JPH09276960A - Manufacture of corrugated sheet for honeycomb body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily manufacture a corrugated sheet having different corrugated height at a desired position, in a low cost by pressing the desired position of the corrugated sheet with one pair of pressing blocks after corrugating process. SOLUTION: One pair of the pressing blocks 2, 3 having flat pressing surface 2a, 3a each are prepared and the desired position of the corrugated sheet 1 is pressed with both pressing blocks 2, 3. By this method, since the top parts of each corrugated part in the corrugated sheet 1 is fallen down with the pressing surfaces 2a, 3a of the pressing blocks 2, 3 and crushed, the corrugated sheet 1 before pressing process is worked to the corrugated sheet having partially low corrugated height. In this work, a prescribed value of tension force is given in the longitudinal direction of the corrugated sheet 1 so as to cancell the elongating strain caused by crushing of the corrugated top part of the corrugated sheet 1 to prevent the warp and the waviness of the whole corrugated sheet. Then, such a tension force is set according to the material, thickness, width size of the corrugation, shape, crushing quantity, etc., of the corrugated sheet 1.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for manufacturing a corrugated plate for a honeycomb body.

[0002]

2. Description of the Related Art Conventionally, Japanese Unexamined Patent Publication (Kokai) No. 3-1188839 discloses a method of manufacturing a metal carrier for an exhaust gas purifying catalyst. In this manufacturing method, first, a corrugated plate and a flat plate are overlapped and wound to form a honeycomb body. Then, after disposing the outer cylinder on the outer periphery of the honeycomb body, heating is performed in a non-oxidizing atmosphere to integrate at least the corrugated plate and the flat plate by diffusion bonding to obtain a metal carrier. In the obtained metal carrier, a cell is coated with a catalyst supporting layer such as alumina powder, and the catalyst supporting layer is further supported with a catalyst metal such as Pt to form an exhaust gas purifying catalyst.

In such an exhaust gas purifying catalyst, if the corrugated plate and the flat plate in the honeycomb body are uniformly diffusion-bonded to each other, local buckling or local buckling may occur due to thermal stress due to repeated expansion and contraction during use. Plastic deformation is likely to occur,
This causes defects such as cracks in the honeycomb body. For this reason, in this publication, corrugated plates having partially different wave heights are adopted, whereby at least the contact pressure at the contact portion between the corrugated plate and the flat plate is partially changed to partially increase the bonding strength. Propose to change. Here, as a method for producing a corrugated plate having partially different wave heights, as described in Japanese Utility Model Laid-Open No. Sho 63-170023, a pair of wave shaping variants having peaks and valleys of partially different heights. In general, a roller is prepared, and a flat plate is sandwiched between a pair of wave-shaped irregularly shaped rollers and fed in the longitudinal direction to form a corrugated plate having partially different wave heights.

[0004]

However, the exhaust gas purifying catalyst is different from the corrugated plate in that if the corrugated plate and the flat plate are made of different materials, have different sizes, use conditions, etc., the action of thermal stress during use is different. The effect cannot be obtained unless the portion that changes the bonding strength with the flat plate is changed variously depending on the material and the like. Here, as described above, when it is attempted to make the wave heights partially different at the stage of forming a flat plate into a corrugated plate by a pair of corrugated deforming rollers, depending on the pair of corrugating deforming rollers, only a specific part is formed. The wave height cannot be different. In addition, if the pair of wave-forming irregularly shaped rollers makes one round, the wave heights are always different. Thus, depending on the pair of wave shaping irregular rollers, the portions of the corrugated plate having different wave heights are limited. However, if a plurality of pairs of wave-shaped irregularly shaped rollers are prepared, the manufacturing cost will increase due to a large initial cost.

Further, when a pair of wave-shaped irregularly shaped rollers is used, it is difficult to perform phase matching in which the peaks and troughs of partially different heights of both wave-shaped irregularly shaped rollers are aligned in the circumferential direction. The present invention has been made in view of the above conventional circumstances, and it is an object of the present invention to provide a method for manufacturing a corrugated sheet for a honeycomb body, which can inexpensively and easily manufacture corrugated sheets having different wave heights at desired portions. And

[0006]

[Means for Solving the Problems]

