Device and method for manufacturing the element with a honeycomb structure of the rolled layers of metal sheets

 

(57) Abstract:

The proposed invention discloses a device for the manufacture of an element with a honeycomb structure consisting of a set of typed at least one package to at least partially structured metal sheets forming multiple channels for the passage of fluid. The device includes a pivotable around an axis acting on each package using a twisting device and the locking in solid form the core segments. The shape formed by at least two core segments. Each profile segment can rotate around a respective axis parallel to the axis of the twisting fixture, against the direction of rotation of the latter. The proposed device has a high resistance to impact of external factors, such as dust. 2 C. and 22 C.p. f-crystals, 6 ill.

The invention relates to a device and method for manufacturing the element with a honeycomb structure consisting of a set of at least partially structured metal sheets forming multiple channels for the passage of fluid.

The increasingly stringent requirements of traistaru housings-carriers. As such shells-carriers can be used metal elements with a honeycomb structure. This element consists of a set of typed, for example, in one package at least partially structured metal sheets. This package is rolled into a roll by twisting in opposite directions around the Central zone. This embodiment of the element with a honeycomb structure is known, for example, from U.S. patent 4923109.

From the application WO 90/03220 known metal body vehicle catalytic Converter for vehicles, which consists of at least partially structured metal sheets. This case-storage media includes at least three pack of metal sheets, with at least three of them folded in half along the respective fold lines in the Central area of the element with a honeycomb structure and in such a state folded into a roll by twisting relative to each other in one direction around a Central area where the bend line.

The prior art also known device for the manufacture of such buildings vehicles catalytic converters, including turning around the Central asilinae segments. The inner loop of a closed shape corresponds to the outer contour of the element with a honeycomb structure in its final twisted condition. The most common form, which have elements with a honeycomb structure is cylindrical. In order to ensure the collapse in the coil packs around the Central zone of the core segments are moved toward the package in such a way that during the rotation of the fork twisting device package, respectively, packages, adjacent(ut) to the edge of the core segments, and this region forms the arrester. At the end of the manufacturing process, the mold is completely closed, and the element with a honeycomb structure, thus, is given its final form.

Since the form consists of two core segments, moving towards each other and away from each other, such a device has a relatively complicated construction. In the manufacturing process of the element with a honeycomb structure in such a device, you must continuously comply with the specified consistency of movement of the profile segments. Due to wear and tear, dust, etc. on the guides of the profile segments can form deposits that may violate the consistency of their permesso vehicles catalytic converters, there is a danger that in the process of closing the form of at least one profile segment will continue to move against the direction of movement of the plot package, which has yet to be collapsing into a roll, which can lead to undesirable deformation of the package, respectively packets. The deformation causes a partial bending of the individual sheets. As a consequence, the structure of the element is broken. First, suffers a strength element with a honeycomb structure, and secondly, there is a local change of cross-sections of the channels. The consequence of changing cross-sections of the channels is something that can no longer be ensured uniform distribution of the flow inside an element with a honeycomb structure. However, the flow profile of the exhaust gas flowing through the housing is a carrier of the catalytic Converter, along with other factors is crucial for the catalytic activity of the catalytic Converter.

Proceeding from the above, the present invention was based on the task to improve the known device and method for manufacturing the element with a honeycomb structure so that the manufacturing process there is no risk of deformation of the packages, sootoday external factors, such as dust, dirt, etc.

According to the invention this task is solved by a device with the characteristics of p. formula 1 of the invention and using the method with the stages of its implementation on p. 21. Preferred embodiments of the device, respectively, the method provided in the respective dependent claims.

Proposed according to the invention a device for the manufacture of an element with a honeycomb structure consisting of a set of typed at least one package to at least partially structured metal sheets forming multiple channels for the passage of a fluid medium, in particular of the body of the carrier of the catalytic Converter, includes the shape of the inner contour of which corresponds to the outer contour of the manufactured element with a honeycomb structure, and rotatable around an axis acting on each package using a twisting device. The device is characterized by the fact that the form covers the twisting device and that in the wall of the form is provided by at least one passing mostly parallel to the Central axis through the window for at least one end of the package. The ex is the device do not apply moving relative to each other core segments. This ensures simplicity and efficiency of the design of the device.

