JP3811487B2 - Method and apparatus for manufacturing honeycomb body - Google Patents

Description

  The present invention relates to a method and an apparatus for manufacturing a honeycomb body that can be used for a metal carrier. This manufacturing method and manufacturing apparatus are particularly suitable for use in manufacturing a metal carrier by diffusion bonding.

  A general honeycomb body is manufactured by winding a flat plate made of metal foil and a corrugated corrugated sheet in a spiral shape around a winding shaft. At this time, in order to bring the top portion of the corrugated plate and the flat plate into contact with each other, a tension in the rearward direction relative to the winding direction, that is, a rear tension is applied to the flat plate.

This rear tension is normally generated by the mechanism shown in FIG. In this mechanism, a flat plate W ₁ is wound around a foil material reel 80, and a brake 81 is provided on the shaft of the foil material reel 80. If by this mechanism, by operating the brake 81, is imparted a backward tension F in a plate W ₁ between the winding unit (not shown) with the foil material reel 80. Further, the rear tension may be generated by the mechanism shown in FIG. In this mechanism, a tension generating unit 82 composed of a cylinder or the like is provided between the foil material reel 80 around which the flat plate W ₁ is wound and the winding unit. In the case of this mechanism, a rear tension F is applied to the flat plate W ₁ by extending the rod of the cylinder.

As a method for measuring the generated rear tension F, the mechanism shown in FIG. 6 or FIG. 7 is usually employed. That is, the flat plate W ₁ is supplied horizontally from the foil material reel 80, and the three rollers 90 to 92 are provided so as to be rotatable around a horizontal rotation axis. The central roller 91 is provided via a load meter 93 such as a load cell. In the mechanism shown in FIG. 6, the flat plate W ₁ is provided so that the lower surface of the roller 90, the upper surface of the roller 91, and the lower surface of the roller 92 can be sequentially advanced. Further, in the mechanism shown in FIG. 7, the flat plate W ₁ is provided so that the upper surface of the roller 90, the lower surface of the roller 91, and the upper surface of the roller 92 can be sequentially advanced. During these periods, the rear tension F generated by the brake 81 or the like is measured by the load meter 93.

During this time, each of the rollers 90 to 92 is slightly shaken, which may cause the flat plate W ₁ to meander horizontally with respect to the corrugated plate and winding shaft (not shown), but the meandering of the flat plate W ₁ is not shown. It is corrected by a fixed guide that is placed on the base of the machine. Then, the deviation between the flat plate W ₁ and corrugated plate which can not be corrected by the fixed guides, is corrected by the pressing force of the application to the end face of the honeycomb body after winding.

The honeycomb body obtained in this way is joined by brazing the contact portion between the flat plate W ₁ and the corrugated plate so that the gap between the flat plate W ₁ and the corrugated plate forms a porous structure, and is housed in the outer cylinder. Used as a carrier. The metal carrier has a catalyst support layer formed on a porous inner surface, and serves as an exhaust gas purifying catalyst.

  However, in the above-described conventional manufacturing method, the rear tension measured by the load meter 93 is confirmed in the quality inspection of the honeycomb body after winding and heat treatment, and the rear tension is not changed during winding. Not. This is because in the conventional brazing honeycomb body, the contact portion between the flat plate and the corrugated sheet is joined by brazing in a later process, so that a high rear tension is not required and the rear tension is not required to be managed as much. Because. For this reason, in the conventional manufacturing method, the quality of the honeycomb body cannot be confirmed in the middle of winding, and a honeycomb body in which the contact between the flat plate and the corrugated sheet is not uniform may be manufactured.

  Moreover, in the said conventional manufacturing method, the meandering of a flat plate is only corrected by the fixed guide fixed to the fixed base. This is because the conventional brazing honeycomb body does not require such a high rear tension, so that it is easy to correct the meandering of the flat plate even with the fixed guide, and the slight deviation between the flat plate and the corrugated plate is after winding. This is because it is thought that correction is possible by applying a pressing force to the end face. However, if the swaying of each roller increases due to long-term use, the flat plate meanders, and the flat plate and the corrugated plate are wound with a large deviation in the horizontal direction. Even if a pressing force is applied to the end face of the honeycomb body obtained in this way, a flat plate having low rigidity buckles and closes a part of the pores, resulting in a defective product.

