Method for applying glue to a first layer, and a honeycomb structure

Abstract

The invention relates to a method for applying glue to a first layer (1), which has a wave structure (2), wherein the first layer (1) 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 (2) of the first layer (1) has a plurality of troughs (9) and crests (10) extending parallel to one another, which in each case extend at an angle of inclination (11) to the width direction (6) of more than zero degrees and at most 45 degrees along a progression direction. The invention also relates to a method for producing a honeycomb structure (19) having the first layer (1) to which glue was applied, and to a honeycomb structure (19).

Description

[0001] Method for applying glue to a first layer and a honeycomb structure The present invention relates to a method for applying glue to a first layer having a corrugated structure. The invention further relates to a method for producing a honeycomb structure with the glued first layer and to a honeycomb structure. The layer having a corrugated structure is used, for example (but possibly not exclusively), to form a honeycomb structure of a honeycomb body for exhaust gas aftertreatment, as is used in particular as a catalyst carrier body in exhaust systems of mobile internal combustion engines. Such a honeycomb structure or the 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.A variety of different designs of honeycomb bodies for exhaust gas aftertreatment have already been proposed. Basically, a distinction is made between honeycomb bodies made of ceramic and metal (steel or non-ferrous material). Honeycomb bodies can also be made of 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 twisted 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, for example, extend in a straight line, twisted and / or diagonally between the end faces of such a honeycomb body. With the aim of achieving the closest possible contact between the exhaust gas and the walls of the honeycomb body, orthe catalytic coating placed there, measures have already been proposed to reduce laminar flow of the exhaust gas through the honeycomb body. For example, openings can be provided in the channel walls so that communicating channels are formed. It is also known to provide deflection structures, guide vanes, etc. in the channels in order to achieve targeted flow deflection in the channels, pressure differences between the channels, or similar. DE 102012004918 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. The layers forming the honeycomb structure are connected to one another via soldered joints. These soldered joints are formed by first applying an adhesive material to the layers.The honeycomb body is then coated with a solder material that adheres (exclusively) to the adhesive material. Subsequent heating of the honeycomb body liquefies the solder material and forms solder joints. The solder used to create the solder joints usually comprises a hard solder that only liquefies at temperatures above 450 degrees Celsius. The adhesive material itself cannot create solder joints, but only serves to adhere the solder material. The adhesive material can be applied directly to the layers using stamps or labels, for example, or can be applied across the end faces of the honeycomb structure using capillary forces. The aim is to use as little solder material as possible, while also controlling the distribution of the solder material as precisely as possible. The solder material increases the weight of the honeycomb body and covers the surface area otherwise available for a catalytic coating.The soldered joints produced influence the expansion or expansion behavior of the honeycomb body or honeycomb structure and therefore represent a significant factor influencing the durability of the honeycomb body. The object of the present invention is to at least partially solve the problems cited with reference to the prior art. In particular, a honeycomb body is to be provided that has a predictable expansion behavior and the longest possible durability. To this end, the smallest possible amount of solder material is to be applied and the soldered joints are to be formed, if possible, only at predetermined locations on the honeycomb structure. A method having the features according to patent claim 1 and a honeycomb structure having the features according to patent claim 7 contribute to solving these problems. Advantageous 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 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 shown. A method is proposed for applying glue to a first layer having a corrugated structure. The first 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. The corrugated structure of the first layer has a plurality of wave troughs and wave crests running parallel to one another, each of which extends at an inclination angle relative to the width direction of greater than zero angular degrees and at most 45 angular degrees along a direction of extension.The method comprises at least the following steps: a) providing a gluing device with at least one roller, the surface of which is wetted with a glue material; b) arranging the structured first layer in the gluing device; c) contacting the structured first layer with the surface of the roller exclusively in a first region of the wave crests facing the roller and transferring the glue material from the surface to the first region. In particular, the first layer is (substantially) rectangular. In particular, the extent of the first layer along the extension direction is greater than along the width direction. In particular, the entire first layer is structured, i.e., it has the corrugated structure over the entire extent in the width direction and in the extension direction (i.e., in particular, no smooth / unstructured areas). 