JP2002224752A - Manufacturing method of corrugated plate for catalyst support - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a corrugated plate without generating a scratch or crack and of a corrugated plate without generating a chink when the corrugated plate is led into a pipe. SOLUTION: This manufacturing method consists of a central corrugation part forming process, forming a central corrugation part at the center of a flat plate, and a side corrugation part forming process, forming side corrugation parts at both ends in a state of holding the central corrugation part. As the side corrugation parts at both ends are formed in the state of holding the central corrugation part at the side corrugation parts after the central corrugation part forming process, no material supply shortage to a mold is generated and no scratch nor crack is generated. Another manufacturing method consists of a rough corrugated plate forming process, forming a rough corrugated plate, and a correction process, correcting the rough corrugated plate by inserting a bar-shaped core into the concavity of the corrugated plate and giving a pressure to the same direction of the corrugation part in a state of the core inserted. Thus, the radius-shaped corrugation part is not collapsed and no openings are generated when the core is inserted into the pipe by pressing.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a corrugated sheet for supporting an exhaust gas purifying catalyst provided in an exhaust system of an automobile or a motorcycle.

[0002]

2. Description of the Related Art As shown in FIG. 12, an exhaust purification catalyst support provided in an exhaust system of an automobile or a motorcycle has a pipe member 200 and a corrugated plate 10 incorporated in the pipe member 200 as shown in FIG.
0. The corrugated sheet 100 is formed of a heat-resistant steel material because it is exposed to high-temperature exhaust gas. Corrugated sheet 100
Has a shape in which the surface area on which the catalyst is supported is widened, and usually has a hairpin shape with five peaks in cross section. Such corrugated sheet 10
No. 0 was manufactured by a method of simultaneously pressing five crests using a female mold and a male mold. Then, the corrugated sheet 100 was press-fitted into the pipe member 200 and brought into close contact therewith, and then brazed to form a catalyst support.

[0003] The hairpin-shaped catalyst support has a coarse cell and a thick cell wall, and thus is resistant to abnormally high temperature due to engine misfire or the like, and is mounted on a 2.4-cycle engine.

[0004]

The heat-resistant steel material used for the corrugated sheet 100 is, for example, a 20% Cr-5% Al steel sheet having a thickness of 0.5 mm, an elongation of about 15%, and a hardness of about 15%. 2
20 HV. For this reason, this heat-resistant steel sheet has poor formability, and the corrugated sheet 10 is pressed at the time of pressing in the conventional manufacturing method of simultaneous forming.
In addition, cracks and scratches were generated on the mold, and scratches were also generated on the mold, which was a problem. Cracks and abrasions occur
When the side wave portions on both sides are formed during the formation of the central wave portion, it is considered that the supply of the material to the mold is insufficient, and the material is rubbed due to the small elongation of the material. .

When a corrugated sheet is pressed into a pipe, a gap is formed between the corrugated sheet and the inner wall of the pipe and between the corrugated sheets, making it difficult to produce a catalyst support having no gap. It is considered that the gap is generated because the R shape of the corrugated portion is crushed because the corrugated portion of the corrugated plate is compressed in the overlapping direction at the time of press-fitting.

The present invention has been made in view of the above circumstances, and provides a method of manufacturing a corrugated sheet that does not cause abrasion or cracking, and a method of manufacturing a corrugated sheet that does not generate a gap when pressed into a pipe. The task is to provide.

[0007]

According to a method of manufacturing a corrugated sheet of the present invention, a center wave portion forming step of forming a center wave portion at the center of a flat plate, and side waves on both sides of the center wave portion while the center wave portion is held. And forming a side wave portion for forming the portion.

Further, another method of manufacturing a corrugated sheet according to the present invention includes a step of forming a rough corrugated sheet, inserting a rod-shaped core into a concave portion of the formed corrugated sheet, and inserting the core. And a correcting step of pressing in a direction in which the corrugated portions overlap in a state where the corrugated portions overlap each other.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In a method of manufacturing a corrugated sheet according to the present invention, a center wave portion forming step of forming a center wave portion at the center of a flat plate, and forming side wave portions on both sides of the center wave portion while holding the center wave portion. And a step of forming a side wave portion, thereby making it possible to manufacture a corrugated sheet having five peaks. By repeating the side wave portion forming step, nine corrugated sheets can be manufactured. That is, a center wave portion forming step of forming a center wave portion at the center of the flat plate, a side wave portion forming step of forming side wave portions on both sides of the center wave portion while holding the center wave portion, and narrowing the side wave portion. And a side-to-side wave portion forming step of forming side-to-side wave portions on both sides of the holding portion.

