JP2011117371A - Method for manufacturing exhaust gas catalyst device and exhaust gas catalyst device manufactured by this method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To develop a method for manufacturing an exhaust gas catalyst device that enables a core piece to obtain a surface area as large as possible even when the core piece housed in an outer cylindrical body is formed of a single veneer and to be fixed without the need to be welded. <P>SOLUTION: The present invention relates to a method for manufacturing an exhaust gas catalyst device comprising a core piece 3 which is mounted inside an outer cylindrical body 2 into which exhaust gas G is fed, wherein the core piece 3 using a single veneer as a starting material is manufactured by forming pleats 30 having different depths on the veneer in an orderly arrangement and by then rounding the pleated plate A1 in the shape of a column, and is inserted in the outer cylindrical body 2 so that the adjacent pleats 30 are substantially circumscribed each other, and fixing the core piece 3 inserted is done by restricting the core piece 3 on the both sides in the outer cylinder body 2 by a restricting portion 20 formed by inwardly narrowing the openings at the both ends of the outer cylinder body 2. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an apparatus for purifying combustion gas discharged from various internal combustion engines, and in particular, a large surface area can be obtained while forming a core piece from a single plate, and welding processing is also performed. The present invention relates to a novel exhaust gas catalyst device that can fix the core piece without requiring the above.

In general, in an engine that obtains mechanical power by exploding and burning oil in a cylinder, harmful gases such as CO (carbon monoxide), HC (hydrocarbon), and NO _x (nitrogen oxide) are contained in the exhaust gas. Therefore, a catalyst device (purification device) that reduces this kind of harmful substances is incorporated in the exhaust gas discharge path such as a muffler and an exhaust pipe.
As this catalyst device 1 ′, for example, as shown in FIG. 10 (a), there is a monolith type device in which a core piece 3 ′ whose cross section is formed in a honeycomb shape is fitted into an outer cylindrical body 2 ′. While the exhaust gas flows along the core piece 3 ', the exhaust gas is purified by bringing it into contact with a catalyst metal such as platinum or rhodium previously deposited on the wall surface of the flow path. The core piece 3 'is formed in a honeycomb shape in order to increase the contact area (surface area) with the exhaust gas and improve the purification performance.

  However, in manufacturing the honeycomb core piece 3 ', there are the following problems. That is, in order to manufacture the core piece 3 ′ as shown in FIG. 10A, for example, after a metal plate material of a flat plate and a corrugated plate is overlapped, it is wound in a coil shape until an appropriate size is obtained. The core piece 3 ′ is obtained. In such a method, even if the core piece 3 ′ is manufactured, a plurality of components are required, and the number of processes tends to increase due to the increase in the number of members. Cost could increase and the weight would increase.

For this reason, the present applicant, as an example, as shown in FIG. 10B, uses a pipe-shaped member as a starting material, and presses this to form a pleated tube F having a plurality of folds 30 '. However, a technique for using this as a core piece 3 'has been developed, and a patent has been obtained (see, for example, Patent Document 1). In this patent document 1, since a pipe-shaped member is mainly used as a starting material of the core piece 3 ', the core piece 3' can be manufactured relatively easily, and the core piece 3 'is formed using a plurality of pleated tubes F. Even so, a pipe-shaped member having the same diameter can be used as a starting material, so that a corresponding effect is achieved in cost reduction or the like.
However, in this type of automobile-related parts industry, there are always demands for cost and weight reduction, and even with catalytic devices, not only high purification performance but also further weight reduction and low Manufacturing methods for realizing cost reduction are intensively studied every day.

  For this reason, the present applicant has developed a technique for forming a core piece 3 'having a plurality of folds 30' from a single metal plate by pressing as shown in FIG. Has been filed (Japanese Patent Application No. 2008-2111947). Here, in Japanese Patent Application No. 2008-2111947, an application for priority claim based on the application (domestic priority) was subsequently filed (Japanese Patent Application No. 2009-082542). And “previous application”. In addition, the previous application has not been published yet at the time of filing this patent application, and is not a known technique.

JP 2003-113711 A

  The present invention has been made as part of such research and development, and it is possible to obtain as large a surface area as possible while forming the core piece accommodated in the outer cylinder from a single plate, and This is an attempt to develop a new method for manufacturing an exhaust gas catalyst device that can attach a core piece without requiring welding.

  First, an exhaust gas catalyst device manufacturing method according to claim 1 is an exhaust gas catalyst that purifies exhaust gas with a catalyst that is formed by providing a core piece inside an outer cylinder body into which exhaust gas is fed, and is attached to the flow path surface. In the method of manufacturing an apparatus, the core piece is formed by using a single veneer as a starting material and regularly combining folds having different depths on the veneer, and then rounding the creased plate into a cylindrical shape. It is to be inserted inside the outer cylinder so that adjacent folds are almost circumscribed, and when fixing the inserted core piece inside the outer cylinder, both end openings of the outer cylinder are inward. The core piece in the outer cylinder body is regulated from both sides by a regulation part formed by narrowing, and the core piece is fixed.

