JPH09173869A - Manufacture of plain foil with projecting strip for metal honeycomb form and device therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a plain foil with a projecting foil as a constituent member of a metal honeycomb form on which a catalyst for cleaning an exhaust gas is deposited. SOLUTION: An array of projecting parts consisting of a desired number of projecting parts spaced at a desired interval is formed in the width direction of a long plain foil 1 at a first station S1 comprising a pair of upper and lower rolls A1 , A11 for forming an array of projecting strips. In addition, a second-an n-station forming a desired number of arrays of projecting parts at a desired interval in the longitudinal direction of the plain foil. Further, when a step is completed at the n-station, each of the projecting parts forming the array of projecting parts forms a large number of projecting strips 1b installed parallel with the longitudinal direction of the plain foil and mutually connected to each other.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a novel method for manufacturing an essential constituent member of a honeycomb body (hereinafter, simply referred to as a metal honeycomb body) for carrying an exhaust gas purification catalyst made of metal and having a honeycomb structure. .

More specifically, the present invention relates to a flat strip made of a thin steel plate (hereinafter, referred to as "an essential constituent member of a metal honeycomb body").
It is called flat foil. ) And a corrugated plate material prepared by corrugating the flat foil (hereinafter referred to as corrugated foil), the present invention relates to a novel method for producing a flat foil.

More specifically, the present invention relates to a continuous continuous protrusion which is relatively smaller than the corrugated structure (pitch width, wave height) of the corrugated foil in the width direction (direction orthogonal to the length direction) of a long flat foil. The present invention relates to a novel method for producing a flat foil with a protrusion having the above structure.

[0004]

2. Description of the Related Art A flat strip with a protrusion for a metal honeycomb body according to the present invention is used as an essential constituent member of the metal honeycomb body for carrying an exhaust gas purifying catalyst as described above. . First, in order to help understanding of the positioning of the present invention, a conventional metal honeycomb body and its constituent members will be described.

An example of a conventional constituent member of a metal honeycomb body for purifying exhaust gas and its structure is shown in FIGS.
It is shown in FIG. As shown in the figure, this type of metal honeycomb body (H) is a flat foil (1) made of heat-resistant thin steel plate.
And pile up the corrugated foil (2) alternately (see FIG. 9),
A honeycomb structure manufactured by winding this,
It serves as a base for carrying an exhaust gas purification catalyst (for example, a catalyst system using Pt, Rh, Pd, etc.). The metal honeycomb body (H) is housed and fixed in a metal casing (hereinafter referred to as a metal casing) (C) as shown in FIGS. It is said that. The metal carrier (MS) described above is called a metal support (MetalSupport) or a metal substrate (Metal Substrate) in the industry, and is abbreviated as (M).
S) is used. In this sense, FIGS. 10 and 11 also use the abbreviation (MS). Further, in the metal honeycomb body, the abbreviation symbol (H) is used because of the honeycomb structure. Further, in the metal casing, the abbreviation (C) is used for the casing (Casing).

Various structures have been proposed in the art as the metal honeycomb body (H) which is a main constituent element of the metal carrier (MS). FIG. 9 described above.
The metal honeycomb body (H) shown in FIG. 11 is commonly referred to as a wound type in the industry because the flat foil (1) and the corrugated foil (2) are wound and laminated. . 9 shows a perspective view of a pair of flat foil (1) and corrugated foil (2), which are constituent members of a conventional winding type metal honeycomb body (H), and FIG. A perspective view of a metal carrier (MS) manufactured by fixing a metal honeycomb body (H) of a type inside a metal casing (C),
FIG. 11 shows the metal carrier (MS) shown in FIG.
The front view of is shown.

The above-mentioned conventional wound type metal honeycomb body (H) is, for example, 100 μm or less (preferably 50 μm or less).
flat foil (1) and corrugated foil (2) made of a Fe-20% Cr-5% Al heat-resistant thin steel sheet (.mu.m or less) are alternately stacked to have contact portions, and The honeycomb structure is formed into a single spiral shape and has a large number of mesh-like vent holes (cells) (3) for exhaust gas passages in the axial direction.

In addition to the above-mentioned wound type, a flat foil (1) and a corrugated foil (2) are used as the metal honeycomb body (H) which is a main component of the metal carrier (MS) in the industry. Various types have been proposed due to the difference in the method for producing the metal honeycomb body (H) from (1).

