EP1879708A1

EP1879708A1 - Controlled production of metal foil

Info

Publication number: EP1879708A1
Application number: EP06742894A
Authority: EP
Inventors: Jan Hodgson; Günter HOSTER
Original assignee: Emitec Gesellschaft fuer Emissionstechnologie mbH
Current assignee: Vitesco Technologies Lohmar Verwaltungs GmbH
Priority date: 2005-05-13
Filing date: 2006-05-12
Publication date: 2008-01-23
Anticipated expiration: 2026-05-12
Also published as: KR100957732B1; CN100522409C; CN101175584A; JP2008540179A; DE102005022238A1; PL1879708T3; WO2006122718A1; US20080295556A1; RU2007145940A; KR20080011324A; ES2341481T3; DE502006006793D1; EP1879708B1; MY148395A; RU2399450C2

Abstract

The invention relates to a method for producing superimposed structures in a metal foil section (1) by carrying out at least the following steps: a) producing a primary structure (2) using a first tool (3); b) transporting the metal foil section (1) to a second tool (4), said second tool (4) having at least one shape roll (5) that effects onward transport of the metal foil section (1); c) producing a secondary structure (6) using a second tool (4); d) determining the spatial position of the primary structure (2) and the secondary structure (6) in at least one subsection (7) of the metal foil section (1); e) identifying a malposition and adapting an operational parameter of the at least one shape roll (5). The invention also relates to a suitable device and to metal foils produced with this device, said metal foils being suitable for use in the production of catalyst supports which are used in the exhaust gas systems of internal combustion engines.

Description

Regulated metal foil production

The invention relates to a method and a device for generating overlapping structures in a metal foil section. Such metal foil sections are preferably used for the construction of honeycomb bodies which are used, for example, as exhaust gas treatment components in exhaust systems of internal combustion engines.

In the exhaust treatment of mobile internal combustion engines, such. As gasoline and diesel engines, it is known to arrange at least one exhaust treatment component in the exhaust pipe, which provides a relatively large surface area (such as a so-called honeycomb body). If necessary, these components are provided with an application-specific (eg adsorbing, catalytically active and / or another) coating, intimate contact with the passing exhaust gas being realized on account of the large surface area of the component. Such components are, for example, filter elements for filtering out particles contained in the exhaust gas, adsorbers for at least temporarily limited storage of pollutants contained in the exhaust gas (eg NO _x ), catalytic converters (eg 3-way catalyst, oxidation catalytic converter, Reduction catalyst, etc.), diffusers for influencing the flow or turbulence of the flowing exhaust gas or heating elements that heat the exhaust gas just after the cold start of the internal combustion engine to a desired temperature. With regard to the conditions of use in the exhaust system of an automobile, 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 carrier substrates must always be adapted to their function, high-temperature-resistant and corrosion-resistant metal foils are particularly suitable starting materials for their production. It is known to produce honeycomb bodies with a plurality of at least partially structured sheets, 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 sheets are arranged in such a way that channels arranged essentially parallel to one another are formed. To ensure this, a part of the sheets is provided with a structure, for example, a kind of wave structure, sawtooth structure, rectangular structure, triangular structure, omega structure or the like.

It is also known to introduce a second structure in such sheet metal foils, which is intended to prevent a laminar flow forms immediately after the entry of the exhaust gas into the honeycomb body, in which a gas exchange of lying in the center of such a channel areas of the partial exhaust gas stream with the z. B. catalytically active channel wall areas does not take place sufficiently. This second structure or microstructure provides inflow surfaces that result in turbulence of the partial exhaust gas streams inside such a channel. This leads to an intensive mixing of the partial exhaust gas streams themselves, so that intimate contact of the pollutants contained in the exhaust gas with the channel wall is ensured. Furthermore, it is possible to form through these second structures flow passages across the channel, which allow a gas exchange of partial exhaust gas streams in adjacent channels. For this reason, microstructures are known, which include, for example, guide surfaces, nubs, projections, wings, tabs, holes or the like. In this respect, there is a significantly increased variety of variations in the production of such metallic honeycomb body compared to those made of ceramic material because such complex channel walls can not be realized or only with very high technical complexity with ceramic material.