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 first 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 extension of the structured first layer in the height direction) between one millimeter and 10 millimeters, in particular of at most 5 millimeters. In particular, the wave troughs and wave crests each extend at an inclination angle relative to the width direction of greater than one angular degree, preferably of greater than 2 or even 3 angular degrees. In particular, the first inclination angle is at most 35 angular degrees, preferably at most 25, at most 20 or even at most 15 angular degrees.The above (non-exhaustive) division 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 gluing 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, step c) takes place after step b). In particular, steps a) to c) are carried out in the order listed and overlap one another. The roller of the gluing device is, in particular, cylindrical, with an outer circumferential surface of the roller being provided for contacting the first layer. The surface arranged on the outer circumferential surface is, in particular, designed to accommodate the glue material. The surface can be porous, e.g.in the manner of a possibly elastically deformable sponge, or without pores. The wetting of the surface of the roll can in particular be controlled so that the surface has as constant a quantity of adhesive material as possible per unit area of ​​the surface. For this purpose, the roll can be immersed in a bath of adhesive material or can be continuously exposed to adhesive material. A stripping device can be provided by which the quantity of adhesive material present on the surface can be adjusted. According to step c), in particular, the structured first layer comes into contact with the surface of the roll. In this case, the first layer is contacted in particular exclusively in a first region of the wave crests pointing towards the roll. The first region can comprise some of the wave crests and / or a partial region of a wave crest. In particular, the regions of the first layer that lie between the wave crests (e.g.the wave troughs) are not contacted by the surface. In particular, the adhesive material is transferred from the surface (exclusively) to the first region. In particular, no adhesive material is transferred to regions outside the first region. In particular, in step c) only a predetermined first subset of the wave crests or only a predetermined first subregion of a wave crest is contacted by the roll or the surface and applied with adhesive material. In particular, at most 20%, preferably at most 10%, particularly preferably at most 5%, of the wave crests of the first layer are contacted by the roll and applied with adhesive material. Alternatively, at least 90% of the wave crests along the direction of extension are contacted by the roll and applied with adhesive material.In particular, a maximum of 10, preferably a maximum of 5, particularly preferably a maximum of two, corrugation crests of the first layer arranged adjacent to one another along the direction of extension are contacted by the roll and supplied with adhesive material. In particular, along the direction of extension, next to each corrugation crest that is contacted by the roll and supplied with adhesive material, there are always corrugation crests that are not contacted by the roll and supplied with adhesive material. In particular, this only applies to regions of the first layer arranged in alignment with one another along the direction of extension. In particular, at least one of the corrugation crests and / or each of the corrugation crests of the first layer is contacted by the roll or supplied with the adhesive material only over a length of a maximum of 10%, in particular a maximum of 5%, preferably a maximum of 2%, of the extension of the corrugation crests along the direction of extension.In particular, the first region is arranged at a distance from each end face, in particular at a distance of at least two, preferably at least five, particularly preferably at least 10 millimeters. In particular, at least a predetermined second subset of the wave crests or a predetermined second subregion of a wave crest is masked before step c), so that contact of these wave crests or this subregion with the surface of the roll is prevented. The masking comprises, for example, covering the first layer so that only the first regions of the first layer are not covered and can therefore be contacted by the roll. Furthermore, a method for producing a honeycomb structure is proposed, at least comprising the following steps: i. Providing the first layer glued by the described method for gluing the first layer; ii.Arranging another structured region of the same first layer or arranging a structured second layer on the first layer to form a stack; wherein the other region of the first layer or the second layer is structured such that the superimposed wave troughs and wave crests intersect, so that a contact zone between the wave troughs and wave crests is delimited along the direction of travel; iii. Forming the honeycomb structure; iv. Applying a solder material to the honeycomb structure, wherein the solder material adheres to the adhesive material; v. Heating the honeycomb structure which has the solder material and forming solder connections in the contact zones formed in step ii., which were applied with the solder material in step iv. The above (non-exhaustive) division of the method steps into i. to v. 