  According to a second aspect of the present invention, there is provided a method for manufacturing an exhaust gas catalytic device. In addition to the requirement of the first aspect, in forming the restricting portion in the outer cylindrical body, both end openings are partly inside the end portion. It is characterized in that it is formed by a pressing process of crushing.

  According to a third aspect of the present invention, in addition to the requirements of the first or second aspect, the core piece is formed by a combination of at least three types of folds having different depths. It consists of.

  According to a fourth aspect of the present invention, in addition to the requirements of the first, second, and third aspects, the core piece has a length of a single plate that is a starting material as L, and an outer The DL ratio (L / D value) is set to 25 to 35, where D is the diameter when inserted into the cylinder.

  According to a fifth aspect of the present invention, in addition to the requirements of the first, second, third, or fourth aspect, the core piece is configured by repeating a minimum combination pattern of folds having different depths. When a single plate as a starting material of the core piece is subjected to a crease process, the crease is formed by press processing in which this minimum combination pattern is further divided.

  In addition to the requirements of the first, second, third, fourth, or fifth aspect, the manufacturing method of the exhaust gas catalytic device according to claim 6 is characterized in that the outer cylindrical body into which the pleated plate is inserted is elongated. A cylindrical member obtained by cutting the pipe-shaped member into an appropriate length is applied.

  Further, the exhaust gas catalyst device according to claim 7 is a device that purifies exhaust gas by a catalyst that is formed by providing a core piece inside an outer cylinder body into which exhaust gas is fed, and that is attached and formed on a flow path surface. The core piece is formed by radially providing folds having different depths inside the outer cylindrical body, and folds adjacent to each other are installed in a substantially circumscribed state. Item 1, 2, 3, 4, 5 or 6 is characterized by being manufactured.

The above-described problems can be solved by using the configuration of the invention described in each of the claims.
First, according to the first aspect of the present invention, in order to fix the core piece inserted into the outer cylindrical body by narrowing the opening end portion of the outer cylindrical body inward, it is usually performed to fix these two members. It is possible to eliminate joining such as welding and brazing, which can simplify the manufacturing process and reduce the cost of the exhaust gas catalytic device. Moreover, since the process which narrows an outer cylinder inside is performed to the both-ends opening which does not have a core piece, the said process can be performed comparatively easily.

According to the second aspect of the present invention, the process of narrowing the opening end is a pressing process that partially crushes the vicinity of the opening end on both sides, so that the processing itself is relatively easy, but the core piece is removed. It can be securely and firmly fixed in the cylinder.
As the process for narrowing the opening end, in addition to the above-described indenting process, a curling process for processing the entire periphery of the opening end part into a winding shape may be employed, but the indenting process for partially crushing the opening end part may be employed. For example, the material (outer cylinder) can be saved as much as the winding allowance such as curling is not required, and the weight reduction and cost reduction can be further achieved. In addition, in the case of adopting curling, it is preferable to use either one of the open ends (since it is desirable to introduce exhaust gas from the curling end), but both ends should be indented. Thus, the exhaust gas catalyst device can be attached without considering such a direction, leading to improved workability.

  According to the invention of claim 3, since the core piece to be inserted into the outer cylinder is formed by a combination of at least three kinds of folds having different depths, the folds can be formed in a dense state and have the same size. Even in the case of the exhaust gas catalyst device, the purification performance can be improved. In addition, forming the core piece folds together increases the rigidity of the core piece after insertion and increases the number of contact points with the outer cylinder, making it easy to process only the outer cylinder (open end) inward. (It is considered difficult to deform the outer cylinder together with the core piece).

  In addition, according to the invention of claim 4, since the degree of density of the folds of the core piece can be objectively specified, even when the size of the outer cylindrical body is changed, the setting (specification) of the folds of the core piece is easy to determine. The production of the core piece can be standardized (standardized).

  According to the fifth aspect of the present invention, when a single plate as a starting material of the core piece is subjected to a crease process, the crease is formed by further subdividing the minimum combination pattern of folds having different depths. Therefore, even a dense core piece with a large number of pleats can reduce the load (processing load) when performing one-shot press processing, and can perform precise press processing reliably.

  Further, according to the invention described in claim 6, since the outer cylinder is cut out to an appropriate length from the long pipe-shaped member, only when the core piece is fixed in the outer cylinder. In addition, welding can be eliminated from all processes for manufacturing the exhaust gas catalytic device, and the manufacturing process can be further simplified and the cost of the exhaust gas catalytic device can be further reduced.

  Further, according to the invention described in claim 7, since the core piece to be inserted into the outer cylinder is formed from a single plate, the widest possible surface area can be obtained with certainty. Cost reduction and weight reduction can be achieved.

