JPH0947668A - Manufacture of flat foil for metallic honeycomb body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a metallic honeycomb body in which a characteristic for making' exhaust gas to a turbulent flow is excellent by alternately forming an uneven groove having desired height in the cross section at a desired interval in the longitudinal direction of a flat foil and forming an uneven row consisting of an unperforated unevenness part in the cross direction near to both sides of the uneven groove. SOLUTION: A recessed streak groove 1a and a projecting streak groove 1b which have desired height are alternately formed with a desired interval d1 in the direction orthogonal to the passing direction F of exhaust gas at time for being formed into a metallic honeycomb body. Furthermore, uneven rows consisting of arranged parts 11, 12 of an unperforative streak are alternately arranged while keeping a desired interval d2 in the view of the passing direction F of exhaust gas in the parts near to both sides of the respective recessed streak groove 1a and the projecting streak groove 1b. In such a way, when a flat foil consisting of the recessed streak groove 1a and the projecting streak groove 1b is assembled into the metallic honeycomb body, the surface area of the flat foil is increased. Further, exhaust gas flow is made uniformly and effectively into a turbulent flow by the unperforated unevenness part and contact efficiency with a carried catalyst is increased.

Description

Detailed Description of the Invention

[0001]

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

More specifically, the present invention relates to a method for manufacturing a flat plate (hereinafter referred to as a flat foil) made of a thin metal plate which is an essential constituent member of a metal honeycomb body. More specifically, according to the present invention, the flat foil is formed alternately at a desired interval in the longitudinal direction (direction orthogonal to the exhaust gas passage direction when a metal honeycomb body is formed) and the width direction of the flat foil ( Concave groove and convex groove (hereinafter, may be simply referred to as uneven groove) formed in the exhaust gas passage direction in the case of a metal honeycomb body, and a portion near both sides of the uneven groove and the flat foil. The present invention relates to a method for producing a flat foil having a special structure, which has a concavo-convex row composed of non-perforated concavo-convex portions arranged alternately in the width direction.

[0003]

2. Description of the Related Art As described above, the structure of the flat foil, which is an essential constituent member for the metal honeycomb body of the present invention, is special. The related art will be described below in relation to the flat foil having the special structure of the present invention described above. An example of a conventional typical metal carrier for purifying exhaust gas is shown in FIGS. As shown in the figure, a metal carrier of this kind, a flat foil (1 ') made of a heat-resistant thin metal plate and a corrugated strip (hereinafter referred to as corrugated foil) (2') are alternately stacked. At the same time (see FIG. 12), there is provided a honeycomb structure manufactured by winding and molding the same.
It serves as a base material for supporting a catalyst system using t, Rh, Pd, etc.). The metal honeycomb body (H) is housed inside a metal casing (hereinafter referred to as a metal casing) (C) as shown in FIGS. 13 to 14 and fixed to form a metal carrier. Is. In the industry, the above-mentioned metal carrier is referred to as a metal support or a metal substrate, and an abbreviation (MS) is used. In this sense, FIG. 13 and FIG.
4 also uses 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 due to the casing.

Various structures have been proposed as the metal honeycomb body (H), which is the main constituent element of the above-mentioned conventional metal carrier (MS). The metal honeycomb body (H) shown in FIGS. 12 to 14 is the flat foil (1
′) And the corrugated foil (2 ′) are wound and laminated, and thus are called a wound type in the industry.
In addition, FIG. 12 shows a set of flat foil (1 ′) and corrugated foil (2) which are the constituent members of the winding type metal honeycomb body (H).
′) Is a perspective view, and FIG. 13 shows the conventional winding type metal honeycomb body (H) described above in a metal casing (C).
Fig. 1 shows a perspective view of a metal carrier (MS) fixed inside
4 shows a front view of the above-described conventional winding type metal honeycomb body (H).

The above-mentioned conventional winding type metal honeycomb body (H) is, for example, 100 μm or less (preferably 50 μm).
flat foils (1 ') and corrugated foils (2') made of heat-resistant thin-walled steel plate (μm or less) are stacked so as to alternately have abutting portions, and the flat foils (1 ′) and corrugated foils (2 ′) are spirally wound in a batch. And a honeycomb structure having 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, the metal honeycomb body (H), which is a main component of the metal carrier (MS), is manufactured from flat foil and corrugated foil. Various types have been proposed according to the difference in the method.

For example, flat foil and corrugated foil are laminated in a layered manner and stacked on each other (see FIG. 15), and in addition to these, Japanese Patent Laid-Open Nos. 62-273050 and 62-62,050. -273051, Japanese Patent Publication No. 3-502660, Japanese Patent Application Laid-Open No. 4-227855, etc., radial type (see FIG. 16), S-shaped type (see FIG. 17), tongue-shaped type (see FIG. 18), And a metal honeycomb body (H) having an X-wrap type (see FIG. 19) shaped structure are known.

Further, the above-mentioned conventional metal carrier (MS)
As the metal casing (C), a tubular body for accommodating and fixing the metal honeycomb body (H) therein is used. The front (cross-section) shape of the metal casing (C) is not limited to the circular shape shown in FIGS. 13 to 14, and a shape suitable for the front (cross-section) shape of the metal honeycomb body (H), for example, It may have an oval shape, an oval shape, a race and rack shape, a polygonal shape, or another irregular shape.

