length L ₂ and the length per pitch of the wave lower portion for molding the gear 11A.
The crest shaped gear 10A and the crest shaped gear 11A share the central shafts 10B and 10C, and have the same diameter as described above. Tooth height H ₄ of the wave lower portion for forming gear 11A is lower than the tooth height H ₃ of the molding crest section gear 10A.

The crest gear device 10 and the crest gear device 11 are arranged at intervals C in the wave width direction. The interval C increases in proportion to the difference between the crest height of the crest portion 6 and the crest portion 7. This interval C is in the range of peak height × (0.5 to 10 times). The width of the gradually changing portion 8 is determined by the interval C. The difference in peak height is 0.1 mm at maximum, and this maximum 0.1 m
The value of m is a limit value in a range in which the bonding strength of the flat plate 4 and the corrugated plate 5 by the diffusion bonding increases according to the difference in the peak height. Approximately C = 1 for maximum 0.1mm difference in peak height
The distance is 2 mm.

When C = 3 mm, the peak height H ₁ of the wave height portion 6 of the corrugated sheet 5 is 1.22 mm to 1.25 mm,
The peak height of H ₂ Namihiku portion 7 is 1.2 mm. Thus, the flat material 12 is formed into the corrugated sheet 5 by the forming device 9 as follows. While the flat material 12 is being conveyed into the forming device 9, a pair of crest portion forming gears 10A, 1
The crest portion 6 of the corrugated plate 5 is formed by the crest portion gear device 10 made of OA. The wave shape of the crest portion 6 of the corrugated plate 5 matches the one tooth profile of the crest-shaped molded gear 10A.

At the same time, a pair of corrugated molded gears 11A,
The crest portion 7 of the corrugated sheet 5 is formed by the crest portion gear device 11 composed of 11A. Formed gears 11A, 11
The wave shape of the wave bottom 7 of the corrugated plate 5 matches the tooth shape of A. A module M ₁ of the crest portion for molding the gear 10A, since the module M ₂ waves lower portion for molding the gear 11A is turned in the same length, height 6 of the corrugated plate 5 of the same length pitch, Namihiku portion 7 is formed Is done.

With the formation of the crest portions 6 and the crest portions 7 of the corrugated plate 5, the gradually changing portions 8 are forcibly formed between the crest portions 6 of the corrugated plate 5 and the crest portions 7 of the corrugated plate 5. You. At this time, the change in the curved surface from the crest portion 6 to the crest portion 7 of the corrugated sheet 5 is moderated by the gradually changing portion 8, and the amount of elongation in the gradually changing portion 8 of the corrugated sheet 5 is reduced. The corrugated plate 5 shown in FIGS. 1 and 2 is produced by the molding apparatus 9 having the above-described configuration.

Then, as shown in FIG. 4, the honeycomb body 2 is manufactured by winding the metal flat plates 4 and corrugated plates 5 alternately. Next, the flat plate 4 and the corrugated plate 5 of each layer are integrated by diffusion bonding by performing diffusion bonding by heating to a high temperature.
Subsequently, as shown in FIG. 12, the honeycomb body 2 is inserted into the outer cylinder 3 through the tapered portion 13A of the drawing jig 13, and thereafter, as shown in FIGS. The outer peripheral surface 2C of the body 2 and the inner peripheral surface 3C of the outer cylinder 3 are joined by brazing to form the metal honeycomb carrier 1.

According to the above configuration, the crest portion 6 of the corrugated plate 5 can be formed by the crest portion gear device 10 including the pair of crest portion forming gears 10A, 10A. At the same time, a pair of corrugated molded gears 11A, 11A
The crest portion 7 of the corrugated plate 5 can be formed by the crest portion gear device 11 composed of.