These provided with structures sheets are then stacked (possibly alternately with smooth liners), wound together and in a Housing inserted. Thus, a honeycomb body is formed, which has substantially parallel channels.

Furthermore, it is of particular interest in the exhaust gas treatment that an implementation of the pollutants contained in the exhaust gas takes place almost immediately after the start of the internal combustion engine. This should take place in accordance with the statutory provisions or guidelines with a particularly high level of effectiveness. For this reason, thinner sheets have been used in the past. These represent a very low surface-specific heat capacity, ie. h., That the passing exhaust gas relatively little heat is removed or the sheets themselves relatively quickly experience a temperature increase. This is important because the catalytically active coatings currently used in the exhaust system begin only at a certain light-off temperature with the implementation of the pollutants, which is approximately at 230 ° C to 270 ° C. With the aim to implement these pollutants after only a few seconds with an at least 98% effectiveness, sheets are used, which have a sheet thickness, for example, less than 0.1 mm, in particular even less than 0.05 mm.

For the above-mentioned objectives, however, results a number of manufacturing technical and application problems. For example, it should be mentioned that in order to precisely set a flow behavior of the exhaust gas in the honeycomb body, an exact alignment of the microstructures in the channels may be required. In addition, it should be noted that such metal foils are joined together by joining technology, in particular brazed together (brazing, possibly under vacuum) and / or welded. However, this assumes that defined contact areas of the metal foils are present to one another. As a result, the most precise possible alignment of the overlapping structures is to be ensured. However, this could not be ensured with sufficient accuracy so far. Due to external influences in the production of the structures, such as a vibration excitation of the metal foils, there are deviations in the collection and / or forming behavior of the metal foil. Manufacturing inaccuracies or tolerances within the Tools (such as concentricity errors, bearing errors, contour errors of rolling teeth, etc.) lead to an undesirable deviation of the positions of the structures to each other, which varies partially periodically. In addition, inhomogeneities of the material of the metal foils can lead to further deviations of the structures from one another.

The object of the present invention is to at least partially alleviate the technical problems described with reference to the prior art. In particular, a process for the production of such, multi-structured metal foils is to be specified, which ensures the most precise possible alignment of the overlapping structures to each other. The process should also meet the requirements of mass production for such metal foils and show a time and cost-saving way. Furthermore, a device for producing such metal foils should be specified. The metal foils produced by the method or the device should have a particularly precise alignment of the overlapping structures and in particular serve for the production of permanent honeycomb bodies that can be used in the exhaust system of internal combustion engines.

These objects are achieved by a method according to the features of claim 1 and a device according to the features of claim 8. Further advantageous embodiments of the method and the device are given in the dependent formulated claims. In addition, a metal foil section produced by the method and / or device and a honeycomb body produced therefrom are proposed. The features listed individually in the claims are combinable with each other in any technologically meaningful manner and can be supplemented by explanatory facts from the description, wherein further embodiments of the invention are shown.

The method according to the invention for producing superimposed structures in a metal foil section has at least the following steps: a) generating a primary structure with a first tool; b) passing the metal foil portion toward a second tool, the second tool having at least one forming profile roller which causes the metal foil portion to pass; c) generating a secondary structure with the second tool; d) determining a spatial position of primary structure and secondary structure in at least one subregion of the measuring film section; e) detecting a malfunction and adjusting an operating parameter of the at least one profiled roller.

Usually, the production of such structures takes place in a continuous process (or with a frequency greater than 1 feed step per second), wherein the metal foil is unrolled from a reel and fed to the tools. In the method described here, therefore, a metal foil portion is considered, which is transformed. Accordingly, the metal foil section is initially smooth and is supplied to the first tool for producing a primary structure. The primary structure is here preferably a microstructure, ie z. B. an embossing or punching, which extends only to a small portion of the metal foil portion and which is provided in particular for influencing the flow of the exhaust gas later in the channel. In addition, such a primary structure can also be a preparatory measure for the later formation of (other or further) microstructures, for example slots, on which subsections of the metal foil are subsequently deformed, in order to form guide surfaces or the like.

