Classifications

• • 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
  • B21D13/02—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form by pressing
• • 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

Definitions

• the present invention relates to a follow-on composite tool for producing a structured metal foil having at least two structures, wherein one of the two structures at least partially overlays the other structure, wherein the
• Follow-on composite tool consists of a tool shell and a tool lower part. Furthermore, the present invention relates to a method for producing a structured metal foil, which serves in particular as a catalyst carrier body.
• Such structured metal foils are folded into long ribbons and wound into catalyst honeycomb bodies of special geometry.
• the honeycomb bodies have a plurality of honeycomb cells, on the wall of which the catalytic process takes place on a catalytically active coating.
• Catalysts constructed in this way are used primarily in internal combustion engines in order to reduce the pollution of the environment caused by increasing mobility.
• Metal is, in addition to ceramic, due to its advantageous physisch ⁇ technical properties such as high mechanical and thermal stability, an ideal carrier material for the catalytically active coating.
• honeycomb cells This high stability allows extremely thin wall thicknesses of the honeycomb cells, so that a large number of honeycomb cells can be realized in a small construction volume, which additionally have a small total mass.
• the variety of honeycomb cells allows a high conversion rate, which is achieved due to the low mass of the honeycomb body after a short warm-up time.
• a disadvantage of this prior art is that when using interlocking, d. H. combing rolls with increasingly lower material thicknesses of the metal sheet and increasingly smaller profile depths of
• Wave structure comes to burrs when introducing the secondary structure, which has a very disturbing effect on the electrodeposition of the catalytically active coating, so that the conversion capacity of the catalyst is reduced, rather than increased.
• the follow-on composite tool has at least three, in particular spatially separate, working areas, namely a punching area for the removal of film material at certain positions of the
• Metal foil a primary shaping area for introducing the, preferably corrugated, primary structure in the metal foil and a secondary shaping area for introducing the, preferably corrugated, secondary structure into the metal foil, preferably into the primary structure of the metal foil.
• the progressive compound tool With the aid of the progressive compound tool according to the invention, it is possible to produce extremely thin, structured metal strips in one processing step with a single tool, while maintaining the lowest manufacturing tolerances, which was previously not possible.
• the use of a progressive compound tool reduces the formation of burrs on the workpieces so that a complete catalytically active surface can be deposited on the metal support.
• Burrs involve the risk that the active catalyst layer dissolves in the rough operation at the location of the ridge or the burr breaks off and exposes the base material, including increased corrosion.
• the removal of film material at certain positions in the stamping area ensures that a catalyst made from the material has a significantly higher Operating life has in everyday use, as removed by the material removal stresses within the metal foil, and notch effects at the transition areas between the primary and secondary structure can be avoided. It is sometimes desirable for metal foil to be removed at each interface between the primary and secondary structures. There are also application areas in which the film material is only removed at selected locations, for example at selected transitions between the primary structure and the secondary structure.
• a drive for the progressive compound tool for example, offers a press, consisting of a press bed and a driven by an eccentric disc movable bear, wherein the bear is in engagement with the upper tool.
• a press consisting of a press bed and a driven by an eccentric disc movable bear, wherein the bear is in engagement with the upper tool.
• eccentric drive it is not necessary to provide an eccentric drive.
• the operation of the follow-on composite tool with a hydraulic drive is possible.
• the punching area is arranged in the feed direction of the metal foil in front of the primary and the secondary shaping area. This unnecessary but advantageous arrangement of the punching area causes the film material to be removed from the still smooth metal foil can be punched out.
• the stamping region according to the invention significantly lower manufacturing tolerances can be maintained than if the stamping region were connected downstream of the shaping regions, for example.
• additional work areas are provided for introducing additional structures into the metal foil. These do not necessarily have to be spatially separated from the primary and / or secondary shaping area. However, there is a spatial
• embossing and forming insert for introducing the secondary structure, as well as means for positioning the metal foil are provided in the secondary shaping area.
• the means for positioning the metal foil ensure exact positioning of the metal foil in the progressive die.
• the means for positioning the metal foil as sprung Kiemffen in particular consisting of a sprung guide plate with spring-loaded punch and a spring base, are formed, wherein the surfaces of the guide insert and / or the spring base at least partially as the primary structure of the metal foil are formed.
• the special shape of the surfaces serves to be able to hold the provided with a primary structure metal foil in a first step by means of the sprung Kiemstoff.
• At least one forming insert cooperating with a spring-loaded punch is provided for introducing the primary structure into the metal foil.
• the primary structure is not over the entire length of the metal foil, but in stages, introduced. It is necessary to dimension the size of the stamp so as to ensure that a flow of film material during molding is ensured since the very thin metal foil may otherwise tear.