(1) In the method for manufacturing a corrugated plate for a honeycomb body according to claim 1, the corrugated plate and the flat plate are overlapped and wound to form a honeycomb body, and an outer cylinder is arranged on the outer periphery of the honeycomb body, It is used in a method for manufacturing an exhaust gas purifying catalyst carrier in which at least the corrugated plate and the flat plate are integrated by diffusion bonding by heating in an oxidizing atmosphere, and the contact pressure of at least the contact portion between the corrugated plate and the flat plate is adjusted. A method for manufacturing a corrugated sheet for a honeycomb body, in which the joining strength is partially changed by partially changing the corrugated sheet, the corrugated sheet having different corrugated heights is obtained. A wave forming step for obtaining a wave plate having substantially the same wave, and a desired portion of the wave plate is pressed by a pair of pressure blocks after the wave forming step to partially increase the wave height of the wave plate. And a pressurizing step for lowering the pressure.

In the manufacturing method of the first aspect, first, in the wave forming step, a flat plate is formed to obtain a corrugated plate having waves having substantially the same wave height. At this time, it is possible to prepare a pair of wave forming rollers having the same peaks and valleys as a whole, and to adopt a general means for feeding the flat plate in the longitudinal direction while sandwiching the flat plate between the pair of wave forming rollers. For example, since the peaks and valleys of both wave forming rollers are all the same, the phase matching is easy.

Then, in a pressing step after the corrugating step, a desired portion of the corrugated plate is pressed by a pair of pressing blocks.
This partially lowers the wave height of the corrugated sheet. here,
If the pressure positions of the pair of pressure blocks are changed as desired, the parts of the corrugated plate having a low wave height are changed, so that the parts of the corrugated plate having different wave heights are not limited. Further, as long as the wave height is reduced to the same height, it is not necessary to prepare a plurality of pairs of pressure blocks to obtain this effect, and the manufacturing cost can be reduced by the small initial cost. Further, if the pair of blocks each have a flat pressing surface, phase adjustment is not necessary. Even if each block has a convex portion or a concave portion, it is possible to easily perform phase adjustment by moving one of them in parallel. it can.

In this way, since it is possible to variously change the portion for changing the bonding strength depending on the material of the corrugated plate and the flat plate, it is possible to surely alleviate the thermal stress and to prevent the occurrence of cracks in the honeycomb body in the exhaust gas purifying catalyst. Can be prevented. (2) In the method for manufacturing a corrugated plate for a honeycomb body according to claim 2, the corrugated plate and the flat plate are overlapped and wound to form a honeycomb body, and the outer cylinder is arranged on the outer periphery of the honeycomb body, It is used in a method for manufacturing an exhaust gas purifying catalyst carrier in which at least the corrugated plate and the flat plate are integrated by diffusion bonding by heating in an oxidizing atmosphere, and the contact pressure of at least the contact portion between the corrugated plate and the flat plate is adjusted. A method for manufacturing a corrugated sheet for a honeycomb body, in which the joining strength is partially changed by partially changing the corrugated sheet, the corrugated sheet having different corrugated heights is obtained. A wave forming step for obtaining a wave plate having substantially the same wave, and a desired portion of the wave plate is pressed by a pair of pressure blocks after the wave forming step to partially increase the wave height of the wave plate. And a pressurizing step for increasing the pressure.

In the manufacturing method of the second aspect, first, in the wave forming step, as in the manufacturing method of the first aspect, a flat plate is formed to obtain a corrugated plate having waves having substantially the same wave height. Then, in the pressing step after the wave forming step, a desired portion of the corrugated plate is pressed by the pair of pressing blocks. This partially increases the wave height of the corrugated sheet. Here, if the pressure positions of the pair of pressure blocks are changed as desired, the part of the corrugated plate having a high wave height is changed, so that the part of the corrugated plate having a different wave height is not limited. Further, as long as the wave height is increased to the same height, it is not necessary to prepare a plurality of pairs of pressure blocks to obtain this effect, and the manufacturing cost can be reduced by the small initial cost. further,
Even if the pair of blocks each have a convex portion or a concave portion, the phase can be easily adjusted by moving one of them in parallel.

Thus, similarly to the manufacturing method according to the first aspect, it is possible to reliably prevent the occurrence of cracks in the honeycomb body in the exhaust gas purifying catalyst.

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments 1 to 5 which embody the invention described in the claims will be described below with reference to the drawings. (First Embodiment) In the first embodiment, claim 1 is embodied.

