Stock material or miscellaneous articles – All metal or with adjacent metals – Honeycomb – or with grain orientation or elongated elements...
Reexamination Certificate
2000-06-12
2001-11-13
Zimmerman, John J. (Department: 1775)
Stock material or miscellaneous articles
All metal or with adjacent metals
Honeycomb, or with grain orientation or elongated elements...
C428S596000, C428S603000, C502S527180, C502S522000, C422S180000
Reexamination Certificate
active
06316121
ABSTRACT:
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a flat or sheet-like construction such as a metal foil and to a honeycomb body.
European Patent No. EP-0 454 712 B1, which corresponds to U.S. Pat. No. 5,157,010, describes a flat or sheet-like construction which is formed from a metal sheet or foil. The flat construction has at least two structures which are spaced from a reference surface and which superpose one another at least partially. The mutually superposed structures are in the form of grooves or channels. The structures are of different dimensions. Some of the structures form so-called macrostructures and some of the structures form so-called microstructures. The microstructures overlap the macrostructures. European Patent No. EP-0 454 712 B1 also discloses a honeycomb body having a plurality of passages or channels through which a fluid can flow in a flow direction. The honeycomb body is formed from at least one flat or sheet-like configuration. The passages are defined by the structuring of the flat or sheet-like configuration.
A further configuration of a flat or sheet-like construction which is particularly suitable for forming a honeycomb body is known from International Publication No. WO 96/09892, which corresponds to U.S. Pat. No. 5,795,658. The flat construction has structures which are partially mutually superposed. This flat construction also has macrostructures and microstructures. The microstructures extend at an angle relative to the macrostructures. It can also be seen from International Publication No. WO 96/09892 that the microstructures also cross each other. In particular the microstructures cross at the crests of the macrostructures. The flat construction disclosed in International Publication No. WO 96/09892 is made of a metal sheet or foil in which the structures are formed.
Particularly in the region of the partially overlapping structures which are formed for example by the points of intersection of the microstructures, there are problem zones which result in a heavy loading of the material forming the flat construction, during a procedure for shaping the material.
Due to the deformation characteristics of the metal foil or sheet, it is not possible to guarantee that, in the region of the mutually superposed structures, the transition between the mutually superposed structures is satisfactorily produced. That has an effect in particular on structures which are of relatively large dimensions.
International Publication No. WO 96/09892 also describes a metal honeycomb body having a plurality of passages or channels through which a fluid can flow in a flow direction. The passages are formed of metal foils or sheets which are at least partially provided with at least one macrostructure which defines the passages and which determines the honeycomb form of the metal honeycomb body. A part of the sheet metal portions has at least in partial regions additional microstructures. The microstructures extend at an angle to the flow direction, successive microstructures are spaced from one another, and the microstructures cross each other.
German Patent No. DE 38 44 350 C2 discloses a flat construction which has structures. The structures are limb-shaped or bar-shaped portions which are pressed in a bridge-like shape out of a plane of the flat construction. The limb-shaped or bar-shaped portions are provided side-by-side in longitudinally directed zones extending in mutually parallel relationship. The limb-shaped or bar-shaped portions project towards both sides out of the plane of the metal foil or sheet. The limb-shaped or bar-shaped portions which project on both sides are produced by a procedure in which an initially flat smooth metal strip is passed through a pair of embossing-cutting rollers by which the strip is partially slit and the limb-shaped or bar-shaped portions are pressed out towards both sides of the plane of the strip. A flat construction of that kind has no overlapping structures.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a flat construction, in particular a metal foil, which overcomes the above-mentioned disadvantages of the heretofore-known constructions of this general type and which is easier to manufacture and process. A further object of the invention is to provide a honeycomb body which is easier to manufacture.
With the foregoing and other objects in view there is provided, in accordance with the invention, a metal foil, including:
at least two intersecting structures spaced from an imaginary reference surface and defining an intersection region; and
the at least two intersecting structures partially superposing one another in the intersection region and being formed with at least one through opening in the intersection region.
In other words, the flat construction, in particular a metal foil, according to the invention which has at least two structures which are spaced from a reference surface and which are in mutually superposed relationship is distinguished in that there is at least one through opening formed in a region in which the structures overlie or superpose each other. The structures superpose each other insofar as, for example, they cross each other or meet each other. In those regions, during the manufacturing of the structures, the flat construction is subjected to a particularly heavy loading when the structures are produced by a shaping operation. Furthermore, folds, distortions or the like can occur in the region of the mutually superposed structures. This is avoided by the formation of at least one through opening in the region of the mutually superposed structures.
The formation of structures results in an increased level of stiffness in a flat construction. The provision of through openings in the regions of the mutually superposed structures also provides that the flat construction has a higher degree of flexibility. This achieves an improved further processing of the flat construction.
The through opening is preferably formed by at least one slot. In that respect, a preferred configuration of the through opening is one in which there are at least two slots which meet or intersect at an angle and in particular cross one another. Thus, an optimum utilization of material is achieved.
In order to avoid that portions of the structures possibly project in the region of the through opening, so that such portions cause a nuisance or a disturbance, it is proposed that the through opening is formed by at least one perforation.
The process of forming the at least one through opening in the flat construction or metal foil is preferably performed before the structures are formed. That makes it possible to synchronize the formation of the through openings and the structures so that the through openings are always produced at a predetermined location on the flat construction or metal foil.
Configuring the flat construction or the metal foil in accordance with the invention also permits a superimposition of structures which have a similar geometry, in particular if they form relatively large structures within the flat construction because the through opening removes the possible problem zone, before the shaping procedure is carried out.
In accordance with a further feature of the invention, the at least two intersecting structures superpose one another at a given angle in the intersection region.
In accordance with another concept of the invention, a flat or sheet-like construction or a metal foil is provided which has at least two structures which are spaced from a reference surface and which are disposed in an at least partially mutually superposed relationship. The flat construction has at least one through opening formed in a region in which the mutually superposed structures have a common theoretical maximum height with respect to the reference surface, which is greater than a maximum height of at least one structure in that region. In that case, the entire edge of the through opening is disposed at a level with respect to the reference height that is less
Emitec Gesellschaft fuer Emissions-technologie mbH
Greenberg Laurence A.
Lerner Herbert L.
Stemer Werner H.
Zimmerman John J.
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