JP2013015110A - Method of manufacturing honeycomb body in exhaust gas catalyst device, and honeycomb body manufactured by the method, and exhaust gas catalyst device using the honeycomb body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a novel manufacturing method by which a honeycomb body as a core piece in the exhaust gas catalyst device is formed of one piece of a metal sheet and the honeycomb body obtains a wide surface area.SOLUTION: There is provided a method of manufacturing a honeycomb body 3 of an exhaust gas catalyst device 1 that is provided in an outer cylinder body 2 to which exhaust gas G is sent, and that cleans the exhaust gas G using a catalyst deposited and formed on a flow path surface. The honeycomb body 3 is formed by corrugating sheet shaped metallic foil to form a corrugated sheet having a corrugated flow path cross section and winding the corrugated sheet honeycomb-like. In the corrugating, an exhaust gas flow path 31 is formed to draw a zigzag flow guiding wave form on the outer cylinder body 2 in the peripheral direction.

Description

  The present invention relates to an apparatus for purifying combustion gas discharged from various internal combustion engines, and in particular, a large surface area can be obtained while forming a honeycomb body as a core piece from a single metal plate. The present invention relates to a novel method for manufacturing a honeycomb body and an exhaust gas catalyst device to which the honeycomb body is applied.

In general, in an engine that obtains mechanical power by exploding and burning oil in a cylinder, harmful gases such as CO (carbon monoxide), HC (hydrocarbon), and NO _x (nitrogen oxide) are contained in the exhaust gas. Therefore, a catalyst device (purification device) that reduces this kind of harmful substances is incorporated in the exhaust gas discharge path such as a muffler and an exhaust pipe.
As this catalyst device, a monolith type in which a honeycomb body as a core piece whose cross section is formed in a honeycomb shape is fitted into an outer cylindrical body is well known (see FIG. 1). The exhaust gas is purified by bringing it into contact with a catalyst metal such as platinum or rhodium previously deposited on the wall surface of the flow path. The reason why the core piece is formed in a honeycomb shape is to increase the contact area (surface area) with the exhaust gas and improve the purification performance.

  By the way, in order to manufacture such a honeycomb body, for example, corrugation processing (corrugation processing) is performed on a metal plate material (flat plate) having a certain thickness to form a corrugated sheet (corrugated sheet having a channel cross-sectional waveform). In general, a honeycomb body having a desired diameter (size) is obtained by winding it in a coil shape while overlapping it with another flat plate until it has an appropriate size. However, in such a manufacturing method, even by manufacturing a honeycomb body, a corrugated plate is processed from a flat plate, or a plurality of constituent members and processes such as winding while overlapping with another flat plate are required, As a result, the cost and weight of the exhaust gas catalyst device may increase.

For this reason, the present applicant uses a pipe-shaped member formed in a tubular shape as a starting material, presses this to form a plurality of pleats, and uses this as a core piece (honeycomb body) Has been developed and has been patented (see, for example, Patent Document 1).
However, in this type of automotive parts industry, there are always demands for cost and weight reduction, and even with catalytic devices, not only high purification performance but also further weight reduction and cost reduction. Manufacturing methods for realizing the above are intensively studied every day.

JP 2003-113711 A

  The present invention has been made as part of such research and development. A corrugated sheet (corrugated sheet having a channel cross-sectional waveform) is formed from a single metal sheet (flat plate), and only this corrugated sheet is wound. The present inventors have attempted to develop a novel honeycomb body manufacturing method in which a honeycomb body having a desired size can be obtained by rotating and an exhaust gas catalyst device to which the honeycomb body is applied.

First, a method for manufacturing a honeycomb body in an exhaust gas catalyst device according to claim 1 is as follows.
In a method of manufacturing a honeycomb body of an exhaust gas catalyst device that purifies exhaust gas by a catalyst that is provided inside an outer cylinder body into which exhaust gas is sent and is attached to a flow path surface.
In forming the honeycomb body, corrugation processing is performed on a flat metal foil material to form a corrugated sheet having a channel cross-sectional waveform, and the corrugated sheet is formed by winding the corrugated sheet into a honeycomb shape.
In the corrugating process, the exhaust gas flow path is formed so as to draw a zigzag flow guide waveform in the circumferential direction of the outer cylinder.

