GB2072064A - Construction of elliptical metal substrates - Google Patents
Construction of elliptical metal substrates Download PDFInfo
- Publication number
- GB2072064A GB2072064A GB8010040A GB8010040A GB2072064A GB 2072064 A GB2072064 A GB 2072064A GB 8010040 A GB8010040 A GB 8010040A GB 8010040 A GB8010040 A GB 8010040A GB 2072064 A GB2072064 A GB 2072064A
- Authority
- GB
- United Kingdom
- Prior art keywords
- metal substrate
- plate
- mandrel
- recited
- web
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- 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
- F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
- F01N3/2807—Metal other than sintered metal
- F01N3/281—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
-
- 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
- F01N2330/00—Structure of catalyst support or particle filter
- F01N2330/02—Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal
- F01N2330/04—Methods of manufacturing
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Catalysts (AREA)
- Exhaust Gas Treatment By Means Of Catalyst (AREA)
Abstract
A plate mandrel having a generally rectangular cross section is provided, and a first end of a web of metal substrate material is affixed to the plate mandrel. The metal substrate material preferably comprises alternate layers of planar metal foil and corrugated metal foil. As an alternative, a corrugated metal foil may be substituted for the planar foil. The metal substrate material web is wrapped around the mandrel, as by rotation of the mandrel while the web is fed off of a spool, until a substantially uniform thickness of metal substrate surrounding the mandrel is provided, a generally elliptical cylinder being formed. A second end of the web is affixed to a previous wrapping, thus forming a complete elliptical cylindrical metal substrate. The metal substrate is preferably catalyzed and used as a catalytic muffler. <IMAGE>
Description
SPECIFICATION
Construction of elliptical metal substrates
In the construction of metal substrates for catalytic
converters, catalytic mufflers for automobiles, fumes
abatement activities in general, and the like, often
times it is desired to provide a metal substrate that is
elliptical in cross section. In the past, it has been
extremely difficult to accurately and readily con
struct such eliptical cylindrical metal substrates
(also cailed ovals or racetracks). However, it has
been found, according to the present invention, that
when particularly shaped and dimensioned man
drels are employed, elliptical cylindrical metal subs
trates may be easily fabricated.
The metal substrates according to the present
invention are formed from "metal substrate mater
ial". That term, as used in the present specification
and claims, refers, to material having a large amount
of void volume. Conventionally, such material com
prises a planar metal foil sheet with a corrugated foil
sheet disposed thereon. The two sheets may be
attached together or may be separate until being
formed into the elliptical cylindrical metal substrate
in which case they are wrapped together with a pla
nar foil between each corrugated foil layer. While the
term "metal substrate material" refers to a variety of
materials with high void volume that are suitable for
formation into an ellipticai cylindrical metal subs
trate, alternating corrugated and planar foils is a
suitable illustrative embodiment thereof.As an
alternative to one planar and one corrugated foils,
two sheets of corrugated foil can be wrapped
together, providing their corrugations are aslant so
as to prevent nesting, to form an elliptical cylindrical
metal substrate.
According to the method of the present invention,
generally elliptical cylindrical metal substrates hav
ing a major diameter D, a minor diameter d, and a
depth H are formed by practicing the steps of: pro
viding a plate mandrel having a generally rectangu
lar cross section of length L and thickness T and hav
ing a depth approximately H; affixing a first end of a
web of metal substrate material having a width H to
a surface of the plate mandrel; wrapping the metal
substrate material web around the mandrel until a substantially uniform thickness Xis provided of
metal substrates surrounding the mandrel to pro
vide a generally elliptical cylinderwith depth H; pro viding a second end of the metal substrate material
web; and affixing the second end of the web to an
underlying portion of the formed elliptical cylinder.
The approximate dimensions Land T of the plate
mandrel are determined before wrapping by using
the equations 2X + L = D and 2X + T = d. After
calculation of the approximate dimensions, the
optimum dimensions Land Tare empirically deter
mined, to take into account deformation of the metal
substrate material that will occur at the edges of the
plate mandrel during wrapping. Wrapping may be
accomplished in a number of ways, but most suit
ably by affixing the plate mandrel to a rotating com
ponent, and rotating the mandrel with respect to a
roll of metal substrate material to wind i:.e material from the roll around the mandrel.