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 device for forming the honeycomb structure or the device for soldering or heating the honeycomb structure, can also vary. It is also possible for process steps to overlap one another at least partially in time. Most preferably, process steps ii. to v. take place after step i. In particular, steps iv. and v. take place after steps i., ii. and iii. In particular, steps i. to v. are carried out in the order given. In particular, step v. only takes place after steps i. to iv. The glued first layer is provided according to step i. According to step ii., another structured region of the same first layer is arranged, or a structured second layer is arranged on the first layer to form a stack.The other region of the first layer or the second layer is structured such that the superimposed wave troughs and wave crests intersect, so that a contact zone between the wave troughs and wave crests is delimited along the direction of extension. The above statements regarding the first layer also apply in particular to the at least one second layer. In particular, the wave troughs and wave crests of each layer each extend at an angle of inclination relative to the width direction of greater than one degree, preferably greater than 2 or even 3 degrees. In particular, the angle of inclination is at most 35 degrees, preferably at most 25, at most 20, or even at most 15 degrees. If such layers are arranged on top of one another, angles arise between the contacting wave troughs and wave crests that correspond to the sum of the angles of inclination of each layer. The honeycomb structure is formed according to step iii.For this purpose, the stack can be used with the layers stacked exclusively on top of one another, or the stack can be folded and / or wound and / or twisted. Such honeycomb structures are generally known. In step iii, the honeycomb structure produced can be arranged in a housing and thus form a honeycomb body. The honeycomb body or honeycomb structure can generally 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 a fluid inlet side (side) and exits again via a fluid outlet side (side).The fluid inlet / outlet sides, which are preferably arranged essentially parallel or inclined to one another, generally define the length of the honeycomb body in the direction of a central axis of the honeycomb body, which penetrates both sides of the honeycomb body and is arranged perpendicularly and centrally to at least one, preferably both sides. According to step iv., the honeycomb structure is exposed to a solder material, wherein the solder material adheres to the adhesive material. For this purpose, the honeycomb body or the honeycomb structure can, for example, be immersed in a bath comprising solder material or the honeycomb body or the honeycomb structure can be exposed to powdered solder material. The solder material adheres in particular (exclusively) to the first region exposed to the adhesive material. In this case, the solder material adheres in particular only to the regions of the first region accessible to the solder material.In particular, the solder material does not adhere in the contact zones of the wave troughs and crests, but rather in areas that are immediately adjacent to them. In particular, in step iv., the solder material is not arranged between the layers, but in the so-called interstices formed by the contacting corrugated structures. The intersecting corrugated structures of the contacting layers in the honeycomb structure result in a reduction in the interstices between the contacting layers, which are always present in numerous ways when the wave troughs and crests are aligned straight and extend over a long length. This means that with the same cell density of the honeycomb body, a larger surface area can be provided and unwanted accumulations of washcoat (or another coating) in these interstices can be reduced.In addition, the intersecting arrangement of the corrugated structures means that the capillary forces acting along the gussets are regularly interrupted, so that a liquid glue material or a solder material liquefied during step v. does not shift further (along the course of the gusset). This makes it possible in particular to create locally limited first regions and to ensure that solder joints are formed exclusively in these first regions. Furthermore, the arrangement and distribution of the first regions can be freely selected, so that a wide variety of requirements with regard to expansion behavior and strength of the honeycomb structure can be responded to appropriately. In particular, of the layers forming the contact zone, only one layer in the contact zone is wetted with the glue material. In particular, the first layer provided in step i. has a gluing pattern which depends on the parameters defined in step ii.generated contact zones and depending on the honeycomb structure generated in step iii. is predetermined (if necessary computationally) before step i. and generated on the first layer. Especially when the layers or the stacks formed by the layers are folded and / or wound and / or twisted, honeycomb structures are formed which exhibit very different behavior with regard to expansion behavior or fatigue strength. The arrangement of a specific first region of the first layer in the subsequently generated honeycomb structure can also be predicted only with difficulty. Therefore, in particular computationally or within the framework of a simulation, first regions can be determined which assume specific positions in the subsequently generated honeycomb structure, in particular relative to one another, so that certain properties with regard to expansion behavior and fatigue strength can be specifically adjusted.A honeycomb structure is proposed which extends between a fluid inlet side and a fluid outlet side along a central axis. Channels extend between these sides so that a fluid can flow through the honeycomb structure. The honeycomb structure comprises at least one stack which is formed at least by a first layer having a corrugated structure, wherein the first layer extends between a first end side arranged on the fluid inlet side and a second end side arranged on the fluid outlet side along a width direction parallel