JP2010131484A - Method of manufacturing elliptic catalytic converter - Google Patents

Method of manufacturing elliptic catalytic converter Download PDF

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JP2010131484A
JP2010131484A JP2008307783A JP2008307783A JP2010131484A JP 2010131484 A JP2010131484 A JP 2010131484A JP 2008307783 A JP2008307783 A JP 2008307783A JP 2008307783 A JP2008307783 A JP 2008307783A JP 2010131484 A JP2010131484 A JP 2010131484A
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elliptical
elliptic
catalyst
catalytic converter
mat
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JP5162426B2 (en
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Toru Hisanaga
徹 久永
Yoshihiro Umeda
吉宏 梅田
Kazutoyo Masuko
一豊 益子
Tatsu Nakamura
竜 中村
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Yutaka Giken Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing technology capable of reducing manufacturing cost of an elliptic catalytic converter. <P>SOLUTION: An elliptic pipe 17 is made elliptic in an elastic region in Fig.(c), and catalyst 13 wound with a mat 12 is inserted into the elliptic pipe 17 set to a pressing machine 16. That is, a round pipe is formed elliptic not in a plastic region, but in the elastic region. The catalyst wound with the mat is inserted in this state. Release of pressing operation allows the elliptic pipe to return to the round pipe, however, since the load is low and the catalyst is set inside, the phase of the elliptic form is kept. The pressing machine used for forming the round pipe elliptic only forms the round pipe elliptic in the elastic region, needing an inexpensive press of 0.3 ton, for example, resulting in sufficient reduction of the manufacturing cost of the elliptic catalytic converter. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

本発明は、楕円触媒コンバータの製造技術に関する。   The present invention relates to a technique for manufacturing an elliptical catalytic converter.

排ガスのエミッション対策として、触媒コンバータが車両の排気管に装着される。触媒コンバータは、排気管に装着する関係から、セラミックス製の触媒を金属ケースに収めたものが主に採用される。金属ケースであれば排気管に溶接で簡単に接続することができるからである。   As a measure against emission of exhaust gas, a catalytic converter is mounted on the exhaust pipe of the vehicle. Since the catalytic converter is mounted on the exhaust pipe, a catalyst made of a ceramic catalyst in a metal case is mainly used. This is because the metal case can be easily connected to the exhaust pipe by welding.

触媒は、排気管に装着する関係上、円柱形状とされる。さらに、エンジン直下や、車両の床下に配置する関係で、前後幅や、高さ寸法が小さくなる楕円柱形状の触媒が採用される(例えば、特許文献1参照。)。
特開2002−97944公報(図6)
The catalyst has a cylindrical shape because it is attached to the exhaust pipe. Furthermore, an elliptical columnar catalyst with a reduced front-rear width and height dimension is employed because it is disposed directly under the engine or under the floor of the vehicle (see, for example, Patent Document 1).
Japanese Patent Laid-Open No. 2002-97944 (FIG. 6)

特許文献1の図6に示されている縮径装置を使用することを前提に、従来実施されている楕円触媒コンバータの製造方法を次図に基づいて説明する。
図3は従来の楕円管の製造方法を説明する図であり、(a)に示すように、丸管101を準備する。この丸管101は、(b)に示すように、半楕円面102が設けられているプレス下型103と、半楕円面104が設けられているプレス上型105とからなるプレス機106で、塑性加工される。プレス機106から外すと、(c)に示す楕円管107が得られる。
Based on the assumption that the diameter reducing device shown in FIG. 6 of Patent Document 1 is used, a conventional manufacturing method of an elliptic catalytic converter will be described with reference to the following drawings.
FIG. 3 is a diagram for explaining a conventional method of manufacturing an elliptical tube, and a round tube 101 is prepared as shown in FIG. This round tube 101 is, as shown in (b), a press machine 106 composed of a press lower die 103 provided with a semi-elliptical surface 102 and a press upper die 105 provided with a semi-elliptical surface 104. Plastic processing. When removed from the press machine 106, an elliptical tube 107 shown in FIG.