It is sectional drawing (a) which shows the exhaust-gas silencer unit which applies the exhaust gas catalyst apparatus of this invention, and the perspective view (b) and explanatory drawing (c) which show this exhaust gas catalyst apparatus. It is explanatory drawing which shows in order the processing step which forms a plate with a pleat from a single plate, and the processing step which obtains a core piece from this pleated plate. It is explanatory drawing which shows in one step the example which further divides | segments the minimum combination pattern of the crease | fold with which depth differs further finely. It is explanatory drawing which shows the other Example of press work (processing with a pleat). It is explanatory drawing which shows the Example in the case of forming two adjacent pleats sequentially by one press action. It is explanatory drawing which shows a mode that the plate | board with a crease | fold which has a fold with different depth is rounded into a column shape, and this is inserted inside an outer cylinder body. It is explanatory drawing which shows the operation | movement aspect at the time of fixing a core piece inside an outer cylinder body in steps. It is explanatory drawing which shows the Example of the core piece (plate with a crease | fold) which also made the width | variety dimension of a pleat differ in addition to making the depth dimension of a crease differ. An embodiment is shown in which a curling portion is formed by curling on one open end of the outer cylinder, and a core piece is fixed by forming a depression by pushing on the other open end. It is explanatory drawing. It is sectional drawing which shows the conventional exhaust gas catalyst apparatus.

The mode for carrying out the present invention includes one described in the following embodiments, and further includes various methods that can be improved within the technical idea.
In the description, first, the exhaust gas catalytic device 1 to be manufactured in the present invention will be described, and then the manufacturing method of the exhaust gas catalytic device 1 will be described.

  As shown in FIG. 1 as an example, the exhaust gas catalyst device 1 is incorporated in an exhaust silencing unit U and purifies the exhaust gas G discharged from the engine after combustion before being released into the atmosphere. A catalyst (catalyzer material) for reducing harmful substances is adhered and formed on the flow path wall surface of the exhaust gas catalytic device 1, and the exhaust gas G comes into contact with the catalyst material while passing through the inside of the exhaust gas catalytic device 1. To be purified.

  Such an exhaust gas catalyst device 1 includes an outer cylinder 2 that is open at the front and rear, and a core piece 3 that is provided inside the outer cylinder 2. Here, in the present invention, when the core piece 3 is fixed in the outer cylindrical body 2, the opening portions at both ends of the outer cylindrical body 2 are narrowed inward to form the restricting portion 20, thereby restricting the core piece 3 from both sides. 3 is intended to be fixed. That is, since the core piece 3 inserted in the outer cylinder 2 can move in the longitudinal direction of the outer cylinder 2 as it is, a restricting portion 20 is formed in the vicinity of both end openings to prevent the movement of the core piece 3 from both sides ( The core piece 3 is fixed in the outer cylinder 2. The fixing means can fix the core piece 3 without using any welding or brazing (hereinafter simply referred to as welding).

In forming the restricting portion 20 in the outer cylindrical body 2, for example, it is preferable to form the both end openings by a pressing process that partially crushes the vicinity of the end portion (in particular, the restricting portion 20 by the indenting process is recessed). In this embodiment, as shown in FIG. 1 (c), both end openings are fitted in two locations on the opposite diameter line.
Incidentally, as the outer cylindrical body 2, it is preferable to apply a tubular member cut to an appropriate length from a long pipe-shaped member, which is also as much as possible from all the manufacturing steps of the exhaust gas catalytic device 1, This is to eliminate welding.

  For example, as shown in FIGS. 1 and 2, the core piece 3 has folds 30 having different depths (heights / lengths) inside the outer cylindrical body 2 in order to ensure a large contact area with the exhaust gas G. It is formed so as to form a radial shape, and the adjacent folds 30 are inserted so as to be substantially circumscribed with each other. Here, the depth of the fold 30 is a dimension in the LE direction shown in FIG. 2 and can be said to be a fold length or a fold height. In this specification, the depth is referred to as a depth (depth dimension). Incidentally, the dimension in the WI direction shown in the same figure is called the width dimension of the fold 30 and will be described later.

The core piece 3 shown in FIGS. 1 and 2 is formed by regularly arranging three types of folds 30 having different depths as an example. When these folds 30 are shown separately, 30a and 30b are shown. , 30c... That is, in this embodiment, the deep bottom fold is 30a, the middle bottom fold is 30b, and the shallow bottom fold is 30c. Of course, the fold 30 is not necessarily limited to three types.
Here, the core piece 3 (plate A1 with folds) shown in FIGS. 1 and 2 has a permutation of a deep bottom fold 30a, a shallow fold 30c, a middle fold 30b, and a shallow fold 30c as a basic pattern P. All the folds 30 are formed by repeating P. The “basic pattern P” can be said to be the minimum combination pattern P of the folds 30 having different depths.

  Further, in this embodiment, the folds 30 are formed in a more dense state than in the previous application. For example, in FIG. 1C, the folds 30 are formed by repeating the pattern P 10 times. . Therefore, in the state of being attached to the outer cylinder 2, the total number of folds 30 facing inward (projecting inward) is 40. In FIG. 2, the pattern P is repeated 12 times to form the core piece 3, and therefore the total number of folds 30 facing inward is 48 when inserted into the outer cylinder 2. On the other hand, in the previous application, for example, as shown in FIG. 10C, the total number of folds 30 ′ facing the inner side of the outer cylinder 2 is 14.