Then, the conventional metal carrier (M
Since S) is used in a harsh thermal environment such as an exhaust gas system, the contact portions of the foil materials (flat foil and corrugated foil) forming the metal honeycomb body (H) are firmly fixed. . this is,
The metal honeycomb body (H ′) and the metal casing (C), which are the main components of the metal carrier (MS), are generated by the high temperature of the exhaust gas itself and the exothermic reaction between the exhaust gas and the exhaust gas purification catalyst. This is because it is exposed to high temperature and a large thermal stress is applied to each element under such a high temperature atmosphere, and it is firmly fixed by a fixing method such as brazing or welding so as to withstand the thermal stress. .

That is, in the metal honeycomb body (H), from the viewpoint of ensuring the durability under the above-mentioned severe use conditions, the contact portions of the flat foil and the corrugated foil, which are the constituent members, have various methods and methods. Fixed by. For example, the contact portion between the flat foil and the corrugated foil at a desired portion inside the metal honeycomb body (H) is
It is fixed by a fixing means such as brazing or welding (for example, JP-B-63-44466, JP-A-2-21844).
No. 2).

On the other hand, the contact surfaces of the metal honeycomb body (H) and the metal casing (C) are also firmly fixed from the standpoint of preventing the separation of both elements. In addition,
A large thermal stress is generated inside the metal honeycomb body (H), which concentrates and accumulates on the contact surfaces of both elements and induces the separation of both elements, but in order to absorb and relax the above-mentioned thermal stress, A method of fixing a specific portion of the contact surface has also been proposed (see, for example, Japanese Utility Model Laid-Open No. 62-19443).

As described above, the conventional metal carrier (M
In the metal honeycomb body (H) which is a main constituent element of S), the flat foil and the corrugated foil which are the constituent members thereof have a structure in which they are fixed to each other at the peaks and troughs of the corrugated foil. Therefore, since the catalyst substance cannot be supported on the contact portion, the effective area ratio for supporting the catalyst on the entire surface of both foil materials is low. More specifically, a heat-resistant stainless steel foil having a thickness of 50 μm or less is used as this type of flat foil and corrugated foil, but the contact area of both foil materials is 10 to 30 of the total surface area. %, The effective area ratio for the catalyst support is low. In particular, the effective area ratio is extremely low when the corrugated structure of the corrugated foil has a rectangular wave or a trapezoidal wave because of the firm adhesion between the two foil materials.

When this is evaluated from an economical point of view, the thickness of the Fe—Cr 20% —Al 5% system used as both foil materials (flat foil and corrugated foil) for the metal honeycomb body (H) is 50 μm. The following heat-resistant steel foil is priced at a thickness of 1.5 mm
The material is extremely expensive, about 5 times as much as the material of SUS304, and the reduction of the effective area ratio for supporting the catalyst by the contact portion is uneconomical. By the way, the ratio of the material cost of the heat-resistant steel foil to the total cost of the metal carrier (MS) is as high as 50%, and it is necessary to increase the effective area ratio of the heat-resistant steel foil, or to increase the effective area ratio of the predetermined effective area ratio. From the viewpoint of economy, there is a strong demand for improving the exhaust gas purifying ability and reducing the amount of heat-resistant steel foil used.

Furthermore, a point to be considered in the conventional metal carrier (MS) is the fixing means applied to the manufacture of the metal carrier (MS). As described above, in the production of the metal carrier (MS), the contact portions between the two foil materials (flat foil and corrugated foil) constituting the metal honeycomb body (H), the metal honeycomb body (H) and the metal casing (C). From the viewpoint of durability, the abutting part of () is fixed by applying a fixing means such as brazing (welding) or welding. In the brazing method generally adopted as the fixing means, the brazing material used is, for example, Ni because it is the use condition of the metal carrier in a high temperature atmosphere.
It is an expensive brazing material for high temperature such as Ni-Cr system and Ni-Cr system, and it is strongly demanded to reduce the amount of its use from the viewpoint of economy. In addition, the reduction of the amount of brazing filler metal used is because the contact area of the contact portion of both foil materials (flat foil and corrugated foil) is large, as described above. As a result, problems such as reduction of heat resistance of both foil materials due to alloying reaction and diffusion reaction between the brazing material component and the metal component of both foil materials, and further deactivation of the catalyst are induced. There is a strong demand to reduce the amount of brazing filler metal used.

Various improvement measures have been proposed in the art as measures for improving the exhaust gas purification ability of the metal carrier (MS). Among these, particularly focusing on the structure of both foil materials, the following proposals have been made in order to improve the contact efficiency between the exhaust gas flow and the supported catalyst inside the metal honeycomb body (H).

