JP4558960B2

JP4558960B2 - Method for manufacturing corrugated sheet for catalyst support, corrugated sheet and catalyst support

Info

Publication number: JP4558960B2
Application number: JP2001028600A
Authority: JP
Inventors: 直記横山; 安夫加藤
Original assignee: Cataler Corp
Current assignee: Cataler Corp
Priority date: 2001-02-05
Filing date: 2001-02-05
Publication date: 2010-10-06
Anticipated expiration: 2021-02-05
Also published as: JP2002224752A

Description

【０００１】
【発明の属する分野】
本発明は自動車やオートバイの排気装置に配設される排気浄化触媒サポート用波板の製造方法、波板及び触媒サポートに関する。
【０００２】
【従来の技術】
自動車やオートバイの排気装置に配設される排気浄化触媒サポートは図１２に示すように、パイプ材２００とパイプ材２００内に組み込まれた波板１００とから構成されている。波板１００は高温の排気ガスに曝されるため耐熱鋼材で形成されている。波板１００は触媒が担持される表面積を広げた形状を採り、通常断面５山のヘアピン形状をしている。そのような波板１００は、雌型と雄型を使って５山の波部を同時にプレス成形する方法で製造されていた。そして波板１００をパイプ材２００に圧入して密着させた後、ろう付け加工され触媒サポートが形成されていた。
【０００３】
ヘアピン形状の触媒サポートはセルが粗く、セル壁厚が厚いため、エンジン失火などによる異常高温に強く、２・４サイクルエンジンに搭載されている。
【０００４】
【発明が解決しようとする課題】
波板１００に使用される耐熱鋼材は、例えば、組成が２０％Ｃｒ−５％Ａｌ鋼板で、厚さが０．５ｍｍ、伸びが約１５％、硬度が約２２０ＨＶである。このため、この耐熱鋼板は成形性が悪く、同時成形する従来の製造法ではプレス時に波板１００に割れや擦り傷が発生するとともに金型にも擦り傷が発生し、問題であった。割れや擦り傷が発生するのは、中央波部が成形される途中でその両側の側波部が形成される際、金型に材料の供給が不足するため及び材料の伸びが少ないために金型と材料が擦れることによると考えられる。
【０００５】
また、波板をパイプに圧入すると、波板とパイプの内壁及び波板同士に隙間が発生し、隙間のない触媒サポートを作ることが困難であった。隙間が発生するのは、圧入時に波板の波部が重なる方向に圧縮されるため、波部のＲ形状が潰れることによると考えられる。
【０００６】
本発明は上記実情に鑑みてなされたものであり、擦り傷や割れが発生しない波板の製造方法を提供することと、パイプに圧入する際隙間が発生しない波板を製造する方法を提供することを課題とする。
【０００８】
【課題を解決するための手段】
本発明に係る波板の製造方法は、粗波板を作る粗波板形成工程と、作られた粗波板の凹部に棒状のコアを挿入し、コアの挿入された状態で波部が重なる方向に押圧して矯正する矯正工程と、からなることを特徴とする。
【０００９】
【実施の形態】
粗波板形成工程は、平板中央に中央波部を形成する中央波部形成工程と、該中央波部を狭持した状態でその両側の側波部を形成する側波部形成工程と、からなり、５山を持つ波板の製造を可能とする。側波部形成工程を繰り返すことで、９山の波板を製造することができる。すなわち、平板中央に中央波部を形成する中央波部形成工程と、該中央波部を狭持した状態でその両側の側波部を形成する側波部形成工程と、該側波部を狭持した状態でさらにその両側の側々波部を形成する側々波部形成工程とからなるようにする。
【００１０】
前記中央波部形成工程は波状の雌型の中央凹部に平板をその中央が一致するように載置する工程と、波状の雄型の中央凸部が該雌型の中央凹部に圧入する工程と、からなるようにすると、平板中央に確実に中央波部を形成することができる。
【００１１】
また、前記側波部を形成する工程を前記雌型の中央凹部の両側凹部に前記雄型の中央凸部の両側凸部が圧入する工程にすると、中央波部の両側に側波部を確実に形成することができる。側波部形成工程は前記雌型の中央凹部と両側凹部の間の凸部を、前記雄型の中央凸部と両側凸部の間の凹部に圧入する工程でも良い。
また、波状の雄型と雌型の場合は、隣り合う凸部と凸部の間は凹部であり、凹部と凹部の間は凸部であるから、側波部形成工程は、雌型の中央凹部の両側凹部に雄型の中央凸部の両側凸部が圧入するのと、雌型の中央凹部と両側凹部の間の凸部を前記雄型の中央凸部と両側凸部の間の凹部に圧入することが同時に行われる工程でも良い。
【００１２】
さらに、前記雄型は前記両側凸部の中央溝部に前記中央凸部の上端部が加圧手段を介して枢着されていると、雄型を雌型に圧入する際、両側凸部を加圧するだけで最初中央凸部が圧入され、続いて中央波部を狭持した状態で両側凸部が圧入される。したがって、自動化、量産化に適している。
【００１３】
前記加圧手段にはコイルばね、板ばね、油圧ピストン、など適宜使用できる。
【００１４】
本発明の波板の製造方法は、粗波板を作る粗波板形成工程と、作られた粗波板の凹部に棒状のコアを挿入し、コアの挿入された状態で波部が重なる方向に押圧して矯正する矯正工程と、からなる。この波板の製造方法の粗波板形成工程は本発明の波板の製造方法に限定されない。すなわち、いかなる方法で製造された粗波板も擦り傷や割れがなければ、その粗波板の凹部に棒状のコアを挿入し、コアの挿入された状態で波部が重なる方向に押圧して矯正することで、パイプに圧入する際隙間が発生しない波板を製造することができる。