Moreover, the manufacturing method of the honeycomb body in the exhaust gas catalytic device according to claim 2 is in addition to the requirement of claim 1,
The zigzag flow guide waveform drawn by the exhaust gas flow path is such that the exhaust gas flowing in the exhaust gas flow channel always has a component of transfer in the traveling direction, and draws amplitudes of substantially the same magnitude on both sides of the waveform center. It is characterized by being formed.

Moreover, in addition to the requirement of the said Claim 1 or 2, the manufacturing method of the honeycomb body in the exhaust gas catalyst apparatus of Claim 3 is as follows.
The exhaust gas flow path formed so as to draw the zigzag flow guide waveform is such that the exhaust gas inlet portion and the exhaust gas outlet portion overlap each other in one linear portion when viewed from the axial direction of the outer cylinder. It is characterized by being formed.

Moreover, the manufacturing method of the honeycomb body in the exhaust gas catalyst device according to claim 4, in addition to the requirements of claim 1, 2 or 3,
The corrugating process for processing the flat metal foil material into a corrugated sheet having a channel cross-sectional corrugation is a process of forming a corrugated sheet by sandwiching the metal foil material with an opposing pressing member. A split structure that is divided at each straight line portion or each peak portion of the exhaust gas flow path that draws a flow guide waveform
The pressing member is formed by connecting pressing elements corresponding to the number of flow guide waveforms to be formed in a direction extending the shape forming portion.

Moreover, the manufacturing method of the honeycomb body in the exhaust gas catalyst device according to claim 5 is in addition to the requirement according to claim 1, 2, 3 or 4,
An inside / outside communication hole that connects the inside and the outside of the exhaust gas channel is formed near the inflection point of the exhaust gas channel that draws the zigzag flow guide waveform.

Further, the honeycomb body in the exhaust gas catalyst device according to claim 6,
In the honeycomb body of the exhaust gas catalyst device, which is provided inside the outer cylinder body into which the exhaust gas is sent and purifies the exhaust gas by the catalyst formed on the flow path surface,
The honeycomb body is manufactured by the manufacturing method according to claim 1, 2, 3, 4 or 5.

The exhaust gas catalyst device according to claim 7 is:
An exhaust gas catalyst device that purifies exhaust gas by a catalyst that is formed by providing a honeycomb body inside an outer cylinder body into which exhaust gas is fed, and is attached to the flow path surface,
The honeycomb body is characterized in that the honeycomb body according to claim 6 is applied.

The above-described problems can be solved by using the configuration of the invention described in each of the claims.
First, according to the first, sixth and seventh aspects of the invention, a honeycomb body formed by winding a flat plate and a corrugated sheet is usually formed by winding only the corrugated sheet obtained from one flat plate. , While increasing the exhaust gas flow area (area where exhaust gas contacts the catalyst metal attached to the flow wall), the structure of the honeycomb body as a carrier is not complicated, and the processing itself can be performed simply it can.
Furthermore, since the exhaust gas flow path is formed so as to draw a zigzag flow guide waveform, that is, the exhaust gas flow path passes alternately on both sides of the center of the waveform, The corrugated sheet) is extremely easy to wind, and the honeycomb body can be manufactured very efficiently. In other words, if the exhaust gas moving distance is simply increased and the contact area is increased, it is possible to form the exhaust gas flow path in a certain oblique state (that is, in a lotus shape). Even if a corrugated sheet (corrugated sheet having a corrugated channel cross section) is normally wound, the corrugated sheet is like a bamboo shoot spring or a spiral staircase because the exhaust gas flow path is always formed in the same inclination direction (in a lotus shape). It extended in the winding axis direction (lateral deviation) and could not be wound well. In addition, when the sheet is wound while forcibly suppressing such lateral misalignment (while pressing the corrugated sheet from the winding axis direction), the side surface of the honeycomb body wound in a columnar shape is recessed inward (warping). However, in the present invention, there is a problem that subsequent welding is impossible. However, in the present invention, such a problem can be solved, and the honeycomb body and thus the exhaust gas catalyst device can be efficiently manufactured.

