Method for producing a wave structure on a strip-like layer

Abstract

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

Description

[0001] Method for producing a corrugated structure on a band-shaped layer

[0002] The present invention relates to a method for producing a corrugated structure on a strip-shaped layer. Furthermore, the invention relates to a layer produced by the method and a honeycomb body comprising the layer produced in this way.

[0003] The layer having a corrugated structure is used, for example (but possibly not exclusively), in a honeycomb body for exhaust gas aftertreatment, such as is used in particular as a catalyst carrier body in the 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 finds particular application in exhaust gas purification in motor vehicles or in stationary or other mobile systems.

[0004] A variety of different honeycomb designs for exhaust aftertreatment have already been proposed. A basic distinction is made between ceramic and metal honeycombs (steel or non-ferrous material). Honeycombs can also be made of plastic materials.

[0005] A honeycomb body can be constructed from smooth and / or structured layers or sheet metal foils. These layers can be layered, wound, and / or twisted, and finally placed in a housing of the honeycomb body, forming a plurality of channels through which the exhaust gas can flow. The channels can extend, for example, in a straight line, twisted, and / or oblique manner between the end faces of such a honeycomb body.

[0006] With the goal of achieving the closest possible contact between the exhaust gas and the walls of the honeycomb structure, or rather the catalytic coating placed there, measures have already been proposed to reduce laminar flow of the exhaust gas through the honeycomb structure. For example, openings can be provided in the channel walls to form communicating channels. It is also known to provide deflection structures, guide vanes, etc., in the channels to achieve targeted flow deflection within the channels, pressure differences between the channels, or similar.

[0007] DE 102012 004 918 A1 discloses a honeycomb body in which the structured layers have a corrugated structure, with layers arranged adjacent to one another having intersecting corrugated structures. To produce such structured layers, a still unstructured (i.e., in particular, smooth or flat) layer is fed to a rolling device. The rolling device comprises two rollers, which have parallel axes of rotation and each have a surface structure producing the corrugated structure, wherein the surface structures mesh with one another to produce the corrugated structure. For this purpose, the surface structures each have a plurality of parallel second corrugation troughs and second corrugation crests, which extend parallel to each axis of rotation. The layer is fed to the rolling device at an angle such that the corrugated structure impressed on the layer runs obliquely to a direction of extension of the layer.

[0008] In this process, straight-toothed corrugating rollers are used, whereby the still smooth (endless) layer is fed to the corrugating rollers at a non-perpendicular angle. The angle at which the layer is adjusted relative to an imaginary vertical line to the rotational axes of the corrugating rollers depends on the required angle of inclination of the corrugated structure on the structured layer (e.g. a 3-degree feed angle / helix angle produces an approx. 5-degree inclination angle of the corrugated structure on the structured layer). Due to the non-orthogonal feed and the resulting transverse forces, the layer migrates along the rotational axes of the corrugating rollers. Depending on the helix angle on the feed side of the rolling device, the width of the layer, and the width of the corrugating rollers, the layer has a limited length in its direction of extension, after which the corrugating process must be interrupted, as otherwise the layer will migrates out of the rolling device.A known solution is a so-called corrugating block device, which, similar to the typewriter principle, allows the corrugating rollers to be spaced apart and then a transverse feed of the layer, whereby the layer is moved relative to the corrugating rollers along the rotation axes into its initial position. The process for producing the corrugated structure is thus discontinuous because the feed of the layer relative to the rolling device must be interrupted to move the layer.

[0009] Especially in automotive engineering, additional requirements are placed on such a honeycomb body and its production. The focus is on making production as cost-effective and simple as possible.

[0010] The object of the present invention is to at least partially solve the problems cited with reference to the prior art. In particular, the process for producing a corrugated structure is to be further simplified and, if possible, carried out continuously.

[0011] A method having the features according to claim 1 contributes to achieving these objectives. Advantageous further developments are the subject of the dependent claims. The features listed individually in the claims can be combined with one another in a technologically expedient manner and can be supplemented by explanatory facts from the description and / or details from the figures, whereby further embodiments of the invention are demonstrated.

