JPH09174180A - Manufacture of flat foil corrugated with micro-waves (ripples) for metal honeycomb body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide efficient and economical manufacture of flat foil corrugated with micro-waves (ripples) being an useful structural member of metal honeycomb-body to carry catalyst for purification of exhaust gas. SOLUTION: In the manufacture of the flat foil corrugated with the micro- waves (ripples) as the structural member of metal honeycomb body to carry the catalyst for purification of exhaust gas, when a long length flat foil is sent toward lengthwise direction and passes through a pair of upper and lower corrugation forming roll, a flat foil is passed through at least two or more corrugated stations (S=S1 +S2 +......Sn ; n is 2 or more integer) forming corrugations toward width direction (perpendicular direction to the lengthwise direction of the long-length flat foil), and two or more corrugated stations (S=S1 +S2 +......Sn ; n is 2 or more integer) as well so that tooth profile configuration of corrugation forming roll at each corrugated station may be constituted so as to change pitch width successively from large ones to small ones, and the micro-waves (ripples) are made form toward width direction.

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 band material (hereinafter referred to as a flat foil) made of a thin heat-resistant steel plate, which is an essential constituent member of a metal honeycomb body, and a wave prepared by corrugating the flat foil. The present invention relates to a novel method for producing a flat foil of a plate-shaped strip (hereinafter referred to as corrugated foil).

More specifically, the present invention relates to a corrugated structure (pitch width, wave height) 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 (hereinafter referred to as "corrugated structure"). , A microwave or a small wave), and a novel method for producing a flat foil with a microwave (small wave).

[0004]

2. Description of the Related Art A flat foil with a microwave (small wave) for a metal honeycomb body according to the present invention is used as an essential constituent member of a metal honeycomb body for carrying an exhaust gas purifying catalyst as described above. Is. 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.
Is shown in As shown in the figure, this type of metal honeycomb body (H) is formed by alternately stacking flat foils (1) and corrugated foils (2) made of heat-resistant thin steel plate (see FIG. 6). A honeycomb structure manufactured by roll-forming, which serves as a base for supporting 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. In the industry, the metal carrier (MS) described above is a metal support or a metal substrate.
Substrate) and the abbreviation (MS) is used. In this sense, the abbreviations (M
S) is used. Further, in the metal honeycomb body, the abbreviation symbol (H) is used because of the honeycomb structure. Furthermore, the metal casing is
The abbreviation (C) is used for the 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. 6 described above.
~ The metal honeycomb body (H) shown in Fig. 8 is formed by laminating the flat foil (1) and the corrugated foil (2) in a winding manner, and is commonly called a winding type in the industry. . 6 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. FIG. 8 is a perspective view of a metal carrier (MS) manufactured by fixing a metal honeycomb body (H) of a type inside a metal casing (C), and FIG. 8 is a front view of the metal carrier (MS) shown in FIG. Indicates.

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. 7 to 8, and may be, for example, an elliptical shape, an oval shape, a racetrack shape, a polygonal shape, or another 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 or a diffusion reaction between the brazing filler metal component and the metal components of both foil components, and further, deactivation of the catalyst. This has led to 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 a microwave (small wave) as a constituent member of the metal honeycomb body (H) instead of the normal flat foil (1), and particularly It is intended to provide a new and efficient manufacturing process of a flat foil with a microwave (small wave).

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. 9 shows the microwave (small wave).
In the approach of forming the metal honeycomb body (H) using the attached flat foil (1a), the metal honeycomb body (H)
The perspective view of a pair of flat foil (1a) with a microwave (small wave) and corrugated foil (2) which are the constituent members of FIG.

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) has a corrugated pitch width of 2
mm to 5 mm and wave height of 1 mm to 2.5 mm. On the other hand, the corrugated structure of the flat foil (1a) with a microwave (small wave) has a wave pitch width of 0.5 mm to 2 mm and a wave height of 0.1 mm to 1 mm. The flat foil (1a) with a microwave (small wave) of the present invention, which will be described later, also has the same corrugated structure as described above.

