DE102014225629A1 - Honeycomb body, extrusion die, process for producing a honeycomb body and process for producing an extrusion die - Google Patents

Abstract

In order to create a honeycomb body, which is used, for example, as a catalyst body or filter body in motor vehicles, which has a high dimensional stability and is easy to produce, it is proposed that the honeycomb body comprises a base body having a square honeycomb base structure which is parallel to a Longitudinal axis of the honeycomb body and mutually parallel first base walls and parallel to the longitudinal axis of the honeycomb body and perpendicular to the first base walls extending second base walls is formed, wherein the base body has a support structure which comprises support walls, parallel to the longitudinal axis of the honeycomb body and obliquely to the first Base walls and oblique to the second base walls.

Description

The present invention relates to a honeycomb body, which is used for example as a catalyst body or filter body in motor vehicles.

Such a honeycomb body may, for example, have cuboid flow channels, that is, flow channels with a square cross section.

Various embodiments of honeycomb bodies and methods for producing the same are known, for example from EP 1 423 266 B1 , of the EP 1 541 817 A1 , of the EP 1 493 479 B1 , of the US Pat. No. 6,843,822 B2 , of the EP 1 125 704 A1 , of the EP 1 374 971 A1 , of the EP 2 644 244 A2 , of the EP 2 692 406 A1 and the US 8,178,185 B2 known.

The present invention has for its object to provide a honeycomb body which has a high dimensional stability and is easy to produce.

This object is achieved by a honeycomb body comprising a base body having a square honeycomb base structure by parallel to a longitudinal axis of the honeycomb body and mutually parallel first base walls and parallel to the longitudinal axis of the honeycomb body and perpendicular to the first base walls extending second base walls is formed, wherein the base body has a support structure which comprises support walls which extend parallel to the longitudinal axis of the honeycomb body and obliquely to the first base walls and obliquely to the second base walls.

The fact that the honeycomb body comprises a square honeycomb base structure and a support structure, the honeycomb body can be made simple and stable.

An oblique arrangement or an oblique course of the support walls is to be understood in particular as meaning that the support walls do not run parallel or perpendicular to the first base walls and / or the second base walls with respect to at least one spatial direction.

The first base walls preferably run in planes arranged parallel to one another.

The second base walls preferably run in parallel to each other arranged levels.

The planes along which the first base walls extend are preferably perpendicular to the planes along which the second base walls extend.

The planes along which the first base walls extend, the planes along which the second base walls extend, and planes along which the support walls extend preferably have common cut lines.

In one embodiment of the invention it can be provided that base channels of the base body are formed by means of the first base walls and by means of the second base walls.

The base channels have in particular a square cross-section.

Preferably, the base channels are divided by means of the support walls in each case two sub-channels.

The sub-channels preferably have a triangular cross-section.

In particular, it can be provided that the cross sections of the sub-channels have the shape of an isosceles triangle.

It may be favorable if the supporting walls form diagonals of the base channels.

In each base channel preferably at most one or exactly one support wall is arranged.

It can be provided that the support walls have a width which corresponds to at least approximately 1.2 times, in particular at least approximately 1.4 times, a width of base channel walls of the base channels.

In particular, it can be provided that the support walls have a width which corresponds to a width of base channel walls of the base channels multiplied by a factor square root of 2 (2 ^0.5 ).

It can be advantageous if the support walls have a thickness which deviates by, for example, at most approximately +/- 50%, preferably at most approximately +/- 10%, in particular at most approximately +/- 5%, from a thickness of base channel walls of the base channels.

In particular, it may be provided that the thickness of the support walls and the thickness of the base channel walls are substantially identical.

Preferably, the support walls of the base channels, which have a common base channel wall, perpendicular to each other aligned support walls.

Base channels, which have a common base channel wall, in particular directly adjoin one another and are separated from one another by this one common base channel wall.

The width and the thickness in this specification and the appended claims are, in particular, expansions in directions perpendicular to the longitudinal direction of the honeycomb body.