なお、(b)での塑性加工の際に外周の一部が型103、105の合わせ部分に、はみ出し勝ちである。このはみ出し現象は、製品の外観性に影響するので好ましいことではない。   In addition, at the time of plastic working in (b), a part of the outer periphery tends to protrude from the mating part of the molds 103 and 105. This protrusion phenomenon is not preferable because it affects the appearance of the product.

図4は従来の触媒コンバータの製造工程図であり、(a)に示すように、クランプ111、112でクランプした楕円管107に、マット108が巻かれている楕円触媒109を挿入する。
次に、(b)に示すように、複数個の押圧片113が楕円環状に配置されている縮径装置110に楕円管107をセットし、矢印のように押すことで塑性変形領域まで縮径する。縮径装置110から外すと、(c)に示す楕円触媒コンバータ115が得られる。
FIG. 4 is a manufacturing process diagram of a conventional catalytic converter. As shown in FIG. 4A, an elliptical catalyst 109 around which a mat 108 is wound is inserted into an elliptical tube 107 clamped by clamps 111 and 112.
Next, as shown in (b), the elliptical tube 107 is set in the diameter reducing device 110 in which a plurality of pressing pieces 113 are arranged in an elliptical ring shape, and the diameter is reduced to the plastic deformation region by pressing as shown by an arrow. To do. When removed from the diameter reducing device 110, an elliptical catalytic converter 115 shown in (c) is obtained.

以上に説明した製造工程では、楕円管107を製造するプレス機106(図3(b))が必須である。プレス機106としては、丸管101を塑性領域までプレス下型103及びプレス上型105でプレスするため、例えば20トンプレスが必要となり、結果、プレス機106は、高価なものとなる。プレス機106が高価であるため、製造コストが押し上げられ、楕円触媒コンバータ115の製造コストが嵩む。   In the manufacturing process described above, the press machine 106 (FIG. 3B) for manufacturing the elliptical tube 107 is essential. As the press machine 106, since the round tube 101 is pressed to the plastic region by the lower press mold 103 and the upper press mold 105, for example, a 20-ton press is required, and as a result, the press machine 106 becomes expensive. Since the press machine 106 is expensive, the manufacturing cost is increased and the manufacturing cost of the elliptical catalytic converter 115 is increased.

車両用触媒として、楕円触媒コンバータの普及を考えると、製造コストの低減が望まれる。   Considering the widespread use of elliptical catalytic converters as vehicle catalysts, it is desirable to reduce manufacturing costs.

本発明は、楕円触媒コンバータの製造コストを低減することができる製造技術を提供することを課題とする。   An object of the present invention is to provide a manufacturing technique capable of reducing the manufacturing cost of an elliptical catalytic converter.

請求項1に係る発明は、楕円柱状の触媒と、この触媒に巻付けたマットと、このマット及び前記触媒を挿入する金属製の楕円ケースとからなる楕円触媒コンバータの製造方法であって、
金属製の丸管と、前記マットが巻かれている楕円柱状の触媒とを準備する工程と、前記丸管の外周を圧縮操作することで、前記丸管を弾性限度で楕円化する工程と、前記圧縮操作を維持しながら楕円管へ、前記マットが巻付けられている触媒を挿入する工程と、圧縮操作を解除することで、コンバータ中間製品を得る工程と、このコンバータ中間製品の楕円管を縮径することで、縮径された楕円ケースとこの楕円ケースに内蔵されたマット及び触媒からなる楕円触媒コンバータを得る縮径工程と、からなることを特徴とする。
The invention according to claim 1 is a method of manufacturing an elliptical catalytic converter comprising an elliptical columnar catalyst, a mat wound around the catalyst, and a metal elliptical case into which the mat and the catalyst are inserted.
A step of preparing a metal round tube and an elliptical columnar catalyst around which the mat is wound, a step of compressing the outer periphery of the round tube, and making the round tube elliptical with an elastic limit; The step of inserting the catalyst around which the mat is wound into the elliptic tube while maintaining the compression operation, the step of obtaining the converter intermediate product by releasing the compression operation, and the elliptic tube of the converter intermediate product It is characterized by comprising a diameter reduction step of obtaining an elliptical catalytic converter comprising a reduced diameter elliptic case and a mat and a catalyst built in the elliptic case by reducing the diameter.