Thus, in this embodiment, the folds 30 are formed in a dense state. However, as shown in FIG. 2, for example, as shown in FIG. L / D value (this is the DL ratio) when the outer diameter of the core piece 3 (the inner diameter of the outer cylindrical body 2) is used and "L" is the length of the single plate A before the formation of the folds (the length in the fold formation direction). It can be said that the larger the value, the higher the density of the folds 30 (more densely formed). Incidentally, in the core piece 3 shown in FIG. 2, for example, D is φ51 mm and L is 1410 mm, so the DL ratio is about 27.6. On the other hand, in the previous application (for example, in FIG. 10C), this DL ratio is about 10.7, and it is objective that the density of the folds 30 is much higher in this embodiment. Understandable.
Note that the above-described catalyzer material is attached to the inner and outer surfaces of the folds 30 formed densely (that is, the inner and outer surfaces of the core piece 3) and the inner side of the outer cylindrical body 2.

Further, in the present embodiment, as in the previous application, the core piece 3 having the pleats 30 having different depths is formed from one metal plate material (this is referred to as a single plate A). Due to the fact that the folds 30 are formed densely, when the folds 30 are formed on the single plate A, the minimum combination pattern P of the folds 30 having different depths is subjected to press work that is further divided. is there. That is, in this embodiment, for example, one or two folds 30 are formed by a one-shot press action (a single press process is referred to as a “shot” in this specification). This is because when the folds 30 of the minimum combination pattern P are formed by one-shot press action, four folds 30 are formed at a time, and it is considered that press working is extremely difficult.
And, by repeatedly performing such press work (press work that subdivides the minimum combination pattern P), all the folds 30 are formed on the single plate A (this is referred to as a fold plate A1). The corrugated plate A1 is rounded into a columnar shape to obtain the core piece 3.

Hereinafter, an apparatus for performing such press working (hereinafter referred to as a press machine 4) will be described. The press machine 4 is an apparatus that applies a crease process to the single plate A. For example, when forming the crease 30 (the crease 30 in FIGS. 1 and 2) one by one with a one-shot press action, As an example, as shown in FIGS. 3A to 3D, a minimum combination pattern P is formed by a four-step press action.
Here, when it is desired to distinguish the press machine 4 at each stage, the first press die 41, the second press die 42, the third press die 43, and the fourth press die 44 are used. Also, a pair of mold structures that fit with each other with an interval of about the thickness of the single plate A is taken. In addition, for this reason, the upper die of each press die is 41U, 42U, 43U, 44U, and the lower die is 41D, 42D, 43D, 44D.

Here, the upper molds 41U to 44U have a generally concave shape and have an action of forming (forming) the inner peripheral surface of the fold 30, while the lower molds 41D to 44D have a generally convex shape. It is responsible for forming (forming) the outer peripheral surface. Incidentally, the “inner peripheral surface / outer peripheral surface of the fold 30” means that the fold-backed plate A1 (single plate A) becomes the core piece 3 and is inserted into the outer cylinder 2 in the center side of the outer cylinder 2. The surface facing the inner surface is the inner peripheral surface, and the opposite side is the outer peripheral surface.
Moreover, the site | part which forms the inner peripheral surface of the fold 30 in the upper mold | types 41U-44U is made into the pleat processing part 41a-44a, and the site | part which forms the outer peripheral surface of the fold 30 in the lower mold | type 41D-44D To do. Each upper mold 41U to 44U is provided with relief portions 41c to 44c in addition to the crease processing portions 41a to 44a. The folds 30 already formed on the single plate A are formed by the upper die 41U. It is a receiving part for not buffering with -44U, and, thereby, each press action is performed smoothly.

Here, in the embodiment of FIG. 3, since one crease 30 is formed for each press action of one shot, when viewed as a mold structure, the upper molds 41U to 44U become an overall concave image. Therefore, in the above description, it has been described that “the upper die 41 has a concave shape”, but it is also possible to form a plurality of folds 30 by a one-shot press action (see, for example, FIGS. 4 and 5 described later). In such a case, the unevenness of the mold member is not always clear, and the upper mold 41 may not be formed in a concave shape.
Further, the names “upper mold” / “lower mold” in the above description are not absolute, and are merely for distinguishing a pair of mold members. In other words, the names “upper die” / “lower die” in the above description are names (namely, for convenience) due to the fact that the pressing direction (the separation direction of the die) of the pleat processing is the vertical direction. The pressing direction can also be set in the horizontal direction. In this case, the “upper mold” / “lower mold” corresponds to, for example, “right mold” / “left mold”.

Hereinafter, the manufacturing method of the exhaust gas catalyst device 1 will be described. First, the manufacturing mode (press mode) of the core piece 3 will be described based on FIG.
When forming the fold 30 on the single plate A, as shown in FIG. 3A as an example, the single plate A is sandwiched from above and below by the first press die 41, and only one deep bottom fold 30a is formed first. . Thereafter, the first press die 41 is released (for example, the lower die 41D is separated from the upper die 41U), and the molded product A (the same reference numeral as that of the single plate A) after the first shot is pressed is ejector pins. Or the like to protrude from the upper die 41U (or the lower die 41D). Next, the taken-out molded product A is transferred to the second press die 42 (here, the molded product A is sent to the left side in FIG. 3), and the second shot press work is performed.

