JPH08257361A - Winding method for honey comb body - Google Patents

Abstract

PURPOSE: To provide a highly reliable metal support without joining failure even in the case the thickness of foils is made thin by making the contact plane pressure of both flat and corrugated foils optimum in whole range from the center part to the outer circumferential part of a honey comb body at the time when the flat foil and the corrugated foil are layered and wound in a manufacturing method of a honey comb body made of a metal to be employed as a carrier for an exhaust gas purifying catalyst for various kinds of internal combustion engines. CONSTITUTION: Three or more rolls 5 are installed in the circumferential direction of an outer circumference face of a honey comb body 1, the honey comb body 1 is pinched and pressurized by the rolls 5, and while back tension being applied to a flat foil 2, winding of foils is carried out. It is preferable to drive at least three installed rolls 5 and it is more preferable to adjust the roll pressurizing force corresponding to the diameter of the honey comb body 1 during winding. Consequently, the quality of an obtained metal carrier can be stabilized and improved and an exhaust gas purifying function at an engine starting initial stage is improved and gas discharge resistance is lowered by using the obtained thin foil metal carrier.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a winding method for producing a metallic honeycomb body used as a carrier for an exhaust gas purifying catalyst for various internal combustion engines.

[0002]

2. Description of the Related Art As a carrier for an exhaust gas purifying catalyst for an internal combustion engine for automobiles, boilers, power generators, etc., a metal carrier in which an outer cylinder made of heat-resistant stainless steel is fitted with a honeycomb body made of the same or ceramic The ceramic carrier in which the honeycomb body is inserted is used. Since the metal carrier has a smaller heat capacity than the ceramic carrier and is heated to a temperature at which the catalyst acts, it has an excellent exhaust gas purifying ability at the initial stage of engine start. Further, since the wall of the honeycomb body is made of a thin metal foil, it has advantages that exhaust resistance is small and engine output loss is small.

In the conventional metal carrier, the honeycomb body is manufactured by stacking a flat foil made of a metal foil having a thickness of about 50 μm and a corrugated foil obtained by corrugating the flat foil and winding them in a spiral shape. Then, the honeycomb body is fitted into the outer cylinder, the flat foil and the corrugated foil are bonded together, and the honeycomb body and the outer cylinder are bonded together to form a metal carrier. Bonding is performed by brazing, electron beam welding, laser welding, resistance welding, or diffusion bonding by heating in a non-oxidizing atmosphere. If there are insufficient joints, they will peel off during use and the metal carrier will be damaged, so from the center to the outer periphery of the honeycomb body,
The flat foil and the corrugated foil must be joined securely. Therefore, when the flat foil and the corrugated foil are overlapped and wound, it is necessary that the both are surely brought into close contact with each other and an appropriate contact surface pressure is provided.

In order to manufacture a loose honeycomb body, conventionally, the ends of the flat foil and the corrugated foil are sandwiched by a winding shaft, the shaft is rotated, and both side surfaces of the honeycomb body being formed are formed by side plates. It was sandwiched, the plate was rotated in synchronization with the winding shaft, the honeycomb body was rotated by the frictional force, and the flat foil was wound with back tension. However, since the diameter of the honeycomb body is small at the initial stage of winding, the frictional force with the side plate is small.Therefore, if the back tension is increased, the side plate and the honeycomb body slip, and the waves near the center of the winding shaft are slipped. There was a problem that the foil was crushed. Further, when the diameter of the honeycomb body becomes large, there is a problem that the surface pressure is not applied even if the back tension is increased.

In order to deal with such a problem, the inventors of the present invention, when forming the honeycomb body 1 by winding the flat foil 2 and the corrugated foil 3 around the winding shaft 4 as shown in FIG. A prestrain is applied to the corrugated foil 3 by pressing the roll 5 as shown in (a) or the sliding plate 12 as shown in (b) from the outer surface of the honeycomb body 1 in the radial direction by the spring 13. However, a method of winding is proposed in Japanese Patent Application No. 5-5235. According to this method, the corrugated foil 3 in the vicinity of the winding shaft 4 is not crushed because the corrugated foil 3 can be wound without applying excessive back tension, and the corrugated foil 3 is wound in a pre-strained state and flat foil The contact surface pressure between the corrugated foil 2 and the corrugated foil 3 is improved.