  Further, according to the inventions of claims 2, 6 and 7, the exhaust gas flow path is formed as, for example, a triangular wave or a sine wave, and therefore occurs when the exhaust gas flow path is formed in a certain inclined state (in a lotus shape). It is possible to more reliably prevent the adverse effects, specifically the occurrence of the above-mentioned “lateral deviation” and “warping”. In other words, when the exhaust gas flow path is formed as a triangular wave or a sine wave, the inclination of the waveform is formed as two different directions of inclination such as a “C” shape or a “V” shape. This can offset the adverse effects of forming a lotus and reduce the occurrence of these.

  According to the inventions of claims 3, 6 and 7, each linear portion of the exhaust gas flow path is formed so that the exhaust gas inlet portion and the exhaust gas outlet portion are somewhat overlapped in the projected state from the axial direction. Therefore, the exhaust gas contact area can be increased and the exhaust gas passage (penetration) can be prevented from being inhibited.

  In addition, according to the inventions of claims 4, 6, and 7, the pressing member (double helical gear or press mold) for corrugating adopts a dividing structure that is divided at each straight line portion or each mountain portion of the exhaust gas flow path. A pressing member can be formed by connecting an appropriate number of the individual pressing elements. Therefore, if the zigzag flow guide waveform drawn by the exhaust gas flow path is the same pattern, the pressing member is formed by using the pressing element even if the length (number of wavelengths) of the exhaust gas flow path is different. Therefore, the initial cost and running cost of corrugating can be reduced. That is, in the present invention, since the pressing member that hits the mold is formed by the combination of the pressing elements, it is not necessary to individually manufacture the mold one by one in the exhaust gas flow paths having different flow path lengths (number of wavelengths), The mold production cost (production cost of the pressing member) can be remarkably suppressed.

  Further, according to the inventions of claims 5, 6, and 7, since the inner and outer communication holes are formed in the wall surface of the exhaust gas flow path serving as a cell, the exhaust gas passing through one exhaust gas flow path is further separated into another exhaust gas flow path. The contact efficiency, that is, the purification performance can be further improved. Further, such an inner and outer communication hole can be expected to improve the silencing effect.

1 is a cross-sectional view showing an exhaust silencing unit to which an exhaust gas catalyst device of the present invention is applied, and a perspective view showing the exhaust gas catalyst device and a honeycomb body (before winding). A corrugated metal plate material is formed to form a corrugated sheet (corrugated sheet having a channel cross-sectional waveform), and then only the corrugated sheet is wound to obtain a honeycomb body of a desired size. FIG. It is explanatory drawing which shows roughly the manufacturing method of the exhaust gas catalyst apparatus which inserts and brazes the honeycomb body obtained by winding only a corrugated sheet in an outer cylinder body. It is explanatory drawing which shows roughly the Example at the time of using a press die as a corrugating machine. It is a skeleton top view which shows the variation about the zigzag flow guide waveform which an exhaust gas channel draws. The figure (a) which shows an example of the planar view state (before winding) of the exhaust gas flow path which draws a zigzag flow guide waveform, and the state of the internal and external communication holes formed near the bent part of the zigzag flow guide waveform It is an enlarged plan view (b) which shows, and an enlarged plan view (c) which shows an example of the zigzag flow guide waveform which prevents the said communicating hole from being formed. When explanatory drawings (a) and (b) showing two kinds of examples when the exhaust gas flow path is always formed in a constant inclined state with respect to the metal plate material (formed in a lotus), and when this work is wound FIG. 6 is an explanatory diagram (c) and (d) showing lateral deviation and warpage occurring in FIG.

The mode for carrying out the present invention includes one described in the following embodiments, and further includes various methods that can be improved within the technical idea.
In the description, first, the outline of the exhaust gas catalyst device 1 will be described, and then the manufacturing method of the honeycomb body 3 will be described while explaining the manufacturing method of the exhaust gas catalyst device 1.

  First, an outline of the exhaust gas catalyst device 1 will be described. As shown in FIG. 1 as an example, the exhaust gas catalyst device 1 is incorporated in an exhaust silencing unit U and purifies the exhaust gas G discharged from the engine after combustion before being released into the atmosphere. A catalyst (catalyzer material) for reducing harmful substances is adhered and formed on the flow path wall surface of the exhaust gas catalytic device 1, and the exhaust gas G contacts the catalyzer material while passing through the inside of the exhaust gas catalytic device 1. To be purified.

