CN101386214A - 具有改进结构强度的非对称蜂窝状壁流过滤器 - Google Patents

具有改进结构强度的非对称蜂窝状壁流过滤器 Download PDF

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CN101386214A
CN101386214A CNA2008101259215A CN200810125921A CN101386214A CN 101386214 A CN101386214 A CN 101386214A CN A2008101259215 A CNA2008101259215 A CN A2008101259215A CN 200810125921 A CN200810125921 A CN 200810125921A CN 101386214 A CN101386214 A CN 101386214A
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R·I·弗罗斯特
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Abstract

一种蜂窝状过滤器包括一系列相互连通的多孔壁(206)，它限定了一系列第一通道(208)和第二通道(210)。所述第一通道(208)的各个侧面都与所述第二通道相接并且具有大于所述第二通道(210)的水力直径。所述第一通道(208)具有方形截面，且所述第一通道的转角所具有的形状使得所述第一通道的多孔壁(206)邻接角厚度(t3)可与第一(208)和第二通道(210)的多孔壁(206)邻接边缘的厚度(t4)相比。

Description

具有改进结构强度的非对称蜂窝状壁流过滤器
本申请是申请日为“2004年9月17日”、申请号为“200480027597.3”、题为“具有改进结构强度的非对称蜂窝状壁流过滤器”的分案申请。
背景技术
蜂窝状壁流过滤器用于去除柴油机中的碳烟。图1A示出了传统的蜂窝状壁流过滤器，它具有入口端102、出口端104以及从入口端102和出口端104中纵向伸出的一系列相互连接的多孔壁106。相互连接的多孔壁106限定了格状的入口通道108和出口通道110。在入口端102处，用过滤材料112端塞出口通道110，而不端塞入口通道108。虽然图中不可见，但在出口端104处，用过滤材料端塞入口通道108，而不端塞出口通道110。每个入口通道108的所有侧面都与出口通道110相接，反之亦然。图1B示出了用于蜂窝状过滤器的孔眼结构的详细结构图。限定限定入口和出口通道(或孔眼)108和110的多孔壁106是笔直的，并且入口和出口通道108和110具有方形的截面与相等的水力直径。
再回到图1A，柴油机的排气从入口通道108的未堵塞端流入蜂窝状过滤器100并从出口通道110的未堵塞端流出该蜂窝状过滤器。在该蜂窝状过滤器100内部，强制柴油机的排气从入口通道108通过多孔壁106流入出口通道110。由于柴油机的排气流过该蜂窝状过滤器100，则烟灰微粒就积累在多孔壁106上，从而就降低了入口通道108的有效通流面积。有效通流面积的降低产生了穿过该蜂窝状过滤器的压降，而这就导致了柴油机背压的逐渐升高。当压降变得不可接受时，就用热再生来去除捕获在蜂窝状过滤器内的烟尘微粒。而包括金属氧化物杂质、润滑油添加剂、硫酸盐在内的灰尘微粒是非易燃的，无法使用热再生来清除。热再生时，会出现过高的温度峰值，而这会导致该蜂窝状过滤器的热震动、破裂甚至熔化。
