DE102004005809A1 - Method for producing an exhaust filter for an IC machine especially a small engine has a filter element pressed into a sleeve and welded to a mounting flange - Google Patents

Abstract

A method for producing a cost effective exhaust filter for a small IC engine, e.g. lawnmower, chain saw, has a filter element formed out of a mesh structure (2) and pressed into a housing sleeve (4). The sleeve is welded to a mounting flange (5) with mounting holes (21) and is incorporated into the exhaust duct of the IC engine. For simplified assembly the sleeve has a pressed outer ridge (9) to locate onto the mounting flange and providing a simple weld site.

Description

The The present invention relates to a process for the preparation of a Exhaust gas component comprising a honeycomb body inside a housing, the case having a collar element. Furthermore, the invention also relates to a Device for producing such an exhaust gas component.

With Exhaust gas components are in particular devices meant to Treatment of exhaust gases or for the conversion of contained in the exhaust gas Pollutants are used. Fields of application for such exhaust gas treatment components are especially in the mobile area, so for example at Cars, motorbikes, chainsaws, lawn mowers, etc. They are preferably used for cleaning exhaust gases mobile Internal combustion engines, such as diesel engines or Gasoline engines. The exhaust gas generated by these engines usually has Pollutants in different concentrations, especially long-chain Hydrocarbons, carbon monoxide, sulfur, oxides, particles, etc. The exhaust gas treatment component is now used for elimination, Storage or conversion of these pollutants into harmless or less harmful Components. As examples of Such exhaust gas treatment components are catalytic at this point Converter, adsorber, filters, called particle traps. Under exhaust treatment components Here, for example, structures should also be subsumed that have a Influencing the exhaust effect, for example, a flow equalization, a turbulence, a water separation, etc.

These Exhaust gas treatment components preferably have a honeycomb body through which exhaust gas flows and a housing arranged around it. The honeycomb body usually has a variety of for the exhaust gas can flow through Channels, which are arranged substantially parallel to each other. starting material in the manufacture of such a honeycomb body may be ceramic or be metallic material. Since the housing is usually made of metal, it is advantageous to also have a metallic honeycomb body use a similar one Thermal expansion behavior of honeycomb body and housing to realize. This is an extended one Lifespan of the exhaust treatment component even among the high thermal and dynamic stresses in the exhaust system of mobile internal combustion engines possible.

These Exhaust treatment components are thus finally in an exhaust system or exhaust line of the mobile internal combustion engine arranged. For this purpose, the exhaust system has corresponding expansions or constrictions, a movement of the exhaust treatment component inside the Prevent exhaust system. It is also known that the housing itself equipped with certain collar elements or beads that a stop edge for form a seat in the exhaust system. Especially with connection points of the Exhaust pipe, it has proved to be advantageous that the exhaust gas treatment component near her front or at another part of her circumference a collar member which is inserted into a joint of the exhaust pipe can be. Thus, the exhaust treatment component over the Connection of the adjacent arranged line sections of the exhaust system fixed in a simple way. For example, the output of the engine block or the beginning of the bend for positioning a Such exhaust treatment component can be used by a corresponding collar element between the engine block and the manifold arranged and screwed together with these parts. Similar options are also available in the so-called "utility" area (lawnmowers, chainsaws, etc ..), where the exhaust system often has joints due to the amount of space available.

The Production of such metallic exhaust gas treatment components with a collar portion was made in such a way that the first casing will be produced. The collar is near a front of the housing, this became common produced by forming a metal strip, wherein the metal strip after all in the desired (cylindrical) shape of the housing brought and welded at the abutting surface. Should the collar portion is formed in an area between the end faces so were usually two pipe sections selected, between which a collar in the form of an annular disc, or in similar Shape placed and smashed has been.

After this the housing finished with collar, the honeycomb body was placed inside the housing, subjected to a thermal treatment, coated, etc .. Due the fact that for all of these operations are handled by the exhaust treatment component via the housing, because of the collar special requirements for the production given. That's the case for example, on transport and / or processing devices arranged further apart so that the space required per produced exhaust treatment component is large. simultaneously is the handling of such housing difficult because the lateral surface is not "even" or even.