【００１５】
棒状のコアは粗波板の波部の曲率半径と等しい半径のコアが好ましい。波部の形状を損なうことなく矯正できるからである。
【００１６】
前記矯正する工程が雌型と雄型が閉じたとき円筒状キャビティを形成する型で波部が重なる方向に押圧して矯正する工程であると、パイプに圧入する際、隙間が発生しない波板を確実に形成することができる。
【００１７】
また、円筒状キャビティの内径は、圧入すべきパイプの内径に近い方が、パイプに圧入する際、隙間が発生しない波板を、より確実に形成することができる。
矯正された波板は材料のスプリングバック作用で少し広がるので、キャビティの内径はパイプの内径より小さくても良い。
【００１８】
波板に使用される鋼材は、自動車やオートバイの排気装置に配設される排気浄化触媒サポート用の場合は、たとえば、組成が２０％Ｃｒ−５％Ａｌのような耐熱鋼材製の鋼板が適している。耐熱鋼材としてはその他に、SUS304やSUS430などでもよい。
【００１９】
【作用】
本発明の粗波板の製造方法は、中央波部形成工程の後に側波部形成工程で該中央波部を狭持した状態でその両側の側波部を形成するので、金型への材料の供給不足が生ぜず擦り傷や割れの発生が生じにくい。
【００２０】
本発明の波板の製造方法は、粗波板の凹部に棒状のコアを挿入し、コアの挿入された状態で波部が重なる方向に押圧して矯正するので、パイプに圧入する際波部のＲ形状が潰れることがなく、隙間が発生しない。
【００２１】
【実施例】
以下、実施例により本発明を具体的に説明する。
【００２２】
実施例１
実施例１による５山の粗波板の製造プロセスを図１〜図４に示す。図１は厚さ０．５mm、幅１９５mm、長さ１１０mmの耐熱鋼（１８％Ｃｒ−３％Ａｌ）平板１を雄型２と雌型３の間に挿入した状態を示す。雄型２は、山（３）（図では○の中に３と記す）用の中央凸部２１、山（１）（図では○の中に１と記す）と（５）（図では○の中に５と記す）用の両側凸部２２、加圧手段としての波状スプリング２３とからなる。中央凸部２１の元部２１２はコの字状をしており、元部２１２が両側凸部２２のコの字状中央溝部２２２にスプリング２３を介して枢着されている。スプリング２３の一端は中央溝部２２２の頂部に、他端は元部２１２のコの字状凹部の低部に固着されている。したがって、中央凸部２１はスプリング２３の伸縮によって中央溝部２２２をスライドする。
【００２３】
スプリング２３が収縮して中央凸部２１の首部２１１が両側凸部２２の首部２２１に一致すると山（２）（図では○の中に２と記す）、（４）（図では○の中に４と記す）用の凹部を形成する。なお、中央凸部２１の首部２１１が両側凸部２２の先端と一致している。
【００２４】
波状の雌型３は山（３）（図では○の中に３と記す）用の中央凹部３１と山（１）（図では○の中に１と記す）、（５）（図では○の中に５と記す）用の両側凹部３２、及び中央凹部と両側凹部の間に山（２）（図では○の中に２と記す）と（４）（図では○の中に４と記す）用の凸部３３を持っている。
【００２５】
雄型２と雌型３の互いに対応する凹凸の曲率半径は５ｍｍである。
【００２６】
図１の状態で雄型２を図示しない加圧手段で加圧すると、スプリング２３が殆ど収縮しない状態で、雄型２の中央凸部２１が平板１を伴って雌型３の中央凹部３１に圧入されて中央波部の山（３）（図では○の中に３と記す）が形成され出すと同時に、平板１は雌型の山（２）（図では○の中に２と記す）と（４）（図では○の中に４と記す）用の凸部３３で下面から押し上げられ、雄型２の両側凸部２２で上面から押し下げられ、図２の状態になる。さらに雄型２を加圧して降下させると、雄型２の中央凸部２１が雌型３の中央凹部３１に完全に圧入され、平板１に中央波部の山（３）（図では○の中に３と記す）が形成される。
【００２７】
次にこの状態、すなわち、中央波部を狭持した状態でさらに雄型２を加圧すると、スプリング２３が収縮し両側凸部２２が降下し雌型３の山（１）（図では○の中に１と記す）と（５）（図では○の中に５と記す）用の両側凹部３２への圧入を開始すると同時に、中央凸部２１と両側凸部２２との間に山（２）（図では○の中に２と記す）、（４）（図では○の中に４と記す）用の凹部を形成し始め、雌型３の山（２）（図では○の中に２と記す）と（４）（図では○の中に４と記す）用の凸部３３が雄型２の山（２）（図では○のかに２と記す）、（４）（図では○の中に４と記す）用凹部に圧入され始める。さらに、雄型２を加圧すると、スプリング２３が収縮し両側凸部２２が雌型３の山（１）（図では○の中に１と記す）と（５）（図では○の中に５と記す）用の両側凹部３２に圧入され、雌型３の山（２）（図では○の中に２と記す）、（４）（図では○の中に４と記す）用凸部３３が雄型２の山（２）（図では○の中に２と記す）、（４）（図では○の中に４と記す）用凹部に圧入され、最終的に図3に示す状態になり、平板１に両側の側波部が形成される。
【００２８】
図４は成形後、型から取り出した波板の斜視図であるが、擦り傷や割れの発生が無かった。
【００２９】
実施例２
実施例２による波板の製造プロセスを図５〜図７に示す。図５は実施例１で製造した波板１０の波部にコアとしての直径１０ｍｍの丸棒６を挿入して、半円筒状の雄型４とU字状の雌型５のキャビティ内に波板１０の波部が重なる方向と型が閉じる方向が一致するようにセットした状態を示す。雄型４の半円筒の曲率半径と雌型５のＲ部の曲率半径はそれぞれ１５ｍｍで、雄型４と雌型５が閉じた状態で直径３０ｍｍの円筒状キャビティを形成する。図５の状態で雄型４を雌型５に圧入したところ、波板１０は波部が重なる方向に押圧され、図６の状態になった。
