CN100538032C - 废气净化装置 - Google Patents

废气净化装置 Download PDF

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Publication number
CN100538032C
CN100538032C CNB2005800007014A CN200580000701A CN100538032C CN 100538032 C CN100538032 C CN 100538032C CN B2005800007014 A CNB2005800007014 A CN B2005800007014A CN 200580000701 A CN200580000701 A CN 200580000701A CN 100538032 C CN100538032 C CN 100538032C
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waste gas
cleaning plant
amplifier case
hole
gas cleaning
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Expired - Fee Related
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CNB2005800007014A
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CN1820126A (zh
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大野一茂
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Ibiden Co Ltd
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Ibiden Co Ltd
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
    • F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
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  • Chemical & Material Sciences (AREA)
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  • Manufacturing & Machinery (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Structural Engineering (AREA)
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  • Inorganic Chemistry (AREA)
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  • Environmental & Geological Engineering (AREA)
  • Biomedical Technology (AREA)
  • Health & Medical Sciences (AREA)
  • Processes For Solid Components From Exhaust (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)
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Abstract

一种废气净化装置，该废气净化装置(10)被装配于汽车上，由以下单元构成：发动机(20)；与发动机(20)连接的歧管(22)，用于流通燃料燃烧产生的废气；与歧管(22)连接的套管(26)，用于保持负载了废气净化催化剂的蜂窝过滤器(30)。该废气净化装置(10)中，蜂窝过滤器(30)被配置在从废气流通的歧管(22)的最上游部到蜂窝过滤器(30)的前端部的排气路径长度在1m以内的位置。对于上述的蜂窝过滤器(30)，其气孔率大于等于70%，通过沿长度方向层积形成有多个贯通孔的板状部件而成，并使贯通孔连通，连通的贯通孔在两端交错封孔。蜂窝过滤器(30)由无机纤维(陶瓷纤维或金属纤维)或无机泡沫(陶瓷泡沫或金属泡沫)形成。

Description

废气净化装置
技术领域
本发明涉及废气净化装置。
背景技术
以往，作为废气净化装置，提出了改进捕集粒状物质的柴油微粒过滤器(以下称为DPF)的配置位置的装置。例如，特开2000-145430号公报所记载的装置，将DPF配置在发动机的下游的1m以内，将粒状物质捕集到DPF的同时，利用发动机的排气热，使捕集到的粒状物质燃烧，从而使DPF再生。
根据上述公报中所记载的废气净化装置，通过利用排气热使粒状物质燃烧，可以使DPF再生，但是像这样利用排气热使粒状物质燃烧的DPF中，希望能开发出更容易进行再生的装置。
发明内容
本发明是鉴于上述问题提出的，其目的在于提供能够容易进行净化过滤器再生的废气净化装置。
本发明的废气净化装置，为了达到上述的目的，采取了下述措施。即，本发明的废气净化装置是用于净化从内燃机排出的废气的废气净化装置，其具有：
连接管，与所述内燃机连接，用于所述废气流通；
净化过滤器，气孔率大于等于70％，负载有废气净化催化剂，并借助该废气净化催化剂使流通于所述连接管的废气中的粒状物质燃烧，从而进行净化；
并且所述净化过滤器被配置在所述连接管从所述内燃机开始的长度在1m以内的位置。
该废气净化装置中，因为净化过滤器被配置在连接管从内燃机开始的长度在1m以内的位置，所以废气不会被连接管等夺去过多的热，从而可以在保持高温的状态下到达净化过滤器。而且，因为净化过滤器的气孔率大，大于等于70％，所以净化过滤器捕集到的粒状物质和净化过滤器所负载的废气净化催化剂容易接触。其结果，负载了废气净化催化剂的净化过滤器借助废气迅速升温，可以发挥催化剂的作用，而且，粒状物质和催化剂容易接触，所以可以有效地将大量的粒状物质燃烧。因此，与特开2000-145430号公报所记载的废气净化装置相比，能够更容易地使净化过滤器再生。在此，“所述连接管从内燃机开始的长度在1m以内”是指，从废气流通的连接管的最上游部到净化过滤器的前端部的连接管长度。另外，负载了废气净化催化剂之后的净化过滤器的气孔率优选大于等于70％，更优选大于等于80％。
本发明的废气净化装置中，所述净化过滤器优选气孔率小于等于95％。如果气孔率大于95％，则构成净化过滤器的壁的材料变少，从而强度降低，故不为优选。
对于本发明的废气净化装置，在所述净化过滤器中，沿着长度方向平行排列的多个贯通孔在端面交错封孔。
本发明的废气净化装置中，所述净化过滤器在废气通过的壁的内部负载有所述废气净化催化剂，该壁的内部形成有所述粒状物质进入的空间。这样做，与只在壁表面负载废气净化催化剂来捕集粒状物质的情况相比，提高了粒状物质和废气净化催化剂的接触概率，从而可以提高再生的效率。
本发明的废气净化装置中，所述净化过滤器可是通过将至少2个的形成有多个贯通孔的板状部件在长度方向层积，并使该贯通孔连通而形成的。这样做，即使因粒状物质的燃烧热，在净化过滤器的长度方向上产生温度差而施加了热应力，也能够在层积的板状部件之间缓和该应力，所以，与在长度方向一体成型的情况相比，不易产生热应力引起的损伤。
