WO2013063754A1 - 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
WO2013063754A1
WO2013063754A1 PCT/CN2011/081618 CN2011081618W WO2013063754A1 WO 2013063754 A1 WO2013063754 A1 WO 2013063754A1 CN 2011081618 W CN2011081618 W CN 2011081618W WO 2013063754 A1 WO2013063754 A1 WO 2013063754A1
Authority
WO
WIPO (PCT)
Prior art keywords
mold
forming mold
tightening
rolled
rolling
Prior art date
Application number
PCT/CN2011/081618
Other languages
French (fr)
Inventor
Gengsheng CHU
Shuiping DENG
Yuqin ZHANG
Ye Liu
Weichang TAO
Peter Bartholomaeus
Original Assignee
Basf Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Basf Corporation filed Critical Basf Corporation
Priority to RU2014122027A priority Critical patent/RU2609117C2/en
Priority to EP11874960.5A priority patent/EP2773856A4/en
Priority to MX2014004340A priority patent/MX2014004340A/en
Priority to CA2850552A priority patent/CA2850552A1/en
Priority to US14/342,737 priority patent/US20150128676A1/en
Priority to KR1020147011334A priority patent/KR20140094519A/en
Priority to BR112014008084A priority patent/BR112014008084A2/en
Priority to CN201180074560.6A priority patent/CN103906905B/en
Priority to IN3967CHN2014 priority patent/IN2014CN03967A/en
Priority to JP2014539200A priority patent/JP5760152B2/en
Priority to PCT/CN2011/081618 priority patent/WO2013063754A1/en
Publication of WO2013063754A1 publication Critical patent/WO2013063754A1/en

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Classifications

    • 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
    • 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
    • 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
    • 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
    • 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 OR PROFILES, 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 speciality.
  • 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.
  • 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 system includes a forming mold with a plurality of sub-molds, which are movable so that they can be opened and closed; a tightening mold for tightening said forming mold, i.e. for closing the sub-molds thereof; rolling pin(s), which can be inserted into and pulled out of the inner volume of said forming mold and can rotate around a rotation axis.
  • said tightening mold has a shape that cooperates with the shape of said forming mold, so that an action of said tightening mold causes tightening of said forming mold.
  • 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.
  • Figure 1 is a schematic drawing of the system according to the invention.
  • Figure 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 Figure 2;
  • Figure 4 is a drawing corresponding to Figure 2, with the foil stack being already rolled and the tightening mold being already crossed a distance;
  • Figure 5 is a drawing corresponding to Figure 3, with the foil stack being already rolled and the tightening mold being already crossed a distance;
  • Figure 6 is a block diagram showing the process for manufacturing a honeycomb body.
  • Figure 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.
  • Figure 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 Figure 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 Figure 4 and Figure 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 Figure 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 SOI the forming mold 1 is opened.
  • step S02 a foil stack 3 is introduced into the space between the two rolling pins 2 through the gap between two sub-molds, see Figure 2 and Figure 3.
  • step S03 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 S04 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 Figure 4 and Figure 5.
  • a step S05 the rolling pins 2 is pulled out after S04, 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 S06 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)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Agronomy & Crop Science (AREA)
  • Catalysts (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
  • Filtering Materials (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)

Abstract

A system and method for manufacturing a honeycomb body is provided. Said system comprising: a forming mold (1) with a plurality of sub-molds, which are movable so that they can be opened and closed; a tightening mold (6) for tightening said forming mold (1); rolling pin(s) (2), which can be inserted into and pulled out of the inner volume of said forming mold (1) and can rotate around a rotation axis; wherein said tightening mold (6) has a shape that cooperates with the shape of said forming mold (1), so that an action of said tightening mold (6) causes tightening of said forming mold (1).

