EP1633506B1 - Procede et dispositif pour produire une bande de tole structuree - Google Patents

Procede et dispositif pour produire une bande de tole structuree Download PDF

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Publication number
EP1633506B1
EP1633506B1 EP04739723A EP04739723A EP1633506B1 EP 1633506 B1 EP1633506 B1 EP 1633506B1 EP 04739723 A EP04739723 A EP 04739723A EP 04739723 A EP04739723 A EP 04739723A EP 1633506 B1 EP1633506 B1 EP 1633506B1
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EP
European Patent Office
Prior art keywords
metal strip
sheet
primary structure
tools
shaping tools
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
EP04739723A
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German (de)
English (en)
Other versions
EP1633506A1 (fr
Inventor
Gottfried Wilhelm Haesemann
Ludwig Wieres
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Vitesco Technologies Lohmar Verwaltungs GmbH
Original Assignee
Emitec Gesellschaft fuer Emissionstechnologie mbH
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Filing date
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Publication of EP1633506A1 publication Critical patent/EP1633506A1/fr
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Publication of EP1633506B1 publication Critical patent/EP1633506B1/fr
Anticipated expiration legal-status Critical
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2807—Metal other than sintered metal
    • F01N3/281—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
    • F01N3/2814—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates all sheets, plates or foils being corrugated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D13/00—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form
    • B21D13/04—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form by rolling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2807—Metal other than sintered metal
    • F01N3/281—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
    • F01N3/2821—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates the support being provided with means to enhance the mixing process inside the converter, e.g. sheets, plates or foils with protrusions or projections to create turbulence
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49345—Catalytic device making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/496—Multiperforated metal article making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/51—Plural diverse manufacturing apparatus including means for metal shaping or assembling
    • Y10T29/5136—Separate tool stations for selective or successive operation on work
    • Y10T29/5137—Separate tool stations for selective or successive operation on work including assembling or disassembling station

Definitions

  • the present invention relates to a method for producing a structured sheet-metal strip having a primary structure and to an apparatus for introducing at least one primary structure into a sheet-metal strip.
  • Such structured sheet metal strips are preferably used for the production of exhaust gas purification components of mobile combustion machines.
  • Such components are, for example, filter elements for filtering out particles contained in the exhaust gas, adsorbers for at least temporary storage of pollutants contained in the exhaust gas (eg NO x ), catalytic converters (eg 3-way catalyst, oxidation catalyst, reduction catalyst, etc.), diffusers for Strömungsbeeinffussung or turbulence of the flowing exhaust gas, or heating elements that just after the cold start of the internal combustion engine to heat the exhaust gas to a predetermined temperature.
  • the following carrier substrates have proven successful in principle: ceramic honeycomb bodies, extruded honeycomb bodies and honeycomb bodies made of metal foils. Due to the fact that these substrates are always adapt to their functions, high temperature resistant and corrosion resistant metal foils are particularly well suited to serve as a starting material.
  • honeycomb bodies with a plurality of at least partially structured sheet metal foils, which are subsequently introduced into a housing and thus form a carrier body which can be provided with one or more of the abovementioned coatings.
  • the at least partially structured sheet metal foils are arranged so that substantially parallel to each other arranged channels are formed.
  • a part of the sheet metal foil is provided with a primary structure, which is characterized, inter alia, by a regular, repetitive structure, in particular a kind of sinusoidal corrugation, a sawtooth structure, a rectangular corrugation, a triangular corrugation, an omega curl, or the like.
  • Sheet metal foils provided with a primary structure are then stacked on top of one another (optionally alternately with smooth intermediate layers), wound together and inserted into a housing. After a technical joining of the metal foils with the housing, a honeycomb body is formed, which has substantially parallel channels.
  • secondary structures which include, for example, guide surfaces, microstructures, nubs, protrusions, wings, tabs, holes or the like. insofar This results in a significantly increased variety of variations in the production of metallic honeycomb body compared to those made of ceramic material, because with an extrusion process such a complex channel wall can not be realized or with only very high technical complexity.
  • the metal foil is provided by means of interlocking profile tools, for example by the method of corrugating, with a primary structure.
  • the smooth sheet-metal strip is passed through two rollers profiled in the circumferential direction, wherein the roller axes are perpendicular to the bending plane.
