Method for producing a corrugated structure on a strip layer

Abstract

The present invention relates to a method for producing a corrugated structure (1) on a strip layer (2), wherein the layer (2) extends along an extension direction (3) between a first end (4) and a second end (5) and extends along a width direction (6) with respect to the first end face (7) and the second end face (8), wherein the corrugated structure (1) of the structured layer (2) includes a plurality of first corrugated grooves (9) and first corrugated peaks (10) extending parallel to each other, each extending with a first tilt angle (11) greater than zero degrees and at most 15 degrees relative to the width direction (6).

Description

Technical Field

[0001] This invention relates to a method for producing a corrugated structure on a strip layer. The invention also relates to a layer produced by this method, and a honeycomb comprising a layer produced in this manner. Background Technology

[0002] For example (but not exclusively), layers with corrugated structures are used in honeycomb cells for exhaust gas aftertreatment, such as catalyst carriers, particularly in the exhaust systems of mobile internal combustion engines. Specifically, such honeycomb cells provide a large surface area on which catalytically active materials are placed and brought into contact with the exhaust gases flowing through the honeycomb cells. Specific applications of this invention have been found in exhaust gas purification in motor vehicles or in stationary or other mobile systems.

[0003] Several different designs for honeycomb structures used in exhaust gas aftertreatment have been proposed. There are fundamental differences between honeycomb structures made of ceramic and metal (steel or non-ferrous materials). However, honeycomb structures can also be made of plastic materials.

[0004] The honeycomb structure can be constructed from smooth and / or structured layers or metal foil. These layers can be stacked, wound, and / or coiled, and ultimately placed within the shell of the honeycomb structure, thereby forming multiple channels through which exhaust gases can flow. In this context, these channels can extend between the end faces of such a honeycomb structure, for example, in a straight line, in a wound pattern, and / or at an angle.

[0005] To maximize contact between the exhaust gas and the walls of the honeycomb structure or the catalytic coating placed thereon, various measures have been proposed to reduce laminar flow of the exhaust gas through the honeycomb structure. For example, openings can be provided in the channel walls to form interconnected channels. Deflection structures, guide vanes, etc., are also known to be provided in the channels to achieve targeted flow deflection within the channels, pressure differentials between channels, or similar effects.

[0006] DE 10 2012 004 918 A1 discloses a honeycomb structure in which the structured layers have a corrugated structure, wherein layers arranged adjacent to each other have intersecting corrugated structures. To produce such a structured layer, an unstructured (i.e., specifically, smooth or flat) layer is fed to a rolling mill. The rolling mill includes two rolls having axes of rotation parallel to each other and each having a surface structure for generating the corrugated structure, wherein the surface structures interlock to generate the corrugated structure. For this purpose, each surface structure has a plurality of second corrugated grooves and second corrugated peaks running parallel to each other, extending parallel to their respective axes of rotation. The layer is fed to the rolling mill at an angle such that the corrugated structure imprinted on the layer runs obliquely relative to the direction of extension of the layer.

[0007] In this process, straight-toothed corrugated rollers are used, and a still-smooth (continuous) layer is fed to the rollers at an angle other than orthogonal. The dotted-line positioning angle of the layer relative to the rotation axis perpendicular to the corrugated rollers depends on the tilt angle required for the corrugation structure on the structured layer (e.g., a 3-degree supply angle / pitch angle produces an approximately 5-degree tilt angle for the corrugation structure on the structured layer). Due to the non-orthogonal supply and the resulting lateral force, the layer moves along the rotation axis of the corrugated rollers. Depending on the pitch angle on the supply side of the rolling mill, the width of the layer, and the width of the corrugated rollers, the layer has a finite length in its direction of travel after which the corrugating process needs to be interrupted, as otherwise the layer will move out of the rolling mill. One known solution is a so-called corrugated block device, similar to the principle of a typewriter, which allows the corrugated rollers to be spaced apart and subsequently allows the layer to be fed laterally, thereby causing the layer to shift relative to the corrugated rollers along the rotation axis back to its initial position. Therefore, the process for producing the corrugated structure is discontinuous because the supply of the layer relative to the rolling mill must be interrupted to reposition the layer.

[0008] Especially in automotive engineering, additional requirements are placed on this type of honeycomb structure and its manufacturing. Specifically, the focus is on making the manufacturing process as low-cost and simple as possible. Summary of the Invention

[0009] The purpose of this invention is to at least partially solve the problems described in the prior art. Specifically, the method for generating the corrugated structure will be further simplified or implemented as continuously as possible.

