U.S. patent application number 10/497033 was filed with the patent office on 2005-03-03 for finned multi-aperture sheet metal, method of manufacturing the sheet metal, part for exhaust emission control device using the sheet metal, and method of manufacturing the part for exhaust emission control device.
Invention is credited to Shimizu, Keiichi, Taya, Shinichi.
Application Number | 20050044915 10/497033 |
Document ID | / |
Family ID | 19174636 |
Filed Date | 2005-03-03 |
United States Patent
Application |
20050044915 |
Kind Code |
A1 |
Shimizu, Keiichi ; et
al. |
March 3, 2005 |
Finned multi-aperture sheet metal, method of manufacturing the
sheet metal, part for exhaust emission control device using the
sheet metal, and method of manufacturing the part for exhaust
emission control device
Abstract
A holed sheet metal with multiple holes most suitable for
forming a spaced body with a net-like cross section as a part for
exhaust emission control device, a method of manufacturing the
sheet metal, a part for exhaust emission control device using the
sheet metal, and a method of manufacturing the part, wherein a
plurality of holes (3) are formed in a long flat-like sheet metal
(2) to form the finned sheet metal (1), and die holes (3) in the
finned sheet metal (1) are formed by bending fins (8) from the
sheet metal (2) in the direction of one surface side of the sheet
metal, whereby the sheet metal can be easily provided at a low
cost.
Inventors: |
Shimizu, Keiichi;
(Yamaguchi-ken, JP) ; Taya, Shinichi;
(Yamaguchi-ken, JP) |
Correspondence
Address: |
BROWDY AND NEIMARK, P.L.L.C.
624 NINTH STREET, NW
SUITE 300
WASHINGTON
DC
20001-5303
US
|
Family ID: |
19174636 |
Appl. No.: |
10/497033 |
Filed: |
October 15, 2004 |
PCT Filed: |
November 11, 2002 |
PCT NO: |
PCT/JP02/11701 |
Current U.S.
Class: |
72/186 |
Current CPC
Class: |
B21D 31/02 20130101;
F01N 2330/40 20130101; B21D 53/04 20130101; B01J 35/04 20130101;
F01N 3/2821 20130101; F01N 3/2817 20130101; F01N 2330/04 20130101;
B21D 28/36 20130101; F01N 2330/38 20130101 |
Class at
Publication: |
072/186 |
International
Class: |
B21D 028/10 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 29, 2001 |
JP |
2001-364445 |
Claims
1. A finned multi-aperture sheet metal in which a plurality of
holes is formed in a long flat band-like sheet metal, wherein each
of the holes is formed by bending a fin toward one surface side
from the sheet metal.
2. A finned multi-aperture sheet metal in which a plurality of
holes is formed in a long flat band-like sheet metal, wherein each
of the holes are formed by bending a fin toward any one of surface
sides from the sheet metal.
3. A method of manufacturing a finned multi-aperture sheet metal in
which at least holes with a fin are formed in a long flat band-like
sheet metal, wherein a plurality of substantially U-shaped cut
lines is formed on the sheet metal, each of tongue portions formed
based on the respective cut lines is selectively bent toward any
one of surface sides of the sheet metal to form a fin projected in
a bending direction, each of portions surrounded by the cut line is
opened, and thereby holes with a fin are formed.
4. A method of manufacturing a finned multi-aperture sheet metal in
which at least holes with a fin are formed in a long flat band-like
sheet metal, wherein between a perforating roller that is provided
on an outer periphery surface with a plurality of projection-like
blades each of which is capable of forming a substantially U-shaped
cut line on the sheet metal and of bending a tongue portion formed
based on the cut line outwards and a receiving roller that faces
the perforating roller and is provided on an outer periphery
surface with a plurality of grooves each of which is capable of
temporally accommodating the projection-like blade formed on the
perforating roller and the tongue portion bent by the
projection-like blade, a long flat band-like sheet metal is
continuously supplied, the cut lines are formed in substantial
U-shape on the sheet metal by use of the projection-like blades,
each of the tongue portions formed based on the cut lines is bent
outward to form a fin, each of portions surrounded by the cut lines
is opened, and thereby the holes with a fin are formed.