【００３０】
波部の曲率を５ｍｍに保ったまま外形を３０ｍｍに矯正することができた。図７は金型４と５から取り出し、丸棒６を取り除いた波板を示す。金型から取り出すと材料のスプリングバックにより若干広がったが、波部の変形や潰れの無い波板を製造することができた。これを内径２９．４ｍｍ、外形３１．８ｍｍのステンレス製パイプに圧入したところ、波部のＲ形状が潰れることがなく、隙間が発生しなかった。パイプ内壁にろうスラリーを塗布した後波板を圧入し、ろう付け熱処理することで良好なヘアピン形状触媒サポートが完成した。
【００３１】
実施例３
実施例３よる９山の波板の製造プロセスを図８〜図１１に示す。図８は厚さ０．５ｍｍ、幅３５０ｍｍ、長さ１１０ｍｍの耐熱鋼（１８％Ｃｒ-３％Ａｌ鋼）平板１を雄型７と雌型８の間に挿入した状態を示す。雄型７は、山（５）（図では○の中に５と記す）用の中央凸部７１、山（３）（図では○の中に３と記す）と（７）（図では○の中に７と記す）用の第一両側凸部７２、山（１）（図では○の中に１と記す）と（９）（図では○の中に９と記す）用の第二両側凸部７３、加圧手段としての第一波状スプリング７４、第二波状スプリング７５とからなる。
【００３２】
中央凸部７１の元部７１２はコの字状をしており、元部７１２が第一両側凸部７２のコの字状中央溝部７２２に第一スプリング７４を介して枢着されている。第一スプリング７４の一端は中央溝部７２２の頂部に、他端は元部７１２のコの字状凹部の低部に固着されている。したがって、中央凸部７１は第一スプリング７４の伸縮によって中央溝部７２２をスライドする。第一スプリング７４が収縮して中央凸部７１の首部が両側凸部７２の首部に一致すると山（２）（図では○の中に２と記す）、（４）（図では○の中に４と記す）用の凹部を形成する。
【００３３】
第一両側凸部７２の元部は第二両側凸部７３のコの字状中央溝部７３２に第２スプリング７５を介して枢着されている。第二スプリング７５の一端は中央溝部７３２の頂部に、他端は第一両側凸部７２の上面に形成された凹部に固着されている。したがって、第一両側凸部７２は第二スプリング７５の伸縮によって第二両側凸部７３の中央溝部７３２をスライドする。第二スプリングが収縮して第一両側凸部７２の首部が第二両側凸部７３の首部に一致すると、山（２）（図では○の中に２と記す）、（８）（図では○の中に８と記す）用の凹部を形成する。
【００３４】
波状の雌型８は山（５）（図では○の中に５と記す）用の中央凹部８１と山（３）（図では○の中に３と記す）、（７）（図では○の中に７と記す）用の第一両側凹部８２、山（１）（図では○の中に１と記す）、（９）（図では○の中に９と記す）用の第二両側凹部８３を持ち、かつ、中央凹部と第一両側凹部の間に山（４）（図では○の中に４と記す）と（６）（図では○の中に６と記す）用の凸部８４を、第一両側凹部と第二両側凹部の間に山（２）（図では○の中に２と記す）と（８）（図では○の中に８と記す）用の凸部８５を、持っている。
【００３５】
雄型７と雌型８の互いに対応する凹凸の曲率半径は５ｍｍである。
【００３６】
図８の状態で雄型７を図示しない加圧手段で加圧すると、第一スプリング７４、第二スプリング７５が殆ど収縮しない状態で、雄型７の中央凸部７１が平板１を伴って雌型８の中央凹部８１に圧入されて中央波部の山（５）（図では○の中に５と記す）が形成され出すと同時に、平板１は雌型の山（４）（図では○の中に４と記す）と（６）（図では○の中に６と記す）用の凸部８４で下面から押し上げられ、雄型７の第一両側凸部７２で上面から押し下げられる。さらに雄型７を加圧して降下させると、雄型７の中央凸部７１が雌型８の中央凹部８１に完全に圧入され、平板１に中央波部の山（５）（図では○の中に５と記す）が形成される。
【００３７】
次にこの状態すなわち、中央波部を狭持した状態でさらに雄型７を加圧すると、第一スプリング７４が収縮し第一両側凸部７２が降下し雌型８の山（３）（図では○の中に３と記す）と（７）（図では○の中に７と記す）用の第一両側凹部８２への圧入を開始すると同時に、中央凸部７１と第一両側凸部７２との間に山（４）（図では○の中に４と記す）、（６）（図では○の中に６と記す）用の凹部を形成し始め、雌型８の山（４）（図では○の中に４と記す）と（６）（図では○の中に６と記す）用の凸部８４が雄型７の山（４）（図では○の中に４と記す）、（６）（図では○の中に６と記す）用凹部に圧入され始め、図９の状態になる。
【００３８】
さらに、雄型７を加圧すると、第一両側凸部７２が雌型８の第一両側凹部８２に完全に圧入され、側波部の山（３）（図では○の中に３と記す）と（７）（図では○の中に７と記す）及び山（４）（図では○の中に４と記す）と（６）（図では○の中に６と記す）が形成される。次に、この状態すなわち、側波部を狭時した状態でさらに雄型７を加圧すると、第二スプリング７５が収縮し第二両側凸部７３が雌型８の山（１）（図では○の中に１と記す）と（９）（図では○の中に９と記す）用の第二両側凹部８３に圧入され、雌型８の山（２）（図では○の中に２と記す）、（８）（図では○の中に８と記す）用凸部８５が雄型７の山（２）（図では○の中に２と記す）、（８）（図では○の中に８と記す）用凹部に圧入され、最終的に図１０に示す状態になり、平板１に側々波部が形成される。
【００３９】
図１１は成形後、型から取り出した波板の断面図であるが、擦り傷や割れの発生が無かった。
【００４０】
【発明の効果】
以上説明したように、本発明の波板の製造方法によれば、金型への材料の供給不足が生ぜず擦り傷や割れの発生がない。また、パイプに圧入する際、波部のＲ形状が潰れることがなく、隙間が発生しない。
【図面の簡単な説明】
【図１】実施例１の製造プロセスの初期段階を示す断面図である。
【図２】実施例１の製造プロセスの途中段階を示す断面図である。