When the curl package is most appropriate to skip the last two through the window and roll it into a roll in the middle. However, you can also put in the form of one or more folded double batches so that both ends of each package were passed through one common window. The package can also be captured at one end of the twisting device and rolled-type multiple-spiral. You can also crush the captured part of the package twisting device with the formation of an approximately star-shaped center.

The proposed device allows you to produce devices with a cellular structure, preferably having a circular cross-section, however, you can also make elements with different cross-section, in particular polygonal, but rounded on the corners of the cross sections, if the deviation from the round shape is not very large, i.e., the individual sides have approximately the same length.

For twisting, respectively clotting in coil element with a honeycomb structure, for example, of the three packages, as it Aulnay-through window for all packages. Individual packets injected into the mold through a single window. It is obvious that each package is partially out of shape. Fork twisting device captures in the Central zone of each packet and roll the individual packages relative to each other in the roll. In the twisting process, respectively clotting individual packages are moved through the Windows, sliding on him. The twisting process continues until all the packets will not be fully drawn into the form.

In a preferred embodiment, the device window are equidistant relative to each other along the internal perimeter of the form. The advantage of this arrangement is the possibility of manufacturing element with a honeycomb structure having a symmetric structure, respectively symmetrically twisted. If coagulation is required to receive other structure, it can be provided by appropriate arrangement of the Windows.

In the twisting process, respectively clotting parts of the package, still protruding from the form, gradually drawn inside it. To minimize friction between the package and walls of Windows that occur during the retraction of each package, it is proposed to perform convex in p the com implementation of the longitudinal surface of the window between it and the surface of the package there exists a linear touch, which reduces friction between the longitudinal surface of the window and the package.

Further preferably, the device, in which at least the longitudinal surface of the at least one window provided with anti-friction layer. Thanks to this additionally reduces the friction between the package and the longitudinal surface. In a preferred embodiment, the anti-friction layer is wear-resistant, so that there is only a small number of products abrasion between the package and a longitudinal surface, respectively antifriction layer. For this purpose, especially suitable anti-friction layer of a ceramic material. The anti-friction layer can be applied on the longitudinal surface by plasma spraying. Clear width of each box corresponds to the thickness of the package.

To retrieve the element with a honeycomb structure from the mold by pushing the device offers travel along the form and inside the punch. The cross-section of the punch corresponds to the internal cross-sectional shape. This achieves a uniform ejection element with a honeycomb structure from the mold. When this individual leaves the element with a honeycomb structure is not beennow outer, preferably the district, flange, Rethimno connected to the support plate. Preferably the base plate to provide an opening through which passes connected with the punch drive shaft.

To minimize the height of the device serves to provide a base plate with a hole, through which can pass the punch.

To collapse the element with a honeycomb structure twisting device has at least two located on the bracket twisting the mandrel, which can be brought into interaction with a package packages. Twisting the mandrel can pass through the punch. Because twisting the mandrel must withstand occur when you minimize effort, they should be relatively stable, however, on the other hand, they should be performed if possible, thin to the element with a honeycomb structure was not formed any additional major channels. The stability of the torsion bars is provided, for example, by additional clamping the free ends of the mandrels after placing metal sheets. Stabilizing action also provides the cross-sectional shape torsion bars, different from all the emerging when you minimize the form of channels, formed by twisting the bars.

The form of a preferably one-piece. For example, it may be manufactured from a single casting. It is also the form is executed at least two core segments.

For the manufacture of an element with a honeycomb structure having multiple channels for the passage of fluid, composed of multiple layers of at least partially structured metal sheets is proposed a method in which at least one packet trying to enter multiple layers of at least partially structured metal sheets. Each package lay in a shape corresponding to the outer contour of the manufactured element with a honeycomb structure. At least one end of each package is of the form through at least one provided in the form window. Each packet is held in the Central zone of the twisting device, and by turning the twisting device and forms relative to each other packages braid, respectively roll in a roll with a receiving element with a honeycomb structure, which completely fills the entire form.

This method eliminates the need for complicated in the manner which I can only mutual relative rotation of the form and/or twisting of the device.

