Metal Honeycomb Winding with Rolling Guide Elements
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Solution Overview
Problem
The production of large honeycomb bodies with thin metal foils is challenging due to deformation risks and uneven force application during the winding process, which affects the flow behavior in exhaust systems.
Innovation Solution
A device with a central wrapping mandrel, mold segments, and guide elements with rolling bodies to reduce friction and ensure uniform winding, allowing for the production of large honeycomb structures with improved structural integrity and flow behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thin metal foils are used to increase the number of channels per volume and reduce surface-specific heat capacity, then the productivity and thermal response are improved, but the manufacturing precision deteriorates due to deformation risks during winding
Solution Approach 1:
Rolling bodies are introduced as intermediary elements between the metal foils and the guide elements. These rolling bodies reduce direct friction and contact pressure on the thin metal foils during the winding process, preventing deformation while enabling the use of thinner foils to increase channel density
Solution Approach 2:
The mold segments are designed to be movable rather than fixed, allowing them to adapt their position during the winding process. This dynamic adjustment ensures uniform force distribution and prevents localized stress concentrations that could deform thin metal foils
2Length of stationary object
If large honeycomb bodies are produced with metal foils longer than 10000 mm, then the extent and volume are increased, but the manufacturing precision deteriorates due to difficulty in ensuring uniform force application
Solution Approach 1:
The winding process is divided into multiple zones by dividing the mold into several movable mold segments. Each segment can be independently adjusted to ensure uniform force application along the entire length of long metal foils (over 10000 mm), maintaining structural integrity throughout the winding process
Solution Approach 2:
Movable mold segments allow dynamic adjustment of contact points and force distribution during winding of long metal foils. This ensures uniform compression and positioning throughout the entire length of the foil, preventing deformation and ensuring consistent honeycomb structure formation
3Strength
If high forces are applied during winding to ensure structural integrity, then the strength is improved, but the manufacturing precision deteriorates due to deformation of metal foils
Solution Approach 1:
Rolling bodies serve as mediators that distribute applied forces uniformly across the metal foils during winding. This allows sufficient compression force to be applied for structural integrity while preventing localized high-stress points that would deform the foils and distort channel shapes
Solution Approach 2:
The rolling bodies change the pressure distribution parameters during winding, converting concentrated high forces into distributed uniform pressure. This enables achieving the necessary compression for strong bonds while maintaining the geometric precision of the channels
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device enables reliable production of large honeycomb bodies with reduced deformation and enhanced uniformity, ensuring targeted flow behavior in exhaust systems, particularly in mobile exhaust systems.
Implementation Method 1
at least one guide element (7) is formed with at least one rolling body (9), wherein the at least one rolling body (9) reduces friction when guiding the at least one metal foil (14, 15) past the at least one guide element (7)
Data Source
Figure 1~2
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AI summary
A device (1) for winding at least partially structured metal sheets into a honeycomb structure (2) comprises at least one winding mandrel (3) in a central region (4) of the device (1) having a receptacle (5) for at least one metal sheet; at least one shaped segment (6) having at least one guide element (7) for guiding the at least one metal sheet during winding, and at least one pivotable clamping jaw (8), the at least one guide element (7) being designed with at least one roll body (9). Also described is a process for producing a honeycomb body (13) with at least partially structured metal sheets. The invention is particularly suitable for producing large honeycomb bodies.