  • the rollers are equipped, for example, with involute-shaped profile teeth, with the teeth of the rollers meshing with one another.
  • the metal strip to be reshaped is partially lodged on the flanks of the tread teeth and at the same time takes place a deformation by the tooth profile head. This often results in a compression of the material in the region of the flanks and cracking near the tooth profile head.
  • the generated primary structure substantially reflects the profile of the corrugating rolls, which is itself limited by the fact that the teeth roll on each other or cause a certain stiffness due to the rolling process. It is only completely certain ratios of well length to well height of the primary structure produced.
  • An essential feature of this manufacturing method is that the production of the primary structure is no longer produced by rotating, interlocking profile tools, but that a plurality of separate molds perform a kind of lifting movement and press the smooth sheet metal strip in a predetermined counter-form. Due to the fact that the separate molds move toward the counter-mold with a substantially vertical movement, a large number of different, arbitrarily designed embodiments can be achieved for a primary structure. Since a plurality of separate molds are used here, the material load can be further reduced.
  • each mold only processes a relatively small area of the sheet metal strip, wherein (possibly in the spaces between adjacently arranged mold tools or by a defined, temporal sequence of strokes of the molds) offset the change in position of the sheet metal strip due to the staggered, progressive forming process becomes. This results in a particularly material-friendly generation of the primary structure.
  • a counter-mold is positioned on the same side of the sheet metal strip, while on the opposite side of the Blechbandes.
  • a counter-mold has several extremes in which the separate molds intervene and may almost come into contact (so that the gap corresponds approximately only to the sheet thickness). If one now considers these extremes of the counterform, they usually lie on a straight or curved line. This line is located in essentially parallel to the guide direction of the sheet metal strip by the shaping device. Straight to this guide direction or to this line, the separate molds are moved substantially vertically. A more detailed description of this method will be made below with reference to different tools.
  • the structured sheet metal strip is separated so that sheet metal foils are produced.
  • the above-mentioned method is preferably carried out with a sheet-metal strip drawn off from a coil
  • sheet-metal foils with a certain length are used in the case of the exhaust-gas cleaning components described at the beginning. This length depends essentially on the structure of the honeycomb body, wherein lengths are used, for example, up to 40 cm in spirally wound or even only 12 cm in, for example, S-shaped wound sheet metal foils for the production of carrier bodies.
  • a structured sheet-metal strip with a primary structure which is characterized by a corrugation length and a corrugation height, the ratio of corrugation length to corrugation height being less than 2, in particular less than 1.5.
  • well length describes the distance between two similar extremes, for example two directly adjacent wave crests or two directly adjacent wave troughs. It is therefore clear that this refers to the repetition length of the primary structure. Under the wave height is the distance between two opposite extremes to understand, so for example, the distance of a wave crest toward the adjacent trough.
  • corrugation length and corrugation height are perpendicular to each other.
  • a ratio of well length to well height smaller than 2, in particular smaller than 1.5 describes primary structures with relatively steeply sloping flanks.
  • Such primary structures later form when assembled into a honeycomb structure (a support body through which the exhaust gas can flow) channels having advantageous properties.
  • honeycomb structure a support body through which the exhaust gas can flow
  • channels having advantageous properties.
  • such channels are characterized by improved flow behavior, especially since the flanks are relatively close together and thus an intimate contact of the flowing exhaust gas with the z. T. coated channel walls is possible.
  • the sheet metal strip or the sheet metal foil is made of a high-temperature and corrosion-resistant material, and has a thickness which is less than 0.11 mm, in particular less than 0.06 mm and preferably even 0.03 mm.
  • the material preferably contains chromium and / or aluminum (usually with an iron base), and / or comprises a nickel base. Especially with such materials with the specified thicknesses had previously been expected damage to the introduction of the primary structure. On the one hand, this originates from the fact that the stated materials are very easily prone to strain hardening, but on the other hand also represent a risk due to their material thickness.
  • carrier bodies can be produced which have a channel density of more than 200 cpsi ("calls per square inch"), in particular more than 400 cpsi and preferably even more than 800 cpsi.
  • holes and / or slots are introduced into the sheet-metal strip prior to introduction of the sheet metal strip into the shaping device, in particular with the production method stamping.
