JP2004124726A - Fluid treatment device having honeycomb structure therein, and manufacturing method of the same - Google Patents

Fluid treatment device having honeycomb structure therein, and manufacturing method of the same Download PDF

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JP2004124726A
JP2004124726A JP2002286323A JP2002286323A JP2004124726A JP 2004124726 A JP2004124726 A JP 2004124726A JP 2002286323 A JP2002286323 A JP 2002286323A JP 2002286323 A JP2002286323 A JP 2002286323A JP 2004124726 A JP2004124726 A JP 2004124726A
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honeycomb structure
buffer member
necking
diameter
catalyst carrier
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JP4303457B2 (en
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Toru Irie
入江　徹
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Sango Co Ltd
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Sango Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To ensure desired surface pressure by a buffer member and thereby to properly hold the buffer member and honeycomb structure in a cylindrical member, in a fluid treatment device in which the honeycomb structure is held in the metal cylindrical member through the buffer member having substantially no added binder. <P>SOLUTION: The metal cylindrical member C1 has: a body part 11 formed by reducing a diameter of a part housing the buffer member 3 without substantially any added binder; and a necking part 12(13) formed by necking processing of an end part on at least one end side of the body part. The honeycomb structure 2 is held in the cylindrical member C1 through the buffer member. Preferably, the necking may be performed at the end part including a predetermined range 11x(11y) on at least one end side of the body part up to an opening end. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、金属製筒状部材内に実質的にバインダー無添加の緩衝部材を介してハニカム構造体を保持する流体処理装置、及びその製造方法に関し、例えば、筒状部材内に実質的にバインダー無添加の緩衝マットを介してハニカム構造体の触媒担体を保持する触媒コンバータ、及びその製造方法に係る。
【０００２】
【従来の技術】
流体に対してフィルタ機能を有するハニカム構造体が、金属製筒状部材内に緩衝部材を介して内蔵された流体処理装置が知られており、種々の流体の浄化に供されている。例えば、自動車の排気系においては触媒コンバータやディーゼルパティキュレートフィルタ（以下、ＤＰＦという）が搭載されており、触媒担体あるいはフィルタ等（総称して担体といい、以下、触媒担体いうときはこれらを代表する）としてセラミック製の脆弱なハニカム構造体が用いられている。そして、これらのハニカム構造体はセラミックマット等の緩衝部材を介して金属製筒状部材内に保持され流体処理装置が構成され、この一例として触媒コンバータがある。
【０００３】
【特許文献１】
このような触媒コンバータの製造方法に関しては従来から種々の方法が知られており、例えば特開２００２−７０５４４号公報には、保持シール材を用いて排気ガス浄化用触媒コンバータを製造する方法が以下のように列挙されている。即ち、触媒保持体に保持シール材を巻き付けたものを、二分割の金属製シェルに挟み込む方法、それを金属シェル内に圧入する方法、及び、それに金属板を巻回する方法であり、これらは夫々、クラムシェル方式、圧入方式、トーニケット方式として知られている。そして、同公報では、触媒保持体への組付け性を改善するために、セラミック繊維から成るマット状の緩衝部材に有機バインダーを含有（含侵あるいは塗布）させる場合の対策として、保持シール材におけるセラミック繊維のマット状物の充填密度と、有機バインダーの含有量及び特性に関する提案がなされている。
【０００４】
【特許文献２】
同様に、上記のような有機バインダーが添加された緩衝部材に関する種々の問題点に鑑み、特開２００１−１２２３７号公報には、有機バインダーの含有量を少なくすることが提案されている。
【０００５】
【特許文献３】
更に、特開２００１−２８９０２７号公報においては、バインダーが添加されていない無機質繊維マットの採用が提案されている。同公報では、無機質繊維マットに水分を含侵させた後に凍結させ、無機質繊維マットの厚さを薄くした状態でこれを被覆した触媒保持体を、金属シェル内に装着する方法が提案されている。
【０００６】
【特許文献４】
また、特開２００２−３８９３７号公報にも、無膨張性シールマットに低温凝固媒体のバインダーとして水成分を含侵させた後に氷化させることが提案されている。同公報では、無膨張性シールマット自体をこれにより低摩擦とし、ケース内に円滑な操作で迅速に挿入する旨記載されている。
【０００７】
【特許文献５】
一方、特開２００１−２８９０４０号公報には、バインダーが添加されていない無機質繊維マットを、金属シェル内に挿入し、その内壁との間に無機質繊維マットを介設させた状態で、拡張機を挿入し、これによって無機質繊維マットを圧縮して、その内径を触媒保持体の外径より大きくした後、触媒保持体を挿入する方法が提案されている。
【０００８】
【特許文献６】
尚、上記の従来技術は触媒コンバータに関するものであるが、本発明の対象はこれに限らず、前述のＤＰＦ、浄化フィルタ等を含み、更に、特開２００２−５０３８３号公報に記載の燃料電池用改質器等も包含される。
【０００９】
【特許文献７】
更に、本発明の対象である製造方法に関し、スピニング加工に係る従来技術として、例えば特開２００１−１０７７２５号公報に記載の加工方法がある。
【００１０】
【特許文献８】
また、筒状部材の端部を加工するネッキング加工に関し、特許第２９５７１５４号には傾斜スピニング加工が開示されている。
【００１１】
【特許文献９】
同様に、特許第２９５７１５３号には偏芯スピニング加工が開示されている。
【００１２】
【発明が解決しようとする課題】
結局、前掲の特許文献１（特開２００２−７０５４４）及び特許文献２（特開２００１−１２２３７）に記載のような有機バインダーは緩衝部材には添加しないことが好ましいが、前述のように金属シェル内に緩衝部材を介装する場合や圧入する場合には、やはり、緩衝部材の厚さを薄くさせるようなバインダーが必要とされている。
【００１３】
即ち、前掲の特許文献３（特開２００１−２８９０２７）及び特許文献４（特開２００２−３８９３７）においても、無機質繊維マットに水分を含侵させた後に凍結させてその厚さを薄くすることが企図されており、特許文献４に低温凝固媒体のバインダーとして水成分を用いると記載されているように、水分が緩衝部材の厚さを薄くするためのバインダーとして機能していることに変わりはない。従って、これらに必要な工程による製造時間とコストの増加は不可避であるとともに、凍結から解凍に至る過程での繊維の破損が危惧され、緩衝部材が所期の状態に復元するか否か定かではない。
【００１４】
一方、特許文献５（特開２００１−２８９０４０）によれば、実質的にバインダー無添加の緩衝部材を用いることができ、上記のような凍結から解凍に至る過程での問題は生じないが、触媒担体の外径、緩衝部材の厚さ（特に復元後の厚さ）、外筒の内径にはそれぞれバラツキが存在し、これらのバラツキが重畳されるので、触媒担体を保持する力は、それらに大きく左右されることになる。同公報には、これらの誤差に言及されていないので、必要な保持力を恒常的に得ることができるか否か定かではない。
【００１５】
以上の従来技術を整理すると、特許文献１乃至４では、金属製筒状部材内に緩衝材を介して触媒担体（ハニカム構造体）を保持する装置において、組付け時の容易性という観点で、有機バインダー、あるいは水分等の低温凝固媒体のバインダーによって緩衝部材の厚さを薄くすることとし、組付け後にバインダーを焼失あるいは蒸発させ、その結果、緩衝部材のみが残存し、緩衝部材の状態が復元することを前提としている。そして、組付けに関しては、特許文献１、３及び４では緩衝部材を触媒担体に装着（巻回）した状態で筒状部材内に挿入することとし、特許文献５では筒状部材内に緩衝部材を装着し、緩衝部材を圧縮して拡径した状態で触媒担体を挿入することとしている。
【００１６】
このように、特許文献１乃至４では、筒状部材、緩衝部材及び触媒担体のうち、基本的に緩衝部材のみに着目した対応がなされている。確かに、特許文献３及び４に記載のように、有機バインダーが添加されていない緩衝部材を用いることが望ましいが、水分等の低温凝固媒体が緩衝部材の厚さを薄くするためのバインダーとして機能していることに変わりはなく、実質的にバインダー無添加の緩衝部材ということはできない。これに対し、特許文献５においては、実質的にバインダー無添加の緩衝部材が用いられているが、触媒担体の挿入前に緩衝部材を圧縮し、挿入後に緩衝部材の状態が復元することを前提としている。
【００１７】
結局、何れの従来技術においても、実質的にバインダー無添加の緩衝部材を用いた流体処理装置において、緩衝部材に要求される面圧、つまり緩衝部材と触媒担体との間の摩擦力、及び緩衝部材と筒状部材との間の摩擦力を付与する圧力は、バインダー消失後の緩衝部材の状態、あるいは圧縮力除去後の緩衝部材の状態に依拠するものである所、最終的な面圧との関係が明確とされている訳ではなく、また緩衝部材のみの対応ではこの関係を明確にすることは困難である。このため、流体処理装置としての耐久性のバラツキが大きくなることが懸念される。
【００１８】
上記のような緩衝部材に必要な面圧の確保という課題は、昨今の浄化性能向上の要請に伴なう担体の薄壁化、脆弱化により、看過できないものとなりつつある。更に、保持面圧誤差の許容範囲が矮小化することは必至であり、構成部品の誤差によって大きく影響されることなく、所期の面圧を確保し得るようにすることは必須の解決課題である。
【００１９】
そこで、本発明は、金属製筒状部材内に実質的にバインダー無添加の緩衝部材を介してハニカム構造体を保持するハニカム構造体内蔵流体処理装置において、緩衝部材によって所期の面圧を確保し筒状部材内に緩衝部材及びハニカム構造体を適切に保持し得る構成とすることを課題とする。
【００２０】
また、本発明は、実質的にバインダー無添加の緩衝部材を装着したハニカム構造体を金属製筒状部材に収容し、緩衝部材を損なうことなく所期の面圧を確保し筒状部材内に緩衝部材及びハニカム構造体を適切に保持し得る製造方法を提供することを別の課題とする。
【００２１】
【課題を解決するための手段】
上記課題を解決するため、本発明のハニカム構造体内蔵流体処理装置は、請求項１に記載のように、金属製筒状部材内に実質的にバインダー無添加の緩衝部材を介してハニカム構造体を保持するハニカム構造体内蔵流体処理装置において、前記筒状部材が、少なくとも前記緩衝部材を収容する部分の軸方向所定範囲を縮径して成る胴部と、該胴部の少なくとも一端側の端部をネッキング加工して成るネッキング部を備えることとしたものである。尚、本発明における前記緩衝部材には、その保形のためのバインダーは添加されておらず、実質的にバインダー無添加の緩衝部材である。尚、運搬等の便宜に供するため、緩衝部材に微量（０〜５％）の添加剤を含めることとしてもよく、その成分が従来のバインダーと同じもしくは近似していたとしても、これは前述のバインダーに包含されるものではなく、本発明が企図する面圧調整に影響を与えるものでもない。