Description

SYSTEM AND METHOD FOR MANUFACTURING A HONEYCOMB BODY
Technical field
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.
Background
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 speciality. In recent years, 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 .
Device and method for manufacturing a honeycomb body is known form the state of art. For example, 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. In 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. These devices are not only complex, difficult to manufacture, and also lack of accuracy. US 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.
Some of the technical solutions in the art either lead to inadequate performance of honeycomb body and even waste products due the inaccuracy of the honeycomb body's shape. Other solutions, in spite of enhancing the manufacturing precision, cause high complexity in configuration, difficulty in accurate control, and/or high costs in the manufacturing process.
Summary of the invention
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.
According to the invention, the system includes a forming mold with a plurality of sub-molds, which are movable so that they can be opened and closed; a tightening mold for tightening said forming mold, i.e. for closing the sub-molds thereof; rolling pin(s), which can be inserted into and pulled out of the inner volume of said forming mold and can rotate around a rotation axis. According to this invention, said tightening mold has a shape that cooperates with the shape of said forming mold, so that an action of said tightening mold causes tightening of said forming mold.
By means of this system, the honeycomb structure can be manufactured with high accuracy without using complex tightening system, such as those in the prior art .
According to a preferred embodiment, 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. Thus, not only the tightening mold itself, but also the driving train thereof, can be simply constructed and manufactured with low cost. This tightening mold can be easily driven, for example, by an electric motor via a gear-rack transmission, worm transmission and the like.
Other solutions are also possible for providing the forming mold and the tightening mold with cooperating configurations, such as mating structures with thread or groove 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.
Preferably, 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. Thus a manufacturing system with high accuracy can be provided easily .
According to a preferred embodiment, 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. Thus a highly automated system is achieved.
Also for the purpose of providing a highly automated system, 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:
opening the forming mold;
introducing the foil stack into the space between the rolling pins; rotating the rolling pins until the foil stack is fully rolled into the forming mold;
rotating the rolling pins while activating the tightening mold, with the action thereof causing the inner volume of the forming mold decreasing to a first value ;
pulling the rolling pins out of the structure formed by the foil stack;
pushing the rolled-up honeycomb structure into a housing by means of the ejecting part.
By means of this method, 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 .
Preferably, 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.
Brief Description of the Drawings
Figure 1 is a schematic drawing of the system according to the invention;
Figure 2 is a section of the manufacturing system, with the system in a state when the foil stack is being introduced;
Figure 3 is a drawing of the system according to the invention looking from the arrow D in Figure 2;
Figure 4 is a drawing corresponding to Figure 2, with the foil stack being already rolled and the tightening mold being already crossed a distance;
Figure 5 is a drawing corresponding to Figure 3, with the foil stack being already rolled and the tightening mold being already crossed a distance; Figure 6 is a block diagram showing the process for manufacturing a honeycomb body.
Detailed Description
Figure 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.
Figure 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 Figure 3) , which four sub-molds can be opened and closed. For example, 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.
As can be seen from Figure 3, there are gaps between the four sub-molds A in their opening state, through which gap a foil stack 3 to be rolled can be introduced into the forming mold 1. The foil stack 3 is produced by stacking wave metal foils and flat metal foils alternatively.
In the present embodiment, 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 Figure 4 and Figure 5. In one embodiment, 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 Figure 1 includes rolling pins 2, which can be inserted into the inner volume of the forming mold 1. In the shown embodiment, two 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.
One end of the rolling pin 2 is supported in a pin driving shaft 7. 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. Thus, a honeycomb is manufactured. In Figure 5, the central part of the foil stack 3, which has been rolled as a honeycomb structure, is coved by the ejecting part 5.
In one embodiment, 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 mechanics of the manufacturing system, i.e. the manufacturing method is described below:
First, 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.
In step SOI, the forming mold 1 is opened.
In step S02, a foil stack 3 is introduced into the space between the two rolling pins 2 through the gap between two sub-molds, see Figure 2 and Figure 3.
In step S03, 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.
In a step S04, 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. In the mean time, the rolling pins 2 keep rotating. In this embodiment, 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 Figure 4 and Figure 5.
In a step S05, the rolling pins 2 is pulled out after S04, and the tightening mold 6 is further moved, so that the inner volume of the forming mold 1 further decreases to a second value.
In a step S06, 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. In particular, the second value corresponds to the inner size of the forming mold 1 with the four sub- molds fully closed.
List of symbols
1 forming mold
2 rolling pins
3 foil stack
4 rolling pin driving shaft
5 ejecting part
6 tightening mold
7 supporting shaft
8 housing

