CN101298057B - Carrier for exhaust-gas purification - Google Patents

Abstract

A carrier for exhaust-gas purification is disclosed, which is able to effectively protect against getting clogged with the particulate matters in a filter having carriers. The carrier is constituted with a web corrugated to have straight and/or zigzag ridges and then wound up into a column. The carrier for exhaust-gas gas purification is made of the web of wire netting or nonwoven metallic fabric, which is embosed to have ridges and grooves extending at least in a widthwise direction and further wound up spirally or stacked on top of the other into the column.

Description

Carrier for exhaust-gas purification

Technical field

The present invention relates to a kind of carrier for exhaust-gas purification, this carrier for exhaust-gas purification is applied to waste gas purification apparatus, this waste gas purification apparatus makes the waste gas contact and passes through carrier, and burn to being included in harmful substance in the waste gas, redox reaction, come purifying exhaust air thereby remove this harmful substance.

Background technology

In the past, the waste gas purification mode following about Diesel engine was known, that is, and and for SOF (solubility organic principle), the NO among the HC in the purifying exhaust air, CO, the PM (particle matter) _XEtc. harmful substance, with oxidation catalyst or NO _XReducing catalyst is supported on the honeycomb substrate of cordierite, and replaces the end that (alternate) seals the exhaust steam passage of honeycomb substrate, and make waste gas streams cross the wall of honeycomb, and catch PM at the wall of honeycomb substrate, thus purifying exhaust air.There are two types in catalyst with honeycomb substrate, a kind of is the end that alternately seals the gas passage of each honeycomb, seizure is included in the honeycomb substrate of the PM in the waste gas, another is the end that does not seal the gas passage of each honeycomb, make waste gas streams cross gas passage, thus the honeycomb substrate of the harmful substance in the purifying exhaust air.

And Diesel engine is as CO ₂The minimum engine of discharge capacity is restudied, and also adopts the car of Diesel engine increasing on the car always.Carried diesel particulate filter (DPF:Diesel Particulate Filters) at a lot of vehicles recently, particle matter (PM) is captured on the ceramic honeycomb, and under the effect of catalyst with low-temperature burning and burn, thereby purifying exhaust air.And about being included in the PM in the waste gas, its most constituent is the hydrocarbon of unburned carbon black or heavy oil, therefore as long as with the DPF clean-burning fuel, just can not discharge with microparticle.Generally, the catalyst that is supported on the filter makes carbon black burning since about 300 ℃, perhaps makes the NO in the waste gas be oxidized to NO ₂, effectively utilize NO with this ₂

In above-mentioned ceramic honeycomb, especially, has the carrier that does not alternately seal the structure of gas passage end, in order to increase the wall thickness that reduces honeycomb with the contact area of waste gas, do the effort of the mesh count (per 1 square inch mesh count) that increases honeycomb, in the middle of the practical application of used for diesel engine honeycomb substrate, adopt 200～400 eyed structures.And, with respect to pottery honeycomb processed, also realized practical with the exhaust gas purifying catalyst of this honeycomb of heating resisting metal manufacturing with carrier.This metal beehive has and replaces the flat thin plate with the corrugated sheet of the tabular shaping of ripple peace generate shape overlapping and be wound into circinate structure, and constitute minimal thickness by the thickness with plate and keep intensity, increase the area that contacts with waste gas by the mesh count that increases honeycomb simultaneously.

On the other hand, in order to purify the atmosphere in urban district, not only to new car, and the waste gas of in print automobile also needed to purify, from this viewpoint, actively pushing forward DPF is carried on the automobile.Yet, when importing DPF in the existing car that is using at present, owing to can not carry out explicitly Comprehensive Control with motor driven, therefore the situation of DPF cisco unity malfunction occurs often.

As the filter that can be used in the waste gas purification purposes, in recent years, bring into use sheet metal and the non-woven fabric compounded filter that forms of metal.The guider of the sheet metal of this filter makes backblast to the metal nonwoven, thereby the particulates emission material in the seizure waste gas, the complex structure of this filter is limited to 40～50% on the slip of PM, and existence can not be brought up to the above difficulty of this scope.For metal beehive, although the contact area of increase and waste gas is the comparison effective method,, following honeycomb has also been proposed in addition, that is, make the waste gas that in the gas passage that the mesh of honeycomb consists of, flows that turbulent flow, the structure that waste gas is contacted with catalyst energetically occur.This honeycomb increases surface area by plate-shaped is become open-celled structure, although loss is arranged in this, but in gas passage, produce turbulent flow, by turbulent flow, waste gas and catalyst [are for example actively contacted, Next generation catalysts areturbulent:Development of Support and Coating:2004-01-1488 is with reference to internet google].

And, disclosed exhaust gas purification catalyst carrier is when forming multiple scroll in the flat 8-196918 communique of TOHKEMY, be placed in the tubular shell of both ends open, the coiled sheet of the catalyst carrier in housing arranges turbulent generating unit, it is facial that this turbulent flow generating unit forms the variation of flowing that changes wind, and be provided with and stop that the stop section that breaks away from occurs the catalyst carrier of putting into enclosure interior, thereby make the gas that flows through that turbulent flow occur, in the reaction time of prolongation and catalyst, therefore can improve purifying property.

And, the disclosed exhaust gas purifying catalyst of the flat 6-2536 communique of TOHKEMY has urceolus, the first honeycomb ceramics of upper reaches survey and the second honeycomb ceramics of downstream side with carrier structure, the first honeycomb ceramics is by giving prominence to from the second honeycomb ceramics and to the holding member that axial upstream side extends, keeping and the non-contacting state of urceolus.Clip air layer between the first honeycomb ceramics and the urceolus, thereby prevent the heat release from the first honeycomb ceramics.

And, the disclosed exhaust gas purifying catalyst metallic carrier of the flat 1-123638 communique of TOHKEMY, reason because of the catalyst of the purification that is used in the waste gas such as automobile exhaust, honeycomb with alternative arrangement metal plate and ripple plate, and begin to be divided into to downstream side a plurality of from the upstream side of waste gas, with the whirlpool shape of each overlapping arrangement in dull and stereotyped end of the honeycomb structured body of the honeycomb structured body of upstream side and downstream side or the honeycomb structured body of lamination shape, cover along the outer peripheral face of the netted hole direction of honeycomb structured body with cylindrical shell, gripper shoe is installed at two ends at this cylindrical shell, and is fixed on inner barrel by gripper shoe.

And the disclosed waste gas purification apparatus of the flat 10-159552 communique of TOHKEMY reduces or removes the carbon black shape particle in the waste gas that Diesel engine discharges, and has NO is oxidized to NO ₂The first catalyst and the second catalyst that hydrocarbon, carbon monoxide, volatile organic component are carried out oxidation, make be trapped on the second catalyst monolithic (monolith) or among carbon black shape particle at the NO that contains from the first catalyst ₂Gas in burn, thereby the monolithic that uses as the first catalyst carrier is suppressed to Min. with the seizure of carbon black shape particle.

And, the waste gas filter of the disclosed purification of diesel engine exhaust gas of JP special table 2005-534487 communique is made of banded filter course and the metal forming that the part has filter house, and filter course has contact site and filter house, wherein, this filter house consists of by having the material that flow is crossed, this contact site has the catalyst activity cover layer for the gas componant of conversion waste gas, and this filter house is used for filtering and remove degranulation from waste gas.

And, the disclosed waste gas purification apparatus with heating unit of JP special table 2003-509620 communique has catalyst carrier and electric heating unit, this catalyst carrier is configured in the display pipe, and has a honeycomb that waste gas streams is crossed, the two ends of this heating unit have electric contact terminal, in this heating unit, come the stream of regulation complications with the gap by electric insulation, the honeycomb ceramics of this heating unit is fixed on the catalyst carrier by the electric insulation support unit, this honeycomb ceramics be provided in waste gas streams to catalyst carrier dirty on.

Yet, in Diesel engine, NO _XBe in the relation that (trade off) selected in compromise with PM, be difficult to its minimizing, and, because oxygen concentration is high in its waste gas of Diesel engine, therefore in petrol engine, effectively reduce NO by three-way catalyst _XMethod, be difficult to use in Diesel engine.Further, high because of oxidizing temperature as the carbon black of the main component of PM, so need special minimizing device.Although there is the DPF that purifies PM with catalyst-loaded filter, but for wearing out of catalyst, by prior the more catalyst loadings such as platinum are guaranteed performance in filter, but, this vehicle for long especially long distance travel is inadequate, and the possibility that can not bring into play the original performance of removing PM from waste gas becomes greatly.

