CN101076391B - 用二氧化氮再生的带涂层的颗粒陷阱 - Google Patents

用二氧化氮再生的带涂层的颗粒陷阱 Download PDF

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CN101076391B
CN101076391B CN2005800426003A CN200580042600A CN101076391B CN 101076391 B CN101076391 B CN 101076391B CN 2005800426003 A CN2005800426003 A CN 2005800426003A CN 200580042600 A CN200580042600 A CN 200580042600A CN 101076391 B CN101076391 B CN 101076391B
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waste gas
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coating
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W·莫斯
R·布吕科
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Vitesco Technologies Lohmar Verwaltungs GmbH
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Abstract

本发明涉及一种用来减少废气中的颗粒(2)的装置(1)，该装置包括至少一个规定容量(4)的基体结构(3)，该基体结构形成大量可流通的通道(5)，其中通道(5)至少局部地具有用来使通道(5)内的废气转向的结构，并且所述至少一个基体结构(3)至少局部地具有包括载体涂料(7)的第一涂层(6)，其中基体结构(3)的设有第一涂层(6)的体积部分(4)设有10至60克/升的载体涂料(7)。

Description

用二氧化氮再生的带涂层的颗粒陷阱
技术领域
本发明涉及一种具有至少一个可预先规定体积的基体结构的用于减少废气颗粒的装置。基体结构形成大量可流通的通道，其中通道至少局部具有用来使废气在通道内转向的结构。所述至少一个基体结构还至少局部配备一包含载体涂料的第一涂层。这种装置特别用来净化汽车内燃机的废气。因此本发明还涉及一种用于汽车内燃机的废气净化系统以及一种汽车。 
背景技术
已知过滤系统分为所谓的“开式”和“闭式”系统。闭式系统具有规则地交替封闭的通道，以便由此强制待净化废气穿过多孔的通道壁。但是这种封闭系统存在这样的危险，即形成带有大量积聚的炭黑颗粒的区域，所述颗粒最终会堵塞过滤器。这种过滤器可以通过燃烧炭黑颗粒而重新激活，这时必须采取提高过滤器内温度的措施(短时间电加热、直接喷入燃料、添加添加剂等等)。由于这个原因现在大多采用开式系统，因为它不会堵塞，因此不造成高的设备费用。 
在开式系统中不存在完全封闭的通道。但是至少部分通道配备这样的结构，所述结构影响流动以使废气或含在废气内的颗粒不直线形流过，而是向通道壁偏转。为此，例如采用突起、粒结、导流片、通道收窄等等。这种否则将为直线的通道流的改变使得特别是炭黑颗粒与通道壁接触，这样炭黑颗粒便积聚在通道壁表面上，并且可在此优选通过含在废气内的二氧化氮转化。 
因此，对于开式系统特别重要的是，提供足够量的二氧化碳(NO2)，以保证产生的炭黑或产生的颗粒的特别高的转化率。这里作为一种可能性已知，在这种颗粒陷井的上游连接一所谓的氧化催化反应器，该反应器在第一阶段使包含在废气内的一氧化氮(NO)氧化，从而提高废气中的二氧化氮含量，现在富集二氧化氮的废气流出现在过滤器上。这种设置在上游的氧化催化反应器和颗粒分离器的组合常常称为CRT(“连续再生陷阱”)，它例如由EP 0341832可知。 