  In particular, in recent years, a honeycomb body joined by diffusion bonding is being applied to a metal carrier in order to easily join a contact portion between a flat plate and a corrugated plate (for example, Patent Document 1). When manufacturing the honeycomb body for diffusion bonding, similarly to the above, it is for diffusion bonding by winding a flat plate to which backward tension is applied and the corrugated sheet in a spiral manner around the winding shaft. A honeycomb body is manufactured. The contact portion between the flat plate and the corrugated sheet of the obtained diffusion bonding honeycomb body is bonded by performing diffusion bonding. In this honeycomb body for diffusion bonding, it is necessary to ensure the contact surface pressure in order to increase the bonding strength between the flat plate and the corrugated sheet, and it is possible to stably apply a high rear tension according to the state of the honeycomb body during winding. is necessary.

  Here, when manufacturing the honeycomb body for diffusion bonding, similarly to the above-described conventional manufacturing method, it is possible to wind with applying a high rear tension while measuring the rear tension with three rollers or the like. Conceivable. In this case, it is also conceivable to correct the meandering of the flat plate with a fixed guide fixed to a stationary base, as in the conventional manufacturing method.

  However, when the diffusion bonding honeycomb body is manufactured by the conventional manufacturing method as described above, it is easy to be greatly affected by the minute shaking of each roller due to the high rear tension, and the plate meandering manufactures the brazing honeycomb body. It will be bigger than if you do. If the meandering of the flat plate is corrected by a conventional fixed guide, the flat plate rides on the fixed guide or the end portion buckles by the fixed guide. In order to avoid this, if the width of the fixed guides is increased, the flat plate and the corrugated plate are wound with a larger displacement in the horizontal direction. The honeycomb body thus obtained is strongly wound, so that the honeycomb body itself has high rigidity, and is not corrected by applying a pressing force to the end face, and the honeycomb body has a part of the porous plate closed. It is easy to produce.

The present invention has been made in view of the above-described conventional situation, and an object of the present invention is to provide a method and an apparatus for manufacturing a honeycomb body that can prevent the occurrence of defective honeycomb bodies based on meandering of flat plates. . This purpose is particularly significant when manufacturing a diffusion bonding honeycomb body that requires high back tension.
Japanese Patent Laid-Open No. 4-180839

The method for manufacturing a honeycomb body of the present invention includes a honeycomb body that is manufactured by winding a flat plate provided with rear tension and a corrugated corrugated sheet in a spiral manner around a winding shaft. In the manufacturing method of
The corrugated plate is provided so as to be movable in synchronization with meandering of the flat plate parallel to the winding shaft.

  The honeycomb body manufacturing apparatus of the present invention has a tension generating unit that applies a rear tension to a flat plate, and a flat plate that is provided with a rear tension and a corrugated corrugated sheet that are spirally wound around a winding shaft. A winding unit that winds, and a movable guide unit that is provided between the tension generation unit and the winding unit and moves the corrugated plate in synchronization with a meandering plate parallel to the winding shaft. To do.

  Since the corrugated plate is movably provided in synchronism with the meandering of the flat plate parallel to the winding axis, even if the meandering occurs on the flat plate, the corrugated plate can be wound while preventing the horizontal deviation between the flat plate and the corrugated plate.

  If a honeycomb body is manufactured by the honeycomb body manufacturing method and manufacturing apparatus of the present invention, it is possible to prevent the occurrence of defective products.

  In particular, the method and apparatus for manufacturing a honeycomb body according to the present invention has a great significance when manufacturing a honeycomb body for diffusion bonding that requires high backward tension.

