Metal working – Method of mechanical manufacture – Catalytic device making
Reexamination Certificate
2001-06-13
2004-01-06
Cuda-Rosenbaum, I (Department: 3726)
Metal working
Method of mechanical manufacture
Catalytic device making
C029S819000
Reexamination Certificate
active
06671956
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention, which is used in catalytic purification of exhaust gas of an internal combustion engine, relates to an apparatus for mass production of metal substrates and a method of producing metal substrates by continuously inserting pre-made honeycomb bodies into metal outer shells.
2. Description of the Related Art
A “honeycomb body” refers to a thin metal sheet rolled into the shape of a honeycomb, and an “outer shell” refers to a metal pipe in which a honeycomb body is inserted. A “metal substrate” refers to a product in which said honeycomb body has been inserted into the outer shell.
Methods of inserting a honeycomb body into a metal outer shell may be classified into two main types. First is a method of inserting a honeycomb body into a prejoined outer shell in the shape of a pipe as described in Japanese Patent Nos. 5-228376, 6-390, 6-391, 6-47284, 6-63421, 6-182222, 6-238174, 7-24330, 8-206512; and U.S. Pat. No. 5,366,700. Second is a method of inserting a honeycomb body into a nonjoined outer shell in the shape of a “C” or into an outer shell of several pieces cut lengthwise, followed later by joining of the outer shell as described in Japanese Patent Nos. 4-122418, 5-220404, 6-269683, 6-277527; and U.S. Pat. No. 5,316,997.
These methods are appropriate for small-lot production of products of various shapes and sizes. However, while mass production of a single product is characteristic of manufacturing industries such as automobiles and motorcycles, these methods are not appropriate for mass production of metal substrates. In particular, when making an outer shell, the process of cutting the sheet into several pieces and changing the same into the shape of a pipe includes no structural part to secure them in a precise position, which in turn leads to a slight movement therein. Consequently, while in the shape of a pipe, the welding machine for welding both side edges into a unit may not precisely align with the welding area, which in turn becomes a cause of defective products.
Further, an additional sizing process is necessary to shape the pipe into a complete cylinder after welding by evening the girth of the pipe, or to shape it into a track shape, if needed, by compress-molding the cylindrical pipe into the track shape. Sizing, as such, is carried out while supporting the pipe cut into a piece, but at the time of sizing, the pipe can move slightly, which leads to a problem of imprecise sizing.
SUMMARY OF THE INVENTION
An embodiment herein describes an apparatus for mass production of metal substrates used in purification of exhaust gas, and the method of producing metal substrates using the same, which renders transformed pipes immovable for accurate welding at the welding area in addition to efficiently carrying out the sizing operation.
Another embodiment includes an apparatus for mass production of metal substrates used in purification of exhaust gas, and the method of producing metal substrates using the same, which integrates the following processes into one process for simplifying the multi-step manufacturing process of the prior art: tubing process of an outer shell into the shape of a pipe, inserting process of a honeycomb, and welding process of an outer shell.
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Kim Ha-Sik
Moon Byoung-Gi
Park Won-Wook
Cuda-Rosenbaum I
Korea Institute of Machinery and Materials
Meyertons Eric B.
Meyertons Hood Kivlin Kowert & Goetzel P.C.
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