5. A method of manufacturing a finned multi-aperture sheet metal in
which at least holes with a fin are formed in a long flat band-like
sheet metal, wherein on an outer periphery surface of one roller of
a pair of rollers disposed oppositely, a plurality of
projection-like blades each of which is capable of forming a
substantially U-shaped cut line and of bending outwards a tongue
portion formed based on the cut line is formed; on the outer
periphery surface in band, a plurality of grooves each of which is
capable of temporally accommodating a projection-like blade formed
on an outer periphery surface of the other roller and the tongue
portion bent by the projection-like blade is formed; also on an
outer periphery surface of the other roller in band, a plurality of
the projection-like blades is formed; and on the outer periphery
surface in band, a plurality of grooves each of which is capable of
temporally accommodating the projection-like blade formed on the
outer periphery surface of the one roller and the tongue portion
bent by the projection-like blade, a long flat band-like sheet
metal is continuously supplied between the pair of rollers, thereby
substantially U-shaped cut lines are formed on a sheet metal by the
projection-like blades, each of the tongue portions formed based on
the cut lines is bent outwards to form a fin, each of portions
surrounded by the cut line is opened, and thereby holes with a fin
are formed.
6. A part for an exhaust emission control device, wherein a spaced
body that is formed by spirally winding the finned multi-aperture
sheet metal described in the claim 1 and has a net-like cross
section is inserted in a casing.
7. A method of manufacturing a part for an exhaust emission control
device having a spaced body that is formed by spirally winding a
finned multi-aperture sheet metal and has a net-like cross section
in a casing, wherein the finned multi-aperture sheet metal
described in the claim 1 is spirally wound into a diameter smaller
than an inner diameter of a casing followed by inserting in the
casing.
8. A method of manufacturing a part for an exhaust emission control
device having a spaced body that is formed by spirally winding a
finned multi-aperture sheet metal and has a net-like cross section
in a casing, wherein the finned multi-aperture sheet metal
described in the claim 1 is spirally wound, both or either one of
at least part of the finned multi-aperture sheet metal and part of
the spaced body having the net-like cross section is bonded, and
thereby a spaced body having a circular columnar net-like cross
section is formed.
9. A part for an exhaust emission control device, wherein a spaced
body that is formed by spirally winding the finned multi-aperture
sheet metal described in the claim 2 and has a net-like cross
section is inserted in a casing.
10. A method of manufacturing a part for an exhaust emission
control device having a spaced body that is formed by spirally
winding a finned multi-aperture sheet metal and has a net-like
cross section in a casing, wherein the finned multi-aperture sheet
metal described in the claim 2 is spirally wound into a diameter
smaller than an inner diameter of a casing followed by inserting in
the casing.
11. A method of manufacturing a part for an exhaust emission
control device having a spaced body that is formed by spirally
winding a finned multi-aperture sheet metal and has a net-like
cross section in a casing, wherein the finned multi-aperture sheet
metal described in the claim 2 is spirally wound, both or either
one of at least part of the finned multi-aperture sheet metal and
part of the spaced body having the net-like cross section is
bonded, and thereby a spaced body having a circular columnar
net-like cross section is formed.
Description
TECHNICAL FIELD
[0001] The present invention relates to a finned multi-aperture
sheet metal most preferably used in a device that purifies exhaust
emission exhausted from an internal-combustion engine such as an
engine of an automobile, a method of manufacturing the same, a part
for exhaust emission control device such as a supporter and a
filter that use the finned multi-aperture sheet metal, and a method
of manufacturing the part for exhaust emission control device.
BACKGROUND ART
[0002] In an exhaust emission control device of an internal
combustion engine such as an engine of an automobile and a power
generator, a metal supporter in which in a cylindrical casing made
of metal steel such as heat-resistant stainless steel sheet, a
circular columnar honeycomb body made of the same metal steel is
engaged is used.
[0003] Thus constituted conventional metal supporter is generally
manufactured according to such a manner that a honeycomb body
manufactured by spirally winding a flat sheet made of a band-like
sheet metal and a corrugated sheet obtained by corrugating the flat
sheet in a put together state is inserted in a cylindrical metal
casing, followed by bonding a contact portion between the flat
sheet and the corrugated sheet of a spaced body having a net-like
cross section and between a honeycomb body and the casing according
to a method such as brazing, welding or diffusion bonding.
Furthermore, various kinds of catalysts are coated, and thereby an
exhaust emission control device having a purifying function is
manufactured.
[0004] However, in a method of manufacturing a thus constituted
metal supporter, an operation of winding a flat sheet and a
corrugated sheet in a put together state, owing to difference in
the bending elasticity of both sheets and a frictional coefficient
problem at a contact portion between the flat sheet and the
corrugated sheet, cannot be stably carried out; that is, the
manufacture is carried out with extreme difficulty.