A length is an extension parallel to the longitudinal axis of the honeycomb body.

It may be favorable if the support walls form a square support structure within the square honeycomb base structure.

The square support structure preferably has a basic unit (basic cell) which is larger than a basic unit (basic cell, base channel) of the square honeycomb basic structure.

The base body preferably comprises a ceramic material or is formed from a ceramic material.

In particular, it can be provided that the basic body can be produced and further processed as a green body in order ultimately to produce a honeycomb body which comprises a ceramic material or is formed from a ceramic material.

The honeycomb body may be coated, for example. In particular, a catalytically active coating can be provided.

The first base walls, the second base walls and the support walls are preferably formed integrally with each other.

The present invention further relates to an extrusion tool for producing a honeycomb body, in particular a honeycomb body according to the invention.

The invention is in this respect the task of providing an extrusion die, by means of which a stable honeycomb body is easy to produce.

This object is achieved according to the invention in that the extrusion tool comprises the following:
a forming member including a feed portion and a forming portion, wherein the forming member is formed such that a moldable material for producing the honeycomb body is supplied to the feed portion, pressable through the forming member, and can be brought into a predetermined shape in the forming portion, the forming portion being a square one A slot base structure formed by parallel to an extrusion direction and parallel to each other extending first base slots and extending parallel to the extrusion direction and perpendicular to the first base slots second base slots, wherein the shaping portion has an additional slot structure comprising additional slots, which are parallel to the extrusion direction and obliquely to the first base slots and oblique to the second base slots.

The extrusion tool is preferably formed at least partially complementary to the honeycomb body.

The extrusion tool preferably has one or more of the features and / or advantages described in connection with the honeycomb body. In particular, the base slots preferably have single or multiple features of the base walls. The additional slots preferably have single or multiple features of the support walls.

By means of the base slots, the base walls are preferably produced.

By means of the additional slots, the support walls are preferably produced.

It may be favorable if the feed section of the extrusion tool has bores, in particular a multiplicity of bores, through which the moldable material can be fed to the shaping section.

The bores are preferably arranged distributed and / or dimensioned such that the shaping element supplied or feedable material, in particular moldable material, by means of the Zuführabschnitts evenly distributed to the base slots and the additional slots.

In particular, it may be provided that for the supply of moldable material to the additional slots larger-sized holes and / or a larger number of holes is provided as for the supply of moldable material to the base slots, since the additional slots in particular at preferably the same thickness of the base walls to be manufactured and Supporting walls must be supplied with a larger amount of moldable material.

Under a uniform distribution of the moldable material on the base slots and on the additional slots is to be understood in particular that the base slots and the Additional slits in particular adapted locally so much moldable material is supplied, that over the entire cross section of the honeycomb body to be produced across a uniform extrusion rate is guaranteed.

The present invention further relates to a method for producing a honeycomb body, in particular a honeycomb body according to the invention.

The invention is in this respect the task of providing a method by which a stable honeycomb body is easy to produce.

This object is achieved according to the invention by a method for producing a honeycomb body, which comprises:
Providing an extrusion tool according to the invention;
Supplying moldable material to the feed section of the forming element of the extrusion die;
Pressing the moldable material through the forming member, wherein the moldable material spreads in the base slots and the auxiliary slots and thereby base walls and supporting walls of a base body of the honeycomb body are formed.

The basic body obtainable in this way, in particular green body, can then subsequently be dried, fired, coated or otherwise reworked, for example.

The present invention further relates to a method for producing an extrusion tool, in particular an extrusion tool according to the invention.

The invention is in this respect the task of providing a method by which an extrusion tool for producing a stable honeycomb body is easy to produce.