Also according to the present invention, a generally elliptical cylindrical metal substrate is provided having a major diameter D, minor diameter d, and depth H, comprising: a plate having a generally rectangular cross section of length L and thickness T and a depth H, located at the center of the substrate and extending between and terminating generally at the foci of the elliptical cylindrical metal substrate; a plurality of wrappings of metal substrate material disposed around the plate and having a substantially uniform thickness X; and means for maintaining the wrappings and plate integral. The plate is preferably made of high temperature oxidation resistant alloy and the wrappings of metal substrate material comprise alternate layers of planar metal foil and corrugated metal foil.Spot welds comprise the means for maintaining the wrappings and plate integral, affixing the first end of the metal substrate material wrappings to the plate and affixing a second end of the wrappings to a previous, interior wrapping.
It is the primary object of the present invention to provide a simple method for making acceptable elliptical cylindrical metal substrates, and to provide an elliptical cylindrical metal substrate that is suitable for catalyzing and functions well in fume abatement applications in general. This and other objects of the invention will become clear from an inspection of the detailed description of the invention, and from the appended claims.
Figure lisa perspective view of an exemplary elliptical cylindrical metal substrate according to the present invention;
Figure 2 is a schematic end view of the substrate of
Figure 1, illustrating relevant dimensions that are determined for construction;
Figure 3 is a side schematic view illustrating an exemplary method of construction of the substrate of Figure 1; and
Figure 4 is a top schematic view of exemplary mandrel rotating apparatus with a mandrel in place.
A generally elliptical cylindrical metal substrate according to the present invention is shown in exemplary form at 10 in the drawings. The metal substrate 10 has a major diameter D, a minor diameter d, and a depth H. A plate 12 having a generally rectangular cross section of length L and thickness T, and having a depth approximately H, is located at the center of the substrate 10 and extends generally between and terminates substantially at the foci of the elliptical cylindrical metal substrate 10.The plate 12 is used for ease of construction of the substrate 10, and the dimensions of the plate 12 are such that it has a relatively smali cross sectional area compared to the cross sectional area of the metal substrate 10 in general so as not to interfere with the function of the substrate 10 tor fume abatement applications and the like (i.e. as a catalytic muffler).
The metal substrate 10 further comprises a plurality of wrappings 14 at metal substrate material 15 disposed around the plate and having a substantially uniform thickness X (e"a Figure 2) around the plate 12. Metal substrate may vial 15 comprises any suitable material having a large void volume and suit able for use ir! 3 r; retalsubstrate 10, for ultimate use in fume abatement applications and the like. An
exemplary metal substrate material 15 is shown in
Figures 1 and 2, and comprises a planar metal foil
sheet 16 and a corrugated metal foil sheet 17. The
sheets 16 and 17 may be permanently joined
together at a plurality of points, or may originally be
separate and wrapped together in alternate layers to
form the wrappings 14 (i.e. see Figure 3).For most fume abatement applications of the metal substrate
10, the plate 12 will be made from a high temperature oxidation resistant alloy, such as type 316 stain
less steel or Inconel 600, because of the high temperatures (1300 to 18000F)thatthe metal substrate 10
is subjected to while in operation, and the metal substrate material 15 will also be made of materials suitable for such use.
The metal substrate 10 further comprises means, such as spot welds 19 (see Figures 1 and 3) for maintaining the wrappings 14 and plate 12 integral. While spot weldings 19 are suitable, obviously a wide variety of other affixing mechanisms may be employed.
According to the method of the present invention, the elliptical generally cylindrical metal substrate 10 is fabricated in a simple manner, yet the substrate 10 is very suitable for its intended uses, such simplification being possible because of the use of the particu larlyshaped plate 12 as a mandrel. According to the method of the invention, the plate mandrel 12 is provided having the generally rectangular cross section
Land thickness T and depth of approximately H, and a first end of a web W of metal substrate material 15 having a width H is affixed to a surface of the plate mandrel 12 (see Figure 3). Then the metal substrate material web W is wrapped around the mandrel 12 until a substantially uniform thickness X is provided of metal substrate surrounding the mandrel to provide a generally elliptical cylinder with depth H.Then a second end of the metal substrate material web W is provided and the second end is affixed to an underlying portion of the formed elliptical cylinder, as shown at 19 in Figure 1. The approximate dimensions Land T of plate mandrel 12 are determined before wrapping by using the equations: 2X + L = D and 2X + T = d. The desired dimensions D and d are chosen, and then the approximate dimensions Land
T may be calculated. However, because of deformation of the metal substrate material 15 - i.e. elongation of the corrugations that occurs at the edges of the plate mandrel 12 during wrapping, as illustrated generally at 20 in Figure 1-the optimum dimensions Land Tare slightly modified from those determined by utilizing the above equations.After calculation of the approximate dimensions, the optimum dimensions Land Tare empirically determined. For instance, for a 3.2 inch by 6.7 inch by3 inch long racetrack metal substrate 10: 2X + L = 6.7 inches; 2X + T = 3.2 inches; choosing T as .125 inch thick (which ensures no substantial hindrance of the substrate 10 for end use in fume abatement applications and the like), and solving for L, one gets: 6.7 - L = 3.2 - .125; or L = 3.625. Therefore, one would expect a mandrel 12 of 3.625 inches by .125 inches by 3 inches (H) is required. However, because of elongation of the corrugations of sheet 17 during wrapping, working empirically from the approxi
mate calculations, it has been found that a .250 = T
by 4.000 = L mandrel 12 is optimum for making a 3.2
inch by 6.7 inch racetrack.
