Carrier matrix, particularly for a catalytic reactor for the exhaust emission control in the case of internal-combustion engines

• US 4,891,257 A
• Filed: 09/11/1986
• Issued: 01/02/1990
• Est. Priority Date: 09/11/1985
• Status: Expired due to Fees

• Current Assignee: Emitec Gesellschaft für Emissionstechnologie mbH (Continental AG)
• Original Assignee: Sueddeutsche Kuehlerfabrik Julius FR BEHR GmbH & Company KG
• Inventors: Humpolik, Bohumil, Mielke, Josef
• Primary Examiner(s): Zimmerman, John J.
• Application Number:
  US06/905,590
• Time in Patent Office: 1,209 Days
• Field of Search: 428/577, 428/586, 428/592, 428/593, 502/439, 502/527, 72/148, 72/146, 72/147, 29/157 R, 29/240, 242/77.1, 422/180
• US Class Current: 428/592
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: F01N 13/18 Construction facilitating manufacture, assembly, or disassembly
• CPC Class Codes: F01N 2330/04 Methods of manufacturing
• CPC Class Codes: F01N 2450/02 Fitting monolithic blocks into the housing
• CPC Class Codes: F01N 2470/10 Tubes having non-circular cross section
• CPC Class Codes: F01N 3/2814 all sheets, plates or foils being corrugated
• CPC Class Codes: F01N 3/2842 specially adapted for monolithic supports, e.g. of honeycomb type F01N3/2853 - F01N3/2871 take precedence
• CPC Class Codes: Y10T 29/49345 Catalytic device making
• CPC Class Codes: Y10T 428/12333 Helical or with helical component
• CPC Class Codes: Y10T 428/1234 Honeycomb, or with grain orientation or elongated elements in defined angular relationship in respective components [e.g., parallel, inter- secting, etc.]

Abstract

A carrier matrix wound of a carrier strip having undulations in its transverse direction has deflections of the carrier strip, said deflections being arranged in planes. During the winding process, the deflections are created by the insertion of deflection pins between the corresponding winding layers. The deflections pins, in this case, are inserted between the winding layers as a function of the desired cross-section of the carrier matrix so that after the winding process and after the removal of the deflection pins, the carrier matrix can be inserted into a sheath that has the desired cross-section of the carrier matrix. By combining several winding bodies of this type into one carrier matrix, arbitrary cross-sections of carrier matrices can be produced, particularly cross-sections having concave archings. During the making process, the deflection pins are fitted through the corresponding bores of two winding disks that are connected with one another in a torsionally fixed way. The carrier matrix that is produced in this way can then be inserted into a sheath. This can be accomplished by a funnel-shaped arrangement.

Claims

1. A catalytic converter carrier matrix arrangement for exhaust emission control in internal combustion engines comprising:

carrier strip means wound into winding layers with adjacent layers abutting one another to form a carrier matrix, said carrier strip means including undulations which serve to space adjacent winding layers from one another and provide exhaust gas flow accommodating openings which extend transversely of the carrier strip means,

wherein said carrier strip means are wound with a plurality of deflections in each winding layer to form said carrier matrix into a geometric shape with at least one non-curvilinear side, whereby said carrier matrix can be inserted in corresponding geometric shape sheath means.

2. An arrangement according to claim 1, wherein said geometric shape is a trapezoid.

3. An arrangement according to claim 1, wherein said geometric shape is a triangle.

4. An arrangement according to claim 1, wherein said geometric shape is a semi-circle.

5. An arrangement according to claim 1, wherein said geometric shape comprises two adjacent triangles.

6. An arrangement according to claim 1, wherein said matrix includes a pair of separate triangular shape multiple winding layers surrounded by further multiple winding layers.

7. An arrangement according to claim 1, wherein a plurality of deflections for adjacent winding layers are disposed in a common plane, further comprising deflection pins at each of said deflections, whereby an intermediate matrix product is provided for later processing with removal of said deflection pins.

8. An arrangement according to claim 1, wherein at least some of said deflections are formed by deflection pins which are removed after the matrix is formed.

9. An arrangement according to claim 8, wherein a plurality of said deflections are disposed along a plane which bisects an angle formed by the intersection of respective planes through winding layers of the matrix.

10. An arrangement according to claim 2, wherein a plurality of said deflections are disposed along a plane which bisects an angle formed by intersection of respective planes through winding layers of the matrix.