  • Such holes for example, with a diameter of 2 mm to 6 mm, usually serve as a passage for partial exhaust gas streams in exhaust gas purification components, which allow gas exchange of adjacent channels.
  • the slots are usually used as a starting point for the secondary structure, which is produced at the points of the slots by deformation of the sheet metal strip such as everting, bending, widening, etc. In particular, guide surfaces, wings or similar structures are formed. But it is also possible that the holes are arranged directly on the slots.
  • the slots in the edge areas have widenings which reduce the notch effect.
  • the holes or widenings have a radius that is significantly smaller than 1 mm.
  • the production method stamping is favored, since this can be used particularly cost-effectively in the context of a series production.
  • the sheet metal strip is provided after introduction of the primary structure by means of intermeshing profile tools with a secondary structure, which preferably at least partially limits holes and / or slots in the sheet metal strip.
  • This process step is usually carried out before separating the structured sheet-metal strip into separate sheet-metal foils.
  • profile tools mentioned here which mesh with one another, those which do not have flanks which roll on one another are meant in particular. Rather, these are pin-like constructions, which preferably only come into contact with the areas of the sheet metal strip at which later the Secondary structure is formed.
  • the holes and / or slots serve as positioning aids, for example.
  • an apparatus for introducing at least one primary structure into a fed sheet-metal strip having a plurality of separate juxtaposed molds is proposed, each having a contact surface substantially corresponding to a portion of the primary structure, the molds substantially perpendicular to the guide direction of the sheet metal strip and at least partially offset from each other are movable and a counter-mold on the opposite side of the forming tool sheet metal can be positioned, which generates a feed of the sheet metal strip in the guide direction wherein the feed of the sheet metal strip takes place when the molds are not engaged with the sheet metal strip are.
  • a contact surface is to be considered the part of the molds, which comes into contact with the sheet metal strip, that causes its transformation.
  • This contact surface is designed so that they essentially represent a section of the primary structure. This ensures that the forming tools can press or press in the sheet-metal strip with the desired primary structure into a counter-shape.
  • the arrangement of the separate molds side by side is preferably carried out in such a way that in the event that all the molds are in engagement with the sheet metal strip or the counter-mold (ie have their maximum stroke), the contact surfaces of the molds adjacent to each other and / or are positioned substantially parallel to a profile of the counter-mold.
  • the mutually offset movement of the separate molds ensures that sufficient material of the sheet metal strip can be drawn into the deformation region, and thus an excessive stress on the sheet metal strip during the forming is avoided (excessive elongation, excessive compression, work hardening, etc). It is therefore clear that a larger area of the sheet-metal strip is arranged close to the forming tools, but this area is shaped at different times or with different intensity at the same time. Accordingly, a "mutually offset movement" is to be understood that the lifting movement of mutually adjacently arranged molds takes place at different times, at different speeds, with different force and / or with different direction of force.
  • the forming of the sheet-metal strip takes place in such a way that an externally arranged mold (or a mold, which is arranged last in the guide direction) begins with the lifting movement, and temporally successively the adjacent, adjacent molds perform their lifting movement until the other, opposite (or first arranged in the guide direction) mold is reached.
  • an externally arranged mold or a mold, which is arranged last in the guide direction
  • the adjacent, adjacent molds perform their lifting movement until the other, opposite (or first arranged in the guide direction) mold is reached.
  • all separate molds are in engagement with the sheet metal strip, but at most half of the separate molds, in particular less than one third of the separate molds to be in contact with the sheet metal strip.
  • at least 2, preferably at least 3, in particular at least 5, of such forming tools should at the same time exert a force on the sheet-metal strip during the forming in order to enable secure holding and continuous shaping.
  • the primary structure has a corrugation length and a corrugation height, and the ratio of corrugation length to corrugation height is preferably less than 2, wherein the forming tools have a width which is less than 10 times the corrugation length, in particular less than 5 times the corrugation length.
  • the width of the separate molds is defined in more detail. This will be relatively narrow molds specified, which form only a certain number of wave crests or troughs. Most preferably, the width of the molds corresponds to substantially twice the well length. This relatively narrow design of the molds has a particularly gentle deformation of the metal strip result, since at the same time only a very limited area of the sheet metal strip is formed. Thus, material flows in the sheet metal strip are significantly reduced by upsetting or stretching.
