Cell element consisting of metal sheets with reinforcing structures

 

(57) Abstract:

The invention is intended for use primarily in the catalytic converters of exhaust gases of internal combustion engines of vehicles. Cell element in which there are channels for the passage of fluid from one end to the other and which consists of a structured or smooth and structured metal sheets. The thickness of the at least part of the metal sheets is less than 40 μm, preferably about 30 μm. Part of the metal sheets of thickness less than 40 μm provided on separate sections for reinforcement structures representing the microstructure, and/or overlapping of the microstructure, and/or folded areas, and/or folded edge areas. Folded parcels are located in the area of one or both ends of the cell element and preferably extending from the ends to the depth component, in particular 1 to 10 mm, preferably 3 to 5 mm Metal sheets can be connected to each other by soldering, preferably in areas more folded sections. The ends of the metal sheets can also be provided with reinforcing structures, clicks the touch at the ends can be provided also in thicker metal sheets to give at high load cell element additional mechanical rigidity. Cellular elements have stability with minimum weight and resistance to corrosion and mechanical strength. 2 C. and 8 C.p. f-crystals, 3 ill.

The present invention relates to a cellular element with channels for the passage of fluid from one end to the other, which consists of structured or smooth and structured, in particular, corrugated metal sheets and is intended for use primarily in the catalytic converters of exhaust gases of internal combustion engines (ice) vehicles.

Cellular elements of the specified type, consisting of metal sheets, are known, for example, from the application WO 89/07488. With smooth and corrugated metal sheets, alternately alternately accumulated in the package and rolled into a roll. Some metal sheets made thicker in comparison with others. Thicker metal sheets are used to improve the stability of the package, in particular, in those cases when it is inserted into the tubular casing. However, the use of a separate thicker metal sheets in the package associated with higher costs for manufacturing.

In certain cases, the use of cell ale is e, to reduce weight and cost of the cell element, it is preferable to make as thin sheets. However, this contradicts the aim of improving the stability of the cell element and ensure long-term corrosion resistance. Although in most areas of the cell element occur only such loads, which can withstand even a very thin foil, however, when using foil of thickness less than 40 μm, in particular, for example, about 30 μm, there are two difficulties. On the one hand, the manufacture of sheets of thin foil and above all their mechanical connection with each other and/or with the tubular casing is difficult. When connecting such a thin foil, primarily by soldering or welding, it is very easily burned through. On the other hand, the ends of such cell elements during operation exposed to high mechanical loads due to pulsating flows, and significant corrosion and erosion.

As is known, metal cellular elements are also used, for example, in the catalyst of the EXHAUST gas motorized two-wheeled vehicles. In these converters because of the high mechanical loads and/or to the m While in fact, studies have shown, the load is often subjected to only end zone Converter.

Based on the foregoing, the present invention was based on the task to create a cell element with sufficient stability for a variety of applications, which would have minimal mass and would have the corrosion resistance and mechanical strength.

This problem is solved by using the proposed cell element intended for use in catalytic converters of exhaust gases of internal combustion engines of vehicles, consisting of structured or smooth and structured metal sheets forming channels for the passage of fluid from one end to the other, the thickness of at least part of the metal sheets is less than 40 μm. According to the invention at least part of the metal sheets of thickness less than 40 μm provided on separate sections for reinforcement structures representing the microstructure, and/or overlapping of the microstructure, and/or folded areas, and/or folded edge areas.

Preferably made folded areas it is advisable to locate in the area of one or both ends of the cell element, for sections passed from the ends to the depth component is preferably from 1 to 10 mm, preferably from 3 to 5 mm.

It is advisable folded sections positioned along the edges of the metal sheets.

Preferably the metal sheets to be connected together by soldering at least a portion of their mutual contact, preferably in areas more folded sections.

In one preferred embodiment of a cell element at least part of the metal sheets are connected by their ends, preferably by welding or soldering, with the surrounding cell element by a tubular casing, thus reinforcing structure formed by folded edge zones at the ends of these metal sheets.

The ends are connected by a tubular casing of sheet metal can be folded to a depth of from 1 to 10 mm, preferably from 3 to 5 mm.

At least part of the metal sheets at least some areas may have as a reinforcing structures microstructure, preferably the height or depth of 10 to 50 μm, in particular, the overlapping of the microstructure.

Cell element in accordance with izaberete the ical leaves at least 5 μm, preferably 10 μm, thinner smooth metal sheets.

Preferred for use is a cell element in accordance with the invention, the edges of at least part of sheet metal folded at least at one end, preferably to a depth of from 1 to 10 mm, in particular from 3 to 5 mm.

