JPH0258097B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a roller apparatus for forming a corrugated strip, and more particularly to a corrugated strip having a chevron pattern of corrugations.

In the art of producing corrugated strips with chevron patterns using roller equipment, it is known that cracking and tearing of the material can be minimized in several ways. For example, a thicker or more ductile material may be chosen, or the corrugation pattern may be varied so that the radius of the roller arrangement is sufficiently large at the point of peak stress to significantly reduce maximum strain. However, as the material thickness increases, the dimensions
This adds weight and cost, and highly ductile materials may not be suitable for the intended application. On the other hand, changing the corrugation pattern to avoid cracking or tearing, for example by increasing the radius at the angular join points of diagonal chevron stripes, generally results in higher tooling costs. Moreover, as the waveform pattern thus obtained approaches a sinusoidal waveform, it may become unsuitable for end use. Therefore, all of these methods limit design flexibility.

For example, it is known that highly effective monolithic catalytic converter materials for automotive applications can be constructed from corrugated metal foil strips having a continuous, laterally extending corrugated linear stripe chevron pattern. Because of this application, material selection is constrained, and even if suitable heat resistant alloys are available, most have low ductility. One solution to avoid cracking and tearing during corrugation is to increase the thickness of the foil, but this comes at the expense of increasing the size, weight, and cost of the converter. Alternatively, if a straight striped chevron pattern is employed, the heat transfer is sufficiently high, the friction is low, and the pressure drop is small, but it is necessary to use tools to curve the corrugated pattern to avoid cracking or tearing the foil. Not only does this increase the cost of this process, but it can also have a negative impact on the performance of the single substance obtained in this way.

As arrived at the invention, the corrugations of the chevron or twill pattern are inclined at an angle to the direction of feeding the strip onto the roller;
It was found that biaxial strain occurs in the material because the direction of the corrugation is reversed across the strip width. If the magnitude of these biaxial strains exceeds the maximum allowable strain for the material, cracking or tearing will occur.

Analyzing the magnitude of the strain that occurs during roll forming, we find that the strain state is ``forward'' in the waveform.
There is a smooth transition across the strip width from a nearly balanced biaxial strain at the root of what we will refer to as the V to a uniform strain at the root of what we will hereafter refer to as the "backwards" V of the waveform. I found out what to do. "forward",
The "backwards" nomenclature considers the chevron pattern (which can also be called a twill pattern) to be comprised of a collection of V-shaped elements. If the V-shaped element points in the same direction as the direction of movement of the strip material past the rollers, it is considered a forward-facing V-shaped element. On the other hand, if the V-shaped element points in a direction opposite to the direction of movement of the strip material through the rollers, it is considered a backward V-shaped element. It has been found that the most detrimental condition caused by the formation of chevron or twill straight stripe corrugations is the balanced biaxial strain created at the tip of the forward facing V.

The present invention approaches the root cause of the cracking/splitting problem at the tip of a forward-facing V-shape. In accordance with the present invention, it is possible to obtain an improved roller device having a simple and low cost construction, which roller device can produce a desired chevron or twill pattern of corrugations while using thicker material than previously possible. or require any changes to be made. Typically, the roller system includes a pair of toothed rollers, each roller having continuously laterally extending teeth that conform to the desired chevron or twill pattern. According to the invention, each roller is provided with individual transverse rows of teeth, which rows extend non-continuously but intermittently across the roller, such that selected teeth of each row are discontinuous with respect to each other. . This selection is made such that the toothed roller does not have any forward-facing V-tips, but conforms to the desired waveform. Nevertheless, due to the tensile action of the adjacent teeth, a forward V is completely formed in the strip material in the toothless roller region, distributing and reducing the strain in the forward V-shaped corrugation region. produces a waveform. In a preferred embodiment of the improved roller system, each roller includes a set of toothed wheels arranged side by side, with the teeth of each wheel all being diagonally arranged at the same angle. In some embodiments, the forward-facing V-tips are simply removed by chamfering the ends of the teeth around the entire circumference of two adjacent wheels at that location. In another embodiment, the same effect is achieved by simply providing a spacer between the toothed wheels so that each tooth forms the tip of a forward-facing V. Furthermore, if the uniform strain conditions created at the tip of the backward V are likely to promote cracking and tearing, such as when using thicker materials, the tip of the backward V may also form a perfect corrugation. The tooth can be removed in the same way, leaving the tooth intact.