• the surface of the stamp and the Umform donorses are designed so that the primary structure of the metal foil is in the form of a, preferably continuous, shaft.
• the secondary structure again in the form of a shaft or blade, is then introduced into this primary shaft in the secondary shaping area.
• a plurality of punches is associated with a pin which is in operative connection with the tool shell or tool base, preferably sprung, and wherein the bolts have a different length.
• a further object of the present invention was to provide a method that allows the production of very thin, structured metal foil with a large surface while maintaining high quality standards.
• This object is achieved in that a metal foil in a follow-on composite tool in a machining operation with a first and at least one second structure is provided, the secondary structure overlying the primary structure, and removing metal foil material in all or selected transition regions between the first and at least second structures.
• This method according to the invention advantageously allows the production of extremely thin, structured metal strips in one processing step in a single tool while maintaining the lowest possible manufacturing tolerances.
• the method according to the invention is more economical than that described in the prior art, since it can be carried out on a machine with a tool, since progressive dies can be punched and formed in one machining step.
• the inventive method reduces the formation of burrs on the workpieces, so that a complete catalytically active surface can be deposited on the metal support.
• the material removal step provided according to the invention ensures that a catalyst produced from the material has a significantly longer service life
• the method provides that work steps of the machining process are offset in time or individual work steps of the machining process done temporally and spatially offset.
• the temporal offset of the work steps allows the material to flow over during the successive molding operations, so that micro-cracks or structural breaks are avoided.
• a spatial variation of the working steps within the follow-on composite tool can also take place, so that even particularly sensitive metal foils can be processed with very good results.
• the follow-on composite tool preferably introduces the primary and secondary structure into the metal foil as a wave structure, the effective surface without corners and edges which are disadvantageous for the galvanization becomes clear increased. Corners and edges additionally lead to the formation of dead volumes, which reduce the conversion rate of the catalyst and must therefore be avoided.
• the formation of the structure as a wave structure also has the particular advantage that, although the effective surface, but not the flow resistance is increased beyond measure.
• the secondary structure is introduced into the wave crests and / or into the troughs of the primary structure and wherein the waves of the secondary structure preferably have a higher frequency and a lower amplitude than the waves of the first structure.
• sheet material is removed by punching, preferably in slot shape, in the transition region between the first and second structure.
• the punch in the form of a slot is particularly advantageous and easy to implement, but the invention also includes other forms such as bone, Kreis ⁇ or double-hole shape.
• metal foil is processed with a thickness of 0.02 to 0.12 mm, preferably with a thickness of 0.05 mm, and with a foil width of 50 to 210 mm.
• the metal foil by at least one
• Feeding device is guided by the progressive tool.
• the use of at least one intake device, preferably two intake devices at the beginning and at the end of the follow-on composite tool, enables an optimal processing sequence.
• the Secondary structure is introduced into specific wave crestal monuments of the primary structure.
• FIG. 1a shows an example of an inventive progressive compound tool in a perspective view partially freed from attachments
• FIG. 1b is a plan view of the follow-on composite tool according to the invention according to FIG. 1a, FIG.
• FIG. 1c shows a section through the follow-on composite tool according to the invention according to section line A-A in FIG. 1b, FIG.
• FIG. 1d shows a section through the follow-on composite tool according to the invention according to section line F-F in FIG. 1b, FIG.
• FIG. 2 shows a perspective view of a corrugated metal foil produced according to the invention
• FIG. 4 is a perspective view of a corrugated metal foil without punching
• 5a shows a schematic representation of a detail of the open progressive compound tool according to the invention
• 5b a schematic representation of a detail of the closed progressive compound tool according to the invention
• Fig. 6 an enlarged section of Fig. 5a.
• FIGS. 1a to 1d a preferred embodiment of a follow-on composite tool 1 according to the invention is shown by way of example in perspective. For the sake of clarity, some attachments have not been shown.
• This progressive tool 1 can preferably be used in presses with a Pressenbär or a single-acting press.
• FIG. 1b the cutting positions of FIGS. 1c and 1d are marked.
• the secondary shaping area 2 is divided into two areas, the secondary forming area 2 being arranged behind the primary forming area 5 in the feed direction 3 of the metal foil 4.
• the punching area 37 is arranged in front of the primary shaping area 5 in FIG. 1c.
• the follow-on composite tool 1 consists of an upper tool part 6, which is in engagement with a Preßbr not shown, and a lower, fixed
• the upper tool part 6 consists of an upper pressure plate 8 and a lower pressure plate 9.
• the upper pressure plate 8 is in a head plate 10, which cooperates directly with the Preßbr or is attached to it, embedded.
• a punch holding plate 11 is arranged below the lower pressure plate 9.
• the upper dies 12 (to be seen more clearly in FIG. 5) are fixed for introducing the secondary structure in the secondary shaping area.
• the cutting punch 38 of the punching area are held to remove sheet material.
• the bolts 13 are guided in the upper pressure plate 8 and lower pressure plate 9 .
• the bolts 13 are sprung between the two plates 8, 9 by means of springs 14.
• the spring-loaded bolts 13 act on the guided in the guide plate 15 Stamp.
