Method for producing a corrugated structure on a band-shaped layer

Abstract

The invention relates to a method for producing a corrugated structure (1) on a band-shaped layer (2), wherein the layer (2) extends along an extension direction (3) between a first end (4) and a second end (5) and transversely thereto along a width direction (6) between a first end face (7) and a second end face (8), wherein the corrugated structure (1) of the structured layer (2) having the corrugated structure (1) has a plurality of first wave troughs (9) and first wave crests (10) running parallel to one another, which each extend at a first angle of inclination (11) with respect to the width direction (6) of greater than zero angular degrees and at most 15 angular degrees.

Description

The present invention relates to a method for producing a corrugated structure on a strip-shaped layer. The invention further relates to a layer produced by the method and to a honeycomb body having the layer produced in this way.The layer having a corrugated structure is used, for example (but optionally not exclusively) in a honeycomb body for exhaust gas aftertreatment, as is used in particular as a catalyst support body in exhaust systems of mobile internal combustion engines. Such a honeycomb body provides in particular a large surface area on which catalytically active material is positioned and brought into contact with the exhaust gas flowing through the honeycomb body. The invention is used in particular in exhaust gas cleaning in motor vehicles or also in stationary or other mobile installations.A large number of different configurations of honeycomb bodies for exhaust gas aftertreatment have already been proposed. In principle, a distinction is made between honeycomb bodies made of ceramic and metal (steel or also non-ferrous material). However, honeycomb bodies can also be produced from plastic materials.A honeycomb body can be constructed with smooth and / or structured layers or sheet metal foils. These layers can be layered, wound and / or wound and finally placed in a housing of the honeycomb body, so that a plurality of channels through which the exhaust gas can flow are formed. The channels can extend, for example, in a straight line, in a twisted manner and / or obliquely between the end faces of such a honeycomb body.With the aim of the most intimate possible contact of the exhaust gas with the walls of the honeycomb body or the catalytic coating placed there, measures have already been proposed which reduce a laminar flow of the exhaust gas through the honeycomb body. For example, it is possible to use a switch. In this case, openings may be provided in the channel walls, so that channels which communicate with one another are formed. It is likewise known to provide deflecting structures, guide vanes, etc. in the channels in order to achieve a specific flow deflection in the channels, pressure differences between the channels, or the like.DE 10 2012 004 918 A1 discloses a honeycomb body in which the structured layers have a corrugated structure, layers arranged adjacent to one another having intersecting corrugated structures. To produce structured layers of this type, an even unstructured (i.e. in particular smooth or planar) layer is fed to a rolling device. The rolling device comprises two rolls which have axes of rotation running parallel to one another and each have a surface structure producing the corrugated structure, wherein the surface structures mesh with one another in order to produce the corrugated structure. For this purpose, the surface structures each have a plurality of second wave valleys and second wave ridges running parallel to one another, which extend parallel to each axis of rotation. The layer is supplied to the rolling device at an angle, so that the corrugated structure impressed on the layer extends obliquely to a direction of extension of the layer.In this method, therefore, straight toothed corrugating rollers are used, the still smooth (endless) layer being fed to the corrugating rollers in a non-rectangular manner. The angle by which the position is adjusted relative to a perpendicular line imaginary to the axes of rotation of the corrugation rollers is dependent on the required angle of inclination of the corrugation structure on the structured layer (for example. 3 angle degree feed angle / inclination angle generates approximately 5 angle degree inclination angle of the corrugated structure on the structured layer). Due to the non-orthogonal feeding and the resulting transverse forces, the layer travels along the axes of rotation of the corrugating rollers. Depending on the skew angle on the feeding side of the rolling device, the width of the sheet and the width of the corrugating rolls, a limited length of the sheet in its direction of extension results, after which an interruption of the corrugating process is required, since otherwise the sheet will migrate out of the rolling device. A known solution is a so-called corrugating rack device which, similar to the typewriter principle, enables the corrugating rollers to be spaced apart and subsequently a transverse feed of the layer, whereby the layer is displaced relative to the corrugating rollers along the axes of rotation into its initial position. The method for producing the corrugated structure is therefore discontinuous, because the feed of the layer relative to the rolling device must be interrupted in order to displace the layer.Especially in automobile construction, further requirements are placed on such a honeycomb body or its production. Thus, in particular, the focus is to design the production as cost-effective and