Honeycomb structure and method for producing a structured layer

Abstract

The invention relates to a honeycomb structure (1) comprising at least one stack (7) formed at least from a first layer (8) having a corrugation structure (9), wherein the first layer (8) extends along a width direction (12) parallel to a central axis (4) between a first end face (10) arranged on a fluid inlet side (2) and a second end face (11) arranged on a fluid outlet side (3); wherein the corrugation structure (9) of the first layer (8) has as a primary structure a multitude of corrugation valleys (13) and corrugation peaks (14) extending parallel to one another, wherein each extends along a course (16) having an inclination angle (15) to the width direction (12) of more than 0° and at most 15°; wherein the corrugation structure (9) has at least one secondary structure comprising a reverse deformation of the primary structure. The invention also relates to a method for producing a structured layer (8, 20).

Description

Technical Field

[0001] This invention relates to a honeycomb structure and a method for producing structured layers. Background Technology

[0002] Specifically, the honeycomb structure extends along a central axis between the fluid inlet side and the fluid outlet side, with channels extending between the two sides to allow fluid to flow through the honeycomb structure. The honeycomb structure includes at least one stack formed by at least a first layer having a corrugated structure. The first layer extends along a width direction parallel to the central axis between a first end face disposed on the fluid inlet side and a second end face disposed on the fluid outlet side. The corrugated structure of the first layer serves as the main structure, having numerous mutually parallel troughs and crests, each extending along a direction with an angle of inclination greater than 0° and at most 15° relative to the width direction.

[0003] Stacks and channels are formed by arranging another structured region of the same first layer onto the first layer, or by arranging a structured second layer onto the first layer; wherein the region of the first layer or the second layer is structured so that the troughs and crests stacked above and below intersect each other, thereby defining the contact area between the troughs and crests along the orientation.

[0004] Layers with corrugated structures are used, for example (but not exclusively), to form honeycomb structures for exhaust gas aftertreatment, particularly as catalyst carriers in mobile internal combustion engine exhaust systems. Such honeycomb structures or cells provide a large surface area on which catalytically active materials are arranged and in contact with the exhaust gas flowing through the cell. This invention is particularly useful for exhaust gas purification in motor vehicles or stationary or other mobile equipment.

[0005] Numerous different implementations of honeycomb structures for exhaust gas aftertreatment have been proposed in the prior art. Honeycomb structures are generally made of ceramic or metal (steel or non-ferrous metals). However, honeycomb structures can also be produced using plastic.

[0006] The honeycomb structure can be composed of smooth layers and / or structured layers or metal foil. These layers can be stacked, wound, and / or twisted before being installed within the honeycomb shell, thereby forming numerous channels for the passage of exhaust gases. These channels can extend in a straight line, meander, and / or at an angle between the two end faces of the honeycomb structure, for example.

[0007] To ensure that the exhaust gas makes full contact with the walls or catalytic coatings on the walls of the honeycomb structure, existing technologies have proposed numerous methods to weaken the laminar flow state of the exhaust gas within the honeycomb structure. For example, openings can be provided in the channel walls to form interconnected channels. Also known are deflection structures, guide vanes, etc., within the channels as secondary structures to achieve directional airflow deflection and pressure differentials between channels.

[0008] DE 10 2012 004 918 A1 discloses a honeycomb structure in which the structured layers have a corrugated structure, wherein adjacent layers have intersecting corrugated structures.

[0009] In a honeycomb structure with a cross-corrugated pattern, the channels of the structured layers have a defined angle of inclination relative to the width direction. By alternately stacking structured layers with channels facing opposite directions, a three-dimensional contact area pattern is created in which adjacent corrugated structures intersect and contact each other, thereby eliminating the need for (unstructured) smooth foil between the corrugated (structured) layers. To ensure thermomechanical durability during operation, the layers can be connected using form-fitting or material bonding methods. For example, a brazing pretreatment method is mentioned in this connection, where an adhesive-water mixture penetrates axially into the honeycomb structure at the contact points between adjacent layers via capillary action. Welding represents another bonding technique. This allows for material bonding at the contact points arranged at the end faces between two layers.

[0010] The connection relationship between the layers in the contact area affects the expansion or expansion characteristics of the honeycomb or honeycomb structure, and is therefore a key factor representing the durability of the honeycomb.

[0011] In a honeycomb structure with intersecting corrugated patterns, the contact state between adjacent structured layers continuously changes along the cross-section of the honeycomb structure. Therefore, in some regions, the crests and troughs of two adjacent structured layers contact each other at the end face, while in other regions, the contact area is spaced a few millimeters apart from the end face, i.e., offset along the central axis.

[0012] Existing implementations have the following drawbacks: when a (unstructured) smooth layer is lacking, the applicability of material bonding methods (e.g., brazing or welding) is limited. The aforementioned exemplary bonding methods, for example, cannot guarantee the required number of contact areas to bond together in such a honeycomb structure, or cannot guarantee sufficient connectivity in the end-face regions.

[0013] Another drawback stems from the production process of the structured layer. The structured layer can be reshaped using structured corrugated rolls through a corrugation-bending process. During the reshaping operation, especially for inclined extension unit channels, the achievable imprint height, imprint geometry, and corner radius are limited due to layer damage (cracks or holes, etc.), particularly when combining secondary structures. Summary of the Invention

[0014] This invention aims to at least partially solve the aforementioned problems existing in the prior art. Specifically, it provides a honeycomb structure, which is particularly suitable for directional formation of contact areas. Through existing bonding methods (brazing, welding), the honeycomb structure can acquire pre-defined expansion characteristics while maximizing its durability. Furthermore, it proposes a method for producing structured layers, thereby increasing the design freedom (imprint height, imprint geometry, corner radius, etc.) and processing cycle of the tilted corrugated layer during the production process. Specifically, this enables the realization of difficult-to-process geometric features such as high pressure imprinting or corrugation height and small corner radius.

