A dual core metal carrier with a variable diameter waveband and a method of manufacturing the same

Abstract

This invention relates to a dual-core metal carrier with variable-diameter wavebands and its manufacturing method, comprising a variable-diameter waveband and standard wavebands. The variable-diameter waveband includes a low-wave-height segment and a high-wave-height segment. Several layers of standard wavebands are disposed on at least one side of the low-wave-height segment of the variable-diameter waveband. The low-wave-height segment and the standard wavebands, as well as two layers of standard wavebands, are separated by short flat bands. The wave-height value of the high-wave-height segment is equal to the sum of the wave-height value of the low-wave-height segment and the wave-height values ​​of the several standard wavebands disposed on the low-wave-height segment side. One variable-diameter waveband and several layers of standard wavebands constitute a waveband unit. Adjacent waveband units are separated by long flat bands. Several layers of waveband units are rolled to form a metal carrier. The dual-core metal carrier with variable-diameter wavebands and its manufacturing method improve the problem of high back pressure of the carrier, reduce material costs, realize product diversification, and improve the thermal vibration resistance and thermal shock resistance of the metal carrier.

Description

Technical Field

[0001] This invention relates to metal carriers, and more particularly to a dual-core metal carrier with variable diameter wavebands and its manufacturing method. Background Technology

[0002] Metal carriers are mainly used for exhaust gas purification of fuel engines. The exhaust gas needs to have a certain contact area with the inner wall of the carrier to achieve the purification effect. At the same time, the carrier is required to have a certain strength to withstand the thermal shock and thermal vibration environment during vehicle operation.

[0003] Currently, it is known that the wavebands used in metal carriers are all composed of wavebands with the same wave height wound together. If wavebands with different mesh counts are to be wound together, they need to be pressed into multiple wavebands, which are then combined together. After being combined, they can only be dispersed and cannot be aggregated together.

[0004] Current wavebands have the following problems: 1) high back pressure; 2) high material cost; 3) inability to meet diverse needs; 4) wavebands with different mesh counts can only be made by combining multiple inner core sections; 5) the carriers made from existing wavebands have low resistance to thermal vibration and thermal shock. Summary of the Invention

[0005] In view of the shortcomings of the prior art, the purpose of this invention is to provide a dual-core metal carrier with variable diameter waveband and its manufacturing method, so as to solve one or more problems in the prior art.

[0006] To achieve the above objectives, the technical solution of the present invention is as follows:

[0007] A dual-core metal carrier with a variable-diameter waveband includes a variable-diameter waveband and a standard waveband. The variable-diameter waveband includes a low-wave-height segment and a high-wave-height segment. Several layers of standard wavebands are disposed on at least one side of the low-wave-height segment. The low-wave-height segment and the standard wavebands, as well as two layers of standard wavebands, are separated by short flat bands. The wave-height value of the high-wave-height segment is equal to the sum of the wave-height value of the low-wave-height segment and the wave-height values ​​of the several standard wavebands disposed on the low-wave-height segment side. One variable-diameter waveband and several layers of standard wavebands constitute a waveband unit. Adjacent waveband units are separated by long flat bands. Several layers of waveband units are rolled together to form a metal carrier.

[0008] As a further improvement to the above technical solution:

[0009] The length of the standard waveband is the same as the length of the low-wave height segment of the variable-diameter waveband.

[0010] The low-wave high segment is located in the middle of the variable-diameter waveband, and the high-wave high segment is located at both ends of the variable-diameter waveband.

[0011] The variable-diameter waveband is located on both sides of the low-wave high-band standard waveband.

[0012] The wave height value of the low wave height segment of the variable-diameter waveband can be the same as the wave height value of the standard waveband.

[0013] The variable-diameter waveband, standard waveband, short flat band, and long flat band are all made of iron-chromium-aluminum material.