"Wave forming step" First, 20Cr-5Al-
Width 100-130 mm and thickness 50 μm consisting of balance Fe
Prepare a flat plate. In addition, a pair of wave forming rollers having peaks and valleys that are all the same are prepared. Then, as shown in FIG. 1, a corrugated plate 1 having a wave having a substantially equal wave height of 1.3 mm is obtained by a general means for feeding the plate in the longitudinal direction while sandwiching the flat plate between the pair of wave forming rollers. At this time, it is easy to perform the phase matching for matching the peaks and valleys of both wave shaping rollers.

"Pressurizing step" Next, as shown in FIG.
A pair of pressure blocks 2 and 3 each having a flat pressure surface 2a and 3a are prepared, and both pressure blocks 2 and 3 press a desired portion (hatched portion S in FIG. 1) of the corrugated plate 1. As a result, the tops of the waves of the corrugated plate 1 are crushed by being pushed down by the pressing surfaces 2a, 3a of the pressing blocks 2, 3, so that the corrugated plate 1 before the pressing step shown in FIG. As shown in FIG. 3B, the corrugated plate 1a having a partially low wave height is processed. During this period, a tensile force of 5 to 10 kgf, preferably 5 kgf is applied in the longitudinal direction of the corrugated sheet 1 so as to cancel the elongation strain caused by the wave of the corrugated sheet 1 being crushed, so that the entire warp or swell of the corrugated sheet 1a is obtained. To prevent. The tensile force is set according to the material, thickness, width, wave size, shape, crushing margin, etc. of the corrugated sheet 1.

Here, if the pressure position S of the pair of pressure blocks 2 and 3 shown in FIG. 1 is changed as desired, the portion S of the corrugated plate 1a having a low wave height is changed, so that the wave height of the corrugated plate 1a is changed. The site S having different lengths is not limited. Further, it is not necessary to prepare a plurality of pairs of pressure blocks to obtain this effect, and the manufacturing cost can be reduced with a small initial cost. Further, since the pair of blocks 2 and 3 have the flat pressing surfaces 2a and 3a, respectively, the phase matching is unnecessary.

A honeycomb body is obtained from the obtained corrugated sheet 1a and the flat plate by a known means, and a metal carrier of 400 cells is obtained by a known means using an outer cylinder. Since the obtained metal carrier uses the corrugated plate 1a having a low wave height at the desired portion S, in the desired portion S, at least the contact portion between the corrugated plate 1a and the flat plate is compared with other portions. The contact pressure is reduced and the joint strength is reduced. The catalyst carrier layer is coated on this metal carrier, and the catalyst metal is further supported on the catalyst carrier layer to form an exhaust gas purification catalyst.

In this way, since the portion S for changing the bonding strength can be variously changed depending on the material of the corrugated plate 1a and the flat plate, etc., the thermal stress is surely relieved, so that the cracks of the honeycomb body in the exhaust gas purifying catalyst are generated. Can be reliably prevented. (Embodiment 2) The second embodiment also embodies claim 1.

"Wave forming step" First, as in the first embodiment,
The corrugated plate 1 shown in FIG. 1 is obtained from the flat plate. "Pressurizing step" Next, as shown in FIG. 4, a pair of pressing blocks 4 having convex portions 4a, 5a having a rectangular cross-section protruding at the same pitch as the waves of the corrugated plate 1 so as to mesh with each other,
Prepare 5 The tips of the protrusions 4a and 5a are flat pressing surfaces 4b and 5b. And both pressure blocks 4,
At 5, a desired portion of the corrugated plate 1 (hatched portion S in FIG. 1) is pressed as in the first embodiment. As a result, only the tops of the waves of the corrugated plate 1 are crushed between the pressing surfaces 4b, 5b and the bottom surfaces of the pressing blocks 4, 5, so that the corrugated plate 1 before the pressing step shown in FIG. Is processed into a corrugated plate 1b having a partially low wave height as shown in FIG. 5 (B).

Thus, also in the second embodiment, the same operation and effect as in the first embodiment can be obtained. Further, according to the second embodiment, since the wave height of the corrugated plate 1b at the desired portion S is stably lowered at a height different from that of the first embodiment, the cells of the honeycomb body are stably maintained almost entirely, and the exhaust gas Does not impair the function of the purification catalyst. (Embodiment 3) The third embodiment also embodies claim 1.