to the central axis and along an extension direction running transversely to the central axis between a first end and a second end.The corrugated structure of the first layer has a plurality of mutually parallel wave troughs and wave crests, each extending at an inclination angle relative to the width direction of greater than zero angular degrees and at most 45 angular degrees along a direction of extension. The stack and the channels are formed by arranging a different structured region of the same first layer or by arranging a structured second layer on the first layer. The other region of the first layer or the second layer is structured such that the superimposed wave troughs and wave crests intersect, so that a contact zone between the wave troughs and wave crests is delimited along the direction of extension. Solder connections are formed at a plurality of contact zones, wherein a solder connection is formed only at a predetermined subset of the contact zones.In particular, the described honeycomb structure is the honeycomb structure produced by the described method and / or comprises the first layer glued by the described method. In particular, solder joints are present at a maximum of 20%, preferably at a maximum of 10%, particularly preferably at a maximum of 5%, of the contact zones. In particular, the solder joints are distributed substantially evenly over a cross-section of the honeycomb structure extending transversely to the central axis. In particular, the solder joints are arranged at a distance from each end face, in particular at a distance of at least two, preferably at least five, particularly preferably at least 10 millimeters. In particular, at least 90% of all solder joints, in particular 100% of all solder joints are at a distance of at least two millimeters, preferably at least five millimeters, particularly preferably at least 10 millimeters, from the end faces.In particular, at least 90% of all soldered joints, in particular 100% of all soldered joints are located at a distance of at most 20 millimeters, preferably of at most 15 millimeters, particularly preferably of at most 10 millimeters, from the end faces. In particular, each soldered joint extends along a direction parallel to the central axis over a maximum length of at most 10 millimeters, in particular of at most 5 millimeters. In particular, the honeycomb body has a solder quantity of less than 30 g / m² / l, based on a specific geometric surface area (GSA) of the honeycomb body. The specific geometric surface area is the surface provided by the layers in square meters per liter of volume of the honeycomb body or honeycomb structure.A honeycomb body is further proposed, at least comprising the described honeycomb structure and / or the first layer glued by the described method with a corrugated structure. To form a honeycomb structure through which a fluid can flow from the fluid inlet side to the fluid outlet side of the honeycomb body, the first layer is arranged with itself by folding or with at least one other structured layer to form a stack. If necessary, the honeycomb structure is formed by additionally winding, twisting, or folding the stack. Multiple stacks can also be used for this purpose. The described structured layers and the honeycomb body or honeycomb structure are generally known. In this regard, reference is made to the known designs of layers and honeycomb bodies or honeycomb structures. The honeycomb body is intended in particular for exhaust gas aftertreatment. Reference is made to the explanations in the introduction.The at least one layer can, for example, be arranged in the manner of a spiral around the central axis. In particular, two layers or a multiple thereof are used, wherein a pair of layers may have the same structure (type, size, etc.), but are formed with a different orientation of the corrugated structure, so that the troughs and crests of the contacting layers intersect. 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 (crests) and depressions (troughs). Crests and troughs alternate regularly in the direction of extension of the layer. The crests and troughs can form a type of sinusoidal corrugation, zigzag shape, or the like in cross-section. The arrangement of the structure orThe wave crests and troughs in the honeycomb body are now formed in such a way that they run at an angle to the central axis. This creates channel sections for a fluid that do not run parallel to the central axis, but at an angle to it. If an exhaust gas flow or a fluid flow hits an end face of the honeycomb structure or a fluid inlet side of the honeycomb body at right angles, the exhaust gas / fluid is initially split because it penetrates the channel openings formed by the wave crests and troughs and is then deflected inside the honeycomb body. The structure is particularly designed in such a way that the wave crests and troughs in adjacent areas (viewed in the radial direction relative to the central axis) are inclined at different angles or have a different orientation. For example, ifIf there is a deflection to the right in one area, it is preferred that there is a deflection to the left in the area further inside, or vice versa. It is particularly preferred that this alignment or orientation, viewed in the radial direction, always alternates. This leads in particular to the wave crests and wave troughs lying on top of one another in a linear manner, at least partially and preferably at no point on the honeycomb body, but rather crossing one another and thus essentially only forming point-like support points or contact zones with one another. 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, in particular in a zigzag manner. 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 as described here. The catalyst carrier and / or the particle separator can have a catalytically active coating. 