simple as possible.The object of the present invention is to at least partially solve the problems mentioned with respect to the prior art. In particular, the method for producing a corrugated structure should be simplified further or should be carried out as continuously as possible.To achieve these objects, a method with the features according to claim 1 contributes. Advantageous further developments are the subject of the dependent patent claims. The features individually listed in the patent claims can be combined with one another in a technically expedient manner and can be supplemented by explanatory facts from the description and / or details from the figures, wherein further embodiment variants of the invention are shown.A method for producing a corrugated structure in a strip-shaped layer is proposed, wherein the layer extends along an extension direction between a first end and a second end and transversely thereto along a width direction between a first end side and a second end side.The method comprises at least the following steps: a) providing a rolling device having at least two rolls which have axes of rotation running parallel to one another and each have a surface structure which produces the corrugated structure, wherein the surface structures mesh with one another to produce the corrugated structure; wherein the surface structures each have a multiplicity of second corrugation valleys and second corrugation ridges which run parallel to one another and each extend at a second angle of inclination with respect to each axis of rotation of greater than zero angle degree and at most 15 angle degree; b) supplying the strip-shaped (still unstructured) layer to the rolling device at an inclination angle which extends between the direction of extension and a first direction running orthogonally to the axes of rotation, wherein the inclination angle is greater than zero angle degree; c) creating a corrugated structure in the layer by passing the layer through the intermeshing surface structures of the rolls and producing the structured layer, in which the corrugated structure has a plurality of mutually parallel first corrugation valleys and first corrugation ridges, each of which extends at a first angle of inclination with respect to the width direction of greater than zero angle degree and at most 15 angle degree.In particular, the layer is a continuous material which is cut to length after step c), i.e. after the corrugated structure has been produced, to a predetermined length extending along the direction of extent.In particular, the layer is rectangular, in particular as a smooth layer (i.e. before the production of the well structure) and also as a structured layer (i.e. after the production of the well structure). The end sides extend parallel to the direction of extension, the edges of the layer present at the ends extending transversely thereto.In particular, the entire layer is structured after passing through step c), i.e. has the corrugated structure (i.e. in particular no smooth / unstructured regions) over the entire extent in the width direction and in the extension direction.In particular, the extent of the layer in the width direction is between 5 and 1,000 millimeters, preferably less than 200 millimeters.In particular, a material thickness of the (smooth) layer (in a height direction extending transversely to the width and extension direction) is between 20 μm and 2 millimeters, in particular at most 1.0 or even at most 0.5 millimeters.In particular, the corrugated structure has an amplitude (i.e. a maximum extent of the structured layer in the height direction) of between 0.5 and 10 millimeters, in particular of at most 5 millimeters.In particular, the first and / or second wave valleys and first and / or second wave ridges each extend at a first or second angle of inclination relative to the width direction of greater than an angle degree, preferably greater than 2 or even 3 angle degrees. In particular, the first angle of inclination is at most 15 degrees of angle, preferably at most 12, at most 10 or even at most 8 degrees of angle.The above (non-final) classification of the method steps in a) to c) is primarily intended only for differentiation purposes and does not force any sequence and / or dependency. The frequency of the method steps, for example during the setting up and / or operation of the rolling device, can also vary. It is likewise possible for method steps to overlap one another at least partially in terms of time. Very particular preference is given to process steps b) and c) following step a). In particular, steps b) and c) take place in parallel over time. In particular, steps a) to c) are carried out in the sequence mentioned and are superimposed in this case.In particular, the structured layer is led out of the rolling device immediately after it exits from the mutually intermeshing surface structures (substantially) parallel to the first direction (that is to say orthogonally to the axes of rotation).In particular, during step c) there is just no displacement of the layer in the direction along the axes of rotation, so that continuous feeding of the layer can take place in step b). Thus, just no interruption of steps c) and b) is required in order to return the layer to a starting position with respect to the rolling device (see explanations in the introduction).This process advantage is made possible in particular by the use of helical corrugated rolls combined with a defined oblique position of the still unstructured layers on the feed side of the rolling device. A lateral movement of the layer along the surface structure of the corrugated rollers