EP0218062B1 - Support matrix, particularly for a catalytic reactor for purifying exhaust gases of internal-combustion engines - Google Patents

Abstract

1. A procedure for creating for a catalyst reactor, a supporting matrix with any pre-determinable sectional area, for the purpose of purifying the exhaust gases of internal-combustion engines, there being a least one metal conveyer belt, streamlined in its cross-direction, from which the supporting matrix is coiled, the supporting matrix being enclosed by a casing, and characterized in that during the coiling procedure, guiding devices (18) are placed between adjacent coiled positions after every coiled position (22) of the conveyer belt (16) and over the outer coiled position, the guiding devices resting on a pre-determined plane and forming the guiding devices of the conveyer belt (16), in such a way that after the coiling process, the guiding devices (18) may be removed from the supporting matrix (15) and the supporting matrix (15) may be inserted into the casing, by deformation, the casing having the final shape of the supporting matrix (15).

Description

The invention relates to a method for producing a carrier matrix for a catalytic reactor for exhaust gas purification in internal combustion engines, with at least one metallic carrier strip which is profiled essentially in its transverse direction and from which the carrier matrix is wound, which is enveloped by a jacket.

Such a method is known from DE-A 2 302 746. There, smooth tapes are unrolled from two supply rolls, one of which is profiled by means of a corrugating machine. The corrugated and smooth strips are then fed via deflection rollers to a winding machine, which winds the two strips onto a winding core. This creates a carrier matrix in which the smooth and the wavy tape spiral around the winding core.

It is also known (DE-A 2 856 030) to provide a circular or oval cylinder as the winding core, which is pulled out of the carrier matrix after the winding process. The resulting cavity is closed after the winding process by pressing or pressing, the cross section of the winding body being changed. These change options are limited to elliptical or flat oval shapes, otherwise the carrier tape itself would be deformed and damaged.

This also applies to manufacturing processes (GB-A 2 072 064), in which a plate-shaped rectangular winding core remains in the wound carrier body, to which the beginning of the winding carrier tape is welded at a point.

Such production methods can also only be used if the flow resistance of the finished catalyst body caused by the remaining winding core is negligible.

However, it is also known to produce a support matrix for a catalytic reactor (EP-A 1 210 546) in that a blank is produced from alternating layers of smooth and corrugated sheet metal strips each from turns of these wound sheet metal strips of different lengths, the respective lengths of which during the winding process the desired final shape must be designed. The procedure is such that one side of the blank to be wound is tight, i.e. with close to each other and also by spot welding or the like. layers fixed against each other is produced, while the loops formed on the other side remain more or less loose and are only brought into adjacent layers during the subsequent deformation to the final shape. The implementation of such a winding process is quite complex since one side is always tightly wound and the layers have to be fixed there with one another.

The present invention is therefore based on the object of providing a method and a device for producing a carrier matrix with which an arbitrarily definable cross-section can be achieved without great difficulty and thus the possibility can be created of the carrier body thus wound to existing spaces in the exhaust pipe optimally adapt a motor vehicle.

To solve this problem, the characterizing features of claim 1 are provided in a method according to the preamble of claim 1. This procedure ensures that the carrier matrix can already have trapezoidal or triangular cross-sections in a very simple manner, with the deflecting means keeping the layers which are later adjacent to one another at a distance, which only disappears when they are deformed into the final shape. In particular, if the carrier matrix is composed of several wound carrier matrix parts, it becomes possible to provide the cross section of the carrier matrix, in particular with concave curvatures, which could not previously be achieved in such a simple manner. The new method causes the carrier tape to be lifted from the respective underlying winding layer by the deflecting means and is deflected around the deflecting means by the application of the carrier tape. The dimensions of the deflection means leave deflection points on the wound carrier matrix which are adapted to their cross-sectional shape.

