EP0938380B1 - Method and device for producing structured sheet metal - Google Patents

Abstract

The invention relates to a method and a device to produce structured sheet metal. According to the inventive method, a strip of sheet metal (6) initially undergoes a structuring operation wherein a structure (8) is formed, whose structural height (H) is greater than a theoretical structural height (SH), followed by a calibration operation in a calibration unit (9). The structure (8) is guided through two rollers (10, 11) of the calibration unit (9) whereby the height of the structure once it has passed through the calibration unit (9) corresponds to the theoretical structural height (SH).

Description

The invention relates to a method for producing at least of a structured metal sheet, a method for producing a coated Sheet metal package and a device for manufacturing structured metal sheets. Such metal sheets are predominantly too Honeycomb bodies for catalytic converters processed, such as those in particular Exhaust systems of motor vehicles are used. Such a honeycomb body is described for example by EP 0 245 737 B1.

Structured metal sheets are generally used in the prior art produced by intermeshing profile rollers, as is known from EP-A1-0 460 611. The profile rollers preferably have one Involute toothing or a similarly designed toothing. It however, other geometries of the structures, e.g. B. trapezoidal shape, zigzag shape, etc. known.

Sections are separated from the structured, band-shaped metal sheet, which are stacked into a sheet metal stack, with between the textured metal sheets a smooth sheet is inserted. The ends of the For example, stacks become in opposite directions around at least two fixed points devoured. The stack thus deformed is inserted into a casing tube. Then the jacket pipe with the metal sheet stack used subjected to a soldering process in which the jacket tube with the sheet metal stack and the individual sheets are soldered to one another. The casing tube and the sheet metal package have different coefficients of thermal expansion. To ensure that a perfect solder joint between the metal sheets among themselves and the metal sheets and the Cladding tube is reached, the sheet metal package has already been proposed insert with a preload into the jacket tube, so that between the metal sheets and / or the metal sheets and the casing tube none Gap formation occurs. With spirally wound honeycomb bodies is already been proposed in the structured sheet metal at the apex areas the structure to provide radial recesses in which to solder serving material can be inserted.

During the structure-forming step, the band-shaped metal sheet experiences a deformation. Due to fluctuations in the material properties of the metal sheet, there are fluctuations in the structural height of the structured Sheet metal. These fluctuations in structure height are attributed to that the elasticity of the metal sheet within a tolerance band lies. This effect is possibly also due to tolerances of the profile rollers superimposed so that it is not ensured that sheet metal packages always can be inserted into a pipe with the same pre-tension. It is also noted been that the cell density of a honeycomb body at the same Manufacturing process can be different.

EP-A1-0 279 159 is a method for producing at least known a structured metal sheet, in which the structure by interlocking Tooth rolling is formed.

EP-A1-0 460 611 furthermore describes a method and a device for the production of welded layered metal sheets and metal sheet packages known.

EP-A1-0 460 611 discloses a structuring step through which a first metal sheet is provided with a structure by means of profile rollers. A second smooth metal sheet is then placed on the structured sheet applied, the first and the second metal sheet by a second Roll pair is passed.

Proceeding from this, the object of the invention is a method for producing at least one structured metal sheet and one layered sheet metal package and a device for producing structured Specify sheets that ensure that at a Further processing of the structured metal sheets or the metal sheet package to a honeycomb body, fluctuations in a preload with the one Sheet metal package can be inserted into a jacket tube, are low. Another one The aim of the invention is to ensure that a honeycomb body through structured metal sheets is formed, has a constant cell density.

The method according to the invention for producing at least one structured Metal sheet, is characterized in that first in a structure-forming Step formed a band-shaped metal sheet with a structure becomes. During the structure-forming step, a structure is made whose structure height is greater than a target structure height that the structured Should have sheet metal as a finished product. The structure-building step This is followed by a calibration step in which the structure of the metal sheet a force is applied so that after the calibration step the height corresponds to the structure of the target structure height. The fact that during the structure-building step, the structure height is greater than a target structure height it is ensured that the structure height despite springback of the metal sheet is sufficiently high. Furthermore, any tolerances compensated by profile tools. In the calibration step, the Vertex areas of the structure exerted a force by which the structure is deformed so that after the calibration step the height of the structure of the Target structure height corresponds.

After an advantageous further development of the method, the training a structure during the structure-forming step the metal sheet between two interlocking profile tools, preferably between two intermeshing profile rollers, passed through. The total profile height of the Profile tools, especially profile rollers, are preferred larger than the target structure height. Are the profile tools in the form of Profile rollers formed, it can be the profile rollers, for example are rollers with an involute profile.

