Apparatus and process for producing a honeycomb body from intertwined sheet metal layers

• US 6,029,488 A
• Filed: 12/22/1997
• Issued: 02/29/2000
• Est. Priority Date: 06/20/1995
• Status: Expired due to Term

• Current Assignee: Emitec Gesellschaft für Emissionstechnologie mbH (Continental AG)
• Original Assignee: Emitec Gesellschaft für Emissionstechnologie mbH (Continental AG)
• Inventors: Wieres, Ludwig
• Primary Examiner(s): Young, Lee
• Assistant Examiner(s): BLOUNT, STEVEN
• Application Number:
  US08/996,372
• Time in Patent Office: 799 Days
• Field of Search: 29/890, 72/147, 72/146, 72/148, 228/181, 228/173.6
• US Class Current: 72/146
• 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 2330/04 Methods of manufacturing
• CPC Class Codes: F01N 3/281 Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
• CPC Class Codes: Y10T 29/49345 Catalytic device making
• CPC Class Codes: Y10T 29/49908 Joining by deforming

Abstract

An apparatus to produce a honeycomb body having a multiplicity of at least partially structured sheet metal layers forming a multiplicity of fluid-permeable passages. A fork-like intertwining device is rotatable about a central axis and engages each stack. A former surrounds the intertwining device and has an inner contour corresponding to an outer contour of the honeycomb body to be produced. At least one opening in a wall of the former for stack ends extends substantially parallel to the central axis. In a production of the honeycomb body, at least one stack is layered from a multiplicity of at least partially structured sheet metal layers. Each stack is introduced into a former corresponding to the external shape of the honeycomb body to be produced, with at least one end of each stack projecting out of the former through at least one opening. Each stack is held by an intertwining device rotatable about a central axis, in a central region. Each stack is intertwined by rotation of the intertwining device relative to the former to form a honeycomb body, with the stack ends being pulled into the former until the stacks fill the entire former.

Claims

1. An apparatus for producing a honeycomb body, comprising:

at least one fork-like winding device for engaging a stack of a multiplicity of at least partially structured sheet metal layers forming a multiplicity of fluid-permeable passages, said winding device rotatably mounted about a central axis; and

a former surrounding said winding device and having an invariable internal contour corresponding to an external contour of a honeycomb body to be produced from the stack, said former having a wall with at least one opening formed therein, said opening extending substantially parallel to the central axis.

2. The apparatus according to claim 1, wherein said wall has at least two openings formed therein.

3. The apparatus according to claim 2, wherein said openings are disposed equidistantly relative to each other over an inner periphery of said former.

4. The apparatus according to claim 1, wherein said wall has at least one longitudinal surface with a convex cross-section at said at least one opening.

5. The apparatus according to claim 4, wherein said at least one longitudinal surface has a slide layer.

6. The apparatus according to claim 5, wherein said slide layer is wear-resistant.

7. The apparatus according to claim 6, wherein said slide layer is formed of a ceramic material.

8. The apparatus according to claim 5, wherein said slide layer is plasma-sprayed.

9. The apparatus according to claim 1, wherein each stack has a given thickness, and each opening has a width approximately corresponding to the given thickness.

10. The apparatus according to claim 1, including a ram displaceable in longitudinal direction of said former and in said former.

11. The apparatus according to claim 10, wherein said former has a given inner cross-section, and said ram has a cross-section corresponding to said given inner cross-section.

12. The apparatus according to claim 1, including a base plate, said former having an at least partially encompassing outside flange to be releasably connected to said base plate.

13. The apparatus according to claim 12, including an actuating bar connected to said ram and extending through an aperture formed in said base plate.

14. The apparatus according to claim 12, wherein said base plate has an aperture formed therein through which said ram can be passed.

15. The apparatus according to claim 1, wherein said winding device has at least two winding bars to be brought into engagement with said stack.

16. The apparatus according to claim 15, including a carrier on which said winding bars are disposed for bringing said winding bars into engagement with said stack.

17. The apparatus according to claim 15, wherein said winding bars have a cross-section which is adapted to intertwining forces and is as small as possible.

18. The apparatus according to claim 15, wherein said cross-section of said winding bars is in the shape of a drop or a curved drop.

19. The apparatus according to claim 15, wherein said winding device grips said winding bars therein at both ends.

20. The apparatus according to claim 1, wherein said former and said winding device are rotatable relative to each other.

21. The apparatus according to claim 1, wherein said former is of one-piece construction.

22. The apparatus according to claim 1, wherein said former includes at least two former segments.

23. The apparatus according to claim 1, wherein the stacks are folded around bend lines, and said at least one fork-like winding device has a number of winding bars corresponding to the number of stacks and an equal number of openings, for intertwining at least two stacks of sheet metal layers.