This object is achieved according to the invention by a method for producing an extrusion tool, which comprises:
Providing an output element;
Processing the output element in a wire erosion process so that the output element is provided with parallel to an extrusion direction and parallel to each other first base slots and parallel to the extrusion direction and perpendicular to the first base slots extending second base slots;
Processing the output element in a wire erosion process, so that the output element is provided with additional slots which are parallel to the extrusion direction and oblique to the first base slots and obliquely to the second base slots.

The output element is in particular a substantially cuboid solid body, in particular metal body.

By said processing of the output element in a wire erosion process, in particular a shaping section of the shaping element of the extrusion tool can be produced.

Preferably, the output member is further provided with bores to produce the feed portion of the forming member.

The methods according to the invention preferably have one or more of the features and / or advantages described in connection with the honeycomb body according to the invention and / or the extrusion tool according to the invention.

The honeycomb body can be used in particular as a catalyst body and / or filter body.

The honeycomb body according to the invention, the extrusion tool according to the invention and / or the methods according to the invention may furthermore preferably have one or more of the features and / or advantages described below:
The honeycomb body may, for example, be a ceramic shaped body which comprises or forms a carrier material and / or a carrier body for one or more coatings. A coating is in particular a coating for the aftertreatment of exhaust gas from an internal combustion engine.

The honeycomb body can be used in particular as an oxidation-reduction catalyst and / or as a soot filter.

The honeycomb body according to the invention preferably forms the largest possible free cross section with the lowest possible web thicknesses (wall thicknesses, thickness of the base walls and / or supporting walls).

In particular, the support structure and the honeycomb base structure form a truss-like pattern.

The support walls preferably form hypotenuses of substantially isosceles triangular sub-channels of a base channel.

By means of the support structure, in particular a small wall thickness of the base walls can be achieved without risking a collapse or any other undesirable deformation of the honeycomb body after the extrusion step has been carried out.

The square honeycomb base structure is preferably formed such that the base body has 100 base channels per square inch.

Preferably, the honeycomb body has at least about 50 base channels per square inch and / or at most about 400, for example at most about 250, base channels per square inch.

By means of the support structure, preferably the stability of the base body can be ensured.

In particular, smaller wall thicknesses can be realized by using the support structure than if only the square honeycomb basic structure were provided.

The free surface of the honeycomb body may preferably increase by more than 60%, for example by more than 75%, in particular, for example, from about 1344 square meters (surface area) per cubic meter (total volume of the honeycomb body) to about 2,172 square meters per cubic meter.

A wall thickness may be for example at most about 0.3 mm, for example at most about 0.25 mm.

Further preferred features and / or advantages of the invention are the subject of the following description and the drawings of exemplary embodiments.

In the drawings show:

1 a schematic cross section through a honeycomb body, which has a square honeycomb base structure and a support structure;

2 an enlarged view of four base channels of the honeycomb body 1 ;

3 an enlarged view of two base channels of the honeycomb body 1 ;

4 a schematic plan view of an output member for producing an extrusion die, wherein the output member is in an unprocessed state;

5 one of the 4 corresponding schematic representation of the output element, wherein the output element has been provided with first base slots;

6 one of the 4 corresponding schematic representation of the output element, wherein the output element was additionally provided with second base slots;

7 one of the 4 corresponding schematic representation of the output element, wherein the output element was additionally provided with additional slots; and

8th one of the 4 corresponding schematic representation of the output element, wherein the output element has been provided with additional additional slots.

Identical or functionally equivalent elements are provided with the same reference numerals in all figures.

One in the 1 to 3 illustrated embodiment of a whole with 100 The designated honeycomb body is, for example, a carrier element for a catalytic coating for use in an exhaust gas catalytic converter of an internal combustion engine.

Such a honeycomb body 100 in particular, a basic body 102 of a ceramic material.

The main body 102 comprises a square honeycomb basic structure 104 which through first base walls 106 and second base walls 108 is formed.

The first base walls 106 and the second base walls 108 are parallel to a longitudinal axis 110 of the basic body 102 of the honeycomb body 100 aligned.

The first base walls 106 are aligned parallel to each other.