As explained in step b), the forwarding of the metal foil section is effected by a profile roller of the second tool. In other words, the second tool pulls the metal foil section through the first tool. Although devices for clamping and / or guiding the Metal foil portion may also be provided in front of the first tool and / or between the first tool and the second tool, but the feed of the metal foil portion at the desired speed or clock rate is determined via the profile roller.

In addition to the shaping, that is to say the generation of a secondary structure (step c)), the profiled roller also has a transport function of the metal foil section. By engaging the profile roller in the secondary structure of the metal foil portion, a force can be introduced parallel to the feed direction of Metallfolienab- section, wherein the rotational speed of the profile roller determines the feed rate of the metal foil portion.

After the formation of the primary structure and the secondary structure (and possibly further structures), the spatial position of these superimposed structures is now detected according to step d). It is preferred that respective reference points of the primary structure and the secondary structure are detected and the position of these reference points is evaluated to each other. It is possible that their position in one or more planes (parallel, perpendicular and / or obliquely to the surface of the smooth metal foil portion) is detected to each other. The reference points for the primary structure are, in particular, middle points and / or center lines of the primary structure. As reference point for the secondary structure z. B. the extremes of the secondary structure, such as the wave crests or troughs in a corrugated structure.

Now that the spatial position of primary structure and secondary structure is determined, their spatial position is evaluated. In this case, different tolerance ranges or limit values can be specified that differentiate an acceptable position (good position) and a misadventure from one another. If step d) now leads to the result that there is a malfunction, then according to step e) at least one operating parameter of the at least one profiled roller is changed. As operating parameters, in particular the rotational speed of the profiled roller comes into consideration, but it may also be possible by variations of the To adapt position of the profile roller to other components of the second tool, in particular a further profiled roller. By means of such adaptation, the shaping profile of the profiled roller is re-aligned with respect to the distance to the first tool, and the position of the secondary structure in the metal foil section relative to the primary structure is thereby changed. This results in an exact alignment of primary structure and secondary structure. In the method proposed here, a highly dynamic control of the production process of such metal foils with overlapping structures is possible, whereby it is possible to react quickly to material inhomogeneities, external faults or the like automatically.

It is further proposed that the at least one profiled roller is operated at an angular speed, which is changed in step e). The profile rolls for producing the secondary structure have hitherto been operated at a constant angular velocity, one revolution of the profile roll optionally being subdivided into a multiplicity of rotational angle sections or increments and being rotated further at predetermined time intervals by a constant number of increments. This procedure is removed here. If a malfunction is detected, a correction is achieved in that either a selected constant number of increments is rotated further in a changed time interval and / or that the number of increments is varied at a constant time interval. In view of the fact that such a regulation only starts when a malfunction is detected, phases may occur during the process in which there is a constant angular velocity, so that, with regard to a varying angular velocity, a longer temporal phase may possibly be considered ( for example 5 minutes).

However, it is particularly advantageous that step d) is carried out at least once per revolution of the at least one profiled roller. This means that a review of the spatial position of the primary structure and secondary structure takes place at the latest after each revolution of the profile roll. That has the advantage, That this control system is very dynamic and can also respond quickly to disturbances, such as occurring vibration excitations.

It is also preferred that step e) is carried out at least once per revolution of the profile roller. It is possible that the adjustment of the at least one operating parameter of the at least one profile roller is regulated so that after a maximum of one revolution, in particular if only after one revolution step d) is carried out, the deficiency is corrected. However, for an even more dynamic control system, it is advantageous that steps d) and e) be carried out several times per revolution of the profiled roller to effect a correction in less than one revolution of the profiled roller. In the latter case, step d) and e) is preferably carried out at least twice, and in particular at least four times per revolution of the profiled roller.