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 for gluing and / or for producing the honeycomb structure or which carry out the at least one method. In particular, the gluing device or the device provided for carrying out the method for producing the honeycomb structure comprises a data processing system, e.g.a control device that has means for executing the steps of the method and / or that has means that are suitably equipped, configured, or programmed to execute the steps of the method or that execute the method. 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. The "means" can in particular include 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.A computer program is further 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. A computer-readable storage medium is further proposed, comprising instructions which, when executed by a computer, cause the computer to carry out the respective described method or the steps of the respective described method. The statements relating to each method are particularly transferable to the respective other method, the honeycomb structure, 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.The use of indefinite articles ("a", "an", "an" and "anes"), particularly in the patent claims and the description reproducing them, is to be understood as such and not as a number. Terms or components introduced accordingly are therefore to be understood as being present at least once and, in particular, as being able to be present multiple times. As a precaution, it should be noted that the numbers used here ("first", "second", ...) primarily serve (only) to distinguish between several similar objects, quantities or processes, and therefore, in particular, do not necessarily prescribe any dependency and / or sequence of these objects, quantities or processes. Should a dependency and / or sequence be required, 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. The invention and the technical field 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 size relationships shown are only schematic. They show: Fig. 1: a section of a honeycomb body formed by the layers in a perspective view, partly in section; Fig. 2: the section according to Fig. 1 in a view along a central axis of the honeycomb body; Fig. 3: an example of a honeycomb body with the layers according to Fig. 1 and Fig. 2; Fig. 4: the method for gluing a first layer; Fig.5: an embodiment of the method for applying glue to a first layer; Fig. 6: the application of glue in the embodiment according to Fig. 5; Fig. 7: an application of glue in a further embodiment of the method; and Fig. 8: a method for producing a honeycomb structure. Fig. 1 shows a section of a honeycomb body 33 formed by the layers 1, 20 in a perspective view, partly in section. Fig. 2 shows the section according to Fig. 1 in a view along a central axis 28 of the honeycomb body 33. Fig. 3 shows a honeycomb body 33 with the layers 1, 20 according to Fig. 1 and Fig. 2. Figures 1 to 3 are described together below. The honeycomb body 33 has a honeycomb structure 19 which extends between a fluid inlet side 26 and a fluid outlet side 27 along a central axis 28. Channels 29 extend between these sides 26, 27 so that a fluid 30 can flow through the honeycomb structure 19.The honeycomb structure comprises a stack 21 formed by a first layer 1 and additionally by a second layer 20, each having a corrugated structure 2, wherein the layers 1, 20 extend between a first end face 7 arranged on the fluid inlet side 26 and a second end face 8 arranged on the fluid outlet side 27 along a width direction 6 parallel to the central axis 28 and along an extension direction 3 running transversely to the central axis 28 between a first end 4 and a second end 5. The corrugated structure 2 of the layers 1, 20 has a plurality of first wave troughs 9 and first wave crests 10 running parallel to one another, each extending at a first inclination angle 11 relative to the width direction 6 of greater than zero angular degrees and at most 45 angular degrees along a direction of extension.If such layers 1, 20 are arranged on top of one another, angles arise between the contacting wave troughs 9 and wave crests 10 which correspond to the sum of the inclination angles 11 of each layer 1, 20. The layers 1, 20 each have a material thickness in a height direction 32 extending transversely to the width direction 6 and the extension direction 3. The stack 21 and the channels 29 are formed by arranging a different structured region of the same first layer 1 or by arranging the structured second layer 20 on the first layer 1. The other region of the first layer 1 or the second layer 20 is structured such that the superimposed wave troughs 9 and wave crests 10 intersect, so that a contact zone 22 is delimited between the wave troughs 9 and wave crests 10 along the extension direction.Soldered connections 24 are formed on a plurality of contact zones 22, with a soldered connection 24 being formed only on a predetermined subset of the contact zones 22. The honeycomb body 33 has at least two band-shaped layers 1, 20 with a corrugated structure 2. Fig. 3 shows that, at least partially or at least on a fluid inlet side 26 of the honeycomb body 33, a smooth layer without a corrugated structure 2 is arranged between the band-shaped layers 1, 20 with a corrugated structure 2. To form a honeycomb structure 19 through which a fluid 30 can flow from the fluid inlet side 26 to the fluid outlet side 27 of the honeycomb body 33, the layers 1, 20 are arranged with themselves by folding or with at least one other (smooth and / or structured) layer 1, 20 to form a stack 21. In Fig. 3, the honeycomb structure 19 is formed by additionally winding the stack 21. The honeycomb body 33 has a round cross-section.The honeycomb body 33 is formed with a tube-like housing 36. When used for exhaust gas aftertreatment, an