  • a spatially offset lifting movement is to be understood in particular as meaning that all molding tools perform the same lifting movement in terms of their amount, but they are different during the forming process, so that at least a majority of the forming tools are in different stages with regard to their lifting movement.
  • a temporary superimposition of the lifting movement is meant in particular that a plurality of molds are not in their extreme positions at the same time but execute the lifting movement.
  • a camshaft is proposed with mutually offset in the direction of rotation cams.
  • Such a camshaft may for example be designed such that it has a plurality of seen in the axial direction adjacent cam sections, which are arranged offset from one another in the rotational direction, or in the direction of rotation staggered maxima of the cams have.
  • the number of cams of the plurality of separate, juxtaposed molds which are brought into contact with the cam so that they perform their lifting movement.
  • the lifting movement can be easily adjusted by the special design of the cam, so that the speed or the stroke through the Profile of the cam is easily adjustable.
  • the corresponding cams overlap at least partially in an end view of the camshaft in the direction of rotation.
  • the means comprise a carriage, which is arranged movable relative to the molds so that a lifting movement is generated by the relative movement and a suitable connection of the carriage with the molds.
  • the carriage While in the aforementioned camshaft, the relative movement is generated by a rotational movement of the camshaft, the carriage describes a translational or a similar movement, which is carried out in particular with a suitable guide.
  • such a slide is successively brought into contact with the separate dies in such a way that it acts on a force which results in a stroke movement. For example, this can be achieved by passing such a slide past the opposite side of the contact surfaces of the molds, wherein a drainage surface pushes the molds toward the position of the sheet metal strip.
  • the lifting movement in particular its speed and its stroke, can be adjusted by a suitable profiling of this rolling surface.
  • it is possible to influence the cycle frequency of the processing steps by the speed with which the carriage is guided past the forming tools.
  • the separate molds are arranged parallel to each other. In other words, this means that the guide direction of the sheet metal strip is also substantially straight. In such an arrangement of the molds, especially the generation of the lifting movement by means of the camshaft described above offers.
  • the molds are arranged obliquely to each other, in particular at an angle starting from their contact surfaces of at least 5 °. Depending on your required space requirements of the molds or the sheet metal strip working range of the molds, this angle may also vary or be greater, e.g. about 10 °, 15 °, 20 °, etc .. It is very particularly advantageous that the molding tools are arranged radially, with a profiled wheel is provided in a center. In such an oblique arrangement of the molds is usually assumed that the areas of the molds, which form the contact surfaces to each other have the smallest distance. The oblique arrangement of the molds allows a relatively compact construction of the device. The molds, between which preferably always the same angle is present, can ultimately cover a nearly circular area; However, it is also possible that only partial circuit sections, such as a semicircle or a three-quarter circle, are formed by the molding tools.
  • the molds their in this case from a lifting movement, which is directed radially inwardly toward the center, when a deformation or deformation of the sheet metal strip is to be made.
  • a profile wheel is provided in the center, which essentially comprises the negative form of the contact surfaces of the molding tools. This profile wheel can be used simultaneously to advance the structured sheet metal strip when it is connected to a corresponding drive unit.
  • the profile wheel has a direction of rotation and a carriage guided on an outer circular path has an opposite direction of movement.
  • the principle is again realized that the transformation of the sheet metal strip or the production of Primary structure always propagates from the already formed region of the sheet metal strip starting opposite the guide direction. This ensures that smooth areas of the sheet metal strip can be drawn into the profiles.
  • means for a continuous supply and removal of the sheet metal strip are present, which preferably ensure a feed of at least 20 m / min (meters per minute).
  • continuous supply and removal is meant in this context, in particular, that there is a continuous, uninterrupted, automatic transporting of the sheet metal strip, with a time averaged over one hour, a feed of at least 20 m / min is achieved.
  • the means for ensuring the lifting movement of the separate molds are connected to a drive which drives at least one further device from the series of the following devices: a supply device of the sheet-metal strip; a profiling device for generating a secondary structure with intermeshing profile tools; a punching device for producing holes and / or slits in the sheet-metal strip; a separator for producing separate metal foils from the sheet metal strip.
