Method and device for manufacturing cell element

 

(57) Abstract:

The invention relates to a method of manufacturing a cell element, in particular housing-catalyst carrier, of several typed in at least one packet and at least partially structured metal sheets, as well as to a device for manufacturing such a cell element. The method consists in the fact that several at least partially structured metal sheets trying to enter at least one package with the formation in it of channels between the layers. Then, the packet is placed in a mold, where it is held in the Central zone of the twisting device. Twisting the device has the ability to rotate around the Central axis, serving at the same time the axis of coiling. It contains at least two winding mandrels are parallel to the Central axis and passing along the canals. Mandrel influence in the Central area of the package at its respective outer surface. Twisting the device also has positioning elements at least partially in the channels. Package: twisted, rolling into a roll, until the desired degree of curl. This preserves nesme is the original memory location of the structures of the metal sheets. A device for implementing the method comprises a shape and twisting device. The internal shape contour corresponds to the outer contour of the cell element. The invention eliminates the deformation of the walls of the packages. 3 S. and 7 C.p. f-crystals, 6 ill.

The present invention relates to a method of manufacturing a cell element, in particular housing-catalyst carrier, of several typed in at least one package to at least partially structured metal sheets, as well as to a device for manufacturing such a cell element.

Housing-carriers of catalysts used to reduce the content of toxic substances in exhaust gases (OG), in particular in the EXHAUST gas of engines special vehicles (for non-transport activities), can be made in the form of a metallic honeycomb element, i.e. the element having a honeycomb structure. Such cell elements consist of several typed in the package at least partially structured metal sheets. In the US 4923109 described cell element made from a package at least partially structured metal sheets, rolled in mutually opposite directions around the Central zone. trying to pack a few at least partially structured metal sheets, then this package is placed in an open form, formed the core segments of the inner contour of which corresponds to the outer contour of the manufactured cell element, and the package is kept in this form in the Central zone of the twisting device. After this package Relanium, twisting in a certain direction, and then upon reaching the required degree of curl package, close the form and turn of her profile segments in the direction opposite to the direction of rotation of the twisting device.

From DE 19522327 known method of manufacturing a honeycomb element with a multitude of through channels for the passage of fluid from multiple at least partially structured metal sheets. This method is most suitable for the manufacture of a cell element, known from WO 90/03220. Such cell element includes at least three pack of metal sheets, with at least three of them folded in half (folded) by the respective fold line in the Central zone of the cell element and in such folded condition folded into a roll by twisting in one direction around each other and around a Central zone in which naket rebate on the respective fold lines. Then folded so the packages are placed in the form. Each packet is held in the form of a twisting device in the Central zone. Twisting device has a winding mandrel inserted in a folded package in the location of each bend line. By turning the winding mandrel around a Central axis in one direction separate packages roll into a roll.

From WO 94/01661 known cell element, which is formed only from a small number of sheet metal and design which allows you to integrate at least one of the layers of sheet metal at least one elongated electrical conductor or follow this one of the layers in the form of an elongated insulated electrical conductor. For manufacturing such a metallic honeycomb element from at least partially structured metal sheets in WO 94/01661 proposed to produce a small quantity of at least partially structured metallic stripes hollow cone. This hollow cone, respectively round the ring, is subjected to the pressure treatment, deforming in the direction from outside to inside at least three lines, resol. The resulting star-shaped, respectively rosethorne, the structure with protrusions in the form of the blades are twisted, bending rotation in one direction and are located between the inner and outer lines of fracture "blades" around the inner lines of fracture.

It was found that in some areas of the microstructure of the finished cell elements are detected defects that impair quality of these cellular elements. In the mass production on the same equipment large quantities of cellular elements such defects appear irregularly. This leads to the necessity of taking special measures to ensure quality production of honeycomb elements.

