US20150128676A1 - System And Method For Manufacturing A Honeycomb Body - Google Patents

System And Method For Manufacturing A Honeycomb Body Download PDF

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Publication number
US20150128676A1
US20150128676A1 US14/342,737 US201114342737A US2015128676A1 US 20150128676 A1 US20150128676 A1 US 20150128676A1 US 201114342737 A US201114342737 A US 201114342737A US 2015128676 A1 US2015128676 A1 US 2015128676A1
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United States
Prior art keywords
mold
forming mold
tightening
rolled
rolling
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Abandoned
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US14/342,737
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English (en)
Inventor
Gengsheng Chu
Shuiping Deng
Yuqin Zhang
Ye Liu
Weichang Tao
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BASF Corp
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BASF Corp
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Assigned to BASF CORPORATION reassignment BASF CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BARTHOLOMAEUS, PETER, CHU, Gengsheng, DENG, Shuiping, TAO, Weichang, ZHANG, Yuqin, LIU, YE
Publication of US20150128676A1 publication Critical patent/US20150128676A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/40—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling foils which present special problems, e.g. because of thinness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B35/00—Drives for metal-rolling mills, e.g. hydraulic drives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B99/00—Subject matter not provided for in other groups of this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D11/00—Bending not restricted to forms of material mentioned in only one of groups B21D5/00, B21D7/00, B21D9/00; Bending not provided for in groups B21D5/00 - B21D9/00; Twisting
    • B21D11/06—Bending into helical or spiral form; Forming a succession of return bends, e.g. serpentine form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D21/00—Combined processes according to methods covered by groups B21D1/00 - B21D19/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D47/00—Making rigid structural elements or units, e.g. honeycomb structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D47/00—Making rigid structural elements or units, e.g. honeycomb structures
    • B21D47/04—Making rigid structural elements or units, e.g. honeycomb structures composite sheet metal profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
    • B21H7/00—Making articles not provided for in the preceding groups, e.g. agricultural tools, dinner forks, knives, spoons
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2807—Metal other than sintered metal
    • F01N3/281—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C47/00—Winding-up, coiling or winding-off metal wire, metal band or other flexible metal material characterised by features relevant to metal processing only
    • B21C47/02—Winding-up or coiling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D11/00—Bending not restricted to forms of material mentioned in only one of groups B21D5/00, B21D7/00, B21D9/00; Bending not provided for in groups B21D5/00 - B21D9/00; Twisting
    • B21D11/20—Bending sheet metal, not otherwise provided for
    • B21D11/206—Curving corrugated sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/02—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers
    • B21D53/027—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers by helically or spirally winding elongated elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/02—Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal
    • F01N2330/04—Methods of manufacturing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/30—Honeycomb supports characterised by their structural details
    • F01N2330/44—Honeycomb supports characterised by their structural details made of stacks of sheets, plates or foils that are folded in S-form