[0005] For instance, there is a problem (winding difference problem
at the time of winding) in that when a force for winding the flat
sheet and the corrugated sheet works differently at both end
portions in an axial direction of a honeycomb body manufactured as
an intermediate part, a spirally wound honeycomb body does not form
a proper circular columnar form and forms a shape (bamboo-shoot
like) in which one end side in an axial direction of the honeycomb
body projects bamboo-shoot like at a winding center portion and the
other end side thereof recedes mortar-like.
[0006] The present invention intends to provide a perforated sheet
metal most suitable for forming a spaced body with a net-like cross
section of a part for exhaust emission control device, a method of
forming the same, a part for exhaust emission control device having
the perforated sheet metal and a method of manufacturing the same
as one that is less expensive and easy.
DISCLOSURE OF INVENTION
[0007] In order to accomplish the above object, a finned
multi-aperture sheet metal according to the present invention is a
finned multi-aperture sheet metal in which a plurality of holes is
formed in a long flat band-like sheet metal, wherein each of the
holes is formed by bending a fin from the sheet metal toward one
surface side, or each of the holes is formed by bending a fin from
the sheet metal toward any one of surface sides.
[0008] Furthermore, a finned multi-aperture sheet metal
manufacturing method according to the invention is a method of
manufacturing a finned multi-aperture sheet metal where at least
holes with a fin are formed in a long band-like sheet metal,
wherein a plurality of substantially U-shaped cut lines is formed
on the sheet metal, each of tongue portions formed based on the
respective cut lines is selectively bent to any of both surface
sides of the sheet metal to form a fin protruded in a bending
direction, and a portion surrounded by the cut lines is opened to
form a hole with the fin.
[0009] More specifically, a finned multi-aperture sheet metal
manufacturing method according to the invention is a method of
manufacturing a finned multi-aperture sheet metal where at least
holes with a fin are formed in a long band-like sheet metal,
wherein a long flat band-like sheet metal is continuously supplied
between a perforating roller that is provided on an outer periphery
surface with a plurality of projection-like blades that can form
substantially U-shaped cut lines on the sheet metal and bend tongue
portions formed based on the cut lines outwards and a receiving
roller that faces the perforating roller and is provided on an
outer periphery surface with a plurality of grooves that can
temporally accommodate the projection-like blades formed on the
perforating roller and the tongue portions bent by the
projection-like blades, substantially U-shaped cut lines are formed
on the sheet metal by use of the projection-like blades, each of
the tongue portions formed based on the cut lines is bent outward
to form a fin, a portion surrounded by the cut line is opened, and
thereby a hole with the fin is formed.
[0010] Alternatively, of a pair of rollers disposed oppositely, on
an outer periphery surface of one roller, a plurality of
projection-like blades that can form substantially U-shaped cut
lines and bend outwards tongue portions formed based on the cut
lines is formed; on the outer periphery surface in band, a
plurality of grooves that allows temporally accommodating
projection-like blades formed on an outer periphery surface of the
other roller and the tongue portions bent by the projection-like
blades is formed; also on an outer periphery surface of the other
roller in band, a plurality of the projection-like blades are
formed; and on the outer periphery surface in band, a plurality of
grooves that allows temporally accommodating the projection-like
blades formed on the outer periphery surface of the one roller and
the tongue portions bent by the projection-like blades, a long flat
band-like sheet metal is continuously supplied between the pair of
rollers, substantially U-shaped cut lines are formed on a sheet
metal by the projection-like blades, each of the tongue portions
formed based on the cut lines is bent outwards to form a fin, a
portion surrounded by the cut line is opened, and thereby a hole
with a fin is formed.
[0011] A part according to the invention of an exhaust emission
control device is characterized by having a spaced body that is
formed by spirally winding the finned multi-aperture sheet metal
according to the invention and has a net-like cross section in a
casing.
[0012] A manufacturing method according to the invention of a part
of an exhaust emission control device is a method of manufacturing
a part of an exhaust emission control device, the part being formed
by having a spaced body that is formed by spirally winding a finned
multi-aperture sheet metal and has a net-like cross section in a
casing, wherein the finned multi-aperture sheet metal according to
the claim 1 or 2 is wound in a spiral having a diameter smaller
than an inner diameter of a casing, in this state the winding is
loosened in the casing, thereby with tip end portions of fins
formed on the finned multi-aperture sheet metal allowing partially
coming into contact with an opposing finned multi-aperture sheet
metal, and thereby the finned multi-aperture sheet metal is engaged
inside of the casing as a spaced body having a net-like cross
section.
