Title of Invention

A HONEYCOMB BODY FORMED OF ALTERNATING SUBSTANTIALLY EVEN AND AT LEAST PARTIALLY STRUCTURED LAYERS

Abstract The invention relates to a honeycomb body (13) formed from alternating substantially even (10) and at least partially structured (1) layers, in particular catalytic converter support and/or filter, preferably for the exhaust system of an automobile, wherein the layers (1,10) form fluid permeable cavities (12) substantially in an axial flow direction (19), and wherein the structured layers (1) feature structural extremities (4,5), which are in contact with adjacent substantially even layers (10), and wherein the structured layers (1) feature inverted sections (2) in the area of their structural extremities (4, 5), which protrude into the cavities (12) and in a cross section through the honeycomb body (13) that is perpendicular to the direction of flow (19) feature a substantially inverse form to the structural extremities (4, 5), so that recesses (22) are generated in the structural extremities (4, 5) in the area of the inverted sections (2), the area of the inverted sections (2) and/or the structural extremities (4, 5), counter-structures (11) are formed in the essentially even layers (10) that are engaged with the structural extremities (4, 5) and/or with the inverted sections (2).
Full Text Honeycomb body consisting of layers comprising inverted
sections and layers comprising counter-structures
The invention relates to a honeycomb body configured
from alternating layers that are essentially smooth and
layers that are at least partially structured. The
structure of the structured layers is in this case
typically a corrugation, the latter also having
substructures in the form of inverted sections.
In automobile construction especially, increasingly
stringent statutory limits in many countries have
resulted in the accepted use of catalytic converters
for converting harmful constituents of the exhaust gas.
Honeycomb bodies are often used as catalyst supports in
catalytic converters or else as filters, because they
provide a large reaction surface or filter surface per
unit volume.
Such honeycomb bodies are formed essentially from
ceramic material or as metallic honeycomb bodies
comprising a number of layers. In the case of metallic
honeycomb bodies, a distinction is drawn in particular
between two typical types of construction. An early
type of construction, typical examples of which are
shown by DE 29 02 779 Al, is the spiral type, in which
an essentially smooth sheet-metal layer and a
corrugated sheet-metal layer are placed one on top of
the other and spirally wound. In another type of
construction, the honeycomb body is formed by a
multiplicity of alternately arranged smooth and
corrugated or differently corrugated sheet-metal
layers, the sheet-metal layers first being arranged in
one or more stacks and then intertwisted with one
another. This makes the ends of all the sheet-metal
layers come to lie on the outside and allows them to be
connected to a housing or tubular casing, thereby
creating numerous connections, which increase the
durability of the honeycomb body. Typical examples of
these types of construction are described in EP 0 245
737 Bl or WO 90/03220. It has also long been known tc
provide the sheet-metal layers with additional
structures in order to influence the flow and/or
achieve cross-mixing between the individual flow
channels. Typical examples of such configurations are
WO 91/01178, WO 91/01807 and WO 90/08249. Finally,
there are also honeycomb bodies of a conical type of
construction, possibly also with further additional
structures for influencing the flow. Such a honeycomb
body is described for example in WO 97/49905. In
addition, it is also known to leave a clearance for a
sensor, in particular to accommodate a lambda probe, in
a honeycomb body. An example of this is described in
DE 88 16 154 Ul. Honeycomb bodies are also used as
adsorber structures in which contaminate constituents,
such as nitrogen oxides for example, can be at lease
temporarily stored, and also as filters, in particular
particle filters, which may be formed in an open or
closed manner.
In particular in the case of metallic honeycomb bodies,
it has been found that, when they are used in the
exhaust system of an automobile, they are deformed over
time on account of the changing thermal loads. In
particular, it is known that the honeycomb body
telescopes, that is to say part of the honeycomb body
pushes out from one end face of the honeycomb body on
account of the pulsatile gas flows to which it is
exposed, or that the honeycomb body assumes the form of
a barrel, this is to say that the diameter of the
honeycomb body is reduced in the region of the gas
inlet side and/or gas outlet side. Such deformations
and other deformations lead to or are based on the
displaceability of neighboring walls of the cavities in
the direction of flow, which may occur for example in
the case of an absent or defective link in neighboring
walls of the cavities, which is formed with preference
by thermal joining methods, such as soldering or
welding for example.
A catalyst support which is not soldered but is
mechanically fixed in corresponding neighboring layers
by the interaction of webs and recesses is known from
EP 0 298 943 A2 . It is known from DE 27 33 640 Al to
achieve corresponding interlocking by tongues and
corresponding recesses in neighboring layers.
The interlocking of neighboring layers proves to be
problematical whenever there are inverted sections
within the honeycomb body, for example in structured
layers, these inverted sections serving for influencing
the flow, in particular also the connection of cavities
neighboring in the circumferential direction, and are
known from the aforementioned prior art.
Against this background, the invention is based on the
object of providing a metallic honeycomb body which
includes measures for influencing the flow and layers
of which are effectively protected against relative
displacement of neighboring layers in the direction of
flow.
This object is achieved by a honeycomb body with the
features of claim 1. Advantageous developments are the
subject of the dependent claims.
A honeycomb body according to the invention is formed
from alternating layers that are essentially smooth and
layers that are at least partially structured and
serves in particular as a catalyst support and/or
filter, preferably for the exhaust system of an
automobile. In this case, the layers form cavities
that allow a fluid to permeate essentially in an axial-
direction of flow, the structured layers having
structural extremities which are in contact with