After the winding process, the deflecting means are removed from the carrier matrix and the carrier matrix is introduced into the jacket with deformation, which has the final shape of the carrier matrix. The carrier matrix is deformed into the shape of the jacket either before or during insertion into the jacket. This measure ensures that the exhaust gases flowing through the carrier matrix during operation are not hindered by the deflecting means, that is to say the functionality of the carrier matrix is not restricted, but at the same time the desired cross section of the carrier matrix generated by means of the deflecting means is retained.

In an advantageous development, the distance between the deflection means, over which the carrier tape is wound one after the other with continuous winding, corresponds to the length of the carrier tape between the deflections after the carrier matrix has been introduced into the jacket with deformation. The consequence of this is that the spatial position of the deflecting means is no longer bound to the desired cross section of the carrier matrix, but rather the deflecting means can only be introduced as a function of their distance between the winding layers of the carrier tape. It is particularly advantageous to arrange the deflection means on lines, in particular in a star shape. This makes it possible to wind the carrier matrix at a high and uniform winding speed without the need for complicated winding drives.

An advantageous embodiment consists in that the carrier tape is provided with the weak points assigned to the deflections before the winding. This measure has the effect that the deflection points are formed even better and more precisely by the kinks or perforations present in the carrier tape.

In a suitable device for the manufacture A carrier matrix according to the invention is provided with two rotatably connected disks provided with a rotary drive, at least one of which is provided with receptacles for the deflecting means at a distance from the axis of rotation. With the help of this arrangement, it is possible to generate the deflections simultaneously with the winding of the carrier tape by inserting the deflection means. It is particularly advantageous if pins serve as deflecting means which extend at least from a disk into the winding area, an extension drive being able to be provided for the pins and being switchable in accordance with the progressive winding. In principle, it is also possible to provide the rotary drive with only one disk, onto which the carrier tape is wound and into which the deflection means are inserted.

In one development, two coaxial pins, which run parallel to the axis of the disks and are arranged opposite one another in the disks, are provided. This measure enables further automation and acceleration of the winding process. It is particularly advantageous if the outer surfaces of the pins form deflection edges. This causes a more precise definition of the deflection points when winding the carrier tape.

An advantageous further development comprises a device for deforming the carrier matrix and for adapting its shape to the shape of the jacket. With the aid of this device, after the pins serving as deflection means have been removed, the carrier matrix is either first deformed and then inserted into the jacket, or at the same time deformed into the final shape of the carrier matrix when inserted into the jacket.

• Fig. 1 einen aus Raumgründen geforderten Querschnitt für eine Trägermatrix,
• Fig. 2 den Querschnitt einer gewickelten, jedoch noch nicht in einen Mantel eingeführten Trägermatrix,
• Fig. 3 den Querschnitt einer im Mantel befindlichen Trägermatrix,
• Fig. 4a einen aus Raumgründen geforderten Querschnitt für eine weitere Trägermatrix,
• Fig. 4b den Querschnitt eines dreieckförmigen Wickelkörpers,
• Fig. 4c den Querschnitt eines ringförmigen Wickelkörpers,
• Fig. 5 den Querschnitt einer aus drei Trägermatrixteilen zusammengesetzten und in einem Mantel befindlichen Trägermatrix,
• Fig. 6 eine schematisch dargestellte Wickelvorrichtung,
• Fig. 7 einen Teilschnitt der Wickelvorrichtung der Fig. 6,
• Fig. 8 einen Teilschnitt einer automatischen Wickelvorrichtung gemäß der Fig. 6 und
• Fig. 9 eine Einführeinrichtung.

Further features and advantages of the invention result from the subclaims and from the following description of the drawing, in which preferred exemplary embodiments are shown. Show it:

• 1 is a cross section required for a carrier matrix for reasons of space,
• 2 shows the cross section of a wound carrier matrix which has not yet been introduced into a jacket,
• 3 shows the cross section of a carrier matrix located in the jacket,
• 4a is a cross section required for another carrier matrix for reasons of space,
• 4b shows the cross section of a triangular winding body,
• 4c shows the cross section of an annular winding body,
• 5 shows the cross section of a carrier matrix composed of three carrier matrix parts and located in a jacket,
• 6 is a schematically shown winding device,
• 7 is a partial section of the winding device of FIG. 6,
• Fig. 8 is a partial section of an automatic winding device according to FIGS. 6 and
• Fig. 9 an insertion device.