[0013] Furthermore, a manufacturing method according to the
invention of a part of an exhaust emission control device is a
method of manufacturing a part of an exhaust emission control
device, the part being formed by having a spaced body that is
formed by spirally winding a finned multi-aperture sheet metal and
has a net-like cross section in a casing, wherein the finned
multi-aperture sheet metal according to the claim 1 or 2 is wound
in a spiral, at least part of the finned multi-aperture sheet metal
or/and part of the spaced body having a net-like cross section is
bonded, and thereby a spaced body having a circular columnar
net-like cross section is formed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an enlarged perspective view showing a substantial
part of a first embodiment of a finned multi-aperture sheet metal 1
according to the present invention.
[0015] FIG. 2 is an enlarged sectional view showing a substantial
part of the finned multi-aperture sheet metal 1 of FIG. 1.
[0016] FIG. 3 is a plan view of a substantial part showing a
configuration of the finned multi-aperture sheet metal 1 of FIG.
1.
[0017] FIG. 4 is an enlarged explanatory view showing an
articulated side of a fin in a hole with a fin.
[0018] FIG. 5 is an enlarged sectional view showing a substantial
part of a second embodiment of the finned multi-aperture sheet
metal according to the present invention.
[0019] FIG. 6 is an enlarged perspective view of a hole with a fin
and a hole without a fin.
[0020] FIG. 7 is an enlarged explanatory view showing a positional
relationship between a projection-like blade of a perforating
roller, a groove portion of a receiving roller and the finned
multi-aperture sheet metal that are used in a method of
manufacturing a finned multi-aperture sheet metal according to the
invention.
[0021] FIG. 8 is a conceptual diagram of a substantial part of the
perforating roller and the receiving roller that are used in a
method of manufacturing the finned multi-aperture sheet metal of
FIG. 1.
[0022] FIG. 9 is a conceptual diagram of a substantial part of the
perforating roller and the receiving roller that are used in a
method of manufacturing the finned multi-aperture sheet metal of
FIG. 5.
[0023] FIG. 10 is an enlarged diagram showing a configuration in
one cross section of a spaced body that uses the finned
multi-aperture sheet metal of FIG. 1 and has a net-like cross
section.
[0024] FIG. 11 is an enlarged diagram showing a configuration in
one cross section of a spaced body that uses the finned
multi-aperture sheet metal of FIG. 5 and has a net-like cross
section.
BEST MODE FOR CARRYING OUT THE INVENTION
[0025] Firstly, embodiments of a finned multi-aperture sheet metal
according to the present invention will be explained.
[0026] A first embodiment relating to the finned multi-aperture
sheet metal according to the invention is one in which on a sheet
metal formed into a long flat band (including a metal foil. The
same applies below), holes with a fin projected on one surface side
(hereinafter, referred to as "hole with a fin") are formed. Owing
to a length of the fin, a separation can be freely controlled. As
metal that is used for the sheet metal, general-purpose stainless
steel expressed by iron-nickel-chromium alloys, iron-nickel alloys,
iron-chromium-aluminum alloys or iron-chromium alloys can be
applied. Here, to form includes, other than a case where for
instance, only holes with a fin are arranged with regularity and a
case where holes with a fin are formed with some kind or another of
regularity in relationship to holes without a fin (hereinafter,
referred to as "hole without a fin"), a case where holes are formed
at random without any kind of regularity.
[0027] Thus, since a lot of holes such as the holes with a fin or
the holes without a fin are disposed, when it is used as an exhaust
emission control device, a warming-up process can be made
shorter.
[0028] The finned multi-aperture sheet metal 1 according to a first
embodiment shown in FIGS. 1 through 3 is later wound in spiral and
inserted into a part of an exhaust emission control device
described later, wherein in the sheet metal 2, holes with a fin 3
and holes without a fin 4 are alternately arranged in a winding
direction of a spaced body 5 having a net-like cross section
(hereinafter, referred to as spaced body 5. Refer to FIG. 10), and
thereby a column L is formed. A plurality of the columns L is
formed in proximity to each other so that, as shown in FIG. 3, the
holes with a fin 3 or the holes without a fin 4 formed in adjacent
columns L may not come adjacent each other, and thereby a width R
is constituted. In the flat band-like sheet metal 2, a plurality of
the R's is formed with a predetermined distance apart.