(1) Jitsukai Sho 62-90742: This is
A large number of holes satisfying the conditions of hole diameter 0.5 mm to 10 mm and hole arrangement density 1 to 10 holes / cm ³ are bored in the flat foil and the corrugated foil, and exhaust gas is passed between cells to be exhausted. It improves the contact time and contact efficiency between the gas and the catalyst. As a similar technique of this kind, there is Jitsukaihei 4-53448. (2) JP-A-63-258647: This is one in which a small hole having a projection is formed in a base material (a flat foil and a corrugated foil) so that exhaust gas can cross flow and a catalyst can be carried on the projection. is there. The formation of small holes reduces the effective support area of the substrate,
The protrusion compensates for this. As a similar technique of this kind, there is Japanese Patent Laid-Open No. 5-33636. (3) Japanese Patent Publication No. 4-502880: This is to provide an opening in at least a part of the cell wall and to attach a flow surface extending at an inclination to the cell wall in the opening. The flow surface guides the exhaust gas from the inner cell to the outer cell and equalizes the flow velocity distribution, thereby improving the exhaust gas purification ability.

[0017]

In the art, as an attempt to improve the characteristics of the metal honeycomb body (H), the contact efficiency between the exhaust gas and the supported catalyst has been improved as described above.
Attempts have been made to improve the structure by devising the structure of the base material (flat foil and corrugated foil) to make the exhaust gas turbulent, or to make the exhaust gas communicate between cells to make the flow velocity uniform, but this is still unsuccessful. It is enough.

That is, an attempt to form a hole in the base material (flat foil and corrugated foil) or to dispose a perforated protrusion is as follows.
For example, in a system in which these holes or perforated projections are arranged on the side of a corrugated strip, the corrugated structure of the corrugated foil is actually small, specifically, the wave pitch is 2 to 3
mm, the wave height is small such as 1 to 1.5 mm, and in order to allow the exhaust gas to communicate between the cells efficiently, a minimum of 0.5 mm (as disclosed in Japanese Utility Model Laid-Open No. 62-90742) is used. Since it is necessary to form a hole having a diameter, it is difficult to form the hole, and unless a hole having a large diameter is formed, it is ineffective and the effective area of the base material must be small. If the hole has a small diameter, it will be clogged when the washcoat layer (washcoat) for supporting the catalyst is formed, when the catalyst component is supported, or when the exhaust gas is purified (when the metal carrier is used). Can not achieve the results of.

The present invention is intended to improve the above-mentioned drawbacks of the prior art metal carrier (MS) and to meet the expected needs. The present inventors diligently studied measures for improving a metal carrier (MS) from the above viewpoint. As a result, in the metal honeycomb body (H) which is a main constituent element of the metal carrier (MS), the base material (flat foil and corrugated foil) has a small-diameter hole portion or a protruding portion having a small-diameter hole portion. Rather than adopting the conventional method of forming the exhaust gas, in particular for flat foil, exhaust gas is exhausted at the site corresponding to the wall of each cell (exhaust gas vent passage) formed in cooperation with corrugated foil. Concavo-convex grooves for absorbing / relaxing thermal stress and non-perforated concavo-convex patterns arranged alternately to make exhaust gas turbulent, as seen in the gas inflow / outflow direction (exhaust gas passage direction) It was found that it is extremely effective to form an uneven array of parts.

The method for producing a flat foil for a metal honeycomb body of the present invention has been completed based on the above findings. The flat metal foil for a metal honeycomb body manufactured according to the present invention has an uneven row for turbulent exhaust gas and an uneven groove for absorbing / releasing thermal stress, and thus has excellent characteristics. A body (H) can be provided. That is, by using the flat foil for a metal honeycomb body of the present invention, the turbulence characteristic of exhaust gas, and hence the purification characteristic of exhaust gas is excellent, so that the amount of the base material (flat foil and corrugated foil) used is significantly reduced. A metal honeycomb body (H), which is a main component of an exhaust gas purifying metal carrier (MS), is provided, which is capable of achieving excellent heat absorption and relaxation characteristics and has significantly improved durability. .

[0021]

The present invention will be described in brief. The present invention is a method for producing a flat plate (flat foil) made of a thin metal plate which is a constituent member of a metal honeycomb body for carrying an exhaust gas purifying catalyst. In the method for producing a flat foil, the desired spacing (d) in the longitudinal direction of the flat foil as the starting material (the direction orthogonal to the exhaust gas passage direction in the case of a metal honeycomb body)
₁ ) is placed and in the width direction of the flat foil (exhaust gas passage direction when a metal honeycomb body is formed), a groove and a groove having a desired height are alternately formed, and (ii). Non-perforated concavo-convex portions are alternately arranged at desired intervals (d ₂ ) in the widthwise direction of the flat foil (exhaust gas passage direction in the case of a metal honeycomb body) in the vicinity of both sides of each concavo-convex groove. The present invention relates to a method for manufacturing a flat foil for a metal honeycomb body having an uneven groove and an uneven row, which is characterized by being combined with a step of forming an uneven row of parts.

[0022]

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 5 are views for explaining a method of manufacturing a flat foil for a metal honeycomb body according to a first embodiment of the present invention.
FIG. 1 is a perspective view of a flat foil (1) manufactured by the manufacturing method of the first embodiment of the flat foil for metal honeycomb body of the present invention. As shown in the figure, the structure of the flat foil (1) manufactured by the manufacturing method of the first embodiment of the present invention is completely different from that of the conventional flat foil (1 ′) (see FIG. 12). It is a thing.