The step of forming the central corrugated portion includes a step of placing a flat plate in the central concave portion of the wavy female shape so that the center thereof coincides with the central concave portion of the female shape, and a process of press-fitting the central convex portion of the wavy male type into the central concave portion of the female mold. In this case, the central wave portion can be reliably formed at the center of the flat plate.

Further, when the step of forming the side-wave portion is a step of press-fitting both side convex portions of the male central convex portion into both side concave portions of the female central concave portion, side waves are formed on both sides of the central wave portion. The portion can be reliably formed. The side wave portion forming step may be a step of press-fitting the convex portion between the female central concave portion and both concave portions into the concave portion between the male central convex portion and both convex portions. Further, in the case of the wavy male mold and the female mold, a concave portion is formed between adjacent convex portions and a convex portion is formed between the concave portions. Therefore, the side wave portion forming step is performed at the center of the female mold. The male-side central convex portion is press-fit into the male-side central concave portion and the male-side central convex portion between the male-type central convex portion and the male-type central convex portion and the concave portion between the male-type central convex portion. May be simultaneously performed.

Further, when the male die is press-fitted into the female die when the male die is press-fitted into the female die, the upper end of the central convex portion is pivotally connected to the central groove of the both-side convex portions via a pressing means. The central convex portion is first press-fitted only by pressurizing the portion, and then both side convex portions are press-fitted while holding the central wave portion. Therefore, it is suitable for automation and mass production.

As the pressurizing means, a coil spring, a leaf spring, a hydraulic piston, or the like can be appropriately used.

According to another method of manufacturing a corrugated sheet of the present invention, there is provided a step of forming a rough corrugated sheet, a step of inserting a rod-shaped core into a recess of the formed rough corrugated sheet, and a step of inserting the core. And a correcting step of correcting by pressing in a direction in which the wave portions overlap. The coarse corrugated sheet forming step of the corrugated sheet manufacturing method is not limited to the corrugated sheet manufacturing method of the present invention. That is, if there is no scratch or crack on the rough corrugated plate manufactured by any method, a rod-shaped core is inserted into the concave portion of the rough corrugated plate, and the corrugated portion is pressed in a direction in which the corrugated portions overlap in a state where the core is inserted to correct the corrugated plate. By doing so, it is possible to manufacture a corrugated sheet in which no gap is generated when press-fitting into a pipe.

The rod-shaped core preferably has a radius equal to the radius of curvature of the corrugated portion of the rough corrugated plate. This is because the shape can be corrected without impairing the shape of the corrugated portion.

When the correcting step is a step of pressing the corrugated portion in the overlapping direction with a mold forming a cylindrical cavity when the female and male molds are closed,
A corrugated sheet with no gap can be reliably formed.

Further, when the inner diameter of the cylindrical cavity is closer to the inner diameter of the pipe to be press-fitted, a corrugated plate in which no gap is generated when press-fitting the pipe can be formed more reliably. The inner diameter of the cavity may be smaller than the inner diameter of the pipe, because the straightened corrugated sheet spreads a little due to the springback action of the material.

The steel material used for the corrugated sheet is, for example, a heat-resistant steel material having a composition of 20% Cr-5% Al in the case of supporting an exhaust purification catalyst provided in an exhaust system of an automobile or a motorcycle. Steel sheet is suitable. In addition, SUS304 or SUS430 may be used as the heat-resistant steel.

[0019]

According to the method of manufacturing a corrugated sheet of the present invention, the side wave portions on both sides of the center wave portion are formed in the side wave portion forming step after the center wave portion forming step, so that the side wave portions are formed. There is no shortage of material supply, and scratches and cracks are less likely to occur.