【００２２】
前記ネッキング部は、請求項２に記載のように、前記胴部の少なくとも一端側の所定範囲を含み前記筒状部材の開口端に至るまでスピニング加工して成り、前記胴部の中心軸に対して少なくとも偏芯、傾斜及び捩れの何れか一つの関係にある中心軸を有するように構成することができる。
【００２３】
また、本発明の製造方法は、請求項３に記載のように、金属製筒状部材内に実質的にバインダー無添加の緩衝部材を介してハニカム構造体を保持するハニカム構造体内蔵流体処理装置の製造方法において、前記ハニカム構造体の外周に前記緩衝部材を装着した状態で前記筒状部材内に緩やかに収容し、前記筒状部材の少なくとも前記緩衝部材を収容する部分の軸方向所定範囲を縮径して胴部を形成し、該胴部の端部をネッキング加工してネッキング部を形成するものである。
【００２４】
更に、請求項４に記載のように、前記胴部の少なくとも一端側の所定範囲を含み前記筒状部材の開口端に至るまで、前記胴部の中心軸に対して少なくとも偏芯、傾斜及び捩れの何れか一つの関係にある中心軸に沿ってスピニング加工を行い、前記ネッキング部を形成することができる。
【００２５】
【発明の実施の形態】
上記のように金属筒状部材内に実質的にバインダー無添加の緩衝部材を介してハニカム構造体を保持する流体処理装置の具体的一態様として、自動車用触媒コンバータについて図面を参照して説明する。尚、本発明の流体処理装置としては、触媒コンバータのほか、例えばＤＰフィルタ装置や、浄化フィルタがあり、更に、前述の燃料電池用改質器も包含される。筒状部材は外筒、ハウジングあるいはケーシングとも呼ばれ、触媒コンバータの場合には、ハニカム構造体は触媒担体（前述の触媒保持体）に対応する。そして、実質的にバインダー無添加の緩衝部材は、前述のバインダーを含有しない無機質繊維マット等の触媒担体保持用の緩衝マットに対応する。また、ＤＰフィルタ装置の場合には、ハニカム構造体はフィルタに対応し、緩衝部材はＤＰフィルタ用の緩衝マットに対応する。
【００２６】
ハニカム構造体を構成する触媒担体あるいはＤＰフィルタは一般的には円柱状又は円筒状に形成され、円形断面を有するが、これに限らず、楕円形断面、長円断面、複数の曲率を有する面を組み合わせた断面、及び多角形断面等の非円形断面としてもよい。また、触媒担体あるいはＤＰフィルタの流路（セル）断面は、ハニカム（六角形）に限らず、正方形等、任意である。尚、本実施形態の触媒担体（ハニカム構造体）の材質はセラミックであるが、これに限らず、薄肉金属製の所謂メタル担体としてもよい。尚、緩衝部材については、後に詳述する。
【００２７】
図１は本発明の流体処理装置の一実施形態に係る触媒コンバータの外観を示すもので、その断面を図９に示すように、金属製の筒状部材Ｃ１内で、実質的にバインダー無添加の緩衝部材３（以下、特にことわらない限り、単に緩衝部材３という）を介してハニカム構造体の触媒担体２を保持するように構成されている。本実施形態の筒状部材Ｃ１は、図１に示すように、緩衝部材（図９に３で示す）を収容する部分の軸方向所定範囲（図１にＳＡで示す範囲）を縮径して成る胴部１１と、この胴部１１の両端の所定範囲１１ｘ及び１１ｙを含み筒状部材Ｃ１の開口端に至るまでの端部をネッキング加工して成るネッキング部１２及び１３を備えている。尚、図１において、所定範囲ＳＡは後述するサイジング範囲を示し、図１及び図２において、１１ｅは、後述する縮径加工後の痕跡を示し、１２ｊ及び１３ｊはスピニング加工後の条痕を示す。
【００２８】
本実施形態においては、一方のネッキング部１２は、胴部１１の中心軸と同軸の中心軸を有するテーパ部１２ｂ及び首部１２ｃから成る。このネッキング部１２は、胴部１１の所定範囲１１ｘを含み筒状部材Ｃ１の開口端に至るまで、後述するようにスピニング加工によって形成されるので、所定範囲１１ｘに対応する部分に対する加工がオーバラップして行われ、重合加工部１２ａとなる。これに対し、他方のネッキング部１３は、胴部１１の中心軸に対して傾斜した中心軸を有するテーパ部１３ｂ及び首部１３ｃから成る。このネッキング部１３も、胴部１１の所定範囲１１ｙを含み筒状部材Ｃ１の開口端に至るまでスピニング加工によって形成されるので、所定範囲１１ｙに対応する部分に対する加工がオーバラップして行われ、重合加工部１３ａとなる。
【００２９】
図２は本発明の流体処理装置の他の実施形態に係る触媒コンバータの外観を示すもので、本実施形態の筒状部材Ｃ２は、緩衝部材（図９に３で示す）を収容する部分の軸方向所定範囲を縮径して成る胴部１１と、この胴部１１の両端の所定範囲１１ｘ及び１１ｙを含み筒状部材Ｃ２の開口端に至るまでの端部をネッキング加工して成るネッキング部１４及び１３を備えている。本実施形態においては、一方のネッキング部１４は、胴部１１の中心軸に対し偏芯した中心軸を有するテーパ部１４ｂ及び首部１４ｃから成る。このネッキング部１４は、胴部１１の所定範囲１１ｘを含み筒状部材Ｃ２の開口端に至るまで、後述するようにスピニング加工によって形成されるので、所定範囲１１ｘに対応する部分に対する加工がオーバラップして行われ、重合加工部１４ａとなる。尚、他方のネッキング部１３は図１のネッキング部１３と同様であるので、図１と同じ符号を付して説明を省略する。
【００３０】
次に、上記図１に記載の触媒コンバータの製造方法について図３乃至図１０を参照して説明する。先ず、図３に示すように、セラミック製のハニカム構造体に触媒を担持した触媒担体２の外周に、緩衝部材３を一層巻回し、必要に応じ可燃性テープ等によって固定し、一体品１を形成する。尚、本実施形態の触媒担体２は各セル（流路）間の壁が薄く形成されており、従来品に比べて脆弱である。
【００３１】
緩衝部材３は、実質的にバインダー無添加の無機質繊維マットであり、その組成は例えば前掲の特許文献５に記載のものと同様であるが、セラミック繊維製とし、非膨張性のアルミナマットで構成することとしてもよい。更に、熱膨張型のバーミキュライト等を用いた緩衝マットや、それらを組み合わせた緩衝マットとしてもよいが、前述のようなバインダーは添加されていない。あるいは、金属細線を編成したワイヤメッシュ等を用いてもよいし、それをセラミックマットと組み合わせて使用してもよい。更に、それらと金属円環状のリテーナや、ワイヤメッシュ製のシールリング等と組み合わせてもよい。図示は省略するが、緩衝部材３の両端には凸部と凹部を形成しておき、これらが相互に嵌合する一般的な巻回方法を用いるとよい。また、予め円筒状に形成された緩衝部材も存在するので、その場合には円筒状の緩衝部材内に触媒担体２を収容するだけで、緩衝部材３が触媒担体２周りに装着された状態となる。
【００３２】
次に、図３に示すように、上記の一体品１を一対のクランプ装置ＣＨ間に把持し、測定装置ＤＴの押圧体ＰＭによって、緩衝部材３を介して触媒担体２をその軸芯に対して直交する方向に押圧すると共に、触媒担体２に付与される面圧を検知し、該面圧が所定の値となるときの、触媒担体２の軸芯Ｚと押圧体ＰＭとの間の距離Ｒ１を測定する。そして、測定後、押圧体ＰＭを原位置に復帰させた後、クランプ装置ＣＨによる把持を解除する。以下、本実施形態で用いるクランプ装置ＣＨ及び測定装置ＤＴについて説明する。
【００３３】
クランプ装置ＣＨは、例えばコレットチャックで構成され、これによって触媒担体２の上下端部が挟持されてその軸芯Ｚが所定の測定位置にセットされる。本実施形態の測定装置ＤＴは、モータＭＴ駆動のボールスクリュー式アクチュエータΑＣと、その先端にロードセルＬＣを介して支持された反力検知手段たる押圧体ＰＭと、後端に配置された位置検知手段たるロータリエンコーダＲＥを備えている。ロードセルＬＣ及びロータリエンコーダＲＥの検知信号は電子制御装置（以下、コントローラという）ＣＴに入力され、後述の各種データに変換されてメモリ（図示せず）に記憶されると共に、モータＭＴはコントローラＣＴによって駆動制御されるように構成されている。
【００３４】
押圧体ＰＭは触媒担体２の軸芯Ｚに対して直交する方向（図３の左右方向）に進退し、緩衝部材３に当接後これを圧縮し得るように配置される。押圧体ＰＭの当接面積は既知であるので、この押圧体ＰＭによって測定対象たる触媒担体２及び緩衝部材３が押圧されたときの反力が、触媒担体２に対する面圧としてロードセルＬＣによって検知され、コントローラＣＴに入力される。コントローラＣＴにおいては、ロードセルＬＣの検知信号が面圧値に換算されてメモリに記憶され、別途予め入力された所定の面圧値と比較される。また、ロータリエンコーダＲＥによって押圧体ＰＭの進退量及び停止位置がボールスクリュー（図示せず）の回転情報として検知され、コントローラＣＴに入力される。コントローラＣＴにおいては、ロータリエンコーダＲＥの検知信号がリアルタイムで押圧体ＰＭの進退量及び停止位置の値に変換されてメモリに記憶される。尚、これらの検知手段とコントローラＣＴとの間は電気的に接続してもよいし光学的に接続してもよい。
【００３５】
上記のように構成された測定装置ＤＴを以下のように駆動することによって、触媒担体２の軸芯Ｚと押圧体ＰＭとの間の距離と、そのときに触媒担体２に付与される面圧との関係を測定することができる。即ち、押圧体ＰＭを初期位置（図３のＰ０点）から前進（図３の左方向に移動）させて緩衝部材３の一部を押圧し、押圧部における緩衝部材３の圧縮反力が所定の値に到達したときの位置（図３のＰ１点）を検出する。この位置（図３のＰ１点）は、製品となった後の緩衝部材３の面圧値が所定の値となるときの、筒状部材の（縮径加工後の）内壁面の位置に相当する。従って、触媒担体２に付与される押圧力とそれによって生ずる反力（面圧）との関係を、予めコントローラＣＴのメモリに記憶しておき、この関係に基づきロードセルＬＣの検知信号（反力）を面圧値に変換し、これと所定の面圧値とを比較しながら押圧体ＰＭを上記の位置（図３のＰ１点）まで前進させ、押圧体ＰＭの移動距離を求める。
【００３６】
而して、押圧体ＰＭの先端の初期位置（図３のＰ０点）と触媒担体２の軸芯Ｚとの間の所定距離から、ロータリエンコーダＲＥによって検知される押圧体ＰＭの移動距離を差し引けば押圧体ＰＭの先端の位置（即ち、軸芯Ｚからの距離Ｒ１）を判定することができ、この位置が、製品状態（即ち、後述する図２の１次加工部材１０１内で触媒担体２に対する面圧が所定の面圧値で保持されている状態）における筒状部材の（縮径加工後の）内壁面の位置ということになる。このように、本実施形態によれば触媒担体２及び緩衝部材３の寸法や特性値を個別に測定することなく、また緩衝部材３のＧ．Ｂ．Ｄ．値（緩衝マットの充填密度で、面積当り重量／充填間隙寸法）を用いることもなく、所定の面圧値となる位置（図３のＰ１点）を判定することができる。即ち、上記の触媒担体２の軸芯Ｚと押圧体ＰＭの先端との間の距離Ｒ１は、結果的に触媒担体２の外径誤差のみならず緩衝部材３の単位面積当り重量の誤差をも考慮した値となるので、これらの誤差を別途測定する必要はない。
【００３７】
尚、上記測定結果の距離Ｒ１は、次工程に備え、コントローラＣＴのメモリに記憶されるが、必要に応じて表示するように構成してもよい。また、触媒担体２の軸芯Ｚの回りに放射状に複数の測定装置ＤＴを配置し多点測定を行ない、あるいは、軸芯Ｚの回りにクランプ装置ＣＨ及び一体品１を回動（割り出し）させて多点測定を行なうように構成し、各測定値の平均を求めることとしてもよい。特に、触媒担体２が円形断面でない場合には、触媒担体２の形状に応じて多点測定を行なう必要があるので、複数の測定装置ＤＴを配置することが望ましい。押圧体ＰＭは、必ずしも所定の位置（図３のＰ１点）で停止させる必要はなく、この位置を検知後そのまま連続して後退させ、更に、この押圧体ＰＭの後退に同期してクランプ装置ＣＨによる把持を解除させるように構成してもよい。
【００３８】
面圧検知手段としては、図３に破線で示すように、触媒担体２と緩衝部材３との間に感圧素子ＰＳを介装し、この感圧素子ＰＳの検知信号に基づき面圧を直接検知するように構成してもよい。この感圧素子ＰＳとしては、例えば、マトリックス状に電極を配置したセンサシートを利用して圧力分布をリアルタイムで検出するものが市販されているので、これを用いてもよい。このように面圧検知手段を構成すれば、予め測定装置ＤＴによって前述の距離Ｒ１を求める必要はなく、後述の１次加工部材１０１のうちの緩衝部材３を含む胴部を、前記面圧が所定の圧力範囲内となるように緩衝部材３と共に縮径して触媒担体２を保持するように構成することができる。従って、製造時間を大幅に短縮することができる。尚、感圧素子ＰＳが安価で、且つ、触媒コンバータの機能に悪影響を与えないのであれば、サイジング後に抜き出すことなくそのまま放置することとしてもよい。また、上記の測定工程は、触媒担体２及び緩衝部材３が許容誤差範囲内の品質を確保し得るものであれば、個体毎に行うことなくサンプルの測定結果を利用することとし、以下の一連の工程から測定工程を除き、簡略化してもよい。
【００３９】