For example, a flat type and a corrugated layer of a layered type having a structure in which they are in contact with each other in a layered manner and stacked on top of each other, in addition to those disclosed in JP-A-62-173050 and JP-A-62-173051.
No. 3, Special Publication No. 3-502660, JP-A-4-22785
There is known a metal honeycomb body (H) having a radial type, an S-shaped type, a tongue-shaped type, and an X-lap (swastoid) type disclosed in No. 5 and the like. The front (cross-section) shape of the metal honeycomb body (H) is not limited to the circular shape shown in FIGS. 10 to 11, and may be, for example, an elliptical shape, an oval shape, a racetrack shape, a polygonal shape, or any other irregular shape. It may be one of

Then, the conventional metal carrier (M
Since S) is used under severe thermal environmental conditions such as an exhaust gas system, the contact parts of both foil materials (flat foil and corrugated foil) forming the metal honeycomb body (H) are firmly fixed. To be done. This is because the metal honeycomb body (H), which is a main component of the metal carrier (MS), is exposed to the high temperature of the exhaust gas itself and the high temperature generated by the exothermic reaction between the exhaust gas and the exhaust gas purification catalyst. This is because a large thermal stress is applied to each element under such a high temperature atmosphere, and the elements are firmly fixed by a fixing means such as brazing or welding so as to withstand the thermal stress. As the above-mentioned fixing means, a brazing method is widely adopted because of its uniform bonding strength and certainty.

In the above-mentioned brazing method, the brazing material to be used is, for example, Ni-based or Ni-Cr because it is used under the high temperature atmosphere of the metal carrier (MS).
It is an expensive brazing filler metal for high temperature such as a system, and it is strongly demanded to reduce its usage amount from the economical viewpoint. Further, the demand for reducing the amount of brazing filler metal used is that the contact area between the contact portions of both foil materials (corrugated foil and flat foil) becomes large,
The amount of brazing filler metal used increases, which causes problems such as a decrease in heat resistance of both foil components due to an alloying reaction and a diffusion reaction between the brazing filler metal component and the metal components of both foil components, as well as deactivation of the catalyst. From this viewpoint, there is a strong demand for reduction of the amount of brazing filler metal used. In order to meet the above-mentioned needs, the present invention uses a flat foil with protrusions instead of the normal flat foil (1) as a constituent member of the metal honeycomb body (H). The present invention seeks to provide a new and efficient manufacturing process for strip-shaped flat foil.

In the industry, the flat foil (1) is microcorrugated (microcorrugated) with respect to the approach of forming the metal honeycomb body (H) using the flat foil (1) and the corrugated foil (2) as constituent members. The approach of substituting the flat foil (1a ′) with a microwave (small wave) having a microwave and a small wave is also adopted. FIG. 12 shows an approach for constructing a metal honeycomb body (H) by using the flat foil (1a ′) with the microwave (small wave), in which a set of microwaves (members of the metal honeycomb body (H) ( Fig. 3 shows a perspective view of a flat foil (1a ') with small waves and a corrugated foil (2).

As shown in the figure, the microwave (small wave, micro corrugation) has a waveform in the width direction of the long flat foil (direction orthogonal to the length direction of the long flat foil). It is known in the art that the corrugated structure of the flat foil (1a ′) with the microwave (small wave) is generally smaller than the corrugated structure of the corrugated foil (2). More specifically, for example, The corrugated structure of the corrugated foil (2) is configured with a wave pitch width of 2 mm to 5 mm and a wave height of 1 mm to 2.5 mm. On the other hand, flat foil with microwave (small wave) (1a
The corrugated structure of ′) has a wave pitch width of 0.5 mm to 2 mm,
It is configured with a wave height of 0.1 mm to 1 mm. In addition,
The flat foil with protruding strips of the present invention described later is an alternative to the flat foil (1a ′) with the microwave (small wave), and has a relatively small groove structure as described above.

FIG. 13 shows the superiority when a flat foil (1a ') with a microwave (small wave) is used instead of the normal flat foil (1) as a constituent member of the metal honeycomb body (H). Is. Note that FIG. 13 is a partially enlarged view of a metal honeycomb body (H) including a flat foil (1a ′) with a microwave (small wave) and a normal corrugated foil (2). As shown in the figure, the exhaust gas flow passing through the inside of the metal honeycomb body (H) not only flows in the exhaust gas passage direction (F) but also splits in various directions by the microwave (small wave) (1b ′) ( Fa, Fb, Fc). That is, the exhaust gas flow is efficiently agitated and turbulent inside the metal honeycomb body (H) by the microwave (small wave) (1b ′), which increases the contact reaction with the supported catalyst and exhausts the exhaust gas. It improves the gas purifying ability.