After a further advantageous embodiment of the method the calibration step preferably in the form that the metal sheet with the Structure is passed through a gap, the gap height is less than is the target structure height of the metal sheet or the target structure height of the Corresponds to sheet metal. The formation of such a gap can preferably in that two rollers are arranged axially parallel.

To ensure that a honeycomb body that consists of a structured Sheet metal or a sheet metal package is made a constant According to yet another advantageous development, cell density is achieved of the inventive method proposed that after the calibration step the spring property of the structure of the metal sheet is determined. Taking the spring property into account is a cut length determined and a section of a metal sheet according to the cut length separated from the band-shaped metal sheet. By a so manufactured structured metal sheet, a honeycomb body can be produced, the one has reproducible cell density and the metal sheets with a reproducible Preload can be used in a jacket tube. Preferably the determined cut length used as a measure for other sections.

According to another idea according to the invention, a method for Manufacture of a layered sheet metal stack, such as by EP 0 245 737 B1 is known, proposed in which a first band-shaped Sheet metal first a structure-forming step through which the first Sheet metal is formed with a structure whose structure height is greater than lie is the target structure height, then a calibration step in which the Structure of the first metal sheet a force is exerted after the Calibration step the height of the structure corresponds to a target structure height, and a second band-shaped metal sheet is placed on the first metal sheet.

According to an advantageous development of the method, the first becomes band-shaped Metal sheet during the structure-forming step between two no interlocking profile tools, preferably between two combs Profile rollers, passed through.

After a further development of the method, the remaining metal sheet passed between profile tools, especially profile rollers, whose Overall profile height is greater than the target structure height.

A second strip-shaped metal sheet is placed on the first strip-shaped metal sheet Metal sheet. The second metal sheet is preferably after Calibration step placed on the first metal sheet. Alternatively, it is suggested that the second metal sheet before the calibration step on the metal sheet is placed. This measure makes the structured metal sheet calibrated together with the second, preferably smooth metal sheet.

After the calibration step, the spring characteristic of the Structure of the first metal sheet or the spring property of the layered Metal sheets determined and taking into account the spring property a Cut length determined, and the first metal sheet or the layered Metal sheets are cut according to the cut length.

According to a further idea according to the invention, a device for the production of structured metal sheets and / or metal sheet packages with a structuring unit for forming a structure with a structure height proposed, in which the structuring unit, the at least two interlocking profile tools with an overall profile height that is larger is as the target structure, and one in the transport direction of the metal sheet considered subordinate calibration unit through which on the structure a force is exerted on the metal sheet so that the height of the structure corresponds to a predetermined target structure height.

According to an advantageous development of the device according to the invention the structuring unit has at least two intermeshing profile rollers, which preferably have an involute profile. The use of rotatable profile rollers enable a continuous manufacturing process of a structured metal sheet. Alternatively, sequential manufacturing a structure in a metal sheet uses a structuring unit which comprises two profile tools which can be moved towards one another, between which the metal sheet is deformable.

According to yet another advantageous development of the device proposed that the calibration unit have at least two calibration tools has, between which the metal sheet can be placed, and the calibration tools limit a gap whose gap height is smaller than the profile height of profile tools. The gap height preferably corresponds to the target structure height, which should have a structured metal sheet. The gap height is preferably adjustable by adjusting the calibration tools.

The calibration tools are preferably essentially two axially parallel rollers formed. The rollers are preferably like this arranged that the roller axes substantially transverse to the direction of transport of a metal sheet.

According to a further advantageous development of the device, it is proposed that that the calibration unit is a measuring unit, by the spring property of the metal sheet is determined, and a separation unit through which the Sheet metal is cut to length according to the spring properties, subordinate is.

Fig. 1

schematisch eine erste Ausführungsform einer Vorrichtung zum Herstellen strukturierter Metallbleche,

Fig. 2

eine Kalibriereinheit und

Fig. 3

ein zweites Ausführungsbeispiel einer Vorrichtung zum Herstellen strukturierter Bleche.

Further advantages and features of the invention are explained using the exemplary embodiments shown in the drawing. Show it:

Fig. 1

schematically a first embodiment of a device for producing structured metal sheets,

Fig. 2

a calibration unit and

Fig. 3

a second embodiment of a device for producing structured sheets.