[0014] A method for manufacturing a dual-core metal carrier with variable-diameter wavebands includes the following steps:

[0015] 1) Manufacturing of standard wavebands and variable diameter wavebands: Standard wavebands with the same wave height are manufactured by stamping or rolling. Similarly, variable diameter wavebands with low wave height segments and high wave height segments are manufactured by stamping or rolling.

[0016] 2) Waveband unit manufacturing: First, short flat bands are welded to at least one side of the low wave height section of the variable diameter waveband. Then, a layer of standard wavebands is welded to the outside of the short flat band. Multiple layers of standard wavebands are also welded together by short flat bands.

[0017] 3) Waveband unit combination: Waveband units are connected by welding long flat strips, and the two outermost waveband units are also connected by welding long flat strips on their outer sides;

[0018] 4) Waveband winding: The waveband, which is composed of several waveband units, is threaded between two rotating needles connected on the turntable. The turntable is started to drive the two rotating needles to rotate around the center of the turntable to form the waveband.

[0019] 5) Forming metal carrier products: The rolled waveband is installed into the housing to form a metal carrier product.

[0020] As a further improvement to the above technical solution:

[0021] The variable diameter waveband is formed by stamping with an upper die and a lower die, which have low-wave high forming teeth and high-wave high forming teeth respectively.

[0022] The variable diameter waveband is formed by rolling with two pressure rollers having low-wave high forming teeth and high-wave high forming teeth.

[0023] Both sides of the variable-diameter waveband are connected to a standard waveband by short flat strip welding.

[0024] Compared with the prior art, the beneficial technical effects of the present invention are as follows:

[0025] 1) By using a combination of variable diameter wavebands and standard wavebands with different wave heights, the holes in a section of the inner core can be made larger or smaller in a regular manner from the inside to the outside, thereby reducing the back pressure during vehicle operation.

[0026] 2) Because the variable diameter waveband has two different sets of wave heights, it realizes the combination of porous density and meets the diversified needs of products.

[0027] 3) By combining different wave heights of the variable diameter waveband, the exhaust gas flow is mixed, which can reduce the amount of metal foil strip used while ensuring the purification effect, thereby reducing costs;

[0028] 4) By using variable diameter wavebands, different wave height combinations can be provided according to requirements, which reduces the length of the waveband to a certain extent and reduces the thermal creep variable of the carrier during vehicle operation, thereby increasing the carrier's thermal vibration resistance and thermal shock resistance. Attached Figure Description

[0029] Figure 1 A schematic diagram of the structure of the dual-core metal carrier with variable diameter wavebands in this embodiment is shown.

[0030] Figure 2 A schematic diagram of the structure of the dual-core metal carrier variable-diameter waveband with variable-diameter waveband in this embodiment is shown.

[0031] Figure 3 A schematic diagram of the rolling process of the dual-core metal carrier with variable diameter wavebands in this embodiment is shown.

[0032] Figure 4 The stamping die for processing variable diameter wavebands in this embodiment is shown.

[0033] Figure 5 The rolling die with variable diameter waveband of this embodiment is shown.

[0034] Marked in the attached diagram:

[0035] 1. Variable diameter waveband; 11. Low waveband; 12. High waveband; 2. Standard waveband; 3. Short flat waveband; 4. Long flat waveband; 5. Turntable; 51. Rotating needle; 6. Upper die; 7. Lower die; 8. Wave pressure roller. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of this invention clearer, the device proposed by this invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The advantages and features of this invention will become clearer from the following description. It should be noted that the accompanying drawings are in a very simplified form and use non-precise proportions, only for the purpose of conveniently and clearly illustrating the embodiments of this invention. Please refer to the accompanying drawings to make the objectives, features, and advantages of this invention more apparent and understandable. It should be understood that the structures, proportions, sizes, etc., depicted in the accompanying drawings are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the implementation conditions of this invention. Therefore, they do not have substantial technical significance. Any modifications to the structure, changes in the proportional relationships, or adjustments to the size, without affecting the effects and objectives achieved by this invention, should fall within the scope of the technical content disclosed in this invention.