As shown in FIG. 1, the flat foil (1) of the present invention has a desired spacing (i) when viewed in a direction orthogonal to the exhaust gas passage direction (F) when (i) a metal honeycomb body is formed. d ₁₎ the desired height is formed alternately at concave groove and ridges groove (1a, 1b) which has a, viewed in the exhaust gas passage direction (F), a convex formed over the entire width of the flat foil It has a groove and a groove (1a, 1b), and (ii) in the vicinity of both sides of each of the groove and groove (1a, 1b) in the exhaust gas passage direction (F) (of flat foil) (Width direction)
In view of the above, it is configured by having a concavo-convex row consisting of concavo-convex portions (11, 12) of non-perforated strips which are alternately arranged at a desired interval (d ₂ ).

2 to 3 are views for explaining the concavo-convex row forming process applied to the method for manufacturing the flat foil (1) for metal honeycomb body of the present invention shown in FIG. In the method for manufacturing a flat foil for a metal honeycomb body (1) of the first embodiment of the present invention, first, the uneven portions (11, 1
2) is formed, and then the uneven groove (1
a, 1b) is formed. 2 to 3 show a process of forming the concavo-convex line.

The process of forming the concavo-convex line of the present invention is shown in FIG.
In the first step, the starting flat foil (1A) is treated with a pair of upper rolls (4) to produce a flat foil (1B) having only convex portions, as shown in FIG. Then, as a second step, the flat foil (1B) having only the convex portions manufactured in the first step is inverted and treated with the concavo-convex forming roll (4) adopted in the first step to satisfy the above requirements. A flat foil (1C) having a concavo-convex row made up of concavo-convex portions (11, 12) of non-perforated strips arranged alternately is manufactured.

The starting material (1A) used for producing the flat foil (1) for a metal honeycomb body of the present invention is a thin-wall heat-resistant steel flat foil (1A) used for this type of application,
For example, Fe / Cr 20% / having a thickness of 40 μm to 50 μm
A 5% Al type foil material may be used. Flat foil (1
The width and the length in the longitudinal direction of A) may be appropriately determined in consideration of the size of the metal honeycomb body to be manufactured.

In the present invention, in the concavo-convex row consisting of the non-perforated concavo-convex portions (11, 12), the interval between the respective concavo-convex rows is, that is, the distance between the concavo-convex groove (1a, 1b) ( Although it is related to d ₁ ), it may be appropriately determined in consideration of the corrugated structure (wave height, pitch width) of the corrugated foil which is another constituent member used together with the flat foil when manufacturing the metal honeycomb body (H). The interval (d ₂ ) between the non-perforated concave-convex portions (11, 12) may be appropriately determined in consideration of the shape of the concave-convex portions to be formed and the effect of imparting turbulence. Needless to say, the shape of the non-perforated concave-convex portion (11, 12), specifically the planar shape, may be a desired shape such as a circle or an ellipse. Further, the height of the non-perforated concave-convex portions (11, 12) may be appropriately determined in consideration of the effect of imparting turbulence. Generally, the height of the non-perforated uneven portions (11, 12) is 0.1 mm to 1.0 mm.
It is.

In the present invention, the exhaust gas passage direction (F)
The first reason why the uneven portions (11, 12) alternately arranged on the metal foil are non-perforated is to increase the surface area of the flat foil when assembled into a metal honeycomb body, that is, This is to increase the effective surface area for supporting the exhaust gas purifying catalyst on the surface of the flat foil. In addition, the reason why the non-perforated uneven portions (11, 12) are alternately arranged is that when assembled into a metal honeycomb body, the exhaust gas flow is made turbulent uniformly and effectively, so This is to improve the contact efficiency of.

In the present invention, the above-mentioned non-perforated uneven portion is formed, and the flat foil (1A) as a starting material is thin (for example, 40 μm to 50 μm).
Further, in relation to the structure in which the non-perforated concave-convex portions are alternately formed, the non-perforated concave-convex portions (11, 12) can be extremely efficiently formed by the concave-convex row forming process. FIG. 4 is a view showing a concavo-convex row forming device (4A) incorporating the concavo-convex row forming roll (4) shown in FIGS. As described above, in the present invention, the non-perforated concave-convex portion (11, 12) is formed on the thin flat foil (1A).
Since the configuration of forming the concave portion is adopted, the processing stress for forming the uneven portion is small. Therefore, in the concavo-convex row forming roll (4) consisting of a pair of upper roll (41) and lower roll (42), the upper roll (41) is composed of a urethane roll (a hard and elastic polyurethane resin roll) or the like. And can be a very economical device. In addition, the lower roll (42) is a flat foil (1) via a desired spacer (S).
It is composed of a plurality of metal toothed rolls for forming the convex portions in A).