請求項1に係る発明では、丸管を、塑性領域で楕円化するのではなく、弾性領域で楕円化する。尚、弾性変形は周長の変化がなく、塑性変形のようにかみ込み(図3(b)参照。)の発生が防止できる。弾性領域であっても、クランプ状態であれば金型と同様の精度が得られ、塑性変形より精度がよい。   In the invention according to claim 1, the round tube is not ovalized in the plastic region, but ovalized in the elastic region. Note that elastic deformation has no change in circumference and can prevent biting (see FIG. 3B) like plastic deformation. Even in the elastic region, if it is in a clamped state, the same accuracy as that of the mold can be obtained, and the accuracy is better than plastic deformation.

この状態でマットが巻かれた触媒を挿入する。圧縮操作を解除すると楕円管は丸管に戻ろうとするが、この荷重は低く、触媒が内蔵されているため、楕円形状の位相が保たれる。そのため、触媒が破損することなく、後の縮径工程は円滑に進めることができる。   In this state, a catalyst wound with a mat is inserted. When the compression operation is released, the elliptical tube tries to return to the round tube, but this load is low and the catalyst is built in, so that the elliptical phase is maintained. Therefore, the subsequent diameter reduction process can proceed smoothly without damaging the catalyst.

丸管を楕円化する際に使用するプレス機は、弾性領域で丸管を楕円化するだけであるから、例えば廉価な0.3トンプレスで十分である。この結果、楕円触媒コンバータの製造コストを十分に低減することができる。   Since the press machine used for making the round tube oval only makes the round tube oval in the elastic region, for example, an inexpensive 0.3-ton press is sufficient. As a result, the manufacturing cost of the elliptic catalytic converter can be sufficiently reduced.

本発明を実施するための最良の形態を添付図に基づいて以下に説明する。
図1は本発明に係る準備工程から触媒を挿入する工程までを説明する図であり、(a)に示すように、金属製の丸管11と、マット12が巻かれている楕円柱状の触媒13とを準備する(準備工程)。
The best mode for carrying out the present invention will be described below with reference to the accompanying drawings.
FIG. 1 is a diagram for explaining from the preparation step to the step of inserting a catalyst according to the present invention. As shown in FIG. 13 are prepared (preparation process).

次に、(b)に示すように、下プレス型14と上プレス型15とからなる、例えば0.3トンプレス機16で、丸管11を弾性領域で楕円化し楕円管17を得る(楕円化工程)。塑性変形させる必要がないので、プレス機16はプレス力が小さくて廉価なプレス機でよい。下プレス型14及び上プレス型15の当り面18、18は凹面で良く、廉価な上下2分割の廉価な金型を使用することができる。 また、当たり面18、18はフラット面でも良く、より廉価な金型を使用することができる。   Next, as shown in (b), the round tube 11 is ellipticalized in the elastic region by the 0.3 ton press machine 16 composed of the lower press die 14 and the upper press die 15 to obtain an elliptical tube 17 (elliptical tube 17). Process). Since it is not necessary to cause plastic deformation, the press 16 may be an inexpensive press with a small pressing force. The contact surfaces 18 and 18 of the lower press die 14 and the upper press die 15 may be concave surfaces, and an inexpensive metal mold that is inexpensively divided into two parts can be used. Further, the contact surfaces 18 and 18 may be flat surfaces, and a cheaper mold can be used.

