CN109356689B - 一种抗热震非对称蜂窝陶瓷壁流式过滤器 - Google Patents

一种抗热震非对称蜂窝陶瓷壁流式过滤器 Download PDF

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CN109356689B
CN109356689B CN201811375365.7A CN201811375365A CN109356689B CN 109356689 B CN109356689 B CN 109356689B CN 201811375365 A CN201811375365 A CN 201811375365A CN 109356689 B CN109356689 B CN 109356689B
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CN109356689A (zh
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宋锡滨
张兵
张曦
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Shandong Sinocera Functional Material Co Ltd
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Abstract

本发明涉及蜂窝陶瓷过滤器领域，公开了一种抗热震非对称蜂窝陶瓷壁流式过滤器，包括：进口蜂窝陶瓷面和出口蜂窝陶瓷面，进口蜂窝陶瓷面和出口蜂窝陶瓷面均设有进口通道和出口通道，进口通道与出口通道连通，进口通道的出口端和出口通道的进口端封堵，进口通道的内径大于出口通道的内径；进口通道的横截面为正方形，且设有圆角；或相邻两条边由两条连接线连接；或且相邻两条边由两条连接线和圆弧连接，圆弧处于两条连接线之间；出口通道的横截面为正方形，也可设有圆角或倒角。本发明对进口通道横截面进行圆角、双线或双线加圆弧改造，对出口通道横截面不变或圆角或倒角改造。本过滤器具有兼顾良好的力学性能、低背压以及优异的抗热震性能。