With particular reference to Figures 3 and 4, it is
preferable to practice the wrapping step of the
method according to the invention by rotating the
mandrel 12 while feeding the metal substrate mater
ial 15 offofone or more rolls R (depending upon the exact configuration of the metal substrate material
15). Exemplary apparatus for rotating the mandrel 12
preferably includes a pair of spaced discs 22,23, hav
ing projections 24,25, respectively extending from the middle thereof. The projection 24 is keyed into an orifice 26 (see Figure 1) provided in one end of the plate 12, while the other projection 25 merely provides a pivot point for rotation of the mandrel 12 about a fixed axis defined by the projections 24,25.
The disc 22 is connected up, as by shaft 30, to a rotary motor 31 or the like, rotation of shaft 30 by motor 31 resulting in the transmission of the rotary force through the disc 22 and projection 24 to rotate the plate 12 about an axis extending through projections 24 and 25. To remove the mandrel 12 from the rotating assembly, preferably a hydraulic cylinder arrangement 32, orthe equivalent, is provided operatively connected to the disc 23 for longitudinally moving the disc 23 along the axis defined by projections 24 and 25 to detach the mandrel 12 from the projections 24 and 25.
In practicing the method according to the invention, preferably the affixing steps are accomplished by spot welding, as by spot welding a first end of the web W to a surface of the plate 12 (shown at 19 in
Figure 3), and then by spot welding a second end of the web W to an underlying portion of the elliptical cylinder (as shown at 19 in Figure 1). The web W may be constructed to be of exactly the size desired for the construction of a single metal substrate 10, or the web W may merely be severed after a given number of rotations of the mandrel 12, severing of the web W providing the second free end of the substrate 10 that is completing formation, and the first free end of the next substrate 10 to be formed.
After formation of the metal substrate 10, it preferably is catalyzed, at which point is it suitable for use in fume abatement applications, such as a catalytic muffler for an automobile. Other accessory structures also can be provided with the substrate 10 depending upon the exact desired end function thereof.
It will thus be seen that according to the present invention a method of forming a metal substrate has been provided which effects extremely simple and sure formation of the substrate. Also according to the present invention, a metal substrate has been provided which is simple to form yet is eminently suitable for a wide variety of fume abatement applications and the like, where generally elliptical cylindrical metal substrates are desired.
While the invention has been herein shown and described in what is presently conceived to be the most practical and preferred embodiment thereof, it will be apparent to those of ordinary skill in the art that many modifications may be made thereof within the scope of the invention, which scope is to
be accorded the broadest interpretation of the
appended claims so asto encompass all equivalent
structures and methods.
Claims (15)
1. A method of forming a generally elliptical
cylindrical metal substrate having a major diameter
D, a minor diameter d, and a depth H, comprising the
steps of
providing a plate mandrel having a generally
rectangular cross section of length L, thickness T, and having a depth approximately H,
affixing a first end of a web of metal substrate material having a width H to a surface of the plate
mandrel,
wrapping said metal substrate material web
around said mandrel until a substantiallv uniform thickness X is provided of metal substrate surround
ing the mandrel to provide a generally elliptical
cylinder with depth H, providing a second end of the metal substrate
material web, and
affixing the second end of the web to an underly-
ing portion of the formed elliptical cylinder.
2. A method as recited in claim 1 comprising the
further step of determining the aEpproximase dimen
sions Land Tofthe plate mandrel before wrapping by using the equations 2X + L=Dand2X +T=d.
3. A method as recited in claim 2 comprising the
further step of, after calculation of the appro,xirnate dirnensions empirically determining the optimum
dimensions Land T to take into account deformation of the metal substrate material that will occur at the
edges of the plate mandrel during wrapping.
4. A method as recited in claim 1 wherein said
wrapping is accomplished by providing the metal
substrate material web on a roll, and rotating the
mandrel to take up the metal substrate material from
the roll.