A flat foil (1a) with a microwave (small wave)
′) And the corrugated foil (2) are joined by the microwave (small wave) (1b ′) in a state where the contact portions (1c ′) of both foil materials (1a ′, 2) are spot-joined. Regarding the relation that the structure of the contact portion between the flat foil (1a ′) with the microwave (small wave) and the corrugated foil (2) is in the point-bonding state, the ordinary flat foil (1) and corrugated foil (2) It can be said that the contact portions of () are joined in a surface-joined state (or in a line-joined state when viewed in the exhaust gas passage direction). This means that by using the flat foil (1a ') with a microwave (small wave), the brazing of both foil materials can be economically performed. Further, by applying microwaves (small waves) to the flat foil, it is possible to effectively absorb and relax the deformation force based on the thermal stress generated inside the metal honeycomb body (H). As will be described later, the flat strip with a protruding strip of the present invention is an alternative to the flat foil with a microwave (small wave) described above. Therefore, with respect to the flat foil with protruding strips of the present invention, the same symbols as those used to describe the flat foil with microwaves (small waves) are adopted.

As described above, the superiority of the flat foil (1a ') with a microwave (small wave) over the ordinary flat foil (1) is clear. However, the method of using the flat foil is efficient and economical. It is a big problem whether to form microwaves (small waves) in the. As a method for producing a flat foil (1a ') with a microwave (small wave) in the art, for example, Japanese Patent Laid-Open No. 62-27
One approach is proposed in the 9032 publication.

The method disclosed in Japanese Patent Laid-Open No. 62-279032 for producing the flat foil (1a ') with a microwave (small wave) is as follows. (i) A pair of upper and lower corrugated forming rolls having a large number of grooves along the axial direction (which coincides with the length direction of a flat foil continuous in a strip shape) on the surface of the taper-shaped roll main body are arranged in the longitudinal direction of the flat foil. (Ii) a part of the flat foil in the longitudinal direction,
Clamping and holding by the pair of upper and lower waveform forming rolls,
(iii) rolling the corrugated forming roll in the width direction of the flat foil (direction orthogonal to the length direction of the flat foil), forming a taper shape in the longitudinal direction of the flat foil, and corrugating in the width direction. Forming a tapered corrugated portion, (iv) next, the wide side portion of the tapered corrugated plate portion, and the portion continuous with the wide side portion (the portion of the flat foil that has not been treated with the tapered roll) While the corrugating roll is gripping the groove (corrugated plate groove) formed in the wide side portion of the tapered corrugated portion, the corrugating roll is pressed by the corrugating roll, and (v) same as the process of (iii) above. Roll the corrugated forming roll in the width direction of the flat foil,
A flat foil with a microwave (small wave) is manufactured by repeating the processes (iii) to (v).

In the processes of (ii) to (iii), the pair of upper and lower corrugating rolls substantially holds the central portion (intermediate portion in the width direction) of the flat foil by sandwiching it, and It is forced to roll toward one end of the plate width, reversely rotate there, proceed to the other end of the plate width on the opposite side, and then rotate forward again to return to the center of the plate width. In addition, (iv)
In the process, the pair of upper and lower corrugated forming rolls that have returned to the central portion of the plate width are stopped, opened up and down, and return-moved from the forming end point to the forming start point (or conversely, the flat foil may be moved intermittently). You are forced to operate.

As is clear from the above description, the method for producing a flat foil (1a ') with a microwave (small wave) proposed in JP-A-62-299032 has room for improvement from the viewpoint of productivity. It is something to leave.

[0020]

DISCLOSURE OF THE INVENTION The present invention was devised in view of the limitations of the prior art regarding the method for producing a flat foil with a microwave (small wave) useful as a constituent member of the metal honeycomb body (H). . The present invention is intended to provide a flat foil with a protrusion having a special structure having the same excellent characteristics, and a method for producing the flat foil, instead of the flat foil with a microwave (small wave) described above.

The present inventors diligently studied a flat foil material which can be substituted for the flat foil with a microwave (small wave) and an efficient manufacturing method thereof. As a result, the flat foil for the metal honeycomb body (H) is made of a material that is thin and has poor elongation,
For example, Fe-Cr (20%)-Al (5
%) Type heat-resistant steel foil, and also the fact that the microwave corrugated structure is composed of relatively small ones. A flat foil with a conventional microwave (small wave) by converting a conventional microwave (small wave) into a ridge (or a concave line) formed by connecting small protrusions by a method of continuously operating a platform or a multi-stage platform. It was found that a flat foil with convex stripes, which is a substitute for, can be manufactured efficiently and economically.