essentially smooth neighboring layers, and the
structured layers having in the region of their
structural extremities inverted sections which protrude
into the cavities and have a form that is approximately
the inverse of that of the structural extremities in a
cross section through the honeycomb body that runs
perpendicularly to the direction of flow, so that
interruptions are produced in the structural
extremities in the region of the inverted sections.
According to the invention, counter-structures are
formed in the essentially smooth layers in the region
of the inverted sections and/or the structural
extremities and engage with the structural extremities
and/or with the inverted sections.
It is particularly favorable if the structural
extremities and/or the inverted sections interact with
the counter-structures with a positive fit, so that, in
particular, a displacement of the layers with respect
to one another in the direction of flow is prevented.
An inverted section is understood in this connection as
meaning a structure that is formed by re-shaping a
structured layer. Such an inverted section creates an
opening through which the flow can pass and which forms
a connection with a neighboring cavity. Through this
opening, fluid, such as exhaust gas for example, which
flows through the honeycomb body can consequently pass
from one cavity to a neighboring cavity. This opening
is formed with preference in the direction of flow. On
account of the additional flow-accepting edges of the
inverted section, inverted sections advantageously lead
to vortexing of the flow, which counteract the
formation of laminar marginal flows. It is therefore
advisable that a positively fitting connection with
counter-structures does not close the entire opening
created in this way again but takes up only quite a
small part of the opening cross section. In the most
favorable case, the positively fitting connection may
have dimensions that are only of the order of magnitude
of the thickness of the layers.
In particular, it is advantageous to form the inverted
sections symmetrically with respect to the structuring,
that is to say symmetrically in relation to the;
structure minimum or maximum. Structuring is to be
understood in particular as meaning a corrugation that
is customary for example in the case of metallic
honeycomb bodies, for example sinusoidal or triangular
corrugation. Essentially continuous structures are to
be understood in particular as structures which - apart
from the inverted sections - extend over the entire
length of the honeycomb body in the direction of flow.
With preference, the coverage of the cross section
through which flow can pass, brought about by the
counter-structures when they engage in the inverted
section, is as small as possible. Forming of the;
inverted sections in the region of the structural
extremities may also mean, for example, that only part
of the structuring contributes to the inverted section,
that in particular only a relatively small part of the
material of the walls forming the structuring is
inverted, so that the basic form of the structuring is
preserved in the region of the inverted section.
If essentially smooth layers, in particular sheet-metal
layers or layers formed from fibers, are provided with
a counter-structure, which is intended to run in the
honeycomb body approximately transversely in relation
to the later direction of flow, these layers must be.
wound during the formation of the honeycomb body, the
winding direction being precisely such that the;
counter-structures would make such winding considerably
more difficult or even prevent it, since they stiffen
the layer. The counter-structures should therefore be
configured in such a way that the flexibility of the
layers is adequate for winding, even with small radii.
This can be achieved in various ways, in particular of
course by the counter-structures not being elevations
or depressions but simply holes into which the
extremities of the structured layers protrude.
Counter-structures are also possible as elevations
and/or depressions, however, as long as they are
sufficiently pliable as a result of suitable:
dimensioning and/or interruptions. Continuous
elevations and/or depressions can be modified by
interruptions, for example holes or relieving slits, in
such a way that the layer is still sufficiently pliable
in spite of counter-structures being present.
The described forming of the inverted section and
counter-structure has the effect that, in the case of a
honeycomb body according to the invention, a relative
displacement in the direction of flow of two cavity
walls which are neighboring in a direction that is
essentially perpendicular to the direction of flow
cannot occur, since only the honeycomb body as a whole
can be displaced. This is the case even if the layers:
of the honeycomb body according to the invention are;
thermally connected to one another, for example
soldered or welded, and these thermally formed
connections have become at least partially detached.
The reason for this is that the counter-structures
which engage in the inverted section prevent a relative
displacement of two cavity walls neighboring in a
direction that is essentially perpendicular to the
direction of flow.
A layer may be formed from various types of materials.
For example, the forming of at least some of the layers
from sheet metal, with preference corrosion- and high-
temperature-resistant steel sheets or else aluminum
sheets is possible and in accordance with the
invention. Furthermore, according to the invention, at
least some of the layers may be formed from material
that at least partially allows a fluid to flow through,
for example a metallic fiber material. The forming of
at least some of the layers from a composite material,
for example a material that at least partially allows a
fluid to flow through consisting of ceramic and
metallic fibers, is also possible and in accordance
with the invention. Here, a ceramic fiber layer may be:
reinforced by a connection to sheet-metal strips
established by a joining technique.
A honeycomb body according to the invention may
advantageously be used as a catalyst support and/or
filter in the exhaust system of an automobile. It may
be used with particular preference in the form of a
particle filter. Such a particle filter may be both
open and closed. In the case of open particle filters,
particles of dimensions that are significantly larger
than the pores of the filter media used can pass
through the particle filter, so that clogging of the
filter is not possible, whereas no particles can pass