However, in such a method, since the interval between the contact points of the plurality of rolls 5 or the sliding plates 12 with the honeycomb body 1 is fixed, the pressurization state is changed as the diameter of the honeycomb body 1 changes. However, there is a problem that the pressure cannot be effectively applied from the start to the end of winding. Especially, when the diameter of the honeycomb body 1 is small, there is a problem that the interval between the contact points is too wide to apply pressure.

[0007]

DISCLOSURE OF THE INVENTION The present invention is a winding method for producing a metal honeycomb body, which is used as a carrier for an exhaust gas purifying catalyst for various internal combustion engines such as automobiles, boilers, and power generators. Therefore, when the flat foil and the corrugated foil are overlapped and wound, the contact surface pressure between both foils is made proper from the central portion to the outer peripheral portion of the honeycomb body, so that even if the foil thickness is made thin, the bonding failure can be prevented. The purpose is to obtain a highly reliable metal carrier.

[0008]

Means for Solving the Problems The present invention for achieving the above object comprises a method for forming a honeycomb body by winding a flat foil and a corrugated corrugated corrugated foil around a winding shaft. Three or more rolls are arranged in the circumferential direction of the outer peripheral surface of the honeycomb body, and the roll is pressed against the honeycomb body,
A method for winding a honeycomb body is characterized in that a back tension is applied to the flat foil before winding and the honeycomb body is wound. Then, it is preferable to drive three or more rolls arranged, and it is further preferable to adjust the roll pressing force according to the diameter of the honeycomb body being wound.

[0009]

FIG. 1 shows an example of the method of the present invention. The flat foil 2 and the corrugated foil 3 are wound around the winding shaft 4 to form the honeycomb body 1. The corrugated foil 3 is formed by corrugating the flat foil 2. Three or more (three in FIG. 1) rolls 5 are arranged in the circumferential direction of the outer peripheral surface of the honeycomb body 1 that is being formed, and the honeycomb body 1 is pinched by the rolls 5 to detect the shape of the honeycomb body 1. Adjust the clamping pressure. In the example of FIG. 1, roll 5
Is rotatably supported on the tip of the yoke 8, and the cylinder 8 presses the yoke 8 in the radial direction of the honeycomb body 1. Then, the potentiometer 6 is attached to the yoke 8, the shape of the honeycomb body 1 is judged by the amount of movement thereof, and the pressing force by the cylinder 7 is adjusted. In FIG. 1, reference numeral 11 denotes a brake roll, which applies a back tension to the flat foil 2 such that the honeycomb body 1 is not loosened. In addition, side plates 10 are provided along the both side surfaces of the honeycomb body 1 on the planes orthogonal to the winding shaft 4, and the honeycomb body 1 is clamped and rotated from both side surfaces.

To carry out the method of the present invention, a flat foil 2 and a corrugated foil 3 are used.
The tip end of the honeycomb is sandwiched by the winding shaft 4 and sandwiched by the side plate 10, the winding shaft 4 and the side plate 10 are rotated to form the honeycomb body 1 of several windings, and then the honeycomb body 1 is sandwiched by the roll 5. The position of the roll 5 is detected by the potentiometer 6 and the pressing force of the cylinder 7 is adjusted to wind the roll. After the completion of winding, the outermost periphery is fixed by spot welding or the like, the sandwiching by the side plate 10 is released, and the honeycomb body 1 is taken out. According to the method of the present invention, when the foil thickness is thin, the flat foil 2 and the corrugated foil 3 are provided between the adjacent rolls 5.
Even if the slack is generated, the slack can be extruded by adjusting the pressing pressure of each roll 5.