exhaust gas / fluid 30 regularly enters the honeycomb body 33 via the fluid inlet side 26 or into the honeycomb structure 19 via one of the end faces 7, 8 during operation of the honeycomb body 33 and exits again via the fluid outlet side 27 or the other end face 8, 7. The end faces 7, 8 (of the layers 1, 20 or of the honeycomb structure 19), which are arranged parallel to one another, regularly define the length of the honeycomb structure 19 (or the width of the layers 1, 20) in the direction of a central axis 28 of the honeycomb body 33, which penetrates both end faces 7, 8 and is arranged perpendicularly and centrally to both end faces 7, 8. The corrugated structures 2 of the layers 1, 20 are formed over the entire length of the honeycomb body 33 or over the entire width of the layers 1, 20, i.e. between the first end face 7 and the second end face 8.The corrugated structure 2 is formed by elevations (wave crests 10) and depressions (wave troughs 9). Wave crests 10 and wave troughs 9 alternate regularly in the direction of extension 3 of the layers 1, 20. The wave crests 10 and wave troughs 9 form a type of sinusoidal undulation in cross-section. The arrangement of the corrugated structure 2, or the wave crests 10 and wave troughs 9, in the honeycomb body 33 is such that they run obliquely to the central axis 28. This creates channel sections for a fluid 30 that run obliquely to the central axis 28, rather than parallel to it. If an exhaust gas flow or a fluid flow strikes an end face 7, 8 perpendicularly, the exhaust gas / fluid 30 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 33 or the honeycomb structure 19.The corrugated structure 2 is such that the corrugated crests 10 and corrugated troughs 9 in adjacent regions (viewed in the radial direction 35 relative to the central axis 28) 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 alternates as viewed in the radial direction 35. This means that the corrugated crests 10 and corrugated troughs 9 do not lie on top of one another in a linear manner at any point on the honeycomb body 33 of the honeycomb structure 19, but rather cross one another and thus essentially form only point-like support points or contact zones 22 with one another. This results in a structure in which the partial flows of the exhaust gas / fluid 30 are permanently deflected and into adjacent wave crests 10 orWave troughs 9 can flow in, in particular in a zigzag manner. The corrugated structure 2 of the layer 1, 20 and the intersecting arrangement of the corrugated structures 2 in the honeycomb body 33 results in the fact that the interstices 34 between the contacting layers 1, 20, which are always present in multiple numbers when the wave troughs 9 and wave crests 10 are aligned straight and extend over a great length, are reduced, whereby with the same cell density of the honeycomb body 33 or the honeycomb structure 19 a larger surface area can be provided and unwanted accumulations of washcoat (or another coating) in these interstices 34 can be reduced. Fig. 4 shows the method for applying glue to a first layer 1. Fig. 5 shows an embodiment of the method for applying glue to a first layer 1. Fig. 6 shows the application of glue in the embodiment according to Fig. 5. Fig.7 shows the application of glue in another variant of the process. Fig.4 to 7 are described together below. Reference is made to the explanations regarding Figs. 1 to 3. According to step a) of the method, a gluing device 12 is provided with at least one roller 13, the surface 14 of which is wetted with a glue material 15. According to step b), the structured first layer 1 is arranged in the gluing device 12. The first layer 1 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. The first layer 1 is essentially rectangular. The extension of the first layer 1 along the extension direction 3 is greater than along the width direction 6.The corrugated structure 2 of the first layer 1 has a plurality of parallel wave troughs 9 and wave crests 10, each extending along a direction of extension at an inclination angle 11 with respect to the width direction 6 of approximately 8 degrees. According to step c) of the method, contact of the structured first layer 1 with the surface 14 of the roll 13 takes place exclusively in a first region 16 of the wave crests 10 pointing towards the roll 13, and the adhesive material 15 is transferred from the surface 14 to the first region 16. The entire first layer 1 is structured, i.e., it has the corrugated structure 2 (i.e., in particular, no smooth / unstructured regions) over the entire extent in the width direction 6 and in the extension direction 3. The roller 13 of the gluing device 12 is cylindrical, with an outer circumferential surface of the roller 13 being provided for contacting the first layer 1.The surface 14 arranged on the outer circumferential surface is designed to receive the adhesive material 15. The surface 14 can be porous, e.g., in the manner of a sponge, which can be elastically deformed if necessary, or can be designed without pores. The wetting of the surface 14 of the roller 13 can be controlled so that the surface 14 has as constant a quantity of adhesive material 15 as possible per unit area of ​​the surface 14. For this purpose, the roller can be immersed in a bath containing adhesive material 15 or can be continuously exposed to adhesive material 15. A stripping device (not shown) can be provided by which the quantity of adhesive material 15 present on the surface 14 can be adjusted. According to step c), the structured first layer 1 is contacted with the surface 14 of the roller 13. The first layer 1 is contacted exclusively in a first region 16 of the wave crests 10 facing the roller 13.The first region 16 can comprise a portion of the wave crests 10 (see Figs. 6 and 7) and / or a first partial region 17 of a wave crest 10. The regions of the