According to another method of manufacturing a corrugated sheet of the present invention, a rod-shaped core is inserted into a concave portion of a rough corrugated sheet, and the corrugated portion is pressed in a direction in which the corrugated portions are overlapped with the core inserted to correct the corrugated sheet. When press-fitting, the R shape of the wave portion does not collapse, and no gap is generated.

[0021]

The present invention will be described below in detail with reference to examples.

Example 1 FIGS. 1 to 4 show a process for manufacturing a corrugated sheet of five peaks according to Example 1.
Shown in FIG. 1 shows a thickness of 0.5 mm, a width of 195 mm, and a length of 110.
1 shows a state in which a heat resistant steel (18% Cr-3% Al) flat plate 1 having a thickness of 1 mm is inserted between a male mold 2 and a female mold 3. The male mold 2 includes a central convex portion 21 for a mountain, both side convex portions 22 for a mountain and a wavy spring 23 as a pressing means. The base portion 212 of the central convex portion 21 has a U-shape, and the base portion 212 is pivotally connected to the U-shaped central groove portion 222 of the both-side convex portions 22 via a spring 23. One end of the spring 23 is fixed to the top of the central groove 222, and the other end is fixed to the lower part of the U-shaped concave portion of the base 212. Therefore, the central convex portion 21 slides on the central groove portion 222 by the expansion and contraction of the spring 23.

When the spring 23 contracts and the neck 211 of the central projection 21 coincides with the neck 221 of the projection 22 on both sides, a concave portion for a mountain is formed. It should be noted that the neck 211 of the central projection 21 matches the tip of the both-side projection 22.

The wavy female mold 3 has a central concave portion 31 for a mountain and a mountain, both side concave portions 32, and a convex portion 33 for a mountain between the central concave portion and both side concave portions.

The curvature radius of the concave and convex portions of the male mold 2 and the female mold 3 corresponding to each other is 5 mm.

When the male mold 2 is pressed by a pressing means (not shown) in the state shown in FIG. 1, the central projection 21 of the male mold 2 is attached to the center of the female mold 3 with the flat plate 1 while the spring 23 hardly contracts. At the same time as the press-fit into the recess 31 to form the peak of the central wave portion, the flat plate 1 is pushed up from the lower surface by the female peak and the convex portion 33, and is pushed down from the upper surface by the both-side convex portions 22 of the male die 2. , FIG. When the male mold 2 is further pressed and lowered, the central convex portion 21 of the male mold 2 is completely pressed into the central concave portion 31 of the female mold 3, and a peak of a central corrugated portion is formed on the flat plate 1.

Next, when the male mold 2 is further pressurized in this state, that is, in a state where the center wave portion is held, the spring 23
Is contracted, the two-sided convex portions 22 descend, and the press-fitting of the female mold 3 into the two-sided concave portions 32 is started.
Between the convex portion 22 and the both-side convex portions 22, and the concave portion for the female mold 3 and the convex portion 33 for the female mold 3
Starts to be pressed into the recess. Further, when the male mold 2 is pressurized, the spring 23 contracts, and the both-side convex portions 22 are pressed into the both-side concave portions 32 of the female mold 3 and the female mold 3.
The convex portions 33 are press-fitted into the ridges and concave portions of the male mold 2, and finally the state shown in FIG. 3 is obtained.

FIG. 4 is a perspective view of the corrugated sheet taken out of the mold after the molding, and no abrasion or crack was generated.

Embodiment 2 FIGS. 5 to 7 show a manufacturing process of a corrugated sheet according to Embodiment 2. FIG. FIG. 5 shows that a round bar 6 having a diameter of 10 mm as a core is inserted into the corrugated portion of the corrugated plate 10 manufactured in Example 1, and the corrugated portions are formed in the cavities of the semi-cylindrical male mold 4 and U-shaped female mold 5. A state in which the direction in which the wave portions of the plate 10 overlap and the direction in which the mold closes is set to match. The radius of curvature of the half cylinder of the male mold 4 and the radius of curvature of the R portion of the female mold 5 are 15 mm, respectively.
Forms a cylindrical cavity with a diameter of 30 mm in the closed state. When the male mold 4 was pressed into the female mold 5 in the state of FIG.
The corrugated plate 10 was pressed in the direction in which the corrugated portions overlap, and the state shown in FIG. 6 was obtained.