[0012] A method is proposed for producing a corrugated structure in a band-shaped layer, 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 face and a second end face.

[0013] The method comprises at least the following steps: a) providing a rolling device with at least two rollers, 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 to produce the corrugated structure; wherein the surface structures each have a plurality of second wave troughs and second wave crests running parallel to one another, each extending at a second angle of inclination relative to each axis of rotation of greater than zero angular degrees and at most 15 angular degrees; b) feeding the strip-shaped (still unstructured) layer to the rolling device at a helix angle extending between the direction of extension and a first direction orthogonal to the axes of rotation, wherein the helix angle is greater than zero angular degrees;c) producing a corrugated structure in the layer by passing the layer through the intermeshing surface structures of the rollers and producing the structured layer, in which the corrugated structure has a plurality of first corrugation troughs and first corrugation crests running parallel to one another, each extending at a first angle of inclination relative to the width direction of greater than zero angular degrees and at most 15 angular degrees;

[0014] In particular, the layer is a continuous material which, after step c), i.e. after the creation of the corrugated structure, is cut to a predetermined length extending along the direction of extension.

[0015] In particular, the layer is rectangular, especially as a smooth layer (i.e., before the corrugated structure is created) and also as a structured layer (i.e., after the corrugated structure is created). The end faces run parallel to the direction of extension, while the edges at the ends of the layer run perpendicular to it.

[0016] In particular, the entire layer is structured after passing through step c), i.e., it has the corrugated structure (i.e., in particular, no smooth / unstructured areas) across its entire width and in the direction of extension. In particular, the width of the layer is between 5 and 1,000 millimeters, preferably less than 200 millimeters.

[0017] In particular, a material thickness of the (smooth) layer (in a height direction extending transversely to the width and extension direction) is between 20 pm and 2 millimeters, in particular at most 1.0 or even at most 0.5 millimeters.

[0018] In particular, the corrugated structure has an amplitude (i.e. a maximum extension of the structured layer in the height direction) between 0.5 and 10 millimeters, in particular of a maximum of 5 millimeters.

[0019] In particular, the first and / or second wave troughs and first and / or second wave crests each extend at a first or second angle of inclination relative to the width direction of greater than one degree, preferably greater than 2 or even 3 degrees. In particular, the first angle of inclination is at most 15 degrees, preferably at most 12, at most 10, or even at most 8 degrees.

[0020] The above (non-exhaustive) classification of the process steps into a) to c) is primarily intended to serve as a distinction and does not enforce any order and / or dependency. The frequency of the process steps, e.g., during setup and / or operation of the rolling device, can also vary. It is also possible for process steps to overlap one another at least partially. Process steps b) and c) particularly preferably take place after step a). In particular, steps b) and c) take place in parallel. In particular, steps a) to c) are carried out in the order listed and thus overlap.

[0021] In particular, the structured layer is guided out of the rolling device immediately after emerging from the intermeshing surface structures (essentially) parallel to the first direction (i.e. orthogonal to the axes of rotation).

[0022] In particular, during step c), there is no displacement of the layer in the direction along the rotation axes, allowing continuous feeding of the layer in step b). Therefore, there is no need to interrupt steps c) and b) to return the layer to its initial position relative to the rolling device (see the introduction).

[0023] This process-related advantage is made possible in particular by the use of helical-toothed corrugating rollers combined with a defined inclination of the still unstructured layers on the feed side of the rolling device. Lateral movement of the layer along the surface structure of the corrugating rollers in the direction along the rotational axes is thus prevented. This allows a continuous corrugating process to be realized at the usual corrugating speed or feed rate of the layer (i.e., comparable to non-helical corrugated structures of known layers).

[0024] In particular, the helix angle approximately corresponds at least to the first angle of inclination and / or the second angle of inclination. In particular, the helix 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 angle of inclination and / or the second angle of inclination. This applies in particular to angles of inclination that have a constant value along the width direction of the layer or along the rotational axes of the corrugating rollers.