本发明的废气净化装置中，所述净化过滤器可由主要是从无机纤维和无机泡沫中选择的至少1种材料来形成。这样做，利用无机纤维和无机泡沫能够实现气孔率大于等于70％的净化过滤器。这里，作为无机纤维可以列举出例如金属纤维、陶瓷纤维等。其中，作为金属纤维可以列举出从例如铜、铁(铬类不锈钢、铬镍类不锈钢等)以及铝等中选择的1种或至少2种纤维，作为陶瓷纤维可以列举出从例如氧化铝、氧化硅、二氧化钛、氧化锆、氧化硅-氧化铝等氧化物类纤维或碳化硅等碳化物类纤维等中选择的1种或至少2种纤维。作为无机泡沫，可以例如是金属泡沫或陶瓷泡沫，因为其中金属泡沫的强度高，所以优选金属泡沫。作为金属泡沫，可以列举出从例如铜、铁(铬类不锈钢、铬镍类不锈钢等)以及铝等中选择的1种或至少2种泡沫，作为陶瓷泡沫，可以列举出从例如氧化铝泡沫、氧化硅泡沫、碳化硅泡沫等中选择的1种或至少2种泡沫。
本发明的废气净化装置中，废气净化催化剂没有特别限定，可以是例如贵金属、氧化物等。作为贵金属可以列举出从例如铂、钯、铑中选择的1种或至少2种，作为氧化物可以列举出具有钙钛矿构造的物质(LaCoO3，LaMnO3等)以及CeO2等。其中，优选具有钙钛矿构造的氧化物。这样做，不使用是稀有元素的贵金属(铂等)也可以使粒状物质燃烧。作为具有钙钛矿构造的氧化物，可以列举出下述的物质等，例如钙钛矿构造(通式为ABO3)的A位点为从La、Y以及Ce等中选择的1种或至少2种元素，其中La是优选的，并且通式的B位点为从Fe、Co、Ni以及Mn等中选择的1种或至少2种元素。另外，例如可以像La0.75K0.25CoO3等将A位点的元素的一部分取代为K、Sr及Ag等。
附图说明
图1是表示本实施方式的废气净化装置10的结构概要的图。
图2是本实施方式的蜂窝过滤器30的说明图。
图3是本实施方式的蜂窝过滤器30的说明图。
图4是通过本实施方式的废气净化装置10捕集并除去粒状物质的示意图。
图5是表示其他实施方式的废气净化装置40的结构概要的图。
具体实施方式
下面，参照附图对本发明的优选实施方式进行说明。
图1是表示本实施方式的废气净化装置10的结构的概要图。废气净化装置10装配于汽车上，由以下单元构成：发动机20；与发动机20连接的歧管22，用于流通燃料燃烧产生的废气；与歧管22连接的套管26，用于保持负载了废气净化催化剂的蜂窝过滤器30；与套管26连接的排气管24，用于将经净化的废气排出。该废气净化装置10中，如图1所示，蜂窝过滤器30被配置在从发动机20起的排气路径长度在1m以内的位置，即从废气流通的歧管22的最上游部到蜂窝过滤器30的前端部的排气路径长度在1m以内的位置。
发动机20的构成形式是柴油发动机(内燃机)，该柴油发动机是将轻油等烃类燃料喷射到用活塞压缩的空气中使其燃烧，从而产生驱动力。来自发动机20的废气中含有氮氧化物(NOx)、烃(HC)以及一氧化碳(CO)的同时，还含有由燃料中含有的碳元素等产生的粒状物质(以下称为PM)。
蜂窝过滤器30主要由无机纤维形成，其是用于除去发动机20的废气中含有的PM的过滤器。如图2及图3所示，对于该蜂窝过滤器30，将至少2个形成有多个贯通孔31的圆板状的板状部件32沿长度方向层积，并使该贯通孔31连通，在其两端部配置金属制的端部板状部件34，通过向该层积方向施加压力使其固定在套管26内，从而形成该蜂窝过滤器30。借助该端部板状部件34，将板状部件32层积而连通的贯通孔31在端面上交错封孔。因此，废气从蜂窝过滤器30中的上游侧开口的贯通孔31流入，通过其后的壁部33，向下游侧开口的贯通孔31移动，通过该贯通孔31从蜂窝过滤器30流出。这里，在废气通过壁部33时，废气中含有的PM被捕集。并且，与蜂窝过滤器30的内面相比，蜂窝过滤器30的端面承受的因废气产生的热和压力大，但是因端部板状部件34为金属制成的，所以能够防止蜂窝过滤器30的损伤。另外，板状部件32和端部板状部件34的厚度优选为0.1mm～10mm。而且，可以在层积了板状部件32的两端分别各配置1片该端部板状部件34，也可以各配置多片。这里，端部板状部件34是由金属形成的，但也可以由与板状部件32相同的材质的材料形成。而且，这里，蜂窝过滤器30是将板状部件32层积而成，但也可以使用一体成型的蜂窝过滤器。
