CN106089372B - 电加热元件支承结构及应用该结构的汽车废气净化装置 - Google Patents

电加热元件支承结构及应用该结构的汽车废气净化装置 Download PDF

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CN106089372B
CN106089372B CN201610398097.5A CN201610398097A CN106089372B CN 106089372 B CN106089372 B CN 106089372B CN 201610398097 A CN201610398097 A CN 201610398097A CN 106089372 B CN106089372 B CN 106089372B
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夏哲
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Yida world environmental protection technology Limited by Share Ltd
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Abstract

一种电加热元件支承结构及应用该结构的汽车废气净化装置，所述电加热元件支承结构，包含金属催化器载体与加热芯体之间的多个支承元件，所述多个支承元件沿加热芯体均匀间隔分布，所述支承元件包括以正反向交替插装固定在所述加热芯体内的绝缘套管和正向插装固定于各绝缘套管内的销钉，该汽车废气净化装置具有气密的壳体，所述壳体包含筒状的中段以及从中段的前后端向外渐缩的锥形，所述壳体的中段内沿废气流动方向依次设有电加热元件和金属催化器载体；由此，本发明能够简便有效的支撑在电加热元件与承载加热元件的金属催化器载体之间，有效固定加热芯体的形状，具有良好的支撑性和绝缘性，并且制造成本低廉，工艺简单。