In addition, since the starting material is thin as described above, in the projecting strip forming device that connects the small projecting portions to form a projecting strip, the pair of upper and lower projecting row forming rolls are It has been found that both rolls do not have to be made of metal, and one roll can be made of a hard and elastic cylindrical roll made of rubber or synthetic resin. The present invention was developed on the basis of the above-mentioned findings, and according to the present invention, a flat strip with a protruding strip that replaces the conventional flat foil with a microwave (small wave) useful as a constituent member of the metal honeycomb body (H) is provided. An efficient and economical method of manufacturing a foil is provided.

[0023]

The present invention will be described in brief. The present invention is used with a corrugated strip (corrugated foil) as a constituent member of a metal honeycomb body for carrying an exhaust gas purifying catalyst. In the method for producing a flat foil with a plurality of protrusions for a metal honeycomb body, a long flat foil is formed by (i). In the first step, (i) -1. The desired spacing (d) in the direction perpendicular to the length of the flat foil
₂ ) A protrusion row (A) consisting of a desired number of protrusions (a)
And (i) -2. In the longitudinal direction of the long flat foil,
Desired rows are sequentially formed at desired intervals (d ₁ ) in the protrusion row (A), and (ii). The second to nth steps (n) in which the first step is repeated.
Is a desired integer greater than or equal to 2), (ii) -1. When paying attention to a set of protrusion rows (A) and protrusion rows (A) arranged at the interval (d ₁ ). , A similar protrusion row (A) is formed between the pair of protrusion rows (A) and the protrusion row (A) by the second step to the nth step, and (ii) -2. At the end of the n-th process, each of the protrusions (a) forming the protrusion row (A) is arranged in parallel with each other in the longitudinal direction of the flat foil, and a plurality of protrusion lines (1
The method for producing a flat foil with a protrusion strip for a metal honeycomb body, comprising forming the protrusion row (A) so as to form b).

[0024]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The technical constitution and embodiments of the present invention will be described below in detail with reference to the drawings. It goes without saying that the present invention is not limited to the illustrated one.

FIGS. 1 to 5 are views for explaining a first embodiment for producing a flat foil with protrusions (1a) from a long flat foil (starting material) (1) of the present invention. .

FIG. 1 is a view for explaining an apparatus (projection strip forming apparatus) (S) applied to the method for manufacturing a flat strip with projection strips (1a) according to the first embodiment of the present invention. That is, the protruding strip forming apparatus (S) is as shown in FIG. 3 in (i) the width direction of the long flat foil (1) (direction orthogonal to the length direction of the long flat foil). And forming a projection row (A) consisting of a desired number of projections (a) at a desired interval (d ₂ ), and (ii)
A pair of upper and lower cylindrical protrusions capable of continuously forming the protrusions (A) at desired intervals (d ₁ ) in the lengthwise direction of a long flat foil. Forming rolls (A ₁ , A
₁₁ ) 1st station (roll stand)
(S ₁ ), and stations having the same configuration as the first station are arranged in n stages from the second station to the n-th station (S = S ₁ + S ₂ + ... Sn).

FIG. 2 shows the first of the protruding strip forming device (S).
It is a perspective view of a station (S ₁ ). As shown in FIG. 2, the first station (S ₁ ) forms a projection row (A) including a desired number of projections (a) arranged at the desired spacing (d ₂ ). Therefore, it is composed of a pair of upper and lower protrusion row forming rolls (A ₁ , A ₁₁ ). The upper protrusion row forming roll (A ₁ ) is made of a hard and elastic rubber or synthetic resin roll. More specifically, the upper projection row forming roll (A ₁ ) is composed of a hard and elastic polyurethane roll. Further, the lower protrusion row forming roll (A ₁₁ ) is configured by a roll having a metal tooth profile (tooth formation for protrusion formation).