[0010] The method having the features of claim 1 helps to solve these problems. Advantageous further enhancements are the subject of the dependent claims. Features listed separately in the claims may be combined with each other in a technically meaningful manner and may be supplemented by illustrative details from the specification and / or details from the drawings, thereby illustrating other embodiments of the invention.

[0011] A method for generating a corrugated structure in a strip layer is proposed, wherein the layer extends along an extension direction between a first end and a second end, and extends along a width direction transverse to the first end face and the second end face.

[0012] The method includes at least the following steps: a) Provide a rolling mill having at least two rolls having rotation axes parallel to each other and each having a surface structure for generating a corrugated structure, wherein the surface structures mesh with each other to generate a corrugated structure; wherein each surface structure includes a plurality of second corrugated grooves and second corrugated peaks extending parallel to each other, each extending with a second tilt angle greater than zero degrees and not exceeding 15 degrees relative to its respective rotation axis. b) The strip (still unstructured) layer is supplied to the rolling mill with a pitch angle extending between the extension direction and a first direction orthogonal to the axis of rotation, wherein the pitch angle is greater than zero degrees; c) A corrugated structure is formed in the layer by passing the layer through the intermeshing surface structure of the roller and a structured layer is produced, wherein the corrugated structure includes a plurality of first corrugated grooves and first corrugated peaks extending parallel to each other, each extending with a first tilt angle greater than zero degrees and not greater than 15 degrees relative to the width direction.

[0013] Specifically, the layer is a continuous material that is cut into predetermined lengths extending along the extension direction after step c) (i.e., after the corrugated structure has been generated).

[0014] Specifically, the layer is rectangular in shape, serving both as a smooth layer (i.e., before the corrugated structure is created) and as a structured layer (i.e., after the corrugated structure is created). The end faces run parallel to the extension direction, while the edges of the layer extend perpendicularly to them at the ends.

[0015] Specifically, the entire layer is structured after step c), that is, it exhibits a wavy structure over its entire range in both the width and extension directions (i.e., specifically, there are no smooth / unstructured areas).

[0016] Specifically, the length of the layer in the width direction is between 5 mm and 1000 mm, preferably less than 200 mm.

[0017] Specifically, the material thickness of the (smoothing) layer (in the height direction perpendicular to the width and length directions) is between 20 µm and 2 mm, specifically at most 1.0 mm or even at most 0.5 mm.

[0018] Specifically, the wave structure has an amplitude between 0.5 mm and 10 mm (specifically up to 5 mm) (i.e., the maximum range of the structured layer in the height direction).

[0019] Specifically, the first corrugated groove and / or the second corrugated groove, as well as the first corrugated peak and / or the second corrugated peak, each extend relative to the width direction at a first tilt angle or a second tilt angle greater than one degree, preferably greater than 2 degrees or even 3 degrees. Specifically, the first tilt angle is at most 15 degrees, preferably at most 12 degrees, at most 10 degrees or even at most 8 degrees.

[0020] The above (non-exhaustive) division of the method steps into a) through c) is intended primarily for distinguishing purposes and does not impose any order or / or dependency. For example, the number of times the method steps occur may vary during the setup and / or operation of the rolling mill. It is also possible that the method steps overlap at least partially in time. Particularly preferably, method steps b) and c) are performed after step a). Specifically, steps b) and c) occur simultaneously. Specifically, steps a) through c) are performed in the listed order and overlap in the method.

[0021] Specifically, after leaving the interlocking surface structures, the structured layer is immediately (substantially) exported from the rolling mill in a first direction (i.e., orthogonal to the axis of rotation).

[0022] Specifically, during step c), the layer does not shift in the direction along the rotation axis, allowing for continuous layer feeding in step b). Therefore, it is necessary to return the layer to its initial position relative to the rolling mill without interrupting steps c) and b) (see explanation in the background art).

[0023] Specifically, this process advantage becomes possible by using a helical / tilted toothed corrugated roll with a defined helical / tilted orientation combined with the unstructured layers on the supply side of the rolling mill. This prevents lateral movement of the layers along the surface structure of the corrugated roll in the direction of rotation. Therefore, a continuous corrugated process can be achieved at other standard corrugating speeds or supply speeds for the layers (i.e., compared to the non-helical corrugated structures of known layers).

[0024] Specifically, the pitch angle approximately corresponds to at least a first tilt angle and / or a second tilt angle. Specifically, the pitch angle is between 80% and 120% of the first and / or second tilt angles, particularly between 90% and 110%, preferably between 95% and 105%, and most preferably between 98% and 102%. This is particularly suitable for tilt angles with a constant value along the width direction of the layer or along the rotation axis of the corrugated roller.