Description

电加热元件支承结构及应用该结构的汽车废气净化装置
技术领域
本发明涉及环保装置的技术领域，尤其涉及一种电加热元件支承结构及应用该结构的汽车废气净化装置。
背景技术
由于汽车排放标准限值的加严，催化转化技术作为有效的净化方式已经得到广泛应用，现在的催化转化器对三种污染物的转化效率普遍在90％以上(金属催化器充分起燃后)，且车辆三种污染物(HC、CO、NOX)的70％～80％产生在冷起动阶段。例如，FTP75在测试循环下，三种污染物HC、CO、NOX在冷起动阶段排放量占整个循环的84％、83％、51％。为适应新的排放法规要求，降低车辆冷起动排放已经成为新的工作重点。而在金属催化器载体之前加入电加热元件可以提高起燃温度，降低冷启动排放。电加热元件需要稳定的结构以及与外部良好的绝缘性能，因此其固定方式是关键技术。目前已知这样的方案：现有技术绝缘支承装置外壳为金属毛细管，金属毛细管穿过电加热元件齿隙并与之焊接固定，因此金属毛细管外径不能太大，不然无法穿过加热元件齿隙。金属毛细管内置与下部金属催化器载体连接固定的金属销钉，金属毛细管内孔与金属销钉间缝隙仅有0.4～0.5mm，在金属毛细管与金属销钉之间填充入氧化铝和氧化镁组成的压制成粉末的绝缘物质起到绝缘和固定作用，此方案制作费时费力且成品率低费用高昂。
为此，本发明的设计者有鉴于上述缺陷，通过潜心研究和设计，综合长期多年从事相关产业的经验和成果，研究设计出一种电加热元件支承结构及应用该结构的汽车废气净化装置，以克服上述缺陷。
发明内容
本发明的目的在于提供一种电加热元件支承结构及应用该结构的汽车废气净化装置，能够简便有效的支撑在电加热元件与承载加热元件的金属催化器载体之间，有效固定加热芯体的形状，具有良好的支撑性和绝缘性，并且制造成本低廉，工艺简单。
为解决上述问题，本发明公开了一种电加热元件支承结构，包含金属催化器载体与加热芯体之间的多个支承元件，其特征在于：
所述多个支承元件沿加热芯体均匀间隔分布，所述支承元件包括以正反向交替插装固定在所述加热芯体内的绝缘套管和正向插装固定于各绝缘套管内的销钉，所述绝缘套管的尾部具有圆环状端头，各端头也交替分布于加热芯体两侧，且位于加热芯体与金属催化器载体之间的绝缘套管的端头的厚度等于加热芯体与金属催化器载体之间的缝隙宽度，所述销钉从加热芯体远离金属催化器载体的一侧插入绝缘套管内。
其中：各销钉的尾部具有钉帽，其头部贯穿绝缘套管后插入金属催化器载体中，其尾部的钉帽卡在绝缘套管远离金属催化器载体的端部。
其中：所述绝缘套管采用含氧化锆陶瓷来制成，所述销钉采用合金结构钢制成。
其中：所述氧化锆陶瓷由如下质量百分比的组分组成：78-82％的氧化锆、10-12％的氧化镁、2-3％的氧化铝、1.5-2.0％的氧化钇、0.5-0.8％的氧化镧和0.5-0.6％的氧化钐、1％的粘接剂和1％的分散剂，所述合金结构钢包括了下列元素的百分比含量：C:0.38％，Si:0.35％，Mn:0.60％，P:0.03％，S:0.005％，Cr:0.70％，Mo:0.40％，Ni:0.01％，Cu:0.01％，Ti:0.01％，Al:0.07％，余质为Fe。
其中：所述粘接剂为甲基纤维素或乙基纤维素，所述分散剂为聚甲基丙烯酸铵和聚甲基丙烯酸乙酯。
其中：该销钉通过如下步骤制成：(1)对销钉进行锻模；同时变形温度控制在1000℃，挤压力控制在35Mpa，(2)经模锻后的销钉进行正火处理，放入加热炉中加热到1100℃，保温3h，(3)对销钉进行粗加工，加工精度为IT8，表面粗糙度为Ra＝0.89μm，(4)对粗加工后的销钉进行热处理，加热温度为900℃，保温时间为10h，然后冰冷处理，将细冰粒高速喷于销钉表面使其快速冷却。
其中：上述步骤还包含：(5)渗氮共处理，将销钉设于高温炉中，再通入氨气，温度达到680℃，保温13小时后渗氮，渗氮深度为1.12mm，(6)对表面处理后的销轴进行激光精磨加工。
还公开了一种汽车废气净化装置，具有气密的壳体，所述壳体包含筒状的中段以及从中段的前后端向外渐缩的锥形，其特征在于：所述壳体的中段内沿废气流动方向依次设有电加热元件和金属催化器载体，所述电加热元件包括加热芯体以及为加热芯体接入电流的电接头，所述金属催化器载体与加热芯体之间采用如上所述的电加热元件支承结构。
其中：所述加热芯体通过蜂窝状结构的铁铬铝箔带曲折盘旋而成，从而叠加成紧密排列的多个气道。
通过上述结构可知，本发明的电加热元件支承结构及应用该结构的汽车废气净化装置具有如下效果：
1、能够快速有效加热气体，热度也能均匀传导给金属催化器载体，提高后续的催化转化效率；
2、加热芯体与金属催化器载体之间实现有效隔离，能保持金属催化器载体与加热芯体之间的缝隙，防止接触而引起漏电，还可固定加热芯体的位置和形状，防止其在气流的冲击下振动或变形而引起内部结构接触短路；
3、由于位于加热芯体与金属催化器载体之间的端头的厚度等于二者之间的缝隙宽度，绝缘套管的端头卡在缝隙内，可以有效承载气流对加热芯体的冲击力，防止变形。
本发明的详细内容可通过后述的说明及所附图而得到。
附图说明
图1显示了本发明的电加热元件支承结构的汽车废气净化装置的结构示意图。
图2显示了本发明图1的剖视图；
图3显示了本发明电加热元件支承结构的示意图。
附图标记：
1-壳体，2-进气口，3-排气口，4-金属催化器载体，5-加热芯体，6-电接头，7-绝缘套管，8-端头，9-销钉，10-钉帽、11-气道，12-支承元件。
具体实施方式
参见图1至图3，显示了本发明的电加热元件支承结构及应用该结构的汽车废气净化装置。