In FIG. 1, a desired cross-sectional shape of a carrier matrix is shown with the aid of a hatched area 12, which is predetermined, for example, by the carrier matrix being fastened in the region of the cardan tunnel of a motor vehicle and intended to fill the entire available space there. The production of a carrier matrix with the cross section shown in FIG. 1 is explained below with reference to FIG. 2.

In FIG. 2, a carrier matrix 15 consists of a high-temperature-resistant, metallic carrier tape 16 which is wound around a winding core 17 and around deflection means 18. An axis of rotation 19 forms the center of the winding. Reference number 22 denotes a single winding layer of the carrier matrix, which always consists of a full wrapping of the carrier tape 16 around the winding core 17. The carrier tape 16 consists of a smooth and a corrugated metal tape, the width of which corresponds to the desired axial length of the carrier matrix 15. However, it is also possible for the carrier tape 16 to be in the form of a trapezoidal profiled tape. The winding core 17 is of elongated shape, while the deflection means 18 are circular cylindrical bodies. The deflecting means 18 are arranged on both sides of the winding core 17 in a respective plane 21, which each form an obtuse angle with the plane of the winding core 17. It is also possible for the deflecting means 18 to be offset, in particular arranged in a zigzag shape to the plane 21.

The carrier tape 16 is fastened to the right end of the winding core 17 and lies on the upper side thereof. At the left end of the winding core 17, the carrier tape 16 is guided over a deflection means 18, in order to then arrive at a deflection means 18 located at the right end of the winding core 17, parallel to the underside of the winding core 17. A winding layer 22 of the carrier matrix 15 is thus implemented. Thereafter, the carrier tape 16 either lies on the previous winding layer 22 or is wound around a further deflecting means 18. The individual deflecting means 18 are introduced one after the other, always after the winding layer running under the deflecting means to be introduced is wound up, ie only shortly before the carrier tape 16 is to be wound over the respective deflecting means 18. The manner in which the winding core 17 and the deflection means 18 are introduced and fastened in the carrier matrix 15 will be explained later. Overall, the winding of the carrier tape 16 onto the winding core 17 and via the deflecting means 18 results in a carrier matrix 15 with a trapezoidal shape.

In FIG. 3 the finished wound carrier matrix of FIG. 2 is in a jacket 10, the cross section of which corresponds to the cross section 12 shown in FIG. 1. The carrier matrix 15 of FIG. 2 has been introduced into this jacket 10 after the winding core 17 and the deflection means 18 have been removed from the carrier matrix 15. By introducing the carrier matrix 15 into the jacket 10, deflection points 20 have formed, which are located on both sides of the winding core 17 in the plane 21. Depending on the curvature of the carrier tape 16 such a deflection point 20, the deflection points have a more or less large acute angle. Similar to the deflection means 18 of FIG. 2, the two planes 21 containing the deflection points 20 form an obtuse angle with the two parallel side surfaces of the carrier matrix and intersect at an intersection point 23.

The jacket 10 is advantageously made of steel and has the desired cross-section, as shown in FIG. 1, even before the carrier matrix 15 of FIG. 2 is introduced. The production of the jacket 10 is known and will not be explained in more detail. However, the insertion of the carrier matrix 15 into the jacket 10 will be described.

2, the deflection means 18 are arranged such that almost the desired cross section of the carrier matrix 15 is obtained by the winding alone. To produce a different cross section, it is therefore only necessary to arrange the deflecting means 18 differently and to wrap it with the carrier tape 16. In principle, however, it is not necessary to produce a winding body that largely has its final shape when winding the carrier tape 16. If necessary, it may be advantageous not to use a winding core 17, but rather to start winding the carrier matrix 15 immediately with the aid of deflection means 18. In these cases, the beginning of the carrier tape 16 can be fastened to a deflection means 18 or to the winding axis 19. It is also possible to use differently shaped winding cores 17 and / or deflection means 18.

