CN102773015B - 催化剂单元 - Google Patents

催化剂单元 Download PDF

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CN102773015B
CN102773015B CN201110409203.2A CN201110409203A CN102773015B CN 102773015 B CN102773015 B CN 102773015B CN 201110409203 A CN201110409203 A CN 201110409203A CN 102773015 B CN102773015 B CN 102773015B
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CN102773015A (zh
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崔城茂
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Hyundai Motor Co
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Abstract

本发明涉及一种催化剂单元，可以包含载体，从所述载体的前表面到所述载体的后表面可以形成通道，以及塞子，所述塞子将可以沿着除了前表面的中心部分之外的前表面的边缘部分形成的通道封闭，其中在布置有塞子的通道上可以不形成涂覆层，沿着其余的开放的通道可以形成涂覆层。

Description

催化剂单元
相关申请的交叉引用
本申请要求2011年5月13日在韩国知识产权局提交的韩国专利申请第10-2011-0045177号的优先权，该申请的全部内容结合于此用于通过该引用的所有目的。
技术领域
本发明涉及包含催化剂成份的催化剂单元，以根据流动特性减少废气的有害物质。
背景技术
在车辆中，三元催化转换器通常用来净化废气，其布置在排气管上，而且根据车辆的废气流动速率不同，三元催化剂转换器的规格是不同的。
三元催化剂转换器使例如一氧化碳、氮氧化物和碳氢化合物的废气的有害物质同时起反应，以消除这些物质，三元催化剂转换器中主要形成有铂/铑(Pt/Rh)，钯/铑(Pd/Rh)或铂/钯/铑(Pt/Pd/Rh)系列。
同时，产生大量有毒废气的柴油车在燃料消耗效率和动力输出方面很出色，但是和汽油车相比，其包含大量氮氧化物和颗粒物质(particulatematters，PM)。
与汽油车相比，在这样的柴油车中，因为进入的空气在大多数行驶条件下充分燃烧，因此一氧化碳和碳氢化合物极少，排出大量的氮氧化物和PM。
近来，作为后期处理技术，为了应对柴油车加强的废气标准，一直在非常积极地进行柴油颗粒过滤器的研究，为了将柴油颗粒过滤器应用到实际车辆，还有很多部件需要开发。
分别地，铂用于柴油氧化催化剂(DieselOxidationCatalyst，DOC)的涂覆层，柴油颗粒过滤器(DieselParticulateFilter，DPF)应用到DOC+DPF系统和催化颗粒过滤器(CatalyzedParticulateFilter，CPF)。CPF近来在EU车辆制造商中大量生产，其可靠性增加了系统的销售。
而且，已经开发了其上涂覆有催化剂的柴油颗粒过滤器，称为柴油催化的颗粒过滤器。同时，在堇青石载体上涂覆不同种类的催化剂的各种方法是公知的，也有很多现有技术。
例如，有浸渍法和吸取法，所述浸渍法是指，将堇青石载体分别浸渍到具有不同浓度的催化剂溶液中；所述吸取法是指，载体的一端侧面浸渍到催化剂溶液中，在载体另一端侧面形成真空压力来吸取催化剂溶液穿过载体的通道。