These and other objects, advantages, and features of the present invention will become more apparent from the following description and drawings.

Referring to the drawings, FIGS. 1-4 show a first embodiment of a roller apparatus constructed in accordance with the present invention and capable of forming the wavy strip shown in FIG.
A roller type corrugating machine 10 is shown including two. The corrugating machine includes a base 14 having an integral pedestal 16, a pair of parallel rectangular side frame plates 18, 20 bolted to the sides of the base and pedestal, and a leg of each side frame plate 18, 20. It includes a pair of parallel L-shaped lever arms 22, 24 which extend from the pedestal 16 and are pivotally connected at their tips to opposite sides of the pedestal 16 by shoulder bolts 26, 28.

The roller device includes a pair of toothed rollers 30, 32 arranged one on top of the other, with an upper roller 30
is rotatably supported between and by the lever arms 22, 24 via an axle 34, and the lower roller 32 is rotatably supported between and by the side frame plates 18, 20 via an axle 36. freely supported. The strip to be corrugated is fed from right to left across the top 38 of the pedestal between toothed rollers, with the aid of a flat roller pin 40 supported on the pedestal as shown. two rollers 30, 32
The corrugating teeth are meshing gears 42, 44.
They operate synchronously so that they mesh with each other while maintaining a gap with respect to each other. These gears also act as a driving connection for the rollers and the side frames.
They are attached by tapered pins 46, 48 to integral and respective extensions 50, 52 of respective shafts 34, 36 projecting outwardly from plate 18 and lever arm 22, respectively.

The drive force to the toothed rollers from a suitable power source, for example a reduction motor (not shown), is provided by a separate extension 5.
4 and this extension is attached to the other side frame.
A lower roller shaft 3 protrudes outward from the plate 20
6. Therefore, the lower roller 3
2 is driven directly, while the upper roller 30 is driven via meshed gears 42,44.

The depth of the corrugation is controlled by the center-to-center distance between the corrugating rollers, which includes a rotatable upper roller support 22 that acts as a trailing arm;
24. For this adjustment, simply use a pair of setscrews 58, 6.
Only 0 is provided. These set screws are threaded into the swinging ends of the respective lever arms 22, 24 and engage the tops of the respective side frame plates 18, 20. Lateral or lateral movement of the lever arms 22, 24, and thus the upper roller 30, is prevented by a pair of rectangular restraining fingers 62, 64. These restraining fingers are attached to the respective side frame plates 18,
It is bolted to the outer surface of 20, and the adjustment screw 5
8 and 60 are in contact with the outer surface of the lever arm on which it is installed. Once the proper adjustment has been made with the adjustment screw, this position of the rotatable upper roller is fixed by tightening the pair of shoulder bolts 66,68. These shoulder bolts extend downwardly through the respective lever arms 22, 24 between the adjustment screw and the upper roller and are threadedly engaged with the tops of the respective side frame plates 18, 20. It is therefore easier to adjust the rollers 30, 32 to accommodate strip materials of slightly different thickness or ductility.

Turning now to the details of the corrugating rollers 30, 32, each roller is formed with a set of toothed wheels 70 which are identical except for certain important features which will be explained below. The number of wheels 70 is twice the number of chevrons in the pattern (for example, the number of wheels 70 is 16 to make the eight chevron pattern of FIG. 5). Each toothed wheel 70 has a central hole 72 which allows
A toothed wheel is attached to each roller shaft 34, 36.
They are placed side by side on top. The toothed wheel 70 has a respective key slot connection 74,
76, and their axial restraint is provided by radial shoulders 78, 80 integrally formed with the respective axles at one end of the wheel set and at the opposite end. This is done by respective snap rings 82, 84 located at the top.