through a closed particle filter. Furthermore, the use
of a honeycomb filter according to the invention near
the engine, in particular upstream of a turbocharger,
is advantageously possible. Use as an adsorber for one
or more components of the exhaust gas, such as nitrogen
oxides (N0x) for example, is also possible and in
accordance with the invention. Furthermore, the basic
configuration of a honeycomb body according to the
invention as described above in the prior art, that is
to say for example as a spiral form, an S form or an
involute form, is possible and in accordance with the
invention, as are all the embodiments, additions and/or
possibilities for use that are described in the cited
prior art.
According to an advantageous configuration of the:
honeycomb body according to the invention, the:
honeycomb body is formed from
a) at least one layer that is essentially smooth and
at least one layer that is at least partially
structured or
b) at least one layer that is at least partially
structured,
inverted sections and/or counter-structures being
formed in a layer that is essentially smooth and/or in
a layer that is at least partially structured. It is;
particularly preferred in this connection that the
honeycomb body is formed by
a) winding at least one layer or
b) stacking a plurality of layers to form at least one
stack and twisting at least one stack.
The forming of the honeycomb body from sheet-metal
layers that are essentially smooth and/or sheet-metal
layers that are at least partially structured
advantageously makes it possible to form a honeycomb
body according to the invention. However, it is
equally advantageous and possible according to the
invention not to configure the honeycomb body
completely from sheet-metal layers but at least partly
to use other layers, in particular metallic layers.
These may be, for example, layers consisting of
material that at least partially allows a fluid to flow
through, for example metallic fiber mats, which may be
used for the configuration of a particle filter, but
also composite materials, which may consist of ceramic
and metallic fibers and possibly also portions of sheet
metal. The use of perforated sheet-metal layers is
also of advantage for some applications.
When the honeycomb body is configured at least partly
from sheet-metal layers, the honeycomb body may for
example be wound or twisted in a spiral form, in an S
form or in an involute form, reference being made to
the prior art cited above for details. However, other
forms of a honeycomb body are also possible and in
accordance with the invention.
According to an advantageous configuration of the
honeycomb body according to the invention, in which
inverted sections are formed in layers that are at
least partially structured with a structure height H,
the height h of the inverted sections is less than or
equal to the structure height H.
According to a further advantageous configuration of
the honeycomb body according to the invention, in which
inverted sections are formed in layers that are at
least partially structured with a structure height H,
the height h of the inverted sections is greater than
the structure height H.
Depending on the height h of the inverted sections, the;
counter-structures may be formed of a matching type.
For example, whenever the height h of the inverted
sections is greater than the structure height H of the
structured layers, the counter-structure may simply
comprise a slit in the neighboring layer, which is for
example essentially smooth. The extent of the slit in
the direction of flow is advantageously made to match
the corresponding extent of the inverted section, so
that a positive fit is obtained. A further possibility
is that the counter-structure also comprises a
corresponding inverted section, or the recess which the
inverted section leaves behind in the structures. With
a corresponding extent of the inverted sections in the
direction of flow, it is also possible here to
establish a positive fit of the inverted section and
the counter-structure between two neighboring walls of
the cavities.
If the height h of the inverted sections is less than
the structure height H of the at least partially
structured layers, a counter-structure may be formed as
a microstructure formed essentially perpendicular to
the direction of flow, for example in the form of a
barrier. Here it is possible that at least one
microstructure is formed in a way corresponding to a
first and/or a second delimitation of the inverted
section in the direction of flow. For example, two
counter-structures which together engage in an inverted
section may be formed, it being possible for the
distance between the counter-structures in the
direction of flow to be chosen such that it corresponds
essentially to the extent of the inverted section in
the direction of flow.
According to the invention, not every inverted section
must be in engagement with a counter-structure;
depending on the application, it may be advantageous to
bring only some of the inverted sections into
engagement with counter-structures, for example only
every tenth one, twentieth one or every second one,
fourth one, etc. Here, the reference to "every tenth
one, twentieth one", etc. means that the tenth,
twentieth, etc. part of the inverted sections is in
engagement with counter-structures.
According to a further advantageous configuration of
the honeycomb body, the height a of a counter-structure
is less than, with preference much less than, the
height h) of the inverted sections.
In this way it is advantageously possible to bring the:
counter-structure and the inverted section into
engagement, or even to produce a positive fit, without
the pressure loss of the flow through the channel being
significantly increased.
According to an advantageous configuration of the
honeycomb body, every inverted section is in engagement
with a counter-structure.
The forming of a counter-structure for every inverted
section is also possible in accordance with the
invention and may be advantageous, depending on the
application.
According to an advantageous configuration of the
honeycomb body, at least some of the counter-structures
comprise inverted sections.
The forming of the counter-structures from inverted
sections allows the honeycomb body to be configured in
a simple way, for example from only one type of layers
which have inverted sections. If these inverted
sections are correspondingly formed, it is possible for
example to dispense with the forming of essentially
smooth layers. Furthermore, it is also possible and in
accordance with the invention also to provide the
essentially smooth layers with inverted sections, which
