A method of manufacturing a cell element made of sheet metal, having at least partially a multilayer structure

 

(57) Abstract:

The invention is intended for the manufacture of cellular elements applied, usually as buildings vehicles catalytic converters. A method of manufacturing a cell element, which is trying to enter in the service and/or roll to roll metal sheets. At least one piece of sheet metal made from original multi-layered material that includes at least one layer of chromium steel and at least one containing mainly aluminium layer, which during the subsequent thermal treatment significantly homogenizers due to the diffusion. At least part of the metal sheets has a structure that increases the elasticity of the cell element before and during heat treatment. Cell element is inserted into a tubular casing with such pre-compression, in which during heat treatment provides permanent adhesion of the sheets to each other at their places of contact. Due to additional microstructures on at least one of the metal sheets is reduced, the total area of contact between the sheets. Additional microstructure may be a structure, the passage of the RH. Metal sheets are interconnected through mutual engagement with geometric circuit structures adjacent sheets. For the tubular casing of the applied material with a lower coefficient of thermal expansion than the material of the cell element. The technical result - the production of a more perfect, cheap and are able to withstand high mechanical load cell elements with high corrosion resistance. 7 C.p. f-crystals, 5 Il.

The invention relates to a method of manufacturing a cell element made of sheet metal, typed in the package and/or rolled.

Cell elements are mainly buildings vehicles catalytic converters for conversion of exhaust gases from the heat engine. These cellular elements are known, for example, from the application WO 89/07488. These case-bearers of the catalyst are subjected to high thermal and mechanical loads. In addition to thermal and mechanical load cell element is exposed to those present in the EXHAUST gas corrosive components. Aggressive gas components can lead to corrosion cell element. For this reason, the cell elements it is advisable significant use of steel sheets with a high content of aluminium for the manufacture of cellular elements. However, the production of honeycomb element of such material is problematic due to the fact that steel with a high content of aluminum has poor prokalivaemosti, and is also associated with high costs.

In U.S. patent 5366139 for manufacturing cell element is proposed to use a metal sheet made of plated aluminum steel. Processing of such sheets in the manufacture of cell element is more economical, because these sheets are easy plastic deformation in cold condition.

After dialing in the service and/or coagulation in a roll of sheet metal, clad with aluminum, they are subjected to subsequent thermal treatment. In the heat treatment of metal sheets, comprising at least one layer of chromium steel and at least one consisting mainly of aluminum layer, largely homogenizers. It was found that in the manufacture of cellular elements, primarily with a relatively large cross-section, is not always ensured the connection of sheet metal with a multi-layered structure between itself and/or with a casing covering the cell element. However nadinoo value for the mechanical strength of the cell element. It was found further that when heat-treated cell element can occur reducing the amount of sheets of the multilayer structure. Reducing the amount of sheets of the multilayer structure due to the fact that aluminum, which forms the outer layer of sheet metal, diffused during the heat treatment in the first layer containing chromium steel. However, aluminum, diffusionally first layer containing chromium steel, increases the volume of this layer is not in the same extent that there is a reduction of the volume of the aluminum layer. In addition, during the homogenization leaves with a multilayer structure have only a slight elasticity.

Based on the foregoing, the invention was based on the objective to develop a method of manufacturing a cell element, the metal sheets of which at least partially consist initially of a multilayer material, which has at least one layer of chromium steel and at least one consisting mainly of aluminum layer, which is in the process of further heat treatment significantly homogenizers due to the diffusion. While the resulting homogenization of leaves decrease dolini, able to perceive a high load.

The specified task according to the invention is solved by the method characterized by the distinguishing signs of paragraph 1 of the claims. Preferred embodiments of the presents in dependent clauses.