Definitions

  • the present invention relates to a system and a method for manufacturing a honeycomb body, more specifically, to system and method for manufacturing an S-type metal honeycomb body.
  • Honeycomb bodies are commonly used in many fields, such as filters, catalyst substrates in the engine exhaust purification system.
  • Honeycomb body has large channel surface area, low back pressure, excellent mechanical performance and catalysis engineering specialty.
  • S-type metal honeycomb body is of particular concern.
  • Metal honeycomb body is usually made of metal foil.
  • the honeycomb structure needs to be continuously tightened so as to define the internal channels of the honeycomb structure.
  • the precision of the honeycomb body manufacturing will affect its life and other properties.
  • WO97/10135 describes a device and a method for manufacturing a honeycomb body.
  • the device includes a fork rolling mechanism, which rotates around an axis and holds the foil stack, and an arc mold segment, which can close to form a mold.
  • the model consists of at least two mold segments, which can rotate around their axes respectively. The axes of rotation are parallel with the rolling axis respectively.
  • CN 101251036A also a device and a method for manufacturing a honeycomb body are known.
  • the device includes a fixed post and two sets of mold segments, which can be closed to form a mold.
  • U.S. Pat. No. 7,318,276B2 discloses a method for finish machining a honeycomb body, wherein the honeycomb structure are processed by means of fine-processing tools after being rolled, so as to meet the required performance.
  • the invention is based on the purpose to provide a system for automatically manufacturing a honeycomb body; the system has simple structure and can produce honeycomb bodies with good stability and long life.
  • the honeycomb structure can be manufactured with high accuracy without using complex tightening system, such as those in the prior art.
  • said forming mold has a conical outer surface, which cooperates with a conical inner surface of said tightening mold, and said tightening mold are displaced in the axial direction in the action.
  • This solution is preferred since the tightening mold can be easily and precisely controlled.
  • the tightening mold can be easily driven, for example, by an electric motor via a gear-rack transmission, worm transmission and the like.
  • the forming mold preferably comprises four sub-molds. But a forming mold with only two, six or more sub-molds is also conceivable, that leads to a simpler solution. More sub-molds bring more evenly distributed acting force to the honeycomb body, but also brings more complexity to the structure.
  • the sub-molds can be closed to form a cylindrical, circumferential closed inner volume.
  • This solution brings the advantage, that the final size of the honeycomb structure is controlled precisely merely by the geometry characters of the sub-molds.
  • a manufacturing system with high accuracy can be provided easily.
  • the manufacturing system further comprises an ejecting part, which is movable in the axial direction so as to push the rolled-up honeycomb structure into a housing.
  • a automatic feeding device for feeding said forming mold with foil stack to be rolled is provided.
  • a method for manufacturing honeycomb body by using the above described system is also suggested.
  • the method comprises the following steps:
  • honeycomb bodies can be automatically produced with high accuracy.
  • the produced honeycomb bodies have gut behavior and long life, because of this precisely controlled process, in which the honeycomb structure is tightened while being rolled up.
  • a further step is provided between the step of pulling the rolling pins out and the step of pushing the rolled-up honeycomb structure into a housing, in which the tightening mold further functions so as to cause the inner volume of the forming mold decreasing to a second value.
  • FIG. 1 is a schematic drawing of the system according to the invention.
  • FIG. 2 is a section of the manufacturing system, with the system in a state when the foil stack is being introduced;
  • FIG. 3 is a drawing of the system according to the invention looking from the arrow D in FIG. 2 ;
  • FIG. 4 is a drawing corresponding to FIG. 2 , with the foil stack being already rolled and the tightening mold being already crossed a distance;
  • FIG. 5 is a drawing corresponding to FIG. 3 , with the foil stack being already rolled and the tightening mold being already crossed a distance;
  • FIG. 6 is a block diagram showing the process for manufacturing a honeycomb body.
  • FIG. 1 shows a system for manufacturing a honeycomb according to the invention.
  • the system includes a frame, driving trains, a forming mold 1 for rolling volume of the honeycomb-type and tightening mold 6 .
  • FIGS. 2 and 3 show a section of the system for manufacturing a honeycomb according to the invention.
  • the forming mold 1 consists of four sub-molds independent of each other (see FIG. 3 ), which four sub-molds can be opened and closed.
  • the four sub-molds are supported on the frame like the jaws of a four-jaw chuck.
  • the sub-molds are preferably movable in the radial direction in their own slide rails respectively.
  • the sub-molds are biased to the direction of opening by springs.
  • the four sub-molds can naturally be arranged in other known means.
  • the foil stack 3 is produced by stacking wave metal foils and flat metal foils alternatively.
  • the four sub-molds of the forming mold 1 are hold in a tightening mold 6 .