所形成的该蜂窝过滤器30在负载了废气净化催化剂之后，气孔率达到大于等于70％且小于等于95％。因此，负载废气净化催化剂前的气孔率优选至少要达到大于等于70％且小于等于97％。并且，该蜂窝过滤器30中，该蜂窝过滤器30的表观密度优选为0.05g/cm3～1.00g/cm3，更优选为0.10g/cm3～0.50g/cm3。
形成于蜂窝过滤器30的贯通孔31的大小优选为1.4mm×1.4mm～16mm×16mm。贯通孔31之间的壁部33的厚度(壁厚)优选为0.2mm～10.0mm的范围，更优选为0.3mm～6.0mm的范围。壁厚小于0.2mm时，捕集效率下降，发生PM泄漏等，如果大于10.0mm，则废气难通过壁部33，从而压力损失变大。并且，每单位截面积的贯通孔31的个数(孔密度)优选为0.16个/cm2～62个/cm2(1.0cpsi～400cpsi)，更优选为0.62个/cm2～31个/cm2(4cpsi～200cpsi)。若贯通孔的数量小于0.16个/cm2时，与蜂窝过滤器30内部的废气接触的壁面积变小，如果大于62个/cm2，则压力损失变大，蜂窝过滤器30的制作变困难。并且，贯通孔31的形状可以是矩形，也可以是三角形或六边形。
蜂窝过滤器30的板状部件32主要由无机纤维形成。该无机纤维的长度优选为0.1μm～300μm，更优选为0.5μm～50μm，无机纤维的径优选为1μm～30μm，更优选为2μm～10μm。并且，该板状部件32中含有用于粘合无机纤维的无机粘合剂。作为无机粘合剂，可以列举出从例如硅酸玻璃、硅酸碱玻璃及硼硅酸玻璃等无机玻璃以及氧化铝溶胶、氧化硅溶胶、氧化钛溶胶等溶胶中选择的1种或至少2种的无机粘合剂。以蜂窝过滤器30中含有的固体成分计算，该蜂窝过滤器30中含有的无机粘合剂的量优选为5重量％～50重量％，更优选为10重量％～40重量％。无机粘合剂的含量小于5重量％时，蜂窝过滤器30的强度变低，如果大于50重量％，则变得难以制作具有高气孔率的蜂窝过滤器30。
优选板状部件32中含有的无机纤维中大多沿着与贯通孔31的形成方向垂直的面取向。这样做，容易形成使废气中含有的PM进入的空间，因为废气容易通过壁部33，所以可以减少初期的压力损失，并且可以使废气中含有的PM浸入到壁部33的内部从而捕集该PM。
并且，板状部件32可以形成为除了含有无机纤维还含有无机颗粒。作为该无机颗粒可以是金属颗粒或陶瓷颗粒。作为金属颗粒，可以列举出从例如金属硅、铝等中选择的1种或至少2种的颗粒。作为陶瓷颗粒，可以列举出从例如氧化铝、氧化硅、氧化硅-氧化铝、氧化锆、堇青石以及莫来石等氧化物类颗粒等中选择的1种或至少2种的颗粒。
蜂窝过滤器30中，作为废气净化催化剂而负载具有钙钛矿构造的LaCoO3。该废气净化催化剂的负载量，优选蜂窝过滤器30的每单位体积的废气净化催化剂的重量为10g/L～100g/L。这里，负载了废气净化催化剂的蜂窝过滤器30，可以是在作为原料的无机纤维上负载废气净化催化剂而制作的，也可以是在作为部件的板状部件32及端部板状部件34上负载废气净化催化剂而制作的，也可以在制作了蜂窝过滤器30之后负载废气净化催化剂而制作。
这里，作为上述含有无机纤维的板状部件32的替代，可以层积主要由无机泡沫形成的板状部件32来制作蜂窝过滤器30。作为该无机泡沫，可以是例如陶瓷泡沫或金属泡沫，因为其中金属泡沫的强度高，所以优选金属泡沫。作为陶瓷泡沫，可以列举出从例如氧化铝泡沫、氧化硅泡沫、碳化硅泡沫等中选择的1种或至少2种泡沫，作为金属泡沫，可以列举出从例如铜、铁(不锈钢等)以及铝等中选择的1种或至少2种泡沫。由该无机泡沫形成的蜂窝过滤器30，其负载了废气净化催化剂之后的气孔率优选大于等于70％且小于等于95％。因此，负载废气净化催化剂之前的气孔率优选至少要达到大于等于70％且小于等于97％。
