JP3065640B2 - Heat-resistant structure and manufacturing method thereof - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a heat-resistant structure used in a high-temperature environment.

That is, a metal corrugated sheet material and a flat plate material as a base material are alternately wound and joined, and the overall cross-sectional shape is an elliptical roll-shaped tubular honeycomb heat-resistant structure, for example, The present invention relates to a heat-resistant structure to be used for a catalytic converter for purifying exhaust gas of an automobile engine or the like and to which a catalyst is attached as a carrier.

"Prior art" As a heat-resistant structure having a honeycomb structure in which the entire cross-sectional shape is an elliptical roll, the following is conventionally used.

First, a heat-resistant structure is used in which a single band-shaped metal corrugated sheet material and a flat sheet material are alternately overlapped and wound from a fixed center and joined, thereby gradually making the overall cross-sectional shape elliptical. I was

Secondly, a single corrugated metal sheet and a flat sheet are alternately overlapped and wound from a fixed center and joined to form a complete circular cross-sectional shape. However, a heat-resistant structure was used which was slightly crushed by applying a partial load from the outer peripheral side, thereby making the overall cross-sectional shape elliptical.

Third, as shown in the schematic front cross-sectional view of FIG. 5, a plurality of sets of metal corrugated sheets 1 and flat sheets 2 are used, and these are repeatedly folded from one side to the other side by 180 degrees, stacked, and joined in layers. Thus, the heat-resistant structure 3 having an overall elliptical cross-sectional shape has been used.

Fourthly, as shown in the schematic front sectional view of FIG. 6, components 4 and 5 are used which are obtained by dividing an oval cross-sectional shape into two parts linearly and planarly. A heat-resistant structure 7 in which both components 4 and 5 are assembled and joined at a planar joining surface 6 has been used. A plurality of sets of metal corrugated sheet material 1 and flat plate material 2 were folded back in a contact state, and these two components 4 and 5 were joined in a straight line.

"Problems to be Solved by the Invention" The following problems have been pointed out in such conventional examples.

First, in the heat-resistant structure according to the first conventional example,
as follows. That is, in this heat-resistant structure, a large space is absolutely formed in the central part due to molding, and for example, when used as a carrier of a catalytic converter, a problem such as a reduction in the purification rate of exhaust gas in the central part has been pointed out. Was.

Next, in the heat-resistant structure according to the second conventional example,
as follows. That is, in this heat-resistant structure, it was pointed out that the unevenness of the corrugated sheet material was easily distorted because an uneven load was applied from the outer peripheral side to slightly crush it, and a uniform cell-shaped honeycomb structure could not be obtained. Thus, for example, when used as a carrier of a catalytic converter, the flow of air, that is, the exhaust gas, is not entirely uniform, which is a problem.

In the heat-resistant structure 3 according to the third conventional example,
as follows. That is, the heat-resistant structure 3 shown in FIG.
However, it has been pointed out that it is necessary to repeatedly fold it in a predetermined manner, so that it is not easy to form, and since it is generally used with the outer tube 8 attached, it is troublesome and time-consuming.

In the heat-resistant structure 7 according to the fourth conventional example,
as follows. That is, the heat-resistant structure 7 shown in FIG.
When a shearing load is applied in the direction along the joint surface 6, it is easily broken in the same direction, and there is a problem in the strength surface. Such a load is received only by the attached outer cylinder 8,
It was pointed out that an excessive load was applied to the outer cylinder 8.

 In the prior art, such a point was pointed out.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and has been made to solve the above-described problems of the related art, in which a pair of symmetrically shaped components having a predetermined bent inner surface and a facing surface are fitted. By assembling and inserting and joining the interposition plate as required as required, first, no space is formed in the central portion, and
Thirdly, it is an object of the present invention to propose a heat-resistant structure and a method of manufacturing the same, which have a uniform cell shape, are easy to mold and do not take time, and are also excellent in strength.