Under circumstances In addition, the following processing steps have an influence on the Shape of the collar, for example, the repeated heating and cooling down during coating or soldering such metallic honeycomb body. This further complicates the action of such exhaust treatment components and also causes difficulties in mounting in the exhaust system mobile internal combustion engines. A uniform design over the series of the collar is important because it may be in connecting sections of Exhaust pipes is integrated. An exceedingly large deviation of the form tolerance could lead to that such compounds are no longer gas-tight, so the environment can be contaminated with unpurified exhaust gas.

task The present invention is useful in the manufacture of exhaust treatment components with collar sections known technical difficulties and To solve problems. In particular, it is an object to provide a method with which produce such exhaust treatment components easily and inexpensively to let. In particular, there is a small space requirement for the manufacturing processes as well as a safe action or transportation of the exhaust gas treatment components in the foreground. In addition, a device for producing a Exhaust treatment component specified with such a collar portion that are in particular for the use in a series production is suitable, with the produced Exhaust treatment components can be produced reliably.

These Tasks are solved with a method according to the features of claim 1 or a device with the features according to claim 10. Advantageous developments of the method are the subject the dependent Claims. It should be noted at this point that the features listed individually in the patent claims combined in any technically meaningful way can and can represent further embodiments of the invention. The invention can be further characterized by features of the description.

• – Erzeugen eines Wabenkörpers;
• – Einführen des Wabenkörpers in ein Gehäuse mit einer Außenfläche;
• – Anbringen wenigstens eines Kragenelementes an die Außenfläche zumindest eines Gehäuses mit Wabenköper.

The method according to the invention for producing an exhaust gas treatment component comprises at least the following steps:

• - Creating a honeycomb body;
• Inserting the honeycomb body into a housing having an outer surface;
• - Attaching at least one collar element to the outer surface of at least one housing with honeycomb body.

Basically at this point once again pointed out that under one Exhaust treatment component of any of the currently known components is to be understood, ie in particular catalytic converter, adsorber, Hydrocarbon traps, particulate filters, etc. These are under circumstances Also meant components in one stage, which alone influence the flow have the goal (turbulence, diversion, ...), which, for example the coating is missing.

in the With regard to the first production step, it should be noted that in principle not a single honeycomb body must be made separately, it is also possible that several honeycomb body at the same time can be produced. Thus, it is also possible, if necessary, several such honeycomb body in the housing provided. With honeycomb body In particular, a structure is meant which on the front side a Variety of for an exhaust gas permeable through openings has, to which advantageously channels connect. With channel is particular the rectilinear course of a flow path meant, wherein the Cross section does not necessarily have to be constant. It is also possible that the channels are at least partially closed and optionally in the Sewer walls holes are provided, so avoid partial exhaust gas flows in adjacent channels can. Advantageously, such a honeycomb body has a relation to a unit cross-sectional area Channel density of up to 1,600 cpsi (cells per square inch; cells per square inch; Conversion: 1 square inch equals approximately 6.4516 square centimeters) on. However, the channel density is preferably within a range of 50 cpsi to 200 cpsi. The honeycomb body can basically made of a ceramic mass or of metallic components be.

At least one of these honeycomb bodies will now be in a housing introduced. The housing has an outer surface that For example, describe by the two end faces and a peripheral surface leaves. This is especially the surfaces meant, which are not in contact with the honeycomb body.

Now According to the invention, it is proposed that at least one collar element on this outer surface of at least one housing honeycombs is attached. "Attach" is here in particular to understand that a fixation of the collar member to the desired Place the outer surface of the housing given is. This is preferably joining technical nature, so that a material connection of collar element and housing is realized. this includes especially welding, Soldering and / or diffusion connections.

In the production of an exhaust gas treatment lungskomponente are different variants of assignments of a collar element in contrast to a housing possible. For example, a collar element can accommodate a plurality of housings, but it is also possible for a plurality of collar elements to be attached to a single housing. In many cases, however, exactly one collar element is attached to a single housing. By "collar element" is meant a separate component which is oriented at least obliquely and preferably substantially perpendicularly to the peripheral surface of the housing The collar element is advantageously formed circumferentially around the circumference of the housing, but this is not necessarily the case The collar element can also have a round, oval, angular or other shape, and it is also possible for the collar element to have recesses, grooves, different material thickness, etc.

advantage in the sequence of processing steps proposed here, that that hampers production or makes it harder to design Collar element is attached to the housing only at the end. All previous ones Processing steps, for example, to complete the Serving honeycomb bodies, can in the usual way Manner performed become. This concludes with one that the case of the honeycombs in the thermal treatment of the honeycomb body or in the coating placed close together and easy to handle. In the case that the case have a substantially cylindrical shape, they can together with the honeycomb bodies also be transported rolling. Only at the end of the manufacturing process becomes the case provided with the collar element. This allows that also such exhaust treatment components can be introduced into existing production chains, and the final processing step on a specially provided Processing station can be made. This leads to a very simple and inexpensive Production. In addition, the collar element is only a low shock and heat load exposed so that a high dimensional accuracy of the collar element ensured after the preparation of the exhaust treatment component is.