[0029] Here, the hole without a fin 4 in the embodiment is a
slender linear hole portion 6 formed so as to be orthogonal to a
direction of arrangement of holes. A hole portion 7 of the hole
with a fin 3 is formed into a substantial rectangle, and the
substantially rectangular hole portion 7 is provided with a fin 8
projected on the same surface side of the sheet metal 2. The fin 8
is a planar chip and a surface thereof is formed so as to direct to
the direction of winding. In the embodiment, the fin 8 is formed
connected to one side on an up-stream side in the winding direction
of four sides that constitute the hole portion 7.
[0030] The articulated side of the fin 8, without restricting to an
upstream side in a winding direction of the hole portion 7, maybe
one side on a downstream side. Furthermore, as shown in, for
instance, FIG. 4, a hole 6 provided with a fin 8 articulated to one
side on an upstream side in a winding direction and a hole portion
7 provided with a fin 8 articulated to one side on a downstream
side in the winding direction may be regularly arranged on the same
column L. Furthermore, the arrangement of the various kinds of
holes in the respective columns L may be different.
[0031] Still furthermore, a second embodiment of a finned
multi-aperture sheet metal 1 relates to one in which holes with a
fin 3 projected on any of surfaces of a long flat band-like sheet
metal 2 are formed in a line.
[0032] As mentioned above, also in the present embodiment, the
holes with a fin 3 and the holes without a fin 4, furthermore, in
the holes with a fin 3, holes with a fin 3A in which a side
articulated to the fin 8 is one side on an upstream side of the
hole portion 7 and holes with a fin 3B in which a side articulated
to the fin 8 is one side on a downstream side of the hole portion
7, and holes with a fin 3C in which the fin 8 is projected on one
surface of the sheet metal 2 and holes with a fin 3D in which the
fin 8 is projected on the other surface may be arranged with
regularity or at random.
[0033] In FIG. 5, as a finned multi-aperture sheet metal 1
according to the second embodiment, a finned multi-aperture sheet
metal 1 is shown in which the hole with a fin 3 and the hole
without a fin 4 are alternately arranged in a direction of winding
the spaced body 5, furthermore, each of the holes with a fin 3 has
an articulated side of the fin 8 on one side on an upstream side of
the hole portion 7, and a hole with a fin 3C in which the fin 8 is
projected on one surface of the sheet metal 2 and a hole with a fin
3D projected on the other surface are alternately arranged.
[0034] In the next place, a method of manufacturing a finned
multi-aperture sheet metal 1 according to the invention will be
explained.
[0035] Fundamentally, as shown in FIG. 6, as to the holes without a
fin 4 formed in the finned multi-aperture sheet metals 1 in the two
embodiments, slender linear holes 6 are bored on a long planar
band-like sheet metal 2. Furthermore, as to the holes with a fin 3,
substantially U-shaped cut lines are formed, a tongue portion 9
formed based on each of the cut lines is selectively bent to any of
surface sides of the sheet metal 2 along a virtual line portion
(shown with a dotted line in FIG. 6) that connects both end
portions of the cut line at the shortest distance to form a fin 8
projected toward the bending direction, and a portion surrounded by
the cut line is opened to form a hole 7 of the hole 3 with a
fin.
[0036] More specifically, as shown in FIGS. 7 and 8, between a
perforating roller 10 that is provided, on an outer periphery
surface thereof in accordance with the arrangement of the holes on
the same column L and the arrangement of the width R's, with
projection-like blades 11 (hereinafter, referred to as blade for
hole with fin 11A) that can form the substantially U-shaped cut
lines and bend tongue portions 9 formed based on the cut lines
along a virtual line portion that connects both end portions of the
cut line at the shortest distance toward the outside that is an
opposite side to a side on which the perforating roller 10 of the
sheet metal 2 is disposed, and projection-like blades 11
(hereinafter, referred to as blade for hole without fin) that can
perforate slender linear holes 6; and a receiving roller 13 that
faces the perforating roller 10 and is provided on an outer
periphery surface thereof with a plurality of grooves 12 that
enable to temporally accommodate the blades for hole with fin 11A
formed on the perforating roller 10, the tongue portions 9 bent by
the projection-like blades 11, and the blades for hole without fin
11B, a long flat band-like sheet metal 2 is continuously supplied,
and the both rollers 10 and 13 are driven to rotate. Thereby, by
use of the blade for hole without fin 11B, the holes without fin 4
are bored in the sheet metal 2. Furthermore, by use of the blades
for hole with fin 11A, substantially U-shaped cut lines are formed
in the sheet metal 2, each of tongue portions 9 formed based on the
cut lines is bent outward of the perforating roller 10 of the sheet
metal 2 to form a fin 8 and a portion surrounded by the cut line is
opened to form a hole 7.