[0025] Specifically, the first tilt angle varies along the route of the corrugated structure between the end faces (i.e., along the width direction of the layer or along the route of the first corrugated groove and the first corrugated peak). Specifically, the same applies to the second tilt angle.

[0026] Specifically, the first tilt angle at the first end face of the structured layer has a specific first value (between greater than zero degrees and 15 degrees). Specifically, the first tilt angle at the second end face of the structured layer has a second value different from the first value (and also particularly between greater than zero degrees and 15 degrees). Specifically, the difference between the first value and the second value is greater than zero degrees, specifically between 1 degree and less than 15 degrees, preferably between one degree and 10 degrees.

[0027] Specifically, the difference increases or decreases monotonically from the first end face toward the second end face. Alternatively, the difference increases from the first end face toward the second end face and then decreases again, possibly repeated multiple times, so that the paths of the first corrugated groove and the first corrugated peak are S-shaped or meandering. Specifically, the first tilt angles at opposite end faces are equal or different from each other.

[0028] Specifically, at least one (preferably two) of the corrugated rollers is segmented such that at least two sections of the corrugated structure arranged adjacent to each other in the width direction are generated by different segments of a single corrugated roller. This allows segments of the corrugated roller subjected to different levels of stress to be replaced at different intervals, thereby reducing tooling and maintenance costs.

[0029] Specifically, the layer is made of steel, non-ferrous materials, or plastic materials.

[0030] Specifically, the layer is a continuous material on which a corrugated structure is continuously generated (i.e., through the uninterrupted supply of the layer to the rolling mill or the uninterrupted generation of the corrugated structure).

[0031] Specifically, the corrugated structure generated between the end faces in step c) is produced with a maximum tolerance of 0.2 mm, preferably 0.1 mm, more preferably 0.05 mm, or even 0.005 mm relative to the height direction extending transversely to the extension and width directions. The tolerance represents the maximum deviation of the component (i.e., the structured layer) from a predetermined value (nominal value) relative to the height direction (i.e., the manufacturing precision of the layer, at least relative to the height direction).

[0032] A strip layer with a corrugated structure is also proposed, wherein the layer extends along an extension direction between a first end and a second end, and extends along a width direction transverse to the first end face and the second end face. The corrugated structure of the layer includes a plurality of first corrugated grooves and first corrugated peaks extending parallel to each other, each extending with a first tilt angle greater than zero degrees and at most 15 degrees relative to the width direction. The corrugated structure is produced by the method according to any one of the preceding claims.

[0033] Specifically, what is visible on the strip layer is regular, because the layer can now be manufactured in a continuous process. In previously known manufacturing processes for such oblique toothed layers, there were pre-visible marks on the layer, which were attributed to the separation of the corrugated roller from the layer and the inability to precisely position the layer.

[0034] A honeycomb structure is also proposed, comprising at least the strip layers having a corrugated structure. To form the honeycomb structure, fluid can flow through it from a first end face to a second end face (and vice versa), by arranging the layers as stacks by folding the layers themselves or combining them with at least one other (smooth and / or structured) layer. If desired, the honeycomb structure can be formed by additionally winding, twisting, or folding the stacks. Multiple stacks can also be used for this purpose.

[0035] The layers and honeycomb structures are generally known. Reference is made to known embodiments of layers and honeycomb structures in this regard.

[0036] The honeycomb structure is specifically designed for exhaust gas aftertreatment. Refer to the description in the background art.

[0037] Honeycomb cells can typically have various shapes, specifically circular, elliptical, polygonal, or similar cross-sections. In many cases, such honeycomb cells are formed with tubular shells. When used for exhaust gas aftertreatment, during operation, exhaust gas / fluid enters through one of two end faces and exits again through the other end face. These end faces are preferably arranged substantially parallel or inclined relative to each other, and typically define the length of the honeycomb cell in the direction of its central axis, which penetrates both end faces and is specifically arranged at the center and perpendicular to at least one, preferably both, end faces.

[0038] The cellular structure also includes at least one of the at least partially structured layers. A single layer may have smooth and structured sections or sections with different structures. At least one layer may be arranged, for example, in a spiral manner around a central axis. Multiple layers may also be used, for example, some of which are smooth and / or have a structure different from at least one other layer. Specifically, two or more layers may be used, where a pair of layers may have the same structure (type, size, etc.) but are formed with different orientations of the corrugated structure, such that the corrugated grooves and corrugated peaks of the layers in contact with each other intersect.