[0025] In particular, the first angle of inclination varies along a profile of the corrugated structure between the end faces (i.e., along the width direction of the layer or along the profile of the first wave troughs and first wave crests). In particular, the same applies to the second angle of inclination. In particular, a first angle of inclination at a first end face of the structured layer has a specific first value (between greater than zero and 15 angular degrees). In particular, a first angle of inclination at a second end face of the structured layer has a second value that differs from the first value (and in particular is also between greater than zero and 15 angular degrees). 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.

[0026] In particular, the difference from the first end face to the second end face becomes exclusively larger or exclusively smaller. Alternatively, the difference from the first end face to the second end face initially increases and then decreases again, possibly repeating this pattern several times, so that the course of the first wave troughs and first wave crests is S-shaped or meandering. In particular, the first angles of inclination on the opposite end faces are the same or different from each other.

[0027] In particular, at least one of the (preferably both) corrugating rollers is segmented, so that at least two sections of the corrugated structure, arranged adjacent to each other along the width direction, are created by different segments of one corrugating roller. This allows segments of the corrugating roller subject to different levels of stress to be replaced at different intervals, thus reducing tooling and maintenance costs.

[0028] In particular, the layer consists of a steel material, a non-ferrous material or a plastic material.

[0029] In particular, the layer is a continuous material on which the corrugated structure is produced continuously (i.e. with a non-interrupted feeding of the layer to the rolling device or a non-interrupted production of the corrugated structure).

[0030] In particular, the corrugated structure created between the end faces by step c) is produced with a maximum tolerance of 0.2 millimeters, preferably 0.1 millimeters, particularly preferably 0.05 millimeters, or even 0.005 millimeters, relative to a height direction running transversely to the extension direction and the width direction. The tolerance refers to the largest deviation on the component (i.e., the structured layer) from a predetermined value (nominal value) relative to the height direction, i.e., the manufacturing accuracy of the layer, at least relative to the height direction.

[0031] Furthermore, a band-shaped layer with a corrugated structure is proposed, wherein the layer extends along a direction of extension between a first end and a second end and transversely thereto along a width direction between a first end face and a second end face. The corrugated structure of the layer has a plurality of mutually parallel first wave troughs and first wave crests, each extending at a first inclination angle relative to the width direction of greater than zero degrees and at most 15 degrees. The corrugated structure is (has been) produced by the described method according to one of the preceding patent claims.

[0032] In particular, no irregularities are visible on the band-shaped layer because the layer can now be manufactured in a continuous process. Previously known manufacturing processes for such helical-toothed layers resulted in visible marks on the layer, which were due to the corrugated rollers offsetting from the layer and the inability to precisely offset the layer.

[0033] A honeycomb body is further proposed, comprising at least the described band-shaped layer with a corrugated structure. 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 in a stack by folding it or with at least one other (smooth and / or structured) layer. If necessary, the honeycomb structure is formed by additionally winding, twisting, or folding the stack. Multiple stacks can also be used for this purpose.

[0034] The described layer and honeycomb structure are generally known. Reference is made to the known designs of layers and honeycomb structures.

[0035] The honeycomb structure is intended primarily for exhaust aftertreatment. Please refer to the explanations in the introduction.

[0036] The honeycomb body can fundamentally have various shapes, in particular a round, oval, polygonal, or similar cross-section. Such a honeycomb body is often formed with a tube-like housing. When used for exhaust gas aftertreatment, an exhaust gas / fluid regularly enters the honeycomb body via one of the two end faces and exits again via the other end face during operation. The end faces, which are preferably arranged essentially parallel or inclined to one another, regularly define the length of the honeycomb body in the direction of a central axis of the honeycomb body, which penetrates both end faces and is arranged perpendicularly and centrally to at least one, preferably both end faces.