  • the forming mold 1 includes a conical outer surface, which engages with a conical inner surface of the tightening mold 6 in such a way, that the he forming mold 1 are contracted continuously by the axial movement (shown by arrow D) of the tightening mold 6 . That result in the tightening of the honeycomb lying in the forming mold 1 , see FIG. 4 and FIG. 5 .
  • the four sub-molds can be contracted to form a close cylindrical cavity.
  • the forming mold 1 and the tightening mold 6 engage with each other preferably by matched conical surfaces thereof. But engagements with other matched shapes can also be envisaged.
  • the system shown in FIG. 1 includes rolling pins 2 , which can be inserted into the inner volume of the forming mold 1 .
  • rolling pins 2 are provided so as to manufacture a double S-shaped honeycomb structure.
  • Other conventional arrangements of the rolling pins for manufacturing corresponding honeycomb structure are also possible.
  • the pin driving shaft 7 can rotate around its longitudinal axis.
  • the rolling pins are driven by the pin driving shaft 7 in such a way, that they rotate around an axis X, which is parallel to both of the rolling pins 2 .
  • the axis X of the rolling pins locates in the center of the forming mold 1 and is equally distanced from the rolling pins 2 .
  • the foil stack 3 is rolled up by the rotation of the rolling pins 2 and form an S-shaped honeycomb structure.
  • the pin driving shaft 7 can by moved axially to a first position, in which the rolling pins 2 are inserted into the volume of the forming mold 1 , and a second position, in which the rolling pins 2 are pulled out of the volume.
  • the system 10 also includes an ejecting part 5 , which can slide on the pin driving shaft 7 so as to push the rolled honeycomb structure into an housing 8 .
  • a honeycomb is manufactured.
  • the central part of the foil stack 3 which has been rolled as a honeycomb structure, is coved by the ejecting part 5 .
  • a supporting shaft 4 for supporting the rolling pins 2 is provided on the other side of the rolling pins 2 .
  • the housing 8 is pushed on the supporting shaft 4 .
  • the supporting shaft 4 is axially movable, such that it can leave the housing 8 when the honeycomb structure is pushed out by the ejecting part 5 .
  • the foil stack 3 is prepared. Usually a foil stack 3 is formed by simply stacking a certain number of wave foils and flat foils. Then a housing 8 for honeycomb is placed into the manufacturing system. For metal honeycomb bomolds, the housing is usually a steel sleeve.
  • step S 01 the forming mold 1 is opened.
  • step S 02 a foil stack 3 is introduced into the space between the two rolling pins 2 through the gap between two sub-molds, see FIG. 2 and FIG. 3 .
  • step S 03 the rolling pin driving shaft 7 is rotated by the driving train.
  • the rolling pins 2 are rotated by the rolling pin driving shaft 7 as such, that the foil stack 3 is rolled into the forming mold 1 .
  • a step S 04 the tightening mold 6 is moved axially, so that the inner volume of the forming mold 1 gradually decreases to a first value, after the foil stack 3 is completely rolled into the forming mold 1 .
  • the rolling pins 2 keep rotating.
  • the tightening mold 6 moves linearly in a direction D in its tightening action. Due to the engagement of the conical inner surface of the tightening mold 6 with the conical outer surface of the forming mold 1 , the sub-molds of the forming mold 1 are displaced inwardly in radial direction by the axial movement of the tightening mold 6 , tightening the honeycomb structure formed by the foil stack 3 , see FIG. 4 and FIG. 5 .
  • a step S 05 the rolling pins 2 is pulled out after S 04 , and the tightening mold 6 is further moved, so that the inner volume of the forming mold 1 further decreases to a second value.
  • a step S 06 after the second value is reached, the ejecting part 5 pushes the rolled-up honeycomb structure into a housing, so that a honeycomb with a housing and a rolled-up honeycomb structure is formed.
  • the second value corresponds to the inner size of the forming mold 1 with the four sub-molds fully closed.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Agronomy & Crop Science (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Catalysts (AREA)
  • Filtering Materials (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
US14/342,737 2011-11-01 2011-11-01 System And Method For Manufacturing A Honeycomb Body Abandoned US20150128676A1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/CN2011/081618 WO2013063754A1 (en) 2011-11-01 2011-11-01 System and method for manufacturing a honeycomb body

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EP (1) EP2773856A4 (enrdf_load_html_response)
JP (1) JP5760152B2 (enrdf_load_html_response)
KR (1) KR20140094519A (enrdf_load_html_response)
CN (1) CN103906905B (enrdf_load_html_response)
BR (1) BR112014008084A2 (enrdf_load_html_response)
CA (1) CA2850552A1 (enrdf_load_html_response)
IN (1) IN2014CN03967A (enrdf_load_html_response)
MX (1) MX2014004340A (enrdf_load_html_response)
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CN108788629A (zh) * 2018-04-28 2018-11-13 无锡市盛和科技有限公司 一种跑道型金属载体芯体生产工艺
CN108856498B (zh) * 2018-04-28 2020-02-07 无锡市盛和科技有限公司 凹凸型同芯载体生产工艺

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US7174635B2 (en) * 2003-12-26 2007-02-13 Sango Co., Ltd. Method for producing a columnar member container

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JP2015501217A (ja) 2015-01-15
JP5760152B2 (ja) 2015-08-05
CN103906905B (zh) 2017-04-26
EP2773856A1 (en) 2014-09-10
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