【図３】実施例１の製造プロセスの最終段階を示す断面図である。
【図４】実施例１の製造プロセスで製造された波板の斜視図である。
【図５】実施例２の製造プロセスの初期段階を示す断面図である。
【図６】実施例２の製造プロセスの最終段階を示す断面図である。
【図７】実施例２の製造プロセスで製造された波板の断面図である。
【図８】実施例３の製造プロセスの初期段階を示す断面図である。
【図９】実施例３の製造プロセスの途中段階を示す断面図である。
【図１０】実施例３の製造プロセスの最終段階を示す断面図である。
【図１１】実施例３の製造プロセスで製造された波板の断面図である。
【図１２】触媒サポートの断面図である。
【符号の説明】
１・・・平板、２、４、７・・・雄型、３、５、８・・・雌型、６・・・コア、１０・・・波板、２１、７１・・・中央凸部、２２、７２、７３・・・両側凸部、２３、７４、７５…加圧手段、３１、８１・・・中央凹部、３２、８２、８３・・・両側凹部[0001]
[Field of the Invention]
The present invention relates to a method of manufacturing a corrugated plate for exhaust purification catalyst support disposed in an exhaust device of an automobile or motorcycle, and a corrugated plate and a catalyst support .
[0002]
[Prior art]
As shown in FIG. 12, the exhaust purification catalyst support disposed in the exhaust system of an automobile or motorcycle is composed of a pipe material 200 and a corrugated plate 100 incorporated in the pipe material 200. Since the corrugated plate 100 is exposed to high-temperature exhaust gas, it is made of a heat-resistant steel material. The corrugated plate 100 has a shape in which the surface area on which the catalyst is supported is increased, and is usually in the shape of a hairpin with five cross sections. Such a corrugated sheet 100 has been manufactured by a method in which five corrugations are simultaneously pressed using a female mold and a male mold. The corrugated plate 100 was pressed into the pipe member 200 and brought into close contact with it, and then brazed to form a catalyst support.
[0003]
Since the hairpin-shaped catalyst support has a rough cell and a thick cell wall, it is resistant to abnormally high temperatures due to engine misfire and the like, and is mounted on a 2.4 cycle engine.
[0004]
[Problems to be solved by the invention]
The heat-resistant steel material used for the corrugated sheet 100 is, for example, a 20% Cr-5% Al steel sheet having a thickness of 0.5 mm, an elongation of about 15%, and a hardness of about 220 HV. For this reason, this heat-resistant steel sheet has poor formability, and the conventional manufacturing method in which simultaneous forming is performed causes a problem in that the corrugated sheet 100 is cracked or scratched during pressing and the mold is also scratched. Cracks and scratches occur when the side wave part on both sides of the central wave part is being formed, because the supply of material to the mold is insufficient and the material is not stretched. It is thought that the material is rubbed.