  In the press work of the second shot, as shown in FIG. 3B, the molded product A in which only one deep bottom fold 30a is formed is fitted into the upper die 42U of the second press die 42, for example. At this time, since the escape portion 42c is formed in the upper die 42U, the deep bottom fold 30a formed in the first shot is accommodated in the upper die 42U without buffering with the upper die 42U. Yes (does not interfere with the press action of the second shot). In this state, the molded product A is sandwiched from above and below by the second press die 42 to form only one shallow fold 30c. Thereafter, the second press die 42 is released, and the molded product A is ejected from the upper die 42U, for example. At this stage, the molded product A is in a state where one deep bottom fold 30a and one shallow bottom fold 30c are formed.

Thereafter, the molded product A is sent to the third press die 43 shown in FIG. 3C, and this time, only one midsole fold 30b is formed. Further, after that, the molded product A in which the three folds 30 are formed is sent to the fourth press die 44 shown in FIG. 3D, where only one shallow fold 30c is formed. The four folds 30 that are the minimum combination pattern P are formed on the molded product A (single plate A) by the four-stage press action.
After that, as shown in FIG. 3E, the molded product A on which the four folds 30 are formed is sent to the first press die 41 to form only one deep bottom fold 30a. Here, FIG. 3 (e) shows a press die 41 substantially the same as FIG. 3 (a). FIG. 3 (e) shows again that the relief portion 41c of the first press die 41 This is to clearly show the state of avoiding buffering with the shallow bottom fold 30c formed previously (in the press action of the fourth shot here).

Note that the second press die 42 and the fourth press die 44 are both die members for forming only one shallow bottom fold 30c, and only the shapes of the escape portions 42c and 44c are different. If the relief 42c of the press die 42 can also be used as the relief 44c of the fourth press die 44), these die can be used in common.
Here, in the above description, the operation of forming one fold 30 on the molded product A (single plate A) one by one at each stage of the press action and sending the formed molded product A to the press mold at the next stage is repeated. However, the present invention is not necessarily limited to this. That is, for example, with the first press die 41, first, all the deep bottom folds 30a are continuously formed on the single plate A (the interval between the deep bottom folds 30a to be formed is ensured so that three folds 30 can be formed. Set), and then the second press die 42 is sent to the second press die 42, where the next shallow bottom folds 30c are all formed (a press configuration that forms all the folds 30 with each press die). It is also possible to take.
Furthermore, it is possible to form two or more folds 30 at a stroke by a one-shot press action. Hereinafter, such other press forms will be described.

The embodiment shown in FIG. 4 is an embodiment in which two folds 30 are formed by a one-shot press action. In this case, the folds 30 of the minimum combination pattern P are completed by two-stage pressing. Become.
Here, first, as shown in FIG. 4A, the single plate A is sandwiched from above and below by the first press die 51, and the middle bottom fold 30b and the shallow bottom fold 30c one by one, a total of two folds 30. Form. Here, the inner two of the four folds 30 are formed first.
Thereafter, the first press die 51 is released, and, for example, the molded product A is ejected from the upper die 51U, and then the molded product A is transferred to the second press die 52.

Next, after the molded product A in which the two inner pleats 30 are formed is fitted into the upper mold 52U of the second press mold 52, for example, as shown in FIG. The deep bottom fold 30a and the shallow bottom fold 30c are formed on both sides of the two folds 30 that have been formed, thereby forming four folds 30 that are the minimum combination pattern P (FIG. 4 ( c)). Thereafter, the molded product A is sent again to the first press die 51 and the second press die 52, and undergoes press processing at each stage alternately.
Of course, not only such an alternating press form by the first press die 51 and the second press die 52 but also the first press die 51 shown in FIG. A press form in which the middle bottom fold 30b and the shallow bottom fold 30c are first formed is also possible. The middle bottom fold 30b and the shallow bottom fold 30c indicated by a two-dot chain line in FIG. A single plate (press-molded product) A in the case of adopting a processing form is shown.
Incidentally, in the previous application, the basic technical idea was to form the minimum combination pattern P by at least one press working.

Here, in the embodiment of FIG. 4, the first shot press is formed from the two inner pleats 30. The reason for this will be described below.
In the press work of the second shot, as described above, the folds 30 (two inside here) formed by the press work of the first shot are fitted into the second press die 52 (upper die 52U) to perform the press work. Is. For this reason, when forming the deep bottom fold 30a (the left side of FIG. 4B) by pressing the second shot, composition flow from the left side can be expected, while the shallow fold 30c (FIG. 4B). The right side of the surface) can be expected to have composition flow from the right side on the opposite side, and the composition flow is generally generated in the deep bottom 30a and the shallow bottom 30c formed by the second shot press working. It is considered that (pressing) is easily performed (see the arrow in FIG. 4B).