Based on the foregoing, the present invention was based on the objective to develop a method that would improve the quality of manufacturing cellular elements. Another object of the invention is to provide such a method of serial manufacturing of cellular elements, which would provide more than simply achieving the required quality of manufacture such cell elements. The next task of the invention is to develop a device for the manufacture of cellular elements stored the cottages according to the invention features a method of manufacturing a honeycomb element with a multitude of through channels for the passage of fluid from multiple at least partially structured metal sheets, namely, that several at least partially structured metal sheets trying to enter at least one package. Then this package is placed in a mold, where it is held in the Central zone of the twisting device, with the possibility of rotation around the Central axis. Then placed in the mold package rolled, rolling into a roll, until the desired degree of curl preserving unchanged at least during the curl formed in the Central area of the structure with the relative position of the structures of the metal sheets. This technology implementation process ensures the absence of any shifts of these structures relative to each other in the Central area of the package, which is a prerequisite for the production of cellular elements of stable quality. Mutual arrangement of the structures of the metal sheets in the Central area of the package, it is preferable to maintain since the formation of such a structure of the package in this Central zone. The cell elements are known, for example, from DE 19521685 A1, the specified structure of the package is preferably retained for future technological operations since the end of the set of sheets in the package. Those Soto package consider it the macrostructure in the Central zone, i.e. at the site of the bend line.

The structure of the package in its Central zone is preferably set in advance. However, the structure of the Central area of the package, which allows to produce the cellular elements of extremely high quality, you can define and empirically.

It has already been mentioned that the macrostructure of the cell elements may have defects. In this case, the defects refers to the deformation of the walls of the channels formed at least partially structured metal sheets. In particular, such deformation defects occur on the border with those areas in which cellular elements have a relatively rigid structure. To avoid deformation of the walls of the channels in locations such hard structures are encouraged to dial in a package of structured metal sheets having corrugations with peaks and troughs alternately with smooth leaves, so that the top of the corrugation of the structured sheet was located essentially between the two troughs of the corrugation adjacent structured sheet. This package has a relatively low rigidity. When the curl package, respectively, packages, patterns related metalsusa areas, the stiffness of which may be greater than the rigidity in the Central zone. However, these more rigid areas are not so pronounced, respectively, are not so hard to cause deformation of the forming channel structures adjacent to these areas, and zones. Forming a package with a relatively soft Central area suitable primarily for the manufacture of cellular elements of small diameter, respectively, with a slight curl.

To avoid the formation of relatively rigid sections in the cross section of the cell element package in its Central zone enough to make relatively mild. In addition, the package can be formed so that its rigidity perpendicular to the longitudinal direction of the structures everywhere was the same. With this purpose it is proposed structured metal sheets to perform in the form of corrugated metal sheets with duplicate with constant pitch peaks and troughs of the corrugation. In this implementation of structured metal sheets offered before a set of such sheets in the package to cut them off from the metal strip so that their length was a multiple of a whole number of steps. Such cutting of sheet metal on sheets merdoyage sheet into the gap between the two troughs of the corrugation adjacent structured list.

Alternatively, the package with low rigidity of its structure in the Central zone of the leaves are invited to dial in the package, which has a relatively high rigidity of its structure in the Central zone. Such a relatively high rigidity to the package in the Central zone can be given, if the package is structured metal sheets having corrugations with peaks and troughs alternately be alternated with layers of smooth metal sheets so that the peaks and troughs of the corrugation adjacent structured sheets were located essentially in a line one above the other perpendicular to the longitudinal direction of these peaks, respectively troughs of the corrugation. When structured metal sheets are designed so that the peaks and troughs of their bumps are repeated with a certain step, the resulting set of package arrangement of layers gives it a relatively high rigidity. When ruanruan such a package, the peaks and troughs of the corrugation adjacent metal sheets are shifted relative to each other. In such movement of the tops of the bumps are not more in line with the troughs of the corrugation adjacent metal sheets, of which the structure of the cell element in the optimum zone ready cell element can be regarded as a relatively rigid core, and the area outside this core is a relatively soft shell. This variant of the proposed method also allows us to produce cell element, the shell of which excluded the formation of pronounced zones with high strength.

When used for production of honeycomb element of structured metal sheets having corrugations with repeated increments of peaks and troughs, it is suggested before you set the package to cut the structured sheets from a metal strip with a length L calculated by the formula L = n a+0.5, where n denotes the element of the set of natural numbers. This approach gives the location of the peaks and troughs of the corrugation typed in the package adjacent the structured metal sheets essentially in a line with each other.