続いて、(c)に示すように、プレス機16に掛けたままの楕円管17へ、マット12が巻付けられている触媒13を挿入する(挿入工程)。   Subsequently, as shown in (c), the catalyst 13 around which the mat 12 is wound is inserted into the elliptical tube 17 hung on the press 16 (insertion step).

図2は本発明に係る縮径工程を説明する図であり、(a)に示すように、下プレス型14と上プレス型15とを開放することで、コンバータ中間製品20を得る(プレス開放工程)。圧縮操作が解除されたことにより、楕円管17は丸管に戻ろうとして、矢印(1)、(1)のように触媒13の長径に沿って、触媒13を挟む。すなわち、矢印(1)、(1)の圧縮力が作用し、触媒13に圧縮応力が発生する。   FIG. 2 is a diagram for explaining a diameter reduction process according to the present invention. As shown in FIG. 2A, by opening the lower press die 14 and the upper press die 15, the converter intermediate product 20 is obtained (press release). Process). When the compression operation is released, the elliptical tube 17 tries to return to the round tube, and sandwiches the catalyst 13 along the long diameter of the catalyst 13 as indicated by arrows (1) and (1). That is, the compressive force indicated by the arrows (1) and (1) acts, and compressive stress is generated in the catalyst 13.

しかし、この圧縮応力は、触媒13が有している圧縮強度より小さいため、触媒13が圧潰される心配はない。結果、触媒13の短径に沿って隙間21、21が発生するものの、楕円管17は楕円形状が維持される。すなわち、触媒13が楕円形状を維持する詰め物または支えの役割を果たす。   However, since this compressive stress is smaller than the compressive strength of the catalyst 13, there is no fear that the catalyst 13 will be crushed. As a result, although the gaps 21 and 21 are generated along the minor axis of the catalyst 13, the elliptical tube 17 is maintained in an elliptical shape. That is, the catalyst 13 serves as a padding or support for maintaining an elliptical shape.

次に、(b)に示すように、コンバータ中間製品20を、複数の押圧片23が楕円環状に配置されている縮径装置24へ移し、押圧片23を矢印のように前進させることで、縮径を行う(縮径工程)。この縮径は塑性領域まで行われる。   Next, as shown in (b), the converter intermediate product 20 is moved to a diameter reducing device 24 in which a plurality of pressing pieces 23 are arranged in an elliptical shape, and the pressing pieces 23 are advanced as indicated by arrows. Reduce diameter (reduction process). This diameter reduction is performed up to the plastic region.

結果、(c)に示すように、楕円ケース25に内蔵されたマット12及び触媒13からなる楕円触媒コンバータ26を得ることができる。
なお、楕円管17は塑性加工前の部材であり、丸管11と周長は変わらない。一方、楕円ケース25は塑性加工後、すなわち縮径加工後の部材であるため、丸管11より周長が小さくなっている。そのため、楕円管17と楕円ケース25とは、呼称及び符号を変えた。
As a result, as shown in (c), the elliptical catalytic converter 26 including the mat 12 and the catalyst 13 built in the elliptical case 25 can be obtained.
The elliptic tube 17 is a member before plastic working, and the circumference is the same as that of the round tube 11. On the other hand, since the elliptic case 25 is a member after plastic processing, that is, after diameter reduction processing, the circumferential length is smaller than the round tube 11. Therefore, the elliptic tube 17 and the elliptic case 25 have different names and symbols.

尚、本発明は、車両、特にエンジン直下や、車両の床下に配置される楕円触媒コンバータの製造に好適であるが、発電用内燃機関など、その他の設備に付設される楕円触媒コンバータの製造に適用することは差し支えない。   The present invention is suitable for manufacturing an elliptical catalytic converter disposed in a vehicle, particularly directly under the engine or under the floor of the vehicle, but for manufacturing an elliptical catalytic converter attached to other equipment such as an internal combustion engine for power generation. It can be applied.