If, as an operating parameter, the position of the profiled roller can be changed to another component, the configuration of the secondary structure is changed. This means, for example, that the shaping sections of the profile rollers continue to interlock and the secondary structure is produced with a greater height. This leads to a higher material requirement per secondary structure segment, so that in this way the position of the primary structure and the secondary structure is shifted relative to each other. With regard to the production of a honeycomb body that has the formation of channels with different channel cross-section result, which may be advantageous in certain applications. However, in order to influence the flow behavior of the exhaust gas in the honeycomb body exactly in this way, a very precise control of the position of the profile rollers is required.

According to a preferred embodiment of the method, step a) comprises punching openings and step c) forming waves in the metal foil section. The openings may be designed as slots, holes or the like. The waves are mainly due to wave crests and wave troughs characterized in that the openings are aligned with respect to these wave crests or troughs. Preferably, the spatial position of the openings and waves in the feed direction and in a plane of the metal foil portion is determined and adapted. Although this is a preferred variant, in particular openings can also be introduced by means of a rotary punching tool and / or a laser in the metal foil section. In principle, a plurality of primary structures or openings can also be introduced simultaneously, so that the metal foil section after step a) has a plurality of rows of primary structures or openings.

It is also proposed that a misalignment affects a position shift from primary structure to secondary structure greater than 0.3 mm. Thus, a limit value for distinguishing a good situation from a deficiency is given. The positional shift is preferably considered in the feed direction of the metal foil portion. As reference points for the primary structure and the secondary structure, their centers or center lines can be used. In the event that the primary structure is an orifice designed as a slot, then its center line is to be used parallel to the course of the wave crests or wave troughs. The maximum permissible positional shift from primary structure to secondary structure is preferably below an absolute value of 0.2 mm, in particular less than 0.1 mm.

According to a further embodiment of the method, the detection of a malfunction is carried out by means of at least one optical sensor. This optical sensor is arranged downstream of the second tool (or a follower tool) and thus considers the spatial position of the primary structure and secondary structure currently formed. In particular, a camera whose image resolution (pixels) permits the determination of a positional shift is particularly suitable as an optical sensor. Based on these pixels can z. B. determines the position shift and a corresponding adjustment of the angular velocity of the at least one profiled roller can be made. According to a further aspect of the invention, an apparatus for producing superimposed structures is proposed which comprises at least the following components: a first tool which can produce openings in a metal foil section, a second tool which has a pair of forming profile rollers through which Metal foil portion can be passed to generate waves, wherein the pair of profile rollers can produce a feed of the metal foil portion by the first tool and the second tool, an apparatus for driving at least one profile roller of the second tool, at least one optical sensor, in a feed direction the second tool is connected downstream, and - at least one control unit, which is in communication with the sensor and the apparatus.

This device is particularly suitable for carrying out a method described according to the invention.

In the case of the device described here, with regard to the first tool, it is preferably a punching machine which separates out sections of the metal foil section. The second tool preferably relates to a corrugating machine. As an apparatus for driving at least one profile roller E- lektro- or servomotors can be advantageous. A drive of the at least one profile roller preferably takes place at a frequency greater than 6 Hz [1 / second], in particular greater than 8 Hz or even 12 Hz. The at least one optical sensor preferably comprises a camera. The at least one control unit evaluates the data of the at least one optical sensor and determines a spatial position of primary structure and secondary structure. In addition, the control unit detects a malfunction and then adjusts an operating parameter of the apparatus for driving the at least one profiled roller. The control unit may include image recognition means, data processing programs, storage elements and the like. A device is preferred in which the at least one sensor is designed such that it has a variable detection field. This means in particular that the detection field can be positioned variable with respect to the metal foil section. Preferably, this ensures a movement of the detection field in the feed direction or perpendicular to it, wherein this can be realized by translational movements and / or by pivoting the sensor. Thus, large positional shifts (as they may occur, for example, at the start of the manufacturing process or a material change) can be detected. In addition, it is possible to detect the reference points for the primary structure and the secondary structure with a single sensor at different areas of the metal foil section. Thus, the technical complexity for determining the spatial position of primary structure and secondary structure can be kept low.