Such an exhaust gas catalyst device 1 includes an outer cylinder body 2 that is opened in the front-rear direction and a honeycomb body 3 that is provided inside the outer cylinder body 2. The honeycomb body 3 has a cross section (flow path cross section) formed in a honeycomb shape so as to ensure a large contact area with the exhaust gas G.
Usually, in order to form such a honeycomb body 3, a corrugated plate (corrugated plate) is first formed from a single metal plate (flat plate) by corrugating (corrugated plate), and this wave is formed. In general, the honeycomb body 3 is formed by winding a plate while overlapping another plate. However, in the present invention, such a honeycomb body 3 is obtained by winding it from one corrugated plate (corrugated plate having a channel cross-sectional corrugation), that is, it is not characterized by being separately stacked with a flat plate. One.
Further, the corrugating process is performed on the flat plate in order to form the exhaust gas flow path 31 as a cell. Normally, the exhaust gas flow path 31 is formed straight in the axial direction of the exhaust gas catalytic device 1. Then, this flow path is formed so as to draw a zigzag flow guide waveform in the circumferential direction of the outer cylindrical body 2, and this is also one of the major features of the present invention.

Hereinafter, the manufacturing method of the honeycomb body 3 will be described together with the manufacturing method of the exhaust gas catalyst device 1.
(1) Manufacture of honeycomb body (a) Preparation of starting material In manufacturing the honeycomb body 3, for example, as shown in FIG. 2, a metal plate material is drawn out (rolled out) from a raw roll wound in a coil shape. This is generally applied as a starting material (metal foil material). At this time, as shown in FIG. 2, it is preferable to sandwich the drawn metal foil material between a pair of pinch rollers PR. This is to remove curl and distortion when the metal plate is wound in a coil shape. In addition, the code | symbol W in a figure is a code | symbol attached | subjected to the workpiece | work as an intermediate processed product (a start state is also included) until such a metal plate material (metal foil material) is formed as the honeycomb body 3.

(B) Corrugated processing (corrugated processing)
The work W from which the winding wrinkles and distortion have been removed by the pinch roller PR is then corrugated by a corrugating machine (corrugating machine) 5 such as a pair of meshing double helical gears 51 as shown in FIG. (Corrugated plate having a channel cross-sectional waveform). Incidentally, since this corrugated sheet (work W) is finally wound up and becomes a cell (exhaust gas channel 31), it can be said that it constitutes a wall of the exhaust gas channel 31.

In the normal corrugating process, the exhaust gas flow path 31 is formed straight along the axial direction of the exhaust gas catalytic device 1, but in the corrugating process, the exhaust gas flow path 31 is not formed straight. In addition, it is not formed in an oblique straight shape (so-called “lotus”) with respect to the axial direction, but is formed so that the exhaust gas flow path 31 draws a zigzag flow guide waveform with respect to the axial direction as viewed from above. To do. That is, from the exhaust gas catalyst device 1 in a completed state, the exhaust gas flow path 31 is formed so as to draw a zigzag flow guide waveform in the circumferential direction of the outer cylindrical body 2. Therefore, in the embodiment shown in FIG. 2, a double helical gear (helical gear) 51 is applied as the corrugating machine 5 instead of a spar gear (spur gear) or a helical gear (helical gear).
Incidentally, in the present specification, a wave as a cross-sectional shape of the exhaust gas flow channel 31 (a wave formed by normal corrugation) is referred to as a “flow channel cross-sectional waveform”, while the exhaust gas flow channel 31 is viewed from a plane ( In particular, a wave (zigzag) before winding is distinguished as a “flow guide waveform”.

  In the embodiment shown in FIG. 2, the double helical gear 51 that forms three mountain shapes corresponding to the length of the exhaust gas flow channel 31 at a time is illustrated, but the double helical gear 51 is divided in each mountain shape unit. Is also possible. In that case, since a normal helical gear (double helical gear) forms one mountain shape (because it is called a helical gear), there are three such helical gears (which are used as gear elements). It is possible to form three mountain shapes at a time by connecting them (provided integrally). Thus, about the press member (corrugating machine 5) which performs waveform processing, such as the double helical gear 51, it is possible to take a divided structure, and the divided element (mold member) is used as the press element. The structure for dividing the pressing member such as the double helical gear 51 will be described later.