FIG. 10 shows the superiority when a flat foil (1a) with a microwave (small wave) is used in place of the normal flat foil (1) as a constituent member of the metal honeycomb body (H). is there. 10 is a partially enlarged view of the metal honeycomb body (H) including the flat foil (1a) with a microwave (small wave) and the 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 (F) by the microwave (small wave) (1b).
a, Fb, Fc). That is, the exhaust gas flow is the microwave (small wave) inside the metal honeycomb body (H).
By (1b), the mixture is efficiently agitated and turbulent, which increases the catalytic reaction with the supported catalyst and improves the exhaust gas purification ability.

In addition, a flat foil (1) with a microwave (small wave)
The a) and the corrugated foil (2) are joined by the microwave (small wave) (1b) at the contact portions (1c) of the two foil materials (1a, 2) in a point-joined state. Flat foil with microwave (small wave) (1
As far as the structure of the contact portion between a) and the corrugated foil (2) is in a point-bonded state, the contact portion between the ordinary flat foil (1) and the corrugated foil (2) is in the surface-bonded state (or It can be said that they are joined in a line joining state (as viewed in the exhaust gas passage direction). This means that the brazing of both foil materials can be economically performed by using the flat foil (1a) with a microwave (small wave). Furthermore, by applying microwaves (small waves) to the flat foil, it is possible to effectively absorb and relax the deforming force based on the thermal stress generated inside the metal honeycomb body (H).

As described above, the superiority of the flat foil (1a) with a microwave (small wave) over the ordinary flat foil (1) is clear. The formation of microwaves (small waves) is a big problem. In the industry, flat foil with microwave (small wave) (1
Examples of the method for producing a) include, for example, JP-A-62-27903.
One approach is proposed in Japanese Patent Publication No. 2).

The method disclosed in Japanese Patent Laid-Open No. 62-279032 for producing the flat foil (1a) with a microwave (small wave) is roughly 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, the method for producing a flat foil (1a) with a microwave (small wave) proposed in JP-A-62-299032 leaves room for improvement in terms of productivity. It is a thing.

[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 inventors diligently studied a method for producing a flat foil with a microwave (small wave). As a result, the flat foil for the metal honeycomb body (H) is made of a thin material having poor elongation, for example, a Fe—Cr (20%)-Al (5%) heat-resistant steel foil having a thickness of 50 μm. It is noted that the microwave corrugated structure is composed of a relatively small one, and from the characteristics of the material and the corrugated structure, the method of continuously operating the multi-stage station of the roll stand, We have found that a flat foil with a microwave (small wave) can be manufactured efficiently and economically.

Further, since the starting material is thin as described above, it is not necessary to configure the pair of upper and lower corrugating rolls of each station in the multi-stage station, for example, in the initial station, both of which are made of metal. It has been found that a cylindrical roll made of hard or elastic rubber or synthetic resin and having no tooth profile can be used. The present invention was developed based on the above findings, and an efficient and economical method for producing a flat foil with a microwave (small wave) useful as a constituent member of a metal honeycomb body (H) according to the present invention is provided. Provided.

[0022]

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 a method for producing a flat foil with a microwave (small wave) for a metal honeycomb body, a long flat foil is formed by: (i) a pair of upper and lower corrugating rolls for forming a corrugation by feeding the long flat foil in a longitudinal direction. At least two corrugating stations (S = S ₁ + S ₂ +) for forming corrugations in the width direction of the flat foil (direction orthogonal to the length direction of the long flat foil) when passing through
... S _n ; n is an integer of 2 or more), and (ii) the tooth profile structure of the corrugating roll of each of the corrugating stations is
Two or more corrugated stations (S = S ₁ + S ₂ + ...) that are arranged so that the pitch width changes in sequence from large to small.
S _n ), and a microwave (small wave) is formed in the width direction of the flat foil with a microwave (small wave) for a metal honeycomb body.

[0023]

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.

1 to 4 are views for explaining the first embodiment of the method for producing a flat foil (1a) with a microwave (small wave) according to the present invention.