Fig. 1 shows schematically a device for producing structured Sheets. The device has a structuring unit 1. The structuring unit 1 comprises two intermeshing profile rollers 2, 3. The Profile rollers 2, 3 have, for example, an involute profile. The axes 4, 5 of the profile rollers 2, 3 run parallel to one another. A strip-shaped metal sheet 6 runs between the profile rolls 2, 3, which is handled by a coil 7. While going through the Structuring unit 1 is given a structure 8 to the metal sheet 6. The structure 8 essentially corresponds to the profile of the profile rolls 2, 3. The structural unit is viewed in the transport direction of the metal sheet 6 1 downstream of a calibration unit 9. The calibration unit 9 has two Calibration tools formed in the form of two rollers 10, 11 are. The rollers 10, 11 are arranged axially parallel to one another. The Shell surfaces of the rollers 10, 11 delimit a gap 12 through which the structured metal sheet 6 is passed. The calibration unit 9 is a measuring unit 13 and a separation unit 14 arranged downstream.

The spring property of the structure 8 'of the Metal sheet 6 determined. Taking into account the spring properties of the A cut length L is determined in structure 6 and a section 15 corresponding to the cut length L of the band-shaped metal sheet 6 in the separation unit 14 separated. The determination of the spring characteristic of the Structure 6 of the metal sheet can be done by a force / displacement measurement.

The profile of the profile rollers 2, 3 is designed so that the height H of the Structure 8 is greater than a predetermined target structure height SH. The Metal sheet 6 is given a structure 8, such as that shown in FIG Fig. 2 is shown. The metal sheet structured in this way is passed through the gap 12 passed between the rollers 10, 11. The height h of the gap 12 is dimensioned such that when the sheet metal 6 passes between the Rolls 10, 11 the structure 8 is compressed, creating the structure 8 'after the calibration unit 9 has a height which is the desired structural height SH corresponds. The rollers 10, 11 are rotatably mounted. Preferably the gap height h is adjustable by means of adjustable rollers 10, 11.

We now refer to the representation of a device according to FIG. 3rd

The device shown in FIG. 3 has a structuring unit 1 on by two spaced apart and axially parallel Profile rollers 2, 3 is formed. The profile unit 1 follows in the transport direction considers a calibration unit 9 to which a measuring unit 13 and a Separating unit 14 connects. The calibration unit 9 is separated by two Rollers 10, 11 arranged parallel to one another and axially parallel are formed. The rollers 10, 11 are rotatably mounted. Limit the lateral surfaces of the rollers 10, 11 a gap 12.

A band-shaped metal sheet 6 is unwound from a coil 7 and the structuring unit 1 supplied. In the structuring unit 1 is the sheet metal 6 is given a structure 8 by the profile rollers 2, 3. The structure 8 has a height H which is greater than the desired structure height SH. The metal sheet 6 structured in this way subsequently follows the calibration unit 10 fed. The metal sheet 6 passes through the gap 12 between the rollers 10, 11. The gap 12 has a height h that is smaller is as the height H of the structure 8. During the passage of the metal sheet 6 a force is exerted on the structure 8 by the calibration unit 9 exercised, through which the height of the structure to the desired structure height SH brought. In front of the calibration unit 9 is on the structured sheet 6 fed a smooth metal sheet 16, which unwound from a coil 17 becomes. The smooth metal sheet 16 and the structured metal sheet 6 pass through the calibration unit 9 together.

The calibration unit 9 is followed by a measuring unit 13, by means of which the spring property of the smooth and the structured metal sheet 6, 16 is determined. On the basis of the spring property determined, a cut length L certainly. A separating unit 14 following the measuring unit 13 separates one Section 18 of the smooth metal sheet 16 and the structured metal sheet 6 from. The structured sheets 6 are stacked one on top of the other, creating a Sheet metal package 19 is created, which after engulfing in a Jacket tube can be used.

Reference list

1

Structuring unit

2, 3

Profile roller

4, 5

axis

6

metal sheet

7

7 coil

8, 8 '

structure

9

Calibration unit

10, 11

roller

12th

gap

13

Unit of measurement

14

Separation unit

15

section

16

Smooth sheet

17th

Coil

18th

section

19th

Sheet metal package

Claims (23)