  Here, as the zigzag flow guide waveform drawn by the exhaust gas flow path 31 (zigzag in a broad sense), for example, as shown in FIGS. 5A to 5D, a triangular wave (in a narrow sense) Zigzag), sine wave (meandering), rectangular wave, sawtooth wave, and the like are conceivable. Of these, triangular wave and sine wave are particularly preferable. This is because problems such as “lateral misalignment” and “warping” that occur when the exhaust gas flow path 31 is formed in a certain inclination (lotus) with respect to the traveling direction of the exhaust gas G can be solved. Hereinafter, the “lateral shift” and “warp” will be described.

  If only the flow path length (contact area) of the exhaust gas G is to be increased, for example, as shown in FIGS. It is also possible to win for a long time. Here, FIG. 7A shows a state in which the exhaust gas flow path 31 is inclined by 15 degrees with respect to the axial direction of the exhaust gas catalytic device 1 (corresponding to a waveform center AX described later), and FIG. It is in a tilted state. However, when the exhaust gas flow path 31 is formed in a lotus in this way, when the work W (corrugated sheet having a flow path cross-sectional waveform) after corrugation processing is to be wound, the work W is shown in FIG. As shown in Fig. 4, the winding extends in the direction of the winding axis like a bamboo spring or a spiral staircase (this is "lateral shift"), and cannot be wound as it is.

Further, in order to prevent such “lateral deviation” from occurring, it is necessary to wind the workpiece W (corrugated sheet having a flow path cross-sectional waveform) being wound while pressing it from both sides in the winding axis direction. As shown in FIG. 7D, for example, the honeycomb body 3 wound in a columnar shape has a side peripheral surface that is recessed inward (this is “warping”), and subsequent welding of the part is not effective. It would be possible.
It is considered that such a problem occurs because the exhaust gas flow path 31 is formed in a lotus shape, that is, is always formed obliquely in a certain direction. Therefore, in this embodiment, the exhaust gas flow path 31 has a zigzag flow guide waveform. It is formed to draw (for example, a triangular wave or a sine wave). That is, by setting the inclination of the flow guide waveform of the exhaust gas flow path 31 to two different directions, the adverse effect when the exhaust gas flow path 31 is formed in a lotus (one inclination) is offset, and the above-described lateral deviation and warpage occur. It is something that is not allowed to occur.

As described above, the triangular wave and the sine wave have a trajectory that draws substantially the same amplitude on both sides of the waveform center AX, while the exhaust gas G flowing in the exhaust gas flow path 31 always has a transfer component in the traveling direction. Therefore, the inclination of the flow guide waveform is not always one (one direction), but has two different inclinations such as “C” shape or “V” shape. The adverse effect of forming 31 as a lotus can be offset.
Incidentally, the triangular wave is an image in which the “V” character is repeated, and the sine wave is an image in which the “S” character is repeated. That is, although the distinction between the two is not necessarily clear, the exhaust gas flow path 31 is bent in an acute shape (so-called pin angle) is a triangular wave, and the exhaust gas flow path 31 is bent in a meandering shape (in an arc). Is considered a sine wave. As described above, the sine wave in the present specification does not necessarily exactly reproduce a mathematical sine curve, but includes a waveform obtained by approximating the acute angle portion of various triangular waves with R and the like.

Further, the zigzag flow guide waveform drawn by the exhaust gas flow channel 31 is, for example, as shown in FIG. 6 (a), when one straight portion in the flow channel is viewed from the axial direction of the exhaust gas catalytic device 1, And the exhaust gas outlet part are preferably formed to overlap each other (preferably such a zigzag degree or an inclined state). In other words, when the exhaust gas inlet portion and the exhaust gas outlet portion are projected from the axial direction of the exhaust gas catalytic device 1, they are formed so that a part of the outlet portion can be seen from the inlet portion. .
By forming the exhaust gas flow path 31 in this way, there is an effect that it is possible to increase the contact efficiency of the exhaust gas G with respect to the flow path wall surface and not to impede the gas passage (penetration). Incidentally, the inclination angle (zigzag degree from the waveform center AX) of the exhaust gas flow channel 31 shown in FIG. 6A is 16 degrees as an example.