[0039] The corrugated structure of the layer is preferably formed along its entire length (i.e., between the first and second end faces). The corrugated structure is formed by ridges (corrugated peaks) and valleys (corrugated grooves) that have been embossed onto the layer by a corrugated roller. The corrugated peaks and grooves alternate regularly in the extension direction of the layer. In cross-section, the corrugated peaks and grooves can form sinusoidal waves, sawtooth shapes, etc. The arrangement of the structure (i.e., the corrugated peaks and grooves) within the honeycomb structure causes it to run at an angle relative to the central axis. This creates channel sections for fluids that do not run parallel to the central axis but at an angle to it. Therefore, when the exhaust gas or fluid flow impacts the end face perpendicularly, the exhaust gas / fluid is first separated as it enters the channel openings formed by the corrugated peaks and grooves and then deflects inside the honeycomb structure. Specifically, the structure is designed such that the corrugated peaks and grooves in adjacent regions (viewed radially relative to the central axis) are tilted at different angles or have different orientations. For example, if a rightward deflection occurs in one region, a leftward deflection preferably occurs in a further inward region, and vice versa. Particularly preferably, this alignment or orientation alternates continuously when viewed in the radial direction. Specifically, this causes the corrugated peaks and grooves located on top of each other at least partially on points on the honeycomb structure, and preferably not at arbitrary points on the honeycomb structure, to form linearly extending contacts, but rather to intersect each other and thus form essentially only point-like contact points with each other. This produces a structure in which a portion of the exhaust gas / fluid flow is permanently deflected and can flow into adjacent corrugated peaks or grooves, especially in a sawtooth pattern.

[0040] Furthermore, the use of honeycomb structures or layers in exhaust systems, such as those of motor vehicles or stationary equipment, is proposed, including internal combustion engines having exhaust systems. The exhaust system includes at least one catalyst support or particulate filter designed to have the honeycomb structure described herein. In this context, the catalyst support and / or particulate filter may include a catalytically active coating.

[0041] Specifically, the intersecting arrangement of the corrugated structure in the layer and the corrugated structure in the honeycomb results in a reduction of the shoulder / corner space between the contact layers. These shoulder / corner spaces are always numerous and extend excessively when the corrugated grooves and corrugated peaks are aligned in a straight line, thereby providing a larger surface area while maintaining the same cell density in the honeycomb and reducing the undesirable accumulation of carrier coating (or other coatings) in these shoulder / corner spaces.

[0042] Specifically, at least one data processing system is provided, which includes means appropriately equipped, configured, or programmed to implement or perform the method.

[0043] Specifically, the rolling mill or the equipment provided for implementing the method includes a data processing system, such as a control unit, which includes means for performing the steps of the method and / or the data processing system includes means appropriately equipped, configured or programmed to perform the steps of the method or to perform the method.

[0044] The device includes, for example, a processor and a memory storing commands to be executed by the processor, as well as a data line or transmission device that enables the transmission of commands, measurements, data, etc., between the aforementioned elements.

[0045] Specifically, a “device” may include one or more of the following components: a controller, a microcontroller, a data storage device, a data connection, a display device (such as a monitor), a counter or timer, at least one additional sensor, a power supply, etc.

[0046] A computer program is further proposed, comprising instructions that, when executed by a computer, cause the computer to perform the method or the steps of the method.

[0047] A computer-readable storage medium is further proposed, comprising instructions that, when executed by a computer, cause the computer to perform the method or steps of the method.

[0048] The description of each method is particularly applicable to methods implemented in layers, cells, uses, data processing systems, and / or computers (i.e., computer programs and computer-readable storage media), and vice versa.

[0049] The use of indefinite articles (“a”, “an”), particularly in the claims and description embodying them, should be understood as such rather than numerals. Therefore, a term or component introduced in this manner is thus understood to appear at least once, and in particular potentially multiple times.

[0050] As a precaution, it should be noted that the numerals used herein (“first,” “second,” …) are primarily (only) used to distinguish between multiple similar objects, quantities, or processes; specifically, they do not necessarily specify any dependency and / or order of these objects, quantities, or processes relative to each other. If dependency and / or order are required, this is expressly stated herein or will be apparent to those skilled in the art upon examination of the specifically described configuration. The description of one of these components may apply equally to all or part of multiple such components to the extent that a component may appear multiple times (“at least one”); however, this is not mandatory.

[0051] The invention and technical background are explained in more detail below with reference to the accompanying drawings. It should be noted that the invention is not intended to be limited to the examples of the cited embodiments. Specifically, it should be noted that the drawings, especially the scale shown, are merely illustrative. As shown in the figures:

[0052] Figure 1 The perspective view shows a cross-section of the honeycomb structure formed by the layers.