In the present invention, the heat-resistant steel foil which is a starting material for forming the row of protrusions (A) is specifically Fe-C.
Since the r (20%)-Al (5%) heat-resistant steel foil is an extremely thin material (for example, having a wall thickness of 50 μm or less) and an extremely low elongation property, a pair of protrusions as described above is used. It is useful for the construction of the station to use one of the sub-row forming rolls as a roll made of hard and elastic rubber or synthetic resin. In this case, when forming each protrusion (a), a pair of upper and lower protrusion row forming rolls (A _{1, A)
Since} the flat foil (1) sandwiched between ₁₁ ) is smoothly formed with the elastic deformation of the rubber or synthetic resin roll on the upper side at the time of forming each protrusion (a), the protrusion (a) is formed. Prevents tearing and thinning. Further, in the present invention, as described above, it is economical to configure one pair of upper and lower projection row forming rolls with one roll being a non-metallic rubber or synthetic resin roll and the other being a metal tooth profile roll. That is.

In the present invention, it goes without saying that both the pair of upper and lower protrusion row forming rolls (A ₁ , A ₁₁ ) may be made of metal. Further, in the present invention, the protruding strip forming device (S = S ₁ + S ₂ + ... S
Next to the final station (Sn) of n), at least one pair of upper and lower straightening rolls may be provided to make the shape of each protruding strip (1b) formed (not shown) uniform. . This is because, when passing through each station, the projection (a) formed at the station at the previous stage may be crushed by the projection row forming roll of the station and the shape of the projection strip (1b) may be deformed. Yes, it is a corrective measure for that.

As shown in FIG. 2, the pair of upper and lower protrusion row forming rolls (A ₁ and A ₁₁ ) is a biaxial roller using a power transmission gear in order to accurately maintain the distance between them. Is preferably driven to rotate. That is, in the pair of upper and lower protrusion row forming rolls (A ₁ and A ₁₁ ) for forming the protrusion (a), one roll is rotationally driven by the motor with reduction gear (M) as shown in the figure. It is fixed to the drive shaft (41). The other roll is fixed to the passive shaft (non-driving shaft) (42). The protrusion row forming rolls (A ₁ , A ₁₁ ) are rotated by meshing rotation of the power transmission gears (43, 44) fixed to the drive shaft (41).
It is rotated in the opposite direction. It goes without saying that a ring gear system, a universal joint system or the like may be adopted as the driving force transmission system instead of the gear direct coupling system. In the figure, reference numerals (45, 46) denote frame portions provided upright on both sides of the pair of upper and lower protrusion row forming rolls (A ₁ , A ₁₁ ). The drive shaft (41), the bearing portion between the passive shaft (42) and the frame portion (45, 46), and the gap adjusting mechanism between the shafts (41, 42) may be appropriately configured. With the above-described configuration, the distance between the pair of upper and lower protrusion row forming rolls (A ₁ , A ₁₁ ) can be accurately controlled to form a protrusion strip similar to a uniform corrugated structure.

3 to 4 show the most characteristic points of the method for manufacturing the flat foil with a protrusion (1a) of the present invention. FIG. 3 shows the projection row (A) formed on the flat foil (1) as the starting material in the first station (S ₁ ) (see FIGS. 1 and 2) of the projection strip forming apparatus (S). It is for explaining the structure. In addition, in FIG. 4, by arranging a large number of stations, each protrusion (a) forming each protrusion row (A) is provided on each of the corresponding protrusions (a) of the adjacent protrusion row (A). FIG. 3 is a schematic diagram showing a state in which a flat strip (1a) with a protrusion strip, which is sequentially connected and finally has a plurality of protrusion strips (1b) in the width direction of the flat foil (1), is manufactured.

As shown in FIGS. 3 to 4, the flat strip (1a) with protrusions of the present invention is manufactured as follows. As shown in FIG. 3, in the first station (S ₁ ), the flat foil (1) as a starting material is
A desired number of protrusions (a) are formed at a desired distance (d ₂ ) in the width direction of the flat foil (1), and a desired distance (d 1) in the length direction of the flat foil ( ₁ ). A desired row (two rows are shown in FIG. 3) is formed to form the projection row (A).

In the present invention, the shape of each of the protrusions (a) forming the row of protrusions (A) may be a desired shape. However, in the arrangement of the multi-stage stations, the distance (d ₁ ) between the protrusion rows (A) is gradually changed by gradually changing the formation position of the protrusions (a) in the length direction of the flat foil (1). In order to form one protrusion strip (1b), it is preferable that the diameter (d ₃ ) of the flat foil (1) in the length direction of the protrusion (a) is long. There is no such thing. This theoretically requires a station of (d ₁ / d ₃ ) in order to connect the protrusions (a) between the respective protrusion rows (A) to form the protrusion stripes (1b). It is clear from this. FIG. 4 shows a state in which the protrusion strip (1b) is gradually completed in the higher-order station in the protrusion strip forming device (S) including a multi-stage station.