Claims

Patent Claims
1. A system for manufacturing a honeycomb body,
comprising :
a forming mold (1) with a plurality of sub-molds, which are movable so that they can be opened and closed; a tightening mold (6) for tightening said forming mold ( 1 ) ;
rolling pin(s) (2), which can be inserted into and pulled out of the inner volume of said forming mold (1) and can rotate around a rotation axis;
characterized in that,
said tightening mold (6) has a shape that
cooperates with the shape of said forming mold (1), so that an action of said tightening mold (6) causes tightening of said forming mold (1) .
2. The system of claim 1, characterized in that, said tightening mold (6) has a conical inner surface, which cooperates with a conical outer surface of said forming mold (1), and said tightening mold (6) are displaceable in the axial direction.
3. The system of claim 1 or 2, characterized in that, said forming mold (1) comprises four sub-molds.
4. The system of claim 1 or 2, characterized in that, said sub-molds can be closed to form a cylindrical, circumferential closed inner volume.
5. The system of claim 1 or 2, characterized in that, further comprising an ejecting part (5), which is movable in the axial direction so as to push the
rolled-up honeycomb structure into a housing (8) .
6. The system of claim 1 or 2, characterized in that, further comprising a rolling pin driving shaft (7), which supports one end of the rolling pin (2), and on which said ejecting part (5) is arranged, such that said ejecting part (5) is slidable on the rolling pin driving shaft (7) .
7. The system of claim 1 or 2, characterized in that, further comprising a automatic feeding device for feeding said forming mold (1) with foil stack (3) to be rolled .
8. A method for manufacturing honeycomb body, wherein the system of one of the above claims is applied, the method comprising the following steps:
opening the forming mold (SOI);
introducing the foil stack into the space between the rolling pins(S02);
rotating the rolling pins until the foil stack is fully rolled into the forming mold (S03) ;
rotating the rolling pins while activating the tightening mold, with the action thereof causing the inner volume of the forming mold decreasing to a first value (S04);
pulling the rolling pins out of the structure formed by the foil stack (S05) ;
pushing the rolled-up honeycomb structure into a housing by means of the ejecting part (S07) .
9. A method of claim 8, characterized in that, 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 (S06) .
PCT/CN2011/081618 2011-11-01 2011-11-01 System and method for manufacturing a honeycomb body WO2013063754A1 (en)

Priority Applications (11)

Application Number Priority Date Filing Date Title
RU2014122027A RU2609117C2 (en) 2011-11-01 2011-11-01 Cellular structure producing device and method
EP11874960.5A EP2773856A4 (en) 2011-11-01 2011-11-01 System and method for manufacturing a honeycomb body
MX2014004340A MX2014004340A (en) 2011-11-01 2011-11-01 System and method for manufacturing a honeycomb body.
CA2850552A CA2850552A1 (en) 2011-11-01 2011-11-01 System and method for manufacturing a honeycomb body
US14/342,737 US20150128676A1 (en) 2011-11-01 2011-11-01 System And Method For Manufacturing A Honeycomb Body
KR1020147011334A KR20140094519A (en) 2011-11-01 2011-11-01 System and method for manufacturing a honeycomb body
BR112014008084A BR112014008084A2 (en) 2011-11-01 2011-11-01 system and method for making honeycomb body
CN201180074560.6A CN103906905B (en) 2011-11-01 2011-11-01 System and method for manufacturing honeycomb body
IN3967CHN2014 IN2014CN03967A (en) 2011-11-01 2011-11-01
JP2014539200A JP5760152B2 (en) 2011-11-01 2011-11-01 System and method for manufacturing a honeycomb body
PCT/CN2011/081618 WO2013063754A1 (en) 2011-11-01 2011-11-01 System and method for manufacturing a honeycomb body

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

Publications (1)

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WO2013063754A1 true WO2013063754A1 (en) 2013-05-10

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EP (1) EP2773856A4 (en)
JP (1) JP5760152B2 (en)
KR (1) KR20140094519A (en)
CN (1) CN103906905B (en)
BR (1) BR112014008084A2 (en)
CA (1) CA2850552A1 (en)
IN (1) IN2014CN03967A (en)
MX (1) MX2014004340A (en)
RU (1) RU2609117C2 (en)
WO (1) WO2013063754A1 (en)

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Publication number Priority date Publication date Assignee Title
CN108788629A (en) * 2018-04-28 2018-11-13 无锡市盛和科技有限公司 A kind of racetrack metallic carrier core production technology
CN108856498B (en) * 2018-04-28 2020-02-07 无锡市盛和科技有限公司 Production process of concave-convex concentric carrier

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KR20140094519A (en) 2014-07-30
EP2773856A1 (en) 2014-09-10
US20150128676A1 (en) 2015-05-14
EP2773856A4 (en) 2016-04-13
IN2014CN03967A (en) 2015-10-23
RU2609117C2 (en) 2017-01-30
CA2850552A1 (en) 2013-05-10
CN103906905B (en) 2017-04-26
BR112014008084A2 (en) 2017-04-11
MX2014004340A (en) 2014-08-01
RU2014122027A (en) 2015-12-10
JP2015501217A (en) 2015-01-15
CN103906905A (en) 2014-07-02
JP5760152B2 (en) 2015-08-05

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