[0037] According to the manufacturing method, the finned
multi-aperture sheet metal 1 that is shown in the first embodiment
of the finned multi-aperture sheet metal 1 and has fins 8 of the
holes with a fin 3 projected on the same surface side of the sheet
metal 2 can be simply and efficiently formed.
[0038] Furthermore, a finned multi-aperture sheet metal 1 that is
shown in the second embodiment of the finned multi-aperture sheet
metal 1 and has fins 8 of the holes with a fin 3 projected on both
surface sides of the sheet metal 2 can be formed as follows.
[0039] That is, as shown in FIG. 9, of a pair of rollers 14A and
14B that are disposed oppositely, on an outer periphery surface of
one roller 14A, blades for holes with a fin 11A that can form
substantially U-shaped cut lines and bend tongue portions 9 formed
based on the cut lines along a virtual line portion that connects
both end portions of the cut line at the shortest distance outward
of the roller 14A of the sheet metal 2, and blades for holes
without a fin 11B that can bore slender linear through holes are
disposed in accordance with the arrangement of the holes 6 and 7 on
the same column L and the arrangement of the widths R, and on the
outer periphery surface, a plurality of grooves 12 that can
temporally accommodate the projection-like blades 11A and 11B
formed on an outer periphery surface of the other roller 14B and
tongue portions 9 bent by use of the blade 11A for hole with a fin
are formed.
[0040] Furthermore, also on an outer periphery surface of the other
roller 14B, the projection-like blades 11A and 11B are formed, and
on the outer periphery surface thereof, a plurality of grooves 12
that can temporally accommodate the projection-like blades 11A and
11B that are formed on the outer periphery surface of the one
roller 11A and tongue portions 9 bent by use of the blade for hole
with fin 11A is formed.
[0041] In any one of the rollers 14A and 14B, the blade for holes
without a fin 11B may be omitted from disposing.
[0042] Then, between the pair of rollers 14A and 14B, a long flat
band-like sheet metal 2 is continuously supplied and the both
rollers 14A and 14B are driven to rotate. Thereby, by use of the
blade for holes without a fin 11B, holes without a fin 4 are formed
on the sheet metal 2 and by use of the blade for holes with a fin
11A, substantially U-shaped cut lines are formed on the sheet metal
2, and the tongue portions 9 formed based on the cut lines are bent
outward of a side where a roller thereon the projection-like blades
11 of the sheet metal 2 are disposed to form fins 8, and portions
surrounded by the cut line are opened to form holes.
[0043] According to the manufacturing method, the finned
multi-aperture sheet metal 1 that is shown in the second embodiment
of the finned multi-aperture sheet metal 1 and has fins 8 of the
holes with a fin 3 projected on both surfaces of the sheet metal 2
can be easily and efficiently formed.
[0044] In the next place, a part for an exhaust emission control
device will be explained with reference to FIGS. 10 and 11.
[0045] Apart for exhaust emission control device 15 according to
the invention is a device mainly used to purify an exhaust gas
exhausted from an internal combustion engine of an automobile and
so on, that is, as a supporter or a filter. A fundamental
constitution thereof is, as described in an existing example, a
constitution in which a circular columnar spaced body 5 is inserted
in a cylindrical casing 16.
[0046] The part for exhaust emission control device 15 according to
the invention has a constitution in which a spaced body 5 formed by
use of the finned multi-aperture sheet metal 1 that is manufactured
according to the above manufacturing method is inserted in a casing
16.
[0047] Next, two embodiments will be explained.
[0048] In a first embodiment, as shown in FIG. 10, a circular
columnar spaced body 5 that is formed by winding spirally only a
finned multi-aperture sheet metal 1 in which fins 8 of holes with a
fin 3 shown in the first embodiment of a finned multi-aperture
sheet metal 1 are projected on the same surface side of a sheet
metal 2 is used.
[0049] The spaced body 5 has an exhaust emission flow path 17 that
is spirally formed with a body portion of the finned multi-aperture
sheet metal 1 as a wall and upstream and downstream sides of which
in an exhaust direction of an exhaust emission of an internal
combustion engine are opened. Inside of the exhaust emission flow
path 17, a plurality of fins 8 of the holes with a fin 3 formed on
the finned multi-aperture sheet metal 1 is projected and located so
as to divide the spiral exhaust emission flow path 17.