[0053] Figure 2 Shown from a perspective along the central axis of the cell: Figure 1 The cross-section shown in the figure;

[0054] Figure 3 It shows that it has the following characteristics: Figure 1 and Figure 2 The honeycomb structure shown in the diagram;

[0055] Figure 4 This illustrates a known method for generating a corrugated structure in the first state;

[0056] Figure 5 : This shows the second state according to Figure 4 Methods;

[0057] Figure 6 This illustrates a method for generating a corrugated structure according to a first design variant;

[0058] Figure 7 This illustrates a method for generating a corrugated structure according to a second design variant;

[0059] Figure 8 : A perspective view showing either the first or second roller according to a first design variant; and.

[0060] Figure 9 The first or second roller according to the second design variant is shown in perspective.

[0061] Figure 1 The cross-section of the honeycomb 27 formed by layer 2 is shown in perspective view. Figure 2 A view from the central axis 30 along the cell 27 is shown. Figure 1 The cross section. Figure 3 It shows that it has the following characteristics: Figure 1 and Figure 2 The honeycomb structure 27 of layer 2. Described together below. Figures 1 to 3 .

[0062] The layers 2 forming the honeycomb structure 29 of the honeycomb 27 each extend along the extension direction 3 between the first end 4 and the second end 5, and extend along the width direction 6 between the first end face 7 and the second end face 8 of the layer. The corrugated structure 1 of the layer 2 includes a plurality of first corrugated grooves 9 and first corrugated peaks 10 extending parallel to each other, each extending with a first tilt angle 11 greater than zero degrees and at most 15 degrees relative to the width direction 6.

[0063] The honeycomb 27 includes at least one strip layer 2 having a corrugated structure 1. Figure 3 A smooth layer 2 without corrugated structure 1 is shown arranged between each strip layer 2 with corrugated structure 1.

[0064] To form the honeycomb structure 29, fluid 32 can flow through the honeycomb structure 29 from the first end face 7 to the second end face 8 of the honeycomb body 27. Layer 2 is arranged in the stack 28 by folding itself or by combining it with at least one other (smooth and / or structured) layer 2. Figure 3 In this process, the honeycomb structure 29 is formed by additional winding layers 28.

[0065] The honeycomb cell 27 has a circular cross-section. The honeycomb cell 27 forms a tubular shell. When used for exhaust gas aftertreatment, during operation, exhaust gas / fluid 32 typically enters the honeycomb cell 27 via one of the two end faces 7, 8 and exits again via the other end face 8, 7. The end faces 7, 8, arranged parallel to each other (respectively, layer 2, honeycomb structure 29, and honeycomb cell 27), typically define the length (or width of layer 2) of the honeycomb cell 27 in the direction of the central axis 30 of the honeycomb cell 27, which penetrates the two end faces 7, 8 and is perpendicular to and centered relative to the two end faces 7, 8.

[0066] The corrugated structure 1 of layer 2 extends along the entire length of the honeycomb 27 and across the entire width of layer 2, i.e., between the first end face 7 and the second end face 8. The corrugated structure 1 is formed by ridges (corrugated peaks 10) and valleys (corrugated grooves 9) embossed into layer 2 by corrugated rollers 13 and 14 (see...). Figure 6 and Figure 7In this process, the corrugated peaks 10 and corrugated grooves 9 alternate regularly in the extension direction 3 of layer 2. In cross-section, the corrugated peaks 10 and corrugated grooves 9 form a sinusoidal wave. The arrangement of the corrugated structure 1, or more precisely, the corrugated peaks 10 and corrugated grooves 9 within the honeycomb 27, causes it to run at an angle relative to the central axis 30. This creates channel sections for the fluid 32, which do not run parallel to the central axis 30, but rather at an angle to it. Therefore, when the exhaust gas or fluid flow impacts the end faces 7, 8 perpendicularly, the exhaust gas / fluid 32 is first separated as it enters the channel openings formed by the corrugated peaks 10 and corrugated grooves 9, and then deflects within the honeycomb 27. The corrugated structure 1 causes the corrugated peaks 10 and corrugated grooves 9 (viewed in the radial direction 33 relative to the central axis 30) in adjacent regions to be tilted at different angles or have different orientations from each other. For example, if a rightward deflection occurs in one region, a leftward deflection is preferably observed in a further inward region, and vice versa. This alignment or orientation alternates continuously when viewed in the radial direction 33. This causes the corrugated peaks 10 and corrugated grooves 9 to not be on top of each other and form line contact at any point on the cell body 27 of the honeycomb structure 29, but rather to intersect each other and thus form essentially only point-like contact points with each other. This produces a structure in which a portion of the exhaust gas / fluid 32 is continuously deflected and can flow into adjacent corrugated peaks 10 or corrugated grooves 9, particularly in a sawtooth pattern.

