JP3768600B2 - Multi-row integrated corrugated sheet for metal catalyst carrier molding - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an improvement of a multi-row integrated corrugated sheet for forming a metal catalyst carrier of a catalytic converter.
[0002]
[Prior art]
Conventionally, a vehicle exhaust system, the catalyst converter for purifying exhaust gas discharged from the engine is mounted, as a catalyst carrier, the thin metal plate was cut in a strip shape as shown in FIG. 3 (e.g., Fe-Cr- A metal catalyst carrier 5 having a honeycomb structure in which a corrugated plate 1 and a flat plate 3 made of an Al alloy are overlapped and these are wound in multiple layers is widely used.
[0003]
And, in manufacturing the metal catalyst carrier 5, in order to eliminate the relative movement between the corrugated plate 1 and the flat plate 3 and prevent the film-out phenomenon, the contact portion of the corrugated plate 1 and the flat plate 3 is joined by welding or brazing, A method is adopted in which the metal catalyst carrier 5 is tightly pressed with a pressurizing jig such as a die, and this is heated in a vacuum state so that the corrugated plate 1 and the flat plate 3 are integrally diffused and joined.
[0004]
However, the metal catalyst carrier 5 is heavier than the flat plate 3 used, and the corrugated plate 1 can absorb thermal stress due to high-temperature exhaust gas, but the flat plate 3 is difficult to absorb thermal stress. Further, there is a possibility that stress distortion occurs at the joint portion between the corrugated plate 1 and the flat plate 3 to cause breakage or dropout.
Therefore, in Japanese Patent Laid-Open No. 5-138040, as shown in FIG. 4 , the thin metal plate 7 is partitioned into a plurality of rows 9a, 9b, 9c, 9d in the winding direction, and each row 9a, 9b, 9c, Waveforms 11 are continuously formed at a predetermined pitch in 9d, and a plurality of metal catalyst carrier moldings in which the phases of the rows 9a, 9b, 9c, 9d are shifted between adjacent ones and wound in multiple layers are formed. A row-integrated corrugated sheet 13 is disclosed.
[0005]
Thus, in the metal catalyst carrier using the corrugated plate 13, a flat plate is not required, so that the weight of the entire metal catalyst carrier can be reduced. As a result, the heat capacity is reduced and the heating time is shortened. In addition, it has excellent thermal stress absorption and does not cause breakage or dropout, and the end portions of the corrugated sheet 11 of the corrugated sheet 13 are meshed with each other to prevent relative movement of the corrugated sheet 13, so that the film-out phenomenon occurs. It does not occur.
[0006]
[Problems to be solved by the invention]
However, in the above wave plate 13, connected only at the intersection point P between each column 9a, 9b, 9c, 9d crest portions 11a and valley portions 11b of mutual waveform 11 as shown in the front view of FIG. 5 Because of this structure, when there is a difference in the coefficient of thermal expansion due to the temperature change for each row 9a, 9b, 9c, 9d due to the inflow of exhaust gas, each row 9a, 9b, 9c, 9d at the intersection P is mutually There is a possibility that the connecting part of the slab may be lost.
[0007]
The present invention has been devised in view of such a situation, and is an improvement on the multi-row integrated corrugated plate as described above, and an improved multi-row integrated type for forming a metal catalyst carrier in which the connection strength between the rows is improved. The object is to provide a corrugated sheet.
[0008]
[Means for Solving the Problems]
In order to achieve such an object, the multi-row integrated corrugated plate according to claim 1 is a strip-shaped metal thin plate that is formed into a plurality of rows in which waveforms are continuously formed with a 120 ° phase shift from each adjacent row. Partitioning, and forming the waveform of each partitioned row with regularity that two valleys are continuous after the peak, and providing a flat portion orthogonal to each row over the entire row, Each flat portion connects adjacent columns.
[0009]
(Function)
The metal catalyst carrier used for the catalytic converter is manufactured by cutting the multi-row integrated corrugated plates according to claim 1 into predetermined dimensions and sequentially stacking them or winding them in multiple layers.
In the multi-row integrated corrugated plate, the flat portion orthogonal to each row is provided over the entire row to improve the connection strength between the adjacent rows, so that the exhaust gas flows into the metal catalyst carrier. Thus, even if there is a difference in the thermal expansion coefficient for each row due to temperature change, each flat portion connects each row to prevent its loss.
In addition, since the multi-row integrated wave train formed the waveform of each row so that the valley portion is continuous next to the peak portion, when the metal catalyst carrier is formed by winding or laminating this, the peak portion and The valley is hardly polymerized in the vertical relationship.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 shows a plan view of one embodiment of a multi-row integrated corrugated sheet according to claim 1 (hereinafter referred to as “corrugated sheet”). The corrugated sheet 25 according to the present embodiment is made of a metal cut into a strip (for example, , Fe-Cr-Al alloy) is divided into a plurality of rows 27 in the axial direction of the metal catalyst carrier to be molded, and each row 27 is shifted in phase by 120 ° from each adjacent row 27. The waveform 29 is continuously formed, and as shown in FIG. 2, the waveform 29 has a regularity in which the valley 29b continues after the peak 29a, such as peak 29a → valley 29b → valley 29b. Thus, the mountain portion 29a and the valley portion 29b are arranged.