  On the other hand, after forming the deep bottom fold 30a and the shallow bottom fold 30c adjacent to each other with the first press die 51, the adjacent middle bottom fold 30b and the shallow bottom fold 30c are sequentially formed with the second press die 52. In the case of going (see FIG. 5), the press work of the second shot is a press in which the deep bottom fold 30a and the shallow bottom fold 30c formed by the first press die 51 are fitted into the upper die 52U. A smooth composition flow cannot be expected, and it is considered that the meat of the molded product A (raw material) hardly flows into the fold processing portion 52a of the mid-bottom fold 30b. That is, in order to perform the press processing of the second shot precisely, the composition flow from the right side in FIG. 5 must be smoothly performed also on the inner bottom fold 30b (fold processing portion 52a) on the back side. Since the shallow bottom fold 30c is formed on the outer side (right side) of the midsole fold 30b, it is considered difficult to cause a smooth composition flow up to the fold processing portion 52a of the midsole fold 30b. In this embodiment, it is formed from two folds 30 near the center.

Next, the aspect which inserts (inserts) the plate A1 with a pleat obtained by such press work in the outer cylinder 2 is demonstrated.
(1) Cylindrical shaping of pleated plate In this embodiment, since the folds 30 are formed densely as described above, it is conceivable that even if the creased plate A1 is simply rolled, it is difficult to form a beautiful cylindrical shape. . Therefore, in such a case, in order to facilitate the insertion of the core piece 3 into the outer cylinder 2, for example, as shown in FIG. It is possible to reshape it into a preferable one.

  Here, reference numerals 71 and 72 in the figure denote an upper mold and a lower mold for convenience of showing a pair of mold members of the mold 7, and reference numeral 73 denotes a pair of connecting tools. This is a member for accurately and smoothly approaching / separating the lower mold 72 (translating reliably). Incidentally, it is preferable to set the distance between the connecting tools 73 to be approximately the same as the outer diameter of the core piece 3, which is the stage before shaping by the shaping mold 7 (the upper mold 71 and the lower mold 72 are separated from each other). ) However, the plate A1 rounded into an oval cross-section is pressed from the left and right (usually, the lower die 72 is also added and pressed from three directions) to stably hold the plate A1 before shaping. This is because it can be done (reliable setting).

(2) Insertion of shaped pleated plate In this way, the creased plate A1 shaped into a substantially cylindrical shape is then opened with a tapered circular hole 81 as shown in FIG. The core piece 3 in which the folds 30 are formed densely by this is securely and smoothly accommodated in the outer cylinder 2 by being inserted (inserted) into the outer cylinder 2 using the guide jig 8. Is something that can be done.
Here, the guide jig 8 is placed on the outer cylindrical body 2, and the guide jig 8 is oriented so that the circular hole 81 gradually narrows downward, Further, the guide jig 8 is set so that the circular hole 81 (small diameter side) matches the inner diameter of the outer cylindrical body 2. Thereafter, a pleated plate A1 shaped into a cylindrical shape is inserted (press-fitted) from above the guide jig 8, and the creased plate A1 passes through the circular hole 81 and It is narrowed to an inner diameter dimension or less, and is smoothly inserted into the outer cylinder 2.

  Here, in the above description, the outer cylindrical body 2 is placed vertically and the pleated plate A1 is inserted from above, but this is because the creased plate A1 in the middle of insertion can weaken the regulation force from the outside. Naturally, it is considered that it is going to spread outward (so-called spring back), so that it is possible to insert (press-fit) the pleated plate A1 by gravity as easily as possible while pressing from the outside. This is because. Of course, the insertion of the creased plate A1 is not necessarily limited to such a form of fitting in the vertical direction, but may be carried out in the horizontal direction or the like as long as the insertion can be performed smoothly.

(3) Fixing mode of core piece In the present invention, as described above, the core piece 3 is fixed by the restricting portions 20 applied to the opening portions at both ends of the outer cylindrical body 2 without performing any welding. For this reason, with respect to the outer cylindrical body 2, preliminary processing (working) for fixing is performed in advance from the stage before the core piece 3 is inserted, and the core piece including such preliminary processing will be described below. The fixing mode 3 will be described.

First, as shown in FIG. 7A, before the core piece 3 is inserted, one open end of the outer cylinder 2 is deformed so as to partially protrude toward the outer peripheral side (preliminary). processing). This is a protrusion for forming the recess 21 in the part, and this is an outer protrusion 21a. In forming the outer protrusion 21a, the outer cylindrical body 2 can be formed by pushing it from the inside to the outside using, for example, a cam mold. Further, when forming the outer protrusion 21a, for example, as shown in the same figure, the circular shape of the opening end is not deformed as much as possible (while maintaining the circular shape of the end surface), and on the depth side (the outer cylindrical body 2). It is preferable that the outer peripheral wall is formed so as to protrude (toward the longitudinal direction). In particular, in FIG. 7A, the outer protrusion 21a is formed so as to gradually protrude toward the outer periphery toward the depth side while forming a cut around the outer protrusion 21a (other than the end face side). This notch is for making it easy to form the recess 21 later, and is therefore referred to as a guide notch 21b. Of course, the outer projecting portion 21a formed at this stage does not narrow the inner diameter of the outer cylindrical body 2, and when the core piece 3 is inserted, it is inserted from the opening end side. It is.
Here, in forming the outer protrusion 21a, the end surface portion of the outer cylindrical body 2 is prevented from being deformed as much as possible when the exhaust gas catalytic device 1 is attached so that the end surface portion of the outer cylindrical body 2 is a fitting portion with the mating member. This is because it is preferable to be a (connecting portion) and not be deformed as much as possible (the counterpart member is often manufactured by another company).

