JP3065641B2 - 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 since uneven load was applied from the outer peripheral side to slightly crush the corrugated material, the corrugation of the corrugated sheet material was easily deformed, and a honeycomb structure having uniform cells 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.

The present invention has been made in view of such circumstances, and has been made in order to solve the problems of the above-described conventional example, and includes a pair of symmetric components having a predetermined bent forming portion and a space forming portion. As a result of fitting and assembling with each other, first, no space is formed in the central portion, second, the cell shape is uniform, and
Fourth, it is an object of the present invention to propose a heat-resistant structure and a method of manufacturing the same, which are easy to form, require no time, and have excellent 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, and the components have a continuous linear portion and curved portion as a whole. In addition, the component includes a bent forming portion in which a plurality of sets of the corrugated sheet material and the flat plate material are folded in an abutting state and linearly overlapped and joined, and a plurality of sets of the corrugated sheet material and the flat plate material are interposed through a space. And a curved space forming part. The component is formed by fitting the bent portion of the other party into the space through the formed opening and assembling and joining.

Claim 2 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 plurality of sets of the corrugated sheet material and the flat plate material are folded back in a contact state, and a bent portion formed in a straight line and a plurality of sets of the corrugated sheet material and the flat plate material are bent through a space. A constituent element including the space forming part is prepared. The components are prepared as a pair of symmetrical shapes in which the linear portion and the curved portion are generally continuous, and when assembled, the entire cross-sectional shape is an elliptical roll.

In the forming step, the bent portions of the components of the other component are fitted into the spaces of the components via the formed openings, and then assembled and joined. 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 the first aspect is configured such that a pair of symmetrical components having a predetermined bent forming portion and a space forming portion are fitted and joined to each other, and the entire cross-sectional shape is elliptical. And a honeycomb structure in the form of a roll. According to the manufacturing method of the second aspect, the heat-resistant structure is manufactured by following the plate material preparing step, the component preparing step, and the forming step. That is, a predetermined bent forming portion and a space forming portion are formed by the prepared corrugated sheet material and the flat plate material, whereby a pair of symmetrical components is prepared. These are fitted into each other and assembled and joined to obtain a predetermined heat-resistant structure.

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 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.

"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 member 1 in which a corrugated shape and unevenness are continuously bent is formed, and a flat band-shaped metal flat plate member 2 is 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 front sectional view for explaining a component preparing step. In the constituent element preparation step, a plurality of sets of the corrugated sheet material 1 and the flat plate material 2 are folded back in a contact state, and the bent forming portions 9 are linearly overlapped.
The components 12, 13 composed of the space forming portion 11 bent through the intermediary 10 are prepared. In other words, in this constituent element preparation step, a plurality of sets of the corrugated sheet material 1 and the flat plate material 2 prepared in the above-mentioned plate material preparation step are used alternately as a set of two sheets. A music forming part 9 is formed,
Subsequently, the space forming portion 11 is formed by bending. Then, the thus obtained one-side crushed substantially S
The components 12 and 13 having a U-shape generally have a straight line portion B and a curved portion C which are continuous with each other and have a symmetric shape with each other. A pair of elliptical rolls is prepared.

The space 10 formed by the space forming portion 11 has a shape and size that can fit the bent forming portion 9, and has an opening 14. In addition, the corrugated sheet material 1 and the flat plate material forming such components 12 and 13 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 forming process described below. Further, for example, a brazing material or the like may be interposed at an end portion in the forming process and brazed by heating. You may do so. 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.

FIG. 3 is a schematic front sectional view showing a heat-resistant structure 15 formed for explanation of a forming step.

In the molding step, after such a component preparation step, 1
The bent portions 9 of the components 12 and 13 of the other component are fitted into the two spaces 10 of the paired components 12 and 13 through the formed openings 14 and assembled, and joined by brazing or the like. Accordingly, a cylindrical heat-resistant structure 15 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 15 will be described.

The heat-resistant structure 15 is manufactured by such a manufacturing method, that is, a plate material preparing step, a component preparing step, and a forming step.

That is, the heat-resistant structure 15 is formed by winding a metal corrugated sheet material 1 having a band shape in which corrugations are continuously bent and a metal flat plate material 2 having a flat band shape to be wound at least one time. The sections are joined to form a cylindrical honeycomb structure having a roll shape with an overall elliptical cross section. The heat-resistant structure 15 is formed by assembling and joining a pair of symmetrical components 12 and 13, and the components 12 and 13 have a straight line portion B and a curved portion C as a whole. In addition, the constituent elements 12 and 13 include a bent forming section 9 in which a plurality of sets of the corrugated sheet material 1 and the flat sheet material 2 are folded back in an abutting state and linearly overlapped and joined.
And a space forming portion 11 in which a plurality of sets of the corrugated sheet material 1 and the flat sheet material 2 are bent through the space. And components 12,13
Is formed by fitting a bent forming portion 9 of the other party into each space 10 through an opening 14 formed and assembled.