(Example)
DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments embodying the present invention will be described below with reference to the drawings.

An outline of a manufacturing apparatus used in this manufacturing method will be described. In this manufacturing apparatus, as shown in FIG. 1, a flat plate W ₁ can be supplied horizontally from a foil material reel (not shown). In the supply direction of the flat plate W _1, a tension generating unit 1, a circumference measuring unit 2, The movable guide unit 5 and the winding unit 3 are sequentially arranged. The tension generating unit 1, the circumference measuring unit 2 and the winding unit 3 are connected to a microcomputer 4.

In the tension generating unit 1, the lower plate 11 is fixed to a stationary base (not shown), and the upper plate 12 facing the lower plate 11 is fixed to a rod of the cylinder 13. The cylinder 13 is connected to the control valve 14, and the control valve 14 is connected to the microcomputer 4. The flat plate W ₁ is supplied between the lower plate 11 and the upper plate 12, and is sandwiched between the lower plate 11 and the upper plate 12 by extension of the rod of the cylinder 13, and a rear tension F is applied. It has become so.

In the circumference measuring unit 2, a roller 21 that can come into contact with the upper surface of the flat plate W ₁ is provided so as to be rotatable around a horizontal rotation axis, and this rotation axis is provided so as to be movable up and down by a cylinder 22. An encoder 23 is connected to the rotation shaft of the roller 21, and the encoder 23
Is connected to the microcomputer 4.

  In the winding unit 3, the winding shaft 31 is provided to be rotatable around a horizontal rotation shaft, and the winding shaft 31 is driven by a motor 35 via gears 32, 33 and a torque sensor 34. ing. The torque sensor 34 is connected to the microcomputer 4. A corrugated plate (not shown) is supplied to the winding shaft 31 from between the circumference measuring unit 2 and the winding unit 3.

The configured manufacturing apparatus as described above, by rotating the motor 35, the winding shaft 31 is rotated in the drawing counterclockwise rotation, while overlapping a flat plate W ₁ and the corrugated plate, around the winding shaft 31 Wind in a spiral. Since the roller 21 of the circumference measuring unit 2 is in contact with the flat plate W ₁ with a relatively small pressure, the meandering of the flat plate W ₁ does not occur. Thus, a diffusion bonding honeycomb body is manufactured.

  The configuration and operation of the movable guide unit 5 will be described below.

As shown in FIG. 1, in the movable guide unit 5 provided between the circumference measuring unit 2 and the winding unit 3, as shown in FIGS. 2 and 3, below the flat plate W ₁ and the corrugated plate W ₂ . the servo motor 51 is provided, the flat plate W ₁ and the traveling direction and parallel to the ball screw 52 of the corrugated plate W ₂ is rotatably provided to the servo motor 51. A ball nut 53 is screwed to the ball screw 52, and a movable base 54 is fixed to the ball nut 53. A slide base 55 is provided on the movable base 54 so as to be slidable parallel to the take-up shaft 31, and flat plate guides 55 a and 55 b protrude upward on both sides of the slide base 55. Corrugated plate guides 56a and 56b are respectively fixed to the outside of the slide table 55 via brackets so as to be positioned above the flat plate guides 55a and 55b. The corrugated plate guides 56a and 56b are respectively connected to the slide table 55 and springs. They are connected by 57a and 57b. Incidentally, the spring 57a, 57 b does not have a large biasing force enough to buckle the flat plate W ₁ and the corrugated W _2.

In manufacturing apparatus to which the movable guide unit 5 is provided, if the meandering flat W ₁ in FIG. 3, for example by the use of a long period of time or the like to the right, the flat plate W ₁ is flat guide 55a and abuts the slide board 55 is right To slide. Therefore, the corrugated sheet guide 56a, 56b to slide to the right against the biasing force of the spring 57a, 57 b, corrugated sheet W ₂ also moves to the right. At this time, if the flat plate W ₁ only slightly meanders, the meandering is corrected by the urging force of the springs 57a and 57b. The same applies to the reverse case. Then, as the winding of the flat plate W ₁ and the corrugated plate W ₂ proceeds, the ball screw 52 is rotated to bring the position of the movable base 54 closer to the winding unit 3.