in the direction along the axes of rotation is thus prevented. Thus, a continuous corrugation process can be realized with the otherwise usual corrugation speed or feed speed of the layer (i.e. comparable to non-helical corrugation structures of known layers).In particular, the inclination angle corresponds approximately to at least the first inclination angle and / or the second inclination angle. In particular, the inclination angle is between 80 and 120%, in particular between 90 and 110%, preferably between 95 and 105%, particularly preferably between 98 and 102%, of the first inclination angle and / or of the second inclination angle. This applies in particular to inclination angles which have a constant value along the width direction of the layer or along the axes of rotation of the corrugating rollers.In particular, the first angle of inclination varies along a course of the corrugated structure between the end sides (i.e. along the width direction of the layer or along the course of the first corrugation valleys and first corrugation ridges). In particular, the same applies to the second inclination angles.In particular, a first angle of inclination at a first end face of the structured layer amounts to a specific first value (between greater than zero and 15 degrees of angle). In particular, a first angle of inclination at a second end face of the structured layer amounts to a second value which differs from the first value (and in this case is in particular likewise between greater than zero and 15 degrees of angle). In particular, the difference between the first value and the second value is greater than zero angular degrees, in particular between one and less than 15 angular degrees, preferably between one and 10 angular degrees.In particular, the difference starting from the first end face and toward the second end face becomes exclusively larger or exclusively smaller. Alternatively, the difference starting from the first end face and toward the second end face first becomes greater and then smaller again, optionally also repeated several times, so that the course of the first wave valleys and first wave ridges is S-shaped or meandering. In particular, the first inclination angles at the mutually opposite end sides are of the same size or different from one another.In particular, at least one of the (preferably both) corrugated rollers is segmented, so that at least two sections of the corrugated structure arranged adjacent to one another along the width direction are produced by different segments of the one corrugated roller. Thus, in particular segments of the corrugated roller with different loads can be exchanged at different intervals, so that costs for tools and maintenance can be reduced.In particular, the layer consists of a steel material, a non-ferrous material or a plastic material.In particular, the layer is a continuous material on which the corrugated structure is produced continuously (i.e. with uninterrupted feeding of the layer to the roll device or uninterrupted production of the corrugated structure).In particular, the corrugated structure produced by step c) between the end sides is produced with a maximum tolerance of 0.2 millimeters, preferably of 0.1 millimeters, particularly preferably of 0.05 millimeters or even of 0.005 millimeters, with respect to a height direction running transversely to the direction of extent and to the width direction. The tolerance denotes the greatest deviation on the component (i.e. the structured layer) from a predetermined value (nominal value) with respect to the height direction, i.e. the manufacturing accuracy of the layer, at least with respect to the height direction.A strip-shaped layer having a corrugated structure is also proposed, wherein the layer extends along an extension direction between a first end and a second end and transversely thereto along a width direction between a first end side and a second end side. The corrugated structure of the layer has a plurality of first corrugation valleys and first corrugation ridges running parallel to one another, which respectively extend at a first angle of inclination with respect to the width direction of greater than zero angle degree and at most 15 angle degree. The corrugated structure has been produced (has been) by the method described according to one of the preceding patent claims.In particular, no irregularities are visible on the strip-shaped layer, because the layer can now be produced in a continuous process. In the previously known production methods of such helical layers, markings were hitherto recognizable on the layer which were attributable to the settling of the corrugating rollers from the layer and to the not exactly possible displacement of the layer.Furthermore, a honeycomb body is proposed, at least having the described strip-shaped layer with a corrugated structure. In order to form a honeycomb structure through which a fluid can flow from the first end face to the second end face (or vice versa) of the honeycomb body, the layer is arranged with itself by folds or with at least one other (smooth and / or structured) layer to form a stack. Optionally, the honeycomb structure is formed by additionally winding, twisting or folding the stack. Several stacks can also be used for this purpose.The described position and the honeycomb body are fundamentally known. In this regard, reference is made to the known designs of layers and honeycomb bodies.The honeycomb body is provided in particular for exhaust gas aftertreatment. Reference is made to the statements in the introduction.The honeycomb body can in principle have various shapes, for example in particular