[0067] The intersecting arrangement of the corrugated structure 1 in the cell 27 of layer 2 results in a reduction of the shoulder / corner space 31. These shoulder / corner spaces 31 are always abundant and extend excessively between the contact layers 2 when the corrugated grooves 9 and the corrugated peaks 10 are aligned in a straight line, thereby providing a larger surface area while maintaining the same cell density of the cell 27 or the cell structure 29, and reducing the undesirable accumulation of carrier coating (or other coating) in these shoulders 31.

[0068] Figure 4 A known method for generating the corrugated structure 1 in the first state is shown. Figure 5 The second state is shown according to Figure 4 The method. Described together below. Figure 4 and 5 . Reference Figures 1 to 3 The description.

[0069] DE 10 2012 004 918 A1 discloses a honeycomb structure 27 in which structured layers 2 have corrugated structures 1, wherein adjacent layers 2 have intersecting corrugated structures 1. To produce such structured layers 2, unstructured (i.e., specifically, smooth or flat) layers 2 are fed to a rolling mill 12. The rolling mill 12 includes two rollers 13, 14, each having a rotation axis 15 running parallel to each other and each having a surface structure 16 for generating the corrugated structure 1, wherein the surface structures 16 mesh with each other to generate the corrugated structure 1. For this purpose, each surface structure 16 includes a plurality of second corrugated grooves 17 and second corrugated peaks 18 running parallel to each other, extending parallel to their respective rotation axes 15. Layers 2 are supplied to the rolling mill 12 at a pitch angle 21 such that the corrugated structures 1 imprinted on layers 2 run at an angle relative to the extension direction 3 of layers 2.

[0070] In this process, straight-tooth corrugated rollers 13 and 14 are used, and the still smooth (continuous) layer 2 is supplied to the corrugated rollers 13 and 14 at an angle different from 90 degrees. The pitch angle 21 of layer 2 relative to a virtual line (first direction 20) perpendicular to the rotation axis 15 of the corrugated rollers 13 and 14 depends on the first tilt angle 11 required for the corrugated structure 1 on the structured layer 2 (e.g., a supply angle / pitch angle 21 of 3 degrees produces a first tilt angle 11 of approximately 5 degrees for the corrugated structure 1 on the structured layer 2). Due to the non-orthogonal supply and the resulting lateral force, layer 2 moves along the rotation axis 15 of the corrugated rollers 13 and 14 (see...). Figure 4 The first state and Figure 5 (Second state in the process). Depending on the pitch angle 21 on the supply side of the rolling mill 12, the width of layer 2, and the width of the corrugated rollers 13 and 14, layer 2 has a finite length in its extension direction 3 (after which the corrugating process needs to be interrupted), because otherwise layer 2 will move out of the rolling mill 12. A known solution is a so-called corrugated stop device, similar to the principle of a typewriter, which allows the corrugated rollers 13 and 14 to be spaced apart and then fed laterally, thereby causing layer 2 to shift relative to the corrugated rollers 13 and 14 along the rotation axis 15 to its initial position ( Figure 4 Therefore, the process for generating the corrugated structure 1 is discontinuous because the supply of layer 2 relative to the rolling mill 12 must be interrupted in order to move layer 2.

[0071] Figure 6 A method for generating the corrugated structure 1 according to a first design variant is shown. See also Figures 1 to 5 The description.

[0072] According to step a) of the method, a rolling mill 12 is provided, which includes two rolls 13 and 14. The two rolls 13 and 14 have rotation axes 15 running parallel to each other and each has a surface structure 16 that generates a corrugated structure 1, wherein the surface structures 16 mesh with each other to generate the corrugated structure 1. Each surface structure 16 has a plurality of second corrugated grooves 17 and second corrugated peaks 18 running parallel to each other, each extending at a second tilt angle 19 of approximately 5 degrees relative to its respective rotation axis 15.

[0073] According to step b) of the method, the strip (still unstructured) layer 2 is supplied to the rolling mill 12 at a pitch angle 21 extending between the extension direction 3 and the first direction 20 orthogonal to the rotation axis 15, wherein the pitch angle 21 is approximately 5 degrees.