从EP 0341832出发进行了许多努力以进一步开发这种元件，从而使原则上在理论上一部分废气可以重新流出的开式系统变得更有效。这里特别感兴趣的是用来使废气流在通道内转向的结构。此外还注意到，不仅采用光滑壁形成通道，而且用纤维材料和/或不透气材料制造通道。作为一种已经非常有效的“开式”结构颗粒过滤器的示例，请参照德国实用新型DE20117873U1。 
发明内容
本发明的一个目的是提供一种用来减少废气中的颗粒的装置，该装置转化颗粒方面更有效。此外，该装置应该结构简单并且易于批量制造。此外应该提供有效的废气净化系统和保护环境的汽车。 
这些目的通过具有本发明的特征的用于减少废气中的颗粒的装置实现。本装置还具有其它优良的结构以及特别优选的应用领域。应该指出，单独列出的特征可以用任何在工艺方面有价值的方式相互组合，并揭示本发明的另一些优良结构。其它实施形式可以从说明书的特征的描述得到。 
用来减少废气中的颗粒的具有至少一个规定体积的基体结构的装置具有大量可流通的通道。所述通道至少局部地具有用于使通道内的废气转向的结构。此外至少一个基体结构至少局部地具有包含载体涂料的第一涂层。本装置的特征是，基体结构的设有第一涂层的体积部分每升包括20克至40克的载体涂料，至少一个基体结构在流动方向上具有至少为120毫米的长度。 
“基体结构”特别是指一种具有大量通道的蜂窝体。这种基体结构例如安装在壳体或套管内，但是也可在一个壳体内设置多个这种基体结构。 基体结构具有预定的体积。该体积是指由通道构成的体积，通道壁和通道本身都算入其中。通道优选基本相互平行并沿流动方向延伸。通道密度例如为100-600cpsi(“每平方英寸单元数”，大致相当于每平方厘米15.9-93个通道)，优选为200-400cpsi(相当于约每平方厘米31-52个通道)。 
通道内还设有用来使废气转向的结构。这些结构例如可以包括伸入通道内的突起、粒结等以及导流片、孔、凹陷等等。这些结构使得流过通道的废气的至少一部分局部转向。这些结构优选具有使至少部分废气流能流入相邻通道的效果。为此，可形成从一个通道到相邻通道的单独的流动通道，但是例如也可以使这部分废气穿过可透气的通道壁。基体结构的通道的这种实施例特别优选是所谓的开式系统，如本文开头已经说明的那样。 
这里所述的装置是用来减少颗粒的带涂层的装置。所述第一涂层包括载体涂料、具有凹凸不平的表面的多孔氧化铝。这种载体涂料层例如用来容纳起催化作用的材料，其特征同样是对(炭黑)颗粒的高吸附能力。 
本发明的一个目的是将第一涂层设计成使得在装置内可以进行二氧化氮的再生。到来的富集NO2的废气流以常规方式接触堆积的颗粒并使之转化(例如变成二氧化碳)。但由此造成的炭黑或颗粒的氧化同时使二氧化氮减少并使一氧化氮增加。然而，这会使可用的二氧化氮被迅速用完，并且不能再进一步转化。因此，本文提供一种装置，其中已经用过的一氧化氮重新氧化成二氧化氮，以使位于下游的通道分区可重新用于颗粒的转化。 
该目的这样实现，即，使基体结构的设有第一涂层的体积每升[l]包括10-60克[g]的载体涂料。载体涂料的量优选为20-40g/l，特别是25-35g/l。因此，本发明的载体涂料的量远低于通常采用的量(例如约200g/l)。减小载体涂料的量使得通道具有更大的可自由流通的通道横截面，此外形成粗糙度略小的通道表面。这例如使得炭黑或颗粒不会过多地积聚在装置的入口区域内，而是形成较小的但在装置或通道的长度上均匀分布的颗粒堆积。这继而使通道存在足够的自由表面，该表面例如可以添加催化活性物质。这开启了这样的可能性，即，一方面废气与催化活性涂层反应并进行一氧化碳的氧化，另一方面，可进行炭黑或颗粒的氧化。试验表明，与普通颗粒过滤器相比，这可使颗粒的排放减少20％以上。 
按照本装置的另一实施例，第一涂层设有至少一种贵金属，其中所述至少一种贵金属的量为在基体结构的设有第一涂层的体积部分中每升[l]包括0.35-3.53克[g]。这大致相当于每立方英尺10-60克的含量[g/ft3]。所用的贵金属优选为铂。特别优选贵金属的量为1.3g/l(或36.8g/ft3)至1.5g/l(或42.5g/ft3)。已经证明，这种量的贵金属对于使二氧化氮再生同样是特别有效的。 