first layer 1 that lie between the wave crests 10 (e.g., the wave troughs 9) are not contacted by the surface 14 of the roll 13. The transfer of the adhesive material 15 from the surface 14 takes place exclusively to the first region 16. Thus, no adhesive material 15 is transferred to regions outside the first region 16. In step c), only a predetermined first subset of the wave crests 10 and only a predetermined first partial region 17 of a wave crest 10 is contacted by the roll 13 or the surface 14 and applied with adhesive material 15 (see Figs. 5, 6, and 7). Each of the wave crests 10 of the first layer 1 is contacted by the roll 13 only over a length 31, which is at most 10% of the extension of the wave crests 10 along the direction of travel.with the glue material 15 (see Figs. 6 and 7). The first region 16 is arranged at a distance from each end face 7, 8 (see Figs. 6 and 7). In the method, a predetermined second subset of the wave crests 10 or a predetermined second sub-region 18 of a wave crest 10 is masked before step c), so that contact between these wave crests 10 or this sub-region 18 and the surface 14 of the roll 13 is prevented (see Fig. 5). The masking 37 comprises a cover of the first layer 1, so that at least the first regions 16 of the first layer 1 are not covered and can therefore be contacted by the roll 13. Fig. 8 shows a method for producing a honeycomb structure 19 or a honeycomb body 33. Reference is made to the explanations for Figs. 1 to 7. According to step i. the first layer 1 glued by the described method for gluing the first layer 1 is provided. According to step ii.another structured region of the same first layer 1 is arranged, or a structured second layer 20 is arranged on the first layer 1 to form a stack 21. The region of the first layer 1 or the second layer 20 is structured such that the superimposed wave troughs 9 and wave crests 10 intersect, so that a contact zone 22 between the wave troughs 9 and wave crests 10 is delimited along the direction of travel. According to step iii., the honeycomb structure 19 is formed. For this purpose, the stack 21 with the layers 1, 20 stacked exclusively on top of one another can be used, or the stack 21 can be folded and / or wound and / or twisted. Such honeycomb structures 19 are generally known. If necessary, the honeycomb structure 19 is also arranged in a housing 36 to form a honeycomb body 33. According to step iv. the honeycomb structure 19 orof the honeycomb body 33 with a solder material 23, wherein the solder material 23 adheres to the glue material 15. For this purpose, the honeycomb structure 19 or the honeycomb body 33 can, for example, be immersed in a bath comprising solder material 23 or the honeycomb structure 19 or the honeycomb body 33 can be exposed to powdered solder material 23. The solder material 23 only adheres to the areas of the first area 16 that are accessible to the solder material 23. The solder material 23 therefore does not adhere in the contact zones 22 of the wave troughs 9 and wave crests 10, but rather in areas that are immediately adjacent thereto. In step iv., the solder material 23 is therefore not arranged between the layers 1, 20 but in the so-called interstices 34 that are formed by the mutually contacting corrugated structures 2. According to step v. the honeycomb structure 19 or the honeycomb body 33 is heated,which has the solder material 23, and the formation of solder connections 24 in the contact zones 22 formed in step ii., which were applied with the solder material 23 in step iv. The intersecting corrugated structures 2 of the mutually contacting layers 1, 20 in the honeycomb structure 19 result in the reduction of the interstices 34 between the mutually contacting layers 1, 20, which always occur in large numbers when the corrugation troughs 9 and corrugation crests 10 are aligned straight and extend over a large length 31, whereby a larger surface can be provided with the same cell density of the honeycomb body 33 or the honeycomb structure 19 and undesired accumulations of washcoat (or another coating) in these interstices 34 can be reduced. In addition, the intersecting arrangement of the corrugated structures 2 means that the capillary forces acting along the gussets 34 are regularly interrupted, so that a liquid glue material 15 ora solder material 23 liquefied during step v. is not displaced further (along the course of the gusset 34). This makes it possible to create locally limited first regions 16 and to ensure that solder joints 24 are formed exclusively in these first regions 16. Furthermore, the arrangement and distribution of the first regions 16 can be freely selected so that a wide variety of requirements with regard to expansion behavior and strength of the honeycomb structure can be responded to appropriately. For this purpose, the first layer 1 provided in step i. can have a gluing pattern 25 (see Fig. 7), which is predetermined (if necessary mathematically) before step i. depending on the contact zones 22 created in step ii. and depending on the honeycomb structure 19 created in step iii. and is created on the first layer 1. Especially when folding and / or winding and / or twisting the layers 1, 20 orThe stacks 21 formed by the layers 1, 20 form honeycomb structures 19, which exhibit very different behaviors with regard to expansion behavior or fatigue strength. Furthermore, the arrangement of a specific first region 16 of the first layer 1, 20 in the subsequently produced honeycomb structure 19 is difficult to predict. Therefore, first regions 16 can be determined, in particular mathematically or within the framework of a simulation, which occupy specific positions in the subsequently produced honeycomb structure 19, in particular relative to one another, so that specific properties with regard to expansion behavior and fatigue strength can be specifically adjusted.