And, although the carbon black of PM main component is filtered and burning by filter, but travel on continuously at the vehicle that carries DPF in the situation of road etc. of obstruction, the frequency of ignition temperature of PM that the engine exhaust temperature reaches catalyst is extremely low, its result, because of the carbon black blocking filter, this causes the obstruction of blast pipe, thereby has the possibility that causes vehicle not travel.Further, when being deposited on carbon black on the filter and surpassing the ignition temperature of carbon black because of the variation of driving conditions, the burning of PM heavy explosion can cause the damage of DPF, or burn out filter, or even breaking out of fire.Therefore, by the deposition of the detection carbon blacks such as pressure sensor, when the deposition of carbon black surpasses certain value, come the active combustion carbon black by the additional device that improves EGT recently.And, device following in being provided with the engine of waste gas purification apparatus is known, that is, in the later half and instroke of expansion stroke, use common rail (common rail) fuel injection device to come burner oil and make its burning, thereby improve delivery temperature; Perhaps, come the above-mentioned fuel that sprays of oxidation heating by the oxidation catalyst that is arranged on the rear; Perhaps, come oxidation heating fuel by the oxidation catalyst that is arranged on the rear, thereby improve EGT, above-mentioned fuel is from the fuel supply system on the upper reaches that is arranged in addition PM and removes device.Although this PM cleaning system is dangerous low because of the carbon black plugged filter, but, be in the low situation of the frequency of high temperature the waste gas such as running at a low speed, drive the waste gas temperature elevation system that uses described fuel, thereby waste in vain fuel, the problem that therefore exists fuel cost to increase.Especially, in the low situation of the active temperature of PM catalyst, the driving of waste gas temperature elevation system is increasing, and fuel cost increases.

Summary of the invention

The object of the present invention is to provide a kind of carrier for exhaust-gas purification, it is in order to address the above problem, to consist of the structure of the gas passage that waste gas was passed through self of carrier in fundamentally different from existing product modes.And, in order to bring into play the performance of the carrier structure upper limit that surpasses the honeycomb that is formed by thin plate, with wire netting or metal nonwoven fabric roll around or stacked, form cylinder or prismatic column, and, between belt body, form the exhaust steam passage that extends with straight line or zigzag, make hardly waste gas by the space of belt body, and make most of waste gas along the contact of the channel wall of belt body and pass through, thereby make waste gas that turbulent flow occur, increase simultaneously the contact area of waste gas and belt body wall, by the effect of the catalyst that supports with the surface, improve the redox reaction that harmful substance is carried out, thereby remove harmful substance, avoid occuring as existing, because particle matter causes the phenomenon that the carrier mesh stops up or stops up.In addition, particle matter is contacted in the belt body wall that impacts passage to be passed through, make waste gas often unimpededly flow through passage, and according to circumstances make the impact of waste gas and belt body or make a part of waste gas pass through belt body, catch the harmful substances such as particle matter along exhaust steam passage at the belt body wall, for example, be detained or the seizure particle matter at crooked route, and the engine waste gas heat when utilizing the engine exhaust temperature to raise heats and fires described particle matter, perhaps under the effect of catalyst, about 70～99% of the harmful substance in the waste gas is carried out redox and remove, thus purifying exhaust air.And, this carrier for exhaust-gas purification is applied in the waste gas purification apparatus of the reduction rate of particle matter in the waste gas that can guarantee about 40～80%.

The present invention relates to a kind of carrier for exhaust-gas purification, the tubular shell that it has the carrier that supported catalyst and places described carrier, described catalyst are used for by to being included in the NO of waste gas _X, HC, particle matter and coal smoke (soot) harmful substance burn or redox reaction and remove the NO that is included in the waste gas _X, HC, particle matter, thereby purify described waste gas; Described carrier is made of the column of belt body being reeled or be laminated into tubular, described belt body is made of wire netting or metal nonwoven, and has a wavy belt body that is configured as at least many crest lines and many grooves, the axle of the relatively described column of described crest line extends with parallel rectilinear form or tilted shape, described groove is between described crest line, and, an end face that is formed with between described belt body along described groove from described column is communicated to the exhaust steam passage of another end face, so that the described waste gas that flows through described exhaust steam passage because of the convex-concave surface of described belt body turbulent flow occurs.

And described belt body is adapted to described wavy belt body and overlaps each other, and it is alternately overlapping perhaps to be adapted to described wavy belt body and tabular belt body, and described tabular belt body is between described wavy belt body.Further, the axle of the relatively described column of described crest line of described wavy belt body tilts with zigzag and extends, and makes described exhaust steam passage form crooked route with this.Under described wavy belt body overlapped each other situation about setting, the described crooked route that is formed by the described crest line of described wavy belt body intersected respectively.Perhaps, described wavy belt body is configured as following shape, namely, only in the shape that specific length has the described crest line of gradient and the described crest line that only extends in parallel in specific length alternately repeatedly forms, and the described exhaust steam passage that forms along the described groove of described wavy band is made of parallel path and crooked route with respect to described column.

And, described carrier is made of the column of overlapping belt body being reeled or be laminated into tubular, this overlapping belt body refers to, described wavy belt body and described tabular belt body are overlapped as one, and perhaps the described wavy belt body that the angle of inclination of the described crest line more than 2 is identical or different carries out overlapping belt body as a cover each other.

And, consist of the described wire netting of described belt body or described metal nonwoven by stainless steel or Aludirome consist of.And equitant described belt body is engaged by solder each other, and this solder is pricker or pricker paper tinsel.At least one side end face of described carrier is engaged by described solder further, and soldering section forms the wire at the intermittence that has predetermined width and extend with the radiation curve-like, perhaps forms the wire that width broadens and extends with the radiation curve-like at outer circumferential side.And when having reeled described wavy belt body, on the position of the presumptive area on the adjacent described belt body of described crest line, the described belt body of described column each other by described solder brazing together at least.Further, on adjacent described belt body, described belt body each other the described presumptive area of soldering the position described column axially on mutually dislocation.

And tilt 10 °～50 ° angle of the axle of the relatively described column of described crest line of described wavy belt body, and described exhaust steam passage forms described crooked route.And in 0 °～50 ° angular range, the gradient more than 2 kinds is adopted in the described crest line combination of described wavy belt body in the described zigzag gradient of the axle of relatively described column.Further, a plurality of described column series connection are provided in the described tubular shell, and the angle of inclination of the described crest line of the described wavy belt body of described column is identical with downstream side or different at the upstream side of described waste gas.And the linear diameter that consists of the metal wire of described wire netting is 0.03mm～0.35mm.

And the mesh of described wire netting is 16～200 meshes.The mesh of described wire netting at the mesh number on the ordinate of metal mesh belt more than the mesh number on the horizontal line at described metal mesh belt, described mesh number on the described ordinate of described metal mesh belt is set as 30～100, and the described mesh number on described horizontal line is set as 60～200.

And the wavy concavo-convex spacing of described wavy belt body is 1mm～6mm.Further, the wavy concavo-convex height of described wavy belt body is 0.5mm～5mm.

And, the wire surface of the described belt body that consists of described carrier be coated with at least a in aluminium oxide, silica, zirconia, the cerium oxide more than.Further, on the surface of described overlay, support one or more catalyst of from platinum, silver, potassium, palladium, iridium, iron, copper, barium, selecting.

And, when described waste gas when being formed on the described exhaust steam passage between the described belt body along described groove, when being included in described harmful substance in the described waste gas and contacting with described belt body with the state flow mistake of turbulent flow, and under the effect of described supported catalyst, carry out redox reaction supporting, be removed with this.Further, being supported on described supported catalyst is oxidation catalyst, three-way catalyst or NO that hydrocarbon class A fuel A, ammonia or urea are played a role as reducing agent _XReducing catalyst.

And, described carrier for exhaust-gas purification is: set the filter that is built-in with described carrier in the exhaust passage of discharging described waste gas, make described waste gas by described filter, so that described belt body catches described harmful substance, and make described harmful substance contact by described belt body, with described harmful substance is burnt, redox reaction, thereby described harmful substance is removed, purify described waste gas with this.

That is, described carrier for exhaust-gas purification can be installed to waste gas purification apparatus and uses.

And, described belt body is formed with jog at width, described belt body is being reeled or be laminated under the state of described column, mutually stacked described jog makes described belt body engaging mutually so that the flow direction of the waste gas of described belt body described column axially on mutually do not misplace.

And, described filter is made of the described column of overlapping belt body being reeled or be laminated into tubular, described overlapping belt body refers to, described wavy belt body and described tabular belt body are overlapped as one, and perhaps the described wavy belt body that the angle of inclination of the described crest line more than 2 is identical or different carries out overlapping belt body as a cover each other.Further, at least one side end face of described filter is engaged by solder, and soldering section forms the wire at the intermittence that has predetermined width and extend with the radiation curve-like, and perhaps the degree of soldering section is wide broadens and extend with the radiation curve-like at outer circumferential side.

And described filter consists of in the mode that the series connection of the flow direction of described waste gas sets with a plurality of described columns.Further, the angle of inclination of the described crest line of described wavy belt body is with little at the upstream side of described waste gas and be shaped in the large mode of downstream side.Will at least 3 described belt bodies be configured as in the situation of described wavy belt body as a cover, described filter, the thin and thick mode of outside mesh sets and forms with the inboard mesh of described belt body.

