Method and device for the manufacture of an element with a honeycomb structure of the heat-treated double-layer or multilayer foil

 

(57) Abstract:

The invention is intended for making the body of the carrier of the catalytic Converter device of neutralization of exhaust gases, used mainly in vehicles. Method and device for manufacturing cell element at least one sheet of foil consisting of at least two different layers, in particular of steel coated with rolling a cladding layer of aluminum. The foil is at least partially provided with a structure resulting from forming, and then type in the package or roll into a roll with the formation of the cell element. Before pressure treatment, the foil is subjected to heat treatment, due to it dzhoulevo heat. The heat treatment is conducted in an atmosphere of predetermined composition, which is an inert gas which mixed with some oxygen. Heating is carried out using induction coils or source of electric voltage. The technical result is an increase in deformability subjected to rolling cladding foil in a cold condition and the possibility of obtaining on the foil of the oxide layer, sizespokane manufacturing cell element, first of all corps carrier of the catalytic Converter device of neutralization of exhaust gases, mainly used in vehicles. The basic design of these cellular elements are described, for example, in application EP 0454712 B1. In this application also describes a so-called transverse microstructure used to influence the nature of the flow and efficiency of the catalytic Converter. Cell elements are made by folding into a roll, set in the package or twisting of at least partially structured metal sheets, with layers of these metal leaves become such a structure that forms a channel for passage of the EXHAUST gas. Thus, the main structure defines the dimensions of the channels. Under microstructure below in accordance with the prior art means a structure substantially smaller than that of the main structure sizes, and this microstructure should be placed primarily at an angle or perpendicular to the direction of the channels in the cellular element. To obtain a microstructure with such arrangement it is necessary to structure the foil tape in its longitudinal direction or oblique to nwny technological transition and without substantially changing the width of the foil tape.

From application EP 0159468 B1 and US patent 5366139 A known consisting of two or more layers of foil sheets, intended for the manufacture of metallic cellular elements. These foil sheets with layered structure can be produced by the rolling of alloys consisting of the required components, and it is preferable to use steel sheets with a coating of aluminum obtained rolling the cladding. In principle, after rolling these foil sheets can be subjected to homogenization, or diffusion, annealing with getting in the heat - and corrosion-resistant material, which is in every respect suitable for the manufacture of metallic cellular elements. However, such annealing is energy-intensive and expensive, in principle, quite economical process rolling.

In addition, it was also suggested to produce cellular elements of subjected to rolling cladding sheets of foil, yet held annealing, which was proposed to unite with the subsequent, necessary in any case, the soldering process. From the point of view of energy consumption, this option is more appropriate, but it is assumed that the operations necessary for structuring sheet mega. Nevertheless, it was found that certain manufacturing operations, in particular the fabrication of microstructures associated with certain problems due to poor abilities subjected to rolling cladding material to deformation in a cold state, since the leaves are processed rolling the foil cladding is impossible to deform in a cold state by more than 1% without cracking and education gaps.

Further known methods for the production of cellular elements, in which the final phase soldering, and therefore, the heat treatment is subjected not the whole cell whole item. For example, in cellular elements, which are described in WO 89/07488, as well as in cellular elements of the other type, with involute or S-shaped arrangement of the layers of sheet metal firm bonding can also be achieved by the fact that the tubular casing weld or you solder only the ends without heating all of the sheets of foil completely. In this manufacturing process, the foil is not subjected to any diffusion annealing, or any other heat treatment, there is no oxide layer of sufficient thickness, which is suitable for subsequent hell is Britania was used to develop a method of manufacturing a cell element, which does not require annealing or the end of the rolling process or at the end of the manufacturing process, cellular component, but which is technically and energetically optimal way to integrate the proper heat treatment in the manufacturing process of the cell element. Another challenge is to develop appropriate device.