Also the second base walls 108 are aligned parallel to each other.

The first base walls 106 on the one hand and the second base walls 108 on the other hand are aligned perpendicular to each other.

By means of the base walls 106 . 108 are in particular basic channels 112 educated.

Each base channel 112 has a substantially square cross-section, in particular with respect to the longitudinal axis 110 ,

Each base channel 112 is of base channel walls 114 bounded by the base walls 106 . 108 are formed.

The base walls 106 . 108 preferably have a small thickness D _B.

In the production of the main body 102 In an extrusion process can thus easily an undesirable deformation of the body 102 result.

The main body 102 therefore preferably comprises in addition to the square honeycomb basic structure 104 a support structure 116 which has several retaining walls 118 includes or through multiple retaining walls 118 is formed.

The supporting walls 118 are parallel to the longitudinal axis 110 of the basic body 102 aligned.

With the base walls 106 . 108 close the retaining walls 118 preferably an angle α (alpha) of 45 °.

The supporting walls 118 enclose an angle β (beta) of 90 ° with each other (see 3 ).

The supporting walls 118 are so distributed in the body 102 arranged that each base channel 112 by means of exactly one supporting wall 118 in two subchannels 120 shared.

The supporting walls 118 each form a diagonal 122 of the respective base channel 112 ,

The subchannels 120 thus have a substantially isosceles triangular cross section, the triangles abut each other with their hypotenuses.

Adjacent base channels 112 are by means perpendicular to each other aligned support walls 118 in subchannels 120 shared (see in particular 2 ).

The support structure 116 of the basic body 102 is thus a square support structure 116 ,

In particular 3 can be seen, corresponds to a thickness D _{S of} the support walls 118 at least approximately a thickness D _{B of} the base walls 106 . 108 ,

A width B _{S of} the supporting walls 118 However, it is larger than the width B _{B of} the base channel walls 114 of each base channel 112 ,

In particular, the width B _S corresponds to each support wall 118 a base channel 112 the width B _{B of} the base channel walls 114 this base channel 112 multiplied by a factor square root of 2 (2 ^0.5 ).

The in the 1 to 3 illustrated honeycomb body 100 can be produced in particular in an extrusion process.

In particular, this can be an extrusion tool 130 be used.

The extrusion tool 130 , which in particular in the 4 to 8th is shown, preferably comprises a shaping element 132 which consists of an initial element 134 can be produced.

In particular 4 it can be seen, is the starting element 134 For example, as a cuboid solid component, in particular as a metal cuboid, provided.

In particular, by wire erosion can then parallel to each other extending first base slots 136 in the starting element 134 be introduced (see 5 ).

The first basic slots 136 are also parallel to a later extrusion direction 138 aligned.

The extrusion direction 138 is the direction in which a moldable material for producing the honeycomb body 100 through the finished shaping element 132 is pressed through.

The extrusion direction 138 is thus in particular parallel to the longitudinal axis 110 of the manufactured honeycomb body 100 ,

After making the first base slots 136 (please refer 5 ) become in particular also by means of wire erosion second basic slots 140 in the starting element 134 introduced (see 6 ).

The second basic slots 140 are parallel to each other and parallel to the extrusion direction 138 aligned.

Furthermore, the second basic slots 140 perpendicular to the first base slots 136 aligned.

By means of the basic slots 136 . 140 is thus a square slot basic structure 142 of the shaping element 132 educated.

In a further processing step, additional slots are made by means of wire erosion 144 in the starting element 134 introduced (see 7 ).

The additional slots 144 are in particular at an angle of 45 ° obliquely to the base slots 136 . 140 aligned.

In particular, the additional slots cut 144 the basic slots 136 . 140 in common intersections 146 or cutting lines 148 ,

In particular 8th can be seen, are both parallel to each other additional slots 144 as well as perpendicular to each other additional slots 144 in the starting element 134 introduced so that a square additional slot structure 150 results, which in particular by 45 ° relative to the square slot basic structure 142 is aligned rotated.