And, at least 3 described belt bodies are being configured as in the situation of described wavy belt body as a cover, described belt body with little at the linear diameter of inboard metal wire and mesh thin and set in the linear diameter mode large and that mesh is thick of the described metal wire in the outside, is consisted of described filter with this.

And, replace overlapping described spacing from the upper reaches of waste gas streams more the upper reaches to the dirty described wavy belt body that just becomes less and described spacing from waste gas streams consist of described filter more to the dirty described wavy belt body that just becomes larger with this.

And, when described waste gas when being formed on the described crooked route between the described belt body, the described particle matter that is contained in the described waste gas flows through contacting simultaneously with the described wire netting of described belt body or metal nonwoven, perhaps for the time being contact is detained in described crooked route, thus oxidized burning.And, when described waste gas passes through the described crooked route of described exhaust steam passage, process along with the time, catch described particle matter in described crooked route and supporting and carry out oxidation reaction and be removed under the effect of described supported catalyst, described exhaust steam passage is formed between the described belt body by the described groove of described wavy belt body.

This carrier for exhaust-gas purification consists of as described above, therefore, the wavy belt body and the open and flat tabular belt body that are configured as the tabular shaping metal mesh of ripple or metal nonwoven is stacked, and reel or be laminated into helical form, many grooves along wavy belt body form honeycomb, and form along the channel inlet of wavy belt body and outlet not by the exhaust steam passage that seals and connect, and, convex-concave surface by the exhaust steam passage upper belt body, the contact area of waste gas is increased, and by increasing waste gas and the oxidation catalyst that is supported on the belt body, three-way catalyst, NO _XTouch opportunity between the various catalyst such as selective reduction catalyst, and with HC, NO _X, the redox of CO harmful substance is water, carbon dioxide, nitrogen, thereby can promotes to remove the performance of harmful substance.Especially, this exhaust gas purifying catalyst carrier structure, being configured as zigzag by the crest line with the tabular belt body of ripple is zigzag with channel formation, and when increasing the contact area of waste gas, the convex-concave surface of the belt body by consisting of wire netting or metal nonwoven gets muddled exhaust-gas flow, the tabular wall of waste gas and ripple is contacted and flow through when impacting, and, by increasing the touch opportunity between harmful substance and the catalyst, guarantee to carry out the high-performance of redox reaction.And waste gas is not by belt body, and along the groove formation exhaust steam passage of wavy belt body, therefore, exhaust steam passage is not blocked because of particle matters such as carbon blacks, can often guarantee unimpeded.

And this carrier structure has following excellent properties, namely, because catalyst-loaded carrier and the contact area between the waste gas are large, therefore has high purifying property, thus, carrier itself can either realize that the miniaturization formation can realize low-cost production again, and, the NO of use reducing agent _XThe selective reduction catalyst has high performance, can realize making size to dwindle half and get miniaturization, because carrier is to be made by metal, so the problem such as peel off as pottery does not occur, has excellent durability.And carrier is by changing the specification (linear diameter, mesh number, number) of wire netting, and the section shape of the exhaust steam passage that will be formed by the ripple plate is changed into the crooked route of parallel path or zigzag fashion, can control treatment effeciency with this.By exhaust steam passage is formed crooked route, can obtain effectively to catch and remove the function of the particle matter in the waste gas.And this carrier structure replaces existing stainless steel sheeting and will be wound into by the belt body that metal or metal nonwoven form helical form or stacked, thereby makes carrier, and the free degree of the carrier that therefore is shaped is significantly improved, and makes easily and cheapness.For example, in existing 20～30 μ m stainless steel sheeting, almost can not stretch etc., but the raw material of carrier is in the belt body that is made of metal or metal nonwoven as the present invention, the free degree that is shaped is high, can be simply and qurer form.That is, in the situation of the thin plate of 20～30 μ m, almost can not stretch etc., but in situation about being shaped by wire netting or metal nonwoven, the free degree improves.

And, this carrier structure is groove between crest line and this crest line so that belt body by a pair of concavo-convex forming tool or only press the method for shaping, can be shaped simply, and wavy belt body is easy to manufacture and cheap, and belt body twines mutually, so belt body need not to engage each other.

In having the waste gas purification apparatus of this carrier for exhaust-gas purification, because divided exhaust steam passage and catch particle matter (below, PM) etc. part, therefore filter can not stop up because of PM etc., the catch rate of PM can be guaranteed often about 40～80%, and, can pass through coal smoke, HC, NO _XBurn or under the effect of catalyst, carry out redox reaction etc. harmful substance, thereby be removed, thereby filter can not stop up because of PM.Exhaust steam passage along wavy belt body groove forms zigzag, and the concavo-convex wall of the wavy belt body of backblast also flows through, and can catch the PM in the waste gas that impacts, even and seizure PM, exhaust steam passage does not stop up yet, and wherein, this wavy belt body is made of wire netting or metal nonwoven.The specification (linear diameter, mesh number, number) of the mesh by changing the belt body wire netting perhaps forms the section shape of the exhaust steam passage of wavy belt body by change, change jagged shape, thereby can adjust the catch rate of PM.Namely, in filter, the harmful substances such as the PM in the waste gas flow through when the channel wall with crooked route or parallel path contacts, and this harmful substance carried out heating flame or redox reaction, even were it not for the PM in the harmful substance is carried out heating flame or oxidizing fire immediately, PM is in the state that is trapped in wall, the exhaust steam passage of filter itself does not stop up at channel wall yet, and as time goes by the PM that is captured is carried out heating flame or oxidizing fire, thereby be removed, thereby, can realize from waste gas, removing the rate of removing of PM 40～80%, waste gas often can be through flowing through passage for a long time glibly, and bring bad impact for the operating condition of engine.Filter in this waste gas purification apparatus is formed with crooked route and parallel path, because the part of exhaust steam passage and seizure PM forms respectively, therefore exhaust steam passage does not stop up, and the particle matter that is captured is along with the elapsed time, oxidizing fire and being removed little by little under the effect of catalyst, perhaps the EGT of engine raises, thereby by the waste gas heat heating flame or by NO ₂Oxidation is removed, thereby can improve the capturing efficiency of PM in the waste gas.

Description of drawings

Fig. 1 is the key diagram that expression forms the operation of carrier for exhaust-gas purification of the present invention.

Fig. 2 is the front view that is expressed as follows state, that is, and and the wavy belt body of pie graph 1 carrier and the equitant state of tabular belt body.

Fig. 3 is that expression is wound into the front view that helical form forms column by the equitant belt body with Fig. 2.

Fig. 4 is the stereogram that expression forms the operation of column, that is, will have the wavy belt body coiling of different gradient crest lines and form this column.

Fig. 5 is that expression is reeled the wavy belt body of Fig. 4 and the front view of the column that forms.

Fig. 6 is the side view of the column of presentation graphs 5.

Fig. 7 is the key diagram that represents 2 crest lines are adapted to crossing condition, and wherein, these 2 crest lines are crest lines of the wavy belt body of pie graph 4 columns.

Fig. 8 is the cutaway view of the I-I section of presentation graphs 7 columns.

Fig. 9 is the cutaway view of the II-II section of presentation graphs 7 columns.

The key diagram of the state during Figure 10 A exhaust steam passage that to be the slow waste gas of expression flow velocity form by the groove along column.

The key diagram of the state during Figure 10 B exhaust steam passage that to be the fast waste gas of expression flow velocity form by the groove along column.

To be expression be bonded on belt body the key diagram of the state on the end face of filter with solder to Figure 11 A, and above-mentioned joint refers to engage the state with the proportional several parts of channel cross-sectional area of filter.

To be expression be bonded on belt body the key diagram of the state on the end face of filter with solder to Figure 11 B, and expression disconnects the state from the central part of filter to the junction surface that peripheral part extends.

To be expression be bonded on belt body the key diagram of the state on the end face of filter with solder to Figure 11 C, and the expression state that will strengthen to the composition surface at the junction surface that peripheral part extends from the central part of filter.

Figure 12 is expression, and series connection sets under the state of column of 3 carriers in housing, the two side ends of column is fixed on the key diagram of an example on the housing with the block parts.

Figure 13 is expression, and series connection sets under the state of column of 3 carriers in housing, and housing is fixed on column with recess the key diagram of another example on the housing.

Figure 14 is expression, and series connection sets under the state of column of 3 carriers in housing, the two side ends of column is fixed on the key diagram of another example on the housing with the block parts.

Figure 15 is expression, and series connection sets under the state of column of 3 carriers in housing, and housing is fixed on column with recess the key diagram of another example on the housing.

Figure 16 is the key diagram that expression will consist of the state that mode that 2 crest lines of belt body of the column of filter intersect sets.