本発明は、車両のエンジン直下や車両の床下に配置される楕円触媒コンバータの製造に好適である。   The present invention is suitable for manufacturing an elliptical catalytic converter disposed directly under a vehicle engine or under a vehicle floor.

本発明に係る準備工程から触媒を挿入する工程までを説明する図である。It is a figure explaining from the preparation process based on this invention to the process of inserting a catalyst. 本発明に係る縮径工程を説明する図である。It is a figure explaining the diameter reduction process which concerns on this invention. 従来の楕円管の製造方法を説明する図である。It is a figure explaining the manufacturing method of the conventional elliptical tube. 従来の触媒コンバータの製造工程図である。It is a manufacturing process figure of the conventional catalytic converter.

符号の説明Explanation of symbols

11…丸管、12…マット、13…触媒、16…プレス機、17…楕円管、20…コンバータ中間製品、24…縮径装置、25…楕円ケース、26…楕円触媒コンバータ。   DESCRIPTION OF SYMBOLS 11 ... Round tube, 12 ... Matt, 13 ... Catalyst, 16 ... Press machine, 17 ... Ellipse tube, 20 ... Converter intermediate product, 24 ... Diameter reduction apparatus, 25 ... Ellipse case, 26 ... Elliptical catalyst converter

Claims (1)

楕円柱状の触媒と、この触媒に巻付けたマットと、このマット及び前記触媒を挿入する金属製の楕円ケースとからなる楕円触媒コンバータの製造方法であって、
金属製の丸管と、前記マットが巻かれている楕円柱状の触媒とを準備する工程と、
前記丸管の外周を圧縮操作することで、前記丸管を弾性限度で楕円化する工程と、
前記圧縮操作を維持しながら楕円管へ、前記マットが巻付けられている触媒を挿入する工程と、
圧縮操作を解除することで、コンバータ中間製品を得る工程と、
このコンバータ中間製品の楕円管を縮径することで、縮径された楕円ケースとこの楕円ケースに内蔵されたマット及び触媒からなる楕円触媒コンバータを得る縮径工程と、からなることを特徴とする楕円触媒コンバータの製造方法。
A method of manufacturing an elliptical catalytic converter comprising an elliptical columnar catalyst, a mat wound around the catalyst, and a metal elliptical case into which the mat and the catalyst are inserted,
Preparing a metal round tube and an elliptical columnar catalyst around which the mat is wound;
Compressing the outer circumference of the round tube to make the round tube elliptical with an elastic limit;
Inserting the catalyst around which the mat is wound into an elliptical tube while maintaining the compression operation;
A step of obtaining a converter intermediate product by releasing the compression operation;
By reducing the diameter of the elliptical tube of the intermediate product of the converter, the reduced diameter elliptical case and a diameter reducing step for obtaining an elliptical catalytic converter comprising a mat and a catalyst incorporated in the elliptical case are characterized. Manufacturing method of elliptical catalytic converter.
JP2008307783A 2008-12-02 2008-12-02 Manufacturing method of elliptical catalytic converter Expired - Fee Related JP5162426B2 (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2021013886A (en) * 2019-07-11 2021-02-12 株式会社クレファクト Manufacturing method of catalytic converter

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH10305231A (en) * 1997-02-03 1998-11-17 Corning Inc Production of catalytic convertor used for internal combustion engine
JP2002097945A (en) * 2000-09-27 2002-04-05 Calsonic Kansei Corp Catalyst converter and manufacturing method therefor

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH10305231A (en) * 1997-02-03 1998-11-17 Corning Inc Production of catalytic convertor used for internal combustion engine
JP2002097945A (en) * 2000-09-27 2002-04-05 Calsonic Kansei Corp Catalyst converter and manufacturing method therefor

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2021013886A (en) * 2019-07-11 2021-02-12 株式会社クレファクト Manufacturing method of catalytic converter
JP7301356B2 (en) 2019-07-11 2023-07-03 株式会社クレファクト Catalytic converter manufacturing method

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