"Means for Solving the Problems" The technical means of the present invention for achieving the object is as follows.

First, claim 1 is as follows. That is, in this heat-resistant structure, a metal corrugated sheet material in the form of a band, in which corrugations are continuously bent, and a metal plate material in the form of a flat band are alternately wound and at least partially joined. Thus, the honeycomb structure has a roll shape with an overall cross-sectional shape of an ellipse.

The heat-resistant structure is constructed by assembling a pair of symmetrically-shaped components in which a curved portion is entirely continuous. The two components are each formed by joining a plurality of sets of the corrugated sheet material and the flat plate material in an abutting state, and bending and overlapping the inner bent inner surfaces thereof, and the two components have corresponding shapes. Opposite curved surfaces are fitted together and assembled and joined.

Claim 2 is as follows. That is, in addition to the configuration of the above-described claim 1, the heat-resistant structure is thicker than the corrugated sheet material and the flat plate material between the bent inner surfaces in the two components and between the facing surfaces of the two components, respectively. A thick, curved metal interposer is inserted and joined.

Claim 3 is as follows. That is, the method for manufacturing the heat-resistant structure includes the following plate material preparing step, component element preparing step, and forming step.

In the plate material preparing step, a band-shaped metal corrugated plate material in which corrugations are continuously bent and formed, and a flat band-shaped metal flat plate material are prepared.

In the component preparation step, a component is prepared in which a plurality of sets of the corrugated sheet material and the flat plate material are folded back into a contact state, and the folded inner surfaces are bent and stacked. Then, the components are prepared as a pair of symmetrical shapes having a roll shape with an overall elliptical cross section when the curved portions are continuously continuous and assembled.

In the molding step, the two components are then joined together by fitting the opposing surfaces that are greatly curved into corresponding shapes. As a result, a heat-resistant structure having a honeycomb structure in which the entire cross-sectional shape is an elliptical roll is obtained.

[Operation] The present invention is constituted by such means, and operates as follows.

First, the heat-resistant structure according to claim 1 is formed by fitting and assembling and joining a pair of symmetrical components having a predetermined bent inner surface and an opposing surface, and the entire cross-sectional shape is an elliptical roll shape. And a honeycomb structure. In the heat-resistant structure of the second aspect, a thick metal interposition plate is inserted and joined between the bent inner surfaces and between the opposed surfaces. Further, in the manufacturing method according to claim 3, a plate material preparing step, a component preparing step,
Following the molding process, a heat-resistant structure is manufactured. That is,
A pair of symmetric components having a predetermined bent inner surface and a facing surface are prepared by the prepared corrugated sheet material and the flat plate material,
A predetermined heat-resistant structure is obtained by fitting and assembling these two components.

Therefore, first, in this heat-resistant structure, no space is formed at the center in the molding.

Secondly, since this heat-resistant structure is not formed by applying a biased load from the outer peripheral side and crushing the same during molding, no distortion or the like is generated in the corrugations of the corrugated sheet material. Thus, a honeycomb structure having a uniform cell shape is obtained.

Third, the heat-resistant structure is easily and easily manufactured by following a predetermined plate material preparing step, a component preparing step, and a forming step. In the case where an interposition plate is used, manufacturing is particularly simplified and facilitated. In addition, there is no need for troublesome work in using the same.

Fourth, even if a shear load is applied in one direction, it can sufficiently withstand this and has excellent strength. When an interposed plate is used, it is particularly excellent in strength.

"Examples" Hereinafter, the present invention will be described in detail based on examples shown in the drawings.

FIGS. 1, 2, 3, and 4 are provided for explaining an embodiment of a heat-resistant structure and a method of manufacturing the same according to the present invention. First, the manufacturing method will be described in the order of the plate material preparing step, the component preparing step, and the forming step, and then the heat resistant structure will be described.

 The plate material preparation process is as follows.

FIG. 1 is a perspective view for explaining a plate material preparing step. FIG. 1 (1) shows a corrugated plate 1 and FIG. 1 (2) shows a flat plate 2.