[0037] The honeycomb body also has at least one of the described at least partially structured layers. It is possible for a (single) layer to have smooth and structured sections or sections with different structures. This at least one layer can, for example, be arranged in the manner of a spiral around a central axis. It is also possible for multiple layers to be used, with some of the layers, for example, being smooth and / or having a different structure than at least one other layer. In particular, two layers or a multiple thereof are used, with a pair of layers having the same structure (type, size, etc.) but formed with a different orientation of the corrugated structure, so that the wave troughs and wave crests of the contacting layers intersect.

[0038] 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) that were embossed into the layer by the corrugating rollers. Wave crests and troughs alternate regularly in the direction of extension of the layer. The wave crests and troughs can form a type of sine wave, zigzag shape or the like in cross-section. The arrangement of the structure or the wave crests and troughs in the honeycomb body is now such that they run obliquely to the central axis. This creates channel sections for a fluid that run obliquely to the central axis, rather than parallel to the central axis. If an exhaust gas flow orIf a fluid flow hits one end face perpendicularly, the exhaust gas / fluid is initially split because it penetrates into the channel openings formed by the wave crests and wave troughs and is then deflected inside the honeycomb body. The structure is particularly designed in such a way that the wave crests and wave troughs in adjacent regions (viewed in the radial direction relative to the center axis) are inclined at different angles or have a different orientation. If, for example, a deflection to the right occurs in one region, it is preferred that a deflection to the left occurs in the region further inside, or vice versa. It is particularly preferred that this alignment or orientation always alternates when viewed in the radial direction.This results in, in particular, that the wave crests and wave troughs at least partially, and preferably at no point on the honeycomb body, lie on top of one another in a linear fashion, but rather intersect one another, thus essentially forming only point-like contact points. This results in a structure in which the partial flows of the exhaust gas / fluid are permanently deflected and can flow into adjacent wave crests or wave troughs, particularly in a zigzag pattern.

[0039] Furthermore, the use of the honeycomb body or layer in an exhaust system is proposed, e.g., of a motor vehicle or a stationary system having an internal combustion engine with an exhaust system. The exhaust system has at least one catalyst carrier or a particle separator constructed with a honeycomb body described here. The catalyst carrier and / or the particle separator can have a catalytically active coating.

[0040] The corrugated structure of the layer and the intersecting arrangement of the corrugated structures in the honeycomb body leads in particular to the fact that the interstices between the contacting layers, which are always present in many cases when the corrugation troughs and corrugation crests are aligned straight and extend over a large length, are reduced, whereby a larger surface can be provided with the same cell density of the honeycomb body and undesirable accumulations of washcoat (or another coating) in these interstices can be reduced.

[0041] In particular, at least one data processing system is provided which has means which are suitably equipped, configured or programmed to carry out the method or which carry out the method.

[0042] In particular, the rolling device or the device provided for carrying out the method comprises a data processing system, e.g. a control device, which has means for carrying out the steps of the method and / or which has means that are suitably equipped, configured or programmed to carry out the steps of the method or that carry out the method.

[0043] The means include, for example, a processor and a memory in which instructions to be executed by the processor are stored, as well as data lines or transmission devices that enable the transmission of instructions, measured values, data or the like between the elements mentioned.

[0044] The “means” may in particular comprise one or more of the following components: controller(s), microcontroller, data memory, data connection, display devices (such as a display), counter or timer, at least one further sensor, an energy source, etc.

[0045] A computer program is further proposed, comprising instructions which, when the computer program is executed by a computer, cause the computer to carry out the described method or the steps of the described method.

[0046] Furthermore, a computer-readable storage medium is proposed, comprising instructions which, when executed by a computer, cause the computer to carry out the described method or the steps of the described method.

[0047] The statements regarding the method are particularly applicable to the layer, the honeycomb body, the use, the data processing system and / or the computer-implemented method (i.e. the computer program and the computer-readable storage medium) and vice versa.