For the generation of any cross-section of a carrier matrix 15, when using an elastically deformable carrier tape 16, it is not the spatial position of the deflecting means 18 that is decisive, but rather the circumferential length of each individual winding layer 22 of the carrier matrix 15 each individual winding position can be calculated or measured. The successive deflection points 18 can basically be arranged spatially as long as the resulting winding layers have the corresponding circumferential lengths. Due to the elastic deformability of the carrier tape 16, after the winding body 15 has been wound, the core 17 and the surrounding means 18 have been removed, it is possible to press the carrier matrix 15 into the desired shape when it is inserted into the jacket 10 without plastic deformation of the carrier matrix 15 occur.

It is particularly advantageous to design the deflecting means 18 as star-shaped as possible, e.g. to be arranged in the form of a right-angled cross extending from the winding axis. This makes it possible to wind the carrier matrix 15 at a high and uniform winding speed without the need for complicated winding drives.

A desired cross section of a further carrier matrix is shown in FIG. 4a with the aid of a hatched area 32. Such a carrier matrix is produced from a total of three winding bodies from the carrier tape 16, two of which have the triangular cross section of the winding body 35 shown in FIG. 4b and one has the annular cross section of the winding body 36 shown in FIG. 4c. The winding bodies shown in FIGS. 4b and 4c are produced analogously to FIGS. 1 to 3, with no winding core in the winding body of FIG. 4b, but deflection means 39 arranged in a star shape and a core 38 and linear in the winding body of FIG. 4c arranged deflection means 39 are used.

FIG. 5 shows a carrier matrix 15 which is located in a jacket 30, the cross section of which corresponds to the cross section shown in FIG. 4a. The carrier matrix 15 consists of the two winding bodies 35 and the winding body 36 of FIGS. 4b and 4c. After the winding core 38 and the deflection means 39 have been removed, the two winding bodies 35 are inserted into the interior of the winding body 36. A force 37 is then applied to the top of the winding body 36. As a result, the upper part of the annular winding body 36 is arched inwards, so that the entire carrier matrix 15 can thereby be inserted into the preformed jacket 30.

Any cross-section of carrier matrices can be produced by combining several winding bodies into a carrier matrix. In particular, it is possible to provide a carrier matrix with a concave curvature.

6 shows a winding device 50 for producing a carrier matrix. For this purpose, two winding disks 52 are connected to one another in a rotationally fixed manner by means of an axis 51. In each winding disk 52 there are identical bores 53 which are arranged in radially directed planes. The entire winding arrangement 50 is rotated about the axis of rotation 19 manually or with the aid of corresponding drive machines. To wind a carrier matrix, the beginning of it is fastened to the axis 51 and the winding device 50 is then set in a rotational movement. If a deflection means is to be introduced between the winding layers during the winding process, this deflection means is introduced through the corresponding bore 53 into the area between the two winding disks 52 and the carrier tape is wound over it. This is shown again in FIG. 7.

FIG. 7 shows a partial section of the winding device 50 of FIG. 6, namely the area of the connection of the axis 51 to a winding disk 52. This connection is shown by way of example by means of a screw 58, pins 73 being able to be present for the torsional strength. As already mentioned at the beginning, the carrier tape 16 consists of a corrugated and a smooth tape, which are identified in FIG. 7 by the reference numbers 57 and 56. The distance between the two belts 56 and 57 arises from the profiling of the corrugated belt 57. Furthermore, a deflection pin 55 is shown, which extends into the area between the two winding wheels 52, the winding area 66 and on which therefore the smooth belt 56 of the carrier tape 16 rests. The pin 55 is guided by the bore 53 and has an edge 67 in the winding area 66 through which the carrier tape 16 ge is kinked, that is, the angular shape shown in FIG. 3 receives the deflection 20. Each pin 55 runs parallel to the axis of rotation 19 of the winding arrangement 50 and is inserted through two holes 53 belonging to the two winding disks 52 to form a deflection 20. It is particularly advantageous to use two pins to form a deflection point 20 which are inserted into two mutually opposing bores 53 of the two winding disks 52 and thus run coaxially and which extend only slightly into the winding area 66. Due to the stability of the carrier tape 16, in particular due to its profiling, it is sufficient for the formation of deflections to guide the carrier tape 16 over corresponding pins 55 only at its edge. It is also possible to wind the carrier tape 16 onto only one winding disk 52 and to insert it only through these pins 59 to form the deflection points 20.