此外还建议，至少一个基体结构在流动方向上具有至少为120毫米[mm]的长度。其中特别优选采用具有至少150mm的长度的基体结构。 
由此保证，尽管载体涂料对于炭黑的吸附能力降低，但存在足够的可用长度，从而最终几乎可以使所有炭黑颗粒贴合在通道壁上。为此，通道优选具有按规定的间距重复设置的废气转向结构，从而加大炭黑颗粒与第一涂层或通道壁接触的机率。 
按照本装置的另一种实施例，所述至少一个基体结构包括至少局部带结构的金属薄板。基体结构有利地由大量交替设置的光滑和波纹金属薄板构成。所述金属薄板相互卷曲和缠绕以形成蜂窝体。这种蜂窝体装入壳体内并至少部分钎焊。对于波纹金属薄板的实时方式，可参照开头所述的DE20117873U1，其内容完全结合在本说明书中。 
本装置这样的结构是特别优选的，即，其中所述至少一个基体结构至少部分地包括带孔的金属薄板，这些孔可设置在波纹金属薄板和/或光滑金属薄板的区域内。所述孔的直径优选为3mm至10mm，更优选为3mm至8mm。考虑到加工问题，所述孔形成排、列或其它类似图案。也可根据范围在0.5mm至2mm内的单元密度而在所述孔之间至少局部地设置微结构，所述单元的高度在1mm以内。 
此外建议，所述至少一个基体结构包括至少一个过滤层。优选将金属纤维用于过滤层。这种(至少部分金属的)纤维无纺布也可以和金属薄膜复合应用。这种复合优选通过将纤维层与金属薄板的至少一段焊接而实现。在此，第一涂层可既设置在过滤层上或过滤层内，又(或仅在合适时)设置在金属薄板上。 
按照本装置的一种改进结构，所述至少一个基体结构具有至少一个带第一涂层的第一分区和至少一个带第二涂层的第二分区。优选该基体结构的这两个分区在设计上不同。例如特别建议，根据本发明规定的载体涂料仅设置在这两个分区的一个中，优选设置在下游的分区中。但在一些情况下，也可使第一涂层和第二涂层具有相同量的载体涂料，但是涂层在催化活性物质的浓度和类型方面不同。 
按照本发明的装置另一有利实施例，所述至少一个基体结构具有至少一个第一分区和至少一个第二分区，其中所述第一分区和第二分区中的至少一个具有涂层。例如，按照本发明可以有利地形成一基体结构，其中第一分区具有一涂层，而第二分区没有涂层，或者反之。 
特别优选这样的装置，其中所述至少一个基体结构具有至少一个带至少一个过滤层的第一分区和至少一个无过滤器的第二分区，其中所述至少一个第一分区沿流动方向设置在所述至少一个第二分区的下游。特别优选一种结构，其中在所述至少一个无过滤器的第二分区内设置仅仅在设计上不同的金属薄板，例如带有用来使废气流转向的结构的波纹金属薄板和带孔的光滑金属薄板。在这种情况下还优选该无过滤器的第二分区没有用来使废气转向的结构。 
作为特别优选的应用领域，推荐一种用于汽车内燃机的废气净化系统，该系统包括至少一个至少用来将包含在废气中的一氧化氮氧化成二氧化氮的转化器和至少一个沿废气流动方向设置在下游的上述装置。因此，现在说明所谓的“CRT”系统，其中按本发明的用来减少颗粒的装置的实施例结合在其中。可将转化器直接定位在装置的上游(并且在适当时也和它接触)，但也可在这两个部件之间设置间隙或较大的排气管通路。 
按照目前带有涡轮增压器的废气净化系统的一种改进，在内燃机和涡轮增压器之间设置一转化器。该第一转化器由此非常靠近内燃机，并在内燃机起动后立即达到其熄灯温度(约200℃)。这样，保证了转化器在早期便已经存在足够的二氧化氮，以便使在下游捕获的炭黑颗粒转化。在此， 涡轮增压器用作一种流混合器，以使二氧化氮可以在废气流中均匀分布。 
最后，本发明还提出一种汽车，该汽车包括至少一个前面所述类型的装置或至少一个上述废气净化系统。 
附图说明
现在借助于附图详细说明本发明以及技术领域。应该指出，附图表示本发明特别优选的实施例，但是本发明不局限于此。此外附图包括通常不适于按尺寸示出的示意图。 
在附图中： 
图1示出一种汽车废气净化系统的实施方案， 
图2示出带通道的基体结构的局部视图， 
图3示意性地示出该装置的另一种实施方案的结构， 