Thus, in this manufacturing apparatus, since moving the corrugated sheet W ₂ in synchronization with the wobbling of the winding shaft 31 and the parallel flat plate W _1, even if the meandering flat W _1, and the flat plate W ₁ corrugated plate Winding can be performed while preventing horizontal displacement from W ₂ .

Further, in this manufacturing apparatus, the flat plate W ₁ and the corrugated plate W ₂ can be wound while being reliably guided by the rotation of the ball screw 52, so that meandering of the flat plate W ₁ can be prevented more than before.

Therefore, according to this manufacturing method, it is possible to prevent the occurrence of defective products, such as flat plate W ₁ is closed a portion of the porous.

Note that thus obtained honeycomb body, after being housed in the outer tube, the gap between the flat plate W ₁ and the corrugated plate is so as to constitute a porous, is a metal carrier diffusion bonded. This metal carrier has a catalyst support layer formed on a porous inner surface, and serves as an exhaust gas purifying catalyst.

It is a schematic block diagram of the manufacturing apparatus which concerns on the manufacturing method of the Example of this invention. It is a model side view of the movable guide unit in the manufacturing apparatus which concerns on the manufacturing method of the Example of this invention. It is a model front view of the movable guide unit in the manufacturing apparatus which concerns on the manufacturing method of the Example of this invention. It is a schematic block diagram which shows the generation | occurrence | production mechanism of the back tension which concerns on the conventional manufacturing method. It is a schematic block diagram which shows the generation | occurrence | production mechanism of the back tension which concerns on the conventional manufacturing method. It is a schematic block diagram which shows the measurement mechanism of the back tension which concerns on the conventional manufacturing method. It is a schematic block diagram which shows the measurement mechanism of the back tension which concerns on the conventional manufacturing method.

Explanation of symbols

F: Back tension W ₁ ... Flat plate W ₂ ... Corrugated plate 31 ... Winding shaft 5 ... Movable guide unit

Claims (5)

In a method for manufacturing a honeycomb body, a flat plate provided with a back tension and a corrugated sheet formed in a wavy shape are wound around a winding shaft in a spiral shape to manufacture a honeycomb body.
The method for manufacturing a honeycomb body, wherein the corrugated plate is provided so as to be movable in synchronization with meandering of the flat plate parallel to the winding shaft.   A tension generating unit for applying a rear tension to the flat plate, a winding unit for winding the flat plate to which the rear tension is applied and a corrugated corrugated sheet around the winding shaft in a spiral manner; A movable guide unit provided between a tension generating unit and the winding unit and moving the corrugated plate in synchronization with meandering of the flat plate parallel to the winding shaft. Manufacturing equipment. The movable guide unit includes a slide base that slides parallel to the winding shaft, a flat plate guide that protrudes upward on both sides of the slide base, and an outer side of the slide base. A corrugated plate guide fixed to be positioned above the flat plate guide,
When the flat plate snakes and the flat plate guide contacts the flat plate, the slide base slides in the same direction as the flat plate meanders, and the corrugated plate guide fixed to the slide base The apparatus for manufacturing a honeycomb body according to claim 2, wherein the corrugated sheet is brought into contact with the corrugated sheet and moves in synchronization with the sliding of the slide base.   The movable guide unit further includes a movable base, a ball nut to which the movable base is fixed, a ball screw to which the ball nut is screwed, and a servo motor that is rotatably provided with the ball screw, The honeycomb body manufacturing apparatus according to claim 3, wherein the slide base is slidably held on the movable base.   The honeycomb body manufacturing apparatus according to claim 4, wherein the ball nut, the ball screw, and the servo motor bring the position of the movable base closer to the winding unit as the winding of the flat plate and the corrugated plate proceeds.

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