It is further proposed that the at least one sensor is associated with a measuring roller which positions a metal foil section relative to the at least one sensor. By means of the measuring roller, which itself does not effect permanent reshaping of the structures, but merely provides a precise guidance of the metal foil section, takes place, for example. an exact alignment of the secondary structure to the sensor. The measuring roller can in this case be provided with a separate or a drive coupled to the apparatus. Measuring roller and sensor are preferably located on opposite sides of the processed metal foil portion and are in particular arranged in alignment with each other.

According to a further embodiment of the device, lighting means are provided which partially illuminate at least one side of the metal foil section in the detection field of the sensor. Thus, for example, illuminants may be present which are positioned on the opposite side of the metal foil section and radiate through openings (backlight) and / or bulbs arranged on the same side of the metal foil section as the sensor, to at least partially illuminate the detection field visible to the sensor (incident light).

A metal foil section which has been produced by a method according to the invention or with a device according to the invention and which has a length greater than 1 m, with a maximum positional shift of 0.3 mm with respect to primary structure and secondary structure, is now proposed. Such a maximum positional shift is preferably present over significantly greater lengths, for example over 100 m or 1000 m. A production of such precise metal foils over such a length is made possible only by the method according to the invention or the device according to the invention. In this way, it is possible to provide metal foils that are as precise as possible in a series production, whereby a high material yield is ensured at a high production speed.

It is particularly preferred that the metal foil portion has a thickness in the range of 30 microns (0.03 mm) to 150 microns (0.15 mm) and a secondary structure in the ratio of width to height less than 2.0, in particular even smaller 1, 5th Thus, the use of the device or the method for the deformation of very thin, filigree structures is highlighted. The width-to-height ratio indicates that a relatively large deformation of the metal foil portion is realized, the regions of the wave crests and troughs being very small, and thus an exact alignment of primary structure and secondary structure in the manner described above is advantageous.

Most preferably, a honeycomb body is constructed with at least one such metal foil section. Especially in the case of spiral-shaped honeycomb bodies, metal foil sections of a large length must be processed, so that the use of such metal foil sections in this case makes sense in particular. The indicated thickness of the metal foil portion allows for providing a large surface area in a small volume of the honeycomb body, and the width-to-height ratio provides for slender channels that are good Ensure mass transport of the exhaust gas flowing through to the (coated) walls.

The invention and the technical environment are explained in more detail below with reference to the figures. The figures show particularly preferred embodiments, to which the invention is not limited. In particular, it should be noted that the illustrated proportions are only schematic. Show it:

1 shows schematically a first embodiment variant of the device according to the invention;

2 shows schematically a metal foil section in the state according to various

Machining processes;

3 is a schematic representation of a further illustration of a metal foil section with a good layer and a malposition of primary structure and secondary structure;

4 shows schematically and in perspective the positioning of a sensor to a metal foil section;

5 shows schematically the positional shift of a metal foil section produced with and without regulation;

6 shows schematically and in perspective a honeycomb body; and

7 shows schematically a detail of the honeycomb body from FIG. 6.

1 schematically illustrates the production process of a multi-structured metal foil section 1. The following description is based essentially on the feed direction 13, the metal foil section 1 being unwound from a reel 24 and subsequently a first tool 3 and a second tool 4 passes through before it is examined by means of a sensor 11 and a measuring roller 16 and finally a third tool 27 is supplied. Thereafter, the shaping of the metal foil portion 1 is completed, so that the desired metal foil portion 1 can finally be separated by means of a separator 28.

