CN101268261B - 具有端面硬钎焊区域的蜂窝体 - Google Patents

具有端面硬钎焊区域的蜂窝体 Download PDF

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CN101268261B
CN101268261B CN2006800349764A CN200680034976A CN101268261B CN 101268261 B CN101268261 B CN 101268261B CN 2006800349764 A CN2006800349764 A CN 2006800349764A CN 200680034976 A CN200680034976 A CN 200680034976A CN 101268261 B CN101268261 B CN 101268261B
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honeycomb ceramics
soldering
housing
face
metal layer
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L·维尔斯
J·古托夫斯基
M·福伊特
F·库尔斯
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Mainland Yimi Tech Co ltd
Continental Automotive GmbH
Vitesco Technologies GmbH
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
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    • B23K1/00—Soldering, e.g. brazing, or unsoldering
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    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
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    • F01N3/28—Construction of catalytic reactors
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
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    • B23K2101/00—Articles made by soldering, welding or cutting
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/02—Honeycomb structures
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    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2260/00—Exhaust treating devices having provisions not otherwise provided for
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Abstract

本发明涉及一种具有两个相对的端面(2)的蜂窝体(1)，该蜂窝体包括至少一个壳体(3)和至少一个形成通道(4)的金属层(5)，其中所述至少一个端面(2)包括至少一个硬钎焊区域(6)，该硬钎焊区域形成与壳体(3)相邻的、不钎焊的带状范围(7)。本发明还涉及一种用于制造相应蜂窝体的方法和相应蜂窝体的优选应用领域。