a round, oval, polygonal or similar cross section. In many cases, such a honeycomb body is formed with a tube-like housing. In an application for exhaust gas aftertreatment, an exhaust gas / fluid enters regularly during operation of the honeycomb body via one of the two end sides and exits again via the other end side. The end faces which are preferably arranged substantially parallel or else inclined with respect to one another regularly define the length of the honeycomb body in the direction of a central axis of the honeycomb body, which central axis penetrates both end faces and is arranged in particular perpendicularly and centrally with respect to at least one, preferably both end faces.The honeycomb body also has at least one of the described at least partially structured layers. It is possible here for a (single) layer to have smooth and structured sections or sections with different structuring. This at least one layer can be arranged, for example, in the manner of a spiral around a central axis. It is also possible for a plurality of layers to be used, wherein, for example, a part of the layers are smooth and / or structured differently than at least one further layer. In particular, two layers or a multiple thereof are used, wherein a layer pair has the same structure (type, size, etc.), but these are formed with a different orientation of the corrugated structure, such that the corrugation valleys and corrugation ridges of the layers contacting one another cross.The corrugated structure of the layer is preferably formed over the entire length, i.e. between the first end face and the second end face. The corrugated structure is formed by elevations (wave crests) and depressions (wave troughs) which have been impressed into the layer by the corrugated rollers. In this case, wave crests and wave troughs regularly alternate in the direction of extent of the layer. The wave crests and wave troughs can form a kind of sinusoidal wave, zigzag shape or the like in cross section. The arrangement of the structure or wave crests and wave troughs in the honeycomb body is now effected in such a way that they extend obliquely to the central axis. In this way, in particular channel sections for a fluid are formed which do not run parallel to the center axis but obliquely thereto. If an exhaust gas flow or a fluid flow impinges perpendicularly on an end face, the exhaust gas / fluid is first divided because it penetrates into the duct openings formed by the wave crests and wave troughs and is then deflected in the interior of the honeycomb body. In this case, the structure is very particularly formed in such a way that the wave crests and wave troughs in adjacent regions (as viewed in the radial direction with respect to the central axis) are inclined differently or have an orientation which differs from one another. If, for example, a deflection to the right takes place in one region, it is preferred that a deflection to the left takes place in the region lying further inward or vice versa. It is very particularly preferred that this alignment or orientation, viewed in the radial direction, always alternates. This has the result, in particular, that the wave crests and wave troughs lie at least partially on one another, and preferably at no point on the honeycomb body, linearly on one another, but rather cross one another and thus essentially only form punctiform bearing points with one another. This results in a structure in which the partial streams of the exhaust gas / fluid are permanently deflected and can flow into adjacent wave crests or wave troughs, in particular in the manner of a zigzag.Furthermore, the use of the honeycomb body or the layer in an exhaust system is proposed, e.g. of a motor vehicle or a stationary system which has an internal combustion engine with an exhaust system. The exhaust system has at least one catalyst carrier or a particle separator which is designed with a honeycomb body described here. The catalyst support and / or the particle separator may have a catalytically active coating.The corrugated structure of the layer and the intersecting arrangement of the corrugated structures in the honeycomb body have the result, in particular, that the coils between the layers contacting one another, which coils are always present in multiple cases in the case of a straight alignment of the corrugation valleys and corrugation ridges and in the process extend over a large length, with the result that, at the same cell density of the honeycomb body, a larger surface area can be provided and undesired accumulations of washcoat (or of another coating) in these coils can be reduced.In particular, at least one system for data processing is provided, which has means which are suitably equipped, configured or programmed for carrying out the method or which execute the method.In particular, the rolling device or the device provided for carrying out the method comprises a system for data processing, e.g. a control unit, which has means for carrying out the steps of the method and / or which has means which are suitably equipped, configured or programmed for carrying out the steps of the method or which carry out the method.The means comprise, for example, a processor and a memory in which instructions to be executed by the processor are stored, and data lines or transmission devices which enable commands, measured values, data or the like to be transmitted between the elements mentioned.The "means" can comprise in particular one or more of the following components: controller(s), microcontrollers, data memories, data connections, display devices (such as a display), counters or timer (timer), at least one further sensor, an energy source, etc.A computer program is also proposed, comprising instructions which, when the computer program is executed by a computer, cause the computer program to execute the described method or the steps of the described method.A computer-readable storage medium is also proposed, comprising instructions which, when executed by a computer, cause the computer to execute the described method or the steps of the described method.The embodiments of the method are in particular capable of transferring the honeycomb body, the use, the system for data processing and / or the computer-implemented method (i.e. the computer program and the computer-readable storage medium) and vice versa.The use of indefinite articles ("a", "an", and "an"), in particular in the claims and the description reflecting them, is to be understood as such and not as a numerical word. Terms or components introduced therewith are thus to be understood such that they are present at least once and in particular can also be present multiple times.As a precautionary measure, it should be noted that the numerical words used here ("first", "second",... ) are primarily (only) used for distinguishing a plurality of articles, sizes or processes of the same type, that is to say in particular do not necessarily specify a dependence and / or sequence of these articles, sizes or processes with respect to one another. If a dependence and / or sequence is required, this is explicitly stated here or it is obvious to the person skilled in the art when studying the specifically described configuration. If a component can occur multiple times ("at least one"), the description of one of these components can apply equally to all or a part of the plurality of these components, but this is not obligatory.The invention and the technical field are explained in more detail below with reference to the attached figures. It should be noted that the invention is not intended to be limited by the exemplary embodiments listed. In particular, it should be pointed out that the figures and in particular the size relationships illustrated are only schematic. The following are shown: FIG. 1 : a detail of a honeycomb body formed by the layers in a perspective view, partly in section; FIG. 2 : the detail according to FIG. 1 in a view along a central axis of the honeycomb body; FIG. 3 : shows a honeycomb body with the layers according to FIGS. 1 and 2 ; FIG. 4 shows a known method for producing a well structure in a first state; FIG. 5 : the method according to FIG. 4 in a second state; FIG. 6 : shows a method for producing a corrugated structure according to a first embodiment variant; FIG. 7 : shows a method for producing a corrugated structure according to a second variant embodiment; FIG. 8 : shows a perspective view of a first or second roller according to a first embodiment variant; and FIG. 9 : shows a perspective view of a first or second roller according to a second embodiment variant.FIG. 1 shows a detail of a honeycomb body 27 formed by the layers 2 in a perspective view, partly in section. FIG. 2 shows the detail according to FIG. 1 in a view along a central axis 30 of the honeycomb body 27. FIG. 3 shows a honeycomb body 27 with the layers 2 according to FIGS. 1 and 2.The layers 2 of the honeycomb structure 29 forming the honeycomb body 27 each extend along an extension direction 3 between a first end 4 and a second end 5 and transversely thereto along a width direction 6 between a first end side 7 and a second end side 8 of the layer. The corrugated structure 1 of the layers 2 has a plurality of first corrugation valleys 9 and first corrugation ridges 10 which run parallel to one another and each extend at a first angle of inclination 11 with respect to the width direction 6 of greater than zero angle degree and at most 15 angle degree.The honeycomb body 27 has at least one strip-shaped layer 2 having a corrugated structure 1. FIG. 3 shows that a smooth layer 2 without a corrugated structure 1 is arranged between the strip-shaped layers 2 with corrugated structure 1.In order to form a honeycomb structure 29 through which a fluid 32 can flow from the first end face 7 to the second end face 8 of the honeycomb body 27, the layer 2 is arranged with itself by folds or with at least one other (smooth and / or structured) layer 2 to form a stack 28. In FIG. 3, the honeycomb structure 29 is formed by additionally winding the stack 28.The honeycomb body 27 has a round cross section. The honeycomb body 27 is formed with a tube-like housing. When used for exhaust gas after-treatment, an exhaust gas / fluid 32 enters regularly during operation of the honeycomb body 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 one another (of the layers 2 or of the honeycomb structure 29 or of the honeycomb body 27) regularly define the length of the honeycomb body 27 (or the width of the layer 2) in the direction of a central axis 30 of the honeycomb body 27, which passes through both end faces 7, 8 and is arranged perpendicularly and centrally with respect to both end faces 7, 8.The corrugated structure 1 of the layers 2 is formed over the entire length of the honeycomb body 27 or over the entire width of the layer 2, i.e. between the first end face 7 and the second end face 8. The corrugated structure 1 is formed by elevations (corrugation ridges 10) and depressions (corrugation valleys 9) which have been impressed into the layer 2 by the corrugated rollers 13, 14 (see FIGS. 6 and 7 ). Wave crests 10 and wave troughs 9 regularly alternate in the direction of extension 3 of the layer 2. The wave crests 10 and wave troughs 9 form a kind