11. An arrangement according to claim 1, further comprising matrix sheath means surrounding the matrix in close fitting relationship with elastic prestressing of the matrix against inside walls of the matrix sheath means, said sheath means having a geometric shape corresponding to the geometric shape of the matrix.

12. A process for manufacturing a catalytic carrier matrix arrangement for exhaust emission control in internal combustion engines comprising:

winding a carrier strip means into winding layers abutting one another to form a carrier matrix, said carrier strip means including undulations which serve to space adjacent winding layers from one another and provide exhaust gas flow accommodating openings which extend transversely of the carrier strip means,

wherein said carrier strip means are wound with a plurality of deflections in each winding layer to form said carrier matrix into a geometric shape when at least one non-curvilinear side whereby said carrier matrix can be inserted in corresponding geometric shape sheath, and

wherein said deflections are formed by inserting deflection means into respective one of said winding layers during winding of said carrier strip means.

13. A process according to claim 12, wherein said deflection means are successively inserted in a winding layer which is outermost.

14. A process according to claim 12, wherein said deflection means are removed from said carrier matrix after it has been wound.

15. A process according to claim 12, comprising inserting the carrier matrix into a corresponding geometric shape matrix sheath with elastic prestressing of the carrier matrix against inner walls of the matrix sheath.

16. A process according to claim 15, comprising deforming the matrix into its final shape prior to insertion thereof in the sheath.

17. A process according to claim 15, comprising deforming the matrix into its final shape during insertion thereof into the sheath.

18. A process according to claim 15, wherein a distance between said deflections and said carrier strip after deforming of said carrier matrix corresponds to a distance between said successively inserted deflection means.

19. A process according to claim 15, wherein said carrier strip is wound such that a hollow space for accommodating separately produced carrier matrix parts is created.

20. A process according to claim 12, wherein said carrier strip is provided with weakened sections which correspond to said deflections.

21. A process according to claim 12, wherein said deflection means are deflections pins, comprising removing the deflection pins from the matrix after the matrix is formed.

22. A process according to claim 21, wherein a plurality of said deflections are disposed along a plane which bisects an angle formed by the intersection of respective planes through winding layers of the matrix.

23. A process according to claim 22, wherein said geometric shape is a trapezoid.

25. A process according to claim 22, wherein said geometric shape is a triangle.

26. A process according to claim 22, wherein said geometric shape is a semi-circle.

27. A process according to claim 22, wherein said matrix includes a pair of separate triangular shape multiple winding layers surrounded by further multiple winding layers.

28. A device for winding a carrier strip means into a carrier matrix with the carrier strip means wound into winding layers with adjacent layers abutting one another to form a catalytic carrier matrix, said carrier strip means including undulations which serve to space adjacent winding layers from one another and provide exhaust gas flow accommodating openings which extend transversely of the carrier strip means,

wherein said carrier strip means are would with a plurality of deflections in each winding layer to form said carrier matrix into a geometric shape with at least one non-curvilinear side such that said carrier matrix can be inserted in corresponding geometric shape sheath means, and

wherein said device comprises two disks connected with one another in a torsionally fixed matter by a rotating shaft, rotating drive means for said shaft, at least one of said disks being provided with receiving means for receiving deflection means at a distance from rotating shaft, said deflection means serving to form said deflections in each winding layer during rotation of the shaft, wherein means are provided for removing said deflection means from said carrier matrix after the carrier matrix is formed into said geometric shape.

24. A process according to claim 28, comprising inserting the carrier matrix into a corresponding geometric shape matrix sheath with elastic prestressing of the carrier matrix against inner walls the matrix sheath.

29. A device according to claim 28, wherein the receiving means are bores extending in parallel to the rotating shaft.

30. A device according to claim 29, wherein the bores are arranged in lines in a star-shaped manner.

31. A device according to claim 30, wherein said deflection means are pins that are movable at least out of one disk into a winding area.

32. A device according to claim 31, wherein pin drive means is provided for moving said pins, said pin drive means being switchable during said winding.

33. A device according to claim 32, wherein two pins extending in parallel to the rotating shaft are arranged in the disks opposite one another.

34. A device according to claim 33, wherein exterior surfaces of the pins form deflection edges.

35. A device according to claim 34, wherein the distances between successively inserted pins during the progression winding corresponds to the length of the carrier strip between deflections in the carrier strip after it is deformed.

36. A device according to claim 35, including adapting means for deforming the carrier matrix and adapting the shape of the carrier matrix to the shape of a sheath.

37. A device according to claim 36, including weakening means for equipping the carrier strip with weak points assigned to the deflections.