[0074] According to step c), a corrugated structure 1 is formed in layer 2 by passing layer 2 through the intermeshing surface structure 16 of rollers 13 and 14, thereby producing structured layer 2.

[0075] Layer 2 is a continuous material that is cut into predetermined lengths extending along the extension direction 3 after step c) (i.e., after the corrugated structure 1 has been formed).

[0076] Layer 2 is rectangular in shape and serves both as smooth layer 2 (i.e., before the corrugated structure 1 is generated) and as structured layer 2 (i.e., after the corrugated structure 1 is generated).

[0077] After completing step c), the entire layer 2 is structured, that is, it exhibits a corrugated structure 1 over its entire range in the width direction 6 and the extension direction 3 (i.e., specifically, there are no smooth / unstructured areas).

[0078] The corrugated structure 1 has an amplitude (i.e., the maximum range of the structured layer 2 in the height direction 26) (see example). Figure 3 ).

[0079] The first corrugated groove 9 and the first corrugated peak 10 each extend at a first tilt angle 11 of approximately 5 degrees relative to the width direction 6.

[0080] After leaving the intermeshing surface structure 16, the structured layer 2 is immediately exported from the rolling mill 12 in a first direction 20 (i.e., orthogonal to the rotation axis 15 of the rolls 13 and 14).

[0081] Therefore, during step c), layer 2 is not offset, particularly in the direction along the rotation axis 15, so that continuous feeding of layer 2 can occur in step b). Therefore, it is currently necessary to return layer 2 to its initial position relative to the rolling mill 12 without interrupting steps c) and b) (see explanation in the background art).

[0082] Specifically, this process advantage becomes possible by using helical toothed rolls (corrugated rolls) 13, 14 combined with the defined inclined orientation of the unstructured layer 2 on the supply side of the rolling mill 12. Therefore, lateral movement of layer 2 along the surface structure 16 of the corrugated rolls 13, 14 in the direction of the rotation axis 15 is prevented. Thus, a continuous corrugated process can be achieved at other standard corrugating speeds or supply rates of layer 2 (i.e., compared to the known non-inclined corrugated structure 1 of layer 2).

[0083] exist Figure 6 In this case, both the first tilt angle 11 and the second tilt angle 19 are constant.

[0084] Alternatively, the first tilt angle 11 varies along the path of the corrugated structure 1 between end faces 7 and 8 (i.e., along the width direction 6 of layer 2 or along the path of the first corrugated groove 9 and the first corrugated peak 10). Specifically, this also applies to the second tilt angle 19.

[0085] Then, for example, the first angle tilt 11 at the first end face 7 of the structured layer 2 has a specific first value (e.g., 6 degrees). Then, the first tilt angle 11 at the second end face 8 of the structured layer 2 has a second value different from the first value (e.g., 8 degrees). The difference between the first value and the second value is therefore two degrees.

[0086] In this case, the difference increases monotonically from the first end face 7 toward the second end face 8.

[0087] Figure 7 A method for generating the corrugated structure 1 according to a second design variant is shown. (Refer to...) Figure 6 The description.

[0088] Unlike the first design variant, at least one of the corrugated rollers 13, 14 is segmented, such that at least two segments 22, 23 of the corrugated structure 1 arranged adjacent to each other in the width direction 6 are generated by different segments 24, 25 of a single corrugated roller 13. This allows segments 24, 25 of the corrugated roller 13 subjected to different levels of stress to be replaced at different intervals, thereby reducing tooling and maintenance costs.

[0089] Figure 8 A perspective view shows the first or second (corrugated) rollers 13, 14 according to a first design variant. (See reference) Figures 1 to 7 The description.

[0090] Rollers 13 and 14 have a rotation axis 15 and each has a surface structure 16 that generates a corrugated structure 1, wherein the surface structures 16 of the two rollers 13 and 14 mesh with each other to generate the corrugated structure 1. The surface structure 16 includes a plurality of second corrugated grooves 17 and second corrugated peaks 18 running parallel to each other, each extending with a second tilt angle 19 of approximately 8 degrees relative to its respective rotation axis 15. The second corrugated grooves 17 and second corrugated peaks 18 have a helical path along the surface of rollers 13 and 14, i.e., extending along a curve with a constant curvature.

[0091] Figure 9 The first or second (wave) rollers 13, 14 according to a second design variant are shown in perspective view. Reference Figure 8 The description in the text.

[0092] and Figure 8 In contrast, the second corrugated groove 17 and the second corrugated peak 18 here do not have a spiral path, but extend diagonally between the end faces of rollers 13 and 14.