In the concavo-convex line forming roll (4) of the concavo-convex line forming device (4A) shown in FIG. 4, the upper roll (41) is a roll made of rubber or synthetic resin having elasticity such as urethane roll as described above. Composed and lower roll (42)
Is composed of a metal toothed roll. The lower roll (42) is composed of a desired number of rolls spaced by a spacer (S) at a desired distance. It goes without saying that the size of the spacer (S) and the number of the lower rolls (42) are related to the number of the concavo-convex portions (11, 12) arranged alternately. Concavo-convex row forming roll having the above-mentioned configuration (4)
In the above, the roll (41) made of rubber or synthetic resin such as an elastic urethane roll which is the upper roll is elastically deformed, and therefore the metal toothed roll (42) which is the lower roll.
The toothed roll (42) on the other side may be configured so as to have a function as a pressing roll that is pressure-bonded to the surface of the roll, and the toothed roll (42) on the roll surface has a tooth profile for forming a convex portion. Based on the structure of the upper and lower rolls (41, 42), the synthetic resin roll (41) as the upper roll appropriately presses the flat foil (1A) as a starting material between itself and the lower roll (42). In addition, the flat foil can be deformed when the convex portion is formed by the tooth mold of the lower roll (42).

The mode of use of the concavo-convex row forming device (4A) shown in FIG. 4 is (i) the process shown in FIG. 2, that is, the flat foil (1A) as a starting material has a flat row having only convex sections. When manufacturing the foil (1B), it is used in the arrangement relationship of the upper and lower rolls (41, 42) shown in FIG.
In the process shown in Fig. 4, that is, when the flat foil (1B) having convex rows is inverted to form a convex portion to produce a flat foil (1C) having concave and convex rows, the upper and lower rolls (41, Four
In 2), the set position of each roll constituting the lower roll (42) is displaced (right or left) in correspondence with the interval (d ₂ ) between the concave and convex portions (11, 12), and in a fixed state. You can use it.

In the concavo-convex row forming device (4A) shown in FIG. 4, the lower roll (42), that is, the toothed roll for forming convex portions, is fixed to a drive shaft (44) which is rotationally driven by a motor with a reduction gear (43). To be done. Also, the other upper roll (4
1) is fixed to a passive shaft (non-driving shaft) (45). The both rolls are meshed rotations of both power transmission gears (46, 47) of the power transmission gear (46) fixed to the drive shaft (44) and the power transmission gear (47) fixed to the passive shaft (45). Is rotated in the opposite direction. In the figure, reference numerals (48, 49) denote frames provided upright on both sides of the upper and lower rolls (41, 42) of the uneven row forming roll (4). The drive shaft (44)
Also, the bearing portion between the passive shaft (45) and the frame portion (48, 49) or the gap adjusting mechanism between both shafts (44, 45) may be appropriately configured. With the above configuration, the distance between the upper and lower rolls (41, 42) of the concavo-convex row forming roll (4) is accurately controlled, and uniform concavo-convex portions and concavo-convex rows are formed on the flat plate (1A) of the starting material. You can

FIG. 5 shows a flat foil (1C) having a concavo-convex row consisting of non-perforated concavo-convex portions (11, 12) manufactured by the manufacturing process of FIGS. It is a figure explaining the process of processing by 5) and manufacturing the flat foil (1) for metal honeycomb bodies of this invention. As shown, the concavo-convex groove forming roll (5) is composed of a pair of an upper toothed roll (51) and a lower toothed roll (52). The above-mentioned upper and lower toothed rolls (51, 52) are provided with convex strips and concave strips formed at desired intervals on one roll surface and concave strips formed at desired intervals on the other roll surface. And the convex ridges mesh with each other to form concave and convex ridge grooves alternately at predetermined portions of the flat foil (1C). The configuration of the convex and concave portions on the roll surface of the upper and lower toothed rolls (51, 52) for forming the concave and convex linear grooves on the flat foil, that is, the distance between the concave and convex portions and the size of the concave and convex portions. It goes without saying that (depth of the uneven groove formed on the flat foil), the shape of the uneven portion, and the like are set as desired.

In the flat foil (1) for a metal honeycomb body of the present invention, the uneven grooves (1a, 1b) are resistant to thermal stress generated inside the metal honeycomb body (H) when assembled in the metal honeycomb body. It becomes a zone that absorbs / relaxes the base deformation force, and plays an important role in improving the durability of the metal honeycomb body. In the present invention, the uneven groove (1
In a and 1b), since the convex groove and the concave groove are alternately arranged, it is needless to say that the deforming force based on the thermal stress can be uniformly absorbed / relaxed inside the metal honeycomb body (H). There is no such thing. The shape structure of the concavo-convex groove (1a, 1b) of the present invention may be set as desired,
For example, the height may be set to 0.2 to 1.0 mm. Various modifications of the shape structure of the uneven groove (1a, 1b) will be described later with reference to FIGS.