"Wave forming step" First, as in the first embodiment,
The corrugated plate 1 shown in FIG. 1 is obtained from the flat plate. [Pressure Step] Next, as shown in FIG. 6, a pair of pressure blocks 6 and 7 having convex portions 6a and 7a having a substantially rectangular cross-section protruding at the same pitch as the waves of the corrugated plate 1 so as to mesh with each other are provided. prepare. The tip of each convex portion 6a is a contact surface 6b that is aligned with the inner surface of the wave top of the corrugated plate 1. Each convex portion 7a
Has a flat pressing surface 7b. Further, a contact surface 7c that is aligned with the outer surface of the wave top of the corrugated plate 1 is formed on the bottom surface between the respective convex portions 7a facing the contact surface 6b. Then, a desired portion of the corrugated plate 1 (hatched portion S in FIG. 1) is pressed by both pressure blocks 6 and 7 as in the first embodiment. As a result, one of the wave crests of the corrugated plate 1 that protrudes toward the pressure block 6 is crushed between the pressure surface 7 b of the pressure block 7 and the bottom surface of the pressure block 6, while the pressure block 7 is pressed.
What protrudes to the side is only sandwiched between the contact surface 6b of the pressure block 6 and the contact surface 7c of the pressure block 7, so that the wave before the pressure step shown in FIG. Plate 1 is shown in FIG.
As shown in (B), the corrugated plate 1c having a partially low wave height is processed.

Thus, also in the third embodiment, the same operation and effect as in the second embodiment can be obtained. (Embodiment 4) In embodiment 4, claim 2 is embodied. "Wave forming step" First, as in the first embodiment, a flat plate is shown in FIG.
The corrugated sheet 1 shown in is obtained.

"Pressurizing step" Next, as shown in FIG.
A pair of pressure blocks 8 and 9 having convex portions 8a and 9a having a substantially triangular cross section, which project at the same pitch as the waves of the corrugated plate 1 so as to mesh with each other, are prepared. A second convex portion 8b having a curvature smaller than that of the inner surface of the wave top of the corrugated plate 1 and protruding more than the amplitude of the wave is formed at the tip of each convex portion 8a. The tip of each protrusion 9a is a flat holding surface 9b. Further, a concave portion 9c is formed on the bottom surface between the convex portions 9a facing the second convex portion 8b. Then, a desired portion (hatched portion S in FIG. 1) of the corrugated plate 1 is pressed by both pressure blocks 8 and 9 as in the first embodiment. As a result, of the crests of each wave of the corrugated plate 1, the one projecting to the pressure block 9 side is extended by the second protrusion 8b of the pressure block 8, while the one projecting to the pressure block 8 side is pressurized. Since it is only held by the holding surface 9b of the block 9, the corrugated plate 1 before the pressurizing step shown in FIG. 9 (A) has a wave height of a partially high wave as shown in FIG. 9 (B). It is processed into a plate 1d.

Using the obtained corrugated plate 1d, a metal carrier similar to that of the first embodiment is obtained by a known means. Since the obtained metal carrier uses the corrugated plate 1d having a high wave height at the desired portion S, in the desired portion S, at least the contact portion between the corrugated plate 1d and the flat plate is compared with other portions. The contact pressure is improved and the bonding strength is improved. Thus, also in the fourth embodiment, the same operation and effect as in the second embodiment can be obtained. (Fifth Embodiment) In the fifth embodiment, claim 2 is embodied.

"Wave forming step" First, as in the first embodiment,
The corrugated plate 1 shown in FIG. 1 is obtained from the flat plate. [Pressure Step] Next, as shown in FIG. 10, a pair of pressure blocks 10 and 11 having convex portions 10a and 11a having a substantially trapezoidal cross section that protrude at the same pitch as the waves of the corrugated plate 1 are engaged with each other. prepare. Second protrusions 10b and 11b are formed at the tips of the protrusions 10a and 11a, and have a curvature smaller than that of the inner surface of the wave top of the corrugated plate 1 and protrude beyond the amplitude of the wave. In addition, each convex portion 1 facing the second convex portion 10b, 11b
Recesses 10c and 11c are formed on the bottom surface between 0a and 11a. Then, the corrugated plate 1 is formed by the both pressure blocks 10 and 11.
The desired portion (hatched portion S in FIG. 1) is pressed as in the first embodiment. As a result, the crests of the waves of the corrugated plate 1 are held down while the tops of the waves are pressed by the pressure blocks 10,
Since it is extended by the second convex portions 10b and 11b of FIG.
The corrugated sheet 1 before the pressurizing step shown in FIG. 1 (A) is processed into a corrugated sheet 1e having a partially high wave height as shown in FIG. 11 (B).