  • FIG. 1 shows a device 3 for introducing at least one primary structure 5 in a fed sheet-metal strip 1 with a plurality of separate, juxtaposed molds 6, each having a contact surface 14, which substantially corresponds to a portion 15 of the primary structure 5.
  • the molds 6 are substantially perpendicular to the guide direction 4 of the sheet metal strip 1 and at least partially offset from each other movable.
  • the device 3 has means for generating a lifting movement 33 of the molds 6, so that a temporal superimposition of the lifting movement 33 of neighboring molds 6 is possible.
  • these means is the carriage 20, which is arranged so that it can move relative to the forming tools 6, that the lifting movement 33 is generated by the relative movement and a suitable connection of the carriage 20 with the forming tools 6.
  • the molds 6 are obliquely, in particular radially, arranged to each other, which have an angle 21, starting from their contact surfaces 14 of at least 10 °.
  • the carriage 20 is driven at a uniform speed on the circular path 25 with a direction of movement 26.
  • a region is preferably provided, during which the carriage 20 has no contact with a mold 6 during its movement, as shown in the lower left partial section.
  • This subsection, or the period of time required for the carriage 20 to pass through this subsection, is used to implement a feed with respect to the sheet metal strip 1.
  • the profile wheel 23 rotates in the center 22 in the direction of rotation 24.
  • the profile wheel 23 rotates so far that the last formed primary structure 5 is now positioned just near the last in the guide direction 4 mold 6. This feed operation is completed when the carriage 20 just reaches this last arranged mold 6 and causes a lifting movement 33 in him.
  • FIG. 3 schematically shows a further embodiment of a forming device 3 for producing structured metal strips 1 with a primary structure 5.
  • a plurality, this time substantially parallel to each other, forming tools 6 are provided, which can successively offset from one another perform a lifting movement 33.
  • a camshaft 17 with cams 19 offset from one another in the direction of rotation 18 is provided on the side facing away from the contact surfaces 14 of the forming tools 6.
  • These cams 19 press the Forming tools 6 in the illustrated embodiment upwards, with a reduction in the diameter of the cam 19 in turn has a lowering of the molds 6 result.
  • the cams arranged adjacent to each other form a slope or a slope, wherein the cams 19 at different times, depending on the rotational angle of the camshaft 17, come into contact with other molds 6.
  • the molds 6 press the sheet metal strip 1 in a counter-mold 46, which can also perform a lifting movement 33 here.
  • the forming tools 6 arranged on the right start with a deformation of the sheet metal strip 1, wherein gradually the shaping tools 6 arranged further to the left cause a deformation.
  • a feed of the metal strip 1 is effected by this moves along the arrows 47.
  • the counter-mold 46 moves partially to the right in the representation, then lifts upwards, and then moves back to the left, so that its profiling again directly opposite the contact surfaces 14 of the molds 6 is arranged. Then there is again a smooth portion of the sheet metal strip 1 between the molds 6 and the counter-mold 46.
  • 46 comb-shaped elements may be provided in the counter-mold, which serve as an "ejector” and therefore preferably relative to the counter-mold 46 can be relatively moved. This "ejector” thus serve if necessary also for further transport of the sheet metal strip 1, the heavy counter-mold 46 then performs only an up and down movement.
  • the comb-shaped elements can be used in addition to the calibration or fine adjustment of the desired wave height.
  • the cams 19 of the camshaft 17 are designed so that at a certain time or for a certain period of time, none of the cams 19 are in contact with the forming tools 6 and precisely that time or period for advancement of the sheet metal strip 1 is used. This has the advantage that the camshaft 17 can always be driven continuously at the same speed.
  • FIG. 4 shows schematically and in perspective a carrier body 38 as Abgastherapieslcomponente for mobile applications, such as in automobiles, motorcycles, lawn mowers, etc.
  • the sheet metal foils 2 produced by the above method or with the devices described above are stacked and then wound or wound to form a honeycomb structure 39 having a plurality of channels 35 arranged substantially parallel to one another.
  • This honeycomb structure 39 is usually inserted into a corresponding housing 37 and connected to it by joining technology, in particular with a soldering method.