但是，这些方法可以应用到壁流型载体，更特别地，不同种类的涂覆只能应用到具有壁流类型的载体，其中CO或HC流入载体通道的入口，以从其出口流出。
同时，在制造催化剂载体时，不管废气的流动特性将贵金属涂覆在整个载体上，其中的问题是，根据废气的流动特性，贵金属没有有效的被利用。
公开于本发明背景部分的信息仅仅旨在增加对本发明的总体背景的理解，而不应当被视为承认或以任何形式暗示该信息构成已为本领域一般技术人员所公知的现有技术。
发明内容
本发明的各个方面旨在提供一种催化剂单元，其具有通过节省贵金属来降低制造成本的优点。
在本发明的一个方面，催化剂单元可以包含载体，从所述载体的前表面到所述载体的后表面形成通道；以及塞子，所述塞子将沿着除了前表面的中心部分之外的前表面的边缘部分形成的通道封闭，其中在布置有塞子的通道上不形成涂覆层，沿着其余的开放的通道形成涂覆层。
所述不形成塞子的开放的通道可以具有开放的入口和出口，废气从入口流入，并且从出口流出。
入口被塞子封闭的通道的出口被塞子封闭。
在本发明的另一个方面，催化剂单元的制造方法可以包含挤压载体，在所述载体内从前表面到后表面形成通道，用塞子将沿着前表面的边缘部分形成的通道堵塞，以及沿着不被塞子堵塞的开放的通道涂覆催化剂。
在涂覆催化剂溶液的过程中，将载体的前表面浸渍到催化剂溶液中，即泡涂(washcoat)，并且穿过开放的通道从载体的后表面吸取催化剂溶液使得催化剂溶液沿着开放的通道的内部表面涂覆。
在本发明的另一方面，废气净化装置可以包含排气线，废气穿过所述排气线；布置在所述排气线上且具有在排气线附近形成的转换器圆柱部分的转换器外壳，布置在转换器外壳内且减少废气的有害物质的催化剂单元，其中在转换器圆柱部分附近形成的在催化剂单元内的通道的入口被塞子封闭，以形成封闭的通道，沿着封闭的通道不形成涂覆层，沿着其余开放的通道的内部表面形成涂覆层。
转换器圆柱部分的直径可以大于排气线的直径。
如上所述，在根据本发明的催化剂单元中，对应于废气流低的死区形成的通道被塞子封闭，沿着所述封闭的通道的内部表面不形成催化剂涂覆层。相应地，可以节省催化剂的成本，通过封闭废气流低的通道而稳固的保持废气的净化率。
本发明的方法和装置具有其他的特性和优点，这些特性和优点根据并入本文中的附图和随后的具体实施方式将是显而易见的，或者将在并入本文中的附图和随后的具体实施方式中进行详细陈述，这些附图和具体实施方式共同用于解释本发明的特定原理。
附图说明
图1是根据本发明的示例性实施例的催化剂单元的示意性立体图。
图2显示了根据本发明的示例性实施例的催化剂单元的制造方法的流程图。
图3显示了在根据本发明的示例性实施例的催化剂单元中涂覆催化剂的方法的侧视截面图。
图4显示了根据本发明的示例性实施例的布置催化剂单元的条件的侧视截面图。
应了解附图呈现了阐述本发明基本原理的各个特征的一定程度简化的表示，从而不需要按比例绘制。本文所公开的本发明的特定设计特征，包含例如特定尺寸、取向、位置以及形状，将部分地由具体意图的应用以及使用环境确定。
在附图中，附图标记在全部的几个附图中表示本发明的相同或者等效的部分。
具体实施方式
以下将详细参考本发明的不同实施例，本发明的实例在附图中示出并在下面进行描述。虽然结合示例性实施例描述本发明，但应了解该描述不是旨在将本发明限制于那些示例性实施例。相反地，本发明旨在不仅仅覆盖示例性实施例，还覆盖可以包含在由所附权利要求所限定的本发明的精神和范围里的各种替代、改进、等效结构以及其他实施例。
在下文中将参考附图对本发明的示例性实施方案进行具体描述。
图1是根据本发明的示例性实施例的催化剂单元的示意性立体图。
参考图1，从催化剂单元100的前表面到后表面形成通道，其中通道包含开放的通道110和封闭的通道120。在本发明的示例性实施例中，催化剂单元100可以称为“载体”。
更特别地，沿着催化剂单元100的圆周的边缘部分上形成的通道被塞子封闭，以形成封闭的通道120，在中心部分形成开放的通道110。