can be brought into engagement with inverted sections
in the at least partially structured sheet-metal
layers. It is also possible and in accordance with the
invention to configure a honeycomb body in which only
some of the counter-structures are inverted sections
and others are a different type of counter-structure:.
With different types of counter-structure, it is
advantageously possible for example to influence the
pressure conditions inside the honeycomb body. The
distribution of the flow through the honeycomb body
into different regions is also possible and in
accordance with the invention.
According to a further advantageous configuration of
the honeycomb body according to the invention, at least
some of the counter-structures comprise embossings.
The forming of the counter-structures as embossings is
a particularly simple form of the counter-structure.
Such embossings may for example be formed in the layers
that are essentially smooth and/or in layers that are
at least partially structured.
It is particularly preferred in this connection that
the embossings are formed as microstructures which run
essentially transversally to the axial direction of the
honeycomb body.
A microstructure is understood in this connection as
meaning a structure which, when the honeycomb body is
configured at least partly from layers that are at
least partially structured, has a smaller structure
height than the structure of the at least partially
structured layers. A microstructure may be formed both
in layers that are essentially smooth and as a
secondary structure in layers that are at least
partially structured.
According to an advantageous configuration of the
honeycomb body according to the invention, at least
some of the counter-structures comprise at least two
embossings spaced apart in the direction of flow.
Two or more axially spaced-apart embossings
advantageously make the positive fit between the
inverted section and the counter-structure possible
without the interaction of the inverted section and the;
counter-structure causing a significantly increased
pressure loss. In particular, two embossings between
which the distance in the direction of flow corresponds
with preference to the dimensions of an inverted
section in the direction of flow advantageously prevent
relative displacement of the honeycomb body in the
direction of flow, that is to say in particular the
telescoping effect, and so increase the lifetime of the
honeycomb body.
According to a further advantageous configuration of
the honeycomb body according to the invention, the
embossings have perforations, in particular
microperforations. Microperforations are distinguished
by the fact that their dimensions are much smaller than
the dimensions of the structures of the layers that are
at least partially structured. In the case of metallic
layers, in particular sheet-metal layers, the formation
of perforations in the embossings facilitates the
deformability of the layer, in particular the
windability. The embossings are interrupted or
restricted by the perforations.
According to a further advantageous configuration of
the honeycomb body according to the invention, at least
some of the counter-structures are formed as holes.
With corresponding configuration of the inverted
sections, the counter-structures can be brought into
engagement with the latter, in particular even with a
positive fit. Holes as counter-structures are simple
to provide. The dimensions of the holes in the
direction of flow advantageously correspond to the
dimensions of the inverted sections in the direction of
flow.
The form and configuration of the counter-structures
are not restricted to the examples represented here.
In particular, different forms and configurations of
counter-structures may even be formed in a single
honeycomb body or even within a single layer.
According to a further advantageous configuration of
the honeycomb body according to the invention, at least
some of the counter-structures are formed in a layer
that is essentially smooth.
This allows for example the prevention of relative
displacement of the honeycomb body in the direction of
flow in a layer that is at least partially structured
and a layer that is at least essentially smooth.
According to a further advantageous configuration of
the honeycomb body according to the invention, at. least
some of the counter-structures are formed in a layer
that is at least partially structured.
This makes it possible for the invention to be realized
for example in honeycomb bodies which are formed only
from layers that are at least partially structured, in
particular metallic layers such as sheet-metal layers.
However, in the same way, counter-structures can be
formed according to the invention both in layers that
are essentially smooth and in layers that are at least
partially structured.
A further advantageous configuration of a honeycomb
body according to the invention is distinguished in
that the quotient of
a) the sum of the height (h) of the inverted section
and the height (a) of the counter-structure and
b) the radial distance (KH) between two walls of the.
cavities
is less than 1.
That is to say that the following relationship is
obtained:
(h + a)/KH Such a configuration of the inverted sections and the
counter-structures advantageously ensures good long-
term durability even under the very abrasive conditions
in which a honeycomb body is used for example as a
catalyst support in the exhaust system of an
automobile, distinguished for example by the loading
caused by strongly pulsatile gas flows and great
thermal gradients and transients. Relative
displacements in the direction of flow in the honeycomb
body are effectively prevented.
According to a further advantageous configuration of
the honeycomb body according to the invention, at least
some of the layers are metallic layers. It is
particularly preferred in this connection that at least
some of the metallic layers are sheet-metal layers.
These preferably have a thickness of less than 6 0 |am,
with preference less than 40 (am, with particular
preference less than 25 jam.
According to a further advantageous configuration of
the honeycomb body according to the invention, at least
some of the metallic layers at least partially allow a
fluid to flow through. It is particularly preferred in
this connection that at least some of the metallic
layers that at least partially allow a fluid to flow
through are formed from a metallic fiber material, in
particular a sintered metallic fiber material.
According to a further advantageous configuration of
the honeycomb body according to the invention, at least