次に、上記の測定結果の距離Ｒ１に基づき、金属製の筒状部材（図４に加工前の部分を１０で示し、一端部を拡径した状態を１０１で示す）の一端部に対する最終目標形状の内側の半径（Ｒ２）を設定する。即ち、図３の触媒担体２及び緩衝部材３を収容する筒状部材の胴部の外周面の仮想延長面より外側に突出する外周面を有する一端部の最終目標形状（図４に２点鎖線で示す）の内面と、前記胴部の中心軸Ｃとの距離を、最大内側半径Ｒ２として設定する。
【００４０】
そして、図４の左側に示すように、筒状部材の一端部を、その最終目標形状の最大内側半径Ｒ２となるまで拡径して拡径部１０ａを形成する。以後、このように拡径部１０ａが形成された筒状部材を特定する場合には１次加工部材１０１という。このときの拡径手段としては、一般的なパンチの圧入によるプレス加工があるが、スピニング等、他の方法を用いてもよい。このときの拡径量（ｄ２）は、最終目標形状の最大内側半径Ｒ２から筒状部材（の加工前の部分）の内側半径Ｒ０を減算した値である。一方、筒状部材の内側半径Ｒ０から前述の測定結果の距離Ｒ１を減算した値が縮径量（ｄ１）である。即ち、図４に二点鎖線で示す位置が筒状部材の胴部の中心軸Ｃから距離Ｒ１の位置で、このＲ１が後述する胴部１１の最終目標形状の内側半径とされる。
【００４１】
従って、後述する胴部１１の内側半径Ｒ１と拡径部１０ａの最大内側半径Ｒ２との差（ｄ０＝Ｒ２−Ｒ１）が、胴部１１の外周面の仮想延長面より外側に突出する最大幅であり、ｄ０＝ｄ１＋ｄ２の関係にある。換言すれば、筒状部材の一端部に対して拡径される変形量は拡径量（ｄ２）のみであるが、最終的には、胴部１１の外周面に対して変形量（ｄ０）が確保されることになる。つまり、筒状部材の一端部（図４の拡径部１０ａ）の最終目標形状の最大内側半径Ｒ２と縮径後の胴部（胴部１１）の最終目標形状の内側半径Ｒ１との差が、胴部１１の外周面の仮想延長面より外側に突出する最大幅（ｄ０）となるので、拡径及び縮径による変形量を最小限に抑えることができる。
【００４２】
続いて、上記のように筒状部材の一端部を拡径した１次加工部材１０１内に、図５に示すように、触媒担体２に緩衝部材３を装着した一体品１を一対収容して並設し、所定位置に保持する。この場合において、各緩衝部材３の外面は筒状部材の内面に圧接されず、接触しないか、あるいは、緩く接触している程度の関係に設定し、各緩衝部材３は殆ど圧縮力を受けないように設定することが望ましい。尚、図４に示す拡径工程と図５に示す収容工程を逆にしてもよい。
【００４３】
次に、上記一対の一体品１を収容し所定位置に保持した１次加工部材１０１に対し、図６に示すようにサイジングを行い、緩衝部材３が最適圧縮量となる径まで１次加工部材１０１の非加工部（即ち、筒状部材の胴部）を縮径する。この縮径加工をシュリンキング加工という。サイジング方法としては種々の方法が知られているが、本実施形態では図１１に示す縮径装置ＲＤが用いられている。これはフィンガー式と呼ばれ、コレットチャックが利用されている。
【００４４】
即ち、図１１に示すように、円筒状のハウジングＧＤ内に、内側がテーパ面の円筒状の押型ＤＰが液密的摺動自在に収容され、更にこの押型ＤＰに対して、複数の割り型（コレット型）ＤＶが摺動自在に収容されている。図６に示すように、各々の割り型ＤＶの外側はテーパ面に形成されており、押型ＤＰの内側のテーパ面に対し摺動自在に配設される。押型ＤＰ及び割り型ＤＶは、油圧駆動装置（図示せず）によって駆動されるように構成されており、油圧によって押型ＤＰがハウジングＧＤの軸方向（長手方向）に駆動され、この押型ＤＰの軸方向移動に応じて割り型ＤＶが径方向（軸芯方向）に駆動されるように構成されている。尚、油圧駆動装置（図示せず）は図３に示すコントローラＣＴによって制御されるように構成することができる。
【００４５】
而して、図６に示すサイジング工程において、油圧駆動装置（図示せず）を駆動し、押型ＤＰを油圧によってハウジングＧＤの軸方向に駆動すると（図６の左方に移動すると）、割り型ＤＶは径方向（軸芯方向）に移動し、筒状部材（１次加工部材１０１）の胴部及び緩衝部材３を圧縮しつつ縮径することとなる。このときの縮径量は油圧駆動装置の制御によって正確に制御され、筒状部材（１次加工部材１０１）の中心軸Ｃ（前述の触媒担体２の軸芯Ｚと一致）と内壁面との間の距離が、前述の測定結果の距離Ｒ１となるまで、調心されつつ１次加工部材１０１及び緩衝部材３が縮径され胴部１１が形成される。これにより、触媒担体２は緩衝部材３を介して筒状部材（サイジング後の状態を２次加工部材１０２とする）内で安定した状態で支持される。
【００４６】
尚、本実施形態の縮径装置ＲＤに縮径時の反力検出手段を設け、前述の測定装置ＤＴとしても機能し得るように構成することができる。このように構成することにより、１台の装置で測定とサイジングを行うことができるので、製造効率が極めて良好となる。更に、測定とサイジングとの間の時間間隔を短く設定することができ、測定時の押圧によって全周に亘って均等に薄肉化した緩衝マットが復元する前に筒状部材をセットすればよくなるので、製造効率が一層良好となる。
【００４７】
縮径装置ＲＤの油圧駆動装置（図示せず）はＮＣ制御により任意量のサイジングを行なうことができるように構成されており、微細制御が可能である。更に、縮径時において、例えば逐次（随時）ワークを回転し、割り出し制御（インデックス制御）を行なうこととすれば、全周に亘って一層均一に縮径することができる。尚、縮径装置ＲＤの駆動及び制御媒体として、本実施形態では油圧を用いることとしているが、これに限らず、その駆動及び制御形式については、機械式、電気式、空気圧式等、任意の駆動方法を用いることができ、制御はＣＮＣコントロールを用いることが好適である。
【００４８】
尚、筒状部材（１次加工部材１０１）の少なくとも緩衝部材３を収容する部分の内側の実質的な半径が測定結果の距離Ｒ１を下回り、触媒担体２が破壊する直前まで、図１の押圧体ＰＭによって緩衝部材３を押圧したときの限界距離（Ｒｘとする）を予め測定しておくとよい。そして、ＮＣ制御による縮径装置ＲＤに用い、縮径後に２次加工部材１０２がスプリングバックしたときに２次加工部材１０２の実質的な半径が距離Ｒ１となるように、半径が限界距離Ｒｘより大の範囲で距離Ｒ１を下回る距離となるまで、１次加工部材１０１を緩衝部材３と共に縮径すれば、スプリングバックに影響されることなく、触媒担体２の軸芯Ｚと１次加工部材１０１の内壁面との間の距離が前述の測定結果の距離Ｒ１となるように、１次加工部材１０１の胴部及び緩衝部材３を縮径することができる。
【００４９】
このように、少なくとも緩衝部材３の存在する範囲（図６にＳＡで示す）に亘って１次加工部材１０１が縮径されるので、緩衝部材３が圧縮状態に保持され、その圧縮復元力によって触媒担体２に付与される所定値の面圧によって、触媒担体２が胴部１１内で安定した状態で支持されると共に、軸方向摩擦力が付与される。而して、図６に示す２次加工部材１０２が形成され、スプリングバックも考慮して形成された胴部１１内に、触媒担体２が緩衝部材３を介して適切に保持される。従って、特に脆弱な触媒担体２に対しても、これを破壊することなく適切に胴部１１内に保持することができる。尚、サイジング方法としては、例えば特許文献７に記載のようにスピニングローラＳＰを用い、スピニング加工によるサイジングを行うこととしてもよい。また、例えば図１に記載の感圧素子ＰＳによって、触媒担体２に付与される面圧を監視（モニター）しながら、１次加工部材１０１を縮径することとしてもよい。あるいは、縮径装置ＲＤに設けた反力検出手段にて縮径時の面圧をリアルタイムに監視しながら、１次加工部材１０１を縮径することとしてもよい。
【００５０】
ここで各部の寸法関係の一実施例を示すと、触媒担体２の外径は直径９９．２ｍｍであり、これに厚さ８ｍｍの緩衝部材３が巻回されて、筒状部材（１次加工部材１０１）内に緩やかに挿入される。筒状部材（１次加工部材１０１）の内径は直径１１７ｍｍであり、触媒担体２及び緩衝部材３の挿入後に、図６にＳＡで示す範囲に亘って縮径加工が行われ、内径が直径１０７．２ｍｍとなるまで縮径される。尚、縮径目標とすべき内径は、触媒担体２の外径、緩衝部材３の厚さ、及び筒状部材（１次加工部材１０１）の内径初期値の３つのパラメータにおける誤差が重畳された重畳誤差によって異なるので、予め測定値に基づき最適の目標（ターゲット）内径を算出しておくことが望ましい。本実施例においては、計測の結果、目標内径が１０７．２ｍｍ、即ち最適隙間が（径方向の一方側で）４ｍｍと算出されたものが用いられている。
【００５１】
筒状部材が上記の目標内径となるまでシュリンキング加工されると、緩衝部材３が圧縮されて、所定の充填密度に至ることで触媒担体２が強固に保持されるのであるが、本実施例における充填密度（Ｇ．Ｂ．Ｄ値）は、触媒コンバータにおいて最適とされる０．２乃至０．６ｇ／ｃｍ３の範囲に充分入る。
【００５２】
尚、上記のシュリンキング加工において、筒状部材（１次加工部材１０１）及び緩衝部材３を縮径する過程で、一旦、（縮径工程での）押型ＤＰ及び割り型ＤＶの駆動を停止し、縮径力を開放した（抜重）後に、同駆動を再開し縮径を完了するように構成するとよい。このような加工を行うことにより、緩衝部材３が発生する面圧が全面に亘って均一化されることになる。これは、縮径時の緩衝部材３に対する圧縮により、緩衝部材３を構成する繊維間の関係、即ち、折れ曲がった繊維同志の絡まりが自己復元（ｒｅｌａｘａｔｉｏｎ）され、繊維密度の偏在状態が改善されることで、緩衝部材３自らが面圧分布を正常化（均一化）するためと考えられる。
【００５３】
上記シュリンキング加工における縮径停止回数は、２回以上で適宜設定すればよい。例えば、（径方向の一方側で）４ｍｍの縮径（シュリンク）が必要である場合、２ｍｍ縮径した時点で一旦縮径を停止し、縮径力を開放した後、縮径を再開して、更に２ｍｍ縮径すればよい。この場合において、縮径の停止だけでも効果があるが、若干拡径して抜重すると、一層効果的である。
【００５４】
上記のようにサイジングされた２次加工部材１０２の一端部に対し、更に、図７に示すようにスピニングローラＳＰによるネッキング加工を行なう。先ず、２次加工部材１０２の胴部１１をスピニング装置用のクランプ装置ＣＬによって挟持し、回転不能且つ軸方向移動不能に固定する。そして、胴部１１の中心軸（図６のＣ）に対して少なくとも偏芯、傾斜及び捩れの何れか一つの関係にある中心軸を有し、一部が胴部１１の外周面の仮想延長面より外側に突出する最終目標加工部（図７に示すテーパ部１３ｂ及び首部（ボトルネック部）１３ｃから成るネッキング部１３に至るまでに複数の目標加工部（図示せず）を設定する。この場合において、図７の上方の胴部１１の左端近傍を図８に拡大して示すように、胴部１１の左端側の所定範囲１１ｙを含みネッキング部１３を形成するように設定する。即ち、図８にネッキング部１３を実線で示すように、胴部１１の所定範囲１１ｙ（図８に１点鎖線で示す範囲）に対してもスピニングローラＳＰによるネッキング加工を行ない、所定範囲１１ｙに対応する部分がネッキング部１３の一部を構成し、重合加工部１３ａとなる。
【００５５】
そして、上記複数の目標加工部に基づき複数の加工目標軸（図示せず）を設定し、これら複数の加工目標軸のうちの一つと拡径部１０ａの中心軸（図示せず）が略同軸となるように２次加工部材１０２（図６に示す状態）を支持し、その一端部の外周回りを同径の円形軌跡にて公転する複数のスピニングローラＳＰによって当該一端部に対しスピニング加工を行なう。即ち、２次加工部材１０２の一端部の外周回りに望ましくは等間隔で配置したスピニングローラＳＰを、当該一端部の外周面に密着させて公転させると共に、径方向に駆動して公転軌跡を縮小しつつ軸方向（図７の左方向）に駆動してスピニング加工を行なう。これにより、図７に示す３次加工部材１０３が形成され、一端部が最終目標形状の傾斜軸を有するネッキング部１３に形成される。
【００５６】
続いて、図９に示すように、ネッキング部１３が加工された３次加工部材１０３（図７に示す状態）を１８０度反転させて配置し、他方の端部についても上記と同様にスピニングローラＳＰによるネッキング加工を行なう。この場合における３次加工部材１０３の反転作業は、ネッキング部１３の加工終了後、クランプ装置ＣＬによる３次加工部材１０３の挟持状態を解放し、図示しないロボットハンドによってクランプ装置ＣＬから３次加工部材１０３を取り出し、これを反転させて再度クランプ装置ＣＬに装着することによって行なう。
【００５７】
そして、クランプ装置ＣＬによって胴部１１を再度挟持し、他方の端部に対し、スピニングローラＳＰによって前述と同様に加工し、図９に示すように胴部１１の中心軸（図６のＣ）と同軸のテーパ部１２ｂ及び首部１２ｃから成るネッキング部１２を形成する。この場合において、図９の下方の胴部１１の左端近傍を図１０に拡大して示すように、胴部１１の左端側の所定範囲１１ｘを含みネッキング部１２を形成するように設定する。即ち、図１０にネッキング部１２を実線で示すように、胴部１１の所定範囲１１ｘ（図１０に１点鎖線で示す範囲）に対してもスピニングローラＳＰによるネッキング加工を行ない、所定範囲１１ｘに対応する部分がネッキング部１２の一部を構成し、重合加工部１２ａとなる。
【００５８】