[0015] A cellular structure having the features of claim 1 and a method having the features of claim 9 are used to solve the above-mentioned objectives. Advantageous improvements are the subject matter of the dependent claims. Features listed individually in the claims can be combined with each other in a technically meaningful manner, and further embodiments of the invention can be obtained by combining the description and / or details of the drawings.

[0016] This invention proposes a honeycomb structure extending along a central axis between a fluid inlet side and a fluid outlet side, wherein channels extend between the two sides, allowing fluid to flow through the honeycomb structure. The honeycomb structure includes at least one stack formed by at least a first layer having a corrugated structure. The first layer extends along a width direction parallel to the central axis between a first end face disposed on the fluid inlet side and a second end face disposed on the fluid outlet side. The corrugated structure of the first layer serves as the main structure, having numerous mutually parallel extending troughs and crests, each extending along a direction with an angle of inclination greater than 0° and at most 15° relative to the width direction.

[0017] The corrugated structure has at least one (type) of secondary structures, which include reverse deformations of the main structure. In each case, the extension of the secondary structure along the direction of the distance between the end faces accounts for at most 20%, particularly at most 10%, and preferably at most 5%. By means of reverse deformation, troughs become intermediate crests, or crests become intermediate troughs. Stacks and channels are formed by arranging another structured region of the same first layer onto the first layer, or by arranging a structured second layer onto the first layer. This region of the first layer or the second layer is structured such that the stacked troughs, crests, intermediate crests, and intermediate troughs intersect each other, thereby defining the contact areas along the direction between troughs and intermediate troughs on the one hand and between crests and intermediate crests on the other hand.

[0018] Specifically, the first (and / or second) layer extends in the width direction between the first end face and the second end face, and extends laterally from the first end to the second end in the longitudinal direction.

[0019] Specifically, the first (and / or second) layer is (substantially) rectangular. Specifically, the extent of the layer along the extension direction is greater than the extent along the width direction.

[0020] Specifically, the entire first (and / or second) layer is structured, in other words, it has a corrugated structure throughout its width and extension directions (in other words, there are no smooth / unstructured regions).

[0021] Specifically, the layer ranges from 5 mm to 1000 mm in width, preferably less than 200 mm.

[0022] Specifically, the thickness of the first layer of material (in the height direction extending laterally in both the width and extension directions) is between 20 μm and 2 mm, specifically at most 1.0 mm, or even at most 0.5 mm.

[0023] Specifically, the amplitude of the corrugated structure (in other words, the maximum range of the structured layer in the height direction) is between 0.5 mm and 10 mm, especially up to 5 mm.

[0024] Specifically, the troughs and crests each extend with an angle greater than 1°, preferably greater than 2° or even 3°, relative to the width direction. Specifically, the first angle is at most 15°, preferably at most 12°, at most 10°, or even at most 8°. If such layers are stacked one on top of the other in an intersecting manner, the angle between the contacting troughs and crests corresponds to the sum of the angles of the layers.

[0025] Cellular structures are formed by stacking multiple layers one on top of the other. For this purpose, multiple layers can be stacked directly on top of each other, or the stack can be folded and / or rolled and / or twisted. Such cellular structures are generally known.

[0026] The honeycomb structure produced in the above manner can be arranged inside the shell, thus forming a honeycomb structure.

[0027] The honeycomb or honeycomb structure can have substantially different shapes, specifically circular, elliptical, polygonal, or similar cross-sections. Such honeycombs are typically equipped with a tubular shell. When used for exhaust gas aftertreatment, during operation of the honeycomb, exhaust gas / fluid enters regularly via the fluid inlet side and exits via the fluid outlet side. The fluid inlet and outlet sides are preferably arranged substantially parallel to each other, or they may be arranged at an angle to each other, typically defining the length of the honeycomb along its central axis, which runs through both sides of the honeycomb, and specifically, preferably perpendicularly centered on both sides relative to at least one side.

[0028] Specifically, by means of the reverse deformation of the secondary structure that forms (a finite region of the main structure), a portion of the trough is deformed into an intermediate peak, or a portion of the peak is deformed into an intermediate trough.

[0029] The reverse deformation specifically involves a unique reshaping of the primary structure. The shape of the secondary structure (with inclined surfaces) thus successively transitions to the shape of the primary structure along the orientation of the channel. This successive transition from the shape of the secondary structure to the shape of the primary structure provides surfaces arranged at an incline relative to the fluid flowing through the honeycomb structure along its orientation.

[0030] Alternatively, the reverse deformation can be separated from the main structure by a partition cut, which specifically (at least or only) extends transversely to the orientation. Since the partition cut is specifically constrained to a channel along the longitudinal direction in each case, the additional edge generated within the honeycomb structure in each case can act on the fluid flowing through the honeycomb structure.

[0031] Because of the dividing cuts, it is no longer necessary to form inclined surfaces. For example, this can reduce the flow resistance of the honeycomb structure to the fluid flowing through it.

[0032] Through each intermediate crest or trough, in each case an additional contact area (relative to the main structure) can be formed on the one hand between the trough and the intermediate trough and on the other hand between the crest and the intermediate crest. This additional contact area (similar to the contact area formed by the main structure) is also defined along the orientation.

[0033] Through the secondary structure, specifically through the target method, additional contact areas can be provided, in which brazing or welding connections can be generated.

[0034] Specifically, at least one secondary structure (in other words, a reverse deformation in each case) extends to the end face of the corresponding layer. This allows for the formation or provision of another contact area, either near or directly at the end face. In this way, additional (material bonding) connections can be created in the region of the end face using existing joining methods.

[0035] Specifically, at least one secondary structure (in other words, a reverse deformation in each case) is arranged spaced apart from the end face of the corresponding layer. This allows for the optional formation or provision of another contact area near (but not at) the end face. In this way, additional (material bonding) connections can be created in the region of the end face using existing joining methods.