Figure 17 is the sectional side elevation that passes filter center, is equipped with the column of an example in the housing of this filter, and this column is the belt body that is formed with jog at width to be reeled form.

Figure 18 is the sectional side elevation that passes filter center, is equipped with the column of another example in the housing of this filter, and this column is the belt body that is formed with jog at width to be reeled form.

Figure 19 is the curve map of result of the test of the reduction rate of the CO of harmful substance in the waste gas of comparison product of the present invention and existing product and HC.

Figure 20 is the curve map of the result of the test of the purifying rate of the HC of harmful substance in the waste gas of comparison product of the present invention and existing product.

Figure 21 is the NO of harmful substance in the waste gas of comparison product of the present invention and existing product _XThe curve map of result of the test of purifying rate.

Figure 22 is the curve map of the result of the test of the relation between the reduction rate of particle matter of comparison product of the present invention and existing product and filter inlet are pressed.

Figure 23 is the curve map of the PM purifying rate brought into play of the crest line angle of the expression wavy belt body corresponding with engine speed.

Figure 24 is expression, about the filter of this waste gas purification apparatus, the accelerator in when igniting hypothesis close the time the curve map of melting loss test.

The specific embodiment

The waste gas purification apparatus of built-in carrier for exhaust-gas purification of the present invention is applicable to following situation, namely, make from the waste gas of engine, burner and gas generating source by being provided in the filter on the exhaust passage, and under catalyst action to being included in particle matter (PM), coal smoke (soot), HC, the NO in the waste gas _XBurn etc. harmful substance, perhaps carry out redox reaction and make its conversion and remove, thus purifying exhaust air.For example, relatively be applicable to be provided in the filter on the blast pipe, wherein, this blast pipe ejects the waste gas from new car or used engine, especially from the waste gas of Diesel engine.

Below, with reference to accompanying drawing, the waste gas purification apparatus of built-in carrier for exhaust-gas purification of the present invention is described.

This waste gas purification apparatus built-in filter 20, this filter 20 is made of carrier catalyst-loaded in the gas extraction system 1 (being generically and collectively referred to as Reference numeral 1), and this carrier 1 will be included in particle matter (PM), coal smoke, HC, the NO from the waste gas that the outlet of engine, burner, burner, flue etc. is discharged _XEtc. harmful substance, redox reaction Cheng Shui, carbon dioxide and nitrogen and be removed under the effect of catalyst.

Such as Fig. 1～shown in Figure 3, carrier 1 in this carrier for exhaust-gas purification is characterised in that, the wavy belt body 3 of alternate configurations and tabular belt body 13, wherein, the belt body 8 that this wavy belt body 3 is shaped and is formed by wire netting or metal nonwoven, perhaps such as Fig. 4～shown in Figure 6, dispose one or more wavy belt bodies 3, and to be wound into the whirlpool shape be helical form or stacked, thereby consist of column 4, and form exhaust steam passage 5, the groove 6 of the wavy belt body 3 that this exhaust steam passage 5 is made along shaping belt body 8 is communicated to flow export 10 (Figure 12～Figure 15) of another end face from the inflow entrance 9 of an end face of column 4.Column 4 forms the cylinder body shape of cylinder, prism etc. in terms of overall.End along the groove 6 formed exhaust steam passages 5 of wavy belt body 3 is not sealed, and is communicated to the flow export of another end face from the inflow entrance of an end face, has formed a plurality of honeycombs (honeycomb) structure of extending or extending with zigzag along straight line.In this waste gas purification apparatus, the carrier 1 with exhaust steam passage 5 of Figure 12, rectilinear form shown in Figure 13 is applicable to HC, NO _XDeng the purification of harmful substance, the carrier 1 that has such as Figure 14, zigzag exhaust steam passage 5 shown in Figure 17 is applicable to be included in HC, NO _XIn the purification of harmful substance of particle matter 18 grades.

Belt body 8 both can be the wire netting that forms with various structure braidings, also can be the metal nonwoven.Wavy belt body 3 can form in the following way, that is, and and by the forming tool of the shapes such as gear-like, dull and stereotyped belt body 8 is configured as groove 6 between crest line 7 and the crest line 7 at width, and, by belt body 8 is configured as tabular, also can form tabular belt body 13.And the belt body 8 that forms column 4 is supporting the catalyst of removing harmful substance by redox reaction in its surface.Because belt body 8 is shaped by wire netting or metal nonwoven, and be formed with a plurality of concavo-convex on its surface, support catalyst at convex-concave surface, thereby increased the ability that to bring into play high purification waste gas by the carrier 1 that belt body 8 consists of because of waste gas G and with the contacted chance in surface.Because waste gas G contacts with the belt body wall of carrier 1 and flows through, thereby get muddled both turbulent flows (disturbed flow), and the touch opportunity between waste gas G and the catalyst and increasing time of contact, thereby can promote the redox of harmful substance.The belt body 8 that consists of carrier 1 is being subject to the thermal stress of low temperature and high temperature often repeatedly, and Temperature Distribution is also different because of the position of belt body 8.The wire netting of belt body or metal nonwoven are made of very thin metal wire respectively, therefore can allow neatly the distortion that heat distribution causes, and local plastic deformation etc. do not occur, therefore owing to be coated in the pottery etc. on surface and do not come off, so durability is high.Carrier 1 is by making waste gas G produce turbulent flow, significantly strengthen waste gas and be supported on contacting of carrier 1 lip-deep catalyst in modes such as coatings, thereby can irrespectively improve purifying property with the kind that is supported on the catalyst on the carrier 1, perhaps only want to obtain the purifying property that equates with existing purifying property, then the present invention can realize significantly miniaturization.

And, although not shown, but make wavy belt body 3 pass the concavo-convex forming tools such as running roller type pressure (press) machine of a pair of zigzag, perhaps pressing between running roller only, just wavy belt body 3 can be configured as by the groove 6 between crest line 7 and the crest line 7 consist of wavy.Such as Fig. 1 and shown in Figure 10, the crest line 7 of wavy belt body 3 is configured as the shape that extends in parallel or favours the shape of the axle of column 4, specifically, such as Fig. 4～shown in Figure 6,10 be configured as zigzag with respect to the axle of column 4 from inflow entrance 9 to flow export with forming tool.Thereby, extend along groove 6 abreast and have a plurality of parallel paths 17 thereby carrier 1 forms the crest line 7 of wavy belt body 3, thereby perhaps carrier 1 crest line 7 that forms wavy belt body 3 extends along groove 6 agley and has a plurality of crooked routes 16.And, such as Fig. 5, Fig. 7 and shown in Figure 16, at least 2 wavy belt bodies 3 are wound into helical form as one group, thereby form column 4, wherein, above-mentioned wavy belt body 3 is that juxtaposition becomes the angle of inclination of crest line 7 to extending in the other direction for mutual intersect (cross).Figure 16 shows the mutually stacked state of 2 metal tapes 3, and the wavy belt body 3 usefulness solid lines of a side are represented, wavy belt body 3 with dashed lines of opposite side are represented, and then the crest line 7 that shows wavy belt body 3 is laminated into the state that intersects.Perhaps, although not shown, also can be by following two parts be alternately repeated the crest line 7 of forming shaped on wavy belt body 3, above-mentioned two parts refer to, with respect to the axle of column 4, only in the specific length part that tilts and the part that only extends in parallel in specific length.This waste gas purification apparatus is characterised in that, when the exhaust steam passage 5 of waste gas G by forming along the groove 6 between the belt body 8, harmful substance among the waste gas G becomes turbulent flow when contacting with belt body 8, and be burned or be carried out redox reaction, thereby become water, carbon dioxide and nitrogen and be removed.

As shown in Figure 7, be formed in the crooked route 16 of wavy belt body 3, waste gas G flows through to direction shown in the arrow, and this wavy belt body 3 consists of carrier 1.Such as Fig. 7～shown in Figure 9, in carrier 1, when waste gas G passes through the crooked route 16 of formation between the wavy belt body 3, particle matter 18 in the waste gas flows through when contacting with wavy belt body 3, the bend that perhaps is trapped in for the time being the crooked route 16 that is formed by the groove 6 between the crest line 7 grades in the zone, at this, gradually oxidized burning and burning of particle matter 18.Along with the particle matter 18 that is included among the waste gas G flows through crooked route 16 with waste gas G, flow through when contacting with the belt body wall of wavy belt body 3, wire netting by being supported on belt body 8 or the effect of the catalyst on the metal nonwoven, be removed, the zone but the bend that a part of particle matter 18 is trapped in crooked route 16 for the time being grades, therefore, EGT increases and is burnt by waste gas heat heating or by NO ₂Oxidation is removed, and perhaps, because of gradually oxidized burning and being burnt of the effect of catalyst, therefore, crooked route 16 can not stopped up by particle matter 18, so that waste gas G can unimpededly flow through often.