所述汽车废气净化装置，通过进气管连接于汽车用的内燃机废气排出口后，其具有气密的壳体1，所述壳体1包含筒状的中段以及从中段的前后端向外渐缩的锥形，所述前后端分别具有进气口2和排气口3，所述进气口2与进气管连通，所述排气口3与排气管连通，如图1所示，所述壳体1的中段内沿废气流动方向依次设有电加热元件和金属催化器载体4，所述电加热元件包括加热芯体5以及为加热芯体接入电流的电接头6，所述电接头6从壳体1外侧伸出。图1中箭头表示气流流动方向，在气流方向的前端设置电加热元件，后端设置金属催化器载体4，一方面能够快速有效加热气体，另一方面其热度也能均匀传导给金属催化器载体4，提高后续的催化转化效率，支承在加热芯体5与金属催化器载体4之间的电加热元件支承结构，将二者隔离开来，一方面能保持金属催化器载体与加热芯体之间的缝隙，防止接触而引起漏电，另一方面，可以固定加热芯体的位置和形状，防止其在气流的冲击下振动或变形而引起内部结构接触短路。
如图2所示，加热芯体5通过蜂窝状结构的铁铬铝箔带曲折盘旋而成，从而叠加成紧密排列的多个气道11，多个气道11紧密排列形成蜂窝状的结构，使得加热芯体具有很大的表面积，气体穿过其中可以得到快速加热，铁铬铝箔带的盘旋，有助于增加壳体截面上的加热面积，提高加热效率。
所述电加热元件支承结构包含金属催化器载体4与加热芯体5之间固定的多个支承元件12，所述多个支承元件12沿加热芯体均匀间隔分布，如图3所示，所述支承元件12包括以正反向交替插装固定在所述加热芯体内的绝缘套管7和正向插装固定于各绝缘套管内的销钉9，所述绝缘套管7的尾部具有圆环状端头8，由于绝缘套管7的正方向设置，各所述端头8也交替分布于加热芯体5两侧，且位于加热芯体5与金属催化器载体4之间的绝缘套管的端头8的厚度等于加热芯体5与金属催化器载体4之间的缝隙宽度；各销钉9的尾部具有钉帽10，所述销钉9从加热芯体5远离金属催化器载体4的一侧插入绝缘套管7内，其头部贯穿绝缘套管7后插入金属催化器载体4中，其尾部的钉帽10卡在绝缘套管7远离金属催化器载体4的端部。由于销钉9与绝缘套管7固定，销钉9的头部与金属催化器载体4固定，而位于加热芯体5与金属催化器载体4之间的端头8的厚度等于二者之间的缝隙宽度，绝缘套管的端头8卡在缝隙内，可以有效承载气流对加热芯体5的冲击力，保持加热芯体5的形状，同时限定了二者的相对位置，则绝缘套管7无需与加热芯体5焊接固定，依靠绝缘套管的端头卡住加热芯体即可实现固定，卡在加热芯体5与金属催化器载体4之间的端头降低了相邻的与其反向插装的绝缘套管在气流冲击力的作用下自加热芯体5内脱离的风险。相比于现有技术，省略了绝缘套管与加热芯体5焊接固定的步骤，简化制作工艺，节约成本。
其中，为更好的提高电加热元件支承结构的支承保护性能和使用寿命，所述绝缘套管7和销钉9的材质进行了优化，本发明采用含氧化锆陶瓷来制成绝缘套管7，所述氧化锆陶瓷由如下组分(质量百分比)组成：78-82％的氧化锆、10-12％的氧化镁、2-3％的氧化铝、1.5-2.0％的氧化钇、0.5-0.8％的氧化镧和0.5-0.6％的氧化钐、1％的粘接剂和1％的分散剂，所述粘接剂可为甲基纤维素或乙基纤维素，所述分散剂为聚甲基丙烯酸铵和聚甲基丙烯酸乙酯，由此，通过氧化钇、氧化镧、氧化钐显著提高了氧化锆陶瓷的致密度，降低了氧化锆陶瓷的加工难度和加工成本，降低了晶界处的残余应力，提高了晶粒的晶间强度；细化了晶粒，提高氧化锆陶瓷的致密度，最终降低氧化锆陶瓷高温摩擦系数，由此，通过这种组分制成的氧化锆陶瓷既具有较好的绝缘性和耐高温性，并且膨胀率与其内插装固定的金属材质销钉接近，使二者在高温下能保持较好的紧固性。
所述销钉采用合金结构钢，其包括了下列元素的百分比含量：C:0.38％，Si:0.35％，Mn:0.60％，P:0.03％，S:0.005％，Cr:0.70％，Mo:0.40％，Ni:0.01％，Cu:0.01％，Ti:0.01％，Al:0.07％，余质为Fe，该销钉通过如下步骤制成：(1)下料：镦粗拔长棒料，对销钉进行锻模；同时变形温度控制在1000℃，挤压力控制在35Mpa，(2)经模锻后的销钉进行正火处理，放入加热炉中加热到1100℃，保温3h，(3)对销钉进行粗加工，加工精度为IT8，表面粗糙度为Ra＝0.89μm，(4)对粗加工后的销钉进行热处理，加热温度为900℃，保温时间为10h，然后冰冷处理，将细冰粒高速喷于销钉表面使其快速冷去，将销钉加热到640℃，保温5.2h，缓慢冷却到室温，硬度为61HRC。由此制成的销钉耐磨性能和抗高温性能更强，寿命更长。
其中，上述步骤还可包含：(5)渗氮共处理，将销钉设于高温炉中，再通入氨气，温度达到680℃，保温13小时后渗氮，渗氮深度为1.12mm，(6)对表面处理后的销轴进行激光精磨加工。
通过上述步骤和组分制成的销钉，其相比现有常用的合金钢销钉寿命提高了50％，耐磨性能和耐高温性能提高了30％，故其性能得到显著的提高。
本发明通过上述步骤和组分制成的销钉和绝缘套筒，既保证了效果，还能确保寿命，避免由于销钉和绝缘套筒的损坏而导致整个设备的损坏，有效提高了使用寿命和工作效率。
其中，所述电加热源以车载蓄电池为电源，以电接头6为一极，外壳为另一极，通电后，加热芯体5开始发热，不仅能够快速加热通过其气道以及铁铬铝箔带之间的绝缘缝隙的气体，而且热能还能较为均匀的传导给后部元件，加快催化反应。
由此可见，本发明的优点在于：能够快速有效加热废气，提高后续催化转化效率，并且采用电加热元件支承结构，能有效保证加热芯体的形状，一方面，防止其在气流的冲击下振动变形，另一方面，防止其与金属催化器载体接触，电加热元件支承结构支承于电加热元件与承载电加热元件的金属催化器载体之间，构件结构简单，制作成本低廉，工艺简洁。
显而易见的是，以上的描述和记载仅仅是举例而不是为了限制本发明的公开内容、应用或使用。虽然已经在实施例中描述过并且在附图中描述了实施例，但本发明不限制由附图示例和在实施例中描述的作为目前认为的最佳模式以实施本发明的教导的特定例子，本发明的范围将包括落入前面的说明书和所附的权利要求的任何实施例。