[0036] Specifically, in a cross-section extending laterally to the direction, the contact surface of the secondary structure that forms a contact area with the adjacent layer is larger than the contact surface of the main structure.

[0037] Specifically, the main structure includes, for example, sinusoidal (or different or similar shapes) corrugations of layers. For example, the sinusoidal corrugations specifically have alternating maximum and minimum values ​​along the longitudinal direction, thereby forming an amplitude. Specifically, reverse deformation can, for example, form flattened maximum or minimum values ​​of the corrugations (in other words, no longer point-like in the cross-section, but line-like along the longitudinal direction), so that the contact surface formed by the line-like maximum or minimum values ​​is larger than the contact surface formed by the point-like maximum or minimum values.

[0038] Specifically, in each trough and / or peak of the first (and / or second) layer, a secondary structure is provided in each case (only or at least).

[0039] Specifically, the layer has only intermediate peaks or only intermediate troughs as secondary structures. Alternatively, the layer has two types of secondary structures, in other words, intermediate peaks and intermediate troughs.

[0040] Specifically, in each case, the secondary structure is arranged in the same position relative to the width direction (in other words, for example, equidistant from the end face of the corresponding layer in each case).

[0041] Specifically, a plurality of secondary structures spaced apart from each other along the orientation are provided on the first layer. Specifically, at least partially, several secondary structures arranged spaced apart from each other along the orientation are provided for each trough or crest. In this way, (material bonding) connections between adjacent layers can be generated or provided in a targeted manner at specific locations in the cellular structure.

[0042] Specifically, on the first (and / or second) layer, a plurality of alternating intermediate peaks and peaks are provided in sequence along a longitudinal direction extending laterally in the width direction, wherein a plurality of alternating intermediate troughs and troughs are provided in sequence along the longitudinal direction, offset from the width direction (and / or orientation).

[0043] Specifically, intermediate crests and intermediate troughs are provided alternately along the longitudinal direction (optionally arranged offset from each other and / or spaced apart along the width direction and / or orientation).

[0044] In this paper, offset along the width direction specifically refers to the fact that the intermediate peaks and troughs are not aligned sequentially along the longitudinal direction. Separated arrangement along the width direction specifically refers to the fact that the intermediate peaks and troughs are not only not aligned longitudinally, but also not overlapping.

[0045] Specifically, the intermediate peaks and intermediate troughs are offset from and / or spaced apart from each other along the width direction and / or orientation.

[0046] The proposed honeycomb structure ensures a reproducible and abundant number of connection points per cross-sectional area (transverse to the width direction) based on the cell density within the honeycomb structure. Specifically, the bonding quality of the connection points can be improved (e.g., through larger contact surfaces or contact areas). Specifically, the bonding quality of the contact areas or contact surfaces between adjacent layers can be improved using capillary-based adhesive or welding methods. Specifically, by providing secondary structures, additional support points (contact portions of adjacently arranged layers) can be created, thereby improving the mechanical stability of the honeycomb structure and ensuring a uniform distribution of constant preload on all sides of the honeycomb structure (fluid inlet side, fluid outlet side). Furthermore, the risk of damage to the honeycomb structure during production and operation can be reduced. Additionally, this invention significantly improves the volumetric efficiency of the honeycomb structure for optional waste gas purification or treatment. Specifically, the heating performance of the honeycomb structure can be improved by balancing thermal mass and enhancing interlayer heat transfer. Specifically, providing secondary structures only results in a small increase in back pressure (when fluid flows through the honeycomb).

[0047] Specifically, at most 20%, preferably at most 10%, and particularly preferably at most 5%, of the contact area of ​​the cellular structure contains brazing or welding connections (hereinafter referred to as connections). These connections are formed during or after the production of the cellular structure. Specifically, these connections are distributed substantially uniformly across the cross-section of the cellular structure extending transversely to the central axis. However, intentionally non-uniform distributions or patterns of connections may also occur.

[0048] Specifically, the connections (at least some of the materials combined) of the cellular structure are arranged at a distance of no more than 10 mm from the corresponding nearest end face of the layer. Specifically, at least 30%, and especially at least 45%, of these connections extend all the way to the end face.

[0049] Specifically, at least 90% (or even 100%) of all (material bonding) connections are located at a distance of up to 20 mm, preferably up to 15 mm, and particularly preferably up to 10 mm from the (nearest) end face.

[0050] Specifically, each (material bond) connection extends along a direction parallel to the central axis for a maximum length of up to 10 mm, and more particularly up to 5 mm.

[0051] The present invention also proposes a method for producing a structured layer with a corrugated structure. The layer extends along its width between a first end face and a second end face, and laterally and longitudinally from the first end to the second end. The corrugated structure, as the main structure, has a large number of mutually parallel extending troughs and crests, each extending along its orientation with an angle of inclination greater than 0° and at most 15° relative to the width direction. Furthermore, the corrugated structure has at least one secondary structure comprising a reverse deformation of the main structure, wherein in each case the secondary structure extends along its orientation in the distance between the end faces by at most 20%. By means of reverse deformation, a trough becomes an intermediate crest, or a crest becomes an intermediate trough.

[0052] The method includes at least the following steps: a) Provide rolling mill equipment, which includes at least a first roll pair and a second roll pair; b) Feed the still unstructured layers to the rolling mill; c) The layers are reshaped by passing the unstructured layers through the first pair of rolls, forming an intermediate form of a corrugated structure; d) The layers are reshaped by passing the layers in the intermediate form through the second pair of rolls, and a corrugated structure is formed.

[0053] The above method steps are divided (not exhaustively) into a) through d) primarily for differentiation purposes and not intended to enforce any order and / or dependency. For example, the number of method steps may vary during the installation and / or operation of the rolling mill. Similarly, method steps may overlap at least partially in time. Specifically, steps a) through d) are performed in the stated order.

[0054] Rolling equipment is generally known; specifically, the rolls of a roll pair mesh with each other, thus structuring the layer as it passes through the roll pair.