(1)含有无机纤维的蜂窝过滤器的制造方法
下面，对含有无机纤维的蜂窝过滤器的制造方法的一例进行说明。相对1L水，以5g～100g的比例分散无机纤维(氧化铝纤维等)，相对100重量份无机纤维，添加10重量份～40重量份比例的无机粘合剂(氧化硅溶胶等)和1重量份～10重量份比例的有机粘合剂(丙烯酸树脂等)，并且，根据需要添加少量硫酸铝等凝结剂、聚丙烯酰胺等凝聚剂，充分搅拌，调制抄制用浆料。利用空孔筛网抄制抄制用浆料，该空孔筛网上形成有规定形状的孔(正方形等)，这些孔相互距离规定间隔，通过在100℃～200℃干燥获得的抄制物，从而制作如图2(c)所示的板状部件32。含有该无机纤维的板状部件32受到压力时可能变形，所以，根据需要进行压缩以调节气孔率和厚度。这里，例如通过利用模具挤出成型来一体成型蜂窝过滤器30时，无机纤维大多向挤出方向(贯通孔31的形成方向)取向，但是如果在该抄制工序中制作，如图2所示，无机纤维更多地沿与贯通孔31的形成方向垂直的面取向。因此，废气容易在壁部33中流通。而且，在金属板上形成规定形状的孔，并使贯通孔31在两端交错封孔，从而制作端部板状部件34(参照图2(b))。
接着，在板状部件32上负载废气净化催化剂。首先，调制含有废气净化催化剂的溶液(例如浆料或溶胶)，将板状部件32浸于该溶液之后，提起，通过抽吸将残留于贯通孔31等中的多余的溶液去除。然后，通过在80℃～200℃进行干燥，在500℃～700℃进行烧制，可以获得负载有废气净化催化剂的板状部件32。这里，含有废气净化催化剂的溶液，可以是废气净化催化剂的浆料，也可以是负载了废气净化催化剂的氧化物(氧化铝等)的浆料。根据废气净化催化剂的种类及组合等适当选择废气净化催化剂的负载量。最后将板状部件32和端部板状部件34物理层积，从而制作蜂窝过滤器30。如图3所示，将多片端部板状部件34层积插入金属制的套管26并使贯通孔31连通，然后，同样地层积插入规定片数的板状部件32，进一步利用挤压机在插入层积了数片端部板状部件34的方向上施加压力，并通过设置并固定压板，制作蜂窝过滤器30。并且，使用粘合剂将层积的端部板状部件34之间粘接固定。另外，为了便于说明，图3的套管26只示出了将中空圆柱状的套管26上下切断的下侧部分。
(2)由无机泡沫形成蜂窝过滤器的制造方法
1.由陶瓷泡沫形成蜂窝过滤器的制造方法
下面，对由高气孔率无机泡沫中的陶瓷泡沫形成蜂窝过滤器的制造方法的一例进行说明。通过对主要由陶瓷材料(例如，堇青石、氧化铝、莫来石、氧化硅以及钛酸铝等)构成的高气孔率陶瓷泡沫板(例如桥石公司制的陶瓷泡沫等)进行切削加工形成贯通孔31，从而制作上述(1)所述形状的板状部件32。然后，采用上述(1)所述的方法在得到的多片板状部件32上负载废气净化催化剂，并采用上述(1)所述的方法进行层积，从而制作蜂窝过滤器30。另外，端部板状部件34使用上述(1)所述的金属制部件。
2.由金属泡沫形成蜂窝过滤器的制造方法
下面，对由高气孔率无机泡沫中的金属泡沫形成蜂窝过滤器的制造方法的一例进行说明。通过对主要由金属构成的高气孔率金属板(例如住友电气工业制的セルメツト等)进行激光加工形成贯通孔31，从而制作上述(1)所述形状的板状部件32。然后，采用上述(1)所述的方法在得到的多片板状部件32上负载废气净化催化剂，并采用上述(1)所述的方法进行层积，从而制作蜂窝过滤器30。金属泡沫形成的板状部件32受到压力时可能变形，所以，根据需要进行压缩以调节气孔率和厚度。另外，端部板状部件34使用上述(1)所述的金属制部件。