According to one preferred embodiment of the method, the attachment of the at least one collar element by welding with a rotating arc. This represents a special welding process, being straight circumferential welds very good and economical to produce. In this welding process a displacement of the arc column takes place through an external magnetic field. The between the case and The arc generated by the collar element is by means of an external magnetic field generated tangential force rotated. This will be a corresponding Melting bath produced. After the required welding time has expired pressed the two components against each other, leaving a fabric bond takes place. Drive this welding process characterized by very short welding times, lower heat load, low energy consumption, accurate final dimensions and high efficiency out. Due to the low energy input and the splash-free welding technology unnecessary reworking because of heat distortion or holding beads of sweat.

This Procedure is available for the application described here, in particular because In some way tolerances in the production of collar element and housing allowed are. For example, consider other welding methods, so they usually either a large and intensive heat input result or require a very small gap between the to be connected components. The high heat input can be in many make a heat distortion the collar element or other constituents of the exhaust treatment component to Episode. Very low manufacturing tolerances regarding the Collar element or the housing would have to be respected be used, for example, when laser welding should be used, since here almost only a gapless connection is possible.

These ravages are avoided by the use of welding with a circulating arc. By electrical contacting of the components an arc is formed between them, which runs along the edge of the collar member or of the housing by the application of an external magnetic field. This is how a molten bath is generated, which ultimately forms the basis for the material bond. To illustrate the method is particularly to the 2 or the corresponding explanation.

According to a development of the method, the honeycomb body is produced with at least partially structured metallic layers. Thus, it should first be noted that as a preferred embodiment of the honeycomb body, this is constructed with metallic material. The layers may in particular be formed with metal foils, expanded metals, fiber tiles, etc. At least some of these layers are structured, that is to say that at least one smooth and one structured layer or a layer structured in partial regions and in other partial regions smooth is used. The at least partially structured metallic layers preferably form channels which are arranged substantially parallel to one another. The layers can be spirally wound, stacked parallel to each other, wound together or devious arranged. It is particularly advantageous that the ends of the at least partially structured metallic layers are all in contact with an inner surface of the housing, so that secure fixing of the metallic layers to the housing is possible.

In addition, will also suggested that the housing with a diameter of up to 70 mm. This will in particular a preferred application for the above welding process named with circulating arc. Leave such housing to record in a first shot of a corresponding tool and contact with electricity, so that, for example, at the end faces of the Housing Arc forms.

According to one Another embodiment of the method, the housing with generates at least one stop edge. Under a stop edge is in particular a circumferential bead understood that as an attachment for the at least a collar element is used. So if the case with such a stop edge through an opening inserted through the collar element, so is the width of the stop edge or the bead is larger than the inner diameter of this opening of the collar element. This allows an exact positioning of the Collar element on the outer surface of the Housing made become. The bead is preferred before inserting the honeycomb in the case educated. in principle it is also possible that the stop edge by another separate component the outer surface of the housing provided.

According to one advantageous development of the method, the housing with a thickness of 0.2 mm to 2.0 mm produced. Thus, the proposed Procedure in particular the possibility ready to use very thin case with to provide a collar, for example, with a smaller thickness 1.0 mm. Cause for it is above all the very small and localized heat influence, when the fixation of the collar element on the outer surface of the housing by means of the method the rotating or circulating arc is made.

To a development of the method, the housing has at least in the area of Contact with the at least one collar element one of a round cross section deviating cross section. That means with others Words that the cross section of the housing in the area of contact or preferably over the entire length of the housing not cylindrical or round. Rather, you can also be here realize triangular, quadrangular, oval or other cross-sectional shapes. This is particularly due to the cramped space in the places of Exhaust system of advantage, usually for the Attachment of such exhaust treatment components are provided (im manifolds, in a chainsaw, Etc.).

Further is also proposed a method in which the honeycomb body after the insertion in the housing subjected to a thermal joining process becomes. In a thermal joining process In particular, connections between the components of the honeycomb body or between the honeycomb body and the housing educated. For this purpose, soldering, welding and / or diffusion processes are preferred used this for metallic honeycomb bodies applies. In particular It has the high-temperature vacuum brazing for a simultaneous connection from the honeycomb body forming metallic layers with each other and the layers exposed to the housing.

one According to another embodiment of the method, the honeycomb body is present the attachment of the at least one collar element at least partially coated. The coating includes any currently known, used in exhaust treatment components coating. This concerns (in particular Platinum-containing) catalytically active coatings, adsorbent Coatings, etc. It is also possible that the honeycomb body only partially, For example, in an area near a front side, with a Coating is provided. It is also possible that the honeycomb body several Has zones with different coatings. Will that too Coating before the attachment of the at least one collar element carried out, can be used on known production lines for the production of such Exhaust treatment components used be, with only the additional Step of simple and uncomplicated attachment of the collar element, For example, by a rotating arc, still accomplished must become. This simplifies the production significantly and leads to a very cost-effective Production.