Description

具有端面硬钎焊区域的蜂窝体
技术领域
本发明涉及一种具有两个相对端面的蜂窝体，该蜂窝体包括至少一个壳体和至少一个形成通道的金属层。该蜂窝体在至少一个端面上在一个区域中进行硬钎焊。这种蜂窝体的优选应用领域是机动车辆内燃机的排气后处理领域。
背景技术
在所述蜂窝体中，壳体通常由厚壁套管形成，其中，金属层通常包括至少一个至少部分地形成结构的金属薄板。考虑到蜂窝体的应用领域，所述部件都承受高的热交变载荷和动态交变载荷。因此，确保金属层与壳体之间的或各金属层彼此之间的持久连接很重要。这里，已知不是将整个蜂窝体与壳体相钎焊，而是仅将该蜂窝体的部分区域与壳体相钎焊，使得不钎焊的部分区域能够适度地补偿不同的热膨胀性。所述钎焊的部分区域的空间分布总体上也称为钎焊图案。
然而，特别是对于直径大而轴向长度小的较大蜂窝体，在制造好后在金属层与壳体之间的边缘区域中偶尔会出现连接缺陷。特别地，会部分地观察到金属层从壳体上脱离，从而在该位置上出现一种间隙。然而，在该蜂窝体长期受载的情况下，这种间隙可能会导致部件失效。
发明内容
因此，本发明的目的在于，至少部分地解决前述技术问题。特别是应提供一种蜂窝体或一种用于制造该蜂窝体的方法，该方法即使在不利的直径/长度比例的情况下也确保金属层良好地连接在壳体上。同时，该蜂窝体应当具有对蜂窝体各部件的不同热膨胀性的良好补偿，以及对于热交变载荷和动态交变载荷的高强度或高柔韧性。
所述目的通过具有下文所述特征的蜂窝体以及包括具有下文所述步骤的方法来实现。下文还给出了本发明的有利实施形式，其中，在下文单独列出的特征可以以任何技术上合理的方式彼此组合，从而得到本发明的其它实施形式。
根据本发明的具有两个相对端面的蜂窝体包括至少一个壳体和至少一个形成通道的金属层，其中至少一个端面具有至少一个硬钎焊区域。该硬钎焊区域构造成，形成与壳体相邻的不钎焊的带状范围。
“端面”特别是指蜂窝体的、通道从其开始延伸到蜂窝体内部区域中的侧面。根据蜂窝体设计的不同，端面可以基本上是平面，或者也可以至少部分地形成有凸起部和/或凹陷部。另外，该端面也可能具有圆的、椭圆的、近似有棱角的或其它形状。两个端面在形状和钎焊区域的设置方面优选设计成相同的。
为说明(清楚)这里需指出，“硬钎焊”或“钎焊”总是指在高于450℃的温度下使用硬钎料/硬焊料的连接技术。原则上可以在一个端面上设置多个钎焊区域，但在这种情况下一个钎焊区域形成外侧的不钎焊的范围。例如，可设置多个同心(钎焊)区域，或(最外部钎焊)区域的外侧边界确定不钎焊的范围，而另一个或另几个区域与所述(最外部钎焊)区域的内侧边界相邻。
钎焊区域和不钎焊区域的外形优选与蜂窝体或壳体自身的形状相适应。如果例如蜂窝体构造成具有圆形横截面，则钎焊区域优选也是圆的，由此不钎焊的范围则是环形的。钎焊区域以相应的方式与蜂窝体的非圆柱形形状相匹配，其中在可能的情况下不钎焊的带状范围以基本不变的宽度形成。这里，不钎焊的带状范围紧靠壳体并绕壳体内周延伸。这里，该范围包括金属层的至少一个区段或多个由金属层形成的通道。在蜂窝体的这种实施形式中，不再会出现在开头所述的问题。
这特别是适用于这样的蜂窝体，在该蜂窝体中两个相对的端面限定蜂窝体的长度，该蜂窝体具有垂直于该长度的最大尺寸，其中该尺寸与长度的比例至少为2。这特别是指横截面的最大尺寸显著大于蜂窝体长度的蜂窝体。例如对于基本上圆柱状的蜂窝体来说，该最大尺寸至少是100mm或甚至是200mm或达到约400mm。同时，蜂窝体仅具有例如约50mm到70mm的最大长度。
在此范围内，所述尺寸与长度的比例也可以是至少3.5或甚至大于5。正是在蜂窝体的这些实施形式中，这里所提出的钎焊图案是令人惊奇的，这是因为必须在高的热载荷和高的动载荷的同时持久地保持蜂窝体的位于内部的较大容积。这能够例如在较低的排气流速下在疲劳试验/耐久性试验中得到证实。
还提出，不钎焊范围的平均宽度小于所述尺寸的10％。因此该平均宽度优选最大为10mm，优选在5mm到10mm的范围内。然而，通常有利的是，随着所述尺寸的增加而选择更大的平均宽度。
根据蜂窝体的另一实施形式，硬钎焊连接从端面起部分地形成到通道中。其中所述的至少一个硬钎焊区域包含端面的至少60％，优选为80％。
根据蜂窝体的又一实施形式，硬钎焊连接仅在至少一个与端面隔开的部分区段中设置在至少一个层与至少一个壳体之间。例如也就是说，所述至少一个层在两端面之间的中心区域内形成有环绕的部分区段。所述硬钎焊连接优选在所述至少一个层的端部与壳体之间形成。在该实施形式中特别有利的是，所述层包括多个至少部分地形成结构的金属薄板，这些金属薄板用两端在所述部分区段上分别固定在壳体上。然而，原则上也可以考虑用其它材料，例如金属丝布、无纺布/纤维网等，来构造所述层。
同样有利的是，蜂窝体在端面上分别仅具有一个钎焊区域，并且在与端面隔开的位置，在所述至少一个层与所述至少一个壳体之间具有包括硬钎焊连接的钎焊的部分区段。对于蜂窝体的这种实施形式，可在内部区域内产生非常大的“柔性区域”，其中以较少的硬钎料用量确保了金属层与壳体之间的持久的固定。这方面的更具体的信息还可特别地从关于图1的说明中得出。
用于内燃机的包括根据本发明的这种蜂窝体的排气处理部件是特别有利的。作为排气处理部件，特别地考虑到催化转化器、过滤器、颗粒陷阱、吸收器、转化器或燃料电池的部件、混流器、热交换器等。基于蜂窝体和排气处理部件的上下文中所述的优点特别地提出在机动车辆中的应用。
根据本发明的另一方面，提出了一种用于制造蜂窝体(特别是如前文根据本发明所述的蜂窝体)的方法，该方法至少包括以下步骤：
-在壳体的至少一个部分区段上施加硬钎料，
-缠绕或卷绕所述至少一个金属层，
-将金属层至少部分地插入壳体中，
-在端面上钎焊至少一个区域，其中产生与壳体相邻的不钎焊的带状范围，
-加热蜂窝体，以在至少一个部分区段中和所述至少一个区域中形成硬钎焊连接。
在施加硬钎料时，优选将带状钎焊材料施加到壳体内侧上。或者，所述硬钎料也可施加到事先缠绕或卷绕的金属层的外周上。优选将多个金属层(必要时可具有多个叠堆)缠绕或卷绕成，使其形成例如S形、V形或类似的形状，当插入壳体中时，这些金属层分别以其端部与壳体相接触。在钎焊所述至少一个区域时，可用盖印件施加粘合剂，然后添加粉末状钎料，使得该钎料粘附在粘合区域中。优选在每个端面上仅设置一个单个的加装钎料的区域。随后对蜂窝体的加热有利地在高温真空炉中进行，其中在设有硬钎料的位置处形成硬钎焊连接。除了所述硬钎焊连接之外，也可例如在不钎焊的范围中产生其它连接，例如扩散连接。即使在高热载荷和高动载荷的情况下，这种扩散连接也有利于蜂窝体的抗疲劳强度。
附图说明
在下文中将参照附图更加详细地说明本发明和相关技术领域。附图示出特别优选的实施方案，但本发明并不局限于此。图中示意性示出：
图1示出蜂窝体的一个实施方案，以及
图2示出这种蜂窝体用作机动车辆排气处理部件的优选应用。
具体实施方式
图1以透视剖视图示出卷绕成螺旋状的蜂窝体1，该蜂窝体1包括制成波纹状的和平滑的金属薄板17，这些金属薄板17形成具有多个通道4的层5。所述层5通过特别是具体为硬钎焊连接的接合技术与壳体3相连接。
蜂窝体1具有特有的钎焊图案，该钎焊图案由位于端面2上的区域6和位于所述端面之间的、沿周向延伸的部分区段12形成，通过该钎焊图案形成所想要的硬钎焊连接13。所述的钎焊图案的特征在于，硬钎焊区域6分别形成与壳体3相邻的不钎焊的带状范围7。换句话说，在这里形成了无硬钎焊连接的环形带。就此而言，硬钎焊区域6的任何部分都不与蜂窝体1的外边缘或壳体3直接相邻。硬钎焊区域6从端面2起形成到蜂窝体1内的深度11处。这里，区域6的深度11在两个端面2上优选数值相等。不钎焊的带状范围以均匀的宽度10环绕形成，该宽度平均来讲/在中心范围优选小于尺寸9的10％。
根据本发明的蜂窝体1特别是指长度8显著小于最大尺寸9的蜂窝体。因此，例如所述尺寸与长度的比例至少是2，优选为至少3.5。长度8基本上由所述两个端面2限定。最大尺寸9同样优选基于一个端面2，其中对于两端面2不相同和/或端面2具有多边形状的情况，分别是指最大可能的尺寸9。
现在图2示出这种大蜂窝体1的优选应用领域，即用作机动车辆16中，特别是在载重车辆或客车中的内燃机15的排气处理部件14。内燃机15产生的排气经由相应的排气系统18输送到多个排气处理部件14，例如催化转化器、过滤器等。通过与排气处理部件14的接触，排气被净化或处理成，使其能够最终排放到周围环境中。
附图标记表
1    蜂窝体
2    端面
3    壳体
4    通道
5    层
6    区域
7    范围
8    长度
9    尺寸
10   宽度
11   深度
12   部分区段
13   硬钎焊连接
14   排气处理部件
15   内燃机
16   机动车辆
17   金属薄板
18   排气系统