• the guide plate 15 extends over the secondary 2 and primary forming area 5.
• a spring base 17 is provided for counteracting, which is sprung by means of non-visible springs against a base plate (see Fig. 5).
• the lower forming inserts 16 for forming the primary and secondary structures are fixed.
• it can also advantageously have a lifting mechanism which acts as an ejector of the metal foil after the embossing process in order to be able to transport it further in the feed direction 3.
• lower, rigid forming inserts 16 are provided within or separately from the spring base 17 as a counterforming element for introducing the secondary structure into the metal foil.
• the primary forming area 5 consists of a spring-loaded hold-down 36 and with this cooperating punches 20, 21.
• Each punch 20, 21 is actuated directly or via a separate lever 22, 23.
• Each lever 22, 23 consists of a respective bearing part 24, which holds the lever 25 in a bearing block 25 pivotally and the punch 20 articulated with lateral spring-loaded bolt 13 connects.
• the sprung bolts 13 are of different lengths. This ensures that by downward movement of the upper tool part 6 of the punch 21 after the hold down the tape 4 detected. Only after this part of the primary structure has been introduced into the metal foil, the further punch 20 is actuated by a further spring-loaded bolt 13. As a result, a further part of the primary structure is introduced into the metal foil.
• FIGS. 5 and 6 the secondary forming area 2 and the primary forming area 5 are shown schematically.
• Figure 5a represents the starting position with the tool open.
• the metal foil 4 with already introduced primary structure is located between a spring-loaded Umformgan 16 extending from the secondary shaping area 2 to the primary shaping area 5 with gaps therebetween and a spring base 17, which by means not visible springs against a base plate is sprung.
• the Umformein accountsn 16 are opposite upper dies 12 for introducing the secondary structure.
• the upper dies 12 are held within the punch holding plate 11.
• the embossing dies 12, 16 the secondary structure is introduced into the primary structure of the metal foil 4.
• FIG. 6 shows a detail of FIG. 5 enlarged.
• the forming insert 16, as well as the spring base 17 also have the primary structure in waveform. This is necessary in order to be able to clamp the metal foil 4 between the forming insert 16 and the spring base 17.
• the secondary structure is introduced into the troughs of the primary structure of the metal foil 4.
• the secondary structure also has a waveform, but in a higher frequency and / or smaller amplitude than the primary structure.
• FIG. 5 a the upper tool part 6 of the follow-on composite tool 1 is in its uppermost position.
• the press rod now presses on the top plate 10 (FIG. 1c), whereby a downward movement of the upper tool part 6 takes place.
• the die 12 Downward movement of the upper pressure plate 8, the die 12 is pressed from above against the metal foil 4. After a further downward movement, the metal foil 4 strikes the forming insert 16, the secondary structure being formed on further closing. The metal foil is now fixed in the secondary shaping area 2 and thus positioned.
• the embossing punch 21 is moved in the direction of the metal foil for introducing the primary structure. The punch 21 presses the metal foil against the forming insert 16, whereby a part of the primary structure is introduced into the metal foil. Subsequently, the punch 20 moves against the metal foil 4 and against the Umformtiv 16. Due to the temporal sequence of the stamping processes a Nachfpen of metal foil material is made possible. Tearing of the film is avoided with advantage.
• the time can be determined, in which material is punched out of the smooth film 4.
• the punching area 37 is located in front of the primary forming area.
• the metal foil is transported further in the feed direction by means of a pulling feed, so that the newly introduced primary structure can be fixed in the secondary shaping area and thus positioned.
• the primary structure must first be introduced into the metal foil over a partial region, so that the metal foil can then be held in the secondary shaping region.
• Ejector support the dissolution of the film surface. Then the film is free for transport.
• the positioning of the metal foil may also advantageously be adjacent to that of the secondary forming area Stamp 36 will be accepted. It is particularly advantageous if the distances of the primary and / or secondary shaping area and / or punching area from each other are adjustable to compensate for different material behavior.
• the metal foil 4 is shown after passing through the secondary shaping area 2.
• the punched outs were not shown.
• the secondary structure 39 was introduced into the wave crests 40 of the primary structure 41 by means of the upper stamping die.
• the lower Umformein accounts 16 the secondary structure 39 has been introduced in the form of small wave crests in the wave troughs 42 of the primary structure 41.
• FIG. 2 shows a metal foil 4 produced by means of the method according to the invention and by means of the device according to the invention before the secondary structure is formed. This is generated later between the punch-outs 35.
• the primary structure 41 is z. B. a shaft of about 2.5 millimeters in length and about 1, 6 millimeters in height.
• the wavy secondary structure 39 (FIG. 4) has z. B. a length of about 1 millimeter and a height of about 0.5 millimeters.
• FIG. 3 shows a cross-section through a corrugated metal foil 4, the sectional plane being located in the FIG. 2 marked Ill-III.

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Cited By (5)

Citations (4)

• 2004
  • 2004-09-09 ES ES04764996T patent/ES2319901T3/es active Active
  • 2004-09-09 EP EP04764996A patent/EP1793947B1/de not_active Not-in-force
  • 2004-09-09 DK DK04764996T patent/DK1793947T3/da active
  • 2004-09-09 DE DE502004008713T patent/DE502004008713D1/de active Active
  • 2004-09-09 WO PCT/EP2004/010061 patent/WO2006027008A1/de active Application Filing
  • 2004-09-09 PT PT04764996T patent/PT1793947E/pt unknown
  • 2004-09-09 AT AT04764996T patent/ATE417681T1/de active

Patent Citations (4)

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