The teeth 86 of each wheel extend diagonally across that wheel at the same angle, with alternating toothed wheels 70A disposed in an opposite angular orientation to that of the adjacent toothed wheel 70B, and these diagonal teeth 86 extending diagonally across that wheel. The opposite angular orientations of the teeth cause these sets of toothed wheels to define the desired chevron or twill pattern generation pattern for the corrugating rollers 30,32. As mentioned earlier, in the direction of feed of the strip material, the chevron pattern of teeth on the rollers includes V-shaped elements pointing in the forward direction, which is the same as the direction of travel of the strip material through the rollers, and V-shaped elements pointing in the opposite direction, i.e. backwards. element. The forward and backward facing V-shapes formed by intersecting diagonal teeth 86 as previously defined are second and third, respectively.
By means of a set of toothed wheels on each corrugating roller, shown at 88 and 90 in the figure, these Vs are formed at the junction of two adjacent wheels carrying teeth at opposite angles to each other. arise.

In accordance with the present invention, the tip or apex of the forward facing V 88 is located between two adjacent teeth at opposite angles at each forward facing V position, as best seen in Figures 2, 3 and 3a. This is accomplished by forming chamfers 92 on both ends of the teeth around the entire circumference of the wheel. Each of the corrugating rollers 30, 32 is thus formed with transverse rows of individual teeth that extend intermittently, as opposed to normally continuously, across the roller, with selected ones of the teeth in each row (i.e., Teeth forming V-shape 88) are chamfered portions 9
2 are discontinuous with each other (ordinarily they were supposed to be interconnected). Thus, the corrugating roller does not have any forward-facing V-tips, but is consistent with the corrugations of the desired chevron or twill pattern. We are doing so. Nevertheless, the forward-facing V-shaped tip pulls the strip of material in the toothless roller area (i.e., at the paired chamfers 92) by the tensile action of the adjacent teeth 86 forming the forward-facing V-88. It has been found that the distortion is still formed, distributing and weakening the distortion in the forward V-shaped waveform region, creating a complete waveform in the strip. For example, the corrugated strip shown in FIG. 5 has a forward-facing V-tip compared to a rearward-facing V-tip where the corrugated teeth remain continuous, even though they are formed of stainless steel foil using toothed rollers 30, 32. It will be seen that the V-tip is formed relatively blunt.

In addition, if the uniform strain that occurs in the strip material at the tip of the backward V is known to cause cracking and tearing, such as when using thick or less ductile materials, the backward V The tips of the strips may be removed as well and the strip material will still have a perfect corrugation.

The same effect is simply achieved by using a spacer between the toothed wheels whose teeth form the tip of a forward-facing V and secondarily the tip of a rearward-facing V. This is illustrated in the construction of one such corrugating roller in FIG. It should be understood that the other roller is similarly formed. In this embodiment, the toothed rollers shown at 96 are for a double chevron or twill pattern, so that they have a set of only four toothed wheels 98 mounted on the shaft 100 as described above. In this case, the forward-facing V is formed in the strip material by what can be considered as two outer pairs of wheels 98A, and their joints are only made by inserting an annular spacer ring or washer 102 between them. are toothless, leaving what can be considered an adjacent intermediate pair of toothed wheels 98B in forming the tip of the rearward V-shape. As with the previous embodiment, additional spacers may be inserted between the intermediate pair of toothed wheels 98B if the tip of the rearward V is prone to cracking or tearing.

Additionally, in a preferred embodiment, the roller is formed by a set of toothed wheels for ease of manufacture, with a forward-facing V-shaped tip and, secondarily, a rear-facing V-shaped tip with a chamfer to remove the tip. It is to be understood that the corrugating rollers may be arbitrarily configured within the teachings of the present invention to remove teeth that tend to crack or tear the strip material, such as by inserting spacers. . For example, the corrugating roller may be integrally formed and the forward-facing V-tip and, secondarily, the rear-facing V-tip machined away together during tooth formation.

The preferred embodiments described above are illustrative and may be modified and changed within the scope of the following claims.

[Brief explanation of drawings]

FIG. 1 is a side view of a roller-type corrugating machine including an embodiment of a roller device according to the present invention.
FIG. 2 is a top view taken along line 2-2 in FIG. FIG. 3 is a sectional view taken along line 3--3 in FIG. 2. Figure 3a is an enlarged fragmentary view of the toothed wheel of Figure 3; 4 is a perspective view of the corrugating machine of FIG. 1; FIG. 5 is a plan view of a portion of a corrugated metal strip formed by the corrugating machine of FIG. 1; FIG. Figure 6 shows the 5th waveforming machine used in Figure 1.
Figure 3 is a perspective view of another embodiment of a roller device according to the invention, forming a corrugated metal strip similar to that shown with fewer chevrons across it; <Explanation of symbols of main parts>, 30, 32, 96
...Pair of toothed rollers, 86,98...Individual rollers, 88,102...Roller area, 70A,
70B, 98A...Toothed wheel selection pair, 9
2... Chamfered portion, 102... Spacer.