希望有一种具有足够的结构强度而能够经受住热再生的蜂窝状过滤器。为了避免频繁的热再生，则还希望该蜂窝状过滤器具有较大容量来存储烟尘微粒。对于入口和出口通道具有相等水力直径的孔眼结构来说，入口通道的有效通流面积很容易变成远小于出口通道的有效通流面积，从而就产生穿过该蜂窝状过滤器的巨大压降。一种已提出用来减小该压降的方法是使得入口通道的水力直径(或有效横截通流面积)大于出口通道的水力直径。这样由于烟尘微粒在多孔壁入口部分的累积，仍然会使入口通道的有效通流面积趋向于等于出口通道的有效通流面积。
对于图1B中示出的传统蜂窝状孔眼结构，可以通过减小出口孔眼110的水力直径而使得入口孔眼108的水力直径大于出口孔眼110的水力直径。图1C示出了在减小出口孔眼110的水力直径而使得出口孔眼110相较于入口孔眼108具有较小的水力直径之后的图1B的蜂窝状孔眼结构。可以做出另一种修改来增加入口孔眼108的水力直径。该修改具有增加在该蜂窝状过滤器入口部分收集烟尘微粒可用的有效表面积的优点，而这最终会增加该蜂窝状过滤器的整体存储能力。图1D示出了在增加入口孔眼108的水力直径之后的图1C的蜂窝状孔眼结构。在不改变蜂窝状过滤器孔眼密度的情况下，对入口孔眼108水力直径的任何增加都会导致入口孔眼108相邻角之间壁厚的相应减小(比较图1D中的t2和图1C中的t1)。由于减小了入口孔眼各个角之间的壁厚，就降低了该蜂窝状过滤器的结构强度，从而使得该蜂窝状过滤器在热再生过程中更易于热震动和破裂。
从前述可知，需要一种能改善蜂窝状过滤器的存储能力同时又保持通过蜂窝状过滤器的良好流量并且不会显著降低该蜂窝状过滤器结构强度的方法。
发明内容
一方面内，本发明涉及一种包括了一系列相互连通的多孔壁的蜂窝状过滤器，其中所述多孔壁限定了一系列的第一和第二通道。所述第一通道的各个侧面都与所述第二通道相接并且具有大于所述第二通道的水力直径。所述第一通道具有方形截面，而所述第一通道的转角所具有的形状使得所述第一通道的多孔壁邻接角厚度与第一和第二通道的多孔壁邻接边缘的厚度是可比的。
在另一个方面，本发明涉及一种包括了一系列相互连通的多孔壁的蜂窝状过滤器，其中所述多孔壁限定了一系列具有方形截面的第一通道和具有方形截面的第二通道。所述第一通道的各个侧面都与所述第二通道相接。所述第一通道的边缘和第二通道的边缘排列成行。所述第一通道的水力直径大于所述第二通道的水力直径。
在又一个方面，本发明涉及一种用于制作蜂窝状过滤器的挤压模组件，其中所述蜂窝状过滤器包括具有中央区和外围区的孔眼成形模。所述中央区包括一系列排出槽，以切割用于限定一系列第一和第二管脚以及与所述一系列排出槽相连通的一系列第一导孔。外围区包括至少一个第二导孔。第一管脚具有大于第二管脚的横截面积。选择第一管脚的横截形状使得所述排出槽的宽度大致统一。所述挤压模组件包括与所述孔眼成形模同轴安装并与其径向间隔开的表面成形罩，从而限定与所述至少一个第二导孔选择性连通的表面槽。
在随后的描述和所附权利要求中，本发明的其他特性和优点将会变得显而易见。
附图说明
图1A是现有蜂窝状壁流过滤器的立体图。
图1B示出了具有相等水力直径的入口和出口孔眼的标准蜂窝状孔眼结构。
图1C示出了在减小出口孔眼的水力直径之后的图1B的蜂窝状孔眼结构。
图1D示出了在增加入口孔眼的水力直径之后的图1C的蜂窝状孔眼结构。
图2A是根据本发明一个实施例的蜂窝状壁流过滤器的立体图。
图2B示出了根据本发明一个实施例的具有不等水力直径的入口和出口孔眼并且所述入口孔眼带有圆角的蜂窝状孔眼结构。
图2C示出了根据本发明另一个实施例的具有不等水力直径的入口和出口孔眼并且所述入口孔眼带有斜角的蜂窝状孔眼结构。
图2D示出了根据本发明另一个实施例的具有不等水力直径和成行边缘的入口和出口孔眼的蜂窝状孔眼结构。