  • the resulting carrier body 38 can be used as a catalytic converter, particle trap, adsorber, flow mixer, etc. Preference is given to the channels 35, which extend from one end face 40 to the opposite substantially continuous, wherein a connection of adjacent channels 35 may be provided to each other.
  • Sheet metal foils 2 can again be seen in the enlarged section, wherein a part of these sheet metal foils 2 has a primary structure 5.
  • the metal foils 2 have a secondary structure 13, which are at least partially bounded by a hole 10. These holes 10 ensure that gas exchange is possible with respect to adjacent channels 35.
  • the primary structure 5 of the sheet metal foil 2 ensures a very large surface 36 of the carrier body 38, so that an intimate contact of exhaust gas with a coating 34 arranged on the surface 36 is made possible.
  • the metal foils 2 preferably have a thickness 9 which is less than 0.1 mm, in particular less than 0.5 mm.
  • FIG. 5 shows schematically and in perspective a metal foil 2 with a primary structure 5 and a secondary structure 13.
  • the primary structure 5 is of wave-like shape and has wave peaks 41 and troughs 42.
  • the wave peaks 41 and wave troughs 42 extend substantially parallel to each other over the entire length 48 of the sheet metal foil 2.
  • the sheet metal foil 2 is provided with a secondary structure 13, wherein this comprises a plurality of guide surfaces 43, which starting from the troughs 42 upwards and extend down from the wave crests 41 down. Near these guide surfaces 43 holes 10 are provided which peel off a boundary flow in the flow direction 44 along the sheet metal foil 2 and deflect it into adjacent subregions.
  • FIG. 6 1 schematically shows an embodiment of the method for producing multi-structured sheet-metal foils 2 or sheet-metal strips 1.
  • the step identified by (A) comprises the insertion of a plurality of slots 11 in an inner region of the substantially planar sheet-metal strip 1.
  • the slots 11 arranged substantially parallel to the edges of the sheet metal strip 1, but this is not necessarily the case.
  • the slots 11 can be provided in any arrangement to each other.
  • the slots 11 are here at least partially also shown with holes 10 in the edge regions, the holes 10 have the task to avoid crack propagation starting from the edge regions of the slots 11 after the formation of the secondary structure 13.
  • step (B) the sheet-metal strip 1 is first formed, whereby a primary structure 5 having a first corrugated length 7 is produced.
  • a primary structure 5 having a first corrugated length 7 is produced.
  • the primary structure 5 can be easily recognized from the edge, with two similar, adjacent extremes (wave peaks 41 or wave troughs 42) describing the first well length 7.
  • the corrugation height 8 is to be used, wherein here after the first forming step, for example, a first well height 8 is present, and in this phase, the ratio of well length 7 to well height 8 is less than 2.
  • the secondary structure 13 is introduced into the sheet-metal strip 1.
  • the illustrated secondary structure 13 in turn has holes 10 and guide surfaces 43, which are aligned opposite.
  • the secondary structure 13 overlays the primary structure 1.
  • the primary structure 5 is gathered or reshaped to produce a second well length 7 which is smaller than the first well length 7.
  • a corresponding enlargement of the corrugation height 8 takes place, that is, the first corrugation height 8 is smaller than the second corrugated height 8.
  • the ratio of well length 7 to well height 8 can be further reduced, for example to values smaller than 1.5.
  • the method steps (B) and (C) can also be carried out in one production step.
  • the shaping device 3 or the molding tools 6 can be designed such that the primary structure 5 and the secondary structure 13 can be generated simultaneously upon contact with the sheet-metal strip 1.
  • FIG. 7 shows schematically the structure of a production line, as it can be used for the production of structured sheet metal foils.
  • the sheet-metal strip 1 is first fed by means of a feeder 28 to a punching device 29.
  • the openings 10 and / or slots 11 are introduced into the metal strip 1 (not shown in detail).
  • the metal strip 1 is further guided to an adjusting device 32, which checks the advance of the sheet metal strip 1, for example by detecting the punches or the holes 10 and slots 11 exactly.
  • the sheet metal strip 1 of the shaping device 3 is supplied, wherein in the illustrated embodiment, the molds 6 are arranged radially again.
  • the structured sheet-metal strip 1 is now fed to a profiling device 31, which has two profiled tools 12 meshing with one another.