And (a) of Figure 10 A is the cutaway view of this waste gas purification apparatus, (b) is the top view of this waste gas purification apparatus, and shows flowing through of waste gas G in the slow situation of gas flow rate.And (a) of Figure 10 B is the cutaway view of this waste gas purification apparatus, (b) is top view, and shows flowing of waste gas G in the fast situation of gas flow rate.As shown in figure 10, the flow velocity of waste gas G is faster, waste gas G flows through in the cylinder of filter 20 more abreast, therefore, be crooked route 16 by add what have minute angle at the flow path of waste gas G, on the wire netting that the PM that is included among the waste gas G is attached to form exhaust steam passage 5 or the wall of metal nonwoven, waste gas G is flow through on one side, and, the slow situation of the fast situation of gas flow rate and flow velocity is compared in cylinder the characteristic of PARALLEL FLOW and is more strengthened, and its result penetrates the wire netting that consists of exhaust steam passage 5 walls or metal nonwoven and flows, thereby remove the characteristic of PM and weaken by making PM be attached to wall, and then the PM purifying rate reduces.Similarly, in the slow situation of waste gas flow velocity, then have the characteristic opposite with the high situation of flow velocity.

And, in this waste gas purification apparatus, the crest line 7 of wavy belt body 3 is identical or different for the angle of inclination of the axle sawtooth of column 4, and tilt in the scope of axle with roughly 10 °～50 ° angle for column 4, thereby form the crooked route 16 as wrong path of exhaust steam passage 5.And a plurality of column 4 series connection are provided in the tubular shell 2, and the degree of tilt of the crest line 4 of the wavy belt body 3 of column 4 is identical or different in the survey of the upper reaches of waste gas G and downstream side.If consider flowing of waste gas G in the exhaust steam passage 5, then the angle of inclination of crest line 7 is preferably 10 °～50 °.By following method validation the range of tilt angles of crest line 7, that is, and the purifying property of investigation the present invention and the hydrocarbon of the platinum that is supported on existing metal beehive.Think that the present invention can guarantee that one of them reason of high purifying rate is, the surface of the wire netting of belt body 8 or metal nonwoven causes the turbulent flow of waste gas G, thereby increases considerably contacting of waste gas G and catalyst.There is the optimum value for waste gas G in the angle of inclination of crest line 7.Figure 23 shows such situation, and is namely corresponding with the rotating speed of engine, and the PM purifying rate is according to the angle of inclination of the crest line 7 of wavy belt body 3 and different situations.Namely, be in 45 ° the situation in the angle of crest line 7, shown in the curve A of Figure 23, be in the situation of 500rpm～2000rpm at engine speed, the purifying rate of PM is good, is in 30 ° the situation, shown in the curve B of Figure 23 in the angle of crest line 7, be in the situation of 2000rpm～3500rpm at engine speed, the purifying rate of PM is good.Therefore, because engine significantly changes to the high speed of high output of performance from the low speed of idling (idling) running under the road driving condition, and the flow of waste gas G together and significantly changes therewith, so in order to improve the PM purifying rate, with make up angle that a plurality of and low speed is complementary and with the mode of the angle that is complementary at a high speed, change the zigzag angle more than 2 times from the upstream side of waste gas G to downstream side, thereby can obtain the performance of excellent PM purifying rate.

In this waste gas purification apparatus, in the situation at the angle of inclination of the crest line 7 of the upper reaches of waste gas G stream and the wavy belt body 3 of dirty change, to be provided in the upper reaches by the filter 20 that the little wavy belt body 3 of angle is made, to be provided in by the filter 20 that the large wavy belt body 3 of angle is made dirtyly, and can effectively bring into play capturing efficiency like this.That is, in the large situation of exhaust gas flow, because EGT also the chances are high temperature, even therefore catch PM, PM is oxidized burning also, so PM is few for the deposition of filter 20.But exhaust gas flow is little and EGT is also low when low speed, so the many situations of the deposition quantitative change of PM also increase.In this case, if the filter 20 of the wavy belt body 3 that angle is little is provided in the upper reaches, although then be not high catch rate, but can catch PM, thereby the deposition that is arranged on the large filter of dirty angle 20 is reduced, therefore institute can catch PM by filter integral body effectively so that its burden reduces.And, in this waste gas purification apparatus, with large wavy belt body 3 and the reel belt body 8 little with the angle of inclination in angle of inclination of combination crest line 7, thereby can catch evenly from low speed to high speed PM.And, if the crest line angle of the belt body 8 of 1 carrier 1 is certain, and at the carrier 1 of the different crest line angle more than 2 kinds of arranged in series on the flow path of waste gas G, then can obtain stable from low speed to high speed performance.Perhaps, even will make up the different belt body 8 of crest line angle more than 2 kinds and with its coiling or stacked and as 1 carrier 1, also can access stable from low speed to high speed performance.Further, a plurality of carriers 1 by the different belt body 8 in the angle of inclination that will make up crest line 7 are arranged in series on the flow path of waste gas G, can obtain higher purifying rate, simultaneously, therefore owing to can make with same size a plurality ofly, can reduce the cost of manufacture of carrier 1.

The catalyst that is supported on the carrier 1 can use three-way catalyst, oxidation catalyst, NO _XReducing catalyst (NO _XThe selective reduction catalyst).Even the present invention adopts three-way catalyst, oxidation catalyst, NO _XAny one catalyst in the reducing catalyst also can increase substantially purifying property, if guarantee the purifying property identical with existing carrier, then can significantly carry out miniaturization, and can make with low cost.And, for the NO that uses the reducing agents such as urea (perhaps ammonia), light oil _XReducing catalyst more extremely importantly is that waste gas G and the reducing agent that mixes with waste gas G are mixed equably.In the situation that is equipped on the cleaning system on the car body, need waste gas G and reducing agent to be disperseed equably and mix.In carrier in the past, be difficult to disperse and mix owing to density unevenness occurs the relative waste gas G of reducing agent, if but use product of the present invention, then can successfully disperse to mix.This waste gas purification apparatus consists of as a purpose to catch PM, still, in addition, also can be with NO _XReducing catalyst is supported on the filter 20.Use the NO of light oil as reducing agent _XReducing catalyst uses the situation of platinum, silver etc. many as catalyst.In this case, owing to have the effect of burning PM, therefore by supporting NO at filter 20 _XReducing catalyst is catching and burning PM and when purifying, carry out NO _XPurification, thus, can make this waste gas purification apparatus as purifying simultaneously NO _X, PM device play a role.In this waste gas purification apparatus, can support the NO that uses zeolite etc. at filter 20 _XReducing catalyst, and, in the case, also can carry out simultaneously NO by enough same filters 20 _XPurification and the seizure of PM purify, thereby can carry out miniaturization to installing itself, and can realize cost degradation.And, in the carrier of existing ceramic honeycomb and metal beehive, cross a certain mesh from the waste gas streams that exhaust gas entrance enters, and not with state that waste gas in the adjacent mesh mixes under, arrive the outlet of carrier.Yet, a mesh of carrier 1 of the present invention begins from inflow entrance 9 that straight line extends till the flow export 10, simultaneously, mesh is communicated with the porous of adjacent mesh by wire netting or metal nonwoven, thereby so waste gas G mixedly flow through mutually and promote to mix, thus, even be positioned at carrier 1 inflow entrance 9 reducing agent uniformity slightly a little less than, during waste gas G flow through carrier 1, waste gas G proceeded with mixing of reducing agent, its result can obtain high purifying rate.Confirm in the actual tests of using engine, product of the present invention has 3 times SV (l/h) with comparing of existing product, and can access the performance that equates with existing product.Wherein, SV (l/h) is that gas flow is divided by the rate value of carrier capacity.

And the wire netting of formation belt body 8 or metal nonwoven are made of the metal wire of stainless steel or Aludirome.And the diameter of the metal wire of the wire netting of formation belt body 8 is preferably 0.03mm～0.25mm, and the mesh (mesh) that consists of the wire netting of tabular belt bodies 13 with wavy belt body 3 is preferably 30～200 meshes.Further, will at least 2 belt bodies 8 be configured as in the tabular situation of ripple as a cover, be that the mesh of wire netting of the inboard belt body 8 of filter 20 attenuates with carrier 1, and be the mesh overstriking of wire netting of belt body 8 in the outside of filter 20 with carrier 1.The mesh of the wire netting of belt body 8, the ordinate of belt body 8 is different with the mesh number on the horizontal line, and the mesh number on the ordinate of belt body 8 is more than the mesh number on the horizontal line of belt body 8.In this embodiment, the mesh number on the ordinate of belt body 8 is 30～100 meshes, and the mesh number on the horizontal line of belt body 8 is 60～200 meshes.In other words, the ordinate of so-called belt body 8 refers to the metal wire that the length direction of belt body 8 extends, and the horizontal line of belt body 8 refers to the metal wire that the width of belt body 8 extends.In general, the wire netting that forms belt body 8 is woven by ordinate and horizontal line, but the braiding speed of wire netting suffers restraints because of the mesh number of horizontal line.In the many situations of the mesh number of horizontal line, the speed that can once finish braiding with braider slows down, and, weaves required time lengthening that is, its result, and the operating cost that is used for the braided metal net improves.Yet in the many situations of the mesh number of ordinate, although the operation that ordinate is set to braider slightly increases, the mesh number on the horizontal line reduces, and thus, the braiding required time significantly shortens, thereby improves weaving operation efficient.Therefore, want to reduce the manufacturing cost of wire netting, the raise speed speed of braider braiding of the netting index that reduces horizontal line is effective.On the other hand, for example, the surface area of the per unit area of the wire netting that the wire netting that is made of the horizontal line of the ordinate of 80 meshes and 80 meshes and horizontal line by the ordinate of 120 meshes and 40 meshes consist of becomes identical, and is identical thereby the performance of carrier 1 also becomes.