FIG. 8 also shows a partial section of a winding arrangement 50 according to FIG. 6, in which, however, the individual deflecting means are automatically moved into the winding area. For this purpose, there are pins 59 in the bores 53 of the winding wheel 52 of FIG. 8, which are pressed out of the winding area 66 with the aid of springs 62. The springs 62 are located in recesses 63 between the winding wheel 52 and the pins 59. A slider 60, which is connected to the winding wheel 52 by means of a holder 61, is attached to the outside of the winding wheel 52 so that it passes over the pins 59 can be pushed away. When the slider 60 reaches a pin 59 with its inclined end face 65, the forward movement of the slider 60 is deflected into a movement of the pin 59 via the inclined surface 64 of the pin 59. As a result, the tip of the pin 59 extends into the winding area 66, which, by winding the carrier tape 16 over it, results in a deflection 20 thereof. When the pin 59 is pressed in, the spring 62 is also compressed, so that when the slide 60 is pulled back and thus the pin 59 is released, it is automatically pulled out of the winding area 66 again.

It is particularly advantageous to provide the pins 59 with a triangular cross section, the tip of the triangle pointing away from the axis 51 and thus forming an edge for the carrier tape 16. It is also advantageous to connect the slide 60 to the device driving the entire winding arrangement 50, so that the individual pins 59 are automatically inserted into the winding area 66 at the right time.

In a similar way, it is possible to design the individual pins 59 to have different lengths, so that in the initial state they protrude from the disk 52 to different distances. A plate, which is moved parallel to the winding disk 52, then presses the individual pins 59 into the winding area 66 one after the other. The time of pressing in depends on the length of the respective pin 59.

It is also possible to use other devices instead of the winding arrangement shown in FIG. Actuate the individual pins 59 hydraulically, pneumatically or by means of electrically or electronically controlled solenoid valves. Particularly when using electronic devices, for example a correspondingly programmed computing device, in addition to controlling the rotational speed of the winding arrangement and the times of insertion of the individual pins to form the deflection points, the carrier tape can also be used in a particularly advantageous manner before the winding up at the corresponding deflection points Kink or perforation or the like can be provided.

If the carrier matrix is wound and any existing winding cores and deflection pins have been removed, the carrier matrix is transferred into the jacket and thus into its final shape with the aid of the device shown in FIG. 9. In this process, as already mentioned, the cross section of the carrier matrix can be changed without the carrier matrix, in particular the profiling of the carrier tape, being plastically deformed. This is possible because, due to the deflection points of the carrier matrix, the circumferences of the individual winding layers of the carrier matrix are matched to the desired shape.

9, a funnel 70 opens into a holding device 72, in which the jacket 10 is inserted. The outlet cross section of the funnel 70 and the holding device 72 corresponds to the cross section of the casing 10. The carrier matrix 15 is moved forward in the direction 71, so that its cross section is automatically reshaped to the cross section of the casing 10 due to the conical surfaces of the funnel 70.

It is also possible to insert the carrier matrix 15 into the jacket 10 with the aid of other devices. For example, flat jaws, which at least partially have the shape of the desired cross section of the carrier matrix, can hold the carrier matrix on its outer surface and, if necessary, deform it, in order then to insert it into the jacket with the aid of a stamp. It is possible that the jacket consists of several parts and forms the flat jaws. In this case, the individual parts of the jacket have to be welded together, for example, after the carrier matrix has been introduced.