In the plate material preparing step, a band-shaped metal corrugated plate material 1 in which corrugations are continuously bent and formed, and a flat band-shaped metal flat plate material 2 are prepared. The corrugated sheet material 1 is formed by corrugating, pressing, or the like a metal foil such as a stainless steel foil in the form of a strip to form a large number of straight and corrugated irregularities having a predetermined pitch and height in a parallel and continuous manner. Become.
As the flat plate member 2, a metal foil such as a belt-shaped stainless steel foil is used as it is.

 The plate material preparing process is as described above.

 Next, the component preparation step will be described.

FIG. 2 is a schematic sectional front view for explaining a component preparation step, a molding step, and the like. In the component preparation process,
Plural sets of corrugated sheet material 1 and flat sheet material 2 are folded back into contact,
The components 10 and 11 whose bent inner surfaces 9 are bent and stacked are prepared. That is, in this constituent element preparation step, a plurality of sets of corrugated sheet materials 1 and flat plate materials 2 prepared in the above-described plate material preparation step are used alternately as a set of two sheets.
Two-layered components 10 and 11 are formed by being folded back by 180 degrees and having the outer outer surface 13 side longer than the inner opposing surface 12 side, which will be described later, around the inner bent inner surface 9. The two components 10 and 11 have curved portions that are continuous as a whole and have mutually symmetric shapes, and when assembled in the next forming step, the outer surface 13 side, that is, the entire cross-sectional shape is elliptical. A pair of rolls is prepared. Also, the facing surface 12 side is
It has a large curved shape so that it can be fitted to each other. In addition, the corrugated sheet material 1 and the flat sheet material 2 forming such components 10 and 11 are joined by brazing or the like in this component component preparation step. A brazing material or the like may be interposed, and brazing may be performed by heating in a molding process described below.
In the forming step, a brazing material or the like may be interposed at the end and brazed by heating. The corrugated sheet material 1 and the flat sheet material 2 may be entirely joined by brazing or the like, but may be partially joined by brazing or the like.

 The component preparation step is as described above.

 Next, the molding step will be described.

In the forming step, as shown in FIG. 2, after such a constituent element preparing step, the opposite surfaces 12 which are greatly curved into a corresponding shape are fitted to each other, and assembled and brazed. Join. Accordingly, a cylindrical heat-resistant structure 14 having a honeycomb structure, in which the entire cross-sectional shape is an elliptical roll, is obtained.

 The molding process is as described above.

 Next, the heat-resistant structure 14 will be described.

The heat-resistant structure 14 is manufactured by such a manufacturing method, that is, the plate material preparing step, the component preparing step, and the forming step.

That is, the heat-resistant structure 14 is formed by winding a corrugated metal sheet 1 in a band shape in which corrugations are continuously bent to form a metal plate material 2 in a flat band shape. The sections are joined to form a cylindrical honeycomb structure having a roll shape with an overall elliptical cross section. The heat-resistant structure 14 is formed by assembling and joining a pair of symmetrical components 10 and 11 each having a continuous curved portion as a whole.
These two components 10 and 11 are respectively a corrugated sheet 1 and a flat sheet 2
Are folded back in a contact state, and the folded inner surface 9 is bent and overlapped and joined, and the two components 10, 11
In the figure, opposing surfaces 12 curved in a corresponding shape are fitted and assembled and joined.

In the heat-resistant structure 14, the corrugated sheet material 1 and the flat sheet material 2 form a cell wall, and are a planar assembly of a large number of hollow pillar-shaped cells of substantially triangular, substantially semi-hexagonal, substantially trapezoidal and other various shapes. ,
It has a cylindrical honeycomb structure. It is known that it has high heat resistance, is used in a high temperature environment, has excellent weight ratio strength, has high rigidity and strength as well as lightness, and also has excellent fluid rectification effects. Further, because of a large surface area per unit volume, that is, a large surface area of the corrugated sheet material 1 and the flat plate material 2 serving as cell walls, it is used for, for example, a catalytic converter for purifying exhaust gas of an automobile engine. Then, a catalyst for reduction, for example, is adhered to the surfaces of the corrugated sheet material 1 and the flat plate material 2 serving as the cell walls.