下面，使用图4对本实施方式的废气净化装置10的动作进行说明。图4是通过废气净化装置10捕集并除去PM的示意图。首先，起动发动机20。这样，发动机20向被活塞压缩了的空气中喷射燃料并使其燃烧，从而产生驱动力。此时，含有PM的废气从发动机20排出到歧管22，并流入蜂窝过滤器30。蜂窝过滤器30内形成有PM进入的空间，使废气中含有的PM浸入到负载了废气净化催化剂36的壁部33的内部并捕集PM。这里，可以想到，如果蜂窝过滤器30中包含的无机纤维35大多沿着与贯通孔31的形成方向垂直的面取向，则PM可以更深地浸入壁部33的内部并被捕集。并且，因蜂窝过滤器30的气孔率大且热容量小，所以借助废气的热温度迅速上升。而且，蜂窝过滤器30被配置于距发动机20为1m的位置，热损失少，通过废气热达到使废气净化催化剂充分作用的温度(例如大于等于350℃)。此时，如果PM与负载于蜂窝过滤器30的壁部33的内部的废气净化催化剂36接触，则该PM迅速燃烧。其结果，蜂窝过滤器30内很难堆积PM，从而进行强制再生(过剩量的燃料喷射等)的频度变少。
以上所述的本实施方式的废气净化装置10中，负载了废气净化催化剂36的蜂窝过滤器30借助废气迅速升温，从而发挥催化剂作用，而且因为容易和PM接触，所以可以高效地将大量的PM燃烧。所以可以容易地进行蜂窝过滤器30的再生。而且，蜂窝过滤器30的气孔率小于等于95％，所以能够防止强度下降。并且，与只在负载废气净化催化剂的壁表面来捕集PM的情况相比，提高了PM和废气净化催化剂36的接触概率，从而可以提高再生的效率。另外，即使因PM的燃烧热而在蜂窝过滤器30的长度方向上产生温度差而施加了热应力，也可以在层积的板状部件32之间缓和该应力，所以，与在长度方向一体成型的情况相比，难以产生热应力引起的损伤。并且，蜂窝过滤器30的气孔率大且热容量小，所以温度迅速上升，能够使燃烧PM成为可能。还有，负载于蜂窝过滤器30内的废气净化催化剂36是具有钙钛矿构造的氧化物，所以不使用稀有元素即贵金属(铂等)也可以使PM燃烧。
并且，本发明并不限于上述的实施例，只要属于本发明技术的范围，可以使用各种形式实施是自不必说的。
例如，在上述实施方式中是废气净化装置10，其中，将保持蜂窝过滤器30的套管26连接于歧管22，如图5所示，也可以是废气净化装置40，其中将蜂窝过滤器30配置于歧管22内部。这样做，可以更加有效地利用废气热，从而容易进行再生。此外，只要使从发动机20到蜂窝过滤器30的前端部的排气路径的长度在1m以内，可以改变连接管的种类(歧管22、排气管24以及套管26等)及连接的顺序等。
另外，上述的实施方式中，是将废气净化装置10装配在汽车上，但也可以装配在例如列车、船舶、飞机等，也适用于使用发动机20的发电机等。
实验例
下面，将使用蜂窝过滤器30的废气净化装置10的例作为实验例进行说明。
[实验例1]
制作含有作为无机纤维的氧化铝纤维(平均径5μm、平均长300μm)的蜂窝过滤器30。相对1L水，以10g的比例分散氧化铝纤维，相对氧化铝纤维，分别以5重量％和3重量％的比例添加氧化硅溶胶和作为有机粘合剂的丙烯酸乳胶，并且，添加少量硫酸铝、聚丙烯酰胺，充分搅拌，调制抄制用浆料。利用空孔筛网对抄制用浆料进行抄制，该空孔筛网形成有正方形的孔，该孔相互距离规定间隔，在150℃下干燥得到的抄制物，制作直径143.8mm、厚1mm、贯通孔大小4.5mm方形、壁部33的厚2mm、孔密度2.4个/cm2(15.2cpsi)的板状部件32。并且，通过直径143.8mm、厚1.0mm的镍铬类不锈钢制的金属板上形成贯通孔31来制作端部板状部件34，这些贯通孔31在两端交错封孔。
下面，将0.01mol的La(NO3)3 6H2O、0.01mol的Co(OCOCH3)2 4H2O、0.024mol的C6H8O7 H2O(柠檬酸)在20ml的乙醇溶剂中混合搅拌，调制LaCoO3前体溶胶。将板状部件32浸渍于该溶胶中，提起之后，通过抽吸将多余的溶胶去除，在100℃进行干燥，在600℃烧制1小时。另外，通过X射线衍射测定，证明是LaCoO3的钙钛矿构造。以蜂窝过滤器30的每单位体积的废气净化催化剂的重量计，废气净化催化剂的负载量为30g/L。