Claims (17)

1. A procedure for creating, for a catalytic reactor, a supporting matrix with any pre-determinable sectional area, for the purpose of purifying the exhaust gases of internal-combustion engines, there being at least one metal conveyer belt, streamlined in its cross-direction, from which the supporting matrix is coiled, the supporting matrix being enclosed by a casing, and characterised in that during the coiling procedure, guiding devices (18) are placed between adjacent coiled positions after every coiled position (22) of the conveyer belt (16) and over the outer coiled position, the guiding devices resting on a pre-determined plane and forming the guiding devices of the conveyer belt (16), in such a way that after the coiling process, the guiding devices (18) may be removed from the supporting matrix (15) and the supporting matrix (15) may be inserted into the casing, by deformation, the casing having the final shape of the supporting matrix (15).

2. A process according to Claim 1, characterised in that the supporting matrix (15) is given the shape of the casing (10) by deformation prior to insertion into the casing (10).

3. A process according to Claim 1, characterised in that the supporting matrix (15) is given the shape of the casing (10) by deformation during insertion into the casing (10).

4. A process according to one of Claims 1 to 3, characterised in that the distance of the guiding devices (18) across which the conveyer belt (16) is coiled during continuous coiling, equals the length of the conveyer belt (16) between deflections (20), after the supporting matrix (15) has been inserted into the casing (10) by deformation.

5. A process according to one of Claims 1 to 4, characterised in that a section of supporting matrix (36) is coiled, which has one or more cavities (38), into which one or more other specially created sections (35) of the supporting matrix are inserted prior to inserting the matrix into the casing (10) by deformation.

6. A process according to one of Claims 1 to 5, characterised in that the conveyer belt (16) is provided, prior to being coiled, with the weak points attributed to the deflections (20) in the form of bends or perforations.

7. A device to carry out the process according to Claims 1 to 6, characterised in that two discs (52) connected to one another by an axis of rotation (19), and equipped with a rotary drive, of which at least one disc is set at a distance from the axis of rotation (19) with a take-up device for the guiding devices (18), and characterised in that there are pins (55, 59) protruding from at least one disc (52) into the coiling area (66), to act as guiding devices (18).

8. A device according to Claim 7, characterised in that the take-up devices are parallel to the bore-holes (53) along the axis of rotation (19).

9. A device according to Claim 8, characterised in that the bore-holes (53) are arranged radially in lines.

10. A device according to Claim 7, characterised in that a driving motor (60) is provided for the pins (59), the driving motor being adjustable as the coiling procedure progresses.

11. A device according to Claim 7 or 10, characterised in that there are two pins (59) parallel to the axis (51) of the discs (52), the pins being arranged next to one another inside the discs (52).

12. A device according to one of Claims 7 to 11, characterised in that the outer surfaces of the pins (55) form edges of the guides (67).

13. A device according to one of Claims 7 to 12, characterised in that the distance of the pins (55, 59) which follow in sequence as the coiling proceeds, is equal to the length of the conveyer belt (16) after the conveyer belt has been deformed and inserted into the casing (10).

14. A device according to one of Claims 1 to 13, characterised in that there is a mechanism (70) for deforming the supporting matrix (15) and for adapting its shape to the shape of the casing (10).

15. A device according to one of Claims 7 to 14, characterised in that there is a mechanism for providing the conveyer belt (16) with the weak points attributed to the deflections (20), in the form of dents or perforations.

16. A supporting matrix created in accordance with the procedure in Claim 1, characterised in that the conveyer belt (16) has, at the points of deflection (20) a bend which is dependent on the guiding devices (18).

17. A supporting matrix created in accordance with the procedure in Claims 1 and 6, characterised in that it has weak points in the form of bends or perforations at the points of deflection (20).

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