To avoid the formation of large areas, on which the metal sheets do not have or form a loose connection between itself and/or with the casing because of what is happening in the heat treatment process reduce the amount typed in the package and/or rolled metal sheets according to the method according to the invention it is proposed to provide at least part of the metallic sheet structure, which increases the elasticity of the cell element before and during heat treatment. When this cell element is inserted into a tubular casing with such pre-compression that during heat treatment ensures a constant fit of layers of metal sheets to each other at their places of contact. In this process it is possible to make cell element, which is due to appropriate selection of the material of sheet metal is corrosion resistant and has high mechanical and termoustoichivost and with the installation of a cell element in a tubular casing with advanced compression provides a permanent seal steel sheets to each other at their places of contact despite the slight elasticity of the materials used in the heat treatment process. To provide a continuous seal steel sheets to each other at the points of their contact is important for the formation of connections between the metal sheets. Through the heat treatment, the sheets are interconnected at their respective places of contact. Compound leaves with each other is, for example, due to the fact that stale-aluminum alloys have a much lower melting point than steel, resulting in the inner layers of sheet metal with a multilayer structure temporarily melted, forming in the surrounding space of the contact area of the internal connection, which in its properties essentially corresponds to the welded joint. Due to the concentration gradient of the aluminum migrates further into the inner layer of sheet metal, resulting in a concentration of aluminum in the connection zone is reduced, and for this reason, the melting temperature zones of the connection is increased, allowing the joints to harden. In addition or alternative to these compounds metal sheets between at least a portion of the metal sheet can at least partially apply the solder to the sheets at least in certain areas with the finished cell elements, which also contribute to the improvement of the efficiency of the manufacturing process known from the prior art in large quantities, although their influence on the manufacturing process, using sheets of a multilayer structure is not indulged important. For example, in application EP 0220468 B1 describes the different types of double waviness that can be printed on corrugated and/or smooth metal sheets. It is also known application of additional mikrovoloknistoy on mostly smooth metal sheets in cellular element, which is also preferable for the proposed method of manufacture.

There are also having extremely high flexibility of design, in which all leaves in each case are obliquely disposed corrugation with alternating orientation, making the corrugations intersect at an angle, not forming a continuous line of contact, and a relatively small point of contact, as described, for example, in application EP 0245737.

In addition, from application EP 454712 B1 is also known to affect the nature of the flow of the microstructure, which, as it has been unexpectedly found in accordance with the present invention, also have a positive effect on the process ISI area of contact in the cell element, resulting in correspondingly increases the force on each contact surface at a constant elasticity, and form a reliable connection. In addition, such a microstructure can further increase the elasticity. On the other hand, these patterns can be used to create between the metal sheets connections with geometric circuit, thus preventing the displacement of the sheets relative to each other in the manufacturing process and increases the maximum permissible mechanical loading on the finished cell element. Depending on the application microstructure feature so that they rarely or often engages with each other.

Especially preferred embodiment of which additional microstructure of at least part of the metal sheets reduce the total area of contact between them. For this reason, in the heat treatment process is reduced preliminary compression is needed to maintain consistency in the places of contact.

Additional structure is provided to allow the connection between the metal sheets, represent structures undergoing predpochtitel and in the direction of the channels.

In accordance with another preferred option is invited to perform microstructure on adjacent sheets so that the mechanical coupling of adjacent microstructures or did not occur at all or occur only in rare cases. The mechanical coupling may occur as a result of mutual engagement with geometric closure adjacent structures. To avoid such clutches it is preferable that the adjacent tiles had a microstructure with different orientation. The microstructure can have different shapes, respectively, the paths that avoid mutual engagement of adjacent microstructures. Preventing mechanical coupling due to mutual engagement with the geometric circuit, increases the contact pressure of the contact.

However, in the case of a spirally rolled cell element may be a better adhesion of metal sheets to each other by mutual engagement with geometric circuit structures adjacent sheets. Due to this, metal sheets, even at very low pre-compression will not be able to be displaced relative to each other during the heat treatment, in particular they are not, is it mutually siteplease microstructure, respectively, of the structure after homogenization of leaves with a multilayer structure remain in engagement.

Along with the structural changes accumulated in the packet of metal sheets that occur in the heat treatment process, is also expanding a tubular casing, which is made of metal sheets. Due to thermal expansion of the tubular casing precompression inserted into the casing of sheet metal is reduced. For the reliable preservation of pre-compression in cellular element in the heat treatment process in accordance with another preferred option is provided by an elastic seal between the tubular casing and the honeycomb element. In the process of making this gasket compensates for the different degree of shrinkage of the tubular casing and the honeycomb element after the cooling phase.

Preservation of pre-compression in cellular element is also provided through the application for the tubular casing material with a lower coefficient of thermal expansion than the material from which made the cell element.