Thereafter, in the outer cylindrical body 2, a recess 21 is formed at the other opening end as shown in FIG. For this purpose, a cored bar (mandrel) is usually fitted into the outer cylindrical body 2 and the opening end of the outer cylindrical body 2 is crushed (pushed) from the outer peripheral side to form a desired recess 21. In addition, here, the claw-shaped depressions 21 are formed at two opposite positions on the diameter line, and it is preferable that the end face shape of the outer cylindrical body 2 is not deformed as much as possible.
Incidentally, the recess 21 narrows the inner diameter size of the outer cylindrical body 2 and restricts one end side of the core piece 3 inserted into the outer cylindrical body 2 here. Therefore, the outer cylindrical body 2 (the outer cylindrical body 2 into which the core piece 3 is fitted) shown in FIG. 6 has an outer protrusion 21a already formed on the receiving opening end side of the outer cylindrical body 2, and the other A recess 21 is formed at the open end (see FIG. 7C).
Here, in the above description, the outer protruding portion 21a is formed at the opening end portion of the outer cylindrical body 2 and then the recess 21 is formed at the other opening end portion. However, this is done by changing the order. Is also possible.

  As described above, the core piece 3 inserted into the outer cylindrical body 2 in such a state is prevented from moving in the insertion direction by the already formed recess 21. That is, the core piece 3 is received by the recess 21 and the core piece 3 is positioned.

Thereafter, as shown in FIG. 7 (d), the outer cylindrical body 2 is pushed inward from the outer peripheral side on the opening end side where the outer protruding portion 21a is formed, and the recess 21 (restricting portion) 20) is formed. Here, in this embodiment, the depression 21 is formed by simply pushing the outer protrusion 21a without using a cored bar. This is because the guide notch 21b has already been formed around the outer protrusion 21a. It is. In other words, at this stage, the core piece 3 has already been inserted into the outer cylindrical body 2, and the core metal (mandrel) used for this kind of pushing process is usually difficult to insert into the outer cylindrical body 2. In order to be able to form the recess 21 without using gold (only by pressing from the outside), the outer protrusion 21a (guide notch 21b) is formed in advance in the preliminary processing stage shown in FIG. It is a thing.
In this state, the core piece 3 is regulated on both sides by the depressions 21. Therefore, in the present invention, the core piece 3 can be firmly and securely fixed in the outer cylindrical body 2 without requiring any welding. It is.

  In the above description, the guide notch 21b is formed by forming the outer protrusion 21a in the preliminary processing stage. However, only the guide notch 21b is formed by laser cutting or the like, and this is then performed. If the depression 21 can be formed by pushing it into the outside, it is not necessary to form the outer projection 21a in the preliminary processing stage (the formation of the outer projection 21a is not necessarily essential).

  Moreover, as the outer cylinder body 2 into which the core piece 3 is fitted, it is preferable to use a pipe material having an appropriate diameter as a starting material as described above, and cut and apply it to a predetermined length (to eliminate welding). For example, it is also possible to divert the single plate A as a starting material of the core piece 3 as it is or cut into an appropriate length and diverted to the outer cylinder 2. However, in this case, a single veneer is rolled into a cylindrical shape in advance, and the ends are overlapped with each other and joined together by welding or the like to obtain a cylindrical outer cylindrical body 2. .

[Other Examples]
The present invention has the above-described embodiment as one basic technical idea, but the following modifications can be considered. That is, in the above-described embodiment, the folds 30 are mainly formed in a dense manner by changing the depth dimension LE, but for example, as shown in FIG. It is also possible to form it in a high density state. Of course, the fold 30 is not necessarily limited to the three types of combinations, and a wide variety of patterns P can be adopted in shape (different shapes of depth and width), arrangement, and the like.

