JP3226117B2 - Method of winding honeycomb body for metal carrier - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for winding a flat plate and a corrugated sheet of a metal foil honeycomb body used as a metal carrier of a purification catalyst for purifying exhaust gas from automobiles and the like.
In the honeycomb body wound by the method of the present invention, the characteristics of the obtained metal carrier are maximized by using diffusion bonding for bonding the flat plate and the corrugated plate.

[0002]

2. Description of the Related Art As a carrier of an exhaust gas purifying catalyst mounted on an automobile, a ceramic monolith carrier has conventionally been the mainstream. However, since it is made of ceramics, it has problems such as low thermal conductivity and low catalytic activity in the initial stage of starting and careful handling, and in recent years it has shifted to a metal carrier with a metal foil honeycomb structure. I am doing it.

[0003] This metal carrier is formed into a honeycomb body by laminating a foil-shaped flat plate and a corrugated plate obtained by processing the flat plate into a corrugated shape, and then integrally bonding the flat plate and the corrugated plate. Manufactured. Conventionally, brazing was generally used for this joining.However, the number of steps was large, and the obtained metal carrier had limitations in oxidation resistance and constant temperature durability,
For these reasons, the diffusion bonding method has recently attracted attention.

In the diffusion bonding method, it is necessary that the flat plate and the corrugated plate are in contact with each other in a state where a sufficient and tight surface pressure is applied. However, it is difficult to make the wave height of the corrugated sheet uniform without deviation, and simply rolling the flat sheet and the corrugated sheet is insufficient in surface pressure to obtain a uniform and strong joint. It was difficult.

[0005]

SUMMARY OF THE INVENTION Accordingly, the applicant of the present application
Japanese Patent Application No. 2-306833 discloses a method of winding a flat plate while applying a constant rearward tension thereto, and then performing diffusion bonding. According to this method, the honeycomb body is wound tightly,
Since the flat plate and the corrugated plate are strongly adhered to each other, high bonding strength can be obtained.

In the above winding method, for example, when winding a honeycomb body having a radius of 45 mm, there is a close relationship between the tension of the flat plate and the bonding strength as shown in FIG. 5, and the tension of the flat plate increases. Accordingly, the joining strength also increases. However, when wound with a tension t exceeding 4.4 kgf,
There is a problem that the corrugated sheet at the center of the honeycomb body is crushed.

[0007] When the tension is kept constant as described above, the closeness of the flat plate and the corrugated plate at the center and the outer periphery of the honeycomb body are considered to be equal, and the bonding strength is also considered to be equal. However, the reason why only the corrugated sheet at the center is crushed is that the axial torque increases as the honeycomb body is wound, and as a result, the corrugated sheet at the center is crushed at a later stage of the winding.

On the other hand, when wound with a constant tension of less than 4.4 kgf, the corrugated sheet does not collapse, but the bonding strength is reduced over the entire metal carrier, and there is a problem in durability.
The present invention has been made in view of such circumstances,
An object of the present invention is to prevent collapse of a corrugated sheet and sufficiently secure bonding strength.

[0009]

According to the present invention, there is provided a method for winding a honeycomb body for a metal carrier, which comprises the steps of: A method for winding a honeycomb body for a metal carrier for manufacturing a honeycomb body according to the above, comprising: tension applying means for applying tension to a flat plate supplied from a flat plate feeding roller; and a winding shaft of the honeycomb body during winding. Measuring means for directly or indirectly measuring the torque of the coil, and controlling the tension applying means so that the torque measured by the measuring means always falls within a certain range. It is characterized by turning.

[0010]

[0011]

According to the winding method of the present invention, the flat plate is wound on the corrugated plate while being tensioned by the tension applying means. Here, the torque of the winding shaft is constantly monitored by the measuring means, and the tension applying means is controlled so that the torque is always in a constant range. That is, the tension is increased in the early stage of winding because the diameter of the honeycomb body is small, and the tension is decreased in the late stage of winding because the diameter of the honeycomb body is large. As a result, the torque of the winding shaft can be kept constant from the beginning to the end of the winding, and the corrugated plate is prevented from being crushed. Further, the maximum tension can be applied to the flat plate within a range where the corrugated plate does not collapse, so that the bonding strength during diffusion bonding is improved.

[0012]

The present invention will be specifically described below with reference to examples. (Preliminary experiment) Here, three levels of tension t of 4, 8, and 16 kgf were selected, and the minimum radius r of the honeycomb body, at which the corrugated sheet collapsed when wound while applying the tension to a flat plate, was measured. FIG. 3 shows the result of calculating the torque T (T = t × r) of the winding shaft. According to FIG. 3, the shaft torque T is about 0.2 kgf.
・ It was found that the corrugated sheet was crushed when it exceeded m. (Example) Based on the above results, the winding method of this example was performed.

First, FIGS. 1 and 2 show schematic structural explanatory views of a winding device used in this embodiment. The winding device includes a flat plate feeding roller 1, a base roller 2, and a winding roller 3.
, The control device 4, and the guide rollers 21, 22, and 23. A disk 10 is fixed coaxially to the flat plate feeding roller 1, and a brake 1
1 is provided. The disk 10 is a flat plate feeding roller 1
At the same time, it rotates so that the rotation of the flat plate feeding roller 1 is braked via the disk 10 according to the driving condition of the brake 11.