Thus, also in the fifth embodiment, the same operation and effect as those of the fourth embodiment can be obtained. It is also possible to embody claims 1 and 2 at the same time by combining the pressure blocks 2 to 11. Also, a pressure block having another shape can be adopted.

[0026]

As described above in detail, since the method for manufacturing a corrugated plate for a honeycomb body according to the first and second aspects adopts the means according to the first and second aspects, a wave having a different wave height at a desired portion is used. The plate can be manufactured inexpensively and easily. Therefore, according to the method for manufacturing a corrugated plate for a honeycomb body of claims 1 and 2, it is possible to manufacture an exhaust gas purifying catalyst that has a large effect of relaxing thermal stress and is excellent in structural reliability.

[Brief description of drawings]

FIG. 1 is a perspective view of a corrugated plate according to the first to fifth embodiments.

FIG. 2 is a cross-sectional view of a pressure block and a corrugated plate according to the first embodiment.

FIG. 3 is a cross-sectional view of the corrugated sheet before the pressurizing step, and FIG. 3B is a cross-sectional view of the corrugated sheet after the pressurizing step according to the first embodiment.

FIG. 4 is a cross-sectional view of a pressure block and a corrugated plate according to the second embodiment.

5A and 5B are cross-sectional views of a corrugated sheet before the pressing step and FIG. 5B is a sectional view of the corrugated sheet after the pressing step according to the second embodiment.

FIG. 6 is a cross-sectional view of a pressure block and a corrugated plate according to the third embodiment.

7A and 7B are cross-sectional views of a corrugated sheet before the pressing step and FIG. 7B is a sectional view of the corrugated sheet after the pressing step according to the third embodiment.

FIG. 8 is a cross-sectional view of a pressure block and a corrugated plate according to the fourth embodiment.

9A and 9B are a cross-sectional view of a corrugated sheet before a pressurizing step and a cross-sectional view of a corrugated sheet after a pressurizing step according to the fourth embodiment.

FIG. 10 is a cross-sectional view of a pressure block and a corrugated plate according to the fifth embodiment.

11A and 11B are a cross-sectional view of a corrugated sheet before a pressing step and a cross-sectional view of a corrugated sheet after a pressing step according to the fifth embodiment.

[Explanation of symbols]

 1, 1a to 1e ... Corrugated plate 2 to 11 ... Pressing block S ... Desired site

Claims (2)

[Claims] 1. A honeycomb body is formed by stacking and winding a corrugated plate and a flat plate, and an outer cylinder is arranged on the outer periphery of the honeycomb body, and then heated in a non-oxidizing atmosphere to at least the corrugated plate. It is used in a method for manufacturing a carrier for an exhaust gas purifying catalyst, in which a flat plate and a flat plate are integrated by diffusion bonding, and the bonding strength is partially changed by at least partially changing the contact pressure at the contact portion between the corrugated plate and the flat plate. A method for manufacturing a corrugated sheet for a honeycomb body, wherein the corrugated sheet having different wave heights is partially changed to a corrugated sheet having a substantially equal wave height by molding a flat plate. And a pressure step of partially lowering the wave height of the corrugated plate by pressing a desired portion of the corrugated plate with a pair of pressure blocks after the corrugating process. And a method for manufacturing a corrugated plate for a honeycomb body. 2. A honeycomb body is formed by stacking and winding a corrugated plate and a flat plate, and an outer cylinder is arranged on the outer periphery of the honeycomb body, and then heated in a non-oxidizing atmosphere to at least the corrugated plate. It is used in a method for manufacturing a carrier for an exhaust gas purifying catalyst, in which a flat plate and a flat plate are integrated by diffusion bonding, and the bonding strength is partially changed by at least partially changing the contact pressure at the contact portion between the corrugated plate and the flat plate. A method for manufacturing a corrugated sheet for a honeycomb body, wherein the corrugated sheet having different wave heights is partially changed to a corrugated sheet having a substantially equal wave height by molding a flat plate. And a pressure step of partially increasing the wave height of the corrugated plate by pressing a desired portion of the corrugated plate with a pair of pressure blocks after the corrugating process. And a method for manufacturing a corrugated plate for a honeycomb body.