[0048] The use of indefinite articles ("a," "an," "one," and "another"), particularly in the patent claims and the description reproducing them, is to be understood as such and not as a numeral. Terms or components introduced accordingly are therefore to be understood as appearing at least once and, in particular, as being able to appear multiple times.

[0049] As a precaution, it should be noted that the numerals used here ("first", "second", ...) primarily serve (only) to distinguish between several similar objects, quantities, or processes, and therefore do not necessarily prescribe any interdependence and / or sequence of these objects, quantities, or processes. Should a dependence and / or sequence be necessary, this is explicitly stated here or will be obvious to the person skilled in the art upon studying the specifically described embodiment. To the extent that a component can occur multiple times ("at least one"), the description of one of these components can apply equally to all or part of the majority of these components, but this is not mandatory.

[0050] The invention and the technical environment are explained in more detail below with reference to the accompanying figures. It should be noted that the invention is not intended to be limited by the exemplary embodiments cited. In particular, it should be noted that the figures, and in particular the proportions shown, are only schematic. They show:

[0051] Fig. 1 : a section of a honeycomb body formed by the layers in a perspective view, partly in section;

[0052] Fig. 2: the section according to Fig. 1 in a view along a center axis of the honeycomb body;

[0053] Fig. 3: a honeycomb body with the layers according to Fig. 1 and Fig. 2;

[0054] Fig. 4: a known method for producing a corrugated structure in a first state;

[0055] Fig. 5: the method according to Fig. 4 in a second state;

[0056] Fig. 6: a method for producing a corrugated structure according to a first embodiment;

[0057] Fig. 7: a method for producing a corrugated structure according to a second embodiment;

[0058] Fig. 8: a first and second roller according to a first embodiment in a perspective view; and

[0059] Fig. 9: a first and second roller according to a second embodiment in a perspective view. Fig. 1 shows a section of a honeycomb body 27 formed by the layers 2 in a perspective view, partially in section. Fig. 2 shows the section according to Fig. 1 in a view along a center axis 30 of the honeycomb body 27. Fig. 3 shows a honeycomb body 27 with the layers 2 according to Fig. 1 and Fig. 2. Figures 1 to 3 are described together below.

[0060] 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 face 7 and a second end face 8 of the layer. The corrugated structure 1 of the layers 2 has a plurality of mutually parallel first wave troughs 9 and first wave crests 10, each extending at a first inclination angle 11 relative to the width direction 6 of greater than zero degrees and at most 15 degrees.

[0061] The honeycomb body 27 has at least one band-shaped layer 2 with a corrugated structure 1. Fig. 3 shows that a smooth layer 2 without a corrugated structure 1 is arranged between the band-shaped layers 2 with a corrugated structure 1.

[0062] 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 folding 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.

[0063] 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 aftertreatment, an exhaust gas / fluid 32 regularly enters 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 (of the layers 2 or the honeycomb structure 29 or the honeycomb body 27), which are arranged parallel to one another, 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 penetrates both end faces 7, 8 and is arranged perpendicularly and centrally to both end faces 7, 8.

[0064] 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 (wave crests 10) and depressions (wave troughs 9) that were embossed into the layer 2 by the corrugating rollers 13, 14 (see Figs. 6 and 7). Wave crests 10 and wave troughs 9 alternate regularly in the direction of extension 3 of the layer 2. The wave crests 10 and wave troughs 9 form a type of sinusoidal corrugation in cross-section. The arrangement of the corrugated structure 1 or the wave crests 10 and wave troughs 9 in the honeycomb body 27 is such that they run obliquely to the central axis 30. This creates channel sections for a fluid 32 that do not run parallel to the center axis 30, but rather at an angle to it. Therefore, if an exhaust gas flow orIf a fluid flow onto an end face 7, 8 perpendicularly, the exhaust gas / fluid 32 is initially divided because it penetrates into the channel openings formed by the wave crests 10 and wave troughs 9 and is then deflected inside 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 relative to the center axis 30) are inclined at different angles or have a different orientation. If, for example, a deflection to the right occurs in one region, it is preferred that a deflection to the left occurs in the region further inside, or vice versa. This alignment or orientation always changes as viewed in the radial direction 33.This means that the wave crests 10 and wave troughs 9 do not lie on top of one another in a linear manner at any point on the honeycomb body 27 of the honeycomb structure 29, but rather cross one another and thus essentially only form point-like contact points with one another. This results in a structure in which the partial flows of the exhaust gas / fluid 32 are permanently deflected and can flow into adjacent wave crests 10 or wave troughs 9, in particular in a zigzag manner. The corrugated structure 1 of layer 2 and the crossing arrangement of the corrugated structures 1 in the honeycomb body 27 means that the interstices 31 between the contacting layers 2, which are always present in multiple numbers and extend over a great length when the wave troughs 9 and wave crests 10 are aligned straight, are reduced, so that with the same cell density of the honeycomb body 27 orthe honeycomb structure 29 can be provided with a larger surface area and unwanted accumulation of washcoat (or other coating) in these interstices 31 can be reduced.