Proposed according to the invention the cell element is made of structured or alternately interleaved mostly smooth and structured metal sheets. Structured metal sheets preferably are corrugated sheets. Due to the alternate rotation mostly smooth and structured sheet or differently structured sheets are formed channels through which from one end to another can be fluid. Cell element is primarily suitable for use in the catalytic Converter of the EXHAUST gas of the internal combustion engine of the vehicle. To this end the walls of the channels of the cellular elements have a catalytic coating, along which flow the exhaust gases of the engine. As mentioned above, the thickness of at least part of the metal sheets of cellular ale is worth cell element, have a same thickness, component, typically, from about 40 to 60 μm. To reduce the mass of the cell element according to the present invention serves to reduce the thickness of at least part of the sheet, preferably of metal sheets, to less than 40 microns. At the same time to achieve however, sufficient mechanical strength at least those metal sheets whose thickness is less than 40 microns, provide additional reinforcing structures.

Especially important is the presence of such reinforcing structures in end zones where there are the maximum load and where the metal sheets are connected to each other, preferably by soldering. When soldering can occur, for example, the doping of the base material solder that at very small thickness of the base material can significantly change its properties. If the material to be joined by soldering zones increase, this problem does not occur.

Especially just the ends can be enhanced by folding the edges of the metal sheets. This folded section thickness of the layers of sheet metal doubled without significantly increasing the mass of the cell element iletim sheets, for example, by soldering, under certain conditions, can be achieved even some additional elasticity of the cell element under the influence of variable thermal loads.

Rebating may be appropriate along the edges of those metal sheets, which are joined by a tubular casing. In the manufacture of solid compounds in this case, it is also important to provide a reinforced area.

Structured metal sheets preferably also provide additional structures, having them cross the main structuring elements, as described, for example, in application EP 0454712 B1. These additional structures are significantly smaller compared to the main structure of the amplitude and act primarily on the fluid passing through the cell element, improving its contact with the walls forming the honeycomb channels. Used according to the invention a thin metal sheets is much easier to structure in the transverse direction and to crimp in comparison with metal sheets of a thickness exceeding 40 μm. As it was unexpectedly set such microstructure also improve the mechanical properties of thin metal sheets, which allows huts which were held in two intersecting directions at an angle to the direction of the in which the fluid medium passes through the cell element.

Solved by the invention is also a problem when using a cell element in the end zone there are high mechanical loads and/or it is exposed to strong corrosive effect. Due to the folding of the end edges in principle, each foil sheet, regardless of its original thickness can be strengthened in the marginal zone, which allows to use even in extreme cases, more subtle, than hitherto, foil, but increased in the marginal zone.

Other advantages of the invention, as well as different ways of its implementation and examples of its practical use are explained in more detail in the subsequent description with reference to the accompanying drawings, on which:

in Fig. 1 shows the cell element in the final stage of its manufacturing,

in Fig. 2 is a perspective view of part of the corrugated sheet metal in cross section and

in Fig. 3 is a schematic cut of the cellular element explaining the location of the intersecting microstructures.

In Fig. 1 illustrates schematically a cellular element in the final stage of its manufacture. This example shows cell element, helically with the also to other types of cellular elements, in particular, to a cellular elements with S-shaped folded sheets or cellular elements, which are in some other way stopped and typed in the package. Cell element 1 consists of alternately interleaved smooth 2 and 3 corrugated metal sheets. Due to the wavy structure of the corrugated sheets 3 in the finished cell element formed channels 4, which from one end 7 to the other in the direction of S is the flow of exhaust gases. Corrugated sheet 3 and/or smooth sheet 2 can be made of foil of thickness less than 40 μm, in particular, a thickness of about 30 μm. For amplification, respectively, to stiffen such thin foil, it is preferable to provide a microstructure 5, the height, respectively, the depth of which may be, for example, from 10 to 50 μm. Although the sizes of these microstructures is substantially smaller than 4 channels, but they all have the same magnitude, providing significant mechanical reinforcement of thin metal sheets 2, 3.

Alternative and/or in addition to the microstructures 5 the edges of the sheets 2, 3 may be folded to a depth of b, as shown in Fig. 2. On folded section 9 sheet has a dual Tolmin. In General, the metal sheets can thus be processed and connect with each other in the same way as is done with conventional cellular elements. Therefore, in the rest of the processing of folded metal sheets can be produced by known manufacturing methods. The same advantages are achieved as a result of folding of the edge zones 8 of those metal sheets 2, 3, which are designed to connect to (in this case not shown) of the tubular casing. While rebating the edges of the metal sheets creates the same opportunities for their subsequent connections that take place in the case of normal cellular elements, in other words, for joining thin metal sheets to tubular casing can be used conventional methods of connection, such as soldering or welding.