[0002] List of reference symbols first layer corrugated structure direction of extension first end second end width direction first end face second end face trough crest angle of inclination gluing device roller surface glue material first area first partial area second partial area honeycomb structure second layer stack contact zone solder material solder joint gluing pattern fluid inlet side fluid outlet side central axis channel fluid length height direction honeycomb body gusset radial direction housing masking

Claims

Patent claims 1. Method for applying glue to a first layer (1) which has a corrugated structure (2), wherein the first layer (1) 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 (2) of the first layer (1) has a plurality of wave troughs (9) and wave crests (10) which run parallel to one another and each extend at an angle of inclination (11) with respect to the width direction (6) of greater than zero angular degrees and at most 45 angular degrees along a direction of extension; wherein the method comprises at least the following steps: a) providing a gluing device (12) with at least one roller (13), the surface (14) of which is wetted with a glue material (15); b) arranging the structured first layer (1) in the gluing device (12);c) contacting the structured first layer (1) with the surface (14) of the roll (13) exclusively in a first region (16) of the wave crests (10) pointing towards the roll (13) and transferring the adhesive material (15) from the surface (14) to the first region (16).

2. Method according to claim 1, wherein in step c) only a predetermined first subset of the wave crests (10) or only a predetermined first subset (17) of a wave crest (10) is contacted by the roll (13).

3. Method according to one of the preceding claims, wherein at least a predetermined second subset of the wave crests (10) or a predetermined second subset (18) of a wave crest (10) is masked before step c), so that contacting of these wave crests (10); or this second partial region (18) with the surface (14) of the roll (13) is prevented.

4. A method for producing a honeycomb structure (19), at least comprising the following steps: i. Providing the first layer (1) glued by the method according to one of the preceding claims; ii. Arranging another structured region of the same first layer (1) or arranging a structured second layer (20) on the first layer (1) to form a stack (21); wherein the other region of the first layer (1) or the second layer (20) is structured such that the superimposed wave troughs (9) and wave crests (10) intersect, so that a contact zone (22) between the wave troughs (9) and wave crests (10) is delimited along the direction of travel; iii. Forming the honeycomb structure (19); iv. Applying a solder material (23) to the honeycomb structure (19), wherein the solder material (23) adheres to the adhesive material (15); v.Heating the honeycomb structure (19) which has the solder material (23) and forming solder joints (24) in the contact zones (22) formed in step ii., which were applied with the solder material (23) in step iv.

5. The method according to claim 4, wherein of the layers (1, 20) forming the contact zone (22), only one layer (1, 20) in the contact zone (22) is wetted with the glue material (15).

6. The method according to one of the preceding claims 4 and 5, wherein the first layer (1) provided in step i. has a glue pattern (25) which depends on the contact zones (22) created in step ii. and on the honeycomb structure (19) created in step iii. is predetermined before step i. and is produced at least on the first layer (1).

7. A honeycomb structure (19) extending between a fluid inlet side (26) and a fluid outlet side (27) along a central axis (28), with channels (29) extending between these sides (26, 27) so that a fluid (30) can flow through the honeycomb structure (19); wherein the honeycomb structure (19) comprises at least one stack (21) which is formed at least by a first layer (1) which has a corrugated structure (2), wherein the first layer (1) extends between a first end face (7) arranged on the fluid inlet side (26) and a second end face (8) arranged on the fluid outlet side (27) along a width direction (6) parallel to the central axis (28) and along an extension direction (3) running transversely to the central axis (28) between a first end (4) and a second end (5);wherein the corrugated structure (2) of the first layer (1) has a plurality of mutually parallel wave troughs (9) and wave crests (10), each extending at an inclination angle (11) relative to the width direction (6) of greater than zero angular degrees and at most 45 angular degrees along a direction of extension; wherein the stack (21) and the channels (29) are formed by arranging another structured region of the same first layer (1) or by arranging a structured second layer (20) on the first layer (1); wherein the other region of the first layer (1) or the second layer (20) is structured such that the superimposed wave troughs (9) and wave crests (10) intersect, so that a contact zone (22) is delimited between the wave troughs (9) and wave crests (10) along the direction of extension; wherein solder joints (24) are formed at a plurality of contact zones (22);wherein a solder connection (24) is formed only at a predetermined subset of the contact zones (22); 8. The honeycomb structure (19) according to claim 7, wherein the solder joints (24) are arranged at least spaced apart from the end faces (7, 8).

9. The honeycomb structure (19) according to one of the preceding claims 7 and 8, wherein each solder joint (24) has a maximum length (31) along the central axis (28) of at most 5 millimeters.

10. The honeycomb structure (19) according to one of the preceding claims 7 to 9, wherein the honeycomb body (19) has a solder quantity of less than 30 g / m², based on a specific geometric surface area GSA of the honeycomb body (19).

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