图2E是作为圆角半径和孔眼宽度的水力直径的曲线图。
图3是根据本发明一个实施例的挤压模组件的横截面。
具体实施方式
现在将参考在附图中示出的若干较佳实施例来描述本发明。在随后的描述中，将阐明许多具体细节以提供对本发明的透彻理解。然而本领域普通技术人员应该理解没有这些部分或全部的具体细节也能够实现本发明。在其他的实例中，将不会细节描述已知的特性和/或过程步骤以防对本发明主题不必要的淡化。在参考了随后的附图和讨论之后，就能够更好地理解本发明的特性和优点。
为了示意的目的，图2A示出了根据本发明一个实施例的蜂窝状壁流过滤器200。该蜂窝状过滤器200具有其横截面形状由表面(或外壁)204限定的柱状主体202。表面204的轮廓通常是圆形或椭圆形，但是本发明不限于任何具体的表面轮廓。柱状主体202具有由所述表面204横断的一系列相互连通的多孔壁206。多孔壁206在柱状主体202内限定了格状的入口通道208和出口通道210。入口和出口通道208和210沿着柱状主体202的长度方向纵向延伸。一般通过挤压制成该柱状主体202。通常该柱状主体202由诸如堇青石或金刚砂的陶瓷材料制成，但是也可由其他的可挤压材料制成，诸如玻璃、玻璃陶瓷、塑料和金属。
蜂窝状过滤器200具有接受气流(例如废气气流)的入口端212以及过滤气流可经由其离开该蜂窝状过滤器的出口端214。在入口端212处，用过滤材料216堵塞出口通道210的尾部，而不堵塞入口通道208的尾部。通常过滤材料216是由诸如堇青石或金刚砂的陶瓷材料制成。虽然图中不可见，但在出口端214处，用过滤材料216堵塞入口通道208的尾部，而不堵塞出口通道210的尾部。通常用过滤材料堵塞邻近表面204外围的部分孔眼。在蜂窝状过滤器200内部，相互连接的多孔壁206允许气流从入口通道208流入出口通道210。多孔壁206的多孔性是可见的。一般说来，该多孔性应该成为未受损蜂窝状过滤器的结构整体性。对于柴油机的过滤，多孔壁206可以含有平均直径从1到60μm，最好是10到50μm的孔。
图2B示出了蜂窝状过滤器200的孔眼结构的详细结构图。每个入口孔眼208都与出口孔眼210相接，并且反之亦然。为了在使用蜂窝状过滤器200时保持良好的流量，要将入口孔眼208的水力直径制成大于出口孔眼210的水力直径。在该图中，出口孔眼210具有方形的几何形状。在该图中，入口孔眼208也具有方形的几何形状，但是该方形的转角为圆角218。圆角218的一个目的在于使入口孔眼208的邻近转角之间的厚度(t3)与入口孔眼208和出口孔眼210之间的厚度(t4)具有可比性。在一个实施例中，厚度t3是在厚度t4的0.8到1.2倍的范围内。最好是选择圆角218的半径使得孔眼周围的多孔壁厚度大致均匀。同样选择圆角218的半径而使对于选定的孔眼密度和正面闭合面积而言，所述入口孔眼的水力直径是最大的。
如下的表1示出了具有200孔眼/英寸2(约31孔眼/厘米2)孔眼密度和正面闭合面积的孔眼结构的实例。孔眼结构A和B是图2B中示出的本发明孔眼结构的具体实例。孔眼结构C和D是图1C中示出的现有技术孔眼结构的具体实例。
表1
 
孔眼结构 入口孔眼水力直径(mm) 入口孔眼水力直径与出口孔眼水力直径的比率 入口孔眼宽度(mm) 出口孔眼宽度(mm) 圆角半径(mm) 入口孔眼邻近转角间的厚度(mm)
A 1.68 1.7 1.59 0.98 0.30 0.54
B 1.73 2.0 1.64 0.88 0.30 0.47
C 1.59 1.7 1.59 0.93 无 0.28
D 1.64 2.0 1.64 0.83 无 0.22
如下定义孔眼的水力直径DH：
D H = 4 A P - - - ( 1 )