FIG. 3 is a schematic front sectional view showing an example in which the interposition plates 15, 16 are inserted and joined to such a heat-resistant structure 14. That is, in the heat-resistant structure 14 shown in FIG.
Facing surface 12 between the bent inner surfaces 9 and between the two components 10, 11
Corrugated sheet material 1 and flat sheet material 2 constituting them between them
Thick and curved metal interposition plates 15, 16 are inserted and joined. Of course, the curvature of the interposition plate 15 is the bent inner surface 9
Along the curvature, the curvature of the interposition plate 16 is set along the facing surface 12.

FIG. 4 is a schematic front sectional view showing an example in which the outer cylinder 8 is attached to the heat-resistant structure 14. By using the heat-resistant structure 14 inserted and used in the outer cylinder 8 in this manner, there is an advantage that the overall strength is further improved. In order to improve the strength, the outermost peripheral portion of the heat-resistant structure 14 may be formed of a particularly thick plate.

 The heat-resistant structure 14 is configured as described above.

The heat-resistant structure 14 and the method of manufacturing the same according to the present invention are as described above.

 Therefore, it becomes as follows.

First, the heat-resistant structure 14 has a predetermined bent inner surface 9 and a facing surface.
A pair of symmetrically shaped components 10 and 11 having 12 are fitted and assembled and joined, and have a cylindrical honeycomb structure having a roll shape with an overall elliptical cross section. If necessary, thick metal interposed plates 15 and 16 are inserted between the bent inner surfaces 9 and between the opposing surfaces 12, respectively.

Further, in the manufacturing method, the heat-resistant structure 14 is manufactured by following a plate material preparing step, a component preparing step, and a forming step. That is, a pair of symmetrical components 10 and 11 having a predetermined bent inner surface 9 and a facing surface 12 are prepared by the prepared corrugated sheet material 1 and the flat plate material 2, and these two components 10 and 11 are fitted. By combining and assembling and joining, a predetermined heat-resistant structure 14 is obtained.

 Therefore, the following first, second, third, and fourth are obtained.

First, in the heat-resistant structure 14, a space is not formed at the center in the molding. That is, no space is formed at the center as in the above-described conventional example.

Second, since the heat-resistant structure 14 is not formed by applying a partial load from the outer peripheral side and crushing it during molding as in the conventional example of this type, no distortion or the like occurs in the corrugations of the corrugated sheet material 1. Therefore, the heat-resistant structure 14 has a honeycomb structure having a uniform cell shape.

Third, the heat-resistant structure 14 is easily and easily manufactured by following a predetermined plate material preparing step, a component preparing step, and a molding step as described above. In the case where the interposition plates 15 and 16 are used, the positioning inside the components 10 and 11 and between them is easily regulated as predetermined by the interposition plates 15 and 16,
This makes the manufacture of the heat-resistant structure 14 particularly simple and easy. In addition, it is not essential to attach the outer cylinder 8 to the heat-resistant structure 14, so that the use of the outer cylinder 8 is not particularly troublesome.

Fourth, even if a shear load is applied in one direction, it can sufficiently withstand this and has excellent strength. That is, both components 10, 11 of this heat-resistant structure 14 are
Since the largely curved facing surface 12 is fitted, meshed, and assembled, it is unlikely to be broken by a shear load.
When the interposition plates 15 and 16 are used, the positioning of the inside of the two components 10 and 11 and between them is always regulated by the interposition plates 15 and 16 functioning as ribs. Strength is further improved.

[Effects of the Invention] As described above, the heat-resistant structure and the method for manufacturing the same according to the present invention require fitting and assembling a pair of symmetric components having a predetermined bent inner surface and an opposing surface, and The following effects are exhibited by inserting and joining the interposed plates as predetermined.