接下来，将3片端部板状部件34层积插入金属制的套管26内，并使贯通孔31连通，然后，同样地层积插入150片板状部件32，进一步用挤压机在插入层积3片端部板状部件34的方向上施加压力，通过设置并固定压板，得到蜂窝过滤器30。所得到的蜂窝过滤器30在负载废气净化催化剂后的气孔率为70％。气孔率是通过测定蜂窝过滤器30的干燥重量G(g)、蜂窝过滤器30的外形体积V(cm3)、贯通孔31的体积K(cm3)以及构成蜂窝过滤器30的材料的真密度D(g/cm3)，由式(1)求得。
气孔率％＝100×(1-G/((V-K)×D))…式(1)
接着，将制作的负载有LaCoO3的蜂窝过滤器30配置在从歧管22的最上游部到蜂窝过滤器30的前端的排气路径的长度为0.5m的位置，该歧管22与发动机20连接，以此作为实验例1。发动机20是2.0L的柴油发动机。将该实验例1的发动机20到蜂窝过滤器30的长度、蜂窝过滤器30在负载废气净化催化剂前后的气孔率、贯通孔31之间的壁部33的厚度、蜂窝过滤器30的构成材料、蜂窝过滤器30的结构概要等各数值等进行总结并示于表1。另外，该表1中总结并示出了与后述实验例2～12相关的内容。
表1
Figure C200580000701D00131
[实验例2、3]
实验例2、3中制成表1所示的壁厚、孔密度2.4个/cm2(15.2cpsi)、将压缩比例改变为表1所示的气孔率来设计蜂窝过滤器30，除此之外，按照与实验例1相同的方法制作蜂窝过滤器30，与实验例1相同地将蜂窝过滤器30配置在从歧管22的最上游部到蜂窝过滤器30前端的排气路径的长度为0.5m的位置。
[实验例4]
利用辊筒将铬镍类不锈钢合金制金属泡沫(住友电气工业制、セルメツト、平均气孔径400μm)压缩成平均气孔径为80μm，在加工成直径143.8mm、厚1mm的圆盘状之后，通过激光加工制作贯通孔的大小为4.5mm方形、壁部33的厚2mm、孔密度2.4个/cm2(15.2cpsi)的板状部件32。并且，通过激光加工形成贯通孔31的两端交错封孔的孔，以制作端部板状部件34。
接下来，通过与实验例1相同的工序，在板状部件32和端部板状部件34上负载LaCoO3并进行层积，获得由金属泡沫形成的蜂窝过滤器30。实验例4与实验例1相同地将蜂窝过滤器30配置在从歧管22的最上游部到蜂窝过滤器30前端的排气路径的长度为0.5m的位置。
[实验例5～8]
制作与实验例1～4相同的蜂窝过滤器30，将其配置在从歧管22的最上游部到蜂窝过滤器30前端的排气路径的长度为1m的位置。将它们分别作为实验例5～8(参照表1)。
[实验例9～11]
制作与实验例1～3相同的蜂窝过滤器30，将其配置在从歧管22的最上游部到蜂窝过滤器30前端的排气路径的长度为1.5m的位置。将它们分别作为实验例9～11(参照表1)。
[实验例12]
实验例12中制成表1所示的壁厚、改变压缩比例使气孔率为65％来设计蜂窝过滤器30，除此之外，按照与实验例1相同的方法制作蜂窝过滤器30，与实验例5相同地将蜂窝过滤器30配置在从歧管22的最上游部到蜂窝过滤器30前端的排气路径的长度为1.0m的位置。
[再生率测定]
对实验例1～12的再生率进行了测定。该测定是，在不对发动机20运转中排出的PM进行强制再生处理(过剩量的燃料喷射等)的情况下，调查蜂窝过滤器上堆积了多少PM。发动机20的运转是依照2.0L柴油汽车10·15型号废气测定试验的测定方法进行3次循环。在该情况下，测定试验前和试验后的蜂窝过滤器30的重量。并且，在各实验例的蜂窝过滤器30的下游配置PM计数器(TSI公司制凝聚颗粒计数器3022A-S)，从PM颗粒数量掌握没能被蜂窝过滤器30捕集而排出到下游的PM量，其结果，全部的实验例都没有PM流出到蜂窝过滤器30的下游，捕集率全部是100％。此外，预先对该试验中产生的PM的总生成量进行调查的结果，其量为3.5g。由此，从相对于PM的总生成量的PM堆积量(试验前和试验后的重量差)计算再生率。