The reel 24 is a type of storage for metal foil, which is spirally wound up. The reel 24 is usually driven, with a compensating element (not shown), for example a so-called dancer, following it, which compensates for variations in the feed rate of the metal foil section 1. Subsequently, the metal foil portion 1 is passed over a film brake 25, which ensures sufficient tension up to the feed drive of the metal foil section 1. The film brake 25 is preferably a type of felt belt, which is optionally moved counter to the feed direction 13. For safe installation of the metal foil portion 1 on the film brake 25, this can be performed with a permanent magnet (not shown). Under certain circumstances, it is advantageous to regulate the supply of the metal foil section 1 toward the first tool 3 also by means of the film brake 25 as a function of the position of primary structure and secondary structure produced, this being able to be performed separately and / or in addition to control via the profile roller 5 ,

The second tool 4 is designed with a pair of profile rollers 5 which rotate at a predetermined angle of rotation 39 or a predetermined rotational speed. For this purpose, at least one of the forming profile rollers 5 is designed with an apparatus 12 as a drive. This apparatus 12 also causes the transport of the metal foil portion 1 of the film brake 25 to the first tool 3. Between the first tool 3 and the second tool 4, a film guide 26 is provided, for example, the vertical feeding the metal foil portion 1 to the profile rollers 5 ensure. The first tool 3 is preferably a stamping machine according to the lifting principle, wherein the stroke of the plunger 50 is realized via an eccentric 48. For example, the punching machine is capable of inserting elongated holes with the dimensions of 2.5 × 0.8 mm into the smooth metal foil section 1. The punched-out material is removed by means of an opposite suction 49.

Now that the metal foil section 1 is provided by the first tool 3 with a primary structure (not shown here, see FIG. 2) and by the second tool 4 with a secondary structure 6, this is supplied to an arrangement with an optical sensor 11, which is a spatial Location of primary structure and secondary structure in a portion 7 of the metal foil portion 1 determined. The sensor 11 is associated with a measuring roller 16 on the opposite side of the metal foil portion 1, which is driven itself, the drive 51 is preferably connected via a coupling with the apparatus 12 for driving the profile roller 5, for example via a (not shown) belt. On the side of the sensor 11 also bulbs 18 are positioned to at least partially illuminate the portion 7 (Aufiicht).

The image generated by the optical sensor 11 is processed in a control unit 14, for example, a miss is detected. If this is the case, the control unit 14 adjusts at least one operating parameter of the profiled roller 5 of the second tool 4, for example by influencing the apparatus 12 for driving and changing the angular velocity.

After leaving the apparatus for determining the spatial position of the primary structure and secondary structure, the metal foil section 1 is fed via a further film guide 26 to a third tool 27, which likewise comprises a pair of profile rollers 5. With this third tool 27, a tertiary structure (not shown here, see FIG. 2) is introduced into the metal foil section 1 before the metal foil section 1 is cut off by means of a separating device 28 having the desired length. With the process shown here, particularly complex structures can be introduced into a metal foil section, wherein At the same time a high degree of precision over a long period of time in the series production of such metal foil sections is ensured.

Fig. 2 shows schematically a metal foil section 1, as it is present in different areas of the device of Fig. 1. From left to right in FIG. 2, initially a smooth area can be seen, as it is present in the area of the film brake 25, for example. Subsequently, the metal foil section 1 is provided in the region of the first tool 3 with a primary structure 2, in this case oblong holes. Subsequently, as shown on the right, the secondary structure 6 is introduced in the area of the second tool 4, the primary structure 2 being arranged on each corrugation peak 31 in the embodiment variant shown here. In this case, the secondary structure 6 with a width 22 which describes the distance between two adjacent wave crests 31 or wave troughs 32 and generates a predetermined height 23, wherein the height 23 describes the distance of a We len hill 31 to a wave trough 32. After leaving the second tool 2, a tertiary structure 29 is formed in the area of the third tool 27, wherein in the illustrated embodiment, a region of the metal foil section 1 is pressed in between two adjacent primary structures 2. In this way, a so-called microstructure is formed, which will later represent a projecting into a channel guide surface for an exhaust gas flow.