First, no space is formed in the center. Therefore, for example, when used as a carrier for a catalytic converter, the exhaust gas purification rate does not decrease at the center.

Second, the cell shape is uniform. Therefore, the flow of a fluid such as air is generally uniform. For example, when used as a carrier of a catalytic converter, the flow of exhaust gas is also generally uniform and the cleaning rate is uniform.

Third, molding and the like are easy. That is, by following a predetermined plate material preparing step, a component preparing step, and a forming step, it is possible to manufacture easily and easily, and it is not particularly troublesome to use. When an interposition plate is used, the production is further simplified and facilitated.

Fourth, it is also excellent in strength. That is, even if a shear load is applied in one direction, it can sufficiently withstand this and there is no concern about the strength. When an interposed plate is used, the strength is particularly excellent.

As described above, the effects exhibited by the present invention are remarkably large, for example, the problems existing in this type of conventional example are eliminated.

[Brief description of the drawings]

FIGS. 1, 2, 3, and 4 provide an explanation of an embodiment of a heat-resistant structure and a method of manufacturing the same according to the present invention. FIG. 1 is a perspective view for explaining the plate material preparing process, wherein FIG. 1 (1) shows a corrugated plate material and FIG. 1 (2) shows a flat plate material. FIG. 2 is a schematic front sectional view showing a heat-resistant structure formed for explanation of a component preparing step and a forming step. FIG. 3 is a schematic front sectional view showing an example in which an interposition plate is inserted and joined to the heat-resistant structure. FIG. 4 is a schematic front sectional view showing an example in which an outer cylinder is attached to the heat-resistant structure. FIG. 5 is a schematic front sectional view showing a conventional heat-resistant structure. FIG. 6 is a schematic front sectional view showing another conventional heat-resistant structure. DESCRIPTION OF SYMBOLS 1 ... Corrugated plate material 2 ... Flat plate material 3 ... Conventional heat-resistant structure 4 ... Component 5 ... Component 6 ... Joining surface 7 ... Conventional heat-resistant structure 8 ... Outer cylinder 9 ... … Bent inner surface 10… Component 11… Component 12… Opposing surface 13… Outer surface 14… Heat-resistant structure 15… Intermediate plate 16… Intermediate plate A

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Claims (3)

(57) [Claims] 1. A metal corrugated sheet material having a band shape in which corrugations are continuously bent and a flat metal material plate having a flat band shape are alternately wound and at least partially joined. A heat-resistant structure having a honeycomb structure in which the entire cross-sectional shape is in the form of an elliptical roll, wherein the heat-resistant structure is assembled with a pair of symmetrically shaped components having a continuous curved portion as a whole. The two components are each formed by folding a plurality of sets of the corrugated sheet material and the flat plate material in an abutting state, bending the inner bent inner surface and joining them together, and the two components have corresponding shapes. A heat-resistant structure, characterized in that opposing surfaces that are greatly curved are fitted together and assembled. 2. A curved metal member thicker than the corrugated sheet material and the flat plate material, respectively, between the bent inner surfaces in the two components and between the facing surfaces between the two components. The heat-resistant structure according to claim 1, wherein the mounting plate is inserted and joined. 3. A sheet material preparing step of preparing a metal corrugated sheet material in a band shape in which corrugations are continuously bent and formed, and a metal flat plate material in a flat band shape; A plurality of sets of materials are folded back in a contact state to prepare a component whose folded inner surface is bent and overlapped, and the component has an overall cross-sectional shape that is entirely continuous with a curved portion when assembled. A component preparing step of preparing a pair of symmetrical shapes in the form of an elliptical roll; and then, for both the components, the mating facing surfaces that are greatly curved into the corresponding shapes are fitted and assembled. A method for forming a heat-resistant structure having a honeycomb structure in which the entire cross-sectional shape is an elliptical roll.