图4示出颗粒分离装置的另一实施方案的透视图， 
图5为在本发明装置的另一实施例中的反应过程的示意图， 
图6为图4的细部视图。 
具体实施方式
在图1中用虚线示出一汽车，它具有废气净化系统17。废气从内燃机18出发通过排气管26首先流到转化器19，该转化器安装在十分靠近内燃机18的地方。转化器19用于使包含在废气中的一氧化氮氧化成二氧化氮，因此使废气流在内燃机18起动后便立即富含二氧化氮。现在废气沿流动方向10进一步流向涡轮增压器20。在涡轮增压器20内流过的废气产生涡流，从而使二氧化氮均匀分布。然后废气出现在第二催化转化器19上，该第二催化转化器例如继续产生二氧化氮。现在富集NO2的废气流过用来减少颗粒的装置1。已经去除(炭黑)颗粒的废气沿流动方向10离开废气净化系统17。 
图2示出装置1内的化学转化过程。这里装置1由交替设置的波纹金属薄板11和光滑过滤层13构成。金属薄板11的波纹结构形成通道5。因 此所述通道5部分地被过滤层13和金属薄板11包围。在金属薄板11上形成突起22，所述突起促使废气向通道壁或过滤层13偏转。这里突起做成冲出部，以便在金属薄板11中形成孔23，并由此形成连通通道5，其中部分废气流可从一个通道5流向相邻通道5(并优选同时穿过过滤层13)。 
流入的废气至少包含二氧化氮(NO2)、颗粒或含碳成分(C)和氧气(O2)。通过废气流的部分转向，颗粒2积聚在通道壁上，特别是积聚在过滤层13上或过滤层13内。颗粒2在通道壁上的停留时间增大了与二氧化氮接触的可能性，从而促使炭黑颗粒的化学转化。这里，由金属纤维25构成的过滤层13证明是特别有效的。所述过滤层13具有凹凸不平的表面和大量空腔，从而颗粒2能有效地积聚在这里。在颗粒2转化期间，一方面二氧化氮还原成一氧化氮(NO)，另一方面碳氧化成碳氧化合物(CO，CO2)。因此流出的废气中一氧化氮和二氧化碳的比例较高。 
图3示出用于减少颗粒2的装置1的另一实施例的部件。在此，采用两种不同的元件(适当地布置成多次重复并设置成堆叠)以形成通道5。图3的上部示出一波纹金属薄板11。在此，波纹对于通道5的构型是决定性的。除了这些波纹外，金属薄板11还具有突起22和孔23。其中作为示例示出了一部分废气流的流动方向10。相对于废气流首先冲击到其上的突起22，所述废气流的一部分向上偏转，特别是朝相邻设置的过滤层13偏转。但是废气流的另一部分在突起22旁边流过并留在通道5内。接着该部分废气流冲击在另一种反向形成的突起22上，其中可例如由于通道5内的不同压力状况而造成废气流的重新分裂。因此一部分废气通过孔23到达相邻通道5，而其余废气流继续沿通道5流动。 
这里过滤层13具体形成为复合材料。过滤材料(这里用阴影线示出)沿流动方向分别被光滑金属薄板11或金属条限制。如图3的左上方所示(右选为装置1的废气出口端)，设有优选绕过滤层13弯曲并焊接在该过滤层上的窄金属条。由此防止例如具体形成为金属丝无纺布的过滤层13因热和动态负荷而松脱。在视图右下方(优选为废气入口端)，设有较宽的金属条。该金属条优选以与另一金属条类似的方法固定在过滤层13上。该宽金 属条设计成催化转化器基体面和/或用于流入废气流的混合器。为此，所述宽金属条具有许多孔12，这些孔12的至少一部分优选具有比位于它上方的通道的最大通道横截面大的直径。 
图4和6示意性地示出装置1的一种实施方案的变型，其中图6基本上放大地示出图4中标号为VI的区域。这里基体结构3同样设有螺线形卷绕的金属薄板11和过滤层13。金属薄板11的波纹同样形成大量可流通的通道5。具有规定体积4的基体结构3安装在一优选为柱形的壳体34内。装置1也可具有其它横截面形状。基体结构3的长度9至少为150mm。 
在图4左下方以放大图示出基体结构3的一个局部。由该局部视图可以看到，基体结构3具有一第一涂层6。该第一涂层6包括基体结构3的其量为约10至60g/l的载体涂料以及其量为约0.35至3.53g/l的贵金属8。 