FIG. 3 now illustrates a metal foil section 1 (in plan view) with a predetermined length 20. In the upper part of FIG. 3, an exact alignment of the openings 8 with respect to the wave crests 31 can be seen. It can be seen below that the openings 8 are not exactly aligned with respect to the corrugation 9. A center 32 of the opening 8 has a positional shift 10 with respect to the wave crest 31. Furthermore, it is shown below that the position shift 10 is smaller from left to right, since the control has detected the malfunction and made an adjustment of an operating parameter of the profile roller. So z. B. already after a few wave crests 31 or troughs 32 reaches a good position again. Fig. 4 schematically illustrates the positioning of an optical sensor 11 to the metal foil portion 1, which is designed with a predetermined thickness 21. The optical sensor 11 has here indicated schematically a viewing direction 33, which describes its detection field 15. For scanning different portions of the metal foil portion 1, the detection field 15 with respect to the metal foil portion 1 can be varied. This is possible because the sensor 11 has a pivot angle 34 for pivoting the viewing direction 30 and can be moved in different directions of movement 35 relative to the metal foil section 1. In the embodiment shown, illuminating means 18 are provided on the side 19 of the metal foil section 1 opposite the sensor 11, by means of which the opening 8 can be seen in the backlight. Reference point determination is preferably carried out by means of the sensor 11 in such a way that the position of the opening 8 in the backlighting occurs in a first subsection of the detection field 15, while the position of the wave crest 31 is perceived in another subregion of the detection field 15 by reflected light.

Fig. 5 shows schematically a positional shift 10 on the rotation angle 39 of the shaping and the transport effecting profile roller 5. In a first curve 37, the positional displacement 10 is shown, as is usually adjusted in previously known methods due to positional tolerances, material inhomogeneities, etc .. , In particular, such a first course 37, as it also occasionally occurs in known devices, is characterized by periodic fluctuations, which in particular are due to tolerances in the region of the second tool and repeat themselves with the revolutions of the profile rollers. In the second course 38 shown below, the positional shift 10 varies only to a very small extent around the abscissa (corresponds to a positional shift of 0 mm). This course 38 can be further approximated to the abscissa if the control system is designed to be even more dynamic. As an example, an external disturbance 36 was applied during production (eg a vibration excitation). As you can see, it occurs first a relatively large positional shift 10, but this is compensated again after a short period of time or after a short rotational movement of the profile roller.

The preferred use of metal foil sections 1, which were produced by the method according to the invention or with the device according to the invention, are exhaust gas treatment units 45 for use in cleaning exhaust gases of mobile or stationary internal combustion engines. Such an exhaust gas treatment unit 45 is shown by way of example in FIG. 6. The exhaust gas treatment unit 45 comprises a housing 44 in which a honeycomb body 40 is provided. In the embodiment shown, the honeycomb body 40 is constructed with a corrugated layer 41 and a smooth layer 42, which have been spirally wound. In this case, the corrugated layer 41 has overlapping structures, the secondary structure 6, namely the corrugated shape, being recognizable here in this end view. Through this corrugation channels 43 are formed, through which the exhaust gas can enter into inner regions of the honeycomb body 40. A detail (indicated by VII) of this honeycomb body 40 is shown in FIG.

Fig. 7 shows an end view of the honeycomb body 40 in detail. The smooth layer 42 is embodied here with a filter material, while the corrugated layer 41 comprises a metal foil section 1 of the type described above. The corrugated layer 41 and the smooth layer 42 form contact points 46, which serve, for example, to provide technical joining connections and to delimit adjacent channels 43. On at least part of these contact points 46, the corrugated layer 41 and the smooth layer 42 are connected to each other, preferably brazed. The channels 43 delimiting walls, which are formed with the smooth layer 42 and the Welllage 41, are provided with a coating 47 for the catalytic conversion of the exhaust gases.

The invention described above is particularly suitable for the production of multiple overlapping structures in a metal foil section, with a high degree of precision being achieved. This can result in significant costs advantages with regard to the production of such metal foils and a considerable increase in the effectiveness and durability of honeycomb bodies constructed with such metal foils can be achieved.