  • the secondary structure 13 (not shown) is formed.
  • the finished sheet metal strip 1 is still fed to a separating device 30, wherein the sheet metal strip 1 is sheared in sheet metal foils 2 with a predetermined length or width.
  • the shaping device 3 a drive 27 which serves to drive the molds 6, which is at the same time for at least the punching device 29, the profiling device 31 and / or the separating device 30 as a drive available.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Catalysts (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)

Claims (17)

  1. Procédé destiné à la production d'une bande de tôle (1) structurée, comprenant au moins les étapes suivantes :
    - amener une bande de tôle (1) lisse jusqu'à un dispositif de façonnage (3) le long d'une direction de guidage (4) ;
    - introduire une structure primaire (5) dans la bande de tôle (1) lisse au moyen du dispositif de façonnage (3), une pluralité d'outils de façonnage (6) séparés agissant sensiblement de façon perpendiculaire sur la bande de tôle (1) par rapport à la direction de guidage (4) et pressant la bande de tôle (1) dans un contre-moule (46) ;
    - générer avec le contre-moule une avance de la bande de tôle (1) en direction de guidage (4), l'avance de la bande de tôle (1) étant effectuée quand les outils de façonnage (6) ne sont pas en engagement avec la bande de tôle (1).
  2. Procédé selon la revendication 1, dans lequel après l'introduction de la structure primaire (5) la bande de tôle (1) structurée est détachée, de sorte que des feuilles de tôle (2) sont fabriquées.
  3. Procédé selon l'une des revendications 1 ou 2, dans lequel une bande de tôle structurée (1) avec une structure primaire (5) est produite qui est caractérisée par une longueur d'ondulation (7) et une hauteur d'ondulation (8), le rapport entre longueur d'ondulation (7) et hauteur d'ondulation (8) est plus petit que 2, notamment plus petit que 1,5.
  4. Procédé selon l'une quelconque des revendications 1 à 3, dans lequel la bande de tôle (1), respectivement la feuille de tôle (2) est faite d'un matériau résistant aux températures élevées et à la corrosion, contenant de préférence du chrome et/ou de l'aluminium, et/ou basé sur du nickel et a une épaisseur (9) qui est plus petite que 0,11 mm, notamment plus petite que 0,06 mm et de préférence même plus petite que 0,03 mm.
  5. Procédé selon l'une quelconque des revendications 1 à 4, dans lequel avant l'introduction de la bande de tôle (1) dans le dispositif de façonnage (3) des trous (10) et/ou des fentes (11) sont introduits dans la bande de tôle (1), notamment par le procédé de fabrication de poinçonnage.
  6. Procédé selon l'une quelconque des revendications 1 à 5, dans lequel la bande de tôle (1) après l'introduction de la structure primaire (5) est dotée d'une structure secondaire (13) au moyen d'outils de profilage (12) qui sont en engrènement, la structure secondaire (13) limitant de préférence au moins partiellement des trous (10) et/ou des fentes (11) dans la bande de tôle (1).
  7. Dispositif (3) pour introduire au moins une structure primaire (5) dans une bande de tôle (1) amenée avec une pluralité d'outils de façonnage (6) séparés, agencés les uns à coté des autres, qui ont chacun une surface de contact (14), qui correspond sensiblement à une section (15) de la structure primaire (5), les outils de façonnage (6) pouvant être amovibles sensiblement de façon perpendiculaire par rapport à la direction de guidage (4) de la bande de tôle (1) et sont amovibles au moins partiellement de manière décalée les uns par rapport aux autres, caractérisé en ce qu'un contre-moule est positionnable sur le coté de la bande de tôle (1) qui est opposé aux outils de façonnage (6), qui génère une avance de la bande de tôle (1) en direction de guidage (4), l'avance de la bande de tôle (1) étant effectuée lorsque les outils de façonnage (6) ne sont pas en engagement avec la bande de tôle (1).
  8. Dispositif (3) selon la revendication 7, la structure primaire (5) ayant une longueur d'ondulation (7) et une hauteur d'ondulation (8) et le rapport entre la longueur d'onde (7) et hauteur d'ondulation (8) étant de préférence plus petit que 2, caractérisé en ce que les outils de façonnage (6) ont une largeur (16) qui est plus petite que 10 fois la longueur d'onde (7), notamment plus petite que 5 fois la longueur d'onde (7).