And, as shown in Figure 2, about the crest line 7 of wavy belt body 3 and the size between the groove 6, to be that concavo-convex interval P is set as 1mm～6mm between the crest line 7 preferably, if interval P is below the 1mm, then because of the too narrow and small PM etc. that piles with of exhaust steam passage 5, in addition, if interval P more than or equal to 6mm, then can not contact with catalyst because of the too wide waste gas G of exhaust steam passage 5 fully.And, in the longitudinal direction, change by the big or small identical of the spacing P between the crest line 7 that makes carrier 1 or with it, can change the width dimensions of exhaust steam passage 5, thereby can make waste gas G that desirable disorder occurs in flow process.For example, for wavy belt body 3, although not shown, can alternately form the flow path upstream side is large and downstream side is little spacing P and spacing P in contrast to this, perhaps can be in the longitudinal direction form with the spacing P of formed objects.More reduce the spacing between the crest line 7 of wavy belt body 3, then more improve the catch rate of PM, still, on the other hand, if the spacing of crest line 7 is too little, the situation of the stifled full filter 20 of PM can occur then.

Thereby, in this waste gas purification apparatus, in order to obtain high catch rate, take following method relatively to produce effect, that is, it is less that wavy belt body 3 is made into spacing, and it is large to be involved in a part of spacing.Do not burn and be deposited in the situation of filter even passed through in the process of moving long-time PM, the part that spacing is large is not stopped up, so the output of engine can descend, and does not travel but do not affect.Spacing for the crest line 7 of the wavy belt body 3 of filter 20, the filter wall that the large mode of spacing downstream side forms if the spacing that alternately makes up the little mode of downstream side forms so that upstream side is large filter wall and survey with the upper reaches is little, then can correctly adjust waste gas G mobile be a part of waste gas G by the quantity of filter wall, thereby can adjust the PM catch rate.Further, the wavy belt body 3 preferably ripple plate height of concave convex H of crest line 7 and groove 6 is 0.5mm～5mm, if height H is below 0.5mm, then exhaust steam passage 5 is too low, thereby the tendency that has the obstructions such as PM, in addition, if height H is more than 5mm, then exhaust steam passage 5 is too high, thereby waste gas G becomes insufficient with contacting of catalyst.Filter 20 is by the distance P between the adjustment crest line 7 and the height of concave convex H between crest line 7 and the groove 6, can regulate the size of crooked route 16 or parallel path 17, and can regulate flowing of waste gas G, as long as determine these sizes corresponding to size and the performance of engine.

Formation filter 20 is that wire netting or the metal nonwoven of the belt body 8 of carrier 1 applied aluminium oxide (Al ₂O ₃), silica (SiO ₂), zirconia (ZrO ₂), cerium oxide (CeO ₂), titanium oxide (TiO ₂) at least a above pottery.That is, consisting of on the carrier matrix material of carrier 1, be coated with in advance in silica, aluminium oxide, cerium oxide, titanium oxide, the zirconia any one or comprise at least a composite oxide power in these.Further, the oxidation reduction catalyst more than the surface of the ceramic coating layer of the matrix material that covers belt body 8 supports at least a in platinum (Pt), silver (Ag), potassium (K), palladium (Pd), iridium (Ir), iron (Fe), copper (Cu), barium (Ba), ruthenium (Ru), the rhodium (Rh).

And, as shown in figure 11, under the environment of having given the excessive external force such as vibration, perhaps under the environment that is subject to large thermal stress, use when having the filter 20 of carrier 1, for prevent from disperseing, distortion, each other can enough nickel with consisting of the wavy belt body 3 of filter 20 and tabular belt body 13 or wavy belt body 3, the solder such as copper engages.In the situation of using filter 20 under the high temperature more than 600 ℃, the belt body 8 that preferably engages wavy belt body 3 and/or person's tabular belt body 13 with solder suppresses the thermal deformation of the belt body 8 of filter 20 each other.For example, a side end face 25 of filter 20 or two end faces 25 are engaged on closing line 23 (being generically and collectively referred to as 23) by solder.Specifically, shown in Figure 11 A or 11B, soldering section becomes wire closing line 23A, the 23B at the intermittence (intermittent) that has preset width and extend with the radiation curve-like, perhaps shown in Figure 11 C, soldering section becomes and has the width that enlarges to outer circumferential side and the closing line 23C that extends with the radiation curve-like.In Figure 11 A, in order to make the adhesion that applies to belt body 8 end faces impartial, with more past outer circumferential side then closing line 23A more multimode consist of, namely, at outermost perimembranous joint 12 closing line 23A are arranged, engaging at pars intermedia has 8 closing line 23A, and engaging in interior perimembranous has 4 closing line 23A.In Figure 11 B, consist of in the mode on the closing line 23 that is applied to solder without unnecessary external force, that is, engage by forming notch 24 at closing line 23B.Further, impartial to the adhesion that the end face of belt body 8 applies in order to make by closing line 23 in Figure 11 C, with more past outer circumferential side then the thickness of closing line 23C be that the larger mode of width forms.Further, in filter 20, when reeling wavy belt body 3, crest line 7 and belt body 8 contacted the giving on the position of deciding the zone of overlapping wavy belt body 3, apply solder or set the solder paper tinsel, thereby belt body 8 is brazed together each other mutually.Further, between the adjacent belt body 8 that consists of filter 20, the belt body 8 each other position of deciding the zone of giving of soldering preferably misplaces in the axial of column 4.

Usually, in the amplifier case that uses metal forming, on one side pricker paper tinsel or metal forming are wound up in the metal forming, applying solder paste carries out soldering on one side, but the filter 20 that is made of carrier 1 of the present invention can obtain the strong intensity of thermal stress by two end faces 25 of a cylindrical shell of soldering column 4, wherein, this carrier 1 has used wire netting or metal nonwoven.Wire netting or metal nonwoven if be conceived to metal wire, then have flexible nature in all directions, even therefore the junction surface only is set in two ends, also is not vulnerable to mechanical stress, thermal stress, thereby can obtains the filter 20 of sufficient intensity.Namely, although carrier 1 is subject to the effect of low temperature and high temperature often repeatedly, further, Temperature Distribution is also different because of the position of carrier 1, but filter 20 is made by wire netting or metal nonwoven, and be made of very thin metal wire, therefore plastic deformation etc. can not occur in the distortion that therefore can stop very neatly heat distribution to cause.Thereby, even in soldered joint, by disperseing the junction surface, can bring into play the excellent specific property of carrier.In the situation of the end face 25 that welds filter 20, if closing line 23 is extended to the radiation curve-like that passes carrier cylindrical shell central shaft, then carrier improves the rigidity of this soldering part, therefore radiate curvilinear braze welding joint at this and suffer restraints, thereby flexibility reduces.Therefore, in the situation of the closing line 23 that extends with the radiation curve-like, by extending with curve-likes such as whirlpool shapes, can weaken the resistivity for external pressure, in the case, not at the joint everywhere of closing line 23, and notch 24 is set, thereby can obtain higher flexibility.And, by increasing the area of closing line 23, improve the intensity of filter 20.Filter 20 with catalyst is usually different at the pressure of its front and back, the power of therefore being stipulated.Because the power carrier 1 suffered shearing force of this regulation is directly proportional with radius, it is stronger more to arrive peripheral part one side, therefore carries out in the situation of soldering at the end face 25 to filter 20, and it is larger that carrier 1 preferably makes bonding area more arrive periphery.And, there are the crest line 7 of the axioversion of the column 4 after relatively finishing in the wire netting of wavy belt body 3 or metal nonwoven, so for coating solder when having reeled belt body 8 or folder solder paper tinsel, and make solder or solder paper tinsel be positioned at each other contacted zone of belt body 8.Yet belt body 8 is variations of being everlasting of contacted when zone each other, therefore in order effectively to bring into play the effect of solder, preferably with image reading zigzag crest line 7, when having reeled belt body 8, makes solder correctly be positioned at the zone that belt body 8 contacts with each other.