[0030] Then, the wave height portion for molding the gear 10A with the module M ₁ and the module M ₁ of the wave lower portion for molding the gear 11A of the crest portion for molding the gear 10A is turned in the same length 1
Curve length L ₂ per pitch curve length L ₁ and wave low portion molding gear 11A per pitch has become the same length, and the tooth height of the waves lower portion for forming gear 11A H ₄ wave height portion is lower than the tooth height H ₃ of the use molded gears 10A, crest portion 6 of the corrugated plate 5, the peak height of the Namihiku section 7 causes the differences in wave width direction, the pitch in the long, also the wave height of the wave plate 5 The length of the curve per pitch in the longitudinal direction of the portion 6 and the crest 7 can be made equal.

Further, since the crest gear unit 10 and the crest gear unit 11 are installed at a predetermined interval C in the crest direction, crest portions 6 and crest portions 7 having different peak heights in the crest direction.
The gradual change portion 8 can be formed in between. Then, the amount of elongation in the gradually changing portion 8 of the corrugated sheet 5 can be reduced, and the difference in the amount of elongation between the crest portion 6 and the crest portion 7 can be reduced. Therefore, the gradually changing portion 8 of the corrugated plate 5
This has the effect of preventing breakage due to elongation in

In this embodiment, the crest 6 is
Its cross section is composed of a sine curve,
Has a cross-section in which one peak is a trapezoidal curve, but is not limited to such a shape as a crest portion and a crest portion. In the present embodiment, the module M ₁ of the crest portion for molding the gear 10A, the wave lower portion for forming gear 11A
Module M ₂ have the same length, and a number of teeth Z ₁ of the crest portion for molding the gear 10A, since the number of teeth Z ₂ waves lower portion for forming gear 11A also has the same number, diameter also the length Although turned, the module M ₁ and the module M ₂ is sufficient if the length. The number of teeth Z ₁ of the crest portion for molding the gear 10A, the number of teeth Z ₂ waves lower portion for molding the gear 11A may not necessarily be the same number. In this case, the diameter of the crest shaped gear 10A is different from the diameter of the crest shaped gear 11A, and it is necessary to control the rotation speed of these gears at an appropriate ratio.

Further, in this embodiment, the corrugated sheet 5 is
Made of ferrite stainless steel alloy, Cr 10% -40%, Al (aluminum) 1
% To 7%. Although the plate thickness is set to 30 μm to 80 μm, it is not limited to such a material and thickness. In the metal honeycomb carrier according to the first embodiment of the present invention, the corrugated plate 6, the corrugated portion 7, and the gradual change portion 8 are formed on the corrugated plate 5.
The above-described crest portion and one or more crest portions, and one or more gradually changing portions between the crest portion and the crest portion can also be configured, but in such a case, a metal An apparatus for forming a corrugated sheet of a honeycomb carrier includes at least one gear device for crest portions corresponding to at least one crest portion, and at least one gear device corresponding to at least one crest portion.
It can also be configured with the above gear device for crests.

[0034]

As described above, according to the first aspect of the present invention, the crest portion and the crest portion of the corrugated sheet have the same pitch even if the crest height is different in the wave width direction. ,Also,
Since the curve length per pitch of the crest portion and crest portion of the corrugated sheet is the same, there is no significant difference in the elongation amount of the crest portion and crest portion of the corrugated sheet. Breakage due to elongation at the deformed portion can be prevented, and when a corrugated sheet is formed from a flat material, it can be formed straight without being bent in the traveling direction.

According to the second aspect of the present invention, a crest portion gear device including a pair of crest portion formed gears provides:
The crest of the corrugated sheet can be formed. At the same time, the crest portion of the corrugated sheet can be formed by a crest portion gear device including a pair of crest portion forming gears. The module of the crest shaped gear and the module of the crest shaped gear have the same length, and the curve length per pitch of the crest shaped gear and the pitch of the crest shaped gear per pitch are equal. The curve length is the same, and the tooth height of the wave-forming gear is lower than the tooth height of the wave-forming gear. In addition to the difference, the pitch can be the same length, and the curve length per pitch in the longitudinal direction of the crest portion and the crest portion of the corrugated plate can be the same length.