封闭的通道120的入口和出口被塞子122封闭，沿着封闭的通道的内部表面不形成催化剂涂覆层。但是，如图所示，沿着开放的通道110的内部表面形成催化剂涂覆层114。
废气流动穿过形成在催化剂单元100的中心部分的开放的通道，废气几乎不流到催化剂单元100的边缘部分。相应地，废气几乎不流到的边缘部分被塞子122封闭，其上不形成催化剂层从而减少不必要的催化剂的浪费。
开放的通道110是入口和出口开放的流动穿过型(flowthroughtype)，催化剂单元100可由堇青石材料制成。
图2显示了根据本发明的示例性实施例的催化剂单元的制造方法的流程图。
参考图2，在S200中，催化剂单元100(以下，称为载体)被挤压。在这种情况下，从载体100的前表面到后表面同时形成开放的通道。
在载体被挤出以进行制造后，在S210中，用塞子122将边缘通道的入口堵塞。
如果完成了堵塞，在S220中，用催化剂涂覆层114涂覆不被塞子122堵塞的开放的通道110。
图3显示了在根据本发明的示例性实施例的催化剂单元中涂覆催化剂的方法的侧视截面图。
参考图3，在催化剂单元100的前侧或后侧的边缘通道被塞子122封闭的条件下，将催化剂单元100的前侧浸渍到催化剂溶液300，即泡涂。
并且，布置在催化剂单元100后侧上的吸取装置310用来将催化剂溶液300吸取穿过开放的通道110，沿着开放通道110的内部表面形成催化剂涂覆层114。
相应地，沿着形成在边缘部分的封闭的通道120的内部表面不形成催化剂涂覆层，从而减少催化剂用量来节省生产成本。进一步地，由于废气几乎不流动到除催化剂单元100的前表面的中心部分之外的边缘部分，所以净化率几乎不降低。
图4是根据本发明的示例性实施例的布置催化剂单元的条件的侧视截面图。
参考图4，转换器外壳430布置在排气线上，催化剂单元100，即载体，布置在转换器外壳430内。
如图所示，其内部直径变宽的转换器圆柱部分420形成在排气线400附近的转换器外壳430上，催化剂单元100的边缘部分由转换器圆柱部分420的部分支撑。
相应地，在对应于转换器圆柱部分420的催化剂单元100的一部分形成死区410，其中废气几乎不流过死区。
在本发明的一个示例性实施例中，对应于死区410环绕载体100的边缘部分形成的通道的入口或出口被塞子122封闭，在所述封闭的通道内不形成涂覆层。相应地，废气的净化率不会降低，而催化剂元素被有效的利用。
为在随附的权利要求中更方便说明和准确的定义，术语“内”和“外”参考如附图中示出的这些特征的位置用于描述示例性实施例中的特征。
前述对本发明的具体示例性实施方案的描述是为了说明和例证的目的。这些描述并非想穷尽本发明，或者将本发明限定为所公开的精确形式，并且很显然，根据上述教导，可以进行很多改变和变化。对示例性实施例进行选择和描述的目的在于解释本发明的特定原理及其实际应用，从而使得本领域的其它技术人员能够实现并利用本发明的各种不同的示例性实施方案以及各种不同的选择和改变。本发明的范围意在由所附的权利要求书及其等同形式所限定。

Claims (1)

1.一种催化剂单元的制造方法，包含：
挤压载体，在所述载体内从前表面到后表面形成通道；
用塞子将沿着前表面的边缘部分形成的通道堵塞；以及
沿着不被塞子堵塞的开放的通道涂覆催化剂,
其中，在涂覆催化剂溶液的过程中，将载体的前表面浸渍到催化剂溶液中，即泡涂，并且穿过开放的通道从载体的后表面吸取催化剂溶液使得催化剂溶液沿着开放的通道的内部表面涂覆。
CN201110409203.2A 2011-05-13 2011-12-09 催化剂单元 Expired - Fee Related CN102773015B (zh)

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