In addition to the pair of double helical gears 51 described above, for example, a pair of opposed types as shown in FIG. 4 can be used as the corrugating machine 5 (a so-called press machine, which is referred to as a press mold 52). To do). Here, the shape forming portion (meshing portion) of the double helical gear 51 is linear, whereas in the case of the press die 52, it can be understood that the shape forming portion (sandwich surface) has a planar shape.
In addition, when a press die 52 is applied as the corrugating machine 5 and a flow guide waveform (exhaust gas flow path 31) that draws a zigzag shape is pressed by an appropriate number of times by one press operation (pressing press). During the press working, since it is necessary to temporarily stop (interrupt) the transfer of the workpiece W as an intermediate workpiece, the feeding of the workpiece W is an intermittent feeding operation.

Further, when the press die 52 is applied as the corrugating machine 5, for example, as shown in FIG. 4, it is possible to divide the press die 52 in units of each linear portion of the exhaust gas flow path 31, and to divide the press die 52. Each block type is a type element 52n. That is, in forming the press die 52 as a die, the necessary number of die elements 52n are continuously provided (continuously provided in the direction in which the shape forming portion is extended), and the exhaust gas path having a necessary flow path length. 31 (flow guide waveform that draws a zigzag shape) is formed all at once.
In FIG. 4, the reference numerals 52a to 52f are assigned to the respective mold elements. However, a generic name of these mold elements or a reference numeral 52n is also given to represent them (that is, the mold elements are 52f or later). Also can be present).

  In this way, by forming the press die 52 in a divided structure, if the exhaust gas flow channel 31 repeats the same flow guide waveform pattern, the mold depends on the length of the flow channel, that is, the number of wavelengths of the exhaust gas flow channel 31. The press mold 52 can be formed by connecting the elements 52n, and the same mold element 52n can be used for general purposes. For this reason, the manufacturing cost (die cost) of the press die 52 can be suppressed extremely low. In other words, although the exhaust gas flow channel 31 repeats the same flow guide waveform pattern, if the opposed mold 52 is individually manufactured according to the difference in flow channel length (dedicated type), only the mold cost is As a result, the cost becomes enormous and eventually increases the cost of the exhaust gas catalyst device 1 as a whole.

Of course, the technical idea of dividing the press die 52 (pressing member) is also applicable to the case of the double helical gear 51 as described above. Incidentally, in the case of the double helical gear 51, since it is common to form a single mountain shape (valley shape) by a pair of meshing gear elements (because it is called a splint gear), a zigzag flow Rather than using one linear part of the guide waveform as a break (unit) of the gear element, it is generally considered that the gear element is configured with a single mountain shape (valley shape) as a break.
The “pressing member” described in the claims refers to the double helical gear 51 and the press die 52 (that is, the corrugating machine 5 in the end), and the “pressing element” refers to the gear element and the die. Element 52n is shown.

  As described above, in the present invention, not only the flat workpiece W is formed on the corrugated plate (the corrugated plate having the channel cross-sectional waveform) during corrugating, but the exhaust gas flow channel is seen in a plan view of the workpiece W. 31 is formed so as to draw a zigzag flow guide waveform. For this reason, at the bent portion of the zigzag flow guide waveform, an excessive load may be applied to the workpiece W, and for example, a “crack” as shown in FIG. 6B may occur. Here, such “crack” and “crack” are generally properties as a member such as reducing the rigidity and strength of the workpiece W processed into a corrugated plate (corrugated plate having a corrugated channel cross section). In this embodiment, such a “crack” is positively utilized as a communication hole (this is referred to as an internal / external communication hole 32) that allows communication between the inside and outside of the exhaust gas flow path 31. It is. In other words, the exhaust gas G flowing in a zigzag manner along the exhaust gas flow channel 31 is introduced into the different exhaust gas flow channel 31 by this inner / outer communication hole 32 (to make it easier to flow), The contact efficiency is further improved.