Flat foil (1a) with protruding strips (1b) of the present invention
The second characteristic point of the manufacturing method of is shown in FIG. That is, depending on the structure (height, length, etc.) of each protrusion (a) of each protrusion row (A) as an initial condition, the width (Wo) of the flat foil (1) of the starting material The width (Wn) of the flat foil with protrusions (1a), which is the final product, can be made substantially the same. The structure of each projection (a) of each projection row (A) as the initial condition, in other words, the structure of the projection strip (1b) to be finally formed is the metal honeycomb body (H) of this type. ) The corrugated structure of the corrugated foil used as the constituent member is relatively small.

FIG. 5 is a sectional view (enlarged view) taken along the line II of FIG.
FIG. 4 is a cross-sectional structure of a flat strip with protrusions (1a) manufactured by the manufacturing method according to the first embodiment of the present invention. The corrugated structure of the corrugated foil, which is a constituent member of the metal honeycomb body (H), generally has a pitch width of 2 mm to
It is 5 mm and the wave height is 1 mm to 2.5 mm. On the other hand, the structure of the flat foil with protrusions (1a) of the present invention is relatively small as compared with the corrugated structure of the corrugated foil. For example, as shown in FIG. 5, the distance (d ₂ ) between the protrusions (corresponding to the pitch width of the corrugated foil) is 1.0 mm.
~ 1.3 mm, the height (h) of the protrusion is 0.3 mm to 0.5
mm.

As shown in FIG. 5, the protrusion strips (1b) produced by the first embodiment of the method for producing a flat foil with protrusion strips (1a) of the present invention are convex upward (or downward). Convex). This type of protruding strip (1b) has the same function as the microwave (small wave) of the conventional flat foil with microwave (small wave) (see FIG. 12). As a structure of the protruding strips (1b) of the flat foil with protruding strips (1a) of the present invention, the protruding strips are alternately arranged in a concave shape and a convex shape when viewed in the width direction of the flat foil, as described later. Needless to say, it may be a pseudo-microwave (pseudo-small wave), in other words (see FIG. 8).

FIG. 6 shows a flat foil (1a) with a protrusion strip according to the present invention.
It is a figure explaining 2nd embodiment of the manufacturing method of. In the first embodiment, the multi-stage station (S ₁ + S ₂ + ... + S
n) is used to manufacture the flat strip with a protruding strip (1a) using the protruding strip forming apparatus (S) (see FIG. 1),
The second embodiment is characterized in that the protruding strip forming device (S) including only the first station (S ₁ ) is used.

In the case of the second embodiment, it is formed by passing the flat foil (1) a desired number of times (theoretical number of times d ₁ / d ₃ .times. Or more), that is, during the subsequent pass. The protruding portion (a) grows in the length direction of the flat foil (1),
Finally, the protrusion strip (1b) may be formed. It should be noted that the method of growing the above-mentioned (a) into the protruding strip (1b) is such that the protruding strip (1) is successively connected to the protruding strip (a) formed during the previous pass.
Needless to say, the protrusions (a) may be intermittently formed, and the protrusions (1b) may be finally grown. . The second embodiment is a batch type, but since it has one station, it is an economical manufacturing method. In addition,
In the present invention, the flat foil (1) is treated with a theoretical number (d ₁ /
If less than d ₃ ) is passed, the height of the protruding strips (1b) is not constant in the longitudinal direction of the flat foil (1), so that a flat foil with protruding strips is obtained. It is to be understood that the flat foil with protruding strips (1a) of the present invention also includes the above-mentioned embodiments. Furthermore, in the present invention, the protrusion strips (1b) may not necessarily have a structure in which the protrusions (a) having a desired height are completely connected. Flat foil with protrusions of the present invention (1a)
Should be understood to include the above-mentioned aspects.

FIG. 7 to FIG. 8 are views for explaining a third embodiment of the method for producing the flat foil with protrusions (1a) of the present invention. A characteristic point of the third embodiment is the configuration of a pair of upper and lower cylindrical projection row forming rolls, and FIG. 7 shows the projection row forming rolls (A ₁ , A ₁₁ ) of the first station (S ₁ ). It is a schematic diagram showing a configuration of. As shown in the figure, (i) the upper cylindrical projection row forming roll (A ₁ ) is a synthetic resin (hard urethane roll) roll having a desired width that elastically deforms and a metal tooth type roll having a desired width. That is, the metal tooth type rolls for forming the projections (a) are alternately arranged, and,
(ii) The lower cylindrical protrusion row forming roll (A ₁₁ ) is a synthetic resin roll that is elastically deformable of the upper protrusion row forming roll (A ₁ ) and has a metal tooth type roll and the upper protrusion. Synthetic resin rolls elastically deformable to the metal tooth type rolls of the partial row forming rolls (A ₁ ) are alternately arranged in a corresponding positional relationship. The upper and lower projection row forming rolls (A ₁ , A ₁₁ ) have the projections (a) formed on the flat foil (1) which is the starting material, and the projections formed in the previous stage. It goes without saying that they are adhered by a pressing force that does not crush (a).