[测定结果]
对从实验例1～12的发动机到蜂窝过滤器30前端的排气路径的长度、蜂窝过滤器30的气孔率、PM捕集效率、PM堆积量、蜂窝过滤器30的再生率进行总结并示于表2。实验例1～8的捕集效率为100％，再生率为大于等于50％，非常高。另外，在实验例9～11中，因为从发动机到蜂窝过滤器30的距离为1.5m，所以与实验例1～8相比，再生率较低。在实验例12中，负载废气净化催化剂36后的气孔率小于70％，与实验例1～8相比，再生率较低。由该结果可知，如果将气孔率大于等于70％的蜂窝过滤器30配置在距发动机20起1m以内的位置，则PM变得容易燃烧。
表2
Figure C200580000701D00151
本发明是以于2004年6月30日申请的日本国专利申请2004-194407号为要求优先权的基础，其全部内容都被编入本发明。
产业上的可利用性
本发明的废气净化系统，可用于与装配了内燃机的动力机或车辆等相关的产业中，也可用于例如汽车产业、自动二轮车产业等。

Claims (9)

1.一种废气净化装置，其是净化从内燃机排出的废气的废气净化装置，具有：
连接管，与所述内燃机连接，用于所述废气流通；
净化过滤器，负载有废气净化催化剂，负载了废气净化催化剂后的净化过滤器气孔率大于或等于70％，该净化过滤器借助该废气净化催化剂使流通于所述连接管的废气中的粒状物质燃烧，从而进行净化；
并且所述净化过滤器被配置在所述连接管从所述内燃机开始的长度在1m以内的位置。
2.根据权利要求1所述的废气净化装置，其特征在于，所述净化过滤器的气孔率小于或等于95％。
3.根据权利要求1或2所述的废气净化装置，其特征在于，在所述净化过滤器中，沿长度方向平行排列的多个贯通孔在端面上交错封孔。
4.根据权利要求3所述的废气净化装置，其特征在于，所述净化过滤器按在一个端面被封孔而在另一个端面开口的贯通孔和在一个端面开口而在另一个端面被封孔的贯通孔相互交错排列而成。
5.根据权利要求1或2所述的废气净化装置，其特征在于，所述净化过滤器在废气通过的壁的内部负载有所述废气净化催化剂，在该壁的内部形成有所述粒状物质进入的空间。
6.根据权利要求1或2所述的废气净化装置，其特征在于，所述净化过滤器通过将至少2个形成有多个贯通孔的板状部件沿长度方向层积、并使该贯通孔连通而形成。
7.根据权利要求1或2所述的废气净化装置，其特征在于，所述净化过滤器主要由从无机纤维以及无机泡沫中选择的至少1种物质而形成。
8.根据权利要求1或2所述的废气净化装置，其特征在于，所述废气净化催化剂是氧化物。
9.根据权利要求8所述的废气净化装置，其特征在于，所述氧化物具有钙钛矿构造。
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CN102162388B (zh) * 2011-04-27 2013-05-08 上海电力学院 一种汽车尾气光催化减排装置

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US20090113879A1 (en) 2009-05-07
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CN1820126A (zh) 2006-08-16
KR100794541B1 (ko) 2008-01-17
WO2006004175A1 (ja) 2006-01-12
ATE548545T1 (de) 2012-03-15
KR20060036478A (ko) 2006-04-28
EP1762710A4 (en) 2010-08-04
EP1762710B1 (en) 2012-03-07
US7603852B2 (en) 2009-10-20

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