其中A是该孔眼的横截面积，而P是该孔眼的湿润周长。对于方形孔眼，水力直径是该孔眼的宽度。对于圆角的方形孔眼，则水力直径要大于该孔眼的宽度。
从上述表1，本发明孔眼结构A和B的入口孔眼的水力直径分别大于现有技术孔眼结构C和D的入口孔眼的水力直径。在保持与现有技术孔眼结构C和D相同的孔眼密度以及正面闭合面积的同时实现更大的孔眼结构A和B的水力直径。图2E示出了水力直径是如何作为给定孔眼宽度的圆角半径的函数而变化的。在该图中指出了孔眼结构A、B、C和D的位置。该图示出了水力直径与圆角半径的非线性关系。在实际应用中，制作入口孔眼使其具有对应于可实现用于所选孔眼宽度的最大水力直径的圆角半径。
回到图2B，本发明不限于在入口孔眼208的转角处包括圆角218。入口孔眼208的转角例如可以是斜角。图2C示出了入口孔眼208的转角包括斜角220的孔眼结构。在此实施例中，也扩大了入口孔眼208使得(对角)相邻的入口孔眼208的边缘大致排列成行。这就增加了蜂窝状过滤器的整体存储容量并允许保持通过该蜂窝状过滤器的良好流量。斜角220(或代替斜角使用的圆角)能够围绕孔眼的均匀厚度的多孔壁206。对于图2B和2C，特别是图2C中示出的孔眼结构，所述多孔壁206不是笔直的。这就增加了蜂窝状结构对热震动的抵抗能力。在图2C所示的设计内，多孔壁的部分(例如多孔壁206a)仅为入口孔眼208所共有。这些仅为入口孔眼208所共有的多孔壁部分便于热再生期间热量从一个入口孔眼转移到另一个入口孔眼。
可使用圆角和斜角实现遍及该蜂窝状过滤器的大致统一的多孔壁厚度，同时还保持所希望的正面闭合面积、孔眼密度以及入口孔眼与出口孔眼水力直径的比率。通常期望入口孔眼与出口孔眼水力直径的比率的范围是在1.1到2.0之间，更好是1.3到2.0，最好是1.7到2.0。对于柴油机微粒过滤，通常认为范围在10到300孔眼/英寸2(约1.5到46.5孔眼/厘米2)之间，更普遍地是在100到200孔眼/英寸2(约15.5到31孔眼/厘米2)之间的蜂窝状孔眼密度有利于在致密结构内提供足够薄的壁表面积。相互连接的多孔壁厚度能够在保证结构完整性的情况下从最小值0.02英寸.(0.05毫米)向上变化，但是通常要小于0.060英寸(1.5毫米)以使得过滤器体积最小。在较佳孔眼密度处最常选择范围约在0.010到0.030英寸(约0.25到0.76毫米)之间，优选地约在0.010到0.025英寸.(约0.25到0.64毫米)之间的多孔壁厚度。
图2D示出了另一种孔眼结构，其中入口孔眼208的边缘与出口孔眼210的边缘排列成行并且所述围绕蜂窝状过滤器的多孔壁206的厚度是均匀的，同时还无需在入口孔眼208的转角处使用斜角或圆角。然而入口孔眼208转角的圆角或斜角能够进一步改善蜂窝状过滤器的结构强度。在此实施例中的多孔壁206甚至比先前描述实施例中的多孔壁的笔直度还要小，从而进一步改善了对热震动的抵抗力。
适于制造上述蜂窝状过滤器的蜂窝状挤压模具有包括大小管脚交替变化的管脚阵列。所述交变管脚的转角可以是圆的或斜的。出于示意性的目的，图3示出了挤压模组件300的横截面。挤压模组件300包括孔眼成形模302和表面成形罩304。孔眼成形模302用于形成限定蜂窝状过滤器的入口和出口孔眼的相互连接的多孔壁。孔眼成形模302结合表面成形罩304来限定蜂窝状过滤器表面的形状和厚度。孔眼成形模302具有中央区。在所述中央区306内切割一系列的排出槽308以限定一系列的入口和出口管脚310和312。在一个实施例中，入口和出口管脚310和312的横截面是方形，并且入口管脚310的每个转角都包括圆角或斜角。