While keeping the curvature of the wave part at 5 mm,
It could be corrected to 0 mm. FIG. 7 shows the corrugated sheet removed from the molds 4 and 5 and the round bar 6 removed. When it was taken out of the mold, it spread slightly due to the springback of the material, but it was possible to manufacture a corrugated sheet without deformation or collapse of the corrugated portion. When this was pressed into a stainless steel pipe having an inner diameter of 29.4 mm and an outer diameter of 31.8 mm, the R shape of the corrugated portion was not crushed and no gap was generated. After applying the brazing slurry to the inner wall of the pipe, the corrugated plate was press-fitted and subjected to a brazing heat treatment to complete a good hairpin-shaped catalyst support.

Embodiment 3 FIGS. 8 to 1 show a process of manufacturing a corrugated sheet of nine peaks according to a third embodiment.
It is shown in FIG. FIG. 8 shows a heat-resistant steel (18% Cr-3% Al steel) flat plate 1 having a thickness of 0.5 mm, a width of 350 mm, and a length of 110 mm.
Is inserted between the male mold 7 and the female mold 8. Male type 7
Is composed of a central convex portion 71 for a mountain, first side convex portions 72 for a mountain, a second side convex portion 73 for a mountain, a first wavy spring 74 as a pressing means, and a second wavy spring 75. Become.

The base 712 of the central projection 71 has a U-shape. The base 712 is pivotally connected to the U-shaped central groove 722 of the first side projection 72 via the first spring 74. ing. One end of the first spring 74 is fixed to the top of the central groove 722, and the other end is fixed to the lower part of the U-shaped concave portion of the base 712. Therefore, the central convex portion 71 is
The center groove 722 is slid by the expansion and contraction of 4. When the first spring 74 contracts and the neck of the central projection 71 coincides with the neck of the both-side projection 72, a concave portion for a mountain is formed.

The base of the first side projection 72 is the second side projection 7.
The third U-shaped central groove portion 732 is pivotally connected via a second spring 75. One end of the second spring 75 is fixed to the top of the central groove 732, and the other end is fixed to a concave portion formed on the upper surface of the first side convex portion 72. Therefore, the first side projections 72 slide in the central groove 732 of the second side projections 73 by the expansion and contraction of the second spring 75. When the second spring contracts and the neck of the first both-side convex portion 72 coincides with the neck of the second both-side convex portion 73, a concave portion for a mountain is formed.

The wavy female mold 8 has a central concave portion 81 for a mountain, a first both side concave portion 82 for a mountain, and a second side concave portion 83 for a mountain, and between the central concave portion and the first both side concave portions. The ridges and protrusions 84 are provided between the first and second concave portions, and the ridges and convex portions 85 are provided between the first and second concave portions.

The radius of curvature of the concave and convex portions of the male mold 7 and the female mold 8 corresponding to each other is 5 mm.

When the male mold 7 is pressed by a pressing means (not shown) in the state shown in FIG. 8, the first spring 74 and the second spring 7
5 is hardly shrunk, the central convex portion 71 of the male mold 7 is pressed into the central concave portion 81 of the female mold 8 together with the flat plate 1 to form a peak of a central corrugated portion. The male mold 7 is pushed up from the lower surface by the peaks and convex portions 84, and is pushed down from the upper surface by the first side convex portions 72 of the male mold 7. When the male mold 7 is further pressed and lowered, the central convex portion 71 of the male mold 7 is completely pressed into the central concave portion 81 of the female mold 8, and a peak of a central corrugated portion is formed on the flat plate 1.

Next, when the male mold 7 is further pressurized in this state, that is, with the center wave portion held therebetween, the first spring 7
4 contracts, the first side convex portions 72 descend, and the press-fitting of the female mold 8 into the first side concave portions 82 and the first side concave portions 82 is started. , And the peaks of the female mold 8 and the convex portions 84 of the female mold 8 begin to be pressed into the peaks and concave portions of the male mold 7, resulting in the state of FIG. 9.