[0011]
Further, in the middle of these (the middle of the peak portion 29a and the valley portion 29b and the middle of the valley portion 29b and the valley portion 29b), a flat portion 31 having a predetermined width is orthogonal to each row 27 (metal catalyst carrier). In the axial direction), and is provided across all the rows 27, and the adjacent rows 27 are connected to each other by the flat portions 31.
Although not shown, the corrugated plate 25 continuously supplies metal thin plates to a pair of rotating corrugated gears to form the corrugated 29 and flat portions 31 of each row 27, and there are a plurality of corrugated gears. A pair of gears are stacked and a pair of gears mesh with each other, and the corrugated gear is used to process a metal thin plate, thereby forming the corrugated plate 25 having the above-described structure.
[0012]
Since the corrugated plate 25 according to the present embodiment is configured as described above, the corrugated plate 25 is cut into a predetermined size, and the corrugated plate 25 is sequentially laminated, or is wound in multiple layers to produce a metal catalyst carrier. .
According to such a metal catalyst carrier, the crests 29a and the end portions of the troughs 29b of the corrugated 29 of each corrugated plate 25 to be polymerized engage with each other to prevent relative movement between the corrugated plates 25.
[0013]
Further, as described above, in the corrugated plate 13 shown in FIG. 4, each row 9a, 9b, 9c, 9d is connected only at the intersection P between the peak 11a and valley 11b of the waveform 11. Therefore, when a difference occurs in the thermal expansion coefficient due to the temperature change for each row 9a, 9b, 9c, 9d due to the inflow of exhaust gas, the connecting portion between each row 9a, 9b, 9c, 9d is lost. The corrugated sheet 25 according to the present embodiment has the possibility that the flat portions 31 having a predetermined width are arranged in the middle of the peak portions 29a and the valley portions 29b and in the middle of the valley portions 29b and the valley portions 29b. Since the connection strength between the adjacent rows 27 is improved by providing them across the rows 27, even if a difference in the thermal expansion coefficient occurs for each row 27 due to a temperature change due to the inflow of exhaust gas, The flat part 31 will connect each row | line | column 27 and will prevent the defect | deletion.
Therefore, according to the metal catalyst carrier using this embodiment, the connection strength between the rows 27 is improved as compared with the metal catalyst carrier using the conventional example of FIG. Can be prevented.
[0014]
However, in the metal catalyst carrier using the corrugated plate 25 according to the present embodiment, the flat plate is not necessary, and thus the weight of the entire metal catalyst carrier can be reduced. The time can be shortened, the thermal stress is excellently absorbed and there is no possibility of causing breakage or dropout, and the end portions of the corrugated portions 29 of the superposed corrugated plates 25 mesh with each other to prevent relative movement of the corrugated plates 25. No film-out phenomenon occurs.
This eliminates the need for conventional brazing, diffusion bonding, or the like in the manufacturing process, thereby reducing the cost.
[0015]
Furthermore, since the wave train 25 according to the present embodiment forms the waveform 29 of each row 27 so that the trough portion 29b continues after the peak portion 29a, this is wound or laminated to form the metal catalyst carrier. When molded, the peaks 29a and valleys 29b are hardly polymerized in the vertical relationship, and there is an advantage that the catalyst efficiency is improved.
[0016]
【The invention's effect】
As described above, according to the corrugated plate according to the first aspect, the connection strength between the rows is improved as compared with the prior art, and therefore if the metal catalyst carrier is formed using these corrugated plates. Thus, it is possible to reliably prevent the connection portion from being lost due to the difference in the coefficient of thermal expansion between the rows.
[0017]
However, by providing a flat portion on the corrugation, it is possible to freely design a corrugated pattern having regularity in which the trough continues after the crest. As a result, in forming the metal catalyst carrier, By only winding or laminating, the crests and troughs are hardly polymerized in a vertical relationship with each other, and the catalyst efficiency is improved.
[Brief description of the drawings]
1 is a plan view of an embodiment of a corrugated sheet according to claim 1 ;
FIG. 2 is a cross-sectional view taken along the line II-II in FIG.
FIG. 3 is a schematic view showing a conventional method for producing a metal catalyst carrier .
FIG. 4 is a perspective view of a conventional multi-row corrugated plate .
FIG. 5 is a front view of the corrugated sheet shown in FIG.
[Explanation of symbols]
25 Corrugated sheet
27 columns
29 Waveform
29a Yamabe
29b Tanibe
31 Flat part

Claims (1)

The strip-shaped metal thin plate is divided into a plurality of rows in which the waveform (29) is continuously formed by shifting the phase with the adjacent rows (27) by 120 ° , and the waveform (29 of each row (27) partitioned. ) With the regularity in which the two valleys (29b) are continuous next to the peaks (29a), and the flat part (31) orthogonal to each row (27) is formed over all rows. A multi-row integrated corrugated sheet for forming a metal catalyst carrier, wherein the flat portions (31) are connected to each other and adjacent rows (27) are connected to each other.

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