According to a further aspect of the invention, an apparatus for producing an exhaust gas treatment component is proposed. The device comprises a first receptacle for at least one housing with a diameter of 30.0 mm to 70.0 mm and a second receptacle for at least one collar element. In addition, means for generating a welding current and means for generating a rotating magnetic field are provided. The device is thus able to perform the above-mentioned method of attaching the collar member by welding with a circulating arc. The first receptacle for at least one housing is advantageously as a contact for the welding current formed, which is transmitted to the housing. As a means for generating the rotating magnetic field special solenoid coils are particularly advantageous, which form around the housing around a corresponding magnetic field.

The Invention and the technical environment are based on the figures below explained. The figures show particularly preferred embodiments of the invention, to which, however, this is not limited. Show it:

1 schematically and in perspective the representation of an exhaust gas treatment component;

2 schematically and in a partial cross section, the representation of an apparatus for producing an exhaust gas treatment component with a collar member; and

3 schematically an embodiment of the method according to the invention.

1 shows an exhaust treatment component 1 in a perspective, schematic representation. The exhaust treatment component 1 has a honeycomb body 2 on that inside a case 3 is placed. The honeycomb body 2 is with a plurality of metallic layers 7 formed, which are at least partially structured, so that channels 22 are formed. The housing 3 has an outer surface 4 on, extending over the opposite end faces 16 and the peripheral surface 17 extends. The housing 3 also has a thickness 10 for example, in the range of 0.2 mm to 2.0 mm.

On the outside surface 4 of the housing 3 more precisely on the peripheral surface 17 , is a collar element 5 arranged. This has a substantially quadrangular cross-section 11 and has a circumferentially varying collar width 32 on. In the corner areas of the collar element 5 are holes 21 provided, which can be used for example for simultaneous fixation with exhaust pipe sections for attachment. Such exhaust treatment components 1 with a collar element 5 may be arranged in exhaust pipes of automobiles, for example, upstream and / or downstream of a turbocharger. It is also possible, the collar element 5 to arrange between the engine block and the exhaust pipe, wherein a part of the exhaust gas treatment component 1 possibly projects into inner areas of the engine block.

The housing 2 has one over the peripheral surface 17 circumferentially formed stop edge 9 in the form of a bead, against which the collar element 5 rejects. Between this stop edge 9 and the collar element 5 is a technical connection formed.

2 shows schematically and in a partial cross section an apparatus for producing an exhaust gas treatment component with a collar element 5 , The device has a first shot 12 for a housing 3 , in which already a honeycomb body 2 is arranged. Furthermore, the device has a second receptacle 13 on, for fixing the collar element 5 serves. The housing 3 is there with a welding power generator 14 electrically connected. For this it is necessary that also the housing 3 as well as of course the collar element 5 consists of an electrically conductive and weldable material. In addition to the first shot 12 the device has a magnetic field generator 15 on, around the case 2 around a magnetic field generated. The housing 3 will now be essentially centric to the opening 23 of the collar element 5 positioned.

Now, by means of the welding current generator 14 the welding current is generated and sent to the housing 3 is forwarded forms, starting from the end face 16 of the housing 13 an arc 6 towards the edge area near the opening 23 of the collar element 5 out. Thus, a molten bath is generated at these points, in which the end face 16 finally dipped. If the welding current is applied and the magnetic field is formed, a force is created on the arc 6 , where in the 2 schematically on the one hand the magnetic field effect 25 and the force effect 26 are indicated. As a result, the arc 6 towards the circulation 24 emotional. With this method, exhaust gas treatment components having a diameter are preferred 8th manufactured in the range of 30 mm to 70 mm.

3 schematically shows the process in a method for producing an exhaust gas treatment component 1 , For this purpose, according to step A first smooth layers 7 and structured layers 7 stacked on top of each other so that channels arranged substantially parallel to one another 22 are formed. The layers 7 are now wound substantially S-shaped to a cylindrical honeycomb body 2 (see step B). This cylindrical honeycomb body 2 will now be in a housing 3 introduced, which has a diameter 8th of for example 70 mm and likewise a round cross-section 11 Has. At a distance 31 from the frontal area 16 is designed as a bead stop edge 9 educated.