The potentiometer 6 is used to detect the diameter of the honeycomb body 1 during winding, adjust the pressing force of the roll 5 based on the detected value, and determine the timing of ending winding. The reason why a plurality of potentiometers 6 are used is that the shape of the honeycomb body 1 being wound is not a perfect circle but a spiral shape, and therefore an accurate value is obtained by detecting and calculating at multiple points.

Further, by adjusting the pressing force of the roll 5 according to the diameter of the honeycomb body 1 being wound, the contact surface pressure between the flat foil and the corrugated foil from the central portion to the outer periphery can be maintained more appropriately. it can. That is, the back tension during winding is
The honeycomb body 1 acts so as to be tightly wound, and the action becomes stronger in proportion to the diameter of the honeycomb body 1. When the diameter of the honeycomb body 1 is small, the rotational force is small and there is no particular problem.
However, as the diameter of the honeycomb body 1 increases, the rotational force increases, and sometimes the corrugated foil near the center is crushed and the surface pressure may be reduced. Especially, when the corrugated foil has a small thickness, it becomes remarkable.

In order to avoid this phenomenon, when the diameter of the honeycomb body 1 is small, it is effective to minimize the back tension and increase the pressing force of the roll 5 according to the diameter of the honeycomb body 1 being wound. is there. The pressing force of the roll 5 may be continuously changed according to the diameter increased by winding, but may be changed stepwise.

In the method of the present invention, the number of rolls 5 is three or more in the circumferential direction of the honeycomb body 1, and is appropriately determined according to the diameter of the honeycomb body 1 and the foil thickness. The roll 5 may be an integral type or a split roll type. As the clamping force applying means for the roll 5, in addition to the cylinder 7 using air pressure or hydraulic pressure, a known moving mechanism using a small motor can be adopted. As the shape detecting means of the honeycomb body 1, a laser, a proximity switch, or the like can be adopted in addition to the potentiometer 6.

Next, another example of the method of the present invention is shown in FIG.
Similar to the example of FIG. 1, three or more in the circumferential direction of the outer peripheral surface of the honeycomb body 1 being formed by winding the flat foil 2 and the corrugated foil 3 (see FIG. 1).
Then, three rolls 5 are provided. Then, the honeycomb body 1 is pinched while driving the roll 5. In the example of FIG. 2, the roll 5 is pivotally supported on the tip of the yoke 8, the roll 5 is rotationally driven by the motor 9 attached to the yoke 8, and the yoke 8 is pressed in the radial direction of the honeycomb body 1 by the cylinder 7. 1
Reference numeral 0 denotes a brake roll, which applies a back tension to the flat foil 2 so that the honeycomb body 1 is not loosened. In addition, along the both side surfaces of the honeycomb body 1, on the plane orthogonal to the winding shaft 4,
Although a side plate 10 such as
It is not necessary to sandwich the honeycomb body 1, and it may serve as a guide for preventing winding deviation.

In the example of FIG. 2, the flat foil 2 and the corrugated foil 3 are sandwiched at their tips by a winding shaft 4, the winding shaft 4 is rotated to wind several times, and a honeycomb having a diameter such that the rolls 5 do not contact each other. After the body 1 is formed, the honeycomb body 1 is pinched by the rolls 5 and the rolls 5 are driven to rotate and wind the honeycomb body 1. After the winding is completed, the outermost periphery is fixed by spot welding or the like, and the honeycomb body 1 is taken out. During the winding, the pressing pressure of the cylinder 7 is adjusted according to the rotational peripheral speed of each of the rolls 5 provided in the circumferential direction of the honeycomb body 1 and the diameter of the honeycomb body 1 during the winding. The contact surface pressure between the corrugated foil 2 and the corrugated foil 3 is in an appropriate range.

