Controlled Metal Foil Production Process, Apparatus for Performing the Production Process, and Metal Foil

• US 20080295556A1
• Filed: 11/13/2007
• Published: 12/04/2008
• Est. Priority Date: 05/13/2005
• Status: Abandoned Application

• Current Assignee: Emitec Gesellschaft für Emissionstechnologie mbH (Continental AG)
• Original Assignee: Emitec Gesellschaft für Emissionstechnologie mbH (Continental AG)
• Inventors: Hodgson, Jan, Hoster, Gunter
• Application Number:
  US11/939,108
• Publication Number:
  US 20080295556A1
• Time in Patent Office: Days
• US Class Current: 72/11.1
• CPC Class Codes: B21D 13/04 by rolling
• CPC Class Codes: B21D 28/265 with relative movement of sheet and tools enabling the punching of holes in predetermined locations of the sheet, e.g. holes punching with template
• CPC Class Codes: B21D 33/00 Special measures in connection with working metal foils, e.g. gold foils cutting or perforating of metal foil analogous to paper B26
• CPC Class Codes: B21D 43/021 Control or correction devices in association with moving strips
• CPC Class Codes: B30B 3/005 Roll constructions
• CPC Class Codes: F01N 2330/30 Honeycomb supports characterised by their structural details
• CPC Class Codes: F01N 3/2821 the support being provided with means to enhance the mixing process inside the converter, e.g. sheets, plates or foils with protrusions or projections to create turbulence
• CPC Class Codes: Y10T 428/24 Structurally defined web or sheet [e.g., overall dimension, etc.]
• CPC Class Codes: Y10T 428/24149 Honeycomb-like

Abstract

A process produces structures which are superimposed on one another in a metal foil section. The process includes producing a primary structure using a first tool, and transferring the metal foil section to a second tool, the second tool having at least one shaping profiled roller which is responsible for transferring the metal foil section. A secondary structure is produced using the second tool. A spatial position of the primary structure and the secondary structure is determined in at least one subregion of the metal foil section. An incorrect position is detected and an operating parameter of the at least one profiled roller is adapted in dependence on the detected incorrect position. An apparatus is suitable for this process and produces metal foils which are suitable for the production of catalyst support bodies that can be used in exhaust systems of internal combustion engines.

Claims

1. A process for producing structures being superimposed on one another in a metal foil section, which comprises the steps of:

a) producing a primary structure in the metal foil section using a first tool;

b) transferring the metal foil section to a second tool, the second tool having at least one shaping profiled roller being responsible for transferring the metal foil section;

c) producing a secondary structure in the metal foil section using the second tool;

d) determining a spatial position of the primary structure and the secondary structure in at least one subregion of the metal foil section; and

e) detecting an incorrect position and adapting an operating parameter of the at least one shaping profiled roller.

2. The process according to claim 1, which further comprises operating the at least one shaping profiled roller at an angular velocity being altered in the step e).

3. The process according to claim 1, which further comprises carrying out at least the step d) at least once per revolution of the at least one shaping profiled roller.

4. The process according to claim 1, which further comprises carrying out the step e) at least once per revolution of the shaping profiled roller.

5. The process according to claim 1, which further comprises performing the step a) by stamping openings and the step c) by shaping of corrugations into the metal foil section.

6. The process according to claim 1, wherein the incorrect position involves a position shift of the primary structure from the secondary structure of greater than 0.3 mm.

7. The process according to claim 1, which further comprises carrying out a detection of the incorrect position using at least one optical sensor.

8. An apparatus for producing structures being superimposed on one another, the apparatus comprising:

a first tool able to produce openings in a metal foil section;

a second tool having a pair of shaping profiled rollers through which the metal foil section can be passed to produce corrugations, said pair of shaping profiled rollers being able to effect an advance of the metal foil section through said first tool and said second tool;

an appliance for driving at least one of said shaping profiled rollers of said second tool;

at least one optical sensor disposed downstream of said second tool as seen in a direction of advance; and

at least one control unit connected to said optical sensor and said appliance.

9. The apparatus according to claim 8, wherein said at least one optical sensor has a variable detection field.

10. The apparatus according to claim 8, further comprising a measuring roller, said at least one optical sensor is assigned said measuring roller for positioning the metal foil section with respect to said at least one optical sensor.

11. The apparatus according to claim 9, further comprising an illumination device for radiating onto at least part of one side of the metal foil section in the variable detection field of said at least one optical sensor.

12. A metal foil section, comprising:

a body having a primary structure and a secondary structure formed therein, said body having a length of greater than 1.0 m, with a maximum position shift of 0.3 mm being present between said primary structure and said secondary structure.

13. The metal foil section according to claim 12, wherein said body has a thickness in a range from 30 μ

m to 150 μ

m and said secondary structure has a ratio of width to height of less than 2.0.

14. A honeycomb body, comprising:

at least one metal foil section having a primary structure and a secondary structure, said at least one metal foil section having a length of greater than 1.0 m, with a maximum position shift of 0.3 mm being present between said primary structure and said secondary structure.