本実施形態によれば、上記のようにスピニング加工時に２次加工部材１０２（又は３次加工部材１０３）は回転しないため、２次加工部材１０２を確実に保持する構造を容易に構成することができると共に、２次加工部材１０２（又は３次加工部材１０３）に収容された触媒担体２及び緩衝部材３もスピニング加工中に回転（軸芯を中心とする自転）することはないので、安定した保持状態を維持することができる。また、２次加工部材１０２及び３次加工部材１０３の各一端部に対するネッキング加工を容易に連続して行なうことができる。
【００５９】
特に、本実施形態においては、図８及び図１０に示すように、胴部１１の所定範囲１１ｘ及び１１ｙに対してもスピニングローラＳＰによるネッキング加工が行なわれ、所定範囲１１ｘ及び１１ｙに対応する部分がネッキング部１２及び１３の一部を構成し、重合加工部１２ａ及び１３ａとなる。この場合において、ネッキング部１３は傾斜スピニング加工によって形成され、スピニングローラＳＰの公転軌道が筒状部材の軸芯に対して斜めになるので、重合加工部１３ａは、同軸スピニング加工によって形成されるネッキング部１２の重合加工部１２ａより広い範囲とすることが望ましい（後述の偏芯スピニング加工による場合も同様）。
【００６０】
つまり、ネッキング部１３に関しては、図８に示すように、胴部１１のサイジング時に形成された折り曲げ部Ｂ１とは異なる折り曲げ部Ｂ２からネッキング加工が行なわれて重合加工部１３ａとなるので、折り曲げ部が重なることはない。しかも、サイジング時に形成された折り曲げ部Ｂ１は、スピニング加工によるヘリカル方向への積極的な材料の塑性流動によって、全体として均一な板厚に形成される。同様に、ネッキング部１２に関しても、図１０に示すように、胴部１１のサイジング時に形成された折り曲げ部Ｂ３からネッキング加工が行なわれるが、折り曲げ部Ｂ３とは異なる折り曲げ部Ｂ４で折り曲げられるので、折り曲げ部が重なることはなく、折り曲げ部Ｂ４は、スピニング加工によるヘリカル方向への積極的な材料の塑性流動によって、全体として均一な板厚に形成される。
【００６１】
而して、完成品の触媒コンバータには、図１に示すように、サイジングによって胴部１１の外面に形成された平行な複数の痕跡１１ｅ、並びにスピニング加工によってネッキング部１２及び１３の外面に形成された複数の条痕１２ｊ及び１３ｊが残り、図１に破線で示すように痕跡１１ｅの縮径時の両端部はネッキング部１２及び１３の形成時に消失し、痕跡１１ｅは、その両側で条痕１２ｊ及び１３ｊに交差するように連結された形態を呈している。尚、上記の痕跡１１ｅは、図１１に示す縮径装置ＲＤを用いた工法特有のものであるが、図１（及び図２）における線条は説明の便宜上、強調して描いたものであって、実際は薄く、できれば視認できない程度であることが望ましい。また、スピニング加工による条痕１２ｊ及び１３ｊ（及び、後述する１４ｊ）についても同様である。
【００６２】
上記の構成を従来の一般的なサイジング方法による構成と比較すると、例えば図１０において、従来方法によれば、サイジング時に形成される折り曲げ部Ｂ３を境として、そこからネッキング加工によって反対方向に折り曲げられて２回目の折り曲げ部（図示せず）が形成されることになる（即ち、図１０の折り曲げ部Ｂ３とＢ４が同じ位置となる）。従って、前述のように、板厚が減少している折り曲げ部Ｂ３（１回目）に対し、反対方向に折り曲げ部（２回目）が形成されることになるので、この部分の板厚が更に減少し、他の部分に比べて剛性が低い環状の低剛性部分が形成されてしまうおそれがある。尚、図８に示す部位では、従来方法によれば、折り曲げ部Ｂ１から同一方向に折り曲げられて２回目の折り曲げ部（図示せず）が形成されることになるが、同一箇所で２回の折り曲げ部が形成されることに変わりはないので、他の部分に比べて剛性が低くなることは避けられない。
【００６３】
これに対し、本願発明の実施形態に係る上記の触媒コンバータにおいては、折り曲げ部が重なることはなく、しかも材料の塑性流動によって全体として均一な板厚の重合加工部となるので、折り曲げ部で板厚が減少することはない。更に、非加工部、即ち素材のままの部分が完全に無くなり、筒状部材が、その外面の全体に亘って塑性加工が行われることになるので、非加工部という低剛性部分が残ることもない。特に、本実施形態においては、コレット型による縮径加工とスピニング加工との組み合わせにより、板厚増加を伴う加工を行うことができるので、重合加工部における上記の効果が相乗され、一層の効果を奏することができる。尚、サイジングに際しては、面圧を予測し、あるいは、縮径加工時にリアルタイムで検知しつつ、所定量のサイジングを行うとよい。
【００６４】
更に、図１１に示す縮径装置ＲＤに代えて、図１２に示す縮径装置ＲＤｘを用いることとすれば、前述のシュリンキング加工を一層適切に行うことができる。即ち、この縮径装置ＲＤｘにおいては、各割り型ＤＶが２分割され、セグメントＤＳと裏金部材ＤＸによって構成されている。各セグメントＤＳと裏金部材ＤＸの間はＴスロットＤＣで嵌合されており、各セグメントＤＳは着脱可能とされている。つまり、加工対象の筒状部材の径に応じてセグメントＤＳを交換し得るように構成されている。また、セグメントＤＳの両端角に、円滑な曲面を有する肩部ＤＳａ及びＤＳｂが形成されている。これらの肩Ｒは数ミリＲ程度が望ましい。これにより、測定工程における最小縮径時に、即ち、隣接するセグメントＤＳ間の間隙が最小となるときに、この間隙に緩衝部材３の一部を噛み込むことを回避することができる。尚、セグメントＤＳ自体に、あるいはセグメントＤＳと裏金部材ＤＸの間に、感圧センサを設けることとしてもよい。
【００６５】
以上のように、本実施形態に係る触媒コンバータの製造方法においては、従来技術のように触媒担体と筒状部材との間の（固定された）間隙に緩衝部材が圧入されるのではなく、緩衝部材は筒状部材内に緩やかに挿入された後、所謂サイジング加工によって、最適の間隙（即ち、最適のＧ．Ｂ．Ｄ値）となるように筒状部材の胴部が縮径加工される。これにより、従来技術のように筒状部材への挿入時に緩衝部材に外力が加えられることはないので、保形力の弱い実質的にバインダー無添加の緩衝部材であっても、適切に筒状部材内に配置し所期の面圧を発生させ、所定の保持力で触媒担体を筒状部材内に安定した状態で保持することができる。従って、当然ながら、バインダーを含有することによる問題を排除することができる。尚、前述のように板状もしくは筒状に成形された緩衝部材を用いる代わりに、予め触媒担体を筒状部材内に配置しておき、両者間の間隙に、実質的にバインダー無添加の無機繊維を（加圧吹き込み等によって）充填し、その後に筒状部材に対しシュリンキング加工を行うこととしてもよい。
【００６６】
更に、図７に示す実施形態においては、２次加工部材１０２の一端部に対し傾斜スピニング加工（特許文献８）を適用しているが、これに限らず、偏芯スピニング加工（特許文献９）を適用してオフセット状のネッキング部を形成することとしてもよく、この偏芯スピニング加工によれば、図２の右側に示すネッキング部１４を形成することができ、このときに条痕１４ｊが形成される。また、図７に示すように、一部が胴部１１の外周面の仮想延長面より外側に突出する最終目標加工部を設定してネッキング加工を行うこととしているが、これに限らず、通常の、同軸、偏芯、傾斜及び捩れスピニング加工の何れと組み合わせることとしてもよい。尚、同軸、偏芯、傾斜及び捩れスピニング加工においては、本実施形態のようにワーク（筒状部材）固定式が望ましいが、適宜、ワーク回転式を用いることとしてもよい。
【００６７】
尚、触媒コンバータやＤＰＦに対しネッキング部を形成する場合には、上記のスピニング加工によるネッキング加工が好適であるが、これに限らず、その他の塑性加工方法によって形成することとしてもよい。あるいは、別体のネッキング部（コーン部）を溶接等で接続することもできる。シュリンキング加工における筒状部材の胴部の縮径方法も、スピニング加工で行うことも可能である。筒状部材としては、電縫管、シームレス管、多層管等のパイプを適宜切断して用いてもよいし、シェル状の多分割体を結合させた所謂モナカ合せ品、あるいはＣ字状断面の板材を溶接して管状に形成したものを用いてもよい。
【００６８】
更に、本実施形態では触媒担体２は２個としたが、１個でもよい。あるいは、３個以上の触媒担体を直列に配置してもよく、胴部は、各ハニカム構造体に対応する部分毎に適宜縮径してもよいし、連続して縮径してもよい。そして、最終製品としては、自動車の排気系部品に限らず、前掲の特許文献に記載の燃料電池用改質器等、種々の流体処理装置に適用することができる。
【００６９】
【発明の効果】
本発明は上述のように構成されているので以下に記載の効果を奏する。即ち、請求項１に記載のハニカム構造体内蔵流体処理装置においては、少なくとも、実質的にバインダー無添加の緩衝部材を収容する部分の軸方向所定範囲を縮径して成る胴部と、この胴部の少なくとも一端側の端部をネッキング加工して成るネッキング部を備えた金属製筒状部材内に、前記緩衝部材を介してハニカム構造体が保持されているので、緩衝部材によって所期の面圧を確保した状態で筒状部材内に緩衝部材及びハニカム構造体を適切に保持することができる。
【００７０】
前記ネッキング部は、請求項２に記載のように構成すれば、胴部の両端に連続して所望の形状のネッキング部を容易に形成することができる。
【００７１】
また、請求項３に記載のハニカム構造体内蔵流体処理装置の製造方法においては、筒状部材の少なくとも実質的にバインダー無添加の緩衝部材を収容する部分の軸方向所定範囲を縮径して胴部を形成し、該胴部の少なくとも一端側の所定範囲を含み筒状部材の開口端に至るまでの端部をネッキング加工してネッキング部を形成することとしているので、実質的にバインダー無添加の緩衝部材であっても、この緩衝部材によって所期の面圧を確保しつつ筒状部材内に緩衝部材及びハニカム構造体を適切に保持することができる。
【００７２】
更に、請求項４に記載のように前記ネッキング部を形成することとすれば、胴部の両端に連続して所望の形状のネッキング部を容易に形成することができる。
【図面の簡単な説明】
【図１】本発明の流体処理装置の一実施形態に係る触媒コンバータの正面図である。
【図２】本発明の流体処理装置の他の実施形態に係る触媒コンバータの正面図である。
【図３】本発明の一実施形態に係る触媒コンバータの製造方法において、触媒担体及び緩衝部材の測定工程を示す正面図である。
【図４】本発明の一実施形態に係る触媒コンバータの製造方法において、筒状部材の一端部を拡径し、拡径部を形成した１次加工部材を示す断面図である。
【図５】本発明の一実施形態に係る触媒コンバータの製造方法において、触媒担体及び緩衝部材を装着した一体品を１次加工部材内に収容する状態を示す断面図である。
【図６】本発明の一実施形態に係る触媒コンバータの製造方法において、サイジング工程での１次加工部材の縮径状態を示す断面図である。
【図７】本発明の一実施形態に係る触媒コンバータの製造方法において、２次加工部材の一端部に対しスピニングローラによるネッキング加工を行う状態を示す断面図である。
【図８】図７の上方の胴部の左端近傍を拡大して示す断面図である。
【図９】本発明の一実施形態に係る触媒コンバータの製造方法において、一端部にネッキング部が形成された３次加工部材の他方の端部に対し、スピニングローラによるネッキング加工を行なう状態を示す断面図である。
【図１０】図９の下方の胴部の左端近傍を拡大して示す断面図である。
【図１１】本発明の一実施形態に係る触媒コンバータの製造に供する縮径装置を示す斜視図である。
【図１２】本発明の一実施形態に係る触媒コンバータの製造に供する縮径装置の他の例を示す斜視図である。
【符号の説明】
１　一体品，　２　触媒担体，　３　緩衝部材，　１０　筒状部材，
１１　胴部，　１０ａ　拡径部，　１２ｂ，１３ｂ，１４ｂ　テーパ部，
１２ｃ，１３ｃ，１４ｃ　首部，　１２，１３，１４　ネッキング部，
１０１　１次加工部材，　１０２　２次加工部材，　１０３　３次加工部材，
ＤＴ　測定装置，　ＰＭ　押圧体，　ＬＣ　ロードセル，
ＲＥ　ロータリエンコーダ，　ＣＨ，ＣＬ　クランプ装置，
ＳＰ　スピニングローラ，　ＲＤ　縮径装置，　ＧＤ　ハウジング，
ＤＰ　押型，　ＤＶ　割り型，　ＲＤｘ　縮径装置，　ＤＳ　セグメント[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a fluid processing apparatus for holding a honeycomb structure via a buffer member substantially free of a binder in a metal cylindrical member, and a method for manufacturing the same. The present invention relates to a catalytic converter that holds a catalyst carrier of a honeycomb structure via a buffer mat to which no additive is added, and a method for manufacturing the same.