Other advantages and features of predlagaemoe with reference to the drawings, showing:

in Fig. 1 is a schematic depiction of the cross-section of a cell element,

in Fig. 2 is a metal sheet with a multi-layered structure,

in Fig. 3 is a schematic depiction adjacent sheets with dual wave,

in Fig. 4 is obliquely corrugated metal sheets with overlapping corrugations and

in Fig. 5 - schematic design cell element with microstructures.

In Fig. 1 shows a cell element 1, in which the metal sheets 2, 3 after packaging were collapsed into a roll. The metal sheets 3 have a structure forming channels 7 for the passage of fluid. The sheets 3 are initially made of a multilayer material, as shown in Fig. 2. Sheet 3 has a layer 4 of chromium steel, both sides of which is coated with the layer 5, 6, containing mainly aluminum. Layers 4, 5, and 6 of the sheet 3 during subsequent thermal processing largely homogenizers due to the diffusion. Upon completion of the heat treatment clear boundaries between the individual layers disappear.

Shown in the drawing, the exemplary embodiment shown corrugated sheets 3 having a multilayer structure. In principle, the sheets initially the new element.

Typed in the package and rolled metal sheets inserted in the tubular casing 8, formed from sheets 2, 3 cell element is inserted into the tubular casing 8 with such pre-compression, the layers of sheet metal during heat treatment permanently adjoined to each other in places 9 of their contact. This contributes also provided for increasing the elasticity of the structure, which is described in more detail with reference to subsequent drawings.

In Fig. 3 shows one of the many possible double cobbles, in which the tops of the waves 13, 14 corrugated sheet have different amplitude, resulting in only a portion of the tops of the corrugation forms a space 15 in contact with the adjacent metal plates 2. A similar result can be obtained also with different waviness adjacent sheets. In any case the way in the manufacturing process increases the elasticity of the cell element.

In Fig. 4 shows another possibility of simultaneously improving the elasticity and the contact pressure of 9 places of contact in the manufacturing process. Metal sheets 3a, 3b are located obliquely alternately alternate corrugation, so that their corrugations of the effect and hydrodynamic properties.

As shown in Fig. 5, smooth sheets 2 and/or corrugated sheets 3 can have a microstructure 10, which are mainly transverse to the direction S of the channels 7. The structures 10 adjacent metal sheets 2, 3 or has a place of their mutual coupling that prevent process of heat treatment bias layers of the sheets relative to each other even at very low pre-compression, or in such embodiment, when excluded coupling, increases the contact pressure of the contact locations. In any case, the microstructure increases the elasticity in the manufacturing process.

The present invention is intended for the manufacture of more sophisticated, cheap and are able to withstand high mechanical load cell elements with high corrosion resistance, which are usually applied as buildings vehicles catalytic converters.

1. A method of manufacturing a cell element, which is trying to enter in the service and/or roll to roll metal sheets, which at least partially have a structure forming channels for the passage of fluid, and at least one piece of sheet metal made from original m the one containing mainly aluminum layer, which during the subsequent thermal treatment largely homogenized by diffusion, characterized in that at least part of the metal sheets has a structure that increases the elasticity of the cell element before and during heat treatment, and the cell element is inserted into a tubular casing with such pre-compression, in which during heat treatment provides permanent adhesion of the sheets to each other at their places of contact.

2. The method according to p. 1, characterized in that the additional microstructures on at least one of the metal sheets is reduced, the total area of contact between the sheets and thus during the heat treatment decreases the preliminary compression necessary to maintain a permanent seal in contact.

3. The method according to p. 2, wherein the additional structure is a structure that passes transversely or at an angle to the direction of the channels.

4. The method according to p. 2, wherein the additional structure is a structure, taking place mainly in the direction of the channels.

5. The method according to p. 2, 3 or 4, characterized in that the microstructure adjacent to whether Minich microstructures mechanical clutch or does not occur at all, or only occurs in rare cases.

6. The method according to p. 1, characterized in that the metal sheets are interconnected through mutual engagement with geometric circuit structures adjacent sheets so that in the heat treatment process prevents the displacement of the metal sheets with respect to each other even at very low compression.

7. The method according to any of the preceding paragraphs, characterized in that the pre-compression in cellular element is maintained during the heat treatment due to the elastic gasket between the tubular casing and the honeycomb element.

8. The method according to any of the preceding paragraphs, characterized in that the tubular casing is used a material with a lower coefficient of thermal expansion than the material of the cell element.

 

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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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