Also in the example of FIG. 2, the number of rolls 5 is
Three or more pieces in the circumferential direction of the honeycomb body 1 are appropriately determined according to the diameter and the foil thickness of the honeycomb body 1. In addition, one to several pieces are appropriately set in the axial direction of the honeycomb body 1 depending on the length of the honeycomb body 1. As the clamping force applying means for the roll 5, in addition to the cylinder 7 using air pressure or hydraulic pressure, a known moving mechanism using a small motor can be adopted. Further, as in the example of FIG. 1, a shape detecting means such as a potentiometer may be provided to adjust the driving force and the sandwiching pressure of the roll 5 according to the shape of the honeycomb body 1 being formed.

As described above, according to the method of the present invention, the contact surface pressure between the flat foil and the corrugated foil is adjusted to an appropriate range from the central portion to the outer peripheral portion of the honeycomb body, so that they are joined to the metal carrier. When it does, the problem of poor joint is solved. In particular,
The effect is exhibited in diffusion bonding. Furthermore, according to the method of the present invention, it is possible to stably manufacture a thin foil honeycomb body having a thickness of less than 40 μm, which has been difficult in the past. By adopting such a thin foil honeycomb body, the temperature of the carrier is quickly raised to a temperature of 300 ° C. or higher at which the catalyst acts at the initial stage of engine startup, so that the exhaust gas purification capability is further improved. Further, since the resistance of the exhaust gas passing through the honeycomb body is reduced, the engine output loss is further reduced.

[0019]

【Example】

Inventive Example-1: An Al-containing stainless steel flat foil having a thickness of 50 μm and a width of 100 mm, and a corrugated corrugated corrugated foil having a wave height of 1.22 mm are wound by the method of FIG. 1 to form a honeycomb having a diameter of 100 mm. Manufactured body. It was adjusted by the potentiometer 6 and the cylinder 7 so that the distance between the three rolls 5 and the winding shaft 4 was always constant. The pressing force of each roll 5 is 20kgf and the back tension is 5kg.
f The appearance of the obtained honeycomb body was good with no collapse of the corrugated foil and no gap between the flat foil and the corrugated foil.

Invention Example-2: Thickness 30 μm, width 100
mm of Al-containing stainless steel flat foil and corrugated corrugated corrugated foil having a wave height of 1.22 mm were wound by the method shown in FIG. 1 to produce a honeycomb body having a diameter of 100 mm. It was adjusted by the potentiometer 6 and the cylinder 7 so that the distance between the three rolls 5 and the winding shaft 4 was always constant. The pressing force applied by each roll 5 was 18 kgf until the honeycomb body had a diameter of 50 mm, and thereafter 15 kgf. The back tension was 3kgf. The appearance of the obtained honeycomb body was good with no collapse of the corrugated foil and no gap between the flat foil and the corrugated foil.

Inventive Example-3: A flat foil and a corrugated foil having the same foil thickness of 50 μm as in Inventive Example-1 were wound by the method shown in FIG.
A honeycomb body having a diameter of 100 mm was manufactured. 3 rolls 5
The rotational peripheral speed was set to 8 m / min at the initial stage and up to 20 m / min after the honeycomb body diameter was 50 mm. The pressing force by each roll 5 is 20kgf and the back tension is 5kg.
It was set to kgf. The appearance of the obtained honeycomb body was good with no collapse of the corrugated foil and no gap between the flat foil and the corrugated foil.

Conventional Example-1: Same foil thickness as in Invention Example-1 of 5
A 0 μm flat foil and a corrugated foil were sandwiched by the side plate 10 without using the roll 5 and wound with a back tension of 15 kgf. When observing the appearance of the obtained honeycomb body, crushing of the corrugated foil occurred in the center area within a diameter of 30 mm, and the wave height became small. I was seen.

Conventional Example-2: Same foil thickness 3 as Inventive Example-2
A 0 μm flat foil and a corrugated foil were sandwiched by the side plate 10 without using the roll 5 and wound with a back tension of 10 kgf, but the corrugated foil was crushed and wound to a predetermined diameter as in Conventional Example-1. I couldn't. Further, the honeycomb body was wound with a back tension of 5 kgf, but the winding was not enough, and when the honeycomb body was pushed in the axial direction, it easily became a telescope shape.