Now that the honeycomb body 2 in the case 3 is placed, the honeycomb body 2 with a lot 19 brought into contact. The preferred powdered solder 19 is over a front page 18 of the honeycomb body 2 into the channels 22 or in Berei surface of the contact surfaces of the metallic layers 7 with each other or with the case 3 positioned. If necessary, it may be necessary to first place an adhesive or adhesive at the desired locations. To apply the solder 19 In particular, a fluidized bed is suitable, wherein the solder 19 by means of a honeycomb body 2 is introduced by flowing air flow (step C). The thus prepared body becomes a high-temperature furnace according to step D. 30 fed and subjected to a thermal treatment under conditions, so that the desired solder joints uniformly in the interior of the honeycomb body 2 or between honeycomb body 2 and housing 3 form.

The honeycomb body thus joined by joining is subsequently coated. As indicated in step E, the layers are facing 7 then a coating 20 on, with this illustrated coating 20 with a catalyst 27 impregnated. The coating 20 usually also comprises a carrier layer, for example wash-coat.

The final manufacturing step (step F) is now a collar element 5 with the housing 3 connected. This is the case 2 through an opening 23 of the collar element 5 inserted through, with the opening 23 an annular gap 29 towards the housing 3 forms. This gap 29 can be up to one millimeter (1.0 mm) without welding the two components together using the continuous arc welding process 6 to endanger. The arc 6 Now, with appropriate contact with the welding current around the stop edge 9 run around and a weld 28 between housing 3 and the collar element 5 form. This weld 28 does not contain any additional material but is created by a material connection of housing 3 and collar element 5 ,

The Thus produced exhaust treatment component is characterized by the easy handling during the production as well as a high dimensional accuracy in the end desired shape out. The process is also easy in existing production lines integrate and with the welding process of circulating To operate the arc also process reliable. That's what it's all about in particular, the described method for the mass production of exhaust treatment components use.

1

Exhaust gas treatment component

2

honeycombs

3

casing

4

outer surface

5

collar element

6

Electric arc

7

location

8th

diameter

9

stop edge

10

thickness

11

cross-section

12

First admission

13

Second admission

14

Welding current generators

15

Magnetic field generator

16

face

17

peripheral surface

18

front

19

solder

20

coating

21

drilling

22

channel

23

opening

24

circulation

25

magnetic effect

26

force action

27

catalyst

28

Weld

29

gap

30

oven

31

distance

32

collar width

Claims (10)

Method for producing an exhaust gas treatment component ( 1 ) comprising at least the following steps: - producing a honeycomb body ( 2 ); - insertion of the honeycomb body ( 2 ) in a housing ( 3 ) with an outer surface ( 4 ), characterized in that - attaching at least one collar element ( 5 ) to the outer surface ( 4 ) at least one housing ( 3 ) with honeycomb body ( 2 ). Method according to claim 1, characterized in that the attachment of the at least one collar element ( 5 ) by welding with a circulating arc ( 6 ) he follows. Method according to claim 1 or 2, characterized in that the honeycomb body ( 2 ) with at least partially structured metallic layers ( 7 ) is produced. Method according to one of the preceding claims, characterized in that the housing ( 3 ) with a diameter ( 8th ) up to 70 mm [mm]. Method according to one of the preceding claims, characterized in that the housing ( 3 ) with at least one stop edge ( 9 ) is produced. Method according to one of the preceding claims, characterized in that the housing ( 3 ) with a thickness ( 10 ) is produced from 0.2 mm to 2.0 mm. Method according to one of the preceding claims, characterized in that the housing ( 3 ) at least in the region of contact with the at least one collar element ( 5 ) one of a round cross section ( 11 ) different cross section ( 11 ) having. Method according to one of the preceding claims, characterized in that the honeycomb body ( 2 ) after insertion into the housing ( 3 ) is subjected to a thermal joining process. Method according to one of the preceding claims, characterized in that the honeycomb body ( 2 ) before attaching the at least one collar element ( 5 ) is at least partially coated. Device for producing an exhaust gas treatment component ( 11 ) comprising a first photograph ( 12 ) for at least one housing ( 3 ) with a diameter ( 8th ) from 30 mm to 70 mm, a second receptacle ( 13 ) for at least one collar element ( 5 ) and means for generating a welding current ( 14 ) and means for generating a rotating magnetic field ( 15 ).