[0002]
[Prior art]
2. Description of the Related Art A fluid processing apparatus in which a honeycomb structure having a filter function for a fluid is built in a metal tubular member via a buffer member is known, and is used for purifying various fluids. For example, in a vehicle exhaust system, a catalytic converter and a diesel particulate filter (hereinafter, referred to as DPF) are mounted, and a catalyst carrier or a filter (generally referred to as a carrier). In this case, a fragile honeycomb structure made of ceramic is used. These honeycomb structures are held in a metal cylindrical member via a buffer member such as a ceramic mat to constitute a fluid treatment device. An example of this is a catalytic converter.
[0003]
[Patent Document 1]
Various methods for producing such a catalytic converter are conventionally known. For example, Japanese Patent Application Laid-Open No. 2002-70544 discloses a method for producing a catalytic converter for purifying exhaust gas using a holding sealing material. Are listed as follows. That is, a method in which the holding sealing material is wrapped around the catalyst holding body, is sandwiched between two metal shells, a method in which it is pressed into the metal shell, and a method in which a metal plate is wound therearound. These are known as a clamshell method, a press-fit method, and a tonicket method, respectively. In this publication, in order to improve the assemblability to the catalyst holding body, as a countermeasure when an organic binder is contained (impregnated or applied) in a mat-shaped buffer member made of ceramic fiber, the holding sealing material is used. Proposals have been made regarding the packing density of ceramic fiber mats, the content and properties of organic binders.
[0004]
[Patent Document 2]
Similarly, in view of various problems relating to the buffer member to which the organic binder is added as described above, Japanese Patent Application Laid-Open No. 2001-12237 proposes reducing the content of the organic binder.
[0005]
[Patent Document 3]
Further, Japanese Patent Application Laid-Open No. 2001-289027 proposes the use of an inorganic fiber mat to which no binder is added. In this publication, a method is proposed in which the inorganic fiber mat is impregnated with water and then frozen, and the catalyst holder coated with the inorganic fiber mat in a state where the thickness of the inorganic fiber mat is reduced is mounted in a metal shell. .
[0006]
[Patent Document 4]
JP-A-2002-38937 also proposes that a non-expandable seal mat is impregnated with a water component as a binder for a low-temperature coagulation medium and then iced. The publication describes that the non-expandable seal mat itself has a low friction thereby, and is quickly inserted into the case by a smooth operation.
[0007]
[Patent Document 5]
On the other hand, Japanese Patent Application Laid-Open No. 2001-289040 discloses an expander in which an inorganic fiber mat to which a binder is not added is inserted into a metal shell and the inorganic fiber mat is interposed between the metal shell and the inner wall. A method has been proposed in which the inorganic fiber mat is inserted, thereby compressing the inorganic fiber mat, making the inner diameter larger than the outer diameter of the catalyst holder, and then inserting the catalyst holder.
[0008]
[Patent Document 6]
Although the above-mentioned prior art relates to a catalytic converter, the subject of the present invention is not limited to this, and includes the above-mentioned DPF, purification filter, and the like, and further includes a fuel cell described in JP-A-2002-50383. A reformer and the like are also included.
[0009]
[Patent Document 7]
Further, as for a manufacturing method which is an object of the present invention, there is a processing method described in, for example, JP-A-2001-107725 as a conventional technique relating to spinning processing.
[0010]
[Patent Document 8]
Japanese Patent No. 2957154 discloses an inclined spinning process related to the necking process for processing the end of the cylindrical member.
[0011]
[Patent Document 9]
Similarly, Japanese Patent No. 2957153 discloses an eccentric spinning process.
[0012]
[Problems to be solved by the invention]
After all, it is preferable not to add an organic binder as described in Patent Document 1 (Japanese Patent Application Laid-Open No. 2002-70544) and Patent Document 2 (Japanese Patent Application Laid-Open No. 2001-12237) to the cushioning member. When a cushioning member is interposed or press-fitted in the inside, a binder is required to reduce the thickness of the cushioning member.
[0013]
That is, also in the above-mentioned Patent Document 3 (Japanese Patent Application Laid-Open No. 2001-289027) and Patent Document 4 (Japanese Patent Application Laid-Open No. 2002-38937), it is possible to impregnate the inorganic fiber mat with water and then freeze the inorganic fiber mat to reduce its thickness. As described in Patent Document 4, as described in Patent Document 4 using a water component as a binder of the low-temperature coagulation medium, the moisture still functions as a binder for reducing the thickness of the buffer member. . Therefore, the increase in manufacturing time and cost due to the necessary processes is inevitable, and there is a fear that the fiber may be damaged during the process from freezing to thawing, and it is not certain whether the cushioning member returns to the expected state. Absent.
[0014]
On the other hand, according to Patent Document 5 (Japanese Unexamined Patent Application Publication No. 2001-289040), a buffer member substantially free of a binder can be used, and the above-described process from freezing to thawing does not occur. There are variations in the outer diameter of the support, the thickness of the buffer member (particularly the thickness after restoration), and the inner diameter of the outer cylinder, and these variations are superimposed. It will be greatly influenced. Since the publication does not mention these errors, it is not clear whether the necessary holding force can be constantly obtained.
[0015]
To summarize the above prior arts, Patent Documents 1 to 4 disclose, in an apparatus for holding a catalyst carrier (honeycomb structure) through a cushioning material in a metal tubular member, from the viewpoint of ease of assembly. The thickness of the cushioning member is reduced by using an organic binder or a binder of a low-temperature coagulation medium such as moisture, and the binder is burned or evaporated after assembling. As a result, only the cushioning member remains and the state of the cushioning member is restored. It is assumed that Regarding the assembling, Patent Documents 1, 3 and 4 disclose that the buffer member is inserted (wound) into the cylindrical member in a state of being mounted (wound) on the catalyst carrier. In Patent Document 5, the buffer member is inserted into the cylindrical member. Is mounted, and the catalyst carrier is inserted in a state where the diameter of the buffer member is compressed and expanded.
[0016]
As described above, Patent Documents 1 to 4 basically deal with only the buffer member among the tubular member, the buffer member, and the catalyst carrier. Certainly, as described in Patent Documents 3 and 4, it is desirable to use a buffer member to which an organic binder is not added, but a low-temperature coagulation medium such as moisture functions as a binder for reducing the thickness of the buffer member. This is still the case, and it cannot be said that the buffer member is substantially free of a binder. On the other hand, in Patent Document 5, a buffer member substantially free of a binder is used, but it is assumed that the buffer member is compressed before the catalyst carrier is inserted and the state of the buffer member is restored after the catalyst carrier is inserted. And
[0017]
After all, in any of the prior arts, in the fluid treatment apparatus using the buffer member substantially without binder, the surface pressure required for the buffer member, that is, the frictional force between the buffer member and the catalyst carrier, and the buffer The pressure for applying the frictional force between the member and the cylindrical member depends on the state of the buffer member after the binder disappears or the state of the buffer member after the compression force is removed. Is not clarified, and it is difficult to clarify this relationship only with the cushioning member. For this reason, there is a concern that the dispersion of the durability of the fluid processing apparatus will increase.
[0018]
The problem of securing the surface pressure necessary for the cushioning member as described above is becoming overlooked due to the thinning and weakening of the carrier accompanying the recent demand for improvement in purification performance. Furthermore, it is inevitable that the allowable range of the holding surface pressure error is reduced, and it is an essential solution to ensure that the expected surface pressure can be secured without being greatly affected by errors in the components. is there.
[0019]
In view of the above, the present invention provides a fluid treatment apparatus with a built-in honeycomb structure that holds a honeycomb structure through a buffer member substantially free of a binder in a metal cylindrical member, and secures an intended surface pressure by the buffer member. It is an object to provide a configuration in which a buffer member and a honeycomb structure can be appropriately held in a tubular member.
[0020]
Further, the present invention provides a honeycomb structure in which a buffer member substantially free of a binder is mounted in a metal tubular member, and secures an intended surface pressure without damaging the buffer member, and is provided in the tubular member. Another object of the present invention is to provide a manufacturing method capable of appropriately holding a buffer member and a honeycomb structure.
[0021]
[Means for Solving the Problems]
In order to solve the above-mentioned problems, a honeycomb structured body fluid treatment apparatus according to the present invention, as set forth in claim 1, includes a honeycomb structured body via a buffer member substantially free of a binder in a metal tubular member. In the fluid treatment device with a built-in honeycomb structure, the cylindrical member has a body portion formed by reducing at least a predetermined axial direction range of a portion accommodating the buffer member, and at least one end of the body portion A necking portion formed by necking the portion is provided. It should be noted that the buffer member according to the present invention is a buffer member to which substantially no binder is added, to which no binder for shape retention is added. For convenience of transportation, etc., a small amount (0 to 5%) of an additive may be included in the cushioning member, and even if the component is the same as or similar to the conventional binder, this is the same as described above. It is not included in the binder, nor does it affect the surface pressure adjustment contemplated by the present invention.
[0022]
The necking portion is formed by spinning up to the opening end of the tubular member including a predetermined range on at least one end side of the body portion, as described in claim 2, with respect to a central axis of the body portion. Therefore, it can be configured to have a central axis that is at least one of eccentricity, inclination, and twist.
[0023]
Further, according to the manufacturing method of the present invention, as set forth in claim 3, a fluid treatment apparatus with a built-in honeycomb structure for holding the honeycomb structure in a metal tubular member via a buffer member substantially free of a binder. In the manufacturing method, the buffer member is mounted gently in the cylindrical member in a state where the buffer member is mounted on the outer periphery of the honeycomb structure, and a predetermined axial direction range of at least a portion of the cylindrical member that stores the buffer member is set. The body is formed by reducing the diameter, and the end of the body is necked to form a necking portion.
[0024]
Further, as described in claim 4, at least eccentricity, inclination and twist with respect to the center axis of the body portion including a predetermined range on at least one end side of the body portion and reaching the open end of the tubular member. The necking portion can be formed by performing a spinning process along a central axis having any one of the following relationships.
[0025]
BEST MODE FOR CARRYING OUT THE INVENTION
As a specific embodiment of the fluid treatment apparatus that holds the honeycomb structure via the buffer member substantially free of a binder in the metal tubular member as described above, a catalytic converter for an automobile will be described with reference to the drawings. . The fluid treatment device of the present invention includes, for example, a DP filter device and a purification filter in addition to the catalytic converter, and further includes the fuel cell reformer described above. The cylindrical member is also called an outer cylinder, a housing or a casing. In the case of a catalytic converter, the honeycomb structure corresponds to a catalyst carrier (the above-described catalyst holder). The buffer member substantially free of the binder corresponds to the buffer mat for holding the catalyst carrier such as the above-mentioned inorganic fiber mat containing no binder. In the case of a DP filter device, the honeycomb structure corresponds to a filter, and the buffer member corresponds to a buffer mat for the DP filter.
[0026]
The catalyst carrier or DP filter constituting the honeycomb structure is generally formed in a columnar or cylindrical shape and has a circular cross section, but is not limited thereto, and may have an elliptical cross section, an elliptical cross section, and a surface having a plurality of curvatures. And a non-circular cross-section such as a polygonal cross-section. The cross section of the flow path (cell) of the catalyst carrier or DP filter is not limited to a honeycomb (hexagon), but may be an arbitrary square or the like. The material of the catalyst carrier (honeycomb structure) of the present embodiment is ceramic, but is not limited thereto, and may be a so-called metal carrier made of a thin metal. The buffer member will be described later in detail.
[0027]
FIG. 1 shows the appearance of a catalytic converter according to an embodiment of the fluid treatment apparatus of the present invention. As shown in FIG. 9, a cross section of the catalytic converter is substantially free of a binder in a metal tubular member C1. (Hereinafter, simply referred to as a buffer member 3 unless otherwise specified) to hold the catalyst carrier 2 having a honeycomb structure. As shown in FIG. 1, the cylindrical member C <b> 1 according to the present embodiment is formed by reducing the diameter of a predetermined axial direction range (a range indicated by SA in FIG. 1) of a portion that accommodates a buffer member (3 in FIG. The body 11 is provided with necking portions 12 and 13 formed by necking the ends of the body 11 including predetermined ranges 11x and 11y up to the open end of the tubular member C1. In FIG. 1, a predetermined range SA indicates a sizing range described later, and in FIGS. 1 and 2, 11e indicates a trace after diameter reduction processing described later, and 12j and 13j indicate striations after spinning processing. .
[0028]
In the present embodiment, one necking portion 12 includes a tapered portion 12b having a central axis coaxial with the central axis of the body portion 11 and a neck portion 12c. The necking portion 12 is formed by spinning as described later until it includes the predetermined range 11x of the body portion 11 and reaches the open end of the cylindrical member C1, so that the processing corresponding to the predetermined range 11x overlaps. Then, the polymerization processing section 12a is formed. On the other hand, the other necking portion 13 includes a tapered portion 13b having a central axis inclined with respect to the central axis of the body portion 11 and a neck portion 13c. Since the necking portion 13 is also formed by spinning up to the opening end of the cylindrical member C1 including the predetermined range 11y of the body portion 11, the processing corresponding to the predetermined range 11y is performed by overlapping. It becomes the polymerized part 13a.