[0055] In this case, at least two (but optionally more than two) remodeling stages are specifically proposed. This allows the provided structure (primary or secondary structure) to be reproducibly imprinted onto the corresponding layers.

[0056] Specifically, step a) of the method includes providing a rolling apparatus having at least two (preferably three or even four) roll pairs. Each roll pair includes at least or exactly two rolls that mesh with each other.

[0057] Specifically, step b) of the method includes feeding the still unstructured (in other words, smooth) layer into the rolling mill.

[0058] Specifically, step c) includes reshaping the layer by feeding the unstructured layer (according to step b) through the first pair of rolls. In this case, the layer is reshaped by the surfaces of the intermeshing rolls, and an intermediate form of the corrugated structure is imprinted onto the layer.

[0059] For example, within the scope of step c), only certain parts of the corrugated structure (e.g., only the main structure or only the secondary structure and / or parts thereof) and / or only partially shaped structures (e.g., with smaller amplitudes) can be produced.

[0060] Specifically, step d) involves reshaping the layer, which has an intermediate form, by passing it through a second pair of rolls to form a corrugated structure. Specifically, after step d), the layer is in a predetermined state; in other words, all primary and secondary structures have reached a fully formed state.

[0061] Specifically, several steps c) can be provided, wherein for each subsequent step c), the layer having the intermediate form (generated by the previous step c) is further reshaped. Step c) then forms the intermediate form stage, and step d) forms the final form stage of the continuous reshaping of the layers.

[0062] By employing a multi-stage reshaping process, the tilted corrugated layer can be progressively reshaped to the desired imprint geometry. The reshaping steps can occur directly and sequentially on the production line (where the layer passes through at least part of step c and step d simultaneously), using only different portions of the layer, or they can occur independently. As the number of reshaping steps increases, the layer imprinting increases sequentially, where, compared to a single-stage corrugation (without step c), only step d), in each partial step, the layer material can potentially "flow downstream" again in the belt running direction (in other words, the layer's transport direction, specifically longitudinally). Overall, this allows for a higher degree of layer reshaping.

[0063] Specifically, the geometric design of this layer (reshaping degree, rounded corner design, etc.) can also achieve greater freedom.

[0064] Specifically, for the proposed corrugated structure (with inclined extended channels), a continuous reshaping process (in other words, the layers pass through steps c and d) at least partially simultaneously) can be provided, thereby enabling a shorter processing cycle or a reduction in production costs.

[0065] Specifically, the maximum amplitude of the corrugated structure in the intermediate form (after one or the first step c) is at most 80%, especially at most 70%, and preferably at most 50% of the maximum amplitude of the corrugated structure in the structured layer (after step d).

[0066] The present invention also proposes a honeycomb structure having at least the aforementioned honeycomb structure and / or layers having a corrugated structure produced by the method. To form a honeycomb structure from which fluid can flow from the fluid inlet side to the fluid outlet side of the honeycomb structure, the first layer is arranged in a stack by folding itself or with at least one other structured layer. Alternatively, the honeycomb structure can be formed by additionally winding, twisting, or folding the stack. Several stacks can also be used for this purpose.

[0067] The structured layer (without secondary structure) and the honeycomb or cellular structure are generally known. Reference can be made to known embodiments of the layer and the honeycomb or cellular structure.

[0068] Specifically, this honeycomb structure is provided for exhaust gas aftertreatment. Please refer to the preceding description.

[0069] At least one layer may be arranged, for example, in a spiral manner around a central axis. Specifically, two layers or multiples thereof are used, wherein the paired layers may preferably have the same structure (type, size, etc.), but are formed by corrugated structures with different orientations, such that the troughs and crests of the contacting layers intersect.

[0070] The corrugated structure of the layer is preferably formed along its entire length, that is, between the first and second end faces. The corrugated structure is formed by convexities (crests) and concaveities (troughs). In this case, the crests and troughs alternate regularly in the extension direction of the layer. In the cross-section, the crests and troughs can form a sinusoidal corrugation, a sawtooth shape, etc.

[0071] The arrangement of the internal structure, or crests and troughs, within the honeycomb structure causes it to extend at an angle relative to the central axis. This forms a channel portion for fluid, specifically, which does not extend parallel to the central axis but rather at an angle to it. Therefore, if an exhaust gas or fluid flow impacts the end face of the honeycomb structure or the fluid inlet side of the honeycomb body perpendicularly, the exhaust gas / fluid is initially separated as it enters the channel openings formed by the crests and troughs, and subsequently deflects within the honeycomb body. The configuration of the structure is very specific, such that the crests and troughs in adjacent regions (viewed radially relative to the central axis) are tilted differently or have mutually offset orientations. For example, if a rightward deflection occurs in one region, a leftward deflection is preferably located in a further inward region, and vice versa. When viewed radially, it is particularly preferred that this alignment or orientation always alternates. Specifically, this causes the crests and troughs to be at least partially linearly positioned above each other and preferably not at points within the honeycomb body, but rather intersecting each other and thus forming only approximately point-like support points or contact areas between them. This causes a portion of the exhaust gas / fluid flow to be continuously deflected within the structure, and can specifically flow into adjacent crests or troughs in a sawtooth pattern.

[0072] This invention also proposes the application of honeycomb structures or layers in exhaust systems, such as motor vehicles or stationary installations, having an internal combustion engine with an exhaust system. The exhaust system has at least one catalyst carrier or particulate separator equipped with the honeycomb structure described herein. The catalyst carrier and / or particulate separator may have a catalytically active coating.

[0073] Specifically, the present invention provides at least one data processing system having means adapted, configured, or programmed for implementing methods for producing layers.

[0074] Specifically, the apparatus provided for implementing the method for producing cellular structures includes a data processing system (e.g., a control unit) having means for performing each step of the method and / or means adapted, configured, or programmed for performing each step of the method.