[0005]
Further, when the corrugated plate is press-fitted into the pipe, a gap is generated between the corrugated plate, the inner wall of the pipe and the corrugated plate, and it is difficult to make a catalyst support without a gap. It is considered that the gap is generated because the corrugated portion of the corrugated plate is compressed in the direction in which the corrugated portions are overlapped during press-fitting, and the R shape of the corrugated portion is crushed.
[0006]
The present invention has been made in view of the above circumstances, and provides a method for manufacturing a corrugated sheet that does not generate scratches or cracks, and a method for manufacturing a corrugated sheet that does not generate a gap when pressed into a pipe. Is an issue.
[0008]
[Means for Solving the Problems]
Manufacturing method of engaging Ru corrugated sheet in the present invention, a coarse corrugated plate forming step of making a crude corrugated plate, insert the rod-shaped core in the recess of the created coarse corrugated, wave portion in the inserted state of the core And a correction step of correcting by pressing in the overlapping direction.
[0009]
Embodiment
The rough wave plate forming step includes a central wave portion forming step for forming a central wave portion at the center of the flat plate, and a side wave portion forming step for forming side wave portions on both sides of the central wave portion in a state where the central wave portion is sandwiched. This makes it possible to manufacture corrugated plates with five ridges. By repeating the side wave forming process, nine corrugated plates can be manufactured. That is, a central wave portion forming step for forming a central wave portion at the center of the flat plate, a side wave portion forming step for forming side wave portions on both sides of the central wave portion in a state where the central wave portion is held, and the side wave portion are narrowed. In this state, a side wave portion forming step for forming side wave portions on both sides of the holding portion is further included.
[0010]
The central wave portion forming step includes a step of placing a flat plate in a central concave portion of a corrugated female mold so that the center thereof coincides, and a step of press-fitting the corrugated male central convex portion into the central concave portion of the female mold, , The central wave portion can be reliably formed at the center of the flat plate.
[0011]
Further, if the step of forming the side wave portion is a step in which the both side convex portions of the male central convex portion are press-fitted into the both side concave portions of the female central concave portion, the side wave portions are surely provided on both sides of the central wave portion. Can be formed. The side wave portion forming step may be a step of press-fitting a convex portion between the female central concave portion and both side concave portions into a concave portion between the male central convex portion and both convex portions.
In the case of the wavy male mold and female mold, the side wave portion forming step is performed at the center of the female mold because the concave portion is between the adjacent convex portions and the convex portion is between the concave portions and the concave portions. The convex part between the male central convex part and the both side concave part is the concave part between the male central convex part and the both convex parts. It may be a process in which the press-fitting into is simultaneously performed.
[0012]
Further, when the male mold has the upper end of the central convex portion pivotally attached to the central groove portion of the convex portions on both sides via a pressurizing means, both convex portions are added when the male mold is press-fitted into the female mold. The central convex portion is first press-fitted only by pressing, and then the both convex portions are press-fitted while holding the central wave portion. Therefore, it is suitable for automation and mass production.
[0013]
As the pressurizing means, a coil spring, a leaf spring, a hydraulic piston, or the like can be used as appropriate.
[0014]
The corrugated plate manufacturing method of the present invention includes a rough corrugated plate forming step for producing a corrugated corrugated plate, a rod-shaped core inserted into a concave portion of the rough corrugated plate, and a direction in which the corrugated portions overlap with each other with the core inserted. And a correction process for pressing to correct. The rough corrugated sheet forming step of the corrugated sheet manufacturing method is not limited to the corrugated sheet manufacturing method of the present invention. That is, if the rough corrugated plate manufactured by any method is not scratched or cracked, a rod-like core is inserted into the concave portion of the rough corrugated plate, and the corrugated portion is pressed and corrected in the direction in which the core is inserted. By doing so, it is possible to manufacture a corrugated sheet that does not generate a gap when it is press-fitted into a pipe.
[0015]
The rod-shaped core is preferably a core having a radius equal to the radius of curvature of the wave portion of the rough wave plate. It is because it can correct without impairing the shape of a wave part.
[0016]
A corrugated sheet that does not generate a gap when it is press-fitted into a pipe when the correcting process is a process of correcting by pressing in the direction in which the wave portions overlap in a mold that forms a cylindrical cavity when the female mold and the male mold are closed Can be reliably formed.
[0017]
In addition, when the inner diameter of the cylindrical cavity is closer to the inner diameter of the pipe to be press-fitted, a corrugated sheet that does not generate a gap when press-fitted into the pipe can be more reliably formed.
Since the corrected corrugated sheet is slightly expanded by the springback action of the material, the inner diameter of the cavity may be smaller than the inner diameter of the pipe.
[0018]
The steel material used for the corrugated plate is, for example, a steel plate made of heat-resistant steel such as 20% Cr-5% Al in the case of an exhaust purification catalyst support disposed in an exhaust device of an automobile or motorcycle. ing. In addition, SUS304, SUS430, etc. may be used as the heat resistant steel material.