[0050] Furthermore, in a second embodiment, as shown in FIG. 11, a
spaced body 5 that is formed by spirally winding only a finned
multi-aperture sheet metal 1 in which fins 8 of holes with a fin 3
shown in the second embodiment of a finned multi-aperture sheet
metal 1 are projected on both surface sides of a sheet metal 2 is
used.
[0051] The spaced body 5 has a exhaust emission flow path 17 that
is spirally formed with a body portion of the finned multi-aperture
sheet metal 1 as a wall and upstream and downstream sides of which
in an exhaust direction of an exhaust emission of an internal
combustion engine are opened. In the exhaust emission flow path 17,
similarly to the first embodiment, the flow path is surrounded by a
wall made of a body portion of a spirally wound sheet metal 2, and,
in the flow path, a plurality of fins 8 of the holes with a fin 3
formed on the finned multi-aperture sheet metal 1 is projected from
both wall sides that constitute the exhaust emission flow path 17
so as to divide the spirally wound exhaust emission flow path
17.
[0052] In a part for exhaust emission control device 15 thus
constituted, an exhaust emission flowed in the part for exhaust
emission control device 15 from an upstream side in an exhaust
direction of the exhaust emission of an internal combustion engine
passes the flow path with the flow path thereof variously branched
by a wall made of a body portion of the spirally wound finned
multi-aperture sheet metal 1 and fins 8 located inside of the
exhaust emission flow path 17. Furthermore, part of the exhaust
emission, while changing a flow path thereof through an opening of
the hole without a fin 4 or the hole with a fin 3 formed on the
finned multi-aperture sheet metal 1 to an exhaust emission flow
path 17 adjacent through the finned multi-aperture sheet metal 1,
passes the inside of the spaced body 5 and goes through toward a
downstream side in an exhaust direction of an exhaust emission.
[0053] It goes without saying that from the exhaust emission of the
internal combustion engine, during passage of the inside of the
part for exhaust emission control device 15, soot and so on due to,
for instance, incomplete combustion, can be supported or
filtered.
[0054] Subsequently, a manufacturing method according to the
invention of a part for exhaust emission control device 15 will be
explained.
[0055] Firstly, the finned multi-aperture sheet metal 1, before
inserting in a casing 16, is a little bit tightly wound into a
spiral having a diameter smaller than an inner dimension of the
casing 16. Then, in a predetermined position in the casing 16, the
tight winding is unwound and left free to solidly locate in the
casing 16, and thereby rendering in an engaging state.
[0056] An extent of the winding of the finned multi-aperture sheet
metal 1 at this time is set to a winding where when it is released
and becomes a free state in the casing 16, a tip end of the fin 8
comes into contact owing to the elasticity thereof with a back
surface of an opposing sheet metal 2.
[0057] Furthermore, an end side located on an outer periphery of
the wound finned multi-aperture sheet metal 1 is beforehand bonded
to the sheet metal 2 located one go around inside to form a spaced
body 5, and the spaced body 5 may be inserted in the casing 16.
[0058] In the case of a spaced body 5 being thus constituted by
winding only one finned multi-aperture sheet metal 1, in comparison
with the case where one in which two different sheet metals are put
together is spirally wound, a problem of winding difference at the
winding that is so far one of problems can be more overcome. That
is, owing to the fins on both surfaces, the spaced body 5 can be
inhibited from becoming bamboo-shoot-like.
[0059] Furthermore, in the case of a spaced body 5 being formed
with the finned multi-aperture sheet metal 1 that is shown in the
second embodiment of the finned multi-aperture sheet metal 1 and in
which fins 8 of holes with a fin 3 are projected on both surface
sides of a sheet metal 2, in a wound state, some of fins 8
projected into the same exhaust emission flow path 17 from each of
adjacent finned multi-aperture sheet metals 1 collide at tip end
portion thereof and bite each other, and thereby a problem of
winding difference at the winding that is so far one of problems
can be completely overcome.
[0060] In the spaced body 5, when bonding projections are formed
along both sides in a winding direction of the finned
multi-aperture sheet metal 1 with an appropriate separation to keep
constant between finned multi-aperture sheet metals 1 adjacently
located in a wound state and an end side located on an outer
periphery of the wound finned multi-aperture sheet metal 1 is
beforehand bonded to a sheet metal 2 located one go around inside,
the sheet metal 2 can be bonded even in the middle of the spiral by
use of the bonding projections. Furthermore, in the case of a
bonding method such as brazing, a tip end of the fin 8 can be
directly bonded to an opposing finned multi-aperture sheet metal
1.