Further, when the male mold 7 is pressurized, the first both-side convex portions 72 are completely pressed into the first both-side concave portions 82 of the female mold 8,
A peak and a peak of the side wave portion are formed. Next, in this state, that is, in a state where the side wave portion is narrowed, the male mold 7
, The second spring 75 contracts, and the second side convex portions 73 are press-fitted into the ridges and the second concave portions 83 for the female die 8, and the ridges and the convex portions 85 of the female die 8 become the male die 7. Mountains,
Press-fit into the recess for the final state, and finally reach the state shown in FIG.
A side wave portion is formed on the flat plate 1.

FIG. 11 is a cross-sectional view of the corrugated sheet taken out of the mold after the molding, and showed no scratches or cracks.

[0040]

As described above, according to the method for manufacturing a corrugated sheet of the present invention, there is no shortage of material to the mold and no abrasion or cracking. Further, when press-fitting into a pipe, the R shape of the corrugated portion does not collapse, and no gap is generated.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an initial stage of a manufacturing process according to a first embodiment.

FIG. 2 is a cross-sectional view showing an intermediate stage of a manufacturing process according to the first embodiment.

FIG. 3 is a sectional view showing a final stage of the manufacturing process according to the first embodiment.

FIG. 4 is a perspective view of a corrugated sheet manufactured by the manufacturing process of the first embodiment.

FIG. 5 is a cross-sectional view illustrating an initial stage of a manufacturing process according to a second embodiment.

FIG. 6 is a sectional view showing the final stage of the manufacturing process according to the second embodiment.

FIG. 7 is a cross-sectional view of a corrugated sheet manufactured by the manufacturing process according to the second embodiment.

FIG. 8 is a cross-sectional view showing an initial stage of a manufacturing process according to a third embodiment.

FIG. 9 is a cross-sectional view showing an intermediate stage of a manufacturing process according to the third embodiment.

FIG. 10 is a sectional view showing the final stage of the manufacturing process according to the third embodiment.

FIG. 11 is a cross-sectional view of a corrugated sheet manufactured by the manufacturing process according to the third embodiment.

FIG. 12 is a sectional view of a catalyst support.

[Explanation of symbols]

1 ... flat plate, 2, 4, 7 ... male type, 3, 5, 8, ...
・ Female type, 6 ・ ・ ・ Core, 10 ・ ・ ・ Corrugated plate, 21, 71 ・
..Central convex portions, 22, 72, 73 ... both side convex portions, 2
3, 74, 75 ... pressing means, 31, 81 ... central concave part, 32, 82, 83 ... both side concave parts

Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat II (reference) B21D 13/02 F01N 3/28 301P F01N 3/28 301 B21D 53/84 B // B21D 53/84 B01D 53/36 ZABC F term (reference) 3G091 AA02 AA03 AB01 BA07 BA39 GA06 GB01X GB01Z 4D048 BA39X BB04 CA01 4E003 AA01 CA03 4E063 AA01 CA09 DA01 DA02 JA06 MA18 4G069 AA01 AA08 BA17 CA03 EA12 FB75

Claims (6)

[Claims] 1. A center wave portion forming step of forming a center wave portion at the center of a flat plate, and a side wave portion forming step of forming side wave portions on both sides of the center wave portion while holding the center wave portion. A method for producing a corrugated sheet, comprising: 2. The step of forming a central corrugated portion includes the step of placing a flat plate on the central concave portion of a wavy female shape so that the center thereof coincides with the central concave portion of the female shape. 2. The method of manufacturing a corrugated sheet according to claim 1, comprising the step of: 3. The corrugated sheet according to claim 1, wherein the step of forming the side wave portion is a step of press-fitting both side convex portions of the male central convex portion into both side concave portions of the female central concave portion. Production method. 4. The method of manufacturing a corrugated sheet according to claim 2, wherein said male mold has an upper end portion of said central convex portion pivotally connected to a central groove portion of said both convex portions via a pressing means. Method. 5. A process for forming a rough corrugated plate, wherein a rod-shaped core is inserted into a concave portion of the formed rough corrugated plate, and a corrugated portion is pressed in a direction in which the corrugated portions are overlapped with the core inserted to correct the corrugated plate. A method for producing a corrugated sheet. 6. The corrugated sheet according to claim 5, wherein the correcting step is a step of pressing the corrugated portions in a direction in which the corrugated portions overlap with each other by using a mold that forms a cylindrical cavity when the female mold and the male mold are closed. Production method.