[0065] Fig. 4 shows a known method for producing a corrugated 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 explanations regarding Figs. 1 to 3.

[0066] From DE 10 2012 004 918 A1, a honeycomb body 27 is known in which the structured layers 2 have a corrugated structure 1, wherein layers 2 arranged adjacent to one another have intersecting corrugated structures 1. To produce such structured layers 2, a still unstructured (i.e., in particular, smooth or flat) layer 2 is fed to a rolling device 12. The rolling device 12 comprises two rollers 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. For this purpose, the surface structures 16 each have a plurality of second corrugation troughs 17 and second corrugation crests 18 running parallel to one another, which extend parallel to each axis of rotation 15.The layer 2 is fed to the rolling device 12 at an inclination angle 21, so that the corrugated structure 1 embossed onto the layer 2 runs obliquely to an extension direction 3 of the layer 2.

[0067] In this process, straight-toothed corrugated rollers 13, 14 are used, with the still smooth (endless) layer 2 being fed to the corrugated rollers 13, 14 at a non-perpendicular angle. The helix angle 21, by which the layer 2 is positioned relative to an imaginary vertical line (first direction 20) to the rotational axes 15 of the corrugated rollers 13, 14, depends on the required first inclination angle 11 of the corrugated structure 1 on the structured layer 2 (e.g., a 3-degree feed angle / helix angle 21 produces approximately 5 degrees of the first inclination angle 11 of the corrugated structure 1 on the structured layer 2). Due to the non-orthogonal feed and the resulting transverse forces, layer 2 migrates along the rotation axes 15 of the corrugating rollers 13, 14 (see first state in Fig. 4 and second state in Fig. 5).Depending on the helix angle 21 on the feed side of the rolling device 12, the width of the layer 2, and the width of the corrugating rollers 13, 14, a limited length of the layer 2 results in its extension direction 3, after which an interruption of the corrugating process is necessary, since the layer 2 would otherwise migrates out of the rolling device 12. A known solution is a so-called corrugating block device, which, similar to the typewriter principle, enables the corrugating rollers 13, 14 to be spaced apart and then a transverse feed of the layer 2, whereby the layer 2 is displaced relative to the corrugating rollers 13, 14 along the rotation axes 15 into its initial position (Fig. 4). The process for producing the corrugated structure 1 is thus discontinuous because the feed of the layer 2 relative to the rolling device 12 must be interrupted to displace the layer 2.

[0068] Fig. 6 shows a method for producing a corrugated structure 1 according to a first embodiment. Reference is made to the explanations for Figures 1 to 5.

[0069] According to step a) of the method, a rolling device 12 is provided with two rollers 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. The surface structures 16 each have a plurality of second wave troughs 17 and second wave crests 18 running parallel to one another, each extending at a second inclination angle 19 of approximately 5 degrees relative to each axis of rotation 15. According to step b) of the method, the strip-shaped, still unstructured layer 2 is fed to the rolling device 12 at a helix angle 21 extending between the extension direction 3 and a first direction 20 running orthogonally to the axes of rotation 15, wherein the helix angle 21 is approximately 5 degrees.