some of the layers are configured from a composite
material, with preference a composite material
consisting of ceramic and metallic fibers.
The invention is to be described below on the basis of
the exemplary embodiments shown in the drawing, without
being restricted to these. In the drawing:
Figure 1 shows a layer that is at least partially
structured, with inverted sections;
Figure 2 shows a schematic perspective view of part of
a honeycomb body;
Figure 3 shows a schematic cross section through the
part of a honeycomb body from Figure 2, along
the line III;
Figure 4 shows an example of a positive fit by holes
in counter-structures formed in a layer that
is essentially smooth;
Figure 5 shows another example of a positively fitting
connection between smooth and corrugated
layers with inverted sections;
Figure 6 shows a further example of a layer that is at
least partially structured, with inverted
sections, and corresponding layers that are
essentially smooth, with counter-structures;
Figure 7 shows a honeycomb body according to the
invention in cross section;
Figure 8 shows a further example of a layer that is at
least partially structured and a layer that
is essentially smooth, with inverted sections
and counter-structures, in schematic cross
section; and
Figure 9 shows a further example of a layer that is
essentially smooth and a layer that is at
least partially structured, with inverted
sections and counter-structures, in schematic
cross section.
Figure 1 shows a layer 1 that is at least partially
structured, for example consisting of a thin metal
foil, in particular a thin corrosion-resistant steel
foil, with inverted sections 2. In the present
exemplary embodiment, the layer 1 that is at least
partially structured has triangular structures 3 (all
embodiments apply however in the same way to other
forms of corrugation, which however cannot be:
graphically represented as clearly), which extend over
the entire length of the layer 1 apart from the regions;
with inverted sections 2. These structures 3 have in
each case structure maxima 4 and structure minima 5
(together referred to as structural extremities) and
form with other layers cavities that allow a fluid, for
example an exhaust gas, to flow through. Respectively
formed in the region of the structure minima 4 and/or
the structure maxima 5 are inverted sections 2 of ei
height h. In the region of the structural extremities
4, 5, the layer 1 is folded in one direction. An
inverted section 2 is a re-shaping of the material of
the layer 1, the latter being curved or folded in a
second, opposite direction, that is to say forming ei
shape that is approximately inverse in relation to the
basic structure. When a honeycomb body is configured
at least partly from such layers 1, the honeycomb body
can be flowed through by a fluid, in particular exhaust
gas, essentially in the direction of the direction of
flow 19.
Figure 2 shows a schematic perspective view of the
positively fitting interaction between a structured
layer 1 and an essentially smooth layer 10 with a
counter-structure 11. Figure 3 shows a cross section
through Figure 2 along the line III. The structure 3
of the structured layer 1 has structure maxima 4 and
structure minima 5. Furthermore, an inverted section 2
is formed. The inverted section 2 is formed by a re-
shaping of the material of the layer 1. The structure
3 as such (that is to say considered without the
inverted section) has a folding or a curvature in a
first direction. In the case of a triangular
corrugation, as in the present example, this means that
the structure 3 is made up of a first flank 6 and a
second flank 7, which in cross section form two
straight lines. Here, the first flank 6 has a first
flank slope and the second flank 7 has a second flank
slope, the algebraic signs of which are opposite. In
the present example, the inverted section 2 is also
formed by two flanks, namely a first inversion flank 8
and a second inversion flank 9. When the inverted
section 2 is formed, the first inversion flank 8 is
created from the first flank 6 and the second inversion
flank 9 is created from the second flank 7. In cross
section, the first inversion flank 8 and the second
inversion flank 9 form two straight lines, the slopes
of which have different algebraic signs. Consequently,
the folding of the inverted section 2 lies essentially
in a direction that is opposite the direction of the
folding of the structural extremities 4, 5, the forms
of the structure 3 and of the inverted sections 2 being
approximately opposed.
Furthermore, Figures 2 and 3 show two neighboring
metallic layers 10 that are essentially smooth, which
in this example have counter-structures 11 formed as a
microstructure. These counter-structures 11 comprise
an embossing in the form of a barrier, which is formed
in the region neighboring the inverted section 2. This
counter-structure 11 engages in an inverted section 2.
With preference, the counter-structure 11 is formed in
such a way that there is a positive fit between the
counter-structure 11 and the inverted section 2. In
order to increase the flexibility of the layer 10,
which is otherwise very stiff as a result of the
counter-structure 11, relieving slits 22 are present,
preferably with rounded ends, in order to avoid a notch
effect and further tearing. The engagement or positive
fit between the inverted section 2 and the counter-
structure 11 advantageously prevents relative movement
between the layer 1 that is at least partially
structured and neighboring metallic layers 10 that are
essentially smooth. If a honeycomb body, for example a
catalyst support or filter for use in particular in
automobile construction, is configured from such layers
1, 10, relative movement of the layers 1, 10 therein is
advantageously prevented, in particular telescoping of
the honeycomb body is avoided. The layer 1 that is at
least partially structured has triangular structures 3
of a structure height H. The inverted sections 2 are
formed in the region of the structure minima 4 and
structure maxima 5, to be precise symmetrically in
relation to the structural extremities 4, 5. In the
present example, the height h of an inverted section 2
is less than the structure height H of the structures
3. Furthermore, counter-structures 11, the height a of
which is much less than the height h of the inverted
sections 2, are formed in the metallic layers 10 that
are essentially smooth. By way of example, a counter-
structure 11 is depicted for each inverted section 2,
but it is equally possible to provide only some of the
inverted sections 2 with counter-structures 11. When