  9. Dispositif (3) selon la revendication 7 ou 8, caractérisé en ce que des moyens sont prévus qui garantissent un mouvement de course à décalage spatial des outils de façonnage (6) séparés, par quel moyen une superposition temporelle des mouvements de course d'outils de façonnage (6) adjacents est de préférence possible.
  10. Dispositif (3) selon la revendication 9, caractérisé en ce que les moyens comprennent un arbre à cames (17) avec des cames (19) qui sont décalés en direction de rotation (18) les uns par rapport aux autres.
  11. Dispositif (3) selon la revendication 9 ou 10, caractérisé en ce que les moyens comprennent un chariot (20) qui est agencé de façon amovible de manière telle relativement aux outils de façonnage (6) que grâce au mouvement relatif et grâce à une connexion appropriée du chariot (20) avec les outils de façonnage (6), un mouvement de course est généré.
  12. Dispositif (3) selon l'une quelconque des revendications 7 à 11, caractérisé en ce que les outils de façonnage (6) sont agencés parallèlement l'un par rapport à l'autre.
  13. Dispositif (3) selon l'une quelconque des revendications 7 à 11, caractérisé en ce que les outils de façonnage (6) sont agencés obliquement l'un par rapport à l'autre, notamment avec un angle (21) en partant de leurs surfaces de contact (14) d'au moins 5°.
  14. Dispositif (3) selon la revendication 13, caractérisé en ce que les outils de façonnage (6) sont agencés en forme de rayons, une roue profilée (23) étant prévue dans un centre (22).
  15. Dispositif (3) selon la revendication 14, caractérisé en ce que la roue profilée (23) a une direction de rotation (24), et un chariot (20) guidé sur une trajectoire circulaire extérieure (25) a une direction de mouvement (26) opposée.
  16. Dispositif (3) selon l'une quelconque des revendications 7 à 15, caractérisé en ce qu'il existe des moyens pour une amenée et une évacuation continue de la bande de tôle (1), lesquels moyens garantissent de préférence une avance d'au moins 20 m/min.
  17. Dispositif (3) selon l'une quelconque des revendications 7 à 16, caractérisé en ce que les moyens pour garantir le mouvement de course des outils de façonnage (6) séparés sont reliés à un entraînement (27) qui entraîne au moins encore un autre dispositif de la série de dispositifs suivante :
    - un dispositif d'amenée (28) de la bande de tôle (1),
    - un dispositif de profilage (31) destiné à la génération d'une structure secondaire (13) avec des outils de profilage (12) qui sont en engrènement,
    - un dispositif de poinçonnage (1) pour générer des trous (10) et/ou des fentes (11) dans la bande de tôle (1),
    - un dispositif de détachage (30) pour générer à partir de la bande de tôle (1) des feuilles de tôle séparées (2).
EP04739723A 2003-06-18 2004-06-09 Procede et dispositif pour produire une bande de tole structuree Expired - Fee Related EP1633506B1 (fr)

Applications Claiming Priority (2)

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DE10327455A DE10327455A1 (de) 2003-06-18 2003-06-18 Verfahren und Vorrichtung zur Herstellung eines strukturierten Blechbandes
PCT/EP2004/006205 WO2004110664A1 (fr) 2003-06-18 2004-06-09 Procede et dispositif pour produire une bande de tole structuree

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EP1633506A1 EP1633506A1 (fr) 2006-03-15
EP1633506B1 true EP1633506B1 (fr) 2008-07-02

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EP (1) EP1633506B1 (fr)
JP (1) JP2006527659A (fr)
DE (2) DE10327455A1 (fr)
ES (1) ES2308191T3 (fr)
WO (1) WO2004110664A1 (fr)

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EP1633506A1 (fr) 2006-03-15
DE502004007497D1 (de) 2008-08-14
US20060168810A1 (en) 2006-08-03
WO2004110664A1 (fr) 2004-12-23
US8291742B2 (en) 2012-10-23
JP2006527659A (ja) 2006-12-07
DE10327455A1 (de) 2005-01-05
ES2308191T3 (es) 2008-12-01

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