[0093] The teeth of the surface structure 16 shown are always oriented parallel to the central axis 30 along the tooth path, that is, in each cross section running perpendicular to the central axis 30, each tooth has the same functional dimensions (helix angle, head, root and virtual pitch circle diameter). List of reference numerals in the attached diagram: 1. Corrugated structure 2nd floor 3. Direction of extension 4 First end 5 Second end 6. Width direction 7 First end face 8 Second end face 9 First Corrugated Groove 10 First ripple peak 11 First Inclination Angle 12-roll rolling mill 13 First Roller 14 Second Roller 15 Rotation axis 16 Surface Structure 17 Second Corrugated Groove 18 Second ripple peak 19 Second Inclination Angle 20 First Direction 21 Pitch angle 22 First Section 23 Second Section 24 First Segment 25 Second Segment 26. Height Direction 27. Honeycomb 28 stacked 29. Honeycomb structure 30 Central axis 31 Arched shoulders / corner space 32 Fluids 33 Radial direction

Claims

1. A method for producing a corrugated structure (1) on a strip layer (2), wherein the layer (2) extends along an extension direction (3) between a first end (4) and a second end (5), and extends along a width direction (6) laterally thereto between the first end face (7) and the second end face (8); comprising at least the following steps: a) Providing a rolling mill (12) having at least two rolls (13, 14) having rotation axes (15) extending parallel to each other and each having a surface structure (16) that produces the corrugated structure (1), wherein the surface structures (16) mesh with each other to produce the corrugated structure (1); wherein each surface structure (16) includes a plurality of second corrugated grooves (17) and second corrugated peaks (18) extending parallel to each other, each extending relative to its respective rotation axis (15) at a second tilt angle (19) greater than zero degrees and at most 15 degrees. b) The strip layer (2) is supplied to the rolling mill (12) at a pitch angle (21) extending between the extension direction (3) and a first direction (20) orthogonal to the rotation axis (15), wherein the pitch angle (21) is greater than zero degrees; c) By passing the layer (2) through the intermeshing surface structure (16) of the rollers (13, 14), a corrugated structure (1) is formed in the layer (2) and the structured layer (2) is produced, wherein the corrugated structure (1) includes a plurality of first corrugated grooves (9) and first corrugated peaks (10) extending parallel to each other, each extending with a first tilt angle (11) greater than zero degrees and at most 15 degrees relative to the width direction (6).

2. The method according to claim 1, wherein after leaving the intermeshing surface structure (16), the structured layer (2) is immediately exported from the rolling mill (12) in parallel with the first direction (20).

3. The method according to any one of the preceding claims, wherein the pitch angle (21) is between 80% and 120% of at least one of the first tilt angle (11) and the second tilt angle (19).

4. The method according to any one of the preceding claims, wherein the first tilt angle (11) varies along the path of the corrugated structure (1) between the end faces (7, 8).

5. The method according to any one of the preceding claims, wherein at least one of the corrugated rollers (13, 14) is segmented such that at least two segments (22, 23) of the corrugated structure (1) arranged adjacent to each other along the width direction (6) are generated by different segments (24, 25) of the corrugated roller (13, 14).

6. The method according to any one of the preceding claims, wherein the layer (2) is made of steel, non-ferrous or plastic material.

7. The method according to any one of the preceding claims, wherein the layer (2) is a continuous material on which the corrugated structure (1) is continuously generated.

8. The method according to any one of the preceding claims, wherein the corrugated structure (1) generated by step c) between the end faces (7, 8) is generated with a maximum tolerance of 0.2 mm in the height direction (26) extending transversely to the extension direction (3) and the width direction (6).

9. A strip layer (2) having a corrugated structure (1), wherein the layer (2) extends along an extension direction (3) between a first end (4) and a second end (5), and extends along a width direction (6) to its transverse direction between a first end face (7) and a second end face (8), wherein the corrugated structure (1) of the layer (2) comprises a plurality of first corrugated grooves (9) and first corrugated peaks (10) extending parallel to each other, each extending with a first tilt angle (11) greater than zero degrees and at most 15 degrees relative to the width direction (6); wherein the corrugated structure (1) is produced by a method according to any one of the preceding claims.

10. A honeycomb structure (27) comprising at least a strip layer (2) having a corrugated structure (1) according to claim 9, wherein the strip layer (2) is folded or arranged in combination with at least one other layer (2) to form a stack (28), and wherein the stack (28) is formed at least by winding, twisting or folding the stack (28) to form a honeycomb structure (29) through which fluid (32) can flow from the first end face (7) to the second end face (8).

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