[0019]
[Action]
In the method for manufacturing a rough wave plate of the present invention, the side wave portions on both sides thereof are formed in a state where the central wave portion is sandwiched in the side wave portion forming step after the central wave portion forming step. Insufficient supply does not occur and scratches and cracks are less likely to occur.
[0020]
The corrugated plate manufacturing method of the present invention inserts a rod-shaped core into the concave portion of the rough corrugated plate, and presses and corrects in the direction in which the corrugated portion overlaps with the core inserted, so that the corrugated portion is pressed into the pipe. The R shape is not crushed and no gap is generated.
[0021]
【Example】
Hereinafter, the present invention will be described specifically by way of examples.
[0022]
Example 1
A manufacturing process of five rough wave plates according to Example 1 is shown in FIGS. FIG. 1 shows a state in which a heat-resistant steel (18% Cr-3% Al) flat plate 1 having a thickness of 0.5 mm, a width of 195 mm, and a length of 110 mm is inserted between a male mold 2 and a female mold 3. The male mold 2 has a central convex portion 21 for a mountain (3) (indicated by 3 in the circle) , a mountain (1) (indicated by 1 in the circle) and (5) (indicated by a circle in the figure). 2) and a wave spring 23 as a pressurizing means. The base portion 212 of the central convex portion 21 has a U-shape, and the base portion 212 is pivotally attached to the U-shaped central groove portion 222 of the both side convex portions 22 via a spring 23. One end of the spring 23 is fixed to the top of the central groove portion 222, and the other end is fixed to the lower portion of the U-shaped recess of the base portion 212. Therefore, the central convex portion 21 slides on the central groove portion 222 by the expansion and contraction of the spring 23.
[0023]
When the spring 23 contracts and the neck portion 211 of the central convex portion 21 coincides with the neck portion 221 of the convex portions 22 on both sides, peaks (2) (indicated by 2 in circles in the figure ) , (4) (in circles in the figure ) 4)) is formed. The neck portion 211 of the central convex portion 21 coincides with the tips of the both side convex portions 22.
[0024]
The corrugated female mold 3 has a central recess 31 for a mountain (3) (denoted by 3 in the circle) and a mountain (1) (denoted by 1 in the circle in the diagram ) , (5) (in the diagram, o Between the recesses 32 for both sides and the central recesses and the recesses on both sides (2) (shown as 2 in the circle in the figure ) and (4) (4 in the circle in the figure) it has a convex portion 33 for abbreviated).
[0025]
The curvature radii of the concaves and convexes corresponding to each other of the male mold 2 and the female mold 3 are 5 mm.
[0026]
When the male mold 2 is pressed by a pressing means (not shown) in the state of FIG. 1, the central convex portion 21 of the male mold 2 is brought into the central concave portion 31 of the female mold 3 together with the flat plate 1 in a state where the spring 23 hardly contracts. At the same time as the peak of the central wave part (3) (denoted by 3 in the circle) is formed, the flat plate 1 is a female mountain (2) (denoted by 2 in the circle). And (4) is pushed up from the lower surface by the convex portion 33 (denoted by 4 in the circle) and pushed down from the upper surface by the both side convex portions 22 of the male mold 2 to be in the state of FIG. When the male mold 2 is further pressed and lowered, the central convex portion 21 of the male mold 2 is completely press-fitted into the central concave portion 31 of the female mold 3, and the peak (3) of the central wave portion (3 in FIG. Formed as 3) .
[0027]
Next, when the male mold 2 is further pressed in this state, that is, in the state where the central wave portion is held, the spring 23 contracts and the convex portions 22 on both sides descend, and the mountain (1) of the female mold 3 (in FIG. At the same time as press-fitting into both side recesses 32 for ( 1) and (5) (indicated by 5 in the circle) , a peak (2 ) (Denoted as 2 in the circle in the figure ) , (4) began to form a recess for ( denoted as 4 in the circle) , and the female mold 3 peak (2) (in the circle in the figure) 2) (4) (shown as 4 in the circle in the figure) is a male 2 peak (2) (shown as 2 in the circle) , (4) (in the figure) It begins to be press-fitted into the recess for 4) . Further, when the male mold 2 is pressurized, the spring 23 contracts and the convex portions 22 on both sides are the ridges (1) of the female mold 3 (indicated by 1 in the circle) and (5) (in the circle in the figure). 5 (denoted as 5) and press-fitted into the recesses 32 on both sides of the female mold 3 (2) (denoted as 2 in o in the figure) , (4) (denoted as 4 in o in the figure) 33 is press-fitted into the recess for the male mold 2 (2) (denoted as 2 in circle in the figure ) , (4) (denoted as 4 in circle in the figure ) , and finally the state shown in FIG. Thus, side wave portions on both sides are formed on the flat plate 1.
[0028]
FIG. 4 is a perspective view of the corrugated sheet taken out of the mold after molding, but there was no generation of scratches or cracks.