1. A process for producing at least one structured metal sheet, wherein a metal sheet (6) in strip form is firstly subjected to a structure-forming step, characterised in that a structure (8) is formed by means of the structure-forming step, whose structure height (H) is greater than a reference structure height (SH), and thereafter the metal sheet (6) is subjected to a calibration step in which a force is applied to the structure (8) of the metal sheet (6), such that after the calibration step the height (H) of the structure (8') corresponds to the reference structure height (SH).
2. A process according to claim 1 wherein the metal sheet (6) is passed through between two inter-engaging shaped rollers (2, 3) during the structure-forming step.
3. A process according to claim 2 wherein the metal sheet (6) is passed through between shaped rollers (2, 3) whose overall shaped height is greater than the reference structure height (SH).
4. A process according to claim 2 or claim 3 wherein the metal sheet (6) is passed through between two meshing shaped rollers (2, 3) during the structure-forming step.
5. A process according to one of claims 1 to 4, wherein the metal sheet (6) is passed through a gap (12) whose gap height (h) is smaller than the reference structure height (SH) of the metal sheet (6) or corresponds to the reference structure height (SH) of the metal sheet (6).
6. A process according to claim 5 wherein the gap (12) is formed by two rollers (10, 11) with their axes arranged in parallel relationship.
7. A process according to one of claims 1 to 6 wherein after the calibration step the spring property of the structure of the metal sheet (6) is determined, in consideration of the spring property a blank length (L) is ascertained, and a portion (15) is cut off the metal sheet (6) in strip form, corresponding to the blank length (L).
8. A process according to claim 7 wherein the blank length (L) is used as a measurement in respect of further portions.
9. A process for producing a laminated metal sheet pack (19) in which a first metal sheet (6) in strip form is firstly subjected to a structure-forming step by which the first metal sheet (6) is formed with a structure (8), and a second metal sheet in strip form, preferably a smooth metal sheet (16) is laid onto the first metal sheet (6), characterised in that a structure (8) is formed whereof the structure height (H) is greater than the reference structure height (SH) and thereafter is subjected to a calibration step wherein a force is applied to the structure (8) of the first metal sheet (6) such that after the calibration step the height (H) of the structure (8') corresponds to a reference structure height (SH).
10. A process according to claim 9 wherein the metal sheet (6) is passed through between two inter-engaging shaped rollers (2, 3) during the structure-forming step.
11. A process according to claim 10 wherein the first metal sheet (6) is passed through between shaped rollers (2. 3) whose overall shaped profile height is greater than the reference structure height (SH).
12. A process according to claim 10 or claim 11 wherein the first metal sheet (6) is passed through between two meshing shaped rollers (2, 3) during the structure-forming step.
13. A process according to one of claims 9 to 12, wherein the first metal sheet (6) is passed through a gap (12) whose gap height (h) substantially corresponds to the reference structure height (SH) of the first metal sheet (6).
14. A process according to claim 13 wherein the gap (12) is formed by two rollers (10, 11) with their axes parallel.
15. A process according to claim 13 or claim 14 wherein the second metal sheet (16) is laid onto the first metal sheet (6) prior to the calibration step.
16. A process according to one of claims 9 to 14 wherein the second metal sheet (16) is laid onto the first metal sheet (6) after the calibration step.
17. A process according to one of claims 9 to 16 wherein after the calibration step the spring property of the structure of the first metal sheet (6) or the spring property of the laminated metal sheets (6, 16) is ascertained and it or they is or are cut to length in accordance with the spring property.
18. Apparatus for producing structured metal sheets and/or metal sheet packs comprising a structure-imparting unit (1) which has at least two inter-engaging shaped tools (2, 3) for forming a structure with a structure height (H), characterised in that the at least two shaped tools (2, 3) have an overall shaped profile height which is greater than the reference structure height (SH), that a calibration unit (9) which is disposed downstream as considered in the direction of transportation movement of the metal sheet (6, 16) is provided, by which a force is applied to the structure (8) of the metal sheet (6, 16) such that the height (H) of the structure (8') downstream of the calibration unit (9) corresponds to a predetermined reference structure height (SH).
19. Apparatus according claim 18 characterised in that the structure-imparting unit (1) has at least two meshing shaped rollers (2, 3).
20. Apparatus according to claim 18 or claim 19 characterised in that the calibration unit (9) has at least two calibration tools (10, 11) between which the metal sheet (6, 16) can be brought and the calibration tools (10, 11) define a gap (12) whose gap height (h) is smaller than the profile height (PH) of the shaped tools (2, 3).
21. Apparatus according to claim 20 characterised in that the calibration tools are two rollers (10, 11) which are arranged with their axes in parallel relationship.
22. Apparatus according to one of claims 18 to 21 characterised in that arranged downstream of the calibration unit (9) are a measuring unit (1, 3) by which the spring property of the metal sheet (6, 16) is ascertained, and a severing unit (14) by which the metal sheet (6, 16) is cut to length in accordance with the spring property.
23. Apparatus according to one of claims 18 to 22 characterised in that the gap height (h) of the calibration unit (9) is adjustable.

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