[0075] The device includes, for example, a processor and a memory (in which instructions to be executed by the processor are stored), and a data line or transmission device (supporting the transmission of instructions, measurements, data, etc. between the components).

[0076] Specifically, a “device” may include one or more of the following components: controller, microcontroller, data storage, data connection, display device (such as, for example, a display screen), counter or timing element (timer), at least one additional sensor, power supply, etc.

[0077] The present invention also provides a computer program, comprising, when executed by a computer, causing the computer to perform the method or the steps of the method.

[0078] The present invention also provides a computer-readable storage medium including instructions which, when executed by a computer, cause the computer to perform the method or steps thereof.

[0079] Specifically, the description of the method can be transferred to the cellular structure, cellular body, application, data processing system and / or computer-implemented method (in other words, computer program and computer-readable storage medium), and vice versa.

[0080] The use of the indefinite article ("a / an"), especially in the description of the claims and restatements, should be understood as meaning "this" rather than "a quantity." The corresponding term or component is therefore understood to exist at least once, and specifically, may exist multiple times.

[0081] It should be noted that the ordinal numbers used herein (“first,” “second,” etc.) are primarily (only) used to distinguish several similar objects, parameters, or processes, and therefore do not require specifying any dependencies and / or order between these objects, parameters, or processes. If dependencies and / or order are required, they will be explicitly stated in the text or will be readily apparent to those skilled in the art upon reading the specific configuration scheme described. For components that may appear multiple times (“at least one”), the description of one of these components may be equally applicable to all or some of these components; however, no mandatory limitation is imposed.

[0082] The invention and technical environment 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 exemplary embodiments mentioned. Specifically, it should be noted that the drawings shown, and particularly the aspect ratios, are merely illustrative. In the drawings: Figure 1 The details of the honeycomb structure formed by the layers are shown in a perspective view of a partial cross section; Figure 2 A view along the central axis of the cell shows the arrangement of cells according to... Figure 1 Details; Figure 3 It shows that it has the following characteristics: Figure 1 and Figure 2 An example of a layered honeycomb structure; Figure 4 The first layer is shown in perspective; Figure 5 The second layer is shown in perspective; Figure 6 The layer design variations are shown in perspective; Figure 7 The view along the direction shows the following according to Figures 4 to 6 The layer; Figure 8 The perspective view shows the results based on Figure 4 and Figure 5 The details of the honeycomb structure formed by the layers; and Figure 9 The method of producing layers using rolling equipment is shown in the side view.

[0083] Figure 1 The details of the honeycomb 34 formed by layers 8 and 20 are shown in a perspective view of a partial cross section. Figure 2 A view along the central axis 4 of the honeycomb 34 shows the arrangement of the cells according to the following diagram. Figure 1 Details. Figure 3 It shows that it has the following characteristics: Figure 1 and Figure 2 The honeycomb structure consists of layers 8 and 20. Figures 1 to 3 They will be described together below.

[0084] The honeycomb 34 has a honeycomb structure 1 that extends along a central axis 4 between a fluid inlet side 2 and a fluid outlet side 3. Channels 5 extend between the two sides 2 and 3, allowing fluid 6 to flow through the honeycomb structure 1. The honeycomb structure 1 includes a stack 7 formed by a first layer 8 and an additional second layer 20, each having a corrugated structure 9. Layers 8 and 20 extend along a width direction 12 parallel to the central axis 4 between a first end face 10 disposed on the fluid inlet side 2 and a second end face 11 disposed on the fluid outlet side 3, and along a longitudinal direction 23 transverse to the central axis 4 between a first end 24 and a second end 25 (see...). Figure 6 ).

[0085] The corrugated structure 9 of layers 8 and 20, as the main structure, has a large number of parallel extending troughs 13 and crests 14, each extending along the direction 16, with an inclination angle 15 relative to the width direction 12 greater than 0° and at most 15°. If these layers 8 and 20 are stacked one on top of the other, the angle between the contacting troughs 13 and crests 14 corresponds to the sum of the inclination angles 15 of each layer 8 and 20.

[0086] Layers 8 and 20 each have a material thickness in the height direction 31 extending laterally in the width direction 12 and longitudinally in the height direction 23.

[0087] Stacks 7 and channels 5 are formed by arranging another structured region of the same first layer 8 onto the first layer 8, or by arranging a structured second layer 20 onto the first layer 8. This region of the first layer 8 or the second layer 20 is structured such that the stacked troughs 13 and crests 14 intersect each other, thereby defining a contact area 21 between the contact surfaces 22 where the troughs 13 and crests 14 contact each other along the direction 15. For example, material bonding (brazing) connections 35 are formed in multiple contact areas 21, wherein brazing connections 35 are formed only in a predetermined subset of contact areas 21.

[0088] The honeycomb 34 has at least two strip-shaped layers 8 and 20 with corrugated structures 9. Figure 3 It is shown that at least partially or at least on the fluid inlet side 2 of the honeycomb 34, in each case a smooth layer without corrugated structure 9 is arranged between strip layers 8, 20 having corrugated structure 9.

[0089] To form a honeycomb structure 1 from which fluid 6 can flow from the fluid inlet side 2 to the fluid outlet side 3 of the honeycomb body 34, layers 8 and 20 are arranged by folding themselves or with at least one other (smooth and / or structured) layer to form a stack 7. Figure 3 In the process, a honeycomb structure 1 is formed by additionally winding and stacking 7.

[0090] The honeycomb cell 34 has a circular cross-section. The honeycomb cell 34 is equipped with a tubular shell 33. When used for exhaust gas aftertreatment, during the operation of the honeycomb cell 34, the exhaust gas / fluid 6 enters the honeycomb cell 34 regularly via the fluid inlet side 2 or via one of the end faces 10, 11, and exits via the fluid outlet side 3 or the other end face 11, 10. The end faces 10, 11, arranged parallel to each other (layers 8, 20 or honeycomb structure 1), regularly define the length of the honeycomb structure 1 in the direction of the central axis 4 of the honeycomb cell 34 (or the width of layers 8, 20), which passes through the two end faces 10, 11 and is arranged perpendicularly and centrally relative to the two end faces 10, 11.