[0029]
Example 2
The manufacturing process of the corrugated sheet according to Example 2 is shown in FIGS. FIG. 5 shows that a corrugated portion of the corrugated plate 10 manufactured in the first embodiment is inserted with a round bar 6 having a diameter of 10 mm as a core, and waves are inserted into the cavities of a semi-cylindrical male mold 4 and a U-shaped female mold 5. The state which set so that the direction where the wave part of the board | plate 10 overlaps and the direction which a type | mold closes corresponds is shown. The radius of curvature of the half cylinder of the male mold 4 and the radius of curvature of the R portion of the female mold 5 are each 15 mm, and a cylindrical cavity having a diameter of 30 mm is formed with the male mold 4 and the female mold 5 closed. When the male mold 4 was press-fitted into the female mold 5 in the state of FIG. 5, the corrugated sheet 10 was pressed in the direction in which the wave portions overlap, and the state of FIG. 6 was reached.
[0030]
The outer shape could be corrected to 30 mm while maintaining the curvature of the wave part at 5 mm. FIG. 7 shows the corrugated sheet taken out of the dies 4 and 5 and with the round bar 6 removed. When it was taken out from the mold, it was slightly spread by the spring back of the material, but a corrugated sheet without wave portion deformation or crushing could be produced. When this was press-fitted into a stainless steel pipe having an inner diameter of 29.4 mm and an outer diameter of 31.8 mm, the R shape of the wave portion was not crushed and no gap was generated. After applying the brazing slurry to the inner wall of the pipe, the corrugated plate was press-fitted and brazed and heat treated to complete a good hairpin-shaped catalyst support.
[0031]
Example 3
A manufacturing process of nine corrugated plates according to Example 3 is shown in FIGS. FIG. 8 shows a state in which a heat-resistant steel (18% Cr-3% Al steel) flat plate 1 having a thickness of 0.5 mm, a width of 350 mm, and a length of 110 mm is inserted between the male mold 7 and the female mold 8. The male mold 7 has a central protrusion 71 for a mountain (5) (indicated by 5 in the circle in the figure) , a mountain (3) (indicated by 3 in the circle in the figure ) and (7) (indicated by a circle in the figure). first both side protrusions 72 for denoted as 7) into the mountains (1) (referred to as 1 in ○ in the figure) and (9) (referred to as 9 in ○ in the figure) the second for It comprises a convex portion 73 on both sides, a first wave spring 74 as a pressurizing means, and a second wave spring 75.
[0032]
The base portion 712 of the central convex portion 71 has a U-shape, and the base portion 712 is pivotally attached to the U-shaped central groove portion 722 of the first both-side convex portion 72 via a first spring 74. One end of the first spring 74 is fixed to the top of the central groove 722, and the other end is fixed to the lower part of the U-shaped recess of the base 712. Accordingly, the central convex portion 71 slides on the central groove portion 722 by the expansion and contraction of the first spring 74. When the first spring 74 contracts and the neck portion of the central convex portion 71 coincides with the neck portions of the both side convex portions 72, a mountain (2) (indicated in the circle with 2) , (4) (in the circle in the circle) 4)) is formed.
[0033]
The base part of the first both-side convex part 72 is pivotally attached to the U-shaped central groove part 732 of the second two-side convex part 73 via the second spring 75. One end of the second spring 75 is fixed to the top of the central groove 732, and the other end is fixed to a recess formed on the upper surface of the first both-side protrusion 72. Therefore, the first both-side convex portion 72 slides on the central groove portion 732 of the second both-side convex portion 73 by the expansion and contraction of the second spring 75. When the second spring contracts and the neck portion of the first both-side convex portion 72 coincides with the neck portion of the second both-side convex portion 73, a peak (2) (indicated by 2 in a circle in the figure ) , (8) (in the figure) A recess for 8) is formed.
[0034]
The wavy female mold 8 has a central recess 81 for a mountain (5) (shown as 5 in a circle) and a mountain (3) (shown as 3 in a circle) , (7) (shown as a circle) the first sides recesses 82 for referred to 7) in, referred to as 1 in the ○ is a mountain (1) (FIG.), (9) (referred to as 9 in ○ in the figure) the second sides for Convex 83 for convexity (4) (denoted as 4 in circle in the figure ) and (6) ( denoted as 6 in circle in the figure) between the central recess and the first side recesses Convex part 84 for the peaks (2) (denoted as 2 in the circle in the figure ) and (8) ( denoted as 8 in the circle in the figure) between the first both-side recessed part and the second both-side recessed part Have 85.
[0035]
The curvature radii of the concaves and convexes corresponding to each other of the male mold 7 and the female mold 8 are 5 mm.
[0036]
When the male mold 7 is pressed by a pressing means (not shown) in the state of FIG. 8, the central projection 71 of the male mold 7 with the flat plate 1 is female with the first spring 74 and the second spring 75 being hardly contracted. The plate 1 is pressed into the central recess 81 of the mold 8 to form a peak (5) of the central wave portion (indicated by 5 in the circle), and at the same time, the flat plate 1 has a female peak (4) (circle in the drawing). It is pushed up from the lower surface by the convex portion 84 for (6 is written in the circle) and (6) (indicated by 6 in the circle) , and is pushed down from the upper surface by the first both-side convex portion 72 of the male mold 7. When the male mold 7 is further pressed and lowered, the central convex portion 71 of the male mold 7 is completely press-fitted into the central concave portion 81 of the female mold 8, and the peak (5) of the central wave portion (5 in the figure) (Denoted 5 in the inside) is formed.