establishing the relative number of inverted sections 2
per counter-structure 11, when designing the form of
the counter-structure 11 and when deciding whether to
form a pure engagement or a positive fit of the
counter-structure 11 with the inverted section 2, the
kind of use envisaged later may be advantageously taken
into consideration. For example, catalyst supports
that are used in the exhaust system of a spark- ignition
engine are exposed to different loads with respect i;o
pulsation frequency and amplitude, as well as
temperature of the exhaust gas, than for example in the
case of diesel or rotary engines. The position of a
catalyst support with respect to an internal combustion
engine (for example near the engine, in the manifold,
etc) also has great effects on the loads that the
catalyst support has to withstand.
When a honeycomb body is configured as described above,
that is to say by winding or coiling one or more
layers, cavities 12 that allow a fluid to flow in or
through and are delimited by the layers 1, 10 are
formed. The radial distance KH between two neighboring
walls of the cavities 1, 10 corresponds essentially to
the structure height H.
Apart from the type of counter-structures 11 shown i:a
Figures 2 and 3, there are many other possible forms of
counter-structures, some of which are shown by way of
example in further figures. The various types of
counter-structures 11 may be combined as desired in the
honeycomb body according to the invention.
Furthermore, inverted sections 2 and counter-structures
11 also do not have to be formed in the entire
honeycomb body, it also possible and in accordance with
the invention for them to be formed in certain regions,
for example only in an axial or radial subregion. ~.n
another subregion, for example, holes of dimensions
which are greater, with preference much greater, than
the structure repeat length of the structures 3 may be
formed.
Figures 4 and 5 show in a schematic perspective view
how holes 23 can act as counter-structures 11, in that
they interact with structural extremities 4, 5 of the
structure 3 or with inverted sections 2. These
embodiments are particularly advantageous, because the
holes 23 do not reduce, but even increase, the
flexibility of the layers that are essentially smooth.
Such metallic layers 1, 10 may be at least partly thin
sheet-metal layers, with preference of a thickness of
less than 60 \xm, with particular preference less than
40 |j.m, in particular less than 25 ^im. The layers 1, 10
may also consist at least partly of a material that at
least partially allows a fluid to flow through, for
example a metallic fiber material which is for example
sintered from powder, chips or fibers or else applied
to a supporting structure, such as for example an
expanded metal mesh.
Figure 6 shows a further exemplary embodiment of layers
1, 10 for configuring a honeycomb body according to the
invention. Here, the layer 1 that is at lease
partially structured is sinusoidally corrugated and has
structures 3. Also formed are inverted sections 2,
which are curved in a direction which is opposite the
curvature of the corresponding structures 3 in this
region. The inverted sections 2 are formed
symmetrically in relation to the structures 3 in the
region of the structure maxima 4 and the structure
minima 5. Only part of the material forming the
structures 3 contributes to the forming of the inverted
sections 2. The counter-structure 2 is formed as an
embossing. It is also advantageously possible for a
number of counter-structures 11, for example two, to be
formed per inverted section 2, advantageously being
able to be spaced at a distance in the direction oil
flow 19 that corresponds to the extent of the inverted
section 2 in the direction of flow 19.
Figure 7 shows a honeycomb body 13 according to the
invention in cross section, which has a honeycomb
structure 15 formed in a tubular casing 14. The
honeycomb structure 15 is configured from metallic
layers 10 that are essentially smooth and metallic
layers 1 that are at least partially structured, which
have inverted sections 2 according to the invention.,
only shown in an exemplary manner, in the metallic
layers 1 that are at least partially structured and
have counter-structures 11, not shown for the sake or
overall clarity, in the metallic layers 10 that are
essentially smooth. The metallic layers 1, 10 form
cavity walls extending in the direction of flow 19 and
delimiting cavities 12. The distance KH between two
cavities 1, 10 in a direction essentially perpendicular
to the direction of flow 19 is defined in the present
example essentially by the structure height H. Such a
honeycomb body 13 according to the invention allows a
fluid, such as an exhaust gas for example, to flow
through in the direction of flow 19.
Figure 8 schematically shows in cross section a further
example of a counter-structure 11. The layer 1 that is
at least partially structured has an inverted section
2, which protrudes through the counter structure 11,
formed as a hole 23 in the layer 10 that is essentially
smooth, into a radially neighboring cavity. The
matching of the dimensions of the hole 23 to the
dimensions of the inverted section 2 advantageously
allows the forming of a positive fit between the
inverted section 2 and the counter-structure 11.
Figure 9 shows a further example of a counter-structure
11 schematically in cross section. This counter-
structure 11 is formed as an embossing in the layer 10
that is essentially smooth, in the regions in the
direction of flow 19 in which there are inverted
sections 2. The embossing runs in the transversal
direction, that is to say essentially perpendicularly
to the direction of flow 19 in which the layers 1, 10
extend. The embossing has the effect that the
essentially smooth layer has a smooth level 17 and an
embossed level 16. Here, the distance of the smooth
level 17 from the reference plane 18, which is depicted
by dashed lines and is defined by the structure minima
5, corresponds to the structure height H, whereas the
distance of the embossed level 16 from the reference:
plane 18 corresponds to the difference between the
structure height H and the height a of the counter-
structure 11. The embossed level 16 therefore differs
from the smooth level 17 by the height a of a counter-
structure 11. In order to increase the deformability
of the layer 10 that is essentially smooth,
perforations 20 with perforation edges 21 are formed in
the region of the embossing.
In a honeycomb body 13 according to the invention,
relative movements of the layers 1, 10 with respect to
one another in the direction of flow 19 are prevented