[0061] Furthermore, the spaced body 5, when inserted in the casing
16, is preferably bonded between at least part of the sheet metal 2
and an inner surface of the casing 16 by means of brazing, welding
and so on. In particular, in the case of a spaced body 5, before
being inserted into the casing 16, being bonded at an end side
located on an outer periphery of the spaced body 5 to a sheet metal
2 one go around inside, since owing to the bonding a force with
which the sheet metal 2 expands outwards to be free is suppressed;
accordingly, in order to adhere the spaced body 5 and the inner
surface of the casing 16, the brazing, the welding and so on may be
used to bond.
[0062] In the part for exhaust emission control device 15 like
this, in comparison with an existing one in which two metal foils
of a flat foil and a corrugated foil are put together and
constituted into a spiral, only one multi-aperture sheet metal 2 is
necessary to use; accordingly, material cost can be reduced,
resulting in less expensive. Furthermore, the finned multi-aperture
sheet metal 1 that is used in the spaced body 5 according to the
embodiment, being a flat band-like sheet metal, is easy to wind;
accordingly, it has an advantage in that manufacturing cost in the
manufacturing process can be reduced.
[0063] The finned multi-aperture sheet metal 1 shown in the second
embodiment of the finned multi-aperture sheet metal 1, put together
with a long flat band-like sheet metal 2, may be spirally wound to
form a spaced body 5. In this case, the exhaust emission that goes
through the spaced body 5, in the inside surrounded by the long
flat band-like sheet metal 2, goes through the flow path variously
branched by a wall that is a body portion of the finned
multi-aperture sheet metal 1 and fins 8 located inside of the flow
path 17 of the exhaust emission. Furthermore, the exhaust emission,
while partially changing the flow path through an opening of a hole
without a fin 4 or a hole with a fin 3 formed in the finned
multi-aperture sheet metal 1 to the inside of the exhaust emission
flow path 17 adjacent through the finned multi-aperture sheet metal
1, passes through a net structure of the spaced body 5 and goes
through toward a downstream side in an exhaust direction of the
exhaust emission.
[0064] The present invention, without restricting the above
embodiments, may be variously modified as needs arise. The brazing
is fundamentally unnecessary; however, it can be partially applied
to an end surface if necessary. Furthermore, as a catalyst, known
ones can be used; one in which a support layer made of, for
instance, active alumina supports a catalyst such as platinum and
palladium can be used.
[0065] Industrial Applicability
[0066] As explained above, the finned multi-aperture sheet metal
according to the invention is the most preferable one as a sheet
metal that constitutes a spaced body that is disposed inside a part
for exhaust emission control device and has a net-like cross
section. That is, in the part for exhaust emission control device
having a spaced body that uses the multi-aperture sheet metal and
has a net-like cross section, by forming a flow path of exhaust
emission with a body portion of a finned multi-aperture sheet
metal, and by disposing fins of holes with a fin projected into a
flow path of the exhaust emission, including paths going through
the holes, the flow paths in the exhaust emission flow path can be
variously branched; accordingly, a contact area between the spaced
body having the net-like cross section and the exhaust emission can
be enlarged and purification of the exhaust emission can be carried
out. Thus configured part for exhaust emission control device can
fundamentally form the spaced body having a net-like cross section
with one finned multi-aperture sheet metal; accordingly, it is less
expensive in comparison with an existing one.
[0067] Furthermore, according to a manufacturing method according
to the present invention of a finned multi-aperture sheet metal,
the finned multi-aperture sheet metal in which fins of holes with a
fin are projected on the same surface side of the sheet metal and
the finned multi-aperture sheet metal in which fins of holes with a
fin are projected on both surface sides can be simply and
efficiently manufactured.
[0068] According to a manufacturing method according to the
invention of a part for exhaust emission control device, since a
finned multi-aperture sheet metal that is used in a spaced body
that is inserted in the part for exhaust emission control device
and has a net-like cross section is one flat band-like sheet metal,
it can be easily wound, the manufacturing cost in the manufacturing
process can be reduced, and the conventional problem of winding
difference can be overcome.
[0069] Thus, the present invention has an effect that a perforated
sheet metal most suitable for forming a spaced body that is a part
for exhaust emission control device and has a net-like cross
section, a method of manufacturing the same, a part for exhaust
emission control device that uses the perforated sheet metal and a
method of manufacturing the same can be provided as economical and
easy one.
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