[0029]
FIG. 2 shows the appearance of a catalytic converter according to another embodiment of the fluid treatment apparatus of the present invention. The tubular member C2 of this embodiment has a portion for accommodating a buffer member (indicated by 3 in FIG. 9). A trunk portion 11 having a reduced diameter in a predetermined axial direction, and a necking portion formed by necking an end portion including the predetermined ranges 11x and 11y at both ends of the trunk portion 11 and reaching an open end of the tubular member C2. 14 and 13 are provided. In the present embodiment, one necking portion 14 includes a tapered portion 14b having a central axis eccentric to the central axis of the body portion 11 and a neck portion 14c. Since the necking portion 14 is formed by spinning as described later up to the opening end of the cylindrical member C2 including the predetermined range 11x of the body portion 11, the processing corresponding to the predetermined range 11x overlaps. Then, it becomes the polymerization processing section 14a. Since the other necking portion 13 is the same as the necking portion 13 in FIG. 1, the same reference numerals as those in FIG.
[0030]
Next, a method of manufacturing the catalytic converter shown in FIG. 1 will be described with reference to FIGS. First, as shown in FIG. 3, a buffer member 3 is further wound around the outer periphery of a catalyst carrier 2 in which a catalyst is supported on a ceramic honeycomb structure, and if necessary, fixed with a flammable tape or the like, and the integrated article 1 is formed. Form. The catalyst carrier 2 of the present embodiment has a thin wall between the cells (flow paths), and is fragile as compared with a conventional product.
[0031]
The cushioning member 3 is substantially a binder-free inorganic fiber mat, and has the same composition as that described in, for example, the above-mentioned Patent Document 5, but is made of ceramic fiber and is made of a non-expandable alumina mat. You may do it. Further, a buffer mat using thermal expansion type vermiculite or the like or a buffer mat combining them may be used, but the binder as described above is not added. Alternatively, a wire mesh formed by knitting fine metal wires or the like may be used, or it may be used in combination with a ceramic mat. Further, they may be combined with a metal annular retainer, a wire mesh seal ring, or the like. Although not shown, a convex portion and a concave portion are formed at both ends of the buffer member 3, and a general winding method in which these are fitted to each other may be used. In addition, there is also a buffer member formed in a cylindrical shape in advance. In that case, the state in which the buffer member 3 is mounted around the catalyst carrier 2 only by accommodating the catalyst carrier 2 in the cylindrical buffer member. Become.
[0032]
Next, as shown in FIG. 3, the above-mentioned integrated product 1 is gripped between a pair of clamp devices CH, and the catalyst carrier 2 is attached to the axis of the catalyst carrier 2 via the buffer member 3 by the pressing body PM of the measuring device DT. And presses in a direction orthogonal to the surface, detects the surface pressure applied to the catalyst carrier 2, and detects the distance between the axis Z of the catalyst carrier 2 and the pressing body PM when the surface pressure becomes a predetermined value. Measure R1. Then, after the measurement, the pressing body PM is returned to the original position, and then the gripping by the clamp device CH is released. Hereinafter, the clamp device CH and the measurement device DT used in the present embodiment will be described.
[0033]
The clamp device CH is formed of, for example, a collet chuck, whereby the upper and lower ends of the catalyst carrier 2 are clamped, and the axis Z thereof is set at a predetermined measurement position. The measuring device DT of the present embodiment includes a ball screw type actuator ΑC driven by a motor MT, a pressing body PM which is a reaction force detecting means supported at a tip thereof via a load cell LC, and a position detecting means arranged at a rear end. A barrel rotary encoder RE is provided. The detection signals of the load cell LC and the rotary encoder RE are input to an electronic control unit (hereinafter, referred to as a controller) CT, converted into various data described below and stored in a memory (not shown), and the motor MT is controlled by the controller CT. It is configured to be drive-controlled.
[0034]
The pressing body PM moves forward and backward in a direction perpendicular to the axis Z of the catalyst carrier 2 (the left-right direction in FIG. 3), and is arranged so as to be able to compress it after coming into contact with the buffer member 3. Since the contact area of the pressing body PM is known, the reaction force when the catalyst carrier 2 and the buffer member 3 to be measured are pressed by the pressing body PM is detected by the load cell LC as a surface pressure against the catalyst carrier 2. Are input to the controller CT. In the controller CT, the detection signal of the load cell LC is converted into a contact pressure value, stored in the memory, and compared with a predetermined contact pressure value previously input separately. Further, the advance / retreat amount and the stop position of the pressing body PM are detected by the rotary encoder RE as rotation information of a ball screw (not shown), and input to the controller CT. In the controller CT, the detection signal of the rotary encoder RE is converted in real time into values of the amount of retreat and the stop position of the pressing body PM and stored in the memory. Note that these detecting means and the controller CT may be electrically connected or optically connected.
[0035]
By driving the measuring device DT configured as described above as follows, the distance between the axis Z of the catalyst carrier 2 and the pressing body PM and the surface pressure applied to the catalyst carrier 2 at that time are determined. Can be measured. That is, the pressing body PM is advanced (moved to the left in FIG. 3) from the initial position (point P0 in FIG. 3) to press a part of the cushioning member 3, and the compression reaction force of the cushioning member 3 in the pressing portion becomes a predetermined value. Is detected (point P1 in FIG. 3) when the value reaches the value of. This position (point P1 in FIG. 3) corresponds to the position of the inner wall surface (after diameter reduction) of the cylindrical member when the surface pressure value of the cushioning member 3 after it has become a product has a predetermined value. I do. Therefore, the relationship between the pressing force applied to the catalyst carrier 2 and the reaction force (surface pressure) generated thereby is stored in the memory of the controller CT in advance, and based on this relationship, the detection signal (reaction force) of the load cell LC is generated. Is converted into a surface pressure value, and the pressing body PM is advanced to the above-mentioned position (point P1 in FIG. 3) while comparing this with a predetermined surface pressure value, and the moving distance of the pressing body PM is obtained.
[0036]
The moving distance of the pressing body PM detected by the rotary encoder RE is calculated from the predetermined distance between the initial position of the tip of the pressing body PM (point P0 in FIG. 3) and the axis Z of the catalyst carrier 2. By pulling, the position of the tip of the pressing body PM (that is, the distance R1 from the axis Z) can be determined, and this position is determined by the product state (that is, the catalyst carrier in the primary processing member 101 in FIG. 2 described later). This is the position of the inner wall surface (after diameter reduction) of the tubular member in a state where the surface pressure with respect to 2 is maintained at a predetermined surface pressure value. As described above, according to the present embodiment, the dimensions and the characteristic values of the catalyst carrier 2 and the buffer member 3 are not individually measured, and the G.V. B. D. A position (point P1 in FIG. 3) at which a predetermined surface pressure value is obtained can be determined without using a value (filling density of buffer mat, weight per area / filling gap size). That is, the distance R1 between the axis Z of the catalyst carrier 2 and the tip of the pressing body PM results in not only the outer diameter error of the catalyst carrier 2 but also the weight error per unit area of the buffer member 3. Since these values are considered, it is not necessary to measure these errors separately.
[0037]
Note that the distance R1 of the measurement result is stored in the memory of the controller CT in preparation for the next step, but may be displayed as necessary. Further, a plurality of measuring devices DT are arranged radially around the axis Z of the catalyst carrier 2 to perform multipoint measurement, or the clamping device CH and the integrated product 1 are rotated (indexed) around the axis Z. Multi-point measurement may be performed, and an average of each measured value may be obtained. In particular, when the catalyst carrier 2 does not have a circular cross section, it is necessary to perform multipoint measurement according to the shape of the catalyst carrier 2, and thus it is desirable to arrange a plurality of measuring devices DT. The pressing body PM does not necessarily need to be stopped at a predetermined position (point P1 in FIG. 3). After detecting this position, the pressing body PM is continuously retracted, and further, in synchronization with the retraction of the pressing body PM, the clamp device CH is moved. May be released.
[0038]
As a surface pressure detecting means, as shown by a broken line in FIG. 3, a pressure sensitive element PS is interposed between the catalyst carrier 2 and the buffer member 3, and the surface pressure is directly detected based on a detection signal of the pressure sensitive element PS. You may comprise so that it may detect. As the pressure-sensitive element PS, for example, an element that detects a pressure distribution in real time using a sensor sheet in which electrodes are arranged in a matrix is commercially available, and may be used. If the surface pressure detecting means is configured in this manner, it is not necessary to previously determine the distance R1 by the measuring device DT, and the surface pressure of the body including the buffer member 3 of the primary processing member 101 described later is reduced. The catalyst carrier 2 can be configured to be reduced in diameter together with the buffer member 3 so as to be within a predetermined pressure range. Therefore, the manufacturing time can be greatly reduced. If the pressure-sensitive element PS is inexpensive and does not adversely affect the function of the catalytic converter, it may be left as it is without being extracted after sizing. In addition, in the above measurement step, if the catalyst carrier 2 and the buffer member 3 can ensure the quality within the allowable error range, the measurement result of the sample is used without performing the measurement for each individual. The process may be simplified by removing the measurement process from the process of the above.
[0039]
Next, based on the distance R1 of the above measurement result, the final target for one end of the metal tubular member (the part before processing is indicated by 10 in FIG. 4 and the state where the one end is enlarged is indicated by 101). Set the inner radius (R2) of the shape. That is, the final target shape of one end having an outer peripheral surface protruding outward from a virtual extension surface of the outer peripheral surface of the body of the tubular member accommodating the catalyst carrier 2 and the buffer member 3 in FIG. Is set as the maximum inner radius R2.
[0040]
Then, as shown on the left side of FIG. 4, one end of the cylindrical member is expanded to a maximum inner radius R2 of the final target shape to form an expanded portion 10a. Hereinafter, when the tubular member on which the enlarged diameter portion 10a is formed is specified, it is referred to as a primary processing member 101. As the diameter expanding means at this time, there is press working by press fitting of a general punch, but other methods such as spinning may be used. The diameter expansion amount (d2) at this time is a value obtained by subtracting the inner radius R0 of the cylindrical member (the portion before processing) from the maximum inner radius R2 of the final target shape. On the other hand, the value obtained by subtracting the distance R1 of the above-described measurement result from the inner radius R0 of the cylindrical member is the diameter reduction amount (d1). That is, the position shown by the two-dot chain line in FIG. 4 is a position at a distance R1 from the center axis C of the trunk of the tubular member, and this R1 is the inner radius of the final target shape of the trunk 11 described later.
[0041]
Therefore, the difference (d0 = R2-R1) between the inner radius R1 of the body 11 described later and the maximum inner radius R2 of the enlarged diameter portion 10a is equal to the maximum width of the outer periphery of the body 11 protruding outward from a virtual extension surface. Where d0 = d1 + d2. In other words, the amount of deformation expanded to one end of the tubular member is only the amount of expansion (d2), but finally the amount of deformation (d0) to the outer peripheral surface of the body 11 Will be secured. That is, the difference between the maximum inner radius R2 of the final target shape of the one end portion (the enlarged diameter portion 10a in FIG. 4) of the cylindrical member and the inner radius R1 of the final target shape of the trunk portion (the trunk portion 11) after the diameter reduction is obtained. Since the maximum width (d0) protrudes outside the virtual extension surface of the outer peripheral surface of the body portion 11, the amount of deformation due to the expansion and contraction of the diameter can be minimized.
[0042]
Subsequently, as shown in FIG. 5, a pair of the integrated products 1 in which the buffer member 3 is mounted on the catalyst carrier 2 is accommodated in the primary processing member 101 in which one end of the cylindrical member is enlarged as described above. They are juxtaposed and held in place. In this case, the outer surface of each cushioning member 3 is not pressed against the inner surface of the tubular member, and is set so as not to contact or loosely contact, and each cushioning member 3 hardly receives a compressive force. It is desirable to set as follows. Note that the diameter expanding step shown in FIG. 4 and the housing step shown in FIG. 5 may be reversed.
[0043]
Next, sizing is performed on the primary processing member 101 holding the pair of integrated products 1 and holding it at a predetermined position as shown in FIG. The diameter of the non-processed portion 101 (that is, the trunk portion of the cylindrical member) is reduced. This diameter reduction processing is called shrinking processing. Various methods are known as a sizing method. In the present embodiment, a diameter reducing device RD shown in FIG. 11 is used. This is called a finger type, and a collet chuck is used.
[0044]
That is, as shown in FIG. 11, a cylindrical press die DP having a tapered inner surface is slidably housed in a cylindrical housing GD in a liquid-tight manner. (Collet type) DV is slidably accommodated. As shown in FIG. 6, the outside of each split die DV is formed in a tapered surface, and is slidably disposed on the tapered surface inside the pressing die DP. The pressing die DP and the split die DV are configured to be driven by a hydraulic drive device (not shown), and the pressing die DP is driven in the axial direction (longitudinal direction) of the housing GD by hydraulic pressure. The split die DV is configured to be driven in the radial direction (axial direction) according to the directional movement. The hydraulic drive (not shown) can be configured to be controlled by the controller CT shown in FIG.