[0037] like Figures 1 to 5 As shown, the dual-core metal carrier with variable-diameter wavebands in this embodiment includes a variable-diameter waveband 1 and a standard waveband 2. The variable-diameter waveband 1 includes a low-wave-height section 11 in the middle and high-wave-height sections 12 at both ends. A layer of standard waveband 2 is set on both sides of the low-wave-height section 11 of the variable-diameter waveband 1. The length of the standard waveband 2 is the same as the length of the low-wave-height section 11 of the variable-diameter waveband 1. The low-wave-height section 11 and the standard waveband 2 are separated by a short flat strip 3, and the low-wave-height section 11 and the standard waveband 2 are welded together by the short flat strip 3. The wave height value of the high-wave-height section 12 is equal to the sum of the wave height value of the low-wave-height section 11 and the wave height values ​​of the two layers of standard waveband 2 set on both sides of the low-wave-height section 11. One variable-diameter waveband 1 and several layers of standard waveband 2 form a waveband unit. Two adjacent waveband units are separated by a long flat strip 4. Several layers of waveband units are rolled to form a metal carrier.

[0038] The wave height value of the low wave height segment 11 of the variable diameter waveband 1 can be the same as the wave height value of the standard waveband 2, or it can be different from the wave height value of the standard waveband 2.

[0039] The variable-diameter waveband 1, standard waveband 2, short flat band 3, and long flat band 4 are all made of iron-chromium-aluminum material.

[0040] The method for manufacturing a dual-core metal carrier with variable-diameter wavebands in this embodiment includes the following steps:

[0041] 1) Manufacturing of standard waveband 2 and variable diameter waveband 1: Standard waveband 2 with the same wave height is manufactured by stamping or rolling. Similarly, variable diameter waveband 1 with low wave height segment 11 and high wave height segment 12 is manufactured by stamping or rolling.

[0042] 2) Waveband unit manufacturing: First, short flat band 3 is welded to at least one side of the low wave height section 11 of the variable diameter waveband 1. Then, a layer of standard waveband 2 is welded to the outside of the short flat band 3. Multiple layers of standard waveband 2 are also welded together through short flat band 3.

[0043] 3) Waveband unit assembly: Waveband units are connected by welding with long flat strip 4, and the two outermost waveband units are also connected by welding with long flat strip 4 on their outer sides;

[0044] 4) Waveband winding: The waveband composed of several waveband units is threaded between two rotating needles 51 connected on the turntable 5. The turntable 5 is started to drive the two rotating needles 51 to rotate around the center of the turntable 5 to form the waveband.

[0045] 5) Forming metal carrier products: The rolled waveband is installed into the housing to form a metal carrier product.

[0046] The variable-diameter waveband 1 is formed by stamping an upper die 6 and a lower die 7 with low-wave-high forming teeth and high-wave-high forming teeth. The standard waveband 2 can also be formed by stamping the low-wave-high forming tooth section of the upper die 6 and the lower die 7, so that the wave height value of the standard waveband 2 is the same as that of the low-wave-high section 11 of the variable-diameter waveband 1.

[0047] The variable-diameter waveband 1 is also rolled by two pressure rollers 8 with low wave height forming teeth and high wave height forming teeth. The standard waveband 2 can also be rolled by two pressure rollers 8 with low wave height forming teeth, so that the wave height value of the standard waveband 2 is the same as that of the low wave height section 11 of the variable-diameter waveband 1.

[0048] In this embodiment, in the dual-core metal carrier with variable diameter wavebands, the wave height value of the low wave height section 11 of the variable diameter waveband 1 is 0.8 mm, the wave height value of the high wave height section 12 is 2.4 mm, and the wave height value of the standard waveband 2 is 2.4 mm. After being wound by two rotating needles 51 on the turntable 5, a dual-core metal carrier with an inner circle of 600 mesh and an outer circle of 100 mesh is formed.