A rotating shaft of a motor 30 is connected to the winding roller 3 and is driven to rotate by the motor 30. A gear 31 is fixed to a rotation shaft of the motor 30, and the gear 31 is screwed to a gear 33 fixed to a torque sensor 32. That is, the torque sensor 32 detects the torque generated on the rotating shaft of the motor 30, and outputs a signal corresponding to the detected torque.

A signal from the torque sensor 32 is input to the controller 4, and the controller 4 compares the signal with a reference value and outputs a signal for adjusting the driving state of the brake 11.
That is, when the signal from the torque sensor 32 is larger than the reference value, the braking force of the brake 11 is reduced, and when the signal from the torque sensor 32 is smaller than the reference value, the braking force of the brake 11 is increased. Is configured to be output.

In the winding device configured as described above, a flat plate 5 in the form of a foil having a thickness of about 50 μm is wound around the flat plate feeding roller 1, and the flat plate 5 is moved from the guide rollers 21 and 22 to the base roller 2. And is supplied from the guide roller 23 to the winding roller 3. The winding roller 3 is supplied with a corrugated sheet 6 from a supply source (not shown), and the flat plate 5 and the corrugated sheet 6 are superposed and wound on the winding roller 3. When winding, the flat plate 5 has a pulling force from the winding roller 3,
Tension is generated by the braking force of the brake 11 (tension applying means).

Then, the motor 30 and the brake 11 were adjusted so that the tension acting on the flat plate 5 fed from the flat plate feeding roller 3 became 10 kgf at the initial stage of feeding, and winding was started. Then, while performing feedback control of the pressure of the brake 11 so that the torque detected by the torque sensor 32 becomes 0.18 ± 0.005 kgfm, the radius r =
A 45 mm honeycomb body was wound.

That is, when the torque sensor 32 notifies that the torque has exceeded the predetermined value, the control device 4 sends a signal to the brake 11 to decrease the braking force. Thereby, the braking force of the brake 11 is weakened, and the tension acting on the flat plate 5 is weakened, so that the torque is reduced. Conversely, when the torque is lower than the predetermined value, the control device 4 sends a signal for increasing the braking force of the brake 11. As a result, the brake 11 brakes the flat plate feeding roller 1, and the torque acting on the flat plate 5 is increased, thereby increasing the torque.

As described above, the control device 4 constantly monitors the torque and winds the flat feed roller 1 while controlling the braking force. FIG. 4 shows the relationship between the tension acting on the flat plate 5 and the radius of the wound honeycomb body at this time. FIG. 4 shows that the tension t decreases as the radius r of the honeycomb body increases. However, the tension t is 4 kgf at the minimum and 10 kgf at the maximum, which is much larger than the conventional one.

In the obtained honeycomb body, no collapse of the corrugated sheet occurred even at the center. When the obtained honeycomb body was subjected to diffusion bonding, the bonding strength was sufficiently large at the center and gradually decreased toward the outer periphery, but a metal carrier having no practical problem was obtained.

[0021]

Therefore, according to the winding method of the present invention,
The tension of the flat plate can be maximized in a range where the corrugated sheet does not collapse, and the diffusion bonding strength can be improved while preventing the collapse of the corrugated sheet. In addition, the tension acting on the flat plate differs between the central portion and the outer peripheral portion of the honeycomb body, and the joining strength is larger at the central portion and smaller at the outer peripheral portion, but the joining strength at the central portion is extremely large as compared with the conventional case. There is no practical problem since it only gradually decreases toward the outer periphery.

[Brief description of the drawings]

FIG. 1 is a plan view illustrating a schematic configuration of a winding device used in an embodiment of the present invention.

FIG. 2 is a front view illustrating a schematic configuration of a winding device used in one embodiment of the present invention.

FIG. 3 is a graph showing a relationship between a radius of a honeycomb body and a torque in one embodiment of the present invention.

FIG. 4 is a graph showing the relationship between the radius of the honeycomb body and the tension of the flat plate when the torque is constant in one embodiment of the present invention.

FIG. 5 is a graph showing the relationship between the tension of a flat plate and the diffusion bonding strength in a conventional winding method.

[Explanation of symbols]

1: Flat plate feed roller 2: Base roller 3: Winding roller 4: Control device 5: Flat plate 6: Corrugated plate 10: Disk 11: Brake 30:
Motor 32: torque sensor (measuring means)

──────────────────────────────────────────────────続 き Continuation of front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B01J 21/00-37/36 B01D 47/00

Claims (1)

(57) [Claims] 1. A method for winding a honeycomb body for a metal carrier, wherein a flat plate supplied from a flat plate feeding roller is wound on a corrugated sheet so as to produce a cylindrical honeycomb body. and tensioning means for imparting tension to the supplied flat plate, directly the torque of the winding axis of the honeycomb body at the time of winding or the measuring means to indirectly measure provided, was measured by the measuring means A method of winding a honeycomb body for a metal carrier, wherein the winding is performed while controlling the tension applying means so that the torque is always in a constant range.