In the manufacture of cell element is not always possible to arbitrarily choose the length of the structured metal sheets, since the finished cell element, as the body is the carrier of the catalyst, must have certain geometrical parameters, for example, be section of a certain number of channels. Therefore, to obtain a package with a certain structure in the Central area has estoya the construction and location of the positioning elements relative to each other, you can get a package with a relatively high or a relatively low stiffness in the Central zone. You can also set certain parameters of the rigidity of the package in its Central zone, if the positioning elements appropriately to align with the required structure of this Central area of the package.

Another object of the invention is a method of manufacturing cell elements, each cell element has a multitude of through channels for the passage of fluid from multiple at least partially structured metal sheets, providing the possibility of making better cell elements.

According to this method of manufacturing cellular elements are encouraged to recruit from multiple at least partially structured metal sheets at least one package. This package is then placed in a mold, where it is held in the Central zone of the twisting device, with the possibility of rotation around a particular axis. After this package is twisted, rolling into a roll, until the desired degree of curl. The packet in this twisted form of extract, optional after fixation, for example, in a tubular casing, of the form. The described process operation is repeated for each batch of each structure. This structure is provided by the mutual location of structures of sheet metal and is stored in each packet unchanged at least in the process of rolling each of the packages. Due to the fact that the relative positions of the structures of the metal sheets in the Central area of the package, each cell element is the same in a few cellular elements provided almost the same distribution channels for their section. The structure of the Central zone of the package, it is preferable to set the first cell element, including the fabrication of several cell elements. Given the structure of the Central zone of the package, it is preferable to select such a way that the cross section of the cell element were not pronounced hard sections, which are formed near the deformed structure.

The following variant proposed in the invention method is that for the first cell element with respect to one or more subsequent cellular elements trying to enter the package and for this first cell element specify the structure of the Central zone of the package. The same structure is reproduced by the corresponding set of other metal sheets in each of the following acetonitril specified quality criteria.

Another object of the invention is a device for producing at least one cell element, in particular housing-catalyst carrier, of at least one package, recruited from multiple at least partially structured metal sheets forming a multitude of through channels for the passage of fluid. This device has the shape of the inner contour of which almost corresponds to the outer contour of the manufactured cell element. Additionally, there are twisting device, which serves to hold each package in its Central zone, at least in the process of rolling. This twisting device has a fastening device, by which each packet is held in its Central zone so that at least in the process of rolling preserving formed in the Central area of the package structure with the relative position of the structures of the metal sheets.

The fasteners preferably to provide positioning elements that can be inserted at least partially into the channels in the Central zone of each package. The configuration of these positiverate in the form of a mandrel. The width of the fasteners are preferably sized such that it corresponds to the thickness of the package.

Following the proposed method, respectively, the proposed device are explained in more detail on the example of several variants of its implementation, respectively perform with reference to the accompanying drawings on which is shown:

in Fig.1 - scheme of the process of forming a package according to the first variant of carrying out the invention

in Fig.2 - scheme of the process of forming a package according to the second variant of carrying out the invention

in Fig. 3 is a schematic representation in top view of the device package according to one of the variants of its implementation,

in Fig.4 is a first embodiment of a twisting device,

in Fig.5 is a second embodiment of a twisting fixture and

in Fig.6 - section twisting device according to Fig.5.

In Fig. 1 shows a diagram of the process of forming the package 1. The package 1 is assembled from several at least partially structured metal sheets 2. Between spaced one above the other layers of structured metal sheets 2 are smooth metal sheets 3. Structures testuya length cut from a metal strip 5 of the cutting device 6.

Structured metal sheets 2 are corrugated with vertices 7 and valleys 8. Structured sheets 2 typed in the package such alternating alternating layers whose vertices 7 and valleys 8 bumps adjacent structured sheets 2 are mainly located in a single line with each other.