LIST OF REFERENCE NUMBERS

1 metal foil section

2 primary structure

3 first tool

4 second tool

5 profile roller

6 Secondary structure

7 subarea

8 openings

9 waves

10 position shift

11 sensor

12 apparatus

13 feed direction

14 control unit

15 detection field

16 measuring roller

17 device

18 bulbs

19 page

20 length

21 thickness

22 width

23 height

24 reel

25 film brake

26 film guide

27 third tool

28 separating device

29 tertiary structure 30 wave valley

31 wave mountain

32 center

33 Viewing direction

34 Swivel angle

35 direction of movement

36 fault

37 first course

38 second course

39 rotation angle

40 honeycomb bodies

41 Well location

42 smooth position

43 channel

44 housing

45 exhaust treatment unit

46 contact point

47 coating

48 eccentrics

49 suction

50 pestles

51 drive

Claims

claims

1. A method for producing superimposed structures in a metal foil section (1) with at least the following steps: a) generating a primary structure (2) with a first tool (3); b) passing the metal foil section (1) towards a second tool (4), wherein the second tool (4) has at least one shaping profiled roller (5) which causes the metal foil section (1) to pass; c) generating a secondary structure (6) with the second tool (4); d) determining a spatial position of primary structure (2) and secondary structure (6) in at least one subregion (7) of the metal foil section (1); e) detecting a malfunction and adjusting an operating parameter of the at least one profiled roller (5).

2. The method of claim 1, wherein the at least one profiled roller (5) is operated at an angular velocity, which is changed in step e).

3. The method of claim 1 or 2, wherein at least step d) at least once per revolution of the at least one profile roller (5) is performed.

4. The method according to any one of the preceding claims, wherein the step e) at least once per revolution of the profile roller (5) is performed.

5. The method according to any one of the preceding claims, wherein the step a) the punching of openings (8) and step c) comprises the forming of shafts (9) in the metal foil section (1).

6. The method according to any one of the preceding claims, in which a misalignment relates to a position shift (10) of primary structure (2) to secondary structure (6) greater than 0.3 mm.

7. The method according to any one of the preceding claims, wherein the detection of a malfunction by means of at least one optical sensor (11) is performed.

8. Device (17) for generating superimposed structures comprising at least the following components:

a first tool (3) that can produce openings (8) in a metal foil section (1),

- a second tool (4) having a pair of forming profile rollers (5) through which a metal foil section (1) for generating shafts (9) can be passed, the pair of profile rollers (5) advancing the metal foil section (1) by the first tool (3) and the second tool (4),

- An apparatus (12) for driving at least one profiled roller (5) of the second tool (4), - at least one optical sensor (11) in a feed direction (13) the second tool (4) is connected downstream, and

- At least one control unit (14) which is in communication with the sensor (11) and the apparatus (12).

9. Device (17) according to claim 8, wherein the at least one sensor (11) is designed so that it has a variable detection field (15).

10. Device (17) according to claim 8 or 9, wherein the at least one sensor (11) is assigned a measuring roller (16) which positions a metal foil section (1) in relation to the at least one sensor (11).

11. Device (17) according to any one of claims 8 to 10, wherein lighting means (18) are provided which at least partially a side (19) of the metal foil portion (1) in the detection field (15) of the at least one sensor (11) illuminates.

12. The metal foil section (1) produced by a method according to one of claims 1 to 7 or with a device (17) according to one of claims 8 to 11, which has a length (20) greater than 1.0 m, wherein a maximum positional shift (10) of 0.3 mm with respect to primary structure (2) and secondary structure (6).

13. metal foil section (1) according to claim 12, which has a thickness (21) in the range of 30 microns to 150 microns and a secondary structure (6) with a ratio of width (22) to height (23) less than 2.0.

14. honeycomb body (40) comprising at least one metal foil portion (1) according to claim 12 or 13.