[0045]
In the sizing step shown in FIG. 6, when the hydraulic drive device (not shown) is driven to drive the pressing die DP in the axial direction of the housing GD by hydraulic pressure (moving to the left in FIG. 6), the split die is moved. The DV moves in the radial direction (axial direction) and reduces the diameter of the cylindrical member (primary processing member 101) while compressing the body and the buffer member 3. The amount of diameter reduction at this time is accurately controlled by the control of the hydraulic drive device, and the diameter of the central axis C (coincident with the axis Z of the catalyst carrier 2) of the cylindrical member (primary processing member 101) and the inner wall surface is adjusted. The primary processing member 101 and the buffer member 3 are reduced in diameter while the centering is performed until the distance between them becomes the distance R1 of the above-described measurement result, and the body 11 is formed. Thereby, the catalyst carrier 2 is supported in a stable state in the cylindrical member (the state after sizing is referred to as the secondary processing member 102) via the buffer member 3.
[0046]
Incidentally, the diameter reducing device RD of the present embodiment may be provided with a reaction force detecting means at the time of diameter reduction so as to function as the above-described measuring device DT. With such a configuration, measurement and sizing can be performed by one device, so that manufacturing efficiency is extremely improved. Further, the time interval between the measurement and the sizing can be set short, and the cylindrical member can be set before the buffer mat which is uniformly thinned over the entire circumference by the pressing at the time of the measurement is restored. The production efficiency is further improved.
[0047]
The hydraulic drive device (not shown) of the diameter reducing device RD is configured so that an arbitrary amount of sizing can be performed by NC control, and fine control is possible. Further, at the time of diameter reduction, for example, by rotating the work sequentially (as needed) and performing indexing control (index control), the diameter can be reduced more uniformly over the entire circumference. In this embodiment, a hydraulic pressure is used as a drive and control medium of the diameter reducing device RD. However, the present invention is not limited to this, and the drive and control form may be any type such as a mechanical type, an electric type, and a pneumatic type. A driving method can be used, and it is preferable to use CNC control for control.
[0048]
1 until the substantial radius of the inside of the cylindrical member (primary processing member 101) that accommodates at least the buffer member 3 falls below the distance R1 measured and immediately before the catalyst carrier 2 breaks. The limit distance (Rx) when the buffer member 3 is pressed by the body PM may be measured in advance. The radius is used for the diameter reduction device RD by the NC control, and the radius is smaller than the limit distance Rx so that the substantial radius of the secondary processing member 102 becomes the distance R1 when the secondary processing member 102 springs back after the diameter reduction. If the diameter of the primary processing member 101 is reduced together with the buffer member 3 until the primary processing member 101 is reduced in diameter to a distance below the distance R1 in a large range, the axial center Z of the catalyst carrier 2 and the primary processing member 101 are not affected by springback. The diameter of the body of the primary processing member 101 and the buffer member 3 can be reduced so that the distance between the inner wall surface of the first processing member 101 and the inner wall surface becomes the distance R1 of the measurement result described above.
[0049]
As described above, since the diameter of the primary processing member 101 is reduced at least over the range where the buffer member 3 exists (indicated by SA in FIG. 6), the buffer member 3 is held in a compressed state, and the compression restoring force is applied. By the predetermined surface pressure applied to the catalyst carrier 2, the catalyst carrier 2 is supported in a stable state in the body 11, and an axial friction force is applied. Thus, the secondary processing member 102 shown in FIG. 6 is formed, and the catalyst carrier 2 is appropriately held via the buffer member 3 in the body 11 formed in consideration of springback. Therefore, even the particularly fragile catalyst carrier 2 can be properly held in the body 11 without breaking. As a sizing method, for example, as described in Patent Document 7, sizing by spinning may be performed using a spinning roller SP. Alternatively, the primary processing member 101 may be reduced in diameter while monitoring (monitoring) the surface pressure applied to the catalyst carrier 2 by the pressure-sensitive element PS illustrated in FIG. Alternatively, the primary processing member 101 may be reduced in diameter while monitoring the surface pressure at the time of reducing the diameter in real time by the reaction force detecting means provided in the diameter reducing device RD.
[0050]
Here, an example of the dimensional relationship of each part will be described. The outer diameter of the catalyst carrier 2 is 99.2 mm in diameter, and the cushioning member 3 having a thickness of 8 mm is wound therearound to form a cylindrical member (primary processing). It is gently inserted into the member 101). The inner diameter of the cylindrical member (primary processing member 101) is 117 mm in diameter. After the insertion of the catalyst carrier 2 and the buffer member 3, diameter reduction processing is performed over a range indicated by SA in FIG. .2 mm. The inner diameter to be the target of the diameter reduction is obtained by superimposing errors in three parameters of the outer diameter of the catalyst carrier 2, the thickness of the buffer member 3, and the initial inner diameter of the cylindrical member (primary processing member 101). Since it differs depending on the superposition error, it is desirable to calculate an optimum target (target) inner diameter based on the measured value in advance. In the present embodiment, as the measurement result, the target inner diameter is calculated to be 107.2 mm, that is, the optimum gap is calculated to be 4 mm (on one side in the radial direction).
[0051]
When the shrinking process is performed on the cylindrical member to reach the target inner diameter described above, the buffer member 3 is compressed and reaches a predetermined packing density, whereby the catalyst carrier 2 is firmly held. Is well within the range of 0.2 to 0.6 g / cm 3 which is optimized in the catalytic converter.
[0052]
In the shrinking process, during the process of reducing the diameter of the cylindrical member (primary processing member 101) and the buffer member 3, the driving of the press die DP and the split die DV (in the diameter reduction step) is temporarily stopped. After releasing the diameter reducing force (pulling), the drive may be restarted to complete the diameter reduction. By performing such processing, the surface pressure generated by the buffer member 3 is made uniform over the entire surface. This is because the relationship between the fibers constituting the buffer member 3, that is, the entanglement of the bent fibers is relaxed by the compression of the buffer member 3 when the diameter is reduced, and the uneven distribution state of the fiber density is improved. It is considered that the buffer member 3 itself normalizes (uniformizes) the surface pressure distribution.
[0053]
The number of diameter reduction stops in the shrinking process may be appropriately set to two or more. For example, when it is necessary to reduce the diameter (shrink) of 4 mm (on one side in the radial direction), once the diameter has been reduced by 2 mm, the reduction is temporarily stopped, the reduction force is released, and then the reduction is resumed. The diameter may be further reduced by 2 mm. In this case, stopping the diameter reduction is effective, but it is more effective if the diameter is slightly increased and the load is removed.
[0054]
As shown in FIG. 7, necking by the spinning roller SP is further performed on one end of the secondary processing member 102 sized as described above. First, the body 11 of the secondary processing member 102 is clamped by a clamping device CL for a spinning device, and is fixed so that it cannot rotate and cannot move in the axial direction. 6 has at least one central axis of eccentricity, inclination and torsion with respect to the central axis (C in FIG. 6) of the body 11, and a part thereof is a virtual extension of the outer peripheral surface of the body 11. A plurality of target processing portions (not shown) are set up to the final target processing portion (a tapered portion 13b and a neck portion (bottle neck portion) 13c shown in FIG. 7) protruding outside the surface. In this case, as shown in FIG. 8, the vicinity of the left end of the upper torso 11 in FIG. 7 is enlarged so as to include the predetermined range 11y on the left end side of the torso 11 so as to form the necking portion 13. As shown by a solid line in FIG. 8, the necking portion 13 is also subjected to necking by the spinning roller SP for a predetermined range 11y of the body 11 (a range indicated by a dashed line in FIG. 8), and corresponds to the predetermined range 11y. Part is necking 13 constitutes a part of, the polymerization process unit 13a.
[0055]
Then, a plurality of machining target axes (not shown) are set based on the plurality of target machining sections, and one of the plurality of machining target axes and a central axis (not shown) of the enlarged diameter portion 10a are substantially coaxial. The second processing member 102 (the state shown in FIG. 6) is supported so that the spinning process is performed on one end by a plurality of spinning rollers SP which revolve around the outer circumference of one end along a circular locus having the same diameter. Do. That is, the spinning rollers SP, which are preferably arranged at equal intervals around the outer periphery of one end of the secondary processing member 102, are brought into close contact with the outer peripheral surface of the one end and revolved, and are driven in the radial direction to reduce the revolving locus. While performing the spinning process by driving in the axial direction (left direction in FIG. 7). Thereby, the tertiary processing member 103 shown in FIG. 7 is formed, and one end is formed on the necking portion 13 having the inclined axis of the final target shape.
[0056]
Subsequently, as shown in FIG. 9, the tertiary processing member 103 (the state shown in FIG. 7) on which the necking portion 13 has been processed is disposed to be inverted by 180 degrees, and the other end is also rotated in the same manner as described above. Neck processing by SP is performed. In this case, the work of reversing the tertiary processing member 103 is performed by releasing the clamping state of the tertiary processing member 103 by the clamp device CL after the processing of the necking portion 13 is completed, and by using a robot hand (not shown) from the clamp device CL. This is performed by taking out 103, turning it over, and mounting it again in the clamp device CL.
[0057]
Then, the body 11 is again clamped by the clamp device CL, and the other end is processed by the spinning roller SP in the same manner as described above, and as shown in FIG. 9, the central axis of the body 11 (C in FIG. 6). To form a necking portion 12 composed of a tapered portion 12b and a neck portion 12c which are coaxial. In this case, as shown in an enlarged manner in FIG. 10, the vicinity of the left end of the lower body 11 in FIG. 9 is set to include the predetermined range 11 x on the left end side of the body 11 to form the necking part 12. That is, as shown by the solid line of the necking portion 12 in FIG. 10, the necking process by the spinning roller SP is also performed on the predetermined range 11x of the body 11 (the range indicated by the one-dot chain line in FIG. 10). The corresponding part forms a part of the necking part 12, and becomes the overlap processing part 12a.
[0058]
According to the present embodiment, since the secondary processing member 102 (or the tertiary processing member 103) does not rotate during the spinning processing as described above, a structure for securely holding the secondary processing member 102 can be easily configured. In addition, the catalyst carrier 2 and the buffer member 3 accommodated in the secondary processing member 102 (or the tertiary processing member 103) do not rotate (rotate around the axis) during the spinning process, so that they are stable. The holding state can be maintained. In addition, necking of each end of the secondary processing member 102 and the tertiary processing member 103 can be easily and continuously performed.
[0059]
In particular, in the present embodiment, as shown in FIGS. 8 and 10, necking by the spinning roller SP is also performed on predetermined ranges 11x and 11y of the body 11, and portions corresponding to the predetermined ranges 11x and 11y are formed. Constitute a part of the necking portions 12 and 13, and become the overlapped portions 12a and 13a. In this case, the necking portion 13 is formed by inclined spinning, and the orbit of the spinning roller SP is inclined with respect to the axis of the cylindrical member. It is desirable to set the range to be wider than the overlapped portion 12a of the portion 12 (the same applies to eccentric spinning described later).
[0060]
That is, as shown in FIG. 8, the necking portion 13 is subjected to necking processing from a bent portion B2 different from the bent portion B1 formed at the time of sizing of the body portion 11 to form the overlapped portion 13a. Do not overlap. Moreover, the bent portion B1 formed at the time of sizing is formed to have a uniform thickness as a whole due to active plastic flow of the material in the helical direction due to spinning. Similarly, regarding the necking portion 12, as shown in FIG. 10, necking is performed from a bent portion B3 formed at the time of sizing the body portion 11, but since the necking portion 12 is bent at a bent portion B4 different from the bent portion B3, The bent portions do not overlap, and the bent portion B4 is formed to have a uniform thickness as a whole due to active plastic flow of the material in the helical direction by spinning.
[0061]
As shown in FIG. 1, a plurality of parallel traces 11e formed on the outer surface of the body portion 11 by sizing, and formed on the outer surfaces of the necking portions 12 and 13 by spinning, as shown in FIG. A plurality of traces 12j and 13j remain, and as shown by broken lines in FIG. 1, both ends of the trace 11e when the diameter is reduced disappear when the necking portions 12 and 13 are formed. 12j and 13j are connected so as to intersect. The trace 11e is peculiar to the method using the diameter reducing device RD shown in FIG. 11, but the lines in FIG. 1 (and FIG. 2) are drawn in an emphasized manner for convenience of explanation. Therefore, it is desirable that the thickness is actually thin and, if possible, is invisible. The same applies to the streaks 12j and 13j (and 14j described later) by the spinning process.