Of course, how much the inner and outer communication holes 32 are formed or not generated at all is possible. For example, the thickness of the workpiece W at the time of corrugation processing or the zigzag shape in the exhaust gas passage 31 These adjustments can be made by adding an R to the bent portion of the flow guide waveform (see FIG. 6C). By setting at least in this way, when the workpiece W formed in a corrugated plate shape is wound, the workpiece W can be completely prevented from being broken by the inner and outer communication holes 32.
Incidentally, such an internal / external communication hole 32 can be expected not only to improve the contact efficiency between the exhaust gas G and the catalyst metal, but also to achieve a silencing effect.

(C) Corrugated sheet winding (core molding)
The workpiece W (corrugated sheet) on which the exhaust gas flow path 31 that draws a zigzag flow guide waveform as described above is then wound until it reaches a desired size, for example, as shown in FIG. The honeycomb body 3 as a core piece is formed.
Here, when the corrugated workpiece W is wound, it is preferable that welding is appropriately performed at the contact portion between the workpieces W located on the inner and outer circumferences. Reference numeral 6 in the figure denotes a laser for this purpose. It is a welding machine. Further, it is preferable to provide a non-contact type sensor in the vicinity of the laser welding machine 6 for accurately detecting the joining position, that is, the contact position of the workpiece W.
In FIG. 2, the drawing of the workpiece W (metal foil material) from the raw roll, the corrugating process to the workpiece W, and the winding after the corrugating process are performed continuously as a series of steps. However, these are not necessarily performed continuously, and may be once ended (completed) for each process.

Hereinafter, the effect (dominance) of making the flow guide waveform of the exhaust gas flow channel 31 a zigzag shape will be described.
By forming the exhaust gas flow path 31 as a zigzag flow guide waveform, the work W (corrugated sheet having a flow path cross-sectional waveform) after corrugation can be easily wound, and a honeycomb body as a wound body 3 can be reliably joined to the outer cylindrical body 2. That is, if the area of the flow path through which the exhaust gas G flows is simply increased (if the flow path length is increased), for example, as shown in FIGS. However, in this case, when the work W after corrugation processing (corrugated sheet in which the exhaust gas flow path 31 is formed in a lotus) is to be wound, the work W is shown in FIG. In this way, it extends in the direction of the winding axis (lateral deviation) like a bamboo spring or a spiral staircase and cannot be wound as it is. Of course, in order to prevent such a lateral shift from occurring, it is sufficient to wind the workpiece W (corrugated sheet) being wound while forcibly pressing it from both sides in the winding axis direction. It cannot be done.

  Further, in the cylindrical honeycomb body 3 obtained in this way, as shown in, for example, FIG. 7 (d), the side peripheral surface is indented (warped), and subsequent welding at the part is impossible. It was something that would end up. Therefore, in the present embodiment, the exhaust gas flow passage 31 is formed so as to draw a zigzag flow guide waveform (for example, a triangular wave or a sine wave), and the inclination of the flow guide waveform is set to two different directions, The adverse effect of the case where the slope of the waveform is on one side (in the case of a lotus) is offset so that the above-described lateral shift and warpage are not caused.

(2) Fit of honeycomb body into outer cylinder (a) Formation of outer cylinder (production)
Thereafter, the honeycomb body 3 obtained in this way is inserted into the outer cylindrical body 2. If the outer cylindrical body 2 is formed in a pipe shape (cylindrical shape) from the beginning, it is left as it is or By cutting to an appropriate length, the desired outer cylindrical body 2 is obtained, but when the initial state of the outer cylindrical body 2 is a flat plate, in parallel with the above-mentioned “Manufacture of honeycomb body”, It is preferable to form (manufacture) the outer cylindrical body 2 by rounding this flat plate into a cylindrical shape and joining the ends appropriately by welding or the like (see FIG. 3A).

(B) Application of brazing material Next, as shown in FIG. 3A, a brazing material for brazing (which acts as an adhesive) is applied to the inner surface of the outer cylindrical body 2. The brazing material may be applied only to the installation position of the honeycomb body 3.

(C) Inserting the honeycomb body (press-fit into the outer cylinder)
Thereafter, the honeycomb body 3 is inserted (press-fitted) into the outer cylindrical body 2 coated with the brazing material. For example, as shown in FIG. Thus, the honeycomb body 3 is press-fitted into the outer cylinder body 2 by the pushing body 7B while pressing the outer cylinder body 2 from the outer peripheral side.