of sinusoidal wave in cross section. The arrangement of the corrugated structure 1 or the corrugation crests 10 and corrugation troughs 9 in the honeycomb body 27 is effected such that they run obliquely to the central axis 30. Channel sections for a fluid 32 are thus formed, which do not run parallel to the center axis 30, but obliquely thereto. If an exhaust gas flow or a fluid flow impinges perpendicularly on an end face 7, 8, the exhaust gas / fluid 32 is first divided because it penetrates into the duct openings formed by the wave crests 10 and wave troughs 9 and is then deflected in the interior of the honeycomb body 27. The corrugated structure 1 is such that the wave crests 10 and wave troughs 9 in adjacent regions (viewed in the radial direction 33 with respect to the center axis 30) are inclined differently or have an orientation that differs from one another. If, for example, a deflection to the right takes place in one region, it is preferred that a deflection to the left takes place in the region lying further inward or vice versa. This orientation or orientation always changes when viewed in the radial direction 33. This has the result that the wave crests 10 and wave troughs 9 do not lie linearly on one another at any point of the honeycomb body 27 of the honeycomb structure 29, but rather cross one another and thus essentially only form punctiform bearing points with one another. This results in a structure in which the partial streams of the exhaust gas / fluid 32 are permanently deflected and can flow into adjacent wave crests 10 or wave troughs 9, in particular in the manner of a zigzag.The corrugated structure 1 of the layer 2 and the intersecting arrangement of the corrugated structures 1 in the honeycomb body 27 have the result that the coils 31 between the layers 2 contacting one another, which coils are present in multiple cases in the case of a straight alignment of the corrugation valleys 9 and corrugation ridges 10 and extend over a large length, are always reduced, with the result that, with the same cell density of the honeycomb body 27 or of the honeycomb structure 29, a larger surface area is provided and undesired accumulations of washcoat (or of another coating) in these coils 31 can be reduced.FIG. 4 shows a known method for producing a well structure 1 in a first state. FIG. 5 shows the method according to FIG. 4 in a second state. FIGS. 4 and 5 are described together below. Reference is made to the embodiments of FIGS. 1 to 3.DE 10 2012 004 918 A1 discloses a honeycomb body 27 in which the structured layers 2 have a corrugated structure 1, layers 2 arranged adjacent to one another having intersecting corrugated structures 1. To produce structured layers 2 of this type, an still unstructured (i.e. in particular smooth or planar) layer 2 is fed to a rolling device 12. The rolling device 12 comprises two rolls 13, 14 which have axes of rotation 15 running parallel to one another and in each case a surface structure 16 which produces the corrugated structure 1, wherein the surface structures 16 mesh with one another in order to produce the corrugated structure 1. For this purpose, the surface structures 16 each have a plurality of second wave valleys 17 running parallel to one another and second wave ridges 18 which extend parallel to each axis of rotation 15. The layer 2 is supplied to the rolling device 12 at an inclination angle 21 so that the corrugated structure 1 impressed on the layer 2 extends obliquely to an extension direction 3 of the layer 2.In this method, therefore, straight toothed corrugating rollers 13, 14 are used, the still smooth (endless) layer 2 being fed to the corrugating rollers 13, 14 in a non-rectangular manner. The inclination angle 21, by which the layer 2 is adjusted relative to a perpendicular line (first direction 20) imaginary to the axes of rotation 15 of the corrugating rollers 13, 14, is dependent on the required first inclination angle 11 of the corrugated structure 1 on the structured layer 2 (for example. 3 angle degree of feed angle / inclination angle 21 generates approximately 5 angle degree of the first inclination angle 11 of the corrugated structure 1 on the structured layer 2). Due to the non-orthogonal feeding and the transverse forces resulting therefrom, the layer 2 travels along the axes of rotation 15 of the corrugating rollers 13, 14 (see first state in FIG. 4 and second state in FIG. 5 ). Depending on the skew angle 21 on the feed side of the rolling device 12, the width of the layer 2 and the width of the corrugating rolls 13, 14, a limited length of the layer 2 in its extension direction 3 results, after which an interruption of the corrugating process is necessary, since otherwise the layer 2 moves out of the rolling device 12. A known solution is a so-called corrugating rack device which, similar to the typewriter principle, enables the corrugating rollers 13, 14 to be spaced apart and subsequently the layer 2 to be transversely advanced, whereby the layer 2 is displaced relative to the corrugating rollers 13, 14 along the axes of rotation 15 into its initial position (FIG. 4 ). The method for producing the corrugated structure 1 is therefore discontinuous, because the feed of the layer 2 relative to the rolling device 12 must be interrupted in order to displace the layer 2.FIG. 6 shows a method for producing a corrugated structure 1 according to a first embodiment variant. Reference is made to the embodiments of FIGS. 1 to 5.According to step a) of the method, a rolling device 12 is provided having two rolls 13, 14 which have axes of rotation 15 running parallel to one another and each have a surface structure 16 