Claims (1)

[Scope of Claims] 1. A pair of toothed rollers for roll-forming continuous transversely extending corrugations on a strip material, the corrugations having a V-shape pointing forward in the direction in which the corrugations are fed between the rollers. a pair of toothed rollers having a chevron pattern, each of said rollers having transverse rows of individual teeth extending intermittently across it, the teeth of each row being discontinuous with respect to each other; Although it does not have any forward facing V-shaped tip,
When the desired corrugation is conformed to and the strip material is rolled between said pair of toothed rollers, the forward facing V-shaped tip in the area of the toothless rollers is caused by the tensile action of the adjacent teeth to form the strip material. a pair of toothed rollers characterized by a pair of toothed rollers formed to produce a perfect corrugation in the strip material while distributing and minimizing strain at the forward facing tip. 2. A pair of toothed rollers according to claim 1, in which a waveform having a chevron pattern having a V-shape pointing back and forth with respect to the direction of the strip fed between the rollers is continuously applied to the strip material in the lateral direction. A pair of toothed rollers for roll forming, each roller having transverse rows of teeth extending intermittently across it, selected teeth of each row of teeth being discontinuous with respect to each other; Any front or back V
It does not have a tip, but it conforms to the desired corrugation, and the tensile action of the adjacent teeth forms an anteroposterior V tip in the strip material in the area of the toothless roller, creating an anteroposterior V tip. A pair of toothed rollers characterized by dispersing and minimizing strain at the edges while producing a perfect corrugation in the strip material. 3. A pair of toothed rollers according to claim 1, in which a waveform having a chevron pattern having a V-shape pointing back and forth with respect to the direction of the strip fed between the rollers is continuously applied to the strip material in the lateral direction. A pair of toothed rollers for roll forming, each roller containing a set of toothed wheels, each toothed wheel having teeth extending diagonally across it at the same angle, and each set of toothed wheels of a selected pair of said toothed wheels arranged side by side and each tooth being inclined in opposite directions to define a lateral row of individual teeth extending across each roller; A pair of toothed rolls characterized in that the teeth in each row have no adjacent teeth and the teeth in each row do not have any forward facing V-shaped tips but conform to a desired corrugation. 4. A pair of toothed rollers according to claim 2, each roller including a set of toothed wheels, each toothed wheel having teeth extending diagonally across it at the same angle. , each set of toothed wheels arranged side by side, each tooth being inclined in an opposite direction to each other, defining a lateral example of an individual tooth extending across each roller; A pair of toothed rollers characterized in that the teeth in each row do not have teeth in adjacent portions, and the teeth in each row do not have any V-shaped tips in the front-back direction, but are made to match a desired waveform. 5. A pair of toothed rollers according to claim 3, wherein the selected pair of toothed wheels has a chamfered portion in the circumferential direction at one end of each tooth, and has no teeth at an adjacent portion. , a pair of toothed rollers characterized in that each row of teeth does not have any forward facing V-shaped tips, but is adapted to conform to a desired corrugation. 6. A pair of toothed rollers as claimed in claim 4, wherein selected pairs of the toothed wheels have circumferential chamfers at both ends of each tooth, and the teeth are provided at adjacent portions. A pair of toothed rollers, characterized in that each row of teeth does not have any forward-facing or backward-facing V-shaped tips, but is made to conform to a desired waveform. 7. A pair of toothed rollers according to claim 3, wherein a spacer is provided between selected pairs of said toothed wheels, and each row of teeth does not have any forward facing V-shaped tip. , a pair of toothed rollers that are adapted to conform to a desired waveform. 8. A pair of toothed rollers according to claim 4, including a spacer separating the toothed wheels from each other, and each row of teeth does not have any forward or backward V-shaped tips, but has a desired waveform. A pair of toothed rollers, characterized in that they are matched with each other.