According to another preferred variant of execution requested to dial in at least two packages of multiple layers of at least partially structured metal sheets. Then each package is folded in half along the respective fold lines. After that, each packet is placed in a mold corresponding to the outer shape of the manufactured item with a cellular structure, where it is kept twisting device in the Central zone. For this purpose, the area of each fold line is preferably provided on one twisting spindles. When designing a package in the shape of both ends of each package stand out through the same window.

Below other advantages and features of the invention are explained in more detail by embodiments thereof with reference to the accompanying drawings on which is shown:

in Fig. 1 is a schematic top view of the device with three collapsible roll packages

in Fig. 2 and 3 - position packets at different points in the process of rolling,

in Fig. 4 - completely twisted element with a honeycomb structure in the form,

in Fig. 5 - fragment X in Fig. 1 without packages on an enlarged scale and

in Fig. 6 - the device in cross section.

Boxes 8, 9 and 10 are longitudinal surfaces 11, 12, convex in cross section. Each of the longitudinal surfaces 11, 12 is equipped with anti-friction layer 18, 19, made of a ceramic material.

In Fig. 1-6 not shown twisting device, provorachivayuschie packages 1, 2 and 3 around the axis 4 perpendicular to the plane of the drawing. Twisting the device has the appropriate mandrel 24, 25, 26, which are included in each package 1, 2, 3, and turn them in the direction of rotation S twisting devices. Preferably the cross-section torsion bar has a curved drop, which, without requiring additional space, corresponds to the shape of the channel, in any case formed by folding on twisting the mandrel, and at the same time sufficiently to perceive occur when Sortavala and packages 1, 2, 3 are composed of multiple layers of at least partially structured metal sheets. Each package 1, 2, 3 folded along respective lines 21, 22, 23 bend. Folded so the packages 1, 2 and 3 is placed in a mold 5, where each of them is kept twisting device in the Central zone 7, and near each of the lines 21, 22, 23 bend is one twisting spindles 24, 25, 26 twisting devices. Both ends of each package 1, 2, 3 stand out from the mold 5 through the same window 8, 9, 10.

When turning the torsion bars 24, 25, 26 around the Central axis 4 in the direction of S separate packages 1, 2 and 3 simultaneously rolled up into a roll. In the clotting process, packets 1, 2 and 3 slip on antifriction layers 18, 19 into the internal cavity of the form 5. In the finished element 6 with a honeycomb structure packages 1, 2 and 3 are collapsed into a roll around a Central zone 7 and around each other, as shown in Fig. 4.

Ready rolled element 6 with a honeycomb structure can be retrieved from the fixed mould 5 by pushing with the help of the punch 16. During popping the last element 6 can be inserted in the above form 5 cover. In the clotting process, not decisive, Pooram is only their mutual relative movement. In this way can be also manufactured items with a honeycomb structure with a non-circular cross-section, if the deviation from the round shape is not too great. The invention allows economical to produce devices with a cellular structure at low cost tools.

1. Device for the manufacture of an element with a honeycomb structure, in particular housing-carrier catalyst, consisting of a set of typed at least in one package (1, 2, 3) layers at least partially structured metal sheets forming multiple channels for the passage for the fluid, and the device includes a pivotable around a Central axis (4) acting on each package (1, 2, 3) fork twisting device and the form (5), characterized in that the form (5) covers the twisting device, the inner loop of the form (5) is unchanged and corresponds to the outer contour of the manufactured element with a honeycomb structure and the wall (11) of the form (5) is provided with at least one passing mostly parallel to the Central axis (4) through the window (8, 9, 10) for one or more ends of the packages.

2. The device according to p. 1, wherein teto open (8, 9, 10) are equidistant relative to each other along the internal perimeter of the form (5).

4. The device according to PP.1, 2 or 3, characterized in that at least one longitudinal surface (11, 12) at least one window (8, 9, 10) made in cross-section convex.

5. The device according to PP.1 to 3 or 4, characterized in that at least one longitudinal surface (11, 12) at least one window (8, 9, 10) provided with anti-friction layer (18, 19).

6. The device under item 5, wherein the anti-friction layer is wear-resistant.

7. The device according to p. 6, characterized in that the anti-friction layer is made of a ceramic material.

8. Device according to any one of paragraphs.5 to 7, characterized in that the anti-friction layer is applied by plasma spraying.

9. Device according to any one of paragraphs.1 to 8, characterized in that the width (In) of each window (8, 9, 10) approximately corresponds to the thickness (D) of the package (1, 2, 3).