which produces the corrugated structure 1, wherein the surface structures 16 mesh with one another in order to produce the corrugated structure 1. The surface structures 16 each have a plurality of second wave valleys 17 and second wave ridges 18 running parallel to one another, which respectively extend at a second angle of inclination 19 with respect to each axis of rotation 15 of approximately 5 degrees of angle.According to step b) of the method, the strip-shaped, still unstructured layer 2 is fed to the rolling device 12 at a skew angle 21 extending between the direction of extension 3 and a first direction 20 running orthogonally to the axes of rotation 15, wherein the skew angle 21 is approximately 5 degrees of angle.According to step c), the corrugated structure 1 in the layer 2 is produced by passing the layer 2 through the mutually intermeshing surface structures 16 of the rollers 13, 14 and producing the structured layer 2.The layer 2 is a continuous material which is cut to length after step c), i.e. after the corrugated structure 1 has been produced, to a predetermined length extending along the direction of extension 3.The layer 2 is rectangular, both as a smooth layer 2 (i.e. before the production of the well structure 1) and as a structured layer 2 (i.e. after the production of the well structure 1).After passing through step c), the entire layer 2 is structured, i.e. has the corrugated structure 1 (i.e. in particular no smooth / unstructured regions) over the entire extent in the width direction 6 and in the extension direction 3.The corrugated structure 1 has an amplitude (i.e. a maximum extent of the structured layer 2 in the height direction 26) (see, for example, FIG. 3 ).The first wave valleys 9 and first wave ridges 10 each extend at a first angle of inclination 11 with respect to the width direction 6 of approximately 5 degrees of angle.The structured layer 2 is led out of the rolling device 12 immediately after it leaves the mutually intermeshing surface structures 16 parallel to the first direction 20 (i.e. orthogonally to the axes of rotation 15 of the rolls 13, 14).During step c), therefore, there is just no displacement of the layer 2 in the direction along the axes of rotation 15, so that continuous feeding of the layer 2 can take place in step b). Thus, just no interruption of steps c) and b) is required in order to return the layer 2 to a starting position opposite the rolling device 12 (see explanations in the introduction).This process advantage is made possible in particular by the use of helical rollers (corrugated rollers) 13, 14 combined with a defined oblique position of the still unstructured layers 2 on the feed side of the rolling device 12. A lateral movement of the layer 2 along the surface structure 16 of the corrugating rollers 13, 14 in the direction along the axes of rotation 15 is thus prevented. Thus, a continuous corrugation process can be realized with the otherwise usual corrugation speed or feed speed of the layer 2 (i.e. comparable to non-helical corrugation structures 1 of known layers 2).In FIG. 6, the first inclination angles 11 and the second inclination angles 19 are each made constant.Alternatively, the first angle of inclination 11 varies along a course of the corrugated structure 1 between the end sides 7, 8 (i.e. along the width direction 6 of the layer 2 or along the course of the first corrugation valleys 9 and first corrugation ridges 10). In particular, the same applies to the second inclination angles 19.Then, for example, a first angle of inclination 11 at a first end face 7 of the structured layer 2 is a specific first value (e.g. 6 degrees of angle). Then, a first inclination angle 11 at a second end face 8 of the structured layer 2 is a second value different from the first value (e.g. 8 degrees of angle). In this case, the difference between the first value and the second value is thus two degrees of angle.In this case, the difference starting from the first end face 7 and toward the second end face 8 becomes exclusively greater.FIG. 7 shows a method for producing a corrugated structure 1 according to a second embodiment variant. Reference is made to the explanations relating to FIG. 6.In contrast to the first embodiment variant, at least one of the corrugated rollers 13, 14 is segmented, such that at least two sections 22, 23 of the corrugated structure 1 arranged adjacent to one another along the width direction 6 are produced by different segments 24, 25 of the one corrugated roller 13. Thus, segments 24, 25 of the corrugating roll 13 which are subject to different loads can be exchanged at different intervals from one another, so that costs for tools and maintenance can be reduced.FIG. 8 shows a perspective view of a first or second (corrugated) roller 13, 14 according to a first embodiment variant. Reference is made to the embodiments of FIGS. 1 to 7.The roller 13, 14 has an axis of rotation 15 and in each case a surface structure 16 which produces the corrugated structure 1, wherein the surface structures 16 of second rollers 13, 14 mesh with one another in order to produce the corrugated structure 1. The surface structure 16 has a plurality of second wave valleys 17 and second wave ridges 18 running parallel to one another, which respectively extend at a second angle of inclination 19 with respect to each axis of rotation 15 of approximately 8 degrees of angle. The second wave valleys 17 and second wave ridges 18 have a helical course along the surface of the roll 13, 14, i.e. they extend along a curve of constant pitch.FIG. 9 shows a perspective view of a first or second (corrugated) roller 13, 14 according to a second