This task is solved by the method of manufacturing a cell element of at least one sheet of foil consisting of at least two different layers, in particular of steel coated with rolling a cladding layer of aluminum, while the foil at least partially provide the structure of a particular form, the resulting processing pressure, and then type in the package or roll into a roll with the formation of the cell element, and the foil before processing pressure is subjected to heat treatment, due to it dzhoulevo heat. This is essential for the invention is, first, that the heat treatment is not necessarily complete diffusion annealing, performed before processing of the foil pressure to get cellular structures and, if necessary, microstructures in order to ensure on eticho foil is heated by forming in her dzhoulevo heat. This process is optimal from the energy point of view, since the heat loss can be maintained at a very low level. The release of Joule heat occurs when passing through the foil of the electric current. This can be achieved by application to the foil voltage or by creating eddy currents using induction coils. Heating due to dzhoulevo heat most expedient and for the reason that it achieve a high heating rate, for which continuous process requires only a relatively short process areas heat treatment without the use of changing the direction of movement of the tape mechanisms, and when the periodic process stages for heat treatment acceptable to the relatively short duration cycles.

For continuous heating process most appropriately be made by the induction coil while continuously passing the foil through these coils. In a periodic process in the processing of individual cut pieces of foil is most appropriate to summarize these blanks voltage to create in foil current of sufficient strength.

In order to avoid uncontrolled is supported certain atmosphere. Since it is known from literature that excessive oxidation, as is the inclusion of nitrides in the oxide surface negatively affect adhesion with her while in the subsequent coverage, it is most expedient to fill the chamber with an inert atmosphere of definite composition, in particular a noble gas, such as argon, to which for slow and uniform oxidation of the metal foil mixed with only a small amount of oxygen. When the oxygen partial pressure should be below normal atmospheric pressure and preferably be only a few millibars. However, depending on the maximum temperature attainable by a foil with heat-treated in an inert gas can be used and nitrogen, because until reaching a certain temperature of formation of nitrides on the surface can not be afraid. As mentioned above, the foil is not necessary to homogenize completely, because it is not necessary for the further manufacturing process, and during subsequent operation of the cellular elements, such as catalytic converters in the EXHAUST gas vehicles, this is achieved automatically under the influence of Probl the offset resulting from the calcination of the coating.

For cell elements, which in Assembly with the tubular casing attached to the last only ends evolvence or S-shaped spaced layers of metal sheets, it is preferable to leave the ends free from oxides, because it simplifies and improves the technological process of their Assembly. According to the invention for such cases, it is most preferable during heat treatment to isolate from the surrounding atmosphere or to cool the portions of the surface of the metal foil, which in the following will be attached to the tubular casing, thus preventing the oxidation of these areas. In a continuous process that can be implemented by using traveling with the foil clamps, and the foil is then cut on a non-corroded areas and trying to enter into packages. In the periodic process the first foil can be cut into blanks of the desired length, and then clamping the ends of the holders, which can also serve for the supply of electric current. The owners close the ends of the foil blanks, respectively, cooled them, resulting in the oxidation occurs only on the remaining free surface of the foil. In conclusion, heat treated billet can obrabatyvaniya cell element using the stage of heat treatment specified in paragraph 11 claims. Preferred versions of this device are presented in dependent from the above paragraphs and in more detail below with reference to the accompanying drawings on which is shown:

in Fig. 1 is a schematic depiction of a device for the continuous heat treatment, the part is not shown fully known production plant and

in Fig. 2 is a plot of heat treatment in a periodic process.

In Fig. 1 schematically shows the first part of the apparatus for manufacturing cellular elements of the foil 1 with a layered structure. Using satyayuga mechanism 2 foil leaves the supply reel. The foil 1 is contracted with the supply reel by means not shown transporting mechanism, such as a roller with a wavy surface for receiving the corrugated structures. Before filing a foil 1 on any device 7 for forming it passes the transporting section 8, which in addition to foil placed at least one induction coil 6, but preferably two or more spaced opposite each other induction coils 6. To prevent impact not only on the intrinsic properties of the foul is especial targeted surface, the transport section 8 of the foil is mostly in the chamber 5, at the entrance to which, respectively, the output from which foil 1 passes through the sealing gap 9. In the chamber 5 there is an atmosphere of predetermined composition, preferably argon with small amounts of oxygen. A gas mixture of a certain composition, compensating losses resulting from the chemical reaction and leakage through the sealing gap 9, is supplied via the supply line 4.

Since moving the foil due to certain mechanical properties of the supply reel and transport mechanisms cannot be implemented uniformly and without jerks, before and/or after the transporting section 8 is provided with compensating mechanisms 3, providing a uniform motion of the foil and its supporting almost constant tension. The induction coil 6 is designed in such a way that they can be heated passing through the foil 1 to the desired heat treatment temperature. Depending on the specific requirements of this temperature may range from 500 to 1000oC, mainly to a temperature of about 600oC, which lies just below the melting point of aluminum. In special cases, the heat treatment Marilena. In principle, to accelerate the oxidation can be set such a high temperature, so that the mechanical strength of the foil was still sufficient for its further transportation.