[0049] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0050] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements should all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A dual-core metal carrier with variable-diameter wavebands, characterized in that: It includes a variable-diameter waveband (1) and a standard waveband (2). The variable-diameter waveband (1) includes a low-wave height segment (11) and a high-wave height segment (12). The variable-diameter waveband (1) is located on at least one side of the low-wave height segment (11) and several layers of standard wavebands (2) are provided. The low-wave height segment (11) and the standard waveband (2) are separated by a short flat band (3). The wave height value of the high-wave height segment (12) is equal to the sum of the wave height value of the low-wave height segment (11) and the wave height values ​​of the several standard wavebands (2) provided on the side of the low-wave height segment (11). One variable-diameter waveband (1) and several layers of standard wavebands (2) form a waveband unit. Two adjacent waveband units are separated by a long flat band (4). Several layers of waveband units are rolled into a metal carrier.

2. The dual-core metal carrier with variable-diameter waveband as described in claim 1, characterized in that: The length of the standard band (2) is the same as the length of the low-wave high segment (11) of the variable-diameter band (1).

3. The dual-core metal carrier with variable-diameter waveband as described in claim 1, characterized in that: The low-wave high segment (11) is located in the middle of the variable-diameter waveband (1), and the high-wave high segment (12) is located at both ends of the variable-diameter waveband (1).

4. The dual-core metal carrier with variable-diameter waveband as described in claim 1, characterized in that: The variable-diameter waveband (1) is located on both sides of the low-wave high segment (11) with standard wavebands (2).

5. The dual-core metal carrier with variable-diameter waveband as described in claim 1, characterized in that: The wave height value of the low wave height segment (11) of the variable-diameter waveband (1) is the same as the wave height value of the standard waveband (2).

6. The dual-core metal carrier with variable-diameter waveband as described in claim 1, characterized in that: The variable-diameter waveband (1), standard waveband (2), short flat band (3) and long flat band (4) are all made of iron-chromium-aluminum material.

7. A method for manufacturing a dual-core metal carrier with variable-diameter wavebands, comprising the following steps: 1) Manufacturing of standard waveband (2) and variable diameter waveband (1): Standard waveband (2) with the same wave height is manufactured by stamping or rolling. Similarly, variable diameter waveband (1) with low wave height segment (11) and high wave height segment (12) is manufactured by stamping or rolling. 2) Waveband unit manufacturing: First, weld a short flat band (3) to at least one side of the low wave height section (11) of the variable diameter waveband (1), then weld a layer of standard waveband (2) to the outside of the short flat band (3), and the multiple layers of standard waveband (2) are also welded together by the short flat band (3). 3) Waveband unit combination: Waveband units are connected by welding with long flat strips (4), and the two outermost waveband units are also connected by welding with long flat strips (4). 4) Waveband winding: The waveband composed of several waveband units is threaded between two rotating needles (51) connected on the turntable (5). The turntable is started to drive the two rotating needles (51) to rotate around the center of the turntable (5) to form the waveband. 5) Forming metal carrier products: The rolled waveband is installed into the housing to form metal carrier products.

8. The method for manufacturing a dual-core metal carrier with variable-diameter wavebands as described in claim 7, characterized in that: The variable diameter waveband (1) is formed by stamping an upper die (6) and a lower die (7) with low wave high forming teeth and high wave high forming teeth.

9. The method for manufacturing a dual-core metal carrier with variable-diameter wavebands as described in claim 7, characterized in that: The variable diameter waveband (1) is formed by rolling two wave rollers (8) with low wave high forming teeth and high wave high forming teeth.

10. The method for manufacturing a dual-core metal carrier with variable-diameter wavebands as described in claim 7, characterized in that: Both sides of the variable-diameter waveband (1) are welded together with a standard waveband (3) via short flat strips (3).

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