[0091] The corrugated structure 9 of the main structure of layers 8 and 20 is formed along the entire length of the honeycomb body 34 or along the entire width of layers 8 and 20, in other words, between the first end face 10 and the second end face 11. The main structure of the corrugated structure 9 is formed by protrusions (crests 14) and depressions (troughs 13). In this case, the crests 14 and troughs 13 alternate regularly along the longitudinal direction 23 of layers 8 and 20. In cross-section, the crests 14 and troughs 13 form a sinusoidal corrugation. The arrangement of the corrugated structure 9 or the crests 14 and troughs 13 within the honeycomb body 34 causes it to extend obliquely relative to the central axis 4. This forms a channel portion for the fluid 6, which does not extend parallel to the central axis 4 but is oblique to it. Therefore, if the exhaust gas or fluid flow impacts the end faces 10 and 11 perpendicularly, the exhaust gas / fluid 6 is initially separated because it enters the channel opening formed by the crests 14 and troughs 13 and is then deflected inside the honeycomb body 34 or the honeycomb structure 1. The corrugated structure 9 causes the crests 14 and troughs 13 in adjacent regions (viewed radially 36 relative to the central axis 4) to be tilted differently or have mutually offset orientations. For example, if a rightward deflection occurs in one region, a leftward deflection is preferably located further inward in another region, and vice versa. This alignment or orientation always alternates when viewed radially 36. This causes the crests 14 and troughs 13 to be linearly positioned above each other not at the points of the cell 34 of the honeycomb structure 1, but rather to intersect each other and thus only roughly form point-like support points or contact areas 21 between them. This causes a portion of the exhaust gas / fluid 6 to be continuously deflected in the structure and can specifically flow into adjacent crests 14 or troughs 13 in a zigzag pattern.

[0092] The cross arrangement of the wavy structures 9 and wavy structures 9 in the cell 34 of layers 8 and 20 results in a reduction of the voids between the contacting layers 8 and 20, which are always present in large numbers and extend over a greater length when the troughs 13 and crests 14 are aligned in a straight line. This allows for a larger surface area to be provided at the same cell density in the cell 34 or cell structure 1, and reduces the accumulation of undesirable coatings (or other paints) in these voids.

[0093] Figure 4The first layer 8 is shown in perspective. Figure 5 The second layer 20 is shown in perspective. Figure 6 The design variants of layers 8 and 20 are shown in perspective. Figure 7 The view along direction 16 shows the following according to Figures 4 to 6 Layers 8 and 20. Figure 8 The perspective view shows the results based on Figure 4 and Figure 5 Details of the honeycomb structure 1 formed by layers 8 and 20. Figures 4 to 8 This will be described together below. Please refer to the section on... Figures 1 to 3 Explanation.

[0094] In each case, the corrugated structure 9 of layers 8 and 20 has a secondary structure, which includes a reverse deformation of the main structure. In each case, the extension of the secondary structure along the direction 16 at a distance 17 between end faces 10 and 11 accounts for at most 20%. By means of the reverse deformation, the trough 13 in the second layer 20 is transformed into an intermediate peak 18. Figure 5 ), and in the first layer 8, the peak 14 transforms into the intermediate trough 19 ( Figure 4 ).

[0095] according to Figure 6 Layers 8 and 20 have two types of secondary structures. In other words, the intermediate peaks 18 are arranged separately from the end faces 10 and 11, and the intermediate troughs 19 extend all the way to the first end face 10.

[0096] By structuring the second layer 20 ( Figure 5 Arranged on the first floor, 8 ( Figure 4 On top of this, stacks 7 and channels 5 or honeycomb structures 1 are formed. Figure 7 The second layer 20 is structured so that the superimposed troughs 13, crests 14, intermediate crests 18 and intermediate troughs 19 intersect each other, thereby defining the contact area 21 between troughs 13 and intermediate troughs 19 on the one hand and between crests 14 and intermediate crests 18 on the other hand along the direction 16.

[0097] according to Figures 4 to 8 The corrugated structure 9 of the middle layers 8 and 20 has an amplitude of 30 (in other words, the maximum range of the structured layers 8 and 20 in the height direction 31).

[0098] By means of reverse deformation of the secondary structure (forming a finite region of the main structure), a portion of the trough 13 is deformed into the intermediate peak 18 (second layer 20, see below). Figure 5 , Figure 6 Alternatively, a portion of the crest 14 can be deformed into the intermediate trough 19 (first layer 8, see below). Figure 4 , Figure 6 ).

[0099] The reverse deformation specifically involves a unique reshaping of the main structure (in other words, without the dividing cuts, not shown herein). The shape of the secondary structure (with inclined surfaces) thus successively transitions to the shape of the main structure along the orientation 16 of channel 5. This successive transition from the shape of the secondary structure to the shape of the main structure provides surfaces arranged at an incline relative to the fluid 6 flowing through the honeycomb structure 1 along orientation 16.

[0100] Alternatively, reverse deformation can be separated from the main structure by a partition cut (see...). Figures 4 to 8 The dividing cut extends only laterally to direction 16. Since the dividing cut is confined to a channel 5 along the longitudinal direction 23 in each case, the additional edge generated within the honeycomb structure 1 in each case can act on the fluid 6 flowing through the honeycomb structure 1.

[0101] Because of the dividing cuts, it is not necessary to form a sloping surface. For example, since the channel 5 is not at least partially closed by the sloping surface, the flow resistance of the honeycomb structure 1 to the fluid 6 flowing through the honeycomb structure 1 can be reduced.