Claims (9)

1.一种具有两个相对端面(2)的蜂窝体(1)，所述两个相对端面(2)限定蜂窝体(1)的长度(8)，而该蜂窝体(1)具有与长度(8)相垂直的最大尺寸(9)，该蜂窝体包括至少一个壳体(3)和至少一个形成通道(4)的金属层(5)，其中，至少一个端面(2)包括至少一个硬钎焊区域(6)，该硬钎焊区域形成与壳体(3)相邻的不钎焊的带状范围(7)。
2.如权利要求1所述的蜂窝体(1)，其特征在于，所述尺寸(9)与长度(8)的比例至少是2。
3.如权利要求1所述的蜂窝体(1)，其特征在于，所述不钎焊的范围(7)具有小于所述尺寸(9)的10％的平均宽度(10)。
4.如权利要求1所述的蜂窝体(1)，其特征在于，所述至少一个硬钎焊区域(6)形成具有至多10毫米的深度(11)。
5.如权利要求1所述的蜂窝体(1)，其特征在于，仅在至少一个与端面(2)隔开的部分区段(12)中在所述至少一个金属层(5)与所述至少一个壳体(3)之间设置硬钎焊连接(13)。
6.如前述权利要求中任一项所述的蜂窝体(1)，其特征在于，该蜂窝体(1)在端面(2)上分别仅具有一个钎焊区域(6)，并且在与该端面隔开的位置，在所述的至少一个金属层(5)与所述的至少一个壳体(3)之间具有包括硬钎焊连接(13)的钎焊的部分区段(12)。
7.一种用于内燃机(15)的排气处理部件(14)，所述排气处理部件包括如前述权利要求中任一项所述的蜂窝体(1)。
8.一种车辆(16)，该车辆包括如权利要求1至6中任一项所述的蜂窝体(1)或如权利要求7所述的排气处理部件(14)。
9.一种用于制造蜂窝体(1)的方法，该方法至少包括以下步骤：
在壳体(3)的至少一个部分区段(12)上施加硬钎料，
缠绕或卷绕至少一个金属层(5)，
将金属层(5)至少部分地插入壳体(3)中，
在蜂窝体(1)的端面(2)上钎焊至少一个区域(6)，其中产生与壳体(3)相邻的不钎焊的带状范围(7)，
加热蜂窝体(1)，以在至少一个部分区段(12)中和至少一个区域(6)中形成硬钎焊连接(13)。
CN2006800349764A 2005-09-23 2006-09-22 具有端面硬钎焊区域的蜂窝体 Active CN101268261B (zh)

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