Such as Figure 12～shown in Figure 15, the column 4 that a plurality of (among the figure being 3) consists of carrier 1 is provided in the shell 2, for example, is provided in the way of blast pipe, and the end of housing 2 can be connected with blast pipe, perhaps housing 2 can be provided in the blast pipe in the mode that is pressed into.If the crest line 7 that will be formed in the wavy belt body 3 on the carrier 1 forms in the mode that the axle that is parallel to column 4 extends, the exhaust steam passage 5 that then forms along the groove 6 of wavy belt body 3 forms the exhaust steam passage 5 (Figure 12, Figure 13) of rectilinear parallel path 17.Perhaps, if the crest line 7 that will be formed in wavy belt body 3 forms in the mode that the axle for column 4 tilts, the exhaust steam passage 5 that then forms along the groove 6 of wavy belt body 3 forms the crooked route 16 of inclination.Further, if the crest line 7 that will be formed in wavy belt body 3 is to form for the jagged mode of the axle of column 4, the exhaust steam passage 5 that then forms along the groove 6 of wavy belt body 3 forms crooked route 16 (Figure 14, Figure 15).

Figure 12 shows, the example of the filter 20A that is made of the carrier 1 that is provided in the blast pipe.Filter 20A is built in the blast pipe in the mode on the flow direction that is provided in waste gas G.Carrier 20A is made of housing 2 and 3 columns 4 that are provided in the housing 2.The gas passage 5 of carrier 20A connects flow export 10 to another end face from the inflow entrance 9 of an end face, thereby forms linear gas passage 14.Therefore and in carrier 1,3 columns 4 are fixed on the housing 2, by on the end face of the column 4 of the upper downstream side that is positioned at housing 2 that block parts 11 are deposited to housing 2, column 4 can be fixed in the housing 2.Although not shown, in this waste gas purification apparatus, certainly 1 carrier 1 can be provided in the housing 2.And Figure 13 shows another example of the filter 20B that is made of the carrier 1 that is provided in blast pipe.Filter 20B is built in the blast pipe in the mode on the flow direction that is provided in waste gas G.Filter 20B is made of housing 2 and 3 columns 4 that are provided in the housing 2.The gas passage 5 of carrier 20B connects flow export 10 to another end face from the inflow entrance 9 of an end face, thereby forms linear gas passage 14.In this waste gas purification apparatus, 3 columns 4 are fixed on the housing 2, therefore as shown in figure 17, the outer peripheral face of the housing 2 that distortion column 4 is positioned at and form recess 12, thus column 4 can be fixed at housing 2.

And Figure 14 shows, other another example of the filter 20C that is made of the carrier 1 that is provided in the blast pipe.Filter 20C is built in the blast pipe in the mode on the flow direction that is provided in waste gas G.Filter 20C is made of housing 2 and 3 columns 4 that are provided in the housing 2.The gas passage 5 of filter 20C connects flow export 10 to another end face from the inflow entrance 9 of an end face, thereby forms jagged gas passage 15.In this carrier for exhaust-gas purification, for 3 columns 4 are fixed on the housing 2, and on the end face of the column 4 of the upper downstream side that is positioned at housing 2 that block parts 11 are deposited to housing 2, thus column 4 can be fixed in the housing 2.And Figure 15 shows another example of the filter 20D that is made of the carrier 1 that is provided in the blast pipe.Filter 20D is built in the blast pipe in the mode on the flow direction that is provided in waste gas G.Filter 20D is made of housing 2 and 3 columns 4 that are provided in the housing 2.The gas passage 5 of filter 20D connects flow export 10 to another end face from the inflow entrance 9 of an end face, thereby forms jagged gas passage 15.In this carrier for exhaust-gas purification, for 3 columns 4 are fixed on the housing 2, and make the outer peripheral face of the housing 2 that column 4 is positioned at be out of shape to form recess 19, thereby column 4 can be fixed on the housing 2.Further, about filter 20A, 20B, 20C, the 20D that is consisted of by carrier 1, although not shown, but, for make wavy belt body 3 and tabular belt body 13 column 4 axially on mutual dislocation does not occur, for example can realize simply by following method, namely, under the state in column 4 is built in housing 2, make metal wire on the cross-sectional direction of housing 2 with cross shape across the both ends of the column 4 i.e. inflow entrance 9 of an end face and the flow export 10 of another end face.

And, such as Figure 17 or shown in Figure 180, be formed with jog 19 at width, and the mode that is wound into column 4 with the wavy belt body 3 of belt body 8 forms under the state of filter 1, jog 19 mutual stacked and wavy belt bodies 3 are engaged mutually, thus belt body 8 with column 4 axially on wavy belt body 3 mode that mutual dislocation does not occur consist of.In Figure 17, in the axial direction, the central portion that consists of the wavy belt body 3 of column 4 is configured as jog 19, and this jog 19 is recessed into the shape of plate-like by a pair of end difference 21.And in Figure 18, in the axial direction, the central portion that consists of the wavy belt body 3 of column 4 is configured as jog 19, the shape that the wedge section (cuneus) 22 that this jog 19 is highlighted is recessed into.Namely, to the filter 1 as column 4, if apply the axial power such as vibration, thermal stress, external force, then stacked wavy belt body 3 might produce dislocation in the axial direction, but by mutual stacked jog 19, jog 19 plays the function of stopping device between wavy belt body 3, thereby can prevent that wavy belt body 3 from producing dislocation in the axial direction.Under wavy belt body 3 has been shaped the situation of jog 19, in the time will being wound into column 4 with the wavy belt body 3 of jog 19, need to be on the borderline region of jog 19 be shaped in the mode that does not crush the crooked route 16 that waste gas G flows.

Figure 19 shows, and will use the reduction rate of CO and HC among the waste gas G of carrier for exhaust-gas purification of the present invention (the present invention) and use the result of the test that the reduction rate of CO and HC compares among the waste gas G of existing product.In Figure 19, transverse axis is catalyst temperature ℃, and the longitudinal axis is the reduction rate % of harmful substance.That to be catalyst temperature cut down in 150 ℃ to 250 ℃ the low-temperature region harmful substance of product of the present invention is very effective at EGT for the reduction rate of catalyst temperature, insufficient but existing product is cut down in low-temperature region.Thus, can know that the efficient of removing harmful substance of product of the present invention in low-temperature region is high, be removed thereby harmful substance is carried out redox reaction.

For following purifying rate is tested, namely at carrier 1 relatively more of the present invention with support the purifying rate of the harmful substance in the situation of carrier of existing metal beehive of platinum, for the purifying rate of SV (l/h), for example, the experimental rig that is produced as follows (not shown).In housing, arrange respectively and support NO _XThe carrier of the present invention of reducing catalyst (200 meshes) and existing metal beehive carrier (300 meshes), and at entrance side and the outlet side of housing NO is set respectively _XConcentration sensor, and set the supply nozzle of reduction with fuel (light oil) at the entrance side of housing.Be provided with zone for mix waste gas and fuel at the entrance side of housing.The capacity of waste gas is that the temperature of 8000cc and waste gas is 400 ℃, and the diameter of carrier is 240mm, and will reduce with light oil for NO _XThe quantity delivered ratio of exhaust mass is set as 2 times.The result who uses this experimental rig that carrier of the present invention and existing carrier are tested is such as Figure 20 and shown in Figure 21.Figure 20 shows the curve map of the purifying property of the hydrocarbon (HC) when comparing the existing metal beehive shape carrier of carrier 1 of the present invention and supported platinum catalyst, namely show comparison for the curve map of the result of the test of the HC purifying rate of SV (l/h), therefrom can know: even carrier of the present invention 1 is also being kept high-caliber HC purifying rate under 60000SV, and in carrier 1, do not stop up, and the not only purifying rate decline of existing carrier, and in carrier 1, stop up.And Figure 21 shows the NO when comparing the existing metal beehive shape carrier of carrier 1 of the present invention and supported platinum catalyst _XThe curve map of purifying property, namely show comparison for the NO of SV (l/h) _XThe curve map of the result of the test of purifying rate therefrom can be known: even carrier of the present invention 1 is also being kept high-caliber NO under 60000SV _XPurifying rate, and in carrier 1, do not stop up, and the not only purifying rate decline of existing carrier, and in carrier 1, stop up.