Moreover, in FIG. 1C and FIG. 7, the indentation 21 (part where the vicinity of the opening end portion is partially crushed) is shown as the restricting portion 20, but as the restricting portion 20, for example, FIG. As shown, a curling process that rounds the entire perimeter of the open end may be employed (this is referred to as a curling portion 22).
However, it is preferable that such a curling part 22 is only one of both open ends from the attachment state as the exhaust gas catalytic device 1. That is, when the exhaust gas catalyst device 1 is incorporated into the exhaust silencing unit U, as shown in FIG. 9, the exhaust gas G is introduced from the curling end so as not to disturb the flow of the exhaust gas G as much as possible. In order to exhaust the exhaust gas G from the end of the pressing process, it is preferable that the curling part 22 is only one. In other words, if the curling process is performed on both opening end sides of the outer cylindrical body 2, there is a concern that the flow of the exhaust gas G may be disturbed when the exhaust gas G is discharged in the exhaust gas catalytic device 1. Is done.
Further, in FIGS. 1C and 7, the restricting portion 20 (recess 21) is formed at two opposite positions on the diameter line at one opening end so that the process of narrowing the opening end is performed as much as possible. However, the present invention is not necessarily limited to this. For example, as shown in FIG. 9, the recesses 21 may be formed at three positions by 120 degrees.

  INDUSTRIAL APPLICABILITY The present invention can be used for an exhaust gas catalyst device that purifies combustion gas discharged from various internal combustion engines.

DESCRIPTION OF SYMBOLS 1 Exhaust gas catalyst apparatus 2 Outer cylinder 3 Core piece 4 Press processing machine 7 Shaping type 8 Guide jig

2 Outer cylinder 20 Restriction part 21 Recess 21a Outer protrusion 21b Guide cut 22 Curling part

3 core piece 30 fold 30a deep bottom fold 30b middle bottom fold 30c shallow bottom fold

4 Press Machine 41 First Press Die 41U Upper Die (First Press Die)
41D Lower mold (first press mold)
41a Folding part (upper die of the first press)
41b Folding part (lower die of the first press)
41c Escape part (upper die of the first press)

42 Second press die 42U Upper die (second press die)
42D Lower mold (second press mold)
42a Folding section (upper die of the second press)
42b Folding section (lower die of second press)
42c Escape part (upper die of the second press)

43 3rd press mold 43U Upper mold (3rd press mold)
43D Lower mold (third press mold)
43a Folding section (upper die of third press)
43b Folding section (lower die of third press)
43c Escape part (upper die of third press)

44 4th press mold 44U Upper mold (4th press mold)
44D Lower mold (4th press mold)
44a Folding part (upper die of 4th press)
44b Folding section (lower die of 4th press)
44c Escape part (upper die of 4th press)

51 First press die 51U Upper die (first press die)
51D Lower mold (first press mold)
52 2nd press mold 52U Upper mold (2nd press mold)
52D Lower mold (second press mold)
52a Folding section (upper die of second press)

7 Shaping mold 71 Upper mold 72 Lower mold 73 Connecting tool

8 Guide jig 81 Round hole

A Single plate (press molded product)
A1 Plate with fold F Flap tube G Exhaust gas P Pattern (minimum combination pattern of folds with different depths)
U Exhaust silencer unit L Length of single plate (length when all folds are extended)
D Core piece diameter LE Length direction
WI width direction (please)

Claims (7)

In a method of manufacturing an exhaust gas catalytic device that purifies exhaust gas by a catalyst that is formed by providing a core piece inside an outer cylindrical body into which exhaust gas is sent, and attached to a flow path surface,
The core piece is formed from a single veneer as a starting material, and this veneer is formed by regularly combining folds having different depths.
This pleated plate is rounded into a cylindrical shape, and is inserted into the outer cylindrical body so that adjacent folds are almost circumscribed with each other.
In addition, when fixing the inserted core piece in the outer cylinder, the core piece in the outer cylinder is regulated from both sides by a regulating portion formed by narrowing both end openings of the outer cylinder inward to fix the core piece. A method of manufacturing an exhaust gas catalyst device, characterized in that it is designed.
2. The exhaust gas catalyst device according to claim 1, wherein when the restricting portion is formed on the outer cylindrical body, both the opening portions are formed by a pressing process in which the vicinity of the end portion is partially crushed inward. Method.
3. The method of manufacturing an exhaust gas catalyst device according to claim 1, wherein the core piece is formed by a combination of at least three kinds of folds having different depths.
The core piece has a DL ratio (L / D value) of 25 to 25, where L is the length of a single plate as a starting material, and D is the diameter dimension when inserted into the outer cylinder. The method of manufacturing an exhaust gas catalytic device according to claim 1, 2 or 3, wherein the value is set to 35.
The core piece is configured by repeating a minimum combination pattern of folds having different depths,
5. A pleat is formed by press working that further divides the minimum combination pattern when the crease is applied to a single plate as a starting material of the core piece. Method for producing an exhaust gas catalytic device.
A cylindrical member obtained by cutting a long pipe-like member into an appropriate length is applied to the outer cylindrical body to which the pleated plate is inserted. 6. A method for producing an exhaust gas catalyst device according to 4 or 5.
An apparatus for purifying exhaust gas by a catalyst formed by providing a core piece inside an outer cylinder body into which exhaust gas is fed, and attached to the flow path surface,
The core piece is configured such that folds having different depths are provided radially inside the outer cylindrical body, and folds adjacent to each other are substantially circumscribed,
An exhaust gas catalytic device manufactured by the manufacturing method according to claim 1, 2, 3, 4, 5 or 6 when manufacturing the device.

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