FIG. 1 illustrates an apparatus (S) for forming a microwave (small wave) on a long flat foil (1) composed of a multi-stage station of a roll stand. That is,
Microwave (wavelet) forming device (S) is the first wave with the station (stand) consists of a pair of upper and lower corrugating rolls (A _1, A ₁₎ (S _1), and corrugated station of the arrangement Of the desired n stages (n represents a desired integer of 2 or more) are connected in series (S = S).
₁ + S ₂ + ………… S _n ).

FIG. 2 is a perspective view of the first corrugating station (S ₁ ) of the multi-stage (n-stage) stations.
FIG. 3 shows a microwave (small wave) forming device (S = S ₁ + S ₂ + ...), which is composed of _{first to fourth} stations (S _{1 to} S ₄ ) with n = 4 (4 stages). In S ₄ ), a diagram (schematic diagram) for explaining the microwave (small wave) structure (wave pitch width, wave height) and the change in the width of the starting material (flat wave) (width of the flat foil at each station) in each station. Is. 4, in the microwave (wavelet) with a flat foil which is produced in each station of the microwave (wavelet) forming device (S), the station with each wave (S ₁ to S
It shows a plan view of the flat foil for each n).

As shown in FIGS. 1 and 2, the microwave (small wave) forming device (S) of the present invention is composed of corrugating stations connected to another stage (n stages), and
Each corrugating station is composed of a corrugating roll which is set to a desired size corresponding to the pitch and the wave height of the corrugations that are successively molded with reference to the first corrugating roll.
The tooth heights of the corrugating rolls provided at the corrugating stations do not necessarily have to be changed for each station, and may be the same tooth height. In the case of the above-mentioned aspect, a corrugated forming roll having a tooth height higher than the wave height of the microwave (small wave) to be formed may be used, and the distance between the mounting shafts of the roll may be set as desired. The number of consecutively installed steps (n) may be set as desired. Figure 1
As shown in FIG. 2, the first corrugated station (S ₁ )
Is composed of a pair of upper and lower corrugating rolls (A ₁ , A ₁ ) made of metal and having a tooth shape for applying a microwave (small wave).

The pair of upper and lower corrugated forming rolls (A ₁ ,
A ₁ ) is preferably driven to rotate by a biaxial roller using a power transmission gear in order to maintain the distance between them accurately. That is, in a pair of upper and lower wave forming rolls (A ₁ , A ₁ ) for forming microwaves (small waves), one roll is driven by a drive shaft (M) with a reduction gear as shown in FIG. 41) is fixed. The other roll has a passive shaft (driven shaft) (42).
Fixed to Then, both the corrugated forming rolls (A ₁ ,
A ₁ ) is rotated in the opposite direction by the meshing rotation of the power transmission gears (43, 44) fixed to the drive shaft (41). 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, (45, 46) are corrugated forming rolls (A ₁ , A
₁ ) Shows the frame parts erected on both sides. The drive shaft (41), the passive shaft (42) and the frame part (45, 4)
The bearing portion between 6) and the gap adjusting mechanism between both shafts (41, 42) may be appropriately configured. With the above-described structure, the distance between both corrugating rolls (A ₁ , A ₁ ) is precisely controlled by a microwave having a uniform corrugated structure (small wave).
Can be formed.

As shown in FIGS. 3 to 4, the greatest feature of the present invention is that the flat foil (1) as a starting material is corrugated with microwaves at each corrugation station (S _{1 to} S ₄ ). In processing, the corrugated shape of the microwave is sequentially processed so as to approach the shape of the final corrugated structure.

An example of the specifications shown in FIG. 3 is as follows. In the symbols shown in the figure,
(W) is the width of the flat foil, h is the wave height of the microwave, P is the pitch width of the microwave, and the subscript (number) of each symbol is
The position of the corrugated station is shown. Starting material, flat foil (1): width (Wo) 100 mm, thickness 5
0 μm. First corrugated station (S ₁ ): W ₁ = 97.9 mm,
h ₁ = 0.08 mm, P ₁ = 1.07 mm. Second corrugated station (S ₂ ): W ₂ = 95.8 mm,
h ₂ = 0.12 mm, P ₂ = 1.04 mm. Third corrugated station (S ₃ ): W ₃ = 93.7 mm,
_{h 3 = 0.16mm, P 3 =} 1.02mm. 4th wave station (S ₄ ): W ₄ = 91.6 mm,
h ₄ = 0.20 mm, P ₄ = 1.00 mm.