[0102] Through each intermediate crest 18 or intermediate trough 19, in each case an additional contact area 21 (relative to the contact area 21 of the main structure) can be formed on the one hand between the trough 13 and the intermediate trough 19 and on the other hand between the crest 14 and the intermediate crest 18. This additional contact area 21 (similar to the contact area 21 formed by the main structure) is also defined along the direction 16.

[0103] Through the secondary structure, additional contact areas 21 can be provided in a targeted manner, in which brazing or welding connections 35 can be formed.

[0104] According to Figure 6 In layers 8 and 20, the secondary structures forming intermediate troughs 19 each extend to the first end face 10 of layers 8 and 20. This allows another contact area 21 to be formed or provided near or directly at the first end face 10. In this way, additional (material bonding) connections 35 can be specifically created in the region of the first end face 10 using existing bonding methods.

[0105] According to Figure 4 , Figure 5 and Figure 8 In layers 8 and 20, the secondary structures are spaced apart from the end faces 10 and 11, but are located near the first end face. This allows another contact area 21 to be formed or provided near the first end face 10. In this way, other (material bonding) connections 35 can be specifically created in the region of the first end face 10 using existing joining methods.

[0106] In a cross-section extending transversely to direction 16, the contact surface 22 of the secondary structure that forms contact area 21 with adjacent layers 8 and 20 is larger than the contact surface 22 of the main structure (see details). Figure 6 ).

[0107] The main structure includes sinusoidal corrugations in layers 8 and 20. For example, the sinusoidal corrugations have alternating maximum and minimum values ​​along the longitudinal direction 23, thereby forming an amplitude 30. The secondary structure, formed as a reverse deformation, forms flattened maximum or minimum values ​​of the corrugations (in other words, no longer point-like in the cross-section, but line-like along the longitudinal direction 23), so that the contact surface 22 formed by the line-like maximum or minimum values ​​is larger than the contact surface 22 of the main structure formed by the point-like maximum or minimum values.

[0108] exist Figures 4 to 8 In each trough 13 and each peak 14 of the middle layer 8 and 20, only one secondary structure is provided in each case.

[0109] In each case, the corresponding secondary structure is arranged in the same position relative to the width direction 12. In other words, for example, the secondary structure formed as the intermediate crest 18 is equidistant from the first end face 10 of the first layer 8 at a distance of 32.

[0110] According to Figure 6 On layers 8 and 20, multiple secondary structures spaced apart from each other along direction 16 and arranged in different channels 5 are provided. Thus, material bonding connections 35 between adjacent layers 8 and 20 can be generated or provided in a targeted manner at specific locations in the cellular structure 1.

[0111] According to Figure 6 In layers 8 and 20, a plurality of alternating intermediate peaks 18 and peaks 14 are provided in sequence along the longitudinal direction 23 extending laterally in the width direction 12, wherein a plurality of alternating intermediate valleys 19 and valleys 13 are provided in sequence along the longitudinal direction 23, offset from the width direction 12 (and / or direction 16).

[0112] Intermediate peaks 18 and intermediate troughs 19 are provided alternately along the longitudinal direction 23 and are arranged offset from each other and / or spaced apart along the width direction 12 and / or direction 16.

[0113] According to Figure 4 , Figure 5 and Figure 8 In layers 8 and 20, the secondary structures of the honeycomb structure 1 (intermediate peaks 18 and intermediate troughs 19) are arranged at a small distance 32 from the corresponding nearest (here, the first) end face 10.

[0114] According to Figure 7 In layers 8 and 20, approximately 50% of the secondary structure (i.e., only the middle trough 19) extends all the way to the first end face 10.

[0115] Figure 9 A side view illustrates a method for producing layers using rolling mill equipment. See also: [link to relevant information] Figures 1 to 8 Explanation.

[0116] Layer 8 extends along the width direction 12 between the first end face 10 and the second end face 11, and laterally along the longitudinal direction 23 from the first end 24 to the second end 25. The corrugated structure 9, as the main structure, has a large number of mutually parallel extending troughs 13 and crests 14, each extending along a direction 16, with an inclination angle 15 relative to the width direction 12 greater than 0° and at most 15°. Furthermore, the corrugated structure 9 has a secondary structure comprising reverse deformations of the main structure. By means of reverse deformation, a trough 13 becomes an intermediate crest 18, or a crest 14 becomes an intermediate trough 19.

[0117] Step a) of the method includes providing a rolling mill 26 having at least two pairs of rolls 27, 28. Each pair of rolls 27, 28 includes two rolls that mesh with each other.

[0118] Step b) of the method includes feeding the still unstructured (in other words, smooth) layer 8 to the rolling mill 26 (in other words, from right to left in Figure 96).

[0119] Step c) involves reshaping layer 8 by feeding the unstructured layer 8 (according to step b) through the first pair of rolls 27. In this case, layer 8 is reshaped by the surfaces of the intermeshing rolls, and the intermediate form 29 of the corrugated structure 9 is imprinted onto layer 8.

[0120] For example, within the scope of step c), only certain parts of the corrugated structure 9 (e.g., only the main structure or only the secondary structure and / or parts thereof) and / or only partially shaped structures (e.g., with smaller amplitude 30, etc.) can be produced.

[0121] Step d) involves reshaping the layer 8, which has an intermediate form 29, by passing it through the second roll pair 28 to form a corrugated structure 9. After step d), the layer 8 is in a predetermined state, in other words, all the primary and secondary structures have reached a fully formed state.

[0122] Several steps c) (in other words, several pairs of second rolls 28) may be provided, wherein for each subsequent step c), layer 8 having the intermediate form 29 (generated by the previous step c) is further reshaped. Step c) then forms the intermediate form stage, and step d) forms the final form stage of the continuously reshaped layer 8.