Peaks 7 and valleys 8 bumps in structured metal sheets 2 are repeated with the step . Before you set package from the metal strip 5 of the cut sheets 2 length L calculated by the formula L = n a+0.5, where n denotes the element of the set of natural numbers. Data option package execution and layout in it of sheet metal, give it a relatively high rigidity.

Another possible layout of the structured layers of sheet 2 and smooth sheet 3 shown in Fig.2. In the package 9 in Fig.2 layers of structured sheets 2 and smooth sheets 3 are arranged so that the tops of the bumps 7 one structured sheet 2 fall somewhere in the middle between the two cavities 8 of the corrugation adjacent structured sheet 2. The peaks and troughs of the corrugation in structured sheets 2 are repeated with the step . Before you set package structured sheet 2 is cut from the metal strip 5 in this package 1 rigidity, because the top 7 of corrugated structured sheet 2 are located so that they are always between two depressions 8 of the corrugation adjacent structured sheet 2.

In Fig.3 schematically shows a device for manufacturing cell element. In this case we are talking about one of the examples of such devices. A similar device is known from DE 19521685 A1. The device has the form 12 with two profile segments 10, 11. Each core segment 10, 11 has the ability to rotate around the respective axes 13, 14. In close position profile the segments 10, 11 cover formed twisting device 15 cell element. Envelope cell element designated by position 16.

Twisting device 15 is rotatable about the Central axis 17, which is also the axis of coiling. Twisting device 15 holds the package 1 in its Central zone 18.

In Fig.4 schematically illustrates the twisting device 15. This twisting device 15 has a holder 19. At each end of the holder 19 is located on one winding mandrel 20, 21 respectively, each of which act on the corresponding outer surface 32, Ohm in parallel to these mandrels 20, 21. Positioning elements 22 are generally rod shape. They are at least partially into the channels 4 of the package 1, thereby preserving the structure of the package unchanged in its Central zone 18. In twisting device 15 can have multiple rows of positioning elements 22. The latter can also be arranged offset relative to each other. The location of the positioning elements 22 depends mainly on the desired structure of the Central zone 18 of the package. When this positioning elements 22 and the holder 19 is formed of the fixing device 23, which each package 1 is held in its Central zone 18 so that at least in the process of rolling preserving formed in the Central area 18 of the package structure with the relative position of the structures, in particular vertices 7 and valleys 8 bumps, structured metal sheets 2.

In Fig. 5 and 6 shows another embodiment of a twisting device 15. Such twisting device 15 is intended primarily for manufacturing such a cell element with a multitude of through channels for the passage of fluid from multiple at least partially structured metal is avannah metal sheets 2, there are layers, where each batch is folded (folded in half) on the respective fold lines. The packages after they are moved into the open, with specialized segments, the inner contour of which corresponds to the outer contour of the manufactured cell element, are held in the form of a twisting device 15. Not shown in the drawing packages roll into a roll, twisting them in one direction around the other. The production of such cell element is described, for example, in DE 19522327 A1 and DE 19521685 A1. The content of these publications in full included in this description.

Twisting device 15 shown in Fig.5, has three of the holder 19, 24, 25 extending from a common center 26. In the center 26 provided for the drive shaft 27, which provides the rotation of the twisting device 15 around the axis 17. All holders 19, 24, 25 have the same performance. Every two holder 19, 24, 25 form an angle of approximately 120o. At the free end of each of the holder 19, 24, 25 located on one winding mandrel 20, which can interact with the package or packages. These mandrel 20 interact with service mainly in the area of the bend line. In odnonapravlenno, coiling in the same direction. In order to keep at least in the process of rolling the structure of the package unchanged in its Central zone, each holder 19, 24, 25 are positioning elements 22 that can be inserted at least part of their length in the channel 4 of each package. The location of the positioning elements 22 on each holder 19, 24, 25 of the fixing device 23 does not necessarily have to be the same. You can provide a different arrangement of the positioning elements 22.