FIG. 8 is a cross-sectional view (enlarged view) of the flat strip (1a) with a projection strip manufactured by using the projection row forming rolls (A ₁ , A ₁₁ ) shown in FIG. It is a figure corresponding to the said FIG. As shown in FIG. 8, in the third embodiment, a corrugated structure simulating the microwave (small wave) (1b ′) of the conventional technique (see FIG. 12) is manufactured.

[0041]

EFFECT OF THE INVENTION The method for producing the flat foil (1a) having the protrusions, which is useful as a constituent member of the metal honeycomb body (H) of the present invention, uses the flat foil (1) as a starting material in a single roll stand system. At the time of forming a protrusion in a station or a multi-stage station, the protrusions are sequentially formed on the flat foil (1) in a dot shape, and the protrusions are allowed to grow into linear substantially continuous stripes. The protrusion strips having the same function as a wave (small wave) are continuously formed on the flat foil (1). The above-mentioned approach in which the point projections are sequentially grown in the single station or the multi-stage station to form the projection stripes is selected in relation to the characteristics of the starting material (the thickness of the starting material, the processing characteristics of the starting material). It is a thing.

As described above, the method of manufacturing the flat foil with a protrusion (1a) of the present invention enables continuous operation without using a special device. Further, in terms of the characteristics of the starting material, the protrusion row forming roll, in other words, as the protrusion forming roll, in relation to being particularly thin, is made of a non-metallic hard and elastic rubber or synthetic resin. Since the roll can be used, the device itself can be economically constructed.

The present invention efficiently and economically provides a flat foil with a protruding strip useful as a constituent member of a metal honeycomb body for carrying an exhaust gas purifying catalyst.

[Brief description of the drawings]

FIG. 1 is a multi-stage station (S ₁ to S ₁ to which is applied to the method for producing a flat foil (1a) with a protruding strip according to the first embodiment of the present invention.
It is a figure explaining the protrusion line formation apparatus (S) which consists of Sn).

FIG. 2 is a diagram illustrating a configuration of a first station (S ₁ ) of the protruding strip forming apparatus (S) of FIG.

FIG. 3 is a diagram illustrating a structure of a protrusion row (A) formed on a flat foil (1) under the first station (S ₁ ) of FIG.

4] Under the projecting strip forming device (S) comprising the multi-stage stations (S _{1 to} Sn) of FIG. 1, each projecting part (a) of the projecting row (A) grows linearly. It is a figure explaining the state which goes.

5 is a cross-sectional view (enlarged view) of a flat strip with a protrusion strip (1a) manufactured under the protrusion strip forming device (S) of FIG.

FIG. 6 is a diagram illustrating a method of manufacturing the flat foil with protruding strips (1a) according to the second embodiment of the present invention.

FIG. 7 is a diagram illustrating a first station (a pair of upper and lower protrusion row forming rolls) applied to a method for manufacturing a flat foil with protrusion strips (1a) according to a third embodiment of the present invention.

FIG. 8 is a cross-sectional view (enlarged view) of the flat strip with protrusions (a) manufactured by the method for manufacturing the flat strip with protrusions (1a) of the present invention.

FIG. 9 is a perspective view of a pair of flat foil and corrugated foil, which are constituent members of a conventional wound-type metal honeycomb body.

10 is a perspective view of a metal carrier (MS) including a wound-type metal honeycomb body manufactured using the flat foil and the corrugated foil of FIG. 9 and a metal casing.

11 is a front view of the metal carrier (MS) shown in FIG.

FIG. 12 is a perspective view of another set of a flat foil with a microwave (small wave) and a corrugated foil which are constituent members of a conventional wound-type metal honeycomb body.

FIG. 13 is a diagram illustrating the superiority of a conventional flat foil with a microwave (small wave) over a normal flat foil.