FIG. 6 is a diagram for explaining a method of manufacturing the flat foil (1) for metal honeycomb body according to the second embodiment of the present invention.
In the manufacturing process of the first embodiment shown in FIG. 1 to FIG. 5, since the single concavo-convex line forming device shown in FIG. 4 is used, the manufacturing process of the flat foil (1) is a batch type (non- Continuous type). FIG. 6 is characterized in that the flat foil (1) is continuously manufactured. That is, the manufacturing method of the second embodiment of the flat foil for metal honeycomb body (1) of the present invention uses two sets of concave-convex row forming rolls (4, 4 ′), and (i) the first front stage roll ( In 4), a flat foil (1B) in which only convex portions are formed on the flat foil (1A) as a starting material is produced, and (ii) subsequently, the flat foil (1B) is continuously formed as in the first embodiment. Without reversing, only the concave portions are formed on the second rear roll (4 ′) to manufacture the flat foil (1C) having the concave and convex rows. Further continuously, forming a concave and convex groove using a set of concave and convex groove forming rolls,
A flat foil (1) having an uneven row and an uneven groove is continuously manufactured. The structure of the concavo-convex row forming rolls (4, 4 ′) and the concavo-convex groove forming roll (5) applied to the manufacturing process is as follows.
It is substantially the same as that described in the first embodiment. Needless to say, the arrangement relationship between the upper and lower rolls of the second concavo-convex row forming roll (4 ') is opposite to that of the first concavo-convex row forming roll (4).

FIG. 7 illustrates a concavo-convex row forming device (4A) applied to the method for manufacturing the flat foil (1) for a metal honeycomb body of the present invention according to the third embodiment, particularly the manufacturing method according to the third embodiment. It is a figure. A characteristic point of the concavo-convex row forming device (4A) applied to the manufacturing method of the third embodiment is that the first to
The method of forming the concavo-convex row composed of the non-perforated concavo-convex portions (11, 12) in the two steps as seen in the second embodiment is performed in one step. That is, in the first embodiment (see FIGS. 2 to 4), the same concavo-convex row forming roll (4) is used to perform the non-perforated concavo-convex portion (11, 12) in two steps (non-continuous steps). In the second embodiment (see FIG. 6), two sets of the uneven row forming rolls (4, 4 ′) are used to form a non-perforated pattern in two steps (continuous steps). To form a concavo-convex line consisting of concavo-convex portions (11, 12). The third embodiment makes the formation of the concavo-convex rows more efficient and tries to form the concavo-convex rows in one step.

As shown in FIG. 7, the concavo-convex row forming device (4A) applied to the method for manufacturing the flat foil (1) for a metal honeycomb body of the third embodiment of the present invention comprises an upper roll (41).
(4) Concavo-convex row forming roll consisting of a lower roll (42)
The configuration is substantially different from that of the first and second embodiments. As shown in FIG. 7, in the concavo-convex row forming roll (4) of the concavo-convex row forming device (4A) applied to the manufacturing method of the third embodiment, each constituent roll (411a, 412a, ...) is composed of a rubber or synthetic resin roll having elasticity, and each of the other constituent rolls (411, 412, ...) is composed of a metal toothed roll.

Each of the constituent rolls (421, 422 ...) Of the lower roller (42) is composed of a metal toothed roll, and each of the other constituent rolls (421a, 422a ...).
...) is made of hard and elastic rubber or synthetic resin roll. And, the metal toothed rolls (411, 412 ...) Of the upper roll (41) are the lower rolls (4
2) is in contact with the synthetic resin rolls (421a, 422a ...) On the other hand, the metal toothed rolls (421, 422 ...) Of the lower roll (42) are elastic rubbers of the upper roll (41) or Rolls made of synthetic resin (411a, 41
2a ...) so as to abut. In such a contact relationship, the concavo-convex row can be formed at once by the mechanism described in the operation description of FIG. The metal toothed rollers (411, 412 ...) Of the upper roll (41).
...) may be configured to form convex portions, and the metal rollers (421, 422 ...) Of the lower roller (42) may be configured to form concave portions, or vice versa. That is not the case.

The method for manufacturing a flat foil for a metal honeycomb body of the present invention is not limited to the above-mentioned first to third embodiments. For example, the following modifications are possible. In the first to third embodiments, the non-perforated uneven portion (1
Although the roll forming method is adopted as the method for forming the concave-convex row composed of 1, 12) and the method for forming the concave-convex groove (1a, 1b), it goes without saying that the press-forming method may be adopted. is there. Further, in the first to third embodiments, the steps of forming the concave-convex row and forming the concave-convex groove may be reversed. In the case of the press molding method, for example, the uneven groove (1a, 1b) may be formed in the first step, and then the uneven row may be formed in the second step, or the reverse step may be adopted. The press molding method is compared with the roll molding method,
Needless to say, they are inferior in terms of productivity or economy.

Next, the non-perforated uneven portion (11, 12)
The shape structure of the uneven row and the uneven groove (1a, 1b) made of is not limited to that shown in FIG. This point, FIG.
-It demonstrates, citing FIG. (i). FIG. 8 shows a modification of the shape structure of the concave-convex groove (1a, 1b). The uneven groove (1
a, 1b) (see FIG. 1) has a semi-circular shape (semi-arcuate shape) in a cross section in a direction orthogonal to the exhaust gas passage direction (F). In contrast, FIG. 8 (1) has a triangular shape, FIG. 8 (2) has a trapezoidal shape, and FIG. 8 (3) has a rectangular shape.

(Ii). FIG. 9 shows a modification regarding the set length of the concavo-convex groove (1a, 1b) in the width direction of the flat foil. The concavo-convex groove (1a, 1b) shown in FIGS. 1 and 8 is of a full width type formed over the full width of the flat foil (1) when viewed in the width direction. 9 (1) and 9 (2) are positioned as a non-full width type as compared with the full width type. FIG. 9 (1) shows an uneven groove (1a, 1
FIG. 9 (2) shows a cross-sectional shape of the semi-circular shape and the non-full width type, and FIG. 9 (2) shows that the concave and convex grooves (1a, 1b) have a triangular cross-sectional shape and the non-full width type. Showing things.