图5示意性地示出用于减少颗粒2的装置1的横截面。该装置1包括一带有大量可流通的通道5的基体结构3。此处所示的装置1设计成带有两个分区。沿流动方向10看去，该装置1首先具有一带有第二涂层16的第二分区15。该第二涂层16将包含在废气中的一氧化氮氧化成二氧化氮。该第二分区15上直接连接一带有第一涂层6的第一分区14。由于按本发明所述的第一涂层6的设计，第二分区15内形成的二氧化氮用来使颗粒2转化，以便还原成一氧化氮。但是在它下游(还在装置1内)，由于设有第一涂层6，一氧化氮还可以重新氧化。因此在装置1内重新形成的二氧化氮可以重新用于颗粒2的转化。在这里所示的实施方案中，第一分区14和第二分区15布置在一个基体结构3内，该基体结构同样具有规定的长度9。但是原则上也可以在第二分区15和第一分区14之间设置一缝隙，其中优选两个基体结构或者一个转化器和一个基体结构。 
通过此处所推荐的用来减少颗粒的装置，可以重新获取二氧化氮，并由此使包含在废气中的颗粒更有效地得到转化。 
附图标记列表 
1  装置 
2  颗粒 
3  基体结构 
4  体积 
5  通道 
6  第一涂层 
7  载体涂料 
8  贵金属 
9  长度 
10 流动方向 
11 金属薄板 
12 孔 
13 过滤层 
14 第一分区 
15 第二分区 
16 第二涂层 
17 废气净化系统 
18 内燃机 
19 转化器 
20 涡轮增压器 
21 汽车 
22 突起 
23 孔 
24 壳体 
25 纤维 
26 排气管 

Claims (10)

1.用于减少废气中的颗粒(2)的装置(1)，该装置具有至少一个预定体积(4)的基体结构(3)，该基体结构形成大量可流通的通道(5)，其中通道(5)至少局部地具有用来使通道(5)内的废气转向的结构，至少一个基体结构(3)至少局部地具有包含载体涂料(7)的第一涂层(6)，其特征为：基体结构(3)的设有第一涂层(6)的体积(4)中每升包括10克至60克的载体涂料(7)，以及所述至少一个基体结构(3)沿流动方向(10)具有至少120mm的长度(9)，其中，所述通道(5)沿流动方向(10)具有按规定的间距重复设置的废气转向结构，所述至少一个基体结构(3)包括至少一个过滤层(13)，该过滤层(13)沿流动方向(10)被设置在该装置的废气入口端的具有许多孔的金属条界定。
2.按权利要求1的装置(1)，其特征为：第一涂层(6)设有至少一种贵金属(8)，其中基体结构(3)的设有第一涂层(6)的体积(4)中每升包括0.35克至3.53克的所述至少一种贵金属(8)。
3.按权利要求1的装置(1)，其特征为：所述至少一个基体结构(3)至少局部地包括带结构的金属薄板(11)。
4.按权利要求1的装置(1)，其特征为：所述至少一个基体结构(3)至少局部地包括带孔的金属薄板(11)。
5.按权利要求1的装置(1)，其特征为：所述至少一个基体结构(3)具有至少一个第一分区(14)和至少一个第二分区(15)，所述第一分区和第二分区中的至少一个具有涂层(6、16)。
6.按权利要求1的装置(1)，其特征为：所述至少一个基体结构(3)具有至少一个带第一涂层(6)的第一分区(14)和至少一个带第二涂层(16)的第二分区(15)。
7.按权利要求1的装置(1)，其特征为：所述至少一个基体结构(3)具有至少一个带至少一个过滤层(13)的第一分区(14)和至少一个无过滤器的第二分区(15)，其中所述至少一个第一分区(14)沿流动方向(10)设置在所述至少一个第二分区(15)的下游。
8.用于汽车内燃机(18)的废气净化系统(17)，包括至少一个至少用来使包含在废气中的一氧化氮氧化成二氧化氮的转化器(19)和至少一个沿废气流动方向(10)设置在下游的按权利要求1至7之一的装置(1)。
9.按权利要求8的废气净化系统(17)，其中该废气净化系统(17)具有涡轮增压器(20)，其特征为：在内燃机(18)和涡轮增压器(20)之间设置一转化器(19)。
10.汽车(21)，该汽车包括至少一个按权利要求1至7之一的装置(1)或者至少一个按权利要求8或9的废气净化系统(17)。
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