A region of the shaping element 132 in which the basic slots 136 . 140 and the additional slots 144 are arranged, is a shaping section 152 of the shaping element 132 ,

In this shaping section 152 For example, a supplied moldable material can be formed into a desired shape.

In particular, by means of the basic slots 136 . 140 base walls 106 . 108 of a basic body 102 are formed while using the additional slots 144 Retaining walls 118 be formed.

By means of in the 4 to 8th illustrated embodiment of an extrusion tool 130 Thus, in particular in an extrusion step, the entire base body 102 including square honeycomb basic structure 104 and square support structure 116 getting produced.

For feeding the moldable material for producing the basic body 102 is the shaping element 132 further with a feeding section 154 Mistake.

The feeding section 154 includes in particular several holes 156 (in 8th shown in dashed lines).

The holes 156 serve in particular the supply of the moldable material to the slots 136 . 140 . 144 ,

The holes 156 are in particular distributed such that the moldable material over the entire cross section of the shaping section 152 of the shaping element 132 can be uniformly pressed through it, ultimately a uniform extrusion of the body 102 to ensure.

The number of walls 106 . 108 . 118 in the 1 to 3 as well as the number of slots 136 . 140 . 144 in the 5 to 8th can basically be chosen freely and is greatly reduced for ease of representation in the accompanying figures.

Preferably, by means of the extrusion die 130 according to the 4 to 8th in the 1 to 3 illustrated honeycomb body 100 produced.

Through the use of retaining walls 118 for supporting the base walls 106 . 108 can be a honeycomb body 100 be made with small wall thicknesses (thicknesses D _S , D _B ). The honeycomb body 100 As a result, it can have a large free surface, in particular without sacrificing the mechanical stability of the honeycomb body 100 during the extrusion process, after the extrusion process and / or after the completion of the honeycomb body 100 ,

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 1423266 B1 [0003]
• EP 1541817 A1 [0003]
• EP 1493479 B1 [0003]
• US 6843822 B2 [0003]
• EP 1125704 A1 [0003]
• EP 1374971 A1 [0003]
• EP 2644244 A2 [0003]
• EP 2692406 A1 [0003]
• US 8178185 B2 [0003]

Claims (15)

