Non-cylindrical catalytic-converter carrier element and tool, and method for manufacturing it

• US 8,389,438 B2
• Filed: 04/28/2008
• Issued: 03/05/2013
• Est. Priority Date: 06/13/2002
• Status: Expired due to Fees

• Current Assignee: Emitec Gesellschaft für Emissionstechnologie mbH (Continental AG)
• Original Assignee: Emitec Gesellschaft für Emissionstechnologie mbH (Continental AG)
• Inventors: Wieres, Ludwig
• Primary Examiner(s): Taousakis, Alexander P
• Application Number:
  US12/110,825
• Publication Number:
  US 20080206514A1
• Time in Patent Office: 1,772 Days
• Field of Search: 298/90, 298/900.36, 297/00, 295/15, 295/05, 721/48, 422/177, 422/179, 422/180, 428/116, 428/593, 502/439, 502/527.18, 502/527.23, 502/527.24
• US Class Current: 502/439
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B23K 1/0014 Brazing of honeycomb sandwich structures
• CPC Class Codes: B23K 2101/04 Tubular or hollow articles
• CPC Class Codes: F01N 2330/02 Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal
• CPC Class Codes: F01N 2330/04 Methods of manufacturing
• CPC Class Codes: F01N 2330/44 made of stacks of sheets, plates or foils that are folded in S-form
• 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 29/49361 Tube inside tube
• 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.]
• CPC Class Codes: Y10T 428/24149 Honeycomb-like

Abstract

A method for the production of a converter-carrier body having a metallic honeycomb body made of a plurality of metal layers, especially smooth layers and corrugated layers, the layers having layer ends, such that an outer shape of the honeycomb body is formed by the layer ends. At least one stack is produced having several alternately disposed metal layers that are structured such that channels are formed for a fluid to flow through. The at least one stack is transformed into a honeycomb body having a cylindrical form. The honeycomb body is deformed from the cylindrical form so that an outer shape that deviates from the cylindrical form is produced. Additionally, the invention relates to a corresponding converter-carrier body and a tool for the production thereof.

Claims

1. A catalytic-converter carrier element, comprising:

a metallic honeycomb element having;

a plurality of smooth layers and a plurality of corrugated layers with layer ends forming an external shape of said honeycomb element, all of the layer ends of the smooth layers and the corrugated layers being disposed radially on the outside, said smooth and corrugated layers defining cells extending through said honeycomb element;

a first end side with a first surface area; and

a second end side with a second surface area, said first end side and said second end side having, in absolute terms, an identical surface area, but being non-congruent; and

said catalytic converter carrier element having a cross sectional shape of a completely filled honeycomb element; and

said catalytic converter carrier element having only channels extending parallel from one end side to the other end side.

2. The catalytic-converter carrier element of claim 1, wherein:

said first end side has a maximum extent and a minimum extent;

said second end side is substantially round and has a diameter; and

said maximum extent and said minimum extent differ from said diameter by no more than 30%.

7. The catalytic-converter carrier element of claim 1, wherein the plurality of smooth layers and the plurality of corrugated layers are bent into an “

S”

shape.

3. A catalytic-converter carrier element manufactured by manufacturing at least one stack with a plurality of alternately disposed sheet metal layers having layer ends, shaping the at least one stack to form a metallic honeycomb element with a cylindrical shape, the cylindrical shape of the honeycomb element being formed by the layer ends, the sheet metal layers being structured to form cells through which a fluid can flow, and deforming the honeycomb element to produce an external shape different from the cylindrical shape, the catalytic converter carrier element comprising:

a metallic honeycomb element having;

a plurality of smooth layers and a plurality of corrugated layers with layer ends forming an external shape of said honeycomb element, all of the layer ends of the smooth layers and the corrugated layers being disposed radially on the outside, said smooth and corrugated layers defining cells extending through said honeycomb element;

a first end side with a first surface area; and

a second end side with a second surface area, said first end side and said second end side having, in absolute terms, an identical surface area, but being non-congruent; and

said catalytic converter carrier element having a cross sectional shape of a completely filled honeycomb element; and

said catalytic converter carrier element having only channels extending parallel from one end side to the other end side.

4. The catalytic-converter carrier element of claim 3, wherein:

said first end side has a maximum extent and a minimum extent;

said second end side is substantially round and has a diameter; and

said maximum extent and said minimum extent differ from said diameter by no more than 30%.

5. A catalytic-converter carrier element, comprising:

a metallic honeycomb element having;

a stack of alternately disposed smooth sheet metal layers and corrugated sheet metal layers, said smooth and corrugated sheet metal layers having layer ends forming an external shape of said honeycomb element, all of the layer ends of the smooth layers and the corrugated layers being disposed radially on the outside, said smooth and corrugated layers defining cells extending through said honeycomb element through which a fluid can flow;

a first end side being substantially circular and having a first surface area; and

a second end side having a second surface area equal to said first surface area but non-congruent thereto; and

said catalytic converter carrier element having a cross sectional shape of a completely filled honeycomb element; and

said catalytic converter carrier element having only channels extending parallel from one end side to the other end side.

6. The catalytic-converter carrier element according to claim 5, wherein:

said first end side has a maximum extent and a minimum extent;

said second end side has a diameter; and

said maximum extent and said minimum extent differ from said diameter by no more than 30%.