[0062]
When the above configuration is compared with a configuration based on a conventional general sizing method, for example, in FIG. 10, according to the conventional method, a bent portion B3 formed at the time of sizing is used as a boundary to be bent in the opposite direction by necking. Thus, a second bent portion (not shown) is formed (that is, the bent portions B3 and B4 in FIG. 10 are at the same position). Therefore, as described above, since the bent portion (second time) is formed in the opposite direction to the bent portion B3 (first time) where the plate thickness is reduced, the plate thickness of this portion is further reduced. However, there is a possibility that an annular low-rigidity portion having lower rigidity than other portions may be formed. According to the conventional method, the portion shown in FIG. 8 is bent in the same direction from the bent portion B1 to form a second bent portion (not shown). Since the bent portion is still formed, it is inevitable that the rigidity is lower than that of the other portions.
[0063]
On the other hand, in the above-described catalytic converter according to the embodiment of the present invention, the bent portions do not overlap, and furthermore, the plastic flow of the material results in a polymerization processing portion having a uniform plate thickness as a whole. The thickness does not decrease. Furthermore, since the non-processed portion, that is, the portion of the raw material is completely eliminated, and the cylindrical member is subjected to plastic working over the entire outer surface, a low-rigidity portion called the non-processed portion may remain. Absent. In particular, in the present embodiment, since a process involving an increase in the plate thickness can be performed by a combination of the diameter reducing process and the spinning process using the collet mold, the above-described effect in the polymerized portion is synergized, and a further effect is obtained. Can play. In sizing, a predetermined amount of sizing may be performed while predicting the surface pressure or detecting the surface pressure in real time during diameter reduction processing.
[0064]
Further, if the diameter reducing device RDx shown in FIG. 12 is used instead of the diameter reducing device RD shown in FIG. 11, the above-described shrinking process can be performed more appropriately. That is, in the diameter reducing device RDx, each split die DV is divided into two, and is constituted by a segment DS and a back metal member DX. Each segment DS and the back metal member DX are fitted with a T slot DC, and each segment DS is detachable. That is, the segment DS can be exchanged according to the diameter of the cylindrical member to be processed. Further, shoulders DSa and DSb having smooth curved surfaces are formed at both end angles of the segment DS. These shoulders R are desirably about several millimeters R. Thereby, at the time of the minimum diameter reduction in the measurement process, that is, when the gap between the adjacent segments DS is minimized, it is possible to avoid a part of the buffer member 3 from being caught in this gap. Note that a pressure-sensitive sensor may be provided on the segment DS itself or between the segment DS and the back metal member DX.
[0065]
As described above, in the method for manufacturing the catalytic converter according to the present embodiment, the buffer member is not press-fitted into the (fixed) gap between the catalyst carrier and the cylindrical member as in the related art. After the cushioning member is gently inserted into the cylindrical member, the body of the cylindrical member is reduced in diameter by so-called sizing processing so as to have an optimum gap (ie, an optimum GBD value). You. With this, no external force is applied to the cushioning member at the time of insertion into the cylindrical member as in the prior art, so even if the buffering member has a weak shape-retaining force and is substantially free of a binder, it can be appropriately cylindrically shaped. The catalyst carrier can be stably held in the tubular member with a predetermined holding force by arranging the catalyst support in the member and generating an intended surface pressure. Therefore, naturally, the problem caused by the inclusion of the binder can be eliminated. Instead of using a buffer member formed into a plate shape or a cylindrical shape as described above, a catalyst carrier is previously arranged in a cylindrical member, and a substantially binder-free inorganic material is provided in a gap between the two. The fibers may be filled (by pressure blowing or the like), and then the tubular member may be subjected to shrinking.
[0066]
Further, in the embodiment shown in FIG. 7, the inclined spinning processing (Patent Document 8) is applied to one end of the secondary processing member 102, but not limited thereto, and the eccentric spinning processing (Patent Document 9). May be applied to form an offset necking portion. According to this eccentric spinning process, the necking portion 14 shown on the right side of FIG. 2 can be formed. Is done. In addition, as shown in FIG. 7, necking processing is performed by setting a final target processing part that partially protrudes outside a virtual extension surface of the outer peripheral surface of the body part 11, but the present invention is not limited to this. It may be combined with any of the coaxial, eccentric, inclined and torsional spinning processes. In the coaxial, eccentric, inclined and torsion spinning processes, a fixed work (cylindrical member) is preferable as in the present embodiment, but a work rotating type may be used as appropriate.
[0067]
In the case where the necking portion is formed in the catalytic converter or the DPF, the necking process by the above-mentioned spinning process is suitable, but the present invention is not limited to this, and it may be formed by other plastic working methods. Alternatively, a separate necking portion (cone portion) can be connected by welding or the like. The diameter reduction method of the body of the cylindrical member in the shrinking process can also be performed by spinning. As the cylindrical member, a pipe such as an electric resistance welded pipe, a seamless pipe, or a multi-layer pipe may be appropriately cut and used, or a so-called Monaka combined product in which shell-shaped multi-pieces are combined, or a C-shaped cross section A plate formed by welding a plate material may be used.
[0068]
Further, in the present embodiment, the number of the catalyst carriers 2 is two, but may be one. Alternatively, three or more catalyst carriers may be arranged in series, and the body portion may be appropriately reduced in diameter for each portion corresponding to each honeycomb structure, or may be continuously reduced in diameter. The final product is not limited to exhaust system parts of automobiles, and can be applied to various fluid processing devices such as the fuel cell reformer described in the above-mentioned patent document.
[0069]
【The invention's effect】
Since the present invention is configured as described above, the following effects can be obtained. That is, in the fluid treatment apparatus with a built-in honeycomb structure according to the first aspect, at least a body portion formed by reducing the diameter of a predetermined range in the axial direction of a portion that accommodates the buffer member substantially free of the binder, and the body portion. Since the honeycomb structure is held via the cushioning member in a metal tubular member provided with a necking portion formed by necking at least one end of the portion, a desired surface is provided by the cushioning member. The buffer member and the honeycomb structure can be appropriately held in the tubular member in a state where the pressure is secured.
[0070]
If the necking portion is configured as described in claim 2, a necking portion having a desired shape can be easily formed continuously at both ends of the body portion.
[0071]
In the method for manufacturing a fluid treatment apparatus with a built-in honeycomb structure according to a third aspect of the present invention, at least a portion of the cylindrical member accommodating the buffer member substantially free of a binder is reduced in diameter in a predetermined axial direction. Forming a necking portion by forming a necking portion by necking an end portion including a predetermined range on at least one end side of the body portion and reaching an opening end of the tubular member, so that substantially no binder is added. With this cushioning member, the cushioning member can appropriately hold the cushioning member and the honeycomb structure in the tubular member while securing the desired surface pressure.
[0072]
Further, if the necking portion is formed as described in claim 4, a necking portion having a desired shape can be easily formed continuously at both ends of the body portion.
[Brief description of the drawings]
FIG. 1 is a front view of a catalytic converter according to an embodiment of the fluid treatment apparatus of the present invention.
FIG. 2 is a front view of a catalytic converter according to another embodiment of the fluid treatment apparatus of the present invention.
FIG. 3 is a front view showing a measurement step of a catalyst carrier and a buffer member in the method for manufacturing a catalytic converter according to one embodiment of the present invention.
FIG. 4 is a cross-sectional view showing a primary processing member in which one end of a tubular member is enlarged to form an enlarged diameter portion in a method for manufacturing a catalytic converter according to an embodiment of the present invention.
FIG. 5 is a cross-sectional view showing a state in which an integrated product equipped with a catalyst carrier and a buffer member is accommodated in a primary processing member in the method for manufacturing a catalytic converter according to one embodiment of the present invention.
FIG. 6 is a cross-sectional view showing a reduced diameter state of a primary processing member in a sizing step in the method for manufacturing a catalytic converter according to one embodiment of the present invention.
FIG. 7 is a cross-sectional view showing a state in which necking processing by a spinning roller is performed on one end of a secondary processing member in the method for manufacturing a catalytic converter according to one embodiment of the present invention.
FIG. 8 is an enlarged sectional view showing the vicinity of the left end of the upper body part in FIG. 7;
FIG. 9 shows a state in which necking is performed by a spinning roller on the other end of the tertiary processing member having a necking portion formed at one end in the method for manufacturing a catalytic converter according to one embodiment of the present invention. It is sectional drawing.
FIG. 10 is an enlarged cross-sectional view showing the vicinity of the left end of the lower trunk in FIG. 9;
FIG. 11 is a perspective view showing a diameter reducing device provided for manufacturing a catalytic converter according to an embodiment of the present invention.
FIG. 12 is a perspective view showing another example of the diameter reducing device used for manufacturing the catalytic converter according to one embodiment of the present invention.
[Explanation of symbols]
1 integrated product, 2 catalyst carrier, 3 cushioning member, 10 cylindrical member,
11 body, 10a enlarged diameter part, 12b, 13b, 14b tapered part,
12c, 13c, 14c neck, 12, 13, 14 necking,
101 primary processing member, 102 secondary processing member, 103 tertiary processing member,
DT measuring device, PM pressing body, LC load cell,
RE rotary encoder, CH, CL clamping device,
SP spinning roller, RD diameter reduction device, GD housing,
DP stamping type, DV split type, RDx diameter reduction device, DS segment

Claims (4)

金属製筒状部材内に実質的にバインダー無添加の緩衝部材を介してハニカム構造体を保持するハニカム構造体内蔵流体処理装置において、前記筒状部材が、少なくとも前記緩衝部材を収容する部分の軸方向所定範囲を縮径して成る胴部と、該胴部の少なくとも一端側の端部をネッキング加工して成るネッキング部を備えたことを特徴とするハニカム構造体内蔵流体処理装置。In a fluid treatment device with a built-in honeycomb structure that holds a honeycomb structure through a buffer member substantially free of a binder in a metal cylindrical member, the cylindrical member has at least a shaft that accommodates the buffer member. A fluid treatment apparatus with a built-in honeycomb structure, comprising: a body portion having a diameter reduced in a predetermined direction, and a necking portion formed by necking at least one end of the body portion. 前記ネッキング部は、前記胴部の少なくとも一端側の所定範囲を含み前記筒状部材の開口端に至るまでスピニング加工して成り、前記胴部の中心軸に対して少なくとも偏芯、傾斜及び捩れの何れか一つの関係にある中心軸を有することを特徴とする請求項１記載のハニカム構造体内蔵流体処理装置。The necking portion includes a predetermined range on at least one end side of the body portion, and is formed by spinning until reaching an open end of the tubular member, and at least eccentricity, inclination, and twist of the center axis of the body portion. 2. The fluid processing apparatus with a built-in honeycomb structure according to claim 1, wherein the fluid processing apparatus has a central axis in any one of the relations. 金属製筒状部材内に実質的にバインダー無添加の緩衝部材を介してハニカム構造体を保持するハニカム構造体内蔵流体処理装置の製造方法において、前記ハニカム構造体の外周に前記緩衝部材を装着した状態で前記筒状部材内に緩やかに収容し、前記筒状部材の少なくとも前記緩衝部材を収容する部分の軸方向所定範囲を縮径して胴部を形成し、該胴部の端部をネッキング加工してネッキング部を形成することを特徴とするハニカム構造体内蔵流体処理装置の製造方法。In the method for manufacturing a fluid treatment device with a built-in honeycomb structure that holds the honeycomb structure through a buffer member substantially free of a binder in a metal cylindrical member, the buffer member is attached to an outer periphery of the honeycomb structure. In this state, the body is gently housed in the tubular member, and at least a portion of the tubular member that houses the buffer member is reduced in diameter in a predetermined axial direction to form a body, and the end of the body is necked. A method for manufacturing a fluid treatment apparatus with a built-in honeycomb structure, comprising forming a necking portion by processing. 前記胴部の少なくとも一端側の所定範囲を含み前記筒状部材の開口端に至るまで、前記胴部の中心軸に対して少なくとも偏芯、傾斜及び捩れの何れか一つの関係にある中心軸に沿ってスピニング加工を行い、前記ネッキング部を形成することを特徴とする請求項３記載のハニカム構造体内蔵流体処理装置の製造方法。At least one eccentricity with respect to the central axis of the trunk, including a predetermined range on at least one end side of the trunk, and reaching the open end of the tubular member, the central axis in one of the relations of inclination and twist The method for manufacturing a fluid processing apparatus with a built-in honeycomb structure according to claim 3, wherein the necking portion is formed by performing spinning along the honeycomb structure.
JP2002286323A 2002-09-30 2002-09-30 Manufacturing method of fluid processing apparatus with built-in honeycomb structure Expired - Lifetime JP4303457B2 (en)

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JP2012522632A (en) * 2009-04-02 2012-09-27 フォルシア・システム・デシャプモン Manufacturing method of automobile exhaust gas purification member
CN113195126A (en) * 2018-12-26 2021-07-30 日本斯频德制造株式会社 Spinning device, spinning method, and processing roller

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* Cited by examiner, † Cited by third party
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JP2008202505A (en) * 2007-02-20 2008-09-04 Sango Co Ltd Manufacturing method of treatment device for fluid in built-in honeycomb structure
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CN113195126A (en) * 2018-12-26 2021-07-30 日本斯频德制造株式会社 Spinning device, spinning method, and processing roller
CN113195126B (en) * 2018-12-26 2024-02-13 日本斯频德制造株式会社 Spinning device, spinning method and processing roller

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