[0123] By employing a multi-stage reshaping process, the inclined corrugated layer 8 can be progressively reshaped to the desired imprint geometry. As shown in the figure, the reshaping steps can occur directly and sequentially on the production line (where layer 8 passes through steps c and d at least partially simultaneously), using only different portions of the layer. As the number of reshaping steps increases, the imprinting of layer 8 increases successively, where, compared to a single-stage corrugation (without step c), only step d), in each partial step, the material of layer 8 can potentially "flow downstream" again in the belt running direction (in other words, the conveying direction of layer 8, here in the longitudinal direction 23). Overall, this allows for a higher degree of reshaping of layer 8.

[0124] The maximum amplitude 30 of the corrugated structure 9 in intermediate form 29 (after step c) is at most 50% of the maximum amplitude 30 of the corrugated structure 9 after the structured layer 8 in step d).

[0125] List of reference numerals in the attached diagram: 1. Honeycomb structure 2. Fluid inlet side 3. Fluid outlet side 4. Central axis 5 channels 6. Fluid 7. Stacking 8 First layer 9. Corrugated structure 10 First end face 11 Second end face 12 Width direction 13 troughs 14 peaks 15° tilt angle 16. Heading Towards 17 Distance 18 Intermediate peak 19. Mid-trough 20 Second Floor 21 Contact Area 22 Contact Surface 23 Vertical 24 First End 25 Second End 26 Rolling equipment 27 First Roll Pair 28 Second Roll Pair 29 Intermediate Form 30 Amplitude 31. Height direction 32 Distance 33. Shell 34 honeycomb structure 35 connections 36 Radial

Claims

1. A honeycomb structure (1) extending along a central axis (4) between a fluid inlet side (2) and a fluid outlet side (3), wherein a channel (5) extends between the two sides (2, 3) to allow fluid (6) to flow through the honeycomb structure (1); wherein the honeycomb structure (1) comprises at least one stack (7) formed by at least a first layer (8) having a corrugated structure (9), wherein the first layer (8) is in a width direction (12) parallel to the central axis (4). Extending between a first end face (10) arranged on the fluid inlet side (2) and a second end face (11) arranged on the fluid outlet side (3); wherein the corrugated structure (9) of the first layer (8) serves as the main structure, having a large number of mutually parallel extending troughs (13) and crests (14), each extending along a direction (16), with an inclination angle (15) relative to the width direction (12) greater than 0° and at most 15°; wherein the corrugated structure (9) has at least one secondary structure, the secondary structure The structure includes a reverse deformation of the main structure, in each case the secondary structure extends at most 20% along the direction (16) over the distance (17) between the end faces (10, 11), wherein, by means of the reverse deformation, a trough (13) is transformed into an intermediate peak (18), or a peak (14) is transformed into an intermediate trough (19); wherein another structured region of the same first layer (8) is arranged on the first layer (8), or a structured second layer (20) is arranged on the first layer (8). On the stack (7) and the channel (5), wherein the region of the first layer (8) or the second layer (20) is structured such that the stacked troughs (13), crests (14), intermediate crests (18) and intermediate troughs (19) intersect each other, thereby defining the contact area (21) between the troughs (13) and the intermediate troughs (19) on the one hand and between the crests (14) and the intermediate crests (18) on the other hand along the direction (16).

2. The honeycomb structure (1) according to claim 1, wherein the at least one secondary structure extends to one of the end faces (10, 11).

3. The honeycomb structure (1) according to any of the preceding claims, wherein in a cross section extending transversely to the direction (16), the secondary structure is adapted to have a contact surface (22) that forms the contact area (21) with the adjacent layers (8, 20) that is larger than the contact surface (22) of the main structure.

4. The cellular structure (1) according to any of the preceding claims, wherein in each trough (13) and / or each peak (14) of the first layer (8), a secondary structure is provided in each case.

5. The cellular structure (1) according to any of the preceding claims, wherein a plurality of secondary structures spaced apart from each other along the orientation (16) are provided on the first layer (8).

6. The honeycomb structure (1) according to any of the preceding claims, wherein on the first layer (8), a plurality of alternating intermediate peaks (18) and peaks (14) are provided in sequence along a longitudinal direction (23) extending transversely to the width direction (12), wherein a plurality of alternating intermediate valleys (19) and valleys (13) are provided in sequence along the longitudinal direction (23) offset from the width direction (12).

7. The honeycomb structure (1) according to claim 6, wherein the intermediate peaks (18) and intermediate troughs (19) are provided alternately along the longitudinal direction (23).

8. The honeycomb structure (1) according to any one of claims 6 and 7, wherein the intermediate peaks (18) and intermediate troughs (19) are arranged spaced apart from each other along the direction (16).

9. A method for producing a structured layer (8, 20) having a corrugated structure (9), wherein the layer (8, 20) extends along a width direction (12) between a first end face (10) and a second end face (11), and extends laterally along a longitudinal direction (23) from the first end (24) to the second end (25); wherein the corrugated structure (9) as a main structure has a large number of mutually parallel troughs (13) and crests (14), each extending along a direction (16) inclined relative to the width direction (12). Angle (15) is greater than 0° and at most 15°; wherein the corrugated structure (9) has at least one secondary structure comprising a reverse deformation of the main structure, wherein in each case the secondary structure extends at most 20% along the direction (16) over the distance (17) between the end faces (10, 11), wherein the reverse deformation transforms a trough (13) into an intermediate crest (18), or a crest (14) into an intermediate trough (19); wherein the method comprises at least the following steps: a) Provide rolling equipment (26), said rolling equipment (26) including at least a first roll pair (27) and a second roll pair (28); b) Feed the still unstructured layers (8, 20) to the rolling mill (26); c) The layers (8, 20) are reshaped by passing the unstructured layers (8, 20) through the first pair of rolls (27) to form an intermediate form (29) of the corrugated structure (9). d) The layers (8, 20) having the intermediate form (29) are reshaped by passing them through the second pair of rolls (28) to form the corrugated structure (9).

10. The method according to claim 9, wherein the maximum amplitude (30) of the corrugated structure (9) of the intermediate form (29) is at most 80% of the maximum amplitude (30) of the corrugated structure (9) of the structured layer (8, 20).

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