Claims (7)

1.一种电加热元件支承结构，包含金属催化器载体与加热芯体之间的多个支承元件，其特征在于：
所述多个支承元件沿加热芯体均匀间隔分布，所述支承元件包括以正反向交替插装固定在所述加热芯体内的绝缘套管和正向插装固定于各绝缘套管内的销钉，所述绝缘套管的尾部具有圆环状端头，各端头也交替分布于加热芯体两侧，且位于加热芯体与金属催化器载体之间的绝缘套管的端头的厚度等于加热芯体与金属催化器载体之间的缝隙宽度；
各销钉的尾部具有钉帽，所述销钉从加热芯体远离金属催化器载体的一侧插入绝缘套管内，其头部贯穿绝缘套管后插入金属催化器载体中，其尾部的钉帽卡在绝缘套管远离金属催化器载体的端部，绝缘套管的端头卡在缝隙内，以有效承载气流对加热芯体的冲击力，保持加热芯体的形状，同时限定了二者的相对位置，则绝缘套管无需与加热芯体焊接固定，依靠绝缘套管的端头卡住加热芯体即实现固定，卡在加热芯体与金属催化器载体之间的端头降低了相邻的与其反向插装的绝缘套管在气流冲击力的作用下自加热芯体内脱离的风险。
2.如权利要求1所述的电加热元件支承结构，其特征在于：所述绝缘套管采用含氧化锆陶瓷来制成，所述销钉采用合金结构钢制成。
3.如权利要求2所述的电加热元件支承结构，其特征在于：所述合金结构钢包括了下列元素的百分比含量：C:0.38％，Si:0.35％，Mn:0.60％，P:0.03％，S:0.005％，Cr:0.70％，Mo:0.40％，Ni:0.01％，Cu:0.01％，Ti:0.01％，Al:0.07％，余质为Fe。
4.如权利要求2所述的电加热元件支承结构，其特征在于：该销钉通过如下步骤制成：(1)对销钉进行锻模；同时变形温度控制在1000℃，挤压力控制在35Mpa，(2)经模锻后的销钉进行正火处理，放入加热炉中加热到1100℃，保温3h，(3)对销钉进行粗加工，加工精度为IT8，表面粗糙度为Ra＝0.89μm，(4)对粗加工后的销钉进行热处理，加热温度为900℃，保温时间为10h，然后冰冷处理，将细冰粒高速喷于销钉表面使其快速冷却。
5.如权利要求4所述的电加热元件支承结构，其特征在于：上述步骤还包含：(5)渗氮共处理，将销钉设于高温炉中，再通入氨气，温度达到680℃，保温13小时后渗氮，渗氮深度为1.12mm，(6)对表面处理后的销轴进行激光精磨加工。
6.一种汽车废气净化装置，具有气密的壳体，所述壳体包含筒状的中段以及从中段的前后端向外渐缩的锥形，其特征在于：所述壳体的中段内沿废气流动方向依次设有电加热元件和金属催化器载体，所述电加热元件包括加热芯体以及为加热芯体接入电流的电接头，所述金属催化器载体与加热芯体之间采用如权利要求1-5中任一所述的电加热元件支承结构。
7.如权利要求6所述的汽车废气净化装置，其特征在于：所述加热芯体通过蜂窝状结构的铁铬铝箔带曲折盘旋而成，从而叠加成紧密排列的多个气道。
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