by the interaction of inverted sections 2 and counter-
structures 11 assigned to them. This takes place by
the counter-structure 11 and the inverted section 2
being in engagement with each other. In this way it is
also possible in particular for the telescoping of
honeycomb bodies 13 to be prevented.
List of designations
1 layer that is at least partially structured
2 inverted section
3 structure
4 structure maximum
5 structure minimum
6 first flank
7 second flank
8 first inversion flank
9 second inversion flank
10 layer that is essentially smooth
11 counter-structure
12 cavity
13 honeycomb body
14 tubular casing
15 honeycomb structure
16 embossed level
17 smooth level
18 reference plane
19 direction of flow
20 perforation
21 perforation edge
22 relieving slit
23 hole
a height of a counter-structure
h height of an inverted section
H structure height
KH radial distance between two cavity walls
WE CLAIM
1. A honeycomb body (13) formed from alternating substantially even
(10) and at least partially structured (1) layers, in particular catalytic
converter support and/or filter, preferably for the exhaust system of an
automobile, wherein the layers (1,10) form fluid permeable cavities
(12) substantially in an axial flow direction (19), and wherein the
structured layers (1) feature structural extremities (4,5), which are in
contact with adjacent substantially even layers (10), and wherein the
structured layers (1) feature inverted sections (2) in the area of their
structural extremities (4, 5), which protrude into the cavities (12) and
in a cross section through the honeycomb body (13) that is
perpendicular to the direction of flow (19) feature a substantially
inverse form to the structural extremities (4, 5), so that recesses (22)
are generated in the structural extremities (4, 5) in the area of the
inverted sections (2), the area of the inverted sections (2) and/or the
structural extremities (4, 5), counter-structures (11) are formed in the
essentially even layers (10) that are engaged with the structural
extremities (4, 5) and/or with the inverted sections (2).
2. The honeycomb body (13) as claimed in claim 1, wherein the counter-
structures (11) are in a form closure contact with at least a part of the
structural extremities (4,5) and/or inverted sections (2).
3. The honeycomb body (13) as claimed in claim 1 or 2, wherein the
counter-structures in the substantially even layers (10) are formed so
that the flexibility of these layers (10) remains sufficiently high for
coiling, in particular by means of holes and/or recesses in the counter-
structures (11).
4. The honeycomb body (13) as claimed in claim 3, wherein the
honeycomb body (13) is formed by
a) coiling of at least one layer (1) or
b) stacking a plurality of layers (1,10) to at least
one stack and twisting of at least one stack.
5. The honeycomb body (13) as claimed in one of the preceding claims,
wherein the inverted sections (2) are formed in structure layers (1) at
least partially with a structure height (H) and wherein the height (h)
of the inverted sections (2) is less than or equal to the structure height
(H).
6. The honeycomb body (13) as claimed in one of claims 1 to 4, wherein
the inverted sections (2) are formed in structured layers (1) at least
partially with a structure height (H) and wherein the height (h) of the
inverted sections (2) is higher than the structure height (H).
7. The honeycomb body (13) as claimed in one of the preceding claims
wherein the counter-structure (11) is an elevation or depression, the
height (a) of which is smaller, preferably considerably smaller, than the
height (h) of the inverted sections (2).
8. The honeycomb body (13) as claimed in one of the preceding claims,
wherein every inverted section (2) is in engagement with a counter
structure (11).
9. The honeycomb body (13) as claimed in one of the preceding claims,
wherein at least some of the counter-structures (11) comprise inverted
sections (2).
10. The honeycomb body (13) as claimed in one of the preceding claims,
wherein at least some of the counter-structures (11) comprise
embossings.
11. The honeycomb body (13) as claimed in claim 10. wherein the
embossings are formed as microstructures which run substantially
transversally to the axial direction of flow (19) of the honeycomb body
(13)
12. The honeycomb body (13) as claimed in claim 10 or 11, wherein at
least some of the counter structures (11) comprise at least two
embossings spaced apart in the direction of flow.
13. The honeycomb body (13) as claimed in one claims 10 to 12 wherein
the embossings have perforations, preferably microperforations.
14. The honeycomb body (13) as claimed in one of the preceding claims,
wherein at least some of the counter-structures (11) are formed as
holes (23).
15. The honeycomb body (13) as claimed in one of the preceding claims
wherein at least some of the counter-structures (11) are constituted as
holes in the substantially even layers (10), into which the structural
extremities (4,5) and/or the inverted sections (2) protrude, in
particular with a form closure.
16. The honeycomb body (13) as claimed in one of claims 3 to 15 wherein
at least some of the counter-structures (11) are formed in the layers
(1) that are at least partially structured.
17. The honeycomb body (13) as claimed in one of the preceding claims
wherein the quotient of
a) the sum of the height (h) of the inverted section (2) and the height
(a) of the counter structure (11) and
b) the radial distance (KH) between two walls of the cavities (1,10) is
less than 1.
18. The honeycomb body (13) as claimed in one of the preceding claims,
wherein at least some of the layers (1,10) are metallic layers.
19. The honeycomb body (13) as claimed in claim 18, wherein at least
some of the metallic layers (1,10) are sheet-metal layers.
20. The honeycomb body (13) as claimed in claim 19, wherein the sheet-
metal layers (1, 10) have a thickness of less than 60 µm, preferably
less than 40 µm, with particular preference less than 25 urn.
21. The honeycomb body (13) as claimed in one of claims 18 to 20
wherein at least some of the metallic layers (1, 10) at least partially
allow a fluid to flow through.
22. The honeycomb body (13) as claimed in claim 21, wherein at least
some of the metallic layers (1,10) that at least partially allow a fluid to
flow through are formed from a metallic fiber material, in particular a
sintered metallic fiber material.
23. The honeycomb body (13) as claimed in one of the preceding claims,
wherein at least some of the layers (1, 10) are composed of a
composite material, with preference a composite material consisting of
ceramic and metallic fibers.