In the heat-resistant structure 15, the corrugated sheet material 1 and the flat sheet material 2 form a cell wall, and are a planar aggregate of a large number of hollow columnar cells having a substantially triangular shape, a substantially hexagonal shape, a substantially trapezoidal shape, 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, for example, a catalyst for reduction is adhered to the surfaces of the corrugated sheet material 1 and the flat sheet material 2 which are the cell walls as the carrier matrix.

FIG. 4 is a schematic front sectional view showing an example in which the outer cylinder 8 is attached to such a heat-resistant structure 15. And by using the heat-resistant structure 15 by inserting it into 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 15 may be formed by a particularly thick plate.

 The heat-resistant structure 15 is configured as described above.

The heat-resistant structure 15 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 15 is composed of a pair of symmetric components 12, 13 having a predetermined bent forming portion 9 and a space forming portion 11,
The cylindrical honeycomb structure is fitted into each other, assembled and joined, and has a roll shape with an overall cross-sectional shape of an elliptical roll.

In the manufacturing method, the heat-resistant structure 15 is manufactured by following a plate material preparing step, a component preparing step, and a forming step. That is, a predetermined bent forming portion 9 and a space forming portion 11 are formed by the prepared corrugated sheet material 1 and the flat plate material 2, thereby preparing a pair of symmetric components 12 and 13. Then, these are fitted into each other and assembled and joined, whereby a predetermined heat-resistant structure 15 is obtained.

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

First, in the heat-resistant structure 15, 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 15 is not formed by applying a partial load from the outer periphery and crushing the same 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 15 has a uniform cell-shaped honeycomb structure.

Third, the heat-resistant structure 15 can be easily and easily manufactured by following a predetermined plate material preparing step, a component preparing step, and a forming step as described above. Further, the attachment of the outer cylinder 8 is not indispensable, and the use of the outer cylinder 8 is not particularly troublesome.

Fourth, even if a shear load is unilaterally applied, it can sufficiently withstand this and is excellent in strength. That is, since the bent forming portion 9 is fitted and assembled into the space 10 of the space forming portion 11, it is not easily broken by the shear load.

[Effects of the Invention] As described above, the heat-resistant structure and the method for manufacturing the same according to the present invention are such that a pair of symmetrical components having a predetermined bent forming portion and a space forming portion are fitted into each other. By assembling, the following effects are exhibited.

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.

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.

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 for explaining a component preparing step. FIG. 3 is a schematic front sectional view showing a heat-resistant structure formed for explanation of a forming step. 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 ... … Bend forming part 10… Space 11… Space forming part 12… Component 13… Component 14… Opening 15… Heat-resistant structure A… Point B… Linear part C… Curve part

Continuation of the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B01J 21/00-37/36 B01D 53/86 B21D 47/00 B32B 3/00 F01N 3/28

Claims (2)

(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 a roll having an elliptical shape, wherein the heat-resistant structure is formed by assembling a pair of components having a symmetrical shape. A bent portion formed by a plurality of sets of the corrugated sheet material and the flat plate material folded back in a contact state and overlapped and joined in a straight line; And a plurality of sets of flat plate members formed of a space forming portion bent through a space, and the component is assembled and joined by inserting the counterpart bending forming portion into the respective space through the formed opening. A heat-resistant structure, characterized in that: A step of preparing a metal corrugated sheet in the form of a band in which corrugations are continuously bent, and a step of preparing a metal flat plate in the form of a flat band; A plurality of sets of flat plate members are folded back into contact with each other, and a bent portion formed in a straight line, and a plurality of sets of the same wave plate members and flat plate members are formed of a space forming portion bent through a space. Wherein the components are prepared as a pair of symmetrical shapes in which the straight and curved portions are generally continuous, and when assembled, the overall cross-sectional shape is an elliptical roll. An element preparation step, and thereafter, the bent portions of the respective components are fitted into the spaces of the components via the formed openings, and are assembled and joined, so that the entire cross-sectional shape is an elliptical roll. Forming process to obtain a honeycomb structure heat-resistant structure Method for manufacturing a refractory structure characterized by comprising a.