[0070] According to step c), the corrugated structure 1 is produced in the layer 2 by passing the layer 2 through the intermeshing surface structures 16 of the rollers 13, 14 and producing the structured layer 2.

[0071] The layer 2 is a continuous material which, after step c), i.e. after the creation of the corrugated structure 1, is cut to a predetermined length extending along the extension direction 3.

[0072] Layer 2 is rectangular, both as smooth layer 2 (i.e. before the creation of the corrugated structure 1) and as structured layer 2 (i.e. after the creation of the corrugated structure 1).

[0073] After passing through step c), the entire layer 2 is structured, i.e. it has the corrugated structure 1 (i.e. in particular no smooth / unstructured areas) over the entire extent in the width direction 6 and in the extension direction 3.

[0074] The corrugated structure 1 has an amplitude (i.e. a maximum extension of the structured layer 2 in the height direction 26) (see e.g. Fig. 3).

[0075] The first wave troughs 9 and first wave crests 10 each extend at a first angle of inclination 11 relative to the width direction 6 of approximately 5 degrees.

[0076] The structured layer 2 is led out of the rolling device 12 immediately after emerging from the intermeshing surface structures 16 parallel to the first direction 20 (i.e. orthogonal to the axes of rotation 15 of the rollers 13, 14).

[0077] During step c), there is no displacement of layer 2 in the direction along the rotation axes 15, so that layer 2 can be continuously fed in step b). Therefore, there is no need to interrupt steps c) and b) in order to return layer 2 to an initial position relative to the rolling device 12 (see the explanations in the introduction).

[0078] This process-related advantage is made possible in particular by the use of helically toothed rollers (corrugating rollers) 13, 14 combined with a defined inclination of the still unstructured layers 2 on the feed side of the rolling device 12. Lateral movement of the layer 2 along the surface structure 16 of the corrugating rollers 13, 14 in the direction along the rotation axes 15 is thus prevented. Thus, a continuous corrugating process can be realized with the otherwise usual corrugating speed or feed speed of the layer 2 (i.e., comparable to non-helically toothed corrugated structures 1 of known layers 2).

[0079] In Fig. 6, the first inclination angles 11 and the second inclination angles 19 are each constant.

[0080] Alternatively, the first angle of inclination 11 varies along a profile of the corrugated structure 1 between the end faces 7, 8 (i.e., along the width direction 6 of the layer 2 or along the profile of the first wave troughs 9 and first wave crests 10). In particular, the same applies to the second angle of inclination 19.

[0081] Then, for example, a first angle of inclination 11 on a first end face 7 of the structured layer 2 has a specific first value (e.g., 6 degrees). Then, a first angle of inclination 11 on a second end face 8 of the structured layer 2 has a second value that differs from the first value (e.g., 8 degrees). The difference between the first value and the second value is therefore two degrees. The difference only increases from the first end face 7 to the second end face 8.

[0082] Fig. 7 shows a method for producing a corrugated structure 1 according to a second embodiment. Reference is made to the explanations for Fig. 6.

[0083] In contrast to the first embodiment, at least one of the corrugating rollers 13, 14 is segmented, so that at least two sections 22, 23 of the corrugated structure 1, arranged adjacent to one another along the width direction 6, are created by different segments 24, 25 of the one corrugating roller 13. This allows segments 24, 25 of the corrugating roller 13 subject to different levels of stress to be replaced at different intervals, thus reducing tool and maintenance costs.

[0084] Fig. 8 shows a perspective view of a first and second (corrugating) roller 13, 14 according to a first embodiment. Reference is made to the explanations regarding Figs. 1 to 7.