Next, the carrier for exhaust-gas purification of built-in this waste gas purification apparatus described.Waste gas purification apparatus is primarily characterized in that, the filter 20 that making is made of carrier 1, the crooked route 5 of being made a plurality of waste gas G contacts and being passed through by bent groove 6 between stacked metal tape 3, wherein, this carrier 1 will be with fluted wire netting 3 to be wound into helical form to be shaped.Specifically, as shown in Figure 5, filter 20 mainly forms by the column 4 that is wound into successively toroidal by the tabular wire netting 3 of ripple, and this wire netting 3 is made of at the crooked crest line 7 that extends and the groove 6 between the crest line 7 on the width a plurality of.On the surface of the wire netting of the formation metal tape 3 of this waste gas purification apparatus, support and be useful on the oxidation catalyst that the particle matter 8 that is included among the waste gas G is burnt in oxidation, wherein, this metal tape 3 forms columns 4.Such as Figure 12～Figure 15, Figure 17 and shown in Figure 180, filter 20 forms by set one or more (among the figure being 3) columns 4 in housing 2.Filter 20 is provided in the way of blast pipe, and can set this filter 20 by following method, and the end that is about to housing 2 is connected with blast pipe, perhaps housing 2 is pressed in the blast pipe.Flow export 10 from from the inflow entrance 9 of an end face of column 4 to another end face, stacked be to be communicated with between the adjacent wire netting 3 to be formed with a plurality of exhaust steam passages 5, this exhaust steam passage 5 is along the passage of groove 6 by waste gas G.

Compare test for the reduction rate of the PM among the waste gas G of this waste gas purification apparatus (product of the present invention) and the PM reduction rate of existing product.The existing product that is used for test is a kind of metallic filter, is a kind of model of controlling to regenerate by the delivery temperature of engine.Figure 22 shows product of the present invention and the result of the test of existing product under the ETC pattern.In Figure 22, the left side of the longitudinal axis represents PM reduction rate (%), and the right side represents that the representative entrance in the test of filter presses (KPa), and transverse axis represents test number (TN) (n).Once test (test) is the operating range with the about 30Km of the speed of a motor vehicle.Block curve represents PM reduction rate (%), and A is product of the present invention, and B is existing product.And dashed curve represents that the representative entrance in the test of filter presses (KPa), and C is product of the present invention, and D is existing product.Can know that from Figure 22 the PM reduction rate for test number (TN) of product of the present invention remains 45%, but existing product descends along with the increase of test number (TN) but.And, even having increased the entrance pressure of test number (TN) filter, product of the present invention can not descend, and if existing product increases test number (TN), then the entrance drops of filter yet.Thus, the phenomenon of plugged filter does not occur to cause because of PM in product of the present invention, and PM is burnt in successfully oxidation.

Figure 24 is the curve map about the melting loss test of the filter of this waste gas purification apparatus, this melting loss test is to be illustrated in the test that has or not under the inlet temperature for the melting loss of PM catch rate, this inlet temperature refers to, closes the temperature in the situation of accelerator when the hypothesis igniting.Usually, if utilize catalyst, then particle matter (below be called PM) takes fire about 300 ℃.Yet, travel in the situation in urban district etc., the EGT of automobile reach 300 ℃ situation seldom, thereby, the trend that exists the PM seizure amount (deposition) of filter to increase.When automobile when running at a low speed, PM is deposited in the filter, still, when EGT rose to more than 300 ℃ after run at high speed, the PM that deposits took fire, if PM takes fire, then adds its heat release, thereby sometimes moment burning of PM.At this moment, caloric value is inevitable proportional with the PM deposition.Thereby even require again many carriers that also can not melt of the PM that captures as carrier, this carrier is good carrier.Figure 24 shows following investigation result, that is, make filter catch at low temperatures PM, and this filter is imported suddenly high-temperature gas, and whether the investigation filter is subject to melting loss.Can know that although filter of the present invention 20 is made of carrier 1, this carrier 1 is made of wire netting or metal nonwoven, compare with existing cordierite (cordierite) amplifier case to have the durability more than 3 times.Melting loss boundary when Figure 24 shows and is blown into from 600 ℃ of high-temperature gases to filter, ● the situation without melting loss of expression product of the present invention, the seizure amount without the melting loss boundary (8g/ liter) of * expression cordierite honeycomb filter, △ represents the seizure amount (12g/ liter) without the boundary of melting loss of carborundum amplifier case.That is, show the present invention without the seizure amount (28g/ liter) of the boundary of melting loss.The maximum seizure amount (28g/ liter) of the generation melting loss when in addition, ■ represents to be blown into 700 ℃ of high-temperature gases to product of the present invention.And the filter of actual vehicle is the 25g/ liter to the maximum seizure amount of PM.Thereby, can know that the filter 20 of making by the carrier 1 that is made of wire netting or metal nonwoven of the present invention melting loss does not occur and has excellent durability.

Usually, filter is subject to low temperature and high temperature often repeatedly, and Temperature Distribution is also different because of the position of filter.Filter 20 of the present invention is made of the carrier 1 of making of wire netting or metal nonwoven, and wire netting or metal nonwoven are made of very thin metal wire, therefore can stop very neatly and namely follow the trail of the distortion that heat distribution causes, therefore local plastic deformation etc. can not occur, its result, be coated in lip-deep pottery etc. obscission can not occur, therefore have excellent durability.

Claims (17)

1. carrier for exhaust-gas purification is characterized in that having:

Carrier, it is used for catalyst-loaded, and this catalyst is removed the NO that is included in the waste gas by burning or redox reaction _X, HC, particle matter and coal smoke harmful substance, thereby purify described waste gas;

Tubular shell, it is used for depositing described carrier, wherein,

Described carrier is made of the column of belt body being reeled or be laminated into tubular, and described belt body is made of wire netting,

Described belt body is configured as the wavy belt body with many crest lines and many grooves, and the axle of the relatively described column of described crest line extends with tilted shape, described groove between described crest line, and,

Described carrier is adapted to described wavy belt body and overlaps each other,

Between described belt body, be formed with the exhaust steam passage that a end face along described groove from described column is communicated to another end face, the axle of the relatively described column of described crest line of described wavy belt body tilts with zigzag in 10 °～50 ° angular range and extends, make described exhaust steam passage form crooked route with this

Turbulent flow occurs because of the convex-concave surface of described belt body in the described waste gas that flows through described exhaust steam passage.

2. carrier for exhaust-gas purification according to claim 1 is characterized in that, described wavy belt body overlaps each other and sets, and the described crooked route that is formed by the described crest line of described wavy belt body intersects respectively.

3. carrier for exhaust-gas purification according to claim 1 is characterized in that, described belt body is made of stainless steel or Aludirome.

4. carrier for exhaust-gas purification according to claim 1 is characterized in that, equitant described belt body is engaged by solder each other, and this solder is pricker or pricker paper tinsel.

5. carrier for exhaust-gas purification according to claim 4, it is characterized in that, at least one side end face of described carrier is engaged by described solder, soldering section forms the wire at the intermittence that has predetermined width and extend with the radiation curve-like, perhaps forms the wire that width broadens and extends with the radiation curve-like at outer circumferential side.

6. carrier for exhaust-gas purification according to claim 4, it is characterized in that, when having reeled described wavy belt body, on the position of the presumptive area on the adjacent described belt body of described crest line, the described belt body of described column each other by described solder brazing together at least.

7. carrier for exhaust-gas purification according to claim 6 is characterized in that, on adjacent described belt body, described belt body each other the described presumptive area of soldering the position described column axially on mutually dislocation.

8. carrier for exhaust-gas purification according to claim 1, it is characterized in that, in 0 °～50 ° angular range, the gradient more than 2 kinds is adopted in the described crest line combination of described wavy belt body in the described zigzag gradient of the axle of relatively described column.

9. carrier for exhaust-gas purification according to claim 1, it is characterized in that, a plurality of described column series connection are provided in the described tubular shell, and the angle of inclination of the described crest line of the described wavy belt body of described column is identical with downstream side or different at the upstream side of described waste gas.

10. carrier for exhaust-gas purification according to claim 1 is characterized in that, the linear diameter that consists of the metal wire of described wire netting is 0.03mm～0.35mm.

11. carrier for exhaust-gas purification according to claim 1 is characterized in that, the mesh of described wire netting is 16～200.

12. carrier for exhaust-gas purification according to claim 11, it is characterized in that, the mesh of described wire netting at the mesh number on the ordinate of metal mesh belt more than the mesh number on the horizontal line at described metal mesh belt, described mesh number on the described ordinate of described metal mesh belt is set as 30～100, and the described mesh number on described horizontal line is set as 60～200.

13. carrier for exhaust-gas purification according to claim 1 is characterized in that, the wavy concavo-convex spacing of described wavy belt body is 1mm～6mm.

14. carrier for exhaust-gas purification according to claim 1 is characterized in that, the wavy concavo-convex height of described wavy belt body is 0.5mm～5mm.

15. carrier for exhaust-gas purification according to claim 1 is characterized in that, the wire surface of the described belt body that consists of described carrier be coated with at least a in aluminium oxide, silica, zirconia, the cerium oxide more than.

16. carrier for exhaust-gas purification according to claim 15 is characterized in that, supports one or more catalyst in platinum, silver, potassium, palladium, iridium, iron, copper, the barium on the surface of described overlay.

17. carrier for exhaust-gas purification according to claim 1 is characterized in that, the NO that is supported on described supported catalyst and is oxidation catalyst, three-way catalyst or hydrocarbon class A fuel A, ammonia or urea are played a role as reducing agent _XReducing catalyst.

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