The honeycomb bodies obtained in Examples 1 to 3 of the present invention and Conventional Example 1 were fitted into an Al-containing stainless steel outer cylinder and heated in a non-oxidizing atmosphere for diffusion bonding to form a metal carrier. Manufactured. About these, the joining state was evaluated by the cold pressing evaluation method as shown in FIG. That is,
The metal carrier was cut to a thickness of 30 mm to prepare a test metal carrier 15. Next, the stepped cradle 1 placed horizontally
6, the metal carrier 15 is placed with its axis vertical, and the stepped punch 17 is pushed into the metal carrier 15 from above at room temperature, and the load is measured by the load cell 18 and the displacement amount is measured by the displacement meter 19. -A displacement curve was created.

The results are shown in FIG. In all of the examples (a) to (c) of the present invention, no peeling of the joint was observed, and a good plastic deformation curve was drawn. In Conventional Example-1 of (d), defective bonding and peeling were observed between the flat foil and the corrugated foil and between the honeycomb body and the outer cylinder, and a drastic decrease in the load due to this was observed. It was the same as when the honeycomb bodies were insufficiently bonded and opened.

[0026]

INDUSTRIAL APPLICABILITY According to the present invention, when a honeycomb body used for a metal carrier of an exhaust gas purifying catalyst of an internal combustion engine for automobiles, boilers, power generators, etc. is manufactured, a flat foil and a corrugated foil are wound in layers. A method for forming a honeycomb body during winding from the outer peripheral surface by 3
While sandwiching with more than one roll, back tension is applied to the flat foil, preferably the roll is driven, and more preferably the roll pressure is adjusted according to the diameter of the honeycomb body. The contact surface pressure can be made appropriate from the central part to the outer peripheral part of the honeycomb body. Furthermore, a thin foil honeycomb body having a foil thickness of less than 40 μm can be stably manufactured.

Therefore, the metal carrier obtained by bonding the flat foil and the corrugated foil of the honeycomb body manufactured by the method of the present invention by diffusion bonding or the like has high bonding reliability and no defective bonding. Further, the thin foil metal carrier further improves the exhaust gas purifying ability at the initial stage of engine startup and further reduces the loss of engine output.

[Brief description of drawings]

FIG. 1 is an explanatory diagram showing an example of the method of the present invention.

FIG. 2 is an explanatory diagram showing another example of the method of the present invention.

FIG. 3 is an explanatory diagram of an evaluation method in an example.

FIG. 4 is a graph showing evaluation results in Examples,
(A) to (c) are examples of the present invention, and (d) is a conventional example.

FIG. 5 is an explanatory diagram showing an example of a conventional method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Honeycomb body 2 ... Flat foil 3 ... Corrugated foil 4 ... Winding shaft 5 ... Roll 6 ... Potentiometer 7 ... Cylinder 8 ... Yoke 9 ... Motor 10 ... Side plate 11 ... Brake roll 12 ... Sliding plate 13 ... Spring 15 ... Metal carrier 16 ... Stepped cradle 17 ... Stepped punch 18 ... Load cell 19 ... Displacement meter

Claims (3)

[Claims] 1. A method of forming a honeycomb body by winding a flat foil and a corrugated corrugated foil obtained by corrugating the flat foil around a winding shaft to form three or more rolls in a circumferential direction of an outer peripheral surface of the honeycomb body. A method for winding a honeycomb body, which comprises arranging the honeycomb body, pressing the honeycomb body with the rolls, and applying back tension to the flat foil before winding to wind the honeycomb body. 2. The method for winding a honeycomb body according to claim 1, wherein three or more rolls arranged are driven. 3. The method for winding a honeycomb body according to claim 1, wherein the roll pressing force is adjusted according to the diameter of the honeycomb body being wound.