In Fig. 2 not to scale) shows the principal form folded edges in accordance with the invention, a corrugated metal sheet 3. Folded depth b peripheries 9 create gain, which in comparison with the normal cellular elements, without reinforcements, attached to the ends 7 as a great mechanical stability, and a large etc who are getting ready for the mechanical properties of the foil thickness of 60 μm. For a foil thickness of 50 μm can be achieved with the same stability, which previously had been achieved using foil with a thickness of 100 μm. However, at the same time the mass of the cell element as a whole remains relatively small, which primarily improves the characteristics of the cell element during a cold start of the engine.

In Fig. 3 shows the arrangement of microstructures 5, which intersect one another at points 6 corrugated sheet 3. Such overlapping of the microstructure achieve significant benefits not only in the case of corrugated, but, obviously, also in the case of smooth metal sheets 2, as they give these sheets a high mechanical rigidity without significantly their flexibility in the manufacturing process.

It should be noted that the present invention can be used for all known mobile elements consisting of metal sheets, regardless of structural forms and techniques of compounds used to increase mechanical stability. It is most preferable to apply the present invention in cellular elements, made of S-shaped twisted pack of metal sheets. In addition, icih sheets with different corrugation.

Cellular elements with reduced according to the invention with a thickness of at least part of the metal sheets and additional reinforcing structures most appropriate to apply in cases where the corrosion effect is not overly high. On the other hand, the present invention allows the use of cellular elements with the usual thickness of the metal sheets and the reinforcing structures also in those cases in which previously due to the high loads applied metal sheets of greater thickness.

Characteristics of cellular elements, in particular such that are installed near the engine of the vehicle, during a cold start of the engine, and subsequent re-starts may depend on the axial mass distribution. With this purpose you can also use the above rebating to increase, respectively decrease of the mass in some areas of the cell element.

In the catalyst with an electric heated folding the edges of the metal sheets can deliberately influence also on the electrical resistance in its axial distribution and the distribution of heat, abrazos equipped with heating catalytic converters of many known constructions instead of the usual metal sheets without having to make significant changes in their fundamental design and method of manufacture. In cellular elements, electrically separated by air gaps, rebating preferably all metal sheets contributes to the stability of the cell element and makes it the ends are not sensitive to mechanical loads. Simultaneously folded sections form a particularly hot (axial) zone due to eye-catching in comparison with the conventional plots twice) heat resistance, which can be particularly preferred for faster achievement of the catalytic Converter is needed to convert temperature.

1. Cell element intended for use in catalytic converters of exhaust gases of internal combustion engines of vehicles, consisting of structured or smooth and structured metal sheets forming channels for the passage of fluid from one end to the other, the thickness of at least part of the metal sheets is less than 40 μm, characterized in that at least part of the metal sheets of thickness less than 40 μm provided on separate sections for reinforcement structures representing microstructures is">

2. Cell element according to p. 1, characterized in that the thickness of at least part of the metal sheets is approximately 30 μm.

3. Cell element under item 1 or 2, characterized in that the folded areas are located in the area of one or both ends of the cell element and preferably extending from the ends of the deep, part 1 - 10 mm, preferably 3 to 5 mm

4. Cell element according to any one of paragraphs.1 to 3, characterized in that the folded areas are located along the edges of the metal sheets.

5. Cell element according to any one of paragraphs.1 to 4, characterized in that the metal sheets are connected by soldering at least a portion of their mutual contact, preferably in areas more folded sections.

6. Cell element according to any one of paragraphs.1 to 5, characterized in that at least part of the metal sheets are connected by their ends, preferably by welding or soldering, with the surrounding cell element by a tubular casing, thus reinforcing structure formed by folded edge zones at the ends of these metal sheets.

7. Cell element according to p. 5, characterized in that the ends are connected by a tubular metal casing listacasino fact, that at least part of the metal sheets at least in some areas is as a reinforcing structures microstructure, preferably the height or depth of 10 to 50 μm, in particular overlapping microstructure.

9. Cell element according to any one of paragraphs.1 to 8, characterized in that it consists of smooth and structured metal sheets, with structured metal sheets by at least 5 μm, preferably 10 μm, thinner smooth metal sheets.

10. Cell element intended for use preferably in catalytic converters of exhaust gases of internal combustion engines of vehicles, especially in catalytic converters electrically heated, and consisting of structured or smooth and structured metal sheets forming channels for the passage of fluid from one end of the cell element to its other end, characterized in that region at least part of sheet metal folded at least at one end, preferably to a depth of 1 to 10 mm, in particular 3 to 5 mm.

 

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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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