In Fig. 2 schematically illustrates the ongoing periodic mechanism of heat treatment of cut blanks 15 foil. The workpiece 15 foil is clamped in two holders 11, connected by switch 13 source 12 current respectively voltage. The switch 13 is closed for a specified period of time, resulting in a current begins to flow through the foil, warming her. While the holders 11 may have such a form, in which they cover, respectively isolate the ends 14 of the workpieces 15 foil from the surrounding atmosphere, or at least cool these ends. Thus, at sites 14 prevents the formation of an oxide layer, which could complicate their connection with the tubular casing. It is obvious that in the chamber with the atmosphere of a given composition can also be periodic heat treatment, is completely analogous to the processing described in the embodiment of Fig. 1.

It should be noted that the heating by supplying a metal foil electric current also is about being together with her.

The present invention allows the manufacture of cellular elements of subjected to rolling cladding foil when the degree of deformation in the cold more than 1%, in particular, for example, at 3%, what is required to obtain microstructures without the need for complete homogenization of the foil with high costs of energy and technical means. In addition, the foil can also be obtained oxide layer that improves the adhesion of applied subsequently catalytically active coating, making it possible to use simplified Assembly methods without subsequent full heat all cell element.

1. A method of manufacturing a cell element of at least one sheet of foil consisting of at least two different layers, in particular of steel coated with rolling a cladding layer of aluminum, while the foil at least partially provided with a structure resulting from forming, and then type in the package or roll into a roll with the formation of the cell element, characterized in that the foil before processing pressure is subjected to heat treatment, due to it dzhoulevo heat, while heat treatment propodal the amount of oxygen the partial pressure of which is preferably smaller than in a normal atmosphere.

2. The method according to p. 1, characterized in that Joul warmth educed create by induction.

3. The method according to p. 1, characterized in that Joul warmth educed create by application to the foil electric voltage.

4. The method according to PP.1, 2 or 3, characterized in that it is carried out in continuous-wave supplied to the subsequent stage of manufacture of the foil.

5. The method according to any of paragraphs.1 to 4, characterized in that it is carried out in periodic mode on the severed blanks foil.

6. The method according to any of paragraphs. 1 to 5, characterized in that as the inert gas using nitrogen or a noble gas.

7. The method according to any of paragraphs.1 - 6, characterized in that the surface of the foil during heat treatment are isolated from ambient air or cooled, preventing their oxidation.

8. The method according to p. 7, characterized in that the foil is divided into individual blanks, the ends of which during heat treatment clamp holders so that they had no contact with the surrounding atmosphere or cooling holders were not heated to the temperature to which cnyh layers of foil, in particular steel foil with the received rolling a cladding layer of aluminum having at least one transport section, which moves the foil, and at least one means of heat treatment of the foil, characterized in that the said means of heat treatment, the foil is a tool for creating in foil dzhoulevo heat, the device has a camera, in which during heat treatment is foil and in which you can create the atmosphere of a given composition with an inert gas, which is mixed a small amount of oxygen, the partial pressure of which is preferably smaller than in a normal atmosphere.

10. The device according to p. 9, characterized in that it is part of the installation for the manufacture of cellular elements of the foil and is in front of the device for processing foil pressure.

11. The device under item 9 or 10, characterized in that the inert atmosphere is an atmosphere of nitrogen or a noble gas, in particular argon.

12. Device according to any one of paragraphs.9 to 11, characterized in that the storage site is located at the at least one induction coil, characterized in that on each side of the conveyor section is provided at least one induction coil.

14. Device according to any one of paragraphs. 9 to 13, characterized in that before conveying section and/or after it provided a compensatory mechanism to regulate the speed of transportation and acting on the foil tension force.

15. Device according to any one of paragraphs.9 to 11, characterized by the presence of at least two holders for connecting cutoff piece of foil to a source of electrical voltage.

16. The device according to p. 15, characterized in that the holders are shaped so that they close and/or cool the surface of the foil, preventing the oxidation of the foil on these sites.

 

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