In the present invention, it is needless to say that the non-full width type concave-convex grooves (1a, 1b) may have a trapezoidal sectional shape (see FIG. 8 (2)) although not shown. That is. Further, the full width type concave and convex grooves (1a, 1b) are not only divided into two at a desired interval in the width direction of the flat foil as shown in FIG. It may be divided.

In the present invention, the intervals (d ₂ ) of the non-perforated concave-convex portions (11, 12) arranged alternately are not limited to the equal intervals, and the intervals of any length may be used. It should be understood that it is acceptable. For example, in the non-full width type concave-convex groove, if the concave-convex portions are not formed in the divided regions, the intervals (d ₂ ) may not be equal.

The flat foil (1) produced by the present invention is useful as a constituent member of the metal honeycomb body (H). 10 to 11 show examples of application of the flat foil (1) produced by the present invention to the metal honeycomb body (H). FIG. 10 shows that the flat foil (1) of the present invention is a corrugated foil (2) commonly used in this type of metal honeycomb body.
′) (See FIG. 12) and a partially enlarged perspective view of the metal honeycomb body (H) manufactured in combination with the metal honeycomb body (H). More precisely, the metal honeycomb body (H) of FIG. 10 is a partially enlarged perspective view of the metal honeycomb body (H) having a honeycomb structure, for example, a view relating to a wound type metal honeycomb body (H) of the related art. 13 is a view corresponding to a partially enlarged perspective view of FIG.

FIG. 11 shows a metal produced from the flat foil (1) of the present invention and a corrugated foil (2) having a special structure in which a concavo-convex row consisting of non-perforated concavo-convex portions is arranged on the conventional flat foil. It is a partially expanded perspective view of a honeycomb body (H). In the metal honeycomb body (H) shown in FIG. 11, both the flat foil (1) and the corrugated foil (2) have a concavo-convex row composed of non-perforated concavo-convex portions for making exhaust gas turbulent. As shown in FIG.
The turbulence of exhaust gas (in other words, exhaust gas purification capacity) is superior to that of the above. Further, since the flat foil (1) has the uneven groove for absorbing and relaxing the thermal stress, it has excellent durability.

[0047]

According to the present invention, a flat foil having a special structure which is a constituent member for a metal honeycomb body is efficiently manufactured. In particular, according to the present invention, when it is applied to a metal honeycomb body, it is excellent in the property of making the exhaust gas passing through the inside of the metal honeycomb body turbulent, and is excellent in the thermal stress relaxation ability and the effective area ratio for supporting the catalyst. A method for efficiently and economically producing a flat foil for a metal honeycomb body is provided.

[Brief description of drawings]

FIG. 1 is a perspective view of a flat foil manufactured by a manufacturing method according to a first embodiment of the present invention.

FIG. 2 is a concavo-convex row forming process applied to the manufacturing method of the first embodiment of the present invention (a method for producing a flat foil having only convex rows).
FIG.

FIG. 3 is a diagram illustrating a concavo-convex row forming process (a method for manufacturing a flat foil having only concavo-convex rows to a flat foil having concavo-convex rows) applied to the manufacturing method of the first embodiment of the present invention.

FIG. 4 is a front view of the concavo-convex row forming device applied to the manufacturing method according to the first embodiment of the present invention.

FIG. 5 is a diagram illustrating an uneven groove forming process applied to the manufacturing method according to the first embodiment of the present invention.

FIG. 6 is a diagram illustrating a method for manufacturing a flat foil according to a second embodiment of the present invention.

FIG. 7 is a front view of a concavo-convex array forming device applied to the manufacturing method according to the third embodiment of the present invention.

FIG. 8 is a view showing a modified example of the uneven groove (full width length type) formed on the flat foil of the present invention.

FIG. 9 is a view showing a modified example of the uneven groove (non-full width type) formed in the flat foil of the present invention.

FIG. 10 is a partially enlarged perspective view of a metal honeycomb body of a first application example using the flat foil of the present invention.

FIG. 11 is a partially enlarged perspective view of a metal honeycomb body of a second application example using the flat foil of the present invention.

FIG. 12: Flat foil (1 ′) and corrugated foil (2 ′) used for manufacturing a conventional wound type metal honeycomb body (H)
FIG.

FIG. 13 is a perspective view of a metal carrier (MS) using a conventional wound-type metal honeycomb body (H).

FIG. 14 is a front view of a metal carrier (MS) using the conventional wound type metal honeycomb body shown in FIG.

FIG. 15 is a front view of a metal carrier (MS) using a conventional laminated-type metal honeycomb body.

FIG. 16 is a front view of a metal carrier (MS) using a conventional radial type metal honeycomb body.

FIG. 17 is a front view of a metal carrier (MS) using a conventional S-shaped metal honeycomb body.

[Fig. 18] Fig. 18 is a front view of a metal carrier (MS) using a conventional B-type metal honeycomb body.