In the present invention, the microwave (small wave) forming device (S) comprising a roll stand type multi-stage station is used to efficiently convert a flat foil (1a) with a microwave (small wave) having a desired microwave corrugated structure. It can be manufactured well (continuously) and economically. In the structure of the microwave (small wave) forming device (S) of the present invention, the flat foil (1) as a starting material is extremely thin (for example, 50 μm or less). Further, the starting material used for microwave forming, more specifically, the Fe-Cr (20%)-Al (5%) heat-resistant steel foil used for this type of application is inferior in elongation property. It was decided in consideration of this. In the present invention, by adopting a multi-stage station, for example, a multi-stage station having four or more stages, the flat foil (1a) with a microwave (small wave) can be efficiently and economically produced.

Flat foil (1) with microwave (small wave) of the present invention
Other modifications are possible in the manufacturing method of a).
FIG. 5 shows a second embodiment of the method for producing a flat foil (1a) with a microwave (small wave) according to the present invention, particularly the configuration of the first corrugating station (S ₁ ) of the microwave (small wave) forming device (S). Is shown. In the present invention, the flat foil (1) as a starting material for forming a microwave (small wave) is thin as described above. In addition, as described above, the starting material is sequentially corrugated into a corrugated structure having the final design value of the microwave between the multi-stage stations.

That is, in view of the fact that the flat foil (1) of the starting material is thin and the corrugated structure of the microwave of the final design value is formed stepwise, the multistage microwave (small wave) of the present invention is used. In the forming apparatus (S = S ₁ + S ₂ + ... S _n ; n represents a desired integer of 2 or more), at least one of the corrugating rolls of the corrugating station at the initial stage is made of a non-metallic material. It can consist of things. Specifically, one of the corrugating rolls of the corrugating station in the initial stage may be replaced with a synthetic resin roll such as a hard or elastic rubber or urethane roll having no tooth profile. .

FIG. 5 is an explanatory view of the first corrugating station (S ₁ ) of the microwave (small wave) forming device (S) in which the upper corrugating roll (A ₁ ) is made of the synthetic resin. The figure is shown. Two corrugated forming rolls (A
₁ , A ₁ ), that is, the upper synthetic resin corrugating roll (A ₁ ) having no tooth profile and the lower metallic corrugating roll (A ₁ ) are the upper synthetic resin corrugating roll (A _1). )
Due to the elastic deformation of, the boundary surfaces of both rolls are arranged in a pressed state.

Two corrugated forming rolls (A
_In the first corrugation station (S ₁ ) having ₁ , ₁ , A ₁ ), a desired microwave (small wave) (for example, shown in the specifications of the first corrugation station shown in FIG. 3) is efficiently produced. be able to. Further, the first corrugating station of the second embodiment having the above-described structure is economical compared to the first corrugating station of the first embodiment, for example, even if the tooth profile is changed, the rubber roll does not need to be changed. It goes without saying that there is.

[0036]

EFFECTS OF THE INVENTION Flat foil (1a) with a microwave (small wave) useful as a constituent member of the metal honeycomb body (H) of the present invention
The manufacturing method is as follows: Flat foil (1) as starting material is microwaved (small wave) at a multi-stage corrugating station on a roll stand.
When the corrugation processing is performed, the corrugated structure of the microwave can be successively corrugated so as to have the corrugated structure of the final design value. The above-described multi-step and sequential micro-corrugation formation approach has been selected in relation to the properties of the starting material (starting material wall thickness, starting material processing properties).

As described above, the method for producing a flat foil (1a) with a microwave (small wave) of the present invention enables continuous operation without using a special device. In addition, because of the characteristics of the starting material, a non-metallic hard and elastic rubber or synthetic resin roll can be used as a microwave corrugating roll in relation to the fact that it is particularly thin. It can be constructed economically.

According to the present invention, a flat foil with a microwave (small wave) useful as a constituent member of a metal honeycomb body for carrying an exhaust gas purifying catalyst is provided efficiently and economically.