孔眼成形模302的中央区还包括从模入口面315延伸到所述一系列排出槽308的一系列中央导孔314。中央导孔314为排出槽308供应成批材料。选择所述中央导孔314相对于所述排出槽308的大小和位置以实现通过所述排出槽308所希望的流量。作为一个实例，中央导孔314可以对应于每个或所有其他的排出槽308或者可以对应于每个或所有其他排出槽308的交叉点。
孔眼成形模302还包括邻近中央区306形成的外围区316。外围区316提供用于表面成形罩304的安装表面328并且包括用于将成批材料送予围绕所述孔眼成形模302周围空间的导孔318。在一个实施例中，在安装表面318和表面成形罩304之间放入垫片320以限定外围区316和表面成形罩304之间的表面成形容器322。外围区316内的导孔318为表面成形容器322提供成批材料。表面成形罩304与所述中央区306径向间隔开以限定与所述表面成形容器322相连通的表面槽324。成批材料从表面槽324中挤压出来以形成蜂窝状过滤器表面。可以调制所述容器322的容积用以控制成批材料送入表面槽324的速率。
工作期间，将成批材料送入孔眼成形模302内的导孔314和318并且从排出槽308和表面成形槽324中挤出。在表面成形容器322内的成批材料的体积取决于表面成形罩304径向悬挂于所述表面成形容器322上的程度。成批材料流入表面成形槽的速率确定了表面的性质，同时成批材料流送入排出槽的速率确定了多孔壁的性质。
可以使用现有用于制造挤压模的方法来生成上述挤压模组件。可以使用由可加工材料制成的坯料的较低部分内的加工孔来制造所述孔眼成形模。这些孔可以作为导孔。诸如插入式电火花加工之类的加工工艺可用于切割在所述坯料上部内的排出槽。在切割所述槽之后，管脚仍保留在所述坯料的上部上。缩短或完全移除在所述坯料外围的管脚以提供用于表面成形模的安装表面。排出槽以及蜂窝状过滤器的孔眼结构可以具有以上描述的任何几何形状。
虽然结合有限几个实施例描述了本发明，但是已从本公开中获益的本领域普通技术人员应该认识到可以做出其他实施例而不背离在此公开的本发明范围。因此，本发明的范围应仅由所附权利要求限制。

Claims (5)

1.一种用于制作蜂窝状过滤器的挤压模组件，包括：
具有中央区和外围区的孔眼成形模，所述中央区包括一系列排出槽，切割该排出槽用于限定一系列第一和第二管脚以及与所述一系列排出槽相连通的一系列第一导孔，所述外围区包括至少一个第二导孔，第一管脚具有大于第二管脚的横截面积，选择第一管脚的截面形状使得所述排出槽的宽度大致均匀；以及
表面成形罩，它与所述孔眼成形模同轴安装并与其径向隔开从而限定与所述至少一个第二导孔选择性连通的表面槽。
2.如权利要求1所述的挤压模组件，其特征在于，所述第一管脚的截面形状包括带有圆角的方形。
3.如权利要求1所述的挤压模组件，其特征在于，所述第一管脚的截面形状包括带有斜角的方形。
4.如权利要求1所述的挤压模组件，其特征在于，还包括在所述孔眼成形模和所述表面成形罩之间所限定的容器，所述容器与至少一个第二导孔和所述表面槽相连通。
5.如权利要求1所述的挤压模组件，其特征在于，调节所述外部表面容器的容积以控制成批材料流送入所述表面槽的速率。
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WO2005030365A1 (en) 2005-04-07
EP1663447B1 (en) 2010-05-26
ATE468904T1 (de) 2010-06-15
US20050066639A1 (en) 2005-03-31
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