[0085] The rollers 13, 14 have an axis of rotation 15 and each have a surface structure 16 that creates the corrugated structure 1, wherein the surface structures 16 of two rollers 13, 14 mesh with each other to create the corrugated structure 1. The surface structure 16 has a plurality of second wave troughs 17 and second wave crests 18 that run parallel to one another and each extend at a second angle of inclination 19 of approximately 8 degrees relative to each axis of rotation 15. The second wave troughs 17 and second wave crests 18 have a helical shape along the surface of the rollers 13, 14, i.e., they extend along a curve with a constant curvature.

[0086] Fig. 9 shows a perspective view of a first and second (corrugated) roller 13, 14 according to a second embodiment. Reference is made to the explanations for Fig. 8. In contrast to Fig. 8, the second wave troughs 17 and second wave crests 18 do not have a helical shape here, but rather extend between the front ends of the roller 13, 14 along a diagonal.

[0087] The teeth of the surface structures 16 shown are always oriented in the same way to the center axis 30 along the course of a tooth, ie in each cross section running transversely to the center axis 30, each tooth has the same functional dimensions (helix angle, tip, root and virtual pitch circle diameter).

[0088] List of reference symbols

[0089] We 11 Structure Position Extension direction First end Second end Width direction First end face Second end face First trough First crest First inclination angle Rolling device First roll Second roll Rotation axis Surface structure Second trough Second crest Second inclination angle First direction Helix angle First section Second section First segment Second segment Height direction Honeycomb body Stack Honeycomb structure Center axis Gusset 32 ​​Fluid

[0090] 33 radial direction

Claims

Patent claims 1. A method for producing a corrugated structure (1) in 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); at least comprising the following steps: a) providing a rolling device (12) with at least two rollers (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 troughs (17) and second wave crests (18) running parallel to one another, each extending at a second angle of inclination (19) relative to each axis of rotation (15) of greater than zero angular degrees and at most 15 angular degrees; b) feeding the strip-shaped layer (2) to the rolling device (12) at a helix angle (21) extending between the direction of extension (3) and a first direction (20) orthogonal to the axes of rotation (15), the helix angle (21) being greater than zero angular degrees;c) producing a corrugated structure (1) in the layer (2) by passing the layer (2) through the intermeshing surface structures (16) of the rollers (13, 14) and producing the structured layer (2), in which the corrugated structure (1) has a plurality of first corrugation troughs (9) and first corrugation crests (10) running parallel to one another, each of which extends at a first angle of inclination (11) relative to the width direction (6) of greater than zero angular degrees and at most 15 angular degrees; 2. Method according to claim 1, wherein the structured layer (2) is guided out of the rolling device (12) parallel to the first direction (20) immediately after emerging from the intermeshing surface structures (16).

3. Method according to one of the preceding claims, wherein the helix angle (21) is between 80 and 120% of at least the first inclination angle (11) or the second inclination angle (19).

4. Method according to one of the preceding claims, wherein the first angle of inclination (11) varies along a course of the corrugated structure (1) between the end faces (7, 8).

5. Method according to one of the preceding claims, wherein at least one of the corrugating rollers (13, 14) is segmented, so 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 corrugating roller (13, 14).

6. Method according to one of the preceding claims, wherein the layer (2) consists of a steel material, a non-ferrous material or a plastic material.

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

8. Method according to one of the preceding 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 millimeters with respect to a height direction (26) running transversely to the extension direction (3) and to the width direction (6).

9. A band-shaped layer (2) with 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 face (7) and a second end face (8), wherein the corrugated structure (1) of the layer (2) has a plurality of first corrugation troughs (9) and first corrugation crests (10) running parallel to one another, each of which extends at a first angle of inclination (11) relative to the width direction (6) of greater than zero angular degrees and at most 15 angular degrees; wherein the corrugated structure (1) is produced by the method according to one of the preceding claims.

10. Honeycomb body (27), at least comprising a band-shaped layer (2) with a corrugated structure (1) according to claim 9, which is arranged with itself by folding or with at least one other layer (2) to form a stack (28) and at least by winding, twisting or folding the stack (28) forms a honeycomb structure (29) through which a fluid (32) can flow from the first end face (7) to the second end face (8).

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