5. A method as recited in claim 1 wherein the
metal substrate material web includes a first web of
substantially planar metal foil and a second web of
corrugated metal foil, or two corrugated foils, and
wherein the first and second webs are wrapped
together around the mandrel to form said elliptical -cylindrical metal substrate.
6. A method as recited in claim 1 comprising the
further step of catalyzing the metal substrate -Formed.
7. A method as recited in claim 1 wherein said
affixing steps are accomplished by spot welding.
8. A method as recited in claim 1 wherein said
step of providing a second end of the metal subs
trate material web is accomplished by severing a
portion of the web from a roll of web.
9 A generally elliptical cylindrical metal substrate
having a major diameter D, minor diameter d, and
depth H, comprising
a plate having a generally rectangular cross sec
tion of length Land thickness T, and a depth approx- mately H, located at the center of said substrate and
extending between and terminating substantially at
the foci of said elliptical cylindrical metal substrate,
a plurality of wrappings of metal substrate material disposed around said plate and having a substan tally uniform thickness X, and
means for maintaining said wrappings and plate integral.
10. A metal substrate as recited in claim 9 S herein the plate has the approximate dimensions L and T determined by the equations 2, < +L=Danci2)6+T=d, wherein D and d are chosen as desired.
11. A metal substrate as recited in claim 10 wherein the enact dimensions Land 7 differ from the approximate dimensions in thattheytake into account deformation of the metal substrate material at the plate edges.
12. A metal substrate as recited in claim 9 wherein said wrappings of metal substrate material comprise alternate layers of planar metal foil and corrugated metal foil.
13. A metal substrate as recited in claim 9 wherein said plate is a high temperature oxidation resistant alloy.
14. A metal substrate as recited in claim 13 wherein the high temEreraure oxidation resistant alloy is selected from the group consisting essen tiallv of 310 S stainless steel and Inconel 600.
15. 5. A meLai substrate as recited in claim 9 wherein said means ,'or maintaining said wrappings and plate integral comprise means for affixing a first end of said metal substrate material wrappings to said plate and for affixing a second end of said wrappings to a previous wrapping.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8010040A GB2072064A (en) | 1980-03-25 | 1980-03-25 | Construction of elliptical metal substrates |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8010040A GB2072064A (en) | 1980-03-25 | 1980-03-25 | Construction of elliptical metal substrates |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| GB2072064A true GB2072064A (en) | 1981-09-30 |
Family
ID=10512370
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB8010040A Withdrawn GB2072064A (en) | 1980-03-25 | 1980-03-25 | Construction of elliptical metal substrates |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2072064A (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0210546A1 (en) * | 1985-07-29 | 1987-02-04 | Siemens Aktiengesellschaft | Metallic wound flue gas exhaust catalyst support body with a complicated geometric section and method for its manufacture |
| EP0218062A1 (en) * | 1985-09-11 | 1987-04-15 | Süddeutsche Kühlerfabrik Julius Fr. Behr GmbH & Co. KG | Support matrix, particularly for a catalytic reactor for purifying exhaust gases of internal-combustion engines |
| AT384380B (en) * | 1985-10-17 | 1987-11-10 | Mueller Heinz | REINFORCEMENT FOR A SHEET |
| DE3928750A1 (en) * | 1988-09-06 | 1990-03-15 | Calsonic Corp | METHOD FOR PRODUCING A METAL SUBSTRATE FOR A CATALYTIC EXHAUST GAS PURIFIER |
-
1980
- 1980-03-25 GB GB8010040A patent/GB2072064A/en not_active Withdrawn
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0210546A1 (en) * | 1985-07-29 | 1987-02-04 | Siemens Aktiengesellschaft | Metallic wound flue gas exhaust catalyst support body with a complicated geometric section and method for its manufacture |
| US4719680A (en) * | 1985-07-29 | 1988-01-19 | Interatom Gmbh | Method for manufacturing a wound metallic exhaust gas catalyst carrier body having a geometrically complex cross-sectional shape |
| EP0218062A1 (en) * | 1985-09-11 | 1987-04-15 | Süddeutsche Kühlerfabrik Julius Fr. Behr GmbH & Co. KG | Support matrix, particularly for a catalytic reactor for purifying exhaust gases of internal-combustion engines |
| AT384380B (en) * | 1985-10-17 | 1987-11-10 | Mueller Heinz | REINFORCEMENT FOR A SHEET |
| DE3928750A1 (en) * | 1988-09-06 | 1990-03-15 | Calsonic Corp | METHOD FOR PRODUCING A METAL SUBSTRATE FOR A CATALYTIC EXHAUST GAS PURIFIER |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |