CA1317231C - Process for the production of a catalytic converter for exhaust-gas cleaning and catalytic converter produced according to this - Google Patents

Process for the production of a catalytic converter for exhaust-gas cleaning and catalytic converter produced according to this

Info

Publication number
CA1317231C
CA1317231C CA000586695A CA586695A CA1317231C CA 1317231 C CA1317231 C CA 1317231C CA 000586695 A CA000586695 A CA 000586695A CA 586695 A CA586695 A CA 586695A CA 1317231 C CA1317231 C CA 1317231C
Authority
CA
Canada
Prior art keywords
catalytic converter
exhaust
production
metal
catalytic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA000586695A
Other languages
French (fr)
Inventor
Hans A. Harle
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Schwaebische Huettenwerke Automotive GmbH
Original Assignee
Schwaebische Huettenwerke Automotive GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Schwaebische Huettenwerke Automotive GmbH filed Critical Schwaebische Huettenwerke Automotive GmbH
Application granted granted Critical
Publication of CA1317231C publication Critical patent/CA1317231C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/92Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9445Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
    • B01D53/9454Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific device
    • B01J35/56
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28Construction of catalytic reactors
    • F01N3/2803Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00Structure of catalyst support or particle filter
    • F01N2330/14Sintered material
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/10Internal combustion engine [ICE] based vehicles
    • Y02T10/12Improving ICE efficiencies

Abstract

A B S T R A C T

Process for the Production of a Catalytic Converter for Exhaust-Gas Cleaning and Catalytic Converter Pro-duced according to this In a process for the production of a catalytic converter for the cleaning of exhaust gases of internal-combustion engines by means of a catalytic converter body through which flow the exhaust gases, the catalytic converter body (10) is compression-molded from metal wire pieces or metal chips and sintered after molding.

Description

-` 13~723~

PROCESS FOR THE PRODUCTION OF A CATALYTIC CONVERTER FOR

ACCORDING TO THIS

The invention relates to a process for the production of a catalytic converter (also named as catalyst) for the cleaning of the exhaust gases of internal-combustion engines by a catalytic converter body through which flow the exhaust gases, and a catalytic converter body produced according to this.

Catalytic converters are being increasingly used in automobile engine technology to convert noxious exhaust-gas components into harmless ones, with the intention being particularly to reduce the emission of carbon monoxide, hydrocarbons and nitrogen oxides.

:
The principal components of a catalytic exhaust-gas cleaning unit are the catalytic converter carrier, or catalytic converter body, its precious-metal coating and a housing surrounding the catalytic converter body.

.

'~

g :. . .

~31723~

Generally used as a carrier for the catalytic converter is a honeycomb-like-structured ceramic cyl.inder with a circular or oval cross-section. This type has until now been the one which has met with the greatest success as compared to other carrier structures, such as, for example, granulate or profiles and wound sheet-metal strips. The honeycomb character is created by a plurality of finP
channels which run through ~he catalytic converter body in the direction of flow of the exhaust gases. On the catalytic converter body is mounted the actual catalytic converter, for which predominantly platinum, rhodium and palladium are used.

What is problematic, in particular with the use of a catalytic converter body of ceramic, is its fracture-resistant mounting, due to the brittle ceramic material.
In connection w1th the thin-walled honeycomb pattern the catalytic converter body is extremely sensitive to vi-brations, impact and other mechanical influence.s. A15Q
to be ta]cen into account are the exhaust-gas impulses and the high exhaust-gas temperatures, which may reach up to approx. 900 degrees C.

To avoid the rislc of fracture due to external influences or proper motions of the ceramic body, said body is held ~31723~

in a highly heat-resistant wire shrouding, it having to be ensured by so-called bypass seals that exhaust gases do not ~low past the ceramic bloc]s through the wire reti-culation.

The ceramic body and the wire reticulation are in general surrounded by a ca-talytic converter housing which has the additional task of protecting the sensitive cerami¢ body against rapid changes in temperature, e.g., due to splash water and mechanical impacts.

Due to the costly production method and the necessary secure packaging of the catalytic converter body such a catalytic converter is relatively costly and expensive.

The present invention is therefore based on the tas~ of creating a catalytic converter which eliminates the aforementioned disadvantages, in particular which pos-sesses a good or even more improved catalytic effect with a simple structure.

This proble~ is solved according to the invention in that the catalytic converter body is compression-molded from metal wire pieces or metal chips and sintered after molding.

~L3~723~
- 3a -In accordance with a particular embodiment of the invention, there is provided a catalyst for cleaning exhaust gases from combustion Pngines, comprising a catalyst body consisting of compression moulded and then sintered metal wire pieces or metal chips and traversed by the exhaust gases, characterized in that the catalyst body is formed by a plurality of moulded segments of different densities arranged one behind the other.
B

~3~7~3~

The production of diverse molded parts in powder metal-lurgy from metal powder is common knowledge. The powders used are compression-molded in cold or hot condition and subsequently sintered. By sintering is meant a heating in reducing atmosphere to temperatures which lie in the level of 2/3 to 4/5 of the melting poin-t of the metal powder used. In this process the metal sufaces bake together, with a simultaneous consolidation o~ the powder mixture.
Characteristics of a sintered body are its porosity and a small expansion.

Surprisingly, it has now been found that in a molding and sintering of metal wire pieces and/or metal chips, parts with very low density instead of powder can be produced with a high material strength. In particular it has been found that such sintered parts possess a high absorption power for in~iltrations or for a ~low-through. In addition, they exhibit, compared to the known materials, a signifi-cantly higher flowability around the surface. In an inven-tive way it has now been determined that such a body can surprisingly and-very advantageously be used as a cata~-lytic converter body. In the process the body may, after sintering, have to be solely coated in the well-known way with the actuaI catalytic material. If necessar~, an inter-mediate layer (wash-coat) can in the usual way be applied to enlarge the effective surface, after which the body can be covered with the precious metals, such as platinum and rhodium.

5- 13~723~

It is, however, conceivable to produce the sintered body itself from a material which exhibits catalytic properties.
In this case the subsequen-t coa-ting with a catalytic ma-terial can be omitted.

It has now been found that with the process according to the invention a catalytic converter with very good cata-lytic effect is created.

With the catalytic converter body according to the inven-tion, a further disadvantage with the known catalytic converters is also largely reduced. As is generally known, due to the installation of a catalytic converter and the ensuing flow resistance a reduction in the power of the internal-combustion engine must be accepted, which applies parti-cularly to full-load operation.

The catalytic converter body according to the invention produces a lower flow resistance, which thus exerts a positive influence on the power of the com~ s~ion engine.
In the process, the flow resistance can also be controlled or further reduced by a splitting of the catalytic conver-ter body into a plurality of molded segments arranged one after the other.

As is generally know, the flow resistance increases over the length of the catalytic converter body. If,one now - 6 - ~3~7~

uses, in a ~urther embodiment according to the invention, a plurality of molded segments arranged one after the other and contacting one another, with their density decreasing in the direction of flow of the exhaust gas, the flow resistance can be reduced even more intensely.

By the production process according to the invention, such molded segments of differing density, which are then combined accordingly, can be produced without any problems.

Since the catalytic converter body according to the in-vention is not susceptible to fracture, the catalytic converter itself can be made simpler in structure. Thus no flexible mounting is necessary and, as the case may be, even a protective tube or a housing can be eliminated.

As sizes for the metal wire pieces or the metal chips, diameters or widths of approx. 0.1 - 5 mm and lengths of 0.5 - 30 mm are possible. Here, however, the length or width is generally always distinctly greater than the diameter.

As materials for the metal wire pieces the most varied substances are possible, with care solely having to be taken that these are resistant to the high temperatures to be expected. Thus, for example, ferritic and austenitic steel, special alloys and the like are conceivable.

13~3~

In the following, a catalytic converter body according to the invention is shown with regard to its principles with reference to the drawing.

The catalytic converter body is produced in the known way by compression-molding and subse~uently sintered, with the shape being selected so that a cylindrical form is created for the catalytic converter body 10.

To reduce the flow resistance the catalytic converter body 10 is formed from a plurality of cylinder segments 1-4 arranged one after the other. The individual molded segments are pressed close to one another and their den-sity ~ decreases in the direction of through-~low from 1 ~4' As basic material-metal chips can be used instead of short metal wire pieces. These are obtained, for example, by punching, turning, planing or milling in widths of 1-5 mm and lengths of 1-20mm, prePerably of 2~3mm and 5-10mm. Here, the width may also change over the length according to the form of cutting operation.

Claims (4)

1. Catalyst for cleaning exhaust gases from combustion engines, comprising a catalyst body (lo) consisting of compression moulded and then sintered metal wire pieces or metal chips and traversed by the exhaust gases, characterised in that the catalyst body (10) is formed by a plurality of moulded segments (1-4) of different densities arranged one behind the other.
2. Catalyst according to claim 1, characterised in that the density of the moulded segments (1-4) decreases in the flow direction of the exhaust gas.
3. Catalyst according to claim 1 or claim 2, characterised in that the metal wire pieces or metal chips have diameters or widths of 0.1 - 5 mm and lengths of 0.5 - 30 mm.
4. Catalyst according to claim 3, characterised in that the metal wire pieces or metal chips have diameters or widths of 1 - 3 mm and lengths of 2 - 10 mm.
CA000586695A 1987-12-22 1988-12-21 Process for the production of a catalytic converter for exhaust-gas cleaning and catalytic converter produced according to this Expired - Fee Related CA1317231C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DEP3743503.5 1987-12-22
DE19873743503 DE3743503A1 (en) 1987-12-22 1987-12-22 METHOD FOR PRODUCING A CATALYST FOR EXHAUST GAS PURIFICATION AND A CATALYST PRODUCED THEREFORE

Publications (1)

Publication Number Publication Date
CA1317231C true CA1317231C (en) 1993-05-04

Family

ID=6343245

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000586695A Expired - Fee Related CA1317231C (en) 1987-12-22 1988-12-21 Process for the production of a catalytic converter for exhaust-gas cleaning and catalytic converter produced according to this

Country Status (7)

Country Link
EP (1) EP0321761B1 (en)
JP (1) JPH01203042A (en)
KR (1) KR950013323B1 (en)
AT (1) ATE83392T1 (en)
CA (1) CA1317231C (en)
DE (2) DE3743503A1 (en)
ES (1) ES2036659T3 (en)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4024942A1 (en) * 1990-08-06 1992-02-13 Emitec Emissionstechnologie MONOLITHIC METAL HONEYCOMB WITH VARIOUS CHANNEL NUMBER
DE19815004C1 (en) * 1997-09-12 1999-03-25 Inst Umwelttechnologie Und Umw Catalytic purification of flue gases
KR20020043091A (en) * 2000-12-01 2002-06-08 이계안 Closed Coupled Converter structure using metal catalystic

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2555038A1 (en) * 1975-12-06 1977-06-23 Bremshey Ag IC vehicle engine exhaust purifier - has twin catalysts respectively of noble and non noble metal
JPS5490665A (en) * 1977-11-18 1979-07-18 Texaco Development Corp Exhaust system smoke filter and its formation method

Also Published As

Publication number Publication date
KR890010399A (en) 1989-08-08
EP0321761A1 (en) 1989-06-28
KR950013323B1 (en) 1995-11-02
EP0321761B1 (en) 1992-12-16
ATE83392T1 (en) 1993-01-15
DE3743503A1 (en) 1989-07-06
DE3876767T (en) 1993-01-28
ES2036659T3 (en) 1993-06-01
JPH01203042A (en) 1989-08-15
DE3876767D1 (en) 1993-01-28

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