The invention relates to a honeycomb body (13) formed from alternating
substantially even (10) and at least partially structured (1) layers, in particular
catalytic converter support and/or filter, preferably for the exhaust system of an
automobile, wherein the layers (1,10) form fluid permeable cavities (12)
substantially in an axial flow direction (19), and wherein the structured layers (1)
feature structural extremities (4,5), which are in contact with adjacent
substantially even layers (10), and wherein the structured layers (1) feature
inverted sections (2) in the area of their structural extremities (4, 5), which
protrude into the cavities (12) and in a cross section through the honeycomb
body (13) that is perpendicular to the direction of flow (19) feature a
substantially inverse form to the structural extremities (4, 5), so that recesses
(22) are generated in the structural extremities (4, 5) in the area of the inverted
sections (2), the area of the inverted sections (2) and/or the structural
extremities (4, 5), counter-structures (11) are formed in the essentially even
layers (10) that are engaged with the structural extremities (4, 5) and/or with
the inverted sections (2).

Documents:

02087-kolnp-2006 abstract.pdf

02087-kolnp-2006 claims.pdf

02087-kolnp-2006 correspondence others.pdf

02087-kolnp-2006 description(complete).pdf

02087-kolnp-2006 drawings.pdf

02087-kolnp-2006 form-1.pdf

02087-kolnp-2006 form-2.pdf

02087-kolnp-2006 form-3.pdf

02087-kolnp-2006 form-5.pdf

02087-kolnp-2006 international publication.pdf

02087-kolnp-2006 international search authority report.pdf

02087-kolnp-2006 pct form.pdf

02087-kolnp-2006 priority document.pdf

02087-kolnp-2006-correspondence others-1.1.pdf

02087-kolnp-2006-correspondence-1.2.pdf

02087-kolnp-2006-form-18.pdf

02087-kolnp-2006-priority document-1.1.pdf

2087-KOLNP-2006-(27-12-2011)-CORRESPONDENCE.pdf

2087-kolnp-2006-abstract.-1.1.pdf

2087-KOLNP-2006-ABSTRACT.pdf

2087-KOLNP-2006-CANCELLED PAGES.pdf

2087-kolnp-2006-claims.-1.1.pdf

2087-KOLNP-2006-CLAIMS.pdf

2087-kolnp-2006-correspondence.-1.1.pdf

2087-kolnp-2006-correspondence.pdf

2087-kolnp-2006-description (complete).-1.1.pdf

2087-KOLNP-2006-DESCRIPTION (COMPLETE).pdf

2087-kolnp-2006-drawings.-1.1.pdf

2087-KOLNP-2006-DRAWINGS.pdf

2087-kolnp-2006-examination report.pdf

2087-kolnp-2006-form 1.pdf

2087-kolnp-2006-form 18.-1.1.pdf

2087-kolnp-2006-form 18.pdf

2087-kolnp-2006-form 2.-1.1.pdf

2087-KOLNP-2006-FORM 2.pdf

2087-kolnp-2006-form 3.-1.2.pdf

2087-kolnp-2006-form 3.1.pdf

2087-KOLNP-2006-FORM 3.pdf

2087-kolnp-2006-form 5.-1.2.pdf

2087-kolnp-2006-form 5.1.pdf

2087-KOLNP-2006-FORM 5.pdf

2087-KOLNP-2006-FORM-27.pdf

2087-kolnp-2006-gpa.-1.1.pdf

2087-kolnp-2006-gpa.pdf

2087-kolnp-2006-granted-abstract.pdf

2087-kolnp-2006-granted-claims.pdf

2087-kolnp-2006-granted-description (complete).pdf

2087-kolnp-2006-granted-drawings.pdf

2087-kolnp-2006-granted-form 1.pdf

2087-kolnp-2006-granted-form 2.pdf

2087-kolnp-2006-granted-letter patent.pdf

2087-kolnp-2006-granted-specification.pdf

2087-KOLNP-2006-OTHERS.pdf

2087-KOLNP-2006-PETITION UNDER RULE 137.pdf

2087-kolnp-2006-reply to examination report.-1.2.pdf

2087-KOLNP-2006-REPLY TO EXAMINATION REPORT.pdf

2087-kolnp-2006-reply to examination report1.1.pdf

2087-kolnp-2006-specification.pdf

2087-kolnp-2006-translated copy of priority document.-1.1.pdf

2087-kolnp-2006-translated copy of priority document.pdf

abstract-02087-kolnp-2006.jpg


Patent Number 245525
Indian Patent Application Number 2087/KOLNP/2006
PG Journal Number 04/2011
Publication Date 28-Jan-2011
Grant Date 24-Jan-2011
Date of Filing 25-Jul-2006
Name of Patentee EMITEC GESELLSCHAFT FUR EMISSIONS TECHNOLOGIE MBH
Applicant Address HAUPTSTRASSE 150 53797 LOHMAR
Inventors:
# Inventor's Name Inventor's Address
1 MAUS, WOLFGANG GUT HORST, 51429 BERGISCH GLABACH
2 BURECK, ROLF FROBEISTRASSE 12 51429 BERGISCH GLADBACK
PCT International Classification Number F01N 3/28
PCT International Application Number PCT/EP2005/000082
PCT International Filing date 2005-01-07
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10 2004 001 947.9 2004-01-13 Germany