10. Device according to any one of paragraphs.1 to 9, characterized by the presence of the punch (16) moving in the longitudinal direction of the form (5) and into it.

11. The device according to p. 10, characterized in that the cross-section of the punch (16) corresponds to the internal cross predpochtitelno district, the flange (13), Rethimno connected with the support plate (14).

13. The device according to p. 12, characterized in that the supporting plate (14) has an opening (15) through which passes directly connected to the punch (16) drive shaft (17).

14. The device according to p. 12, characterized in that the supporting plate (14) has an opening (15), through which can pass the punch (16).

15. Device according to any one of the preceding paragraphs, characterized in that the twisting device has at least two located on the bracket torsion bars (24, 25, 26), which can interact with the package, respectively, packages (1, 2, 3).

16. The device according to p. 15, characterized in that the twisting of the mandrel (24, 25, 26) are appropriate to the efforts of the curl, but the minimum possible cross-section, in particular in the form of drops or curved drops.

17. The device under item 15 or 16, characterized in that the twisting of the mandrel (24, 25, 26) can be mounted on both sides in the twisting device.

18. Device according to any one of the preceding paragraphs, characterized in that the form (5) and twisting fixture can be rotated relative to each other.

19. Device according to any one of the preds is the corresponding points, characterized in that the form of (5) consists of at least two core segments.

21. Device according to any one of the preceding paragraphs, characterized in that the coagulation of two or more packages (1, 2, 3) of sheet metal, folded double along the lines (21, 22, 23) bend in the device by using a twisting device is provided by twisting the mandrel (24, 25, 26) in an amount corresponding to the number of packets, and the same number of Windows (8, 9, 10).

22. A method of manufacturing element with a honeycomb structure having multiple channels for the passage of fluid, composed of multiple layers of at least partially structured metal sheets, in which trying to enter at least one package (1, 2, 3) multiple layers of at least partially structured metal sheets, each package (1, 2, 3) put in the form (5) corresponding to the external shape of the manufactured element with a honeycomb structure, at least one end of each of the package (1, 2, 3) is of the form (5) through at least one window (8, 9, 10) and each package (1, 2, 3) is held located in the Central zone of the form (5) twisting device, and roll in roll all packages (1, 2, 3) by turning screw with the receiving element with a honeycomb structure, completely filling the entire form (5).

23. The method according to p. 22, in which trying to enter at least two packets (1, 2, 3) multiple layers of at least partially structured metal sheets, each package (1, 2, 3) fold in half with the appropriate line (21, 22, 23) bend and packages (1, 2, 3) put in the form (5) corresponding to the external shape of the manufactured item with a cellular structure, where it is kept twisting device in the Central zone, in the zone of each line (21, 22, 23) the bend is preferably provided on one twisting the mandrel (24, 25, 26).

24. The method according to p. 23, which when putting packages in the form (5) both ends of each package (1, 2, 3) are output through the same window (8, 9, 10).

 

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FIELD: production of honeycomb substrates for catalyst converters for two-wheeled or diesel vehicles.

SUBSTANCE: the invention is dealt with production of honeycomb substrates made out metal sheets piled or rolled in a package and minimized to the honeycomb elements used first of all as honeycomb substrates for catalyst converters in the systems of exhaust gas (EG) neutralization. There is a description of a honeycomb element (1) first of all as a honeycomb substrate for a catalyst converter for systems of two-wheeled vehicles exhaust gas neutralization. The honeycomb substrate for catalyst converter consists of some layers of metal sheets (2, 3) packed as a package or minimized in a roll, which are at least on separate sections are structured or profiled in such a manner, that they form for EG flowing channels (4). At that the metal sheets (2, 3) represent the sheets of high-quality steel of more than 0.08 mm thick with a share of aluminum from 6 up to 12 mass % multiplied by 0.02 mm and divide by "d" - thickness of the metal sheets (2, 3). The technical result - a possibility to use metal sheets depending on the share of aluminum in them and their thickness, that allows to use the sheets taken from production process of manufacture of a material subjected to a hot aluminization.

EFFECT: the invention ensures a possibility to use metal sheets for the purpose depending on the share of aluminum in them and their thickness.

5 cl, 1 dwg

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