[Explanation of Codes] 1a ………… Flat foil with protruding strip 1b ………… Projecting strip 1 ………… Flat foil 2 ………… Corrugated foil S ………… Projecting strip forming device S ₁ , S ₂ …… Sn ………… Each station of the protruding strip forming device A ₁ , A ₁₁ ………… The upper and lower protruding row forming rolls An, A _n1 ………… of the 1st station Vertical projection row forming roll Wo ………… Flat foil width W ₁ , W ₂ …… Wn ………… Width of flat foil with a projection strip manufactured at each station d ₁ ………… Projection row ( Distance between A) d ₂ ………… Distance between the protrusions (a) that make up the protrusion row (A) d ₃ ………… Length of the protrusion (a) (major axis) F ………… Exhaust gas Passing direction Fa, Fb, Fc ............ Exhaust gas diversion direction

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Office reference number FI technical display location B21D 47/00 ZAB B21D 47/00 ZABC F01N 3/28 301 F01N 3/28 301P

Claims (11)

[Claims] 1. A method for producing a flat foil with a plurality of protrusions for a metal honeycomb body, which is used together with a corrugated strip material (corrugated foil) as a constituent member of a metal honeycomb body for supporting an exhaust gas purifying catalyst. In the method, a long flat foil, (i). In the first step, (i) -1. In the width direction of the long flat foil (direction orthogonal to the length direction of the long flat foil), Desired interval (d
₂ ) A protrusion row (A) consisting of a desired number of protrusions (a)
And (i) -2. In the longitudinal direction of the long flat foil,
Desired rows are sequentially formed at desired intervals (d ₁ ) in the protrusion row (A), and (ii). The second to nth steps (n) in which the first step is repeated.
Is a desired integer greater than or equal to 2), (ii) -1. When paying attention to a set of protrusion rows (A) and protrusion rows (A) arranged at the interval (d ₁ ). , A similar protrusion row (A) is formed between the pair of protrusion rows (A) and the protrusion row (A) by the second step to the nth step, and (ii) -2. At the end of the n-th process, each of the protrusions (a) forming the protrusion row (A) is arranged in parallel with each other in the longitudinal direction of the flat foil, and a plurality of protrusion lines (1
The method for producing a flat foil with a protrusion strip for a metal honeycomb body, comprising forming the protrusion row (A) so as to form b). 2. The protrusions (a) constituting the protrusion row (A) are
The method for producing a flat foil with a projection strip for a metal honeycomb body according to claim 1, wherein the flat foil has a convex shape and a concave shape. 3. A protrusion (a) forming a protrusion strip (1b).
2. The method for producing a flat foil with a projection strip for a metal honeycomb body according to claim 1, wherein the flat foil has a convex shape and a concave shape. 4. The projection (a) forming the projection row (A),
The method for producing a flat foil with a projection strip for a metal honeycomb body according to claim 1, wherein the unevenness is alternately repeated in the width direction of the flat foil. 5. A protrusion (a) constituting a protrusion strip (1b).
2. The method for producing a flat foil with a projection strip for a metal honeycomb body according to claim 1, wherein the flat foil is configured by repeating the uneven portions alternately in the longitudinal direction of the flat foil. 6. The method for manufacturing a flat foil with a projection strip for a metal honeycomb body according to claim 1, wherein the projections (a) forming the projection row (A) have a substantially circular shape. 7. The shape of the projections (a) forming the projection row (A) has a long diameter when viewed in the longitudinal direction of the flat foil.
The method for producing a flat foil with a protrusion for a metal honeycomb body according to 1. 8. The structure of the protruding strip (1b) is such that
The flat with protrusion strips for a metal honeycomb body according to claim 1, wherein the distance (d ₂ ) between b) is 0.5 mm to 2.0 mm, and the height of the protrusion (a) is 0.05 mm to 1 mm. Method of manufacturing foil. 9. A protruding strip forming apparatus applied to the method for producing a flat strip with protruding strips for a metal honeycomb body according to claim 1, wherein the protruding strip forming device is a width direction of a long flat foil (long flat foil length). A plurality of pairs of upper and lower cylindrical projection row forming rolls forming a projection row (A) consisting of a desired number of projections (a) at intervals (d ₂ ) in the direction orthogonal to the vertical direction). A protruding strip forming device comprising: 10. The projection strip forming apparatus according to claim 9, wherein the pair of upper and lower cylindrical projection row forming rolls each have a metal projection forming tooth profile made of metal. 11. The projection strip forming apparatus according to claim 9, wherein one of the pair of upper and lower cylindrical projection row forming rolls is made of rubber or synthetic resin having elasticity.