[Brief description of the drawings]

FIG. 1 is a flat foil (1) with a microwave (small wave) of the present invention.
a) A multi-stage station (S ₁ ~
Is a diagram illustrating a microwave consisting S _n) a (wavelet) forming device (S).

FIG. 2 is a diagram illustrating the configuration of a first corrugating station (S ₁ ) of the first embodiment of the microwave (small wave) forming device (S) of FIG.

FIG. 3 is a waveform structure of microwaves manufactured under each wave forming station in a microwave (small wave) forming device (S = S _{1 to} S ₄ ) including _first to fourth wave forming stations. It is a figure explaining.

FIG. 4 is a microwave (small wave) forming device (S = S _{1 to} S _n ) formed by the first to nth wave forming stations, which is manufactured under each wave forming station. It is a top view (schematic diagram) of an attached flat foil.

FIG. 5 is a diagram illustrating a configuration of a first corrugating station (S ₁ ) of a second embodiment of a microwave (small wave) forming device.

FIG. 6 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.

FIG. 7 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. 6 and a metal casing.

8 is a front view of the metal carrier (MS) shown in FIG. 7. FIG.

FIG. 9 is a perspective view of another pair of flat foil with a microwave (small wave) and corrugated foil, which are constituent members of a wound-type metal honeycomb body.

FIG. 10 is a diagram for explaining the superiority of a flat foil with a microwave (small wave) over an ordinary flat foil.

[Explanation of symbols]

1a ………… Flat foil with microwave (small wave) 1b ………… Microwave (small wave) 1c ………… Contact portion between flat foil with microwave (small wave) and corrugated foil 1 ………… Flat foil 2 ………… Corrugated foil S ………… Microwave (small wave) forming device S ₁ , S ₂ , …… S _n ………… Each corrugating station (of microwave (small wave) forming device) A ₁ , A ₁ ………… The upper and lower corrugating forming rolls of the first corrugating station A _n , A _n ………… The upper and lower corrugating forming rolls of the nth corrugating station Wo ………… Flat foil width W ₁ , W ₂ …… W _n ………… Width of flat foil with microwave (small wave) produced at each corrugating station h ₁ , h ₂ …… h _n ………… Microwave produced at each corrugating station height P ₁ of the (wavelet) with a flat foil, P ₂ ...... P _n ............ micro produced in the station with each wave (Wavelet) with a flat foil of a wave pitch F ............ exhaust gas passage direction Fa, Fb, diversion direction of Fc ............ exhaust gas

Claims (4)

[Claims] 1. A flat foil with a microwave (small wave) for a metal honeycomb body, which is used together with a corrugated strip material (corrugated foil) as a constituent member of the metal honeycomb body for supporting an exhaust gas purifying catalyst. In the method, a long flat foil, (i) when the long flat foil is fed in the longitudinal direction and passes through a pair of upper and lower corrugating rolls forming a corrugation, the width direction of the flat foil (long At least two corrugating stations (S = S) for forming corrugations in a direction orthogonal to the length direction of the flat foil)
₁ + S ₂ + ... S _n ; n is an integer of 2 or more), and (ii) the tooth profile structure of the corrugating roll of each of the corrugating stations sequentially changes in pitch width from large to small. 2 or more corrugated stations (S = S ₁ + S ₂ + ...
, S _n ), to form microwaves (small waves) in the width direction, a method for producing a flat foil with microwaves (small waves) for a metal honeycomb body. 2. A long flat foil as a starting material has a thickness of 20 to 1
The method for producing a flat foil with a microwave (small wave) for a metal honeycomb body according to claim 1, wherein the flat foil has a thickness of 00 μm. 3. A microwave (small wave) corrugated structure having a pitch width of 0.5 mm to 2 mm and a wave height of 0.1 mm.
The method for producing a flat foil with a microwave (small wave) for a metal honeycomb body according to claim 2, wherein the flat foil has a thickness of 1 mm. 4. Each corrugated station (S ₁ , S ₂ , ...
The pair of upper and lower corrugated forming rolls (S _n ), one of which is composed of a cylindrical roller made of elastic rubber or synthetic resin and having no corrugation. Method for manufacturing flat foil with waves (small waves).