Moreover, since the gear device for crest portion and the gear device for crest portion are provided at predetermined intervals in the crest direction, a gradually changing portion is provided between the crest portion and crest portion having different peak heights in the crest direction. Can be formed, the amount of elongation in the gradually changing portion of the corrugated sheet can be reduced, and the difference in the amount of elongation between the crest portion and the crest portion can be reduced. Therefore,
This has the effect of preventing breakage due to elongation in the gradually changing portion of the corrugated sheet.

[Brief description of the drawings]

FIG. 1 is a perspective view of a corrugated plate of a metal honeycomb carrier according to an embodiment of the present invention.

FIG. 2 is a side view of the corrugated sheet showing a II section and a II-II section of FIG. 1;

FIG. 3 is an enlarged perspective view of the corrugated sheet of FIG. 1;

FIG. 4 is a perspective view of a honeycomb body in the course of manufacturing.

FIG. 5 is a cross-sectional view of the metal honeycomb carrier.

FIG. 6 is a longitudinal sectional view of the metal honeycomb carrier.

FIG. 7 is a plan view of an apparatus for forming a corrugated sheet of a metal honeycomb carrier according to an embodiment of the present invention.

FIG. 8 is a front view of the corrugated sheet forming apparatus.

FIG. 9 is a perspective view of an apparatus for forming the same corrugated plate.

FIG. 10 is an explanatory view of a molded gear for wave height section.

FIG. 11 is an explanatory view of the formed gear for low wave portion.

FIG. 12 is a sectional view showing a state before the honeycomb body is inserted into the outer cylinder.

FIG. 13 is a cross-sectional view showing a state before a conventional honeycomb body is inserted into an outer cylinder.

FIG. 14 is a conventional corrugated sheet forming apparatus for a metal honeycomb carrier.

FIG. 15 is a plan view illustrating a case where a crest portion and a crest portion are formed on a corrugated sheet of a metal honeycomb carrier according to the related art.

FIG. 16 is a side view showing a case where a crest portion and a crest portion are formed on a corrugated plate of a conventional metal honeycomb carrier.

FIG. 17 is a plan view of a defect in a case where a crest portion and a crest portion are formed on a corrugated sheet of a conventional metal honeycomb carrier.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Metal honeycomb carrier 5 Corrugated sheet 6 Crest part 7 Crest part 8 Slowly changing part 9 Forming device 10 Gear part for crest part 10A Forming gear for crest part 11 Gear device for crest part 11A Forming gear for crest part C Interval

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification code FI B21D 13/04 B21D 47/00 A 47/00 F01N 3/28 301P F01N 3/28 301 B01D 53/36 ZABC

Claims (2)

(57) [Claims] A crest portion (6) formed along one side in the longitudinal direction, and a crest portion (6) formed along the other side in the longitudinal direction and formed lower than the crest portion (6). It has a crest portion (7) having the same pitch, and a gradually changing portion (8) formed between the crest portion (6) and the crest portion (7). A corrugated sheet of a metal honeycomb carrier, wherein the curve lengths (L ₁ , L ₂ ) per pitch of the portion (7) are the same. 2. The metal honeycomb carrier (1) according to claim 1,
A pair of wave height forming gears having a module of a predetermined size.
(10A, 10A) crest gear device (10)
And a module having the same length as the module of the crest shaped gear (10A).
Wheel, crest shaped gear (10A) per pitch
Curve length (L₁) And the length of the curve per pitch (L
_Two), Tooth height (H) of the wave shaped gear (10A)₁)Than
Low tooth height (H _Two) Having a pair of corrugated molded gears
(11A, 11A) gear device for wave crest (11)
The gear device for crest portion (10) and the gear device for crest portion (11)
Indicates that they are installed at a predetermined interval (C) in the wave width direction.
Characteristic apparatus for forming a corrugated sheet of a metal honeycomb carrier.