(D) Brazing heat treatment After that, a heat treatment for brazing is performed. For example, as shown in FIG. 3 (c), the outer cylindrical body 2 in which the honeycomb body 3 is inserted (press-fit). A plurality of (exhaust gas catalyst devices 1) are accommodated in the processing device 8, and heat treatment for an appropriate time is performed to complete brazing. Note that the honeycomb body 3 is integrated with the outer cylindrical body 2 at the stage where the brazing heat treatment is completed, and the exhaust gas catalytic device 1 is obtained.
After that, after the brazing exhaust gas catalytic device 1 is subjected to a pressure test and inspection (NG products are excluded at this stage), numbering is performed to obtain the exhaust gas catalytic device 1 as a final finished product. It is.

  INDUSTRIAL APPLICABILITY The present invention can be used for an exhaust gas catalyst device that purifies combustion gas discharged from various internal combustion engines.

DESCRIPTION OF SYMBOLS 1 Exhaust gas catalyst apparatus 2 Outer cylinder body 3 Honeycomb body 5 Corrugating machine 6 Laser welding machine 7A Outer periphery holding body 7B Pushing body 8 Processing apparatus

3 Honeycomb body 31 Exhaust gas flow path 32 Internal and external communication holes

5 Corrugating machine 51 Double helical gear (pressing member)
52 Press mold (pressing member)
52n type element 52a type element 52b type element 52c type element 52d type element 52e type element 52f type element

AX Waveform center W Workpiece (intermediate processed product)
G Exhaust gas U Exhaust silencer unit PR Pinch roller

Claims (7)

In a method of manufacturing a honeycomb body of an exhaust gas catalyst device that purifies exhaust gas by a catalyst that is provided inside an outer cylinder body into which exhaust gas is sent and is attached to a flow path surface.
In forming the honeycomb body, corrugation processing is performed on a flat metal foil material to form a corrugated sheet having a channel cross-sectional waveform, and the corrugated sheet is formed by winding the corrugated sheet into a honeycomb shape.
In the corrugating process, the exhaust gas flow path is formed so as to draw a zigzag flow guide waveform in the circumferential direction of the outer cylindrical body.
The zigzag flow guide waveform drawn by the exhaust gas flow path is such that the exhaust gas flowing in the exhaust gas flow channel always has a component of transfer in the traveling direction, and draws amplitudes of substantially the same magnitude on both sides of the waveform center. The method for manufacturing a honeycomb body in an exhaust gas catalytic device according to claim 1, wherein the honeycomb body is formed.
The exhaust gas flow path formed so as to draw the zigzag flow guide waveform is such that the exhaust gas inlet portion and the exhaust gas outlet portion overlap each other in one linear portion when viewed from the axial direction of the outer cylinder. The method for manufacturing a honeycomb body in an exhaust gas catalytic device according to claim 1 or 2, wherein the honeycomb body is formed.
The corrugating process for processing the flat metal foil material into a corrugated sheet having a channel cross-sectional corrugation is a process of forming a corrugated sheet by sandwiching the metal foil material with an opposing pressing member. A split structure that is divided at each straight line portion or each peak portion of the exhaust gas flow path that draws a flow guide waveform
The said pressing member is formed by connecting the pressing element according to the number of the flow guide waveforms to form in the direction which extends a shape formation part, It is characterized by the above-mentioned. A method for manufacturing a honeycomb body in an exhaust gas catalytic device.
The inside and outside communication holes that connect the inside and the outside of the exhaust gas channel are formed near the bend of the exhaust gas channel that draws the zigzag flow guide waveform. 5. A method for manufacturing a honeycomb body in an exhaust gas catalytic device according to claim 4.
In the honeycomb body of the exhaust gas catalyst device, which is provided inside the outer cylinder body into which the exhaust gas is sent and purifies the exhaust gas by the catalyst formed on the flow path surface,
This honeycomb body is manufactured by the manufacturing method according to claim 1, 2, 3, 4 or 5. A honeycomb body in an exhaust gas catalyst device.
An exhaust gas catalyst device that purifies exhaust gas by a catalyst that is formed by providing a honeycomb body inside an outer cylinder body into which exhaust gas is fed, and is attached to the flow path surface,
The exhaust gas catalytic device according to claim 6, wherein the honeycomb body according to claim 6 is applied to the honeycomb body.

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