embodiment variant. Reference is made to the explanations relating to FIG. 8.In contrast to FIG. 8, the second wave valleys 17 and second wave ridges 18 do not have a helical course here, but extend between the end-face ends of the roller 13, 14 along a diagonal.List of reference characters1 Corrugated structure 2 Layer 3 Direction of extent 4 First end 5 Second end 6 Width direction 7 First end side 8 Second end side 9 First corrugation trough 10 First corrugation crest 11 First angle of inclination 12 Rolling device 13 First roll 14 Second roll 15 Axis of rotation 16 Surface structure 17 Second corrugation trough 18 Second corrugation crest 19 Second angle of inclination 20 First direction 21 Angle of inclination 22 First section 23 Second section 24 First segment 25 Second segment 26 Height direction 27 Honeycomb body 28 Stack 29 Honeycomb structure 30 Center axis 31 Gusset 32 Fluid 33 Radial directionReferences included in the specificationThis list of documents cited by the applicant has been produced in an automated manner and is only included for the better information of the reader. The list is not part of the German patent application or utility model application. The DPMA does not take any adhesion for any faults or omissions.Patent Literature citedDE 10 2012 004 918 A1 [0006, 0060]

Claims

Method for producing a corrugated structure (1) in a strip-shaped layer (2), wherein the layer (2) extends along an extension direction (3) between a first end (4) and a second end (5) and transversely thereto along a width direction (6) between a first end side (7) and a second end side (8); at least comprising the following steps: a) providing a rolling device (12) having at least two rolls (13, 14) which have axes of rotation (15) running parallel to one another and each have a surface structure (16) producing the corrugated structure (1), wherein the surface structures (16) mesh with one another to produce the corrugated structure (1); wherein the surface structures (16) each have a plurality of second wave valleys (17) and second wave ridges (18) running parallel to one another, which respectively extend at a second angle of inclination (19) with respect to each axis of rotation (15) of greater than zero angular degree and at most 15 angular degree; b) feeding the strip-shaped layer (2) to the rolling device (12) at an inclination angle (21) extending between the direction of extension (3) and a first direction (20) running orthogonally to the axes of rotation (15), wherein the inclination angle (21) is greater than zero angular degree; c) Production of a corrugated structure (1) in the layer (2) by passing the layer (2) through the mutually intermeshing surface structures (16) of the rolls (13, 14) and production of the structured layer (2), in which the corrugated structure (1) has a multiplicity of first corrugation valleys (9) and first corrugation ridges (10) which run parallel to one another and each extend at a first angle of inclination (11) with respect to the width direction (6) of greater than zero angle degree and at most 15 angle degree.Method according to claim 1, wherein the structured layer (2) is led out of the rolling device (12) directly after leaving the mutually intermeshing surface structures (16) parallel to the first direction (20).Method according to one of the preceding claims, wherein the inclination angle (21) is between 80 and 120% of at least one of the first inclination angle (11) and the second inclination angle (19).Method according to one of the preceding patent claims, wherein the first angle of inclination (11) varies along a course of the corrugated structure (1) between the end faces (7, 8).Method according to one of the preceding patent claims, wherein at least one of the corrugated rollers (13, 14) is segmented, such that at least two sections (22, 23) of the corrugated structure (1) arranged adjacent to one another along the width direction (6) are produced by different segments (24, 25) of the one corrugated roller (13, 14).Method according to any of the preceding claims, wherein the layer (2) consists of a steel material, a non-iron material or a plastic material.Method according to one of the preceding patent claims, wherein the layer (2) is a continuous material on which the corrugated structure (1) is continuously produced.Method according to one of the preceding patent claims, wherein the corrugated structure (1) produced by step c) between the end faces (7, 8) is produced with a maximum tolerance of 0.2 millimetres with respect to a height direction (26) running transversely to the direction of extent (3) and to the width direction (6).Strip-shaped 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 transversely thereto along a width direction (6) between a first end side (7) and a second end side (8), wherein the corrugated structure (1) of the layer (2) has a plurality of first corrugation valleys (9) and first corrugation ridges (10) which extend parallel to one another and each extend at a first angle of inclination (11) with respect to the width direction (6) of greater than zero angular degree and at most 15 angular degree; wherein the corrugated structure (1) is produced by the method according to one of the preceding patent claims.Honeycomb body (27), at least comprising a strip-shaped layer (2) with a corrugated structure (1) according to patent claim 9, which is arranged with itself by folding or with at least one other layer (2) to form a stack (28) and forms a honeycomb structure (29), through which a fluid (32) can flow from the first end side (7) to the second end side (8), at least by winding, twisting or folding the stack (28).

Images