[0037]
Next, when the male die 7 is further pressed in this state, that is, with the central wave portion sandwiched, the first spring 74 contracts and the first side convex portion 72 descends, and the mountain (3) of the female die 8 (FIG. Then, press-fitting into the first both-side recess 82 for (7) (shown as 3 in ○) and (7) (shown as 7 in ○ in the figure) is started, and at the same time, the central protrusion 71 and the first both-side protrusion 72 Beginning to form a recess for the mountain (4) (denoted as 4 in the circle in the figure ) and (6) (denoted as 6 in the circle in the figure) between the female and the female ( 8 ) The convex part 84 for (6 in the figure is marked as 4 ) and (6) (in the figure is marked as 6 in the circle) is the mountain 7 of the male mold (4) (in the figure, marked as 4 in the circle). ) , (6) It begins to be press-fitted into the recess for 6 (indicated by 6 in the circle) , and the state shown in FIG. 9 is obtained.
[0038]
Further, when the male mold 7 is pressurized, the first both-side convex portions 72 are completely press-fitted into the first both-side concave portions 82 of the female mold 8, and the side wave crest (3) (indicated by 3 in the circle). ) And (7) (indicated by 7 in the circle) and mountains (4) (indicated by 4 in the circle) and (6) (indicated by 6 in the circle) are formed. The Next, when the male die 7 is further pressed in this state, that is, in a state where the side wave portion is narrowed, the second spring 75 is contracted and the second both-side convex portion 73 is the mountain (1) of the female die 8 (in the drawing). It is press-fitted into the second side recess 83 for (9) ( denoted as 1 in o) and (9) (denoted as 9 in o in the figure ), and the ridge (2) of the female mold 8 (2 in o in the figure) and referred), (8) (referred to as 2 in ○ in 8 and denoted) protruding portion 85 of the male die 7 for mountain (2) (Figure in ○ in the figure), in (8) (Fig ○ And is finally pressed into a state as shown in FIG. 10, and side wave portions are formed on the flat plate 1.
[0039]
FIG. 11 is a cross-sectional view of the corrugated sheet taken out from the mold after molding, but there was no generation of scratches or cracks.
[0040]
【The invention's effect】
As described above, according to the corrugated plate manufacturing method of the present invention, there is no shortage of material supply to the mold, and no scratches or cracks occur. Moreover, when press-fitting into the pipe, the R shape of the wave portion is not crushed and no gap is generated.
[Brief description of the drawings]
1 is a cross-sectional view showing an initial stage of a manufacturing process of Example 1. FIG.
2 is a cross-sectional view showing an intermediate stage in the manufacturing process of Example 1. FIG.
3 is a cross-sectional view showing the final stage of the manufacturing process in Example 1. FIG.
4 is a perspective view of a corrugated sheet manufactured by the manufacturing process of Example 1. FIG.
5 is a cross-sectional view showing an initial stage of a manufacturing process of Example 2. FIG.
6 is a cross-sectional view showing the final stage of the manufacturing process in Example 2. FIG.
7 is a cross-sectional view of a corrugated sheet manufactured by the manufacturing process of Example 2. FIG.
8 is a cross-sectional view showing an initial stage of a manufacturing process in Example 3. FIG.
9 is a cross-sectional view showing an intermediate stage in the manufacturing process of Example 3. FIG.
10 is a cross-sectional view showing the final stage of the manufacturing process in Example 3. FIG.
11 is a cross-sectional view of a corrugated sheet manufactured by the manufacturing process of Example 3. FIG.
FIG. 12 is a cross-sectional view of a catalyst support.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Flat plate, 2, 4, 7 ... Male type | mold, 3, 5, 8 ... Female type | mold, 6 ... Core, 10 ... Corrugated sheet, 21, 71 ... Central convex part 22, 72, 73... Both side convex portions, 23, 74, 75... Pressurizing means, 31, 81.

Claims

A rough corrugated sheet forming process for creating a rough corrugated sheet;
A straightening process in which a rod-shaped core is inserted into the concave portion of the produced rough corrugated plate, and the corrugated portion is pressed and corrected in a state where the core is inserted, and
A method for manufacturing a corrugated sheet comprising:

2. The corrugated sheet manufacturing method according to claim 1 , wherein the correcting step is a step of correcting the corrugated portion by pressing in a direction in which the wave portions overlap with a die that forms a cylindrical cavity when the female die and the male die are closed.

The rough wave plate forming step for forming the rough wave plate includes a central wave portion forming step for forming a central wave portion at the center of the flat plate, and side waves for forming side wave portions on both sides of the central wave portion while sandwiching the central wave portion. The method for manufacturing a corrugated sheet according to claim 1, comprising a part forming step.

The central wave portion forming step includes a step of placing a flat plate in a central concave portion of a corrugated female mold so that the center thereof coincides, and a step of press-fitting the corrugated male central convex portion into the central concave portion of the female mold, The manufacturing method of the corrugated sheet of Claim 3 which consists of these.

A corrugated sheet having an outer diameter substantially circular and a hairpin shape in section produced by the production method according to claim 1.

An exhaust purification catalyst support incorporating the corrugated plate of claim 5 in a pipe.