Honeycomb body ( 100 ) comprising a main body ( 102 ), which has a square honeycomb basic structure ( 104 ) parallel to a longitudinal axis ( 110 ) of the honeycomb body ( 100 ) and parallel to each other extending first base walls ( 106 ) as well as parallel to the longitudinal axis ( 110 ) of the honeycomb body ( 100 ) and perpendicular to the first base walls ( 106 ) extending second base walls ( 108 ), characterized in that the basic body ( 102 ) a support structure ( 116 ), which supporting walls ( 118 ) parallel to the longitudinal axis ( 110 ) of the honeycomb body ( 100 ) and obliquely to the first base walls ( 106 ) and obliquely to the second base walls ( 108 ). Honeycomb body ( 100 ) according to claim 1, characterized in that by means of the first base walls ( 106 ) and by means of the second base walls ( 108 ) Basic channels ( 112 ) of the basic body ( 102 ) are formed, which in particular have a square cross-section. Honeycomb body ( 100 ) according to claim 2, characterized in that the base channels ( 112 ) by means of the supporting walls ( 118 ) into two subchannels ( 120 ) are divided. Honeycomb body ( 100 ) according to claim 3, characterized in that the subchannels ( 120 ) have a triangular cross-section. Honeycomb body ( 100 ) according to one of claims 2 to 4, characterized in that the supporting walls ( 118 ) Diagonals ( 122 ) of the base channels ( 112 ) form. Honeycomb body ( 100 ) according to one of claims 2 to 5, characterized in that in each base channel ( 112 ) at most one supporting wall ( 118 ) is arranged. Honeycomb body ( 100 ) according to one of claims 2 to 6, characterized in that the supporting walls ( 118 ) have a width (B _s ) which is at least approximately 1.2 times, in particular at least approximately 1.4 times, a width (B _B ) of base channel walls ( 114 ) of the base channels ( 112 ) corresponds. Honeycomb body ( 100 ) according to one of claims 2 to 7, characterized in that the supporting walls ( 118 ) have a thickness (D _S ) which is at most approximately 10%, in particular at most approximately 5%, of a thickness (D _B ) of base channel walls ( 114 ) of the base channels ( 112 ) deviates. Honeycomb body ( 100 ) according to one of claims 2 to 8, characterized in that the supporting walls ( 118 ) of base channels ( 112 ) having a common base channel wall ( 114 ) are aligned perpendicular to each other. Honeycomb body ( 100 ) according to one of claims 1 to 9, characterized in that the retaining walls ( 118 ) a square support structure ( 116 ) within the square honeycomb basic structure ( 104 ) form. Honeycomb body ( 100 ) according to one of claims 1 to 10, characterized in that the basic body ( 102 ) comprises a ceramic material or is formed from a ceramic material. Extrusion tool ( 130 ) for producing a honeycomb body ( 100 ), comprising: a shaping element ( 132 ), which has a feed section ( 154 ) and a shaping section ( 152 ), wherein the shaping element ( 132 ) is formed such that a moldable material for producing the honeycomb body ( 100 ) the feeding section ( 154 ), by the shaping element ( 132 ) and in the forming section ( 152 ) can be brought into a predetermined shape, wherein the shaping section ( 152 ) a square slot basic structure ( 142 ) parallel to an extrusion direction ( 138 ) and parallel to each other extending first basic slots ( 136 ) as well as parallel to the extrusion direction ( 138 ) and perpendicular to the first base slots ( 136 ) extending second basic slots ( 140 ) is formed, wherein the shaping section ( 152 ) an additional slot structure ( 150 ), which additional slots ( 144 ) parallel to the extrusion direction ( 138 ) and obliquely to the first base slots ( 136 ) and obliquely to the second base slots ( 140 ). Extrusion tool ( 130 ) according to claim 12, characterized in that the feed section ( 154 ) a variety of holes ( 156 ), through which the moldable material the shaping section ( 152 ), whereby the bores ( 156 ) are arranged distributed and / or dimensioned such that the forming element ( 132 ) supplied mouldable material by means of the Zuführabschnitts ( 154 ) evenly on the base slots ( 136 . 140 ) and on the additional slots ( 144 ) is distributable. Method for producing a honeycomb body ( 100 ), in particular a honeycomb body ( 100 ) according to one of claims 1 to 11, comprising the following: - providing an extrusion tool ( 130 ) according to one of claims 12 or 13; - supplying moldable material to the feed section ( 154 ) of the shaping element ( 132 ); - Pressing the moldable material through the shaping element ( 132 ), wherein the moldable material is in the base slots ( 136 . 140 ) and the additional slots ( 144 ) and thereby base walls ( 106 . 108 ) and retaining walls ( 118 ) of a basic body ( 102 ) of the honeycomb body ( 100 ) are formed. Method for producing an extrusion tool ( 130 ), in particular an extrusion tool ( 130 ) according to any one of claims 12 or 13, comprising: - providing an output element ( 134 ); - Edit the output element ( 134 ) in a wire erosion process, so that the starting element ( 134 ) parallel to an extrusion direction ( 138 ) and parallel to each other extending first base slots ( 136 ) as well as parallel to the extrusion direction ( 138 ) and perpendicular to the first base slots ( 136 ) extending second base slots ( 140 ) is provided; - Edit the output element ( 134 ) in a wire erosion process, so that the starting element ( 134 ) with additional slots ( 144 ), which are parallel to the extrusion direction ( 138 ) and obliquely to the first base slots ( 136 ) and obliquely to the second base slots ( 140 ).

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