FIG. 19 is a front view of a metal carrier (MS) using a conventional X-wrap (swastoid) type metal honeycomb body.

DESCRIPTION OF SYMBOLS 1 ... Flat foil for metal honeycomb body of the present invention 1 '... Conventional flat foil for metal honeycomb body 2, 2' ... Corrugated foil for metal honeycomb body 1A ... Material: Flat foil 1B ………… (Only having convex rows) Flat foil 1C ………… (Starting material) Flat foil 11, 12 ……… Concavo-convex part (concave-convex row) 3 ………… Cell (mesh-like communication passageway) ) 4A ……… Concavo-convex row forming device 4, 4 '……… Concave-convex row forming roll 41 ……… Upper roll 42 ……… Lower roll 43 ……… Reduction gear motor 44 ……… Drive shaft 45 ……… Passive shafts 46, 47 ……… Power transmission gears 48, 49 ……… Frame 5 ……… Rough groove groove forming roll 51 ……… Top toothed roll 52 ……… Lower toothed roll 1a, 1b ……… Roughness Groove H ……… Metal honeycomb body C ……… Metal casing MS: Metal carrier

Claims (14)

[Claims] 1. A method for producing a flat plate (flat foil) made of a thin metal plate which is a constituent member of a metal honeycomb body for carrying an exhaust gas purifying catalyst, wherein the method for producing the flat foil includes (i). A desired spacing (d ₁ ) is placed in the longitudinal direction of the material flat foil (direction orthogonal to the exhaust gas passage direction when the metal honeycomb body is formed), and the width direction of the flat foil (when the metal honeycomb body is formed) In the exhaust gas passage direction), a step of alternately forming a concave groove groove and a convex groove groove of a desired height, and (ii). Forming a desired number of concavo-convex rows composed of non-perforated concavo-convex portions at a desired interval (d ₂ ) with respect to the exhaust gas passage direction when the body is formed. For a metal honeycomb body having concave and convex grooves and concave and convex rows characterized by being combined Method of manufacturing the foil. 2. The method for producing a flat foil for a metal honeycomb body according to claim 1, wherein the desired number of concave-convex rows is formed before the formation of the concave-convex groove. 3. A desired number of concavo-convex rows is formed by using one set of concavo-convex row forming rolls composed of an upper roll and a lower roll, and a convex portion (or concave portion) is formed on the flat foil which is a starting material in the first step. 3. The flat foil for metal honeycomb body according to claim 2, wherein only the convex portion (or the concave portion) is formed and the flat foil having the convex portion from the first step is inverted in the second step. Manufacturing method. 4. A desired number of concavo-convex rows is formed by using two sets of concavo-convex row forming rolls composed of an upper roll and a lower roll side by side, and a concave portion (or a convex portion) is formed by the preceding concavo-convex row forming rolls.
3. The method for producing a flat foil for a metal honeycomb body according to claim 2, wherein only the concave portions (or the convex portions) are formed by a concave-convex forming roll in a subsequent stage without inverting the flat foil. 5. The metal according to claim 2, wherein the desired number of concave-convex rows is formed by using one set of concave-convex row forming rolls composed of an upper roll and a lower roll to form the concave-convex rows in one step. Method for manufacturing flat foil for honeycomb body. 6. One of an upper roll and a lower roll
5. The flat foil for metal honeycomb body according to claim 3 or 4, wherein one roll is an elastic roll made of rubber or synthetic resin, and the other roll is a metal tooth forming roll. Production method. 7. The upper roll and the lower roll are each composed of a desired number of elastic rolls made of rubber or synthetic resin and metal toothed rolls, and the elastic roll made of rubber or synthetic resin on the upper roll side is lower. The method for producing a flat foil for a metal honeycomb body according to claim 5, wherein the flat foil for a metal honeycomb body is placed in contact with the metal toothed forming roll on the roll side. 8. The method for producing a flat foil for a metal honeycomb body according to claim 2, wherein the desired number of concavo-convex rows is formed by one step or two steps by press molding. 9. The flat foil for metal honeycomb body according to claim 2, wherein the uneven groove is formed by an uneven groove forming roll composed of a pair of an upper toothed roll and a lower toothed roll. Manufacturing method. 10. The uneven groove is formed after the uneven row is formed.
The method for producing a flat foil for a metal honeycomb body according to claim 9, which is performed continuously or discontinuously. 11. The method for producing a flat foil for a metal honeycomb body according to claim 1, wherein the uneven groove is formed before the forming of the uneven row. 12. The cross-sectional shape of the concave-convex groove (cross-section orthogonal to the exhaust gas passage direction when a metal honeycomb body is formed) has a shape of
The method for producing a flat foil for a metal honeycomb body according to claim 1, which has a desired shape. 13. The production of a flat foil for a metal honeycomb body according to claim 12, wherein the uneven groove has a cross-sectional shape of at least one selected from a semi-circular shape, a triangular shape, a trapezoidal shape, and a rectangular shape. Method. 14. The uneven groove is a full width type or a non-full width type in the width direction of the flat foil (exhaust gas passage direction when a metal honeycomb body is used).
The method for producing a flat foil for a metal honeycomb body according to 1.