1. A method of manufacturing a honeycomb element with a multitude of through channels (4) for the passage of fluid from multiple at least partially structured metal sheets (2), namely, that (a) several at least partially structured metal sheets (2) gaining at least one packet (1) to form between the layers in the package of channels (4), (b) the package (1, 9) is placed in a mold (12), where it is held in the Central zone (18) twisting fixture (15), with the possibility of rotation around the Central axis (17) and having at least two winding mandrel (20, 21), which are mostly parallel to the Central axis (17), which serves as the Oh zone (18) of the package (1) at its respective outer surface, as well as having positioning elements (22) included at least partially in the channels (4) package (1, 9) twisted, rolling into a roll, until the desired degree of curl preserving unchanged, at least in the process of rolling formed in its Central zone (18) of the structure with the relative position of the structures (7, 8) metal sheets (2).

2. The method of manufacture of cell elements, each cell element has a multitude of through channels for the passage of fluid, of several, at least partially structured metal sheets (2), namely, that (a) several at least partially structured metal sheets (2) gaining at least one packet (1, 9) to form between the layers in the package of channels (4), (b) the package (1, 9) is placed in a mold (12), where it is held in the Central zone (18) twisting fixture (15), with the possibility of rotation around the Central axis (17) and having at least two winding mandrel (20, 21), which are mostly parallel to the Central axis (17), serving at the same time the axis of coiling, and pass in the longitudinal direction of the channels (4) that act in the Central nervous system), included at least partially in the channels (4) package (1, 9) twisted, rolling into a roll, until the desired degree of curl, d) the package (1, 9) twisted as extracted from the form (12), d) stages a) to d) repeat for each package (1, 9) of each of the next cell element forming each package (1, 9) with always the same in its Central zone (18) structure, consisting in the mutual arrangement of structures (7, 8) metal sheets (2), and storing in each package (1, 9) unchanged, at least in the process of rolling a specified structure with the relative position of the structures (7, 8) metal sheets (2).

3. The method according to p. 1 or 2, in which the structure of the package (1, 9) in its Central zone (18) ask for a particular cell or element for the first of several cell elements.

4. The method according to p. 2, in which for the first cell element trying to enter the package (1, 9) and for this first cell element specify the structure of its Central zone (18), with the same structure reproduced by the corresponding set of other metal sheets in each package (1, 9) of each of the next cell element in the case, when made from the first batch (1, 9) cell element udovletvor sheets (2) have corrugations with vertices (7) and depressions (8) and these structured metal sheets trying to enter in the package (9), alternate with layers of smooth sheets (3), so that the top (7) of the corrugations of the structured sheet (2) was located essentially between the two depressions (8) of the corrugation adjacent structured sheet (2).

6. The method according to p. 5, in which the structured metal sheets (2) have corrugations with vertices (7) and depressions (8), repeated from step while before dialing package structured sheets (2) cut from a metal strip so that their length L was a multiple of a whole number of steps .

7. The method according to PP. 1, 2 or 3, wherein the structured metal sheets (2) have corrugations with vertices (7) and depressions (8) and these structured metal sheets trying to enter in the package, alternately with layers of smooth sheets (3), so that the top (7) and depression (8) of the corrugation adjacent structured sheets (2) was located essentially in one line with each other.

8. The method according to p. 7, in which the structured metal sheets (2) have corrugations with vertices (7) and depressions (8), repeated from step while before dialing package structured sheets (2) cut from a metal strip with a length L calculated by the formula

L = n+0,5,

where n denotes the element of the set is, the particular housing-catalyst carrier, of at least one of the package (1, 9), recruited from several, at least partially structured metal sheets (2) forming a multitude of through channels (4) for the passage of fluid, and this device has the form (12), the inner contour of which almost corresponds to the outer contour of the manufactured cell element, and twisting fixture (15), which serves to hold each package (1, 9) in its Central zone (18), at least in the process of rolling and having the ability to rotate around a certain axis (17), characterized in that the fastening device (23) has positioning elements (22) which can be inserted at least partially into the channels (4) in the Central zone (18) of each packet (1, 9), keeping in this way, at least in the process of rolling is formed in the Central zone (18) the structure of the package (1, 9).

10. The device according to p. 9, characterized in that the positioning elements (22) is designed as a mandrel.

 

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