Description

一种抗热震非对称蜂窝陶瓷壁流式过滤器
技术领域
本发明涉及蜂窝陶瓷过滤器领域，特别是涉及一种抗热震非对称蜂窝陶瓷壁流式过滤器。
背景技术
蜂窝陶瓷壁流式过滤器可将汽油机及柴油机尾气中的碳黑去除。目前传统的过滤器设计，它有进口蜂窝陶瓷面和出口蜂窝陶瓷面作为进口和出口，以及将进出口隔开的多孔壁。这些相互连接的壁将过滤器分成了进口通道(简称：I)及出口通道(简称：O)。为捕捉碳黑及灰，进口通道的出口端被封堵，而出口通道的进口被堵。这样的间隔被堵的结构就象国际象棋的棋盘。这种设计可强迫尾气从多孔壁上通过，使得颗粒物沉积在通道里或壁上。通常，进出口通道具有同样面积的正方形截面。当碳黑量达到一定程度，再生过程发生，会烧去这些碳黑。
在应用中，同样发现灰也会沉积在进口通道内。这些灰的颗粒，由金属氧化物，硫酸盐，磷酸盐及其它物质组成，它们不会燃烧，所以不会在再生过程中烧去。因此，这些灰会一直沉积在进口通道内，直到被机械性地清洗出来。所以，在灰被清洗出来前，随着发动机的运行时间增加，进口通道中的灰越来越多，整个尾气处理系统的背压会很明显地增加。
目前，降低灰对背压的影响的一种方法是增大进口通道的面积。对于相同的截面积，这就意味着减少出口通道的面积。用这种方法，在增大的进口通道中可容纳更多的颗粒物(碳黑及灰)，也就是说，过滤器储存颗粒物的能力得到提高，从而降低了背压。在一些空间有限的设计中，这种结构对小过滤器的帮助非常重要。在过滤器目数不变的情况下，进口通道的增大会导致两相邻进口通道的角之间距离变小。当这距离变小后，过滤器的力学强度会减弱，从而在生产及应用中产生一系列的问题。
为使力学强度增加，在进口通道的角上可做一些改变。现有技术中，进口通道的角用了倒角。这样，相邻角之间的距离便增大了，从而增加了强度。还有些专利的进口通道的角用了斜切角，与倒角相比，这样的斜切更增加了相邻角之间的距离，从而更加增加了力学强度。
虽然这些发明可增加力学强度，但同时必须考虑背压及抗热震性能。比方说，在壁厚不变的情况下，以上的发明会过多地减少了进口通道面积，从而增加了背压。与此同时，在进口通道变大的情况下，过滤器可容纳更多的颗粒物。为充分利用这一优点，可把再生时间间隔延长，而因此要求更好的抗热震性能。以前的发明没有很好地解决热震的问题，从而限制了此类大入口小出口设计的潜力。
发明内容
(一)要解决的技术问题
本发明的目的是提供一种抗热震非对称蜂窝陶瓷壁流式过滤器，解决现有技术中力学性能差、背压高和抗热震性能差的问题。
(二)技术方案
为了解决上述技术问题，本发明提供一种抗热震非对称蜂窝陶瓷壁流式过滤器，其特征在于，包括：进口蜂窝陶瓷面和出口蜂窝陶瓷面，所述进口蜂窝陶瓷面和所述出口蜂窝陶瓷面均设有进口通道和出口通道，所述进口通道与所述出口通道连通，所述进口通道的出口端和所述出口通道的进口端封堵，所述进口通道的内径大于所述出口通道的内径；所述进口通道的横截面为正方形，且设有圆角；或所述进口通道的横截面为正方形，且相邻两条边由两条连接线连接，所述两条连接线之间为钝角；或所述进口通道的横截面为正方形，且相邻两条边由两条连接线和圆弧连接，所述圆弧处于所述两条连接线之间，所述两条连接线之间为钝角。
其中，所述进口通道的内径与所述出口通道的内径的比例范围为1.1-1.5。
其中，所述进口通道的横截面为正方形，且设有圆角，相邻所述进口通道的圆角之间的距离与壁厚的比例范围为0.8-1.4。
其中，所述进口通道的横截面为正方形，且设有圆角，所述圆角的半径大于壁厚的20％，且小于0.3mm。
其中，所述进口通道的横截面为正方形，且相邻两条边由两条依次连接的连接线连接，所述两条连接线之间为钝角，且所述连接线与其相连的正方形边的夹角小于30°。
其中，所述进口通道的横截面为正方形，且相邻两条边由两条连接线和圆弧组成的连接部连接，所述圆弧处于所述两条连接线之间，所述两条连接线之间为钝角，所述圆弧长度小于所述连接部长度的30％。
其中，所述出口通道的横截面为正方形。
其中，所述出口通道的横截面为正方形，并设有圆角，所述圆角的半径大于壁厚的20％，且小于0.3mm。
其中，所述出口通道的横截面为正方形，且设有倒角，所述倒角的斜边长度范围为所述出口通道的横截面边长的5％-30％。
(三)有益效果
本发明提供的一种抗热震非对称蜂窝陶瓷壁流式过滤器，对进口通道横截面进行圆角、双线或双线加圆弧改造，本过滤器具有兼顾良好的力学性能、低背压以及优异的抗热震性能。
附图说明
图1为本发明实施例1进口蜂窝陶瓷面的局部结构示意图；
图2为图1中Ⅰ的局部细节图；
图3为本发明实施例2进口蜂窝陶瓷面的局部结构示意图；
图4为图3中Ⅰ的局部细节图；
图5为图3中Ⅱ的局部细节图；
图6为本发明实施例3进口蜂窝陶瓷面的局部结构示意图；
图7为图6中Ⅰ的局部细节图；
图8为图6中Ⅱ的局部细节图；
图9为本发明实施例4进口蜂窝陶瓷面的局部结构示意图；
图10为图9中Ⅰ的局部细节图；
图11为本发明实施例5进口蜂窝陶瓷面的局部结构示意图；
图12为图11中Ⅰ的局部细节图；
图13为图11中Ⅱ的局部细节图；
图14为本发明实施例6进口蜂窝陶瓷面的局部结构示意图；
图15为图14中Ⅰ的局部细节图；
图16为图14中Ⅱ的局部细节图；
图17为本发明实施例7进口蜂窝陶瓷面的局部结构示意图；
图18为图17中Ⅰ的局部细节图；
图19为本发明实施例8进口蜂窝陶瓷面的局部结构示意图；
图20为图19中Ⅰ的局部细节图；
图21为图19中Ⅱ的局部细节图；
图22为本发明实施例9进口蜂窝陶瓷面的局部结构示意图；
图23为图22中Ⅰ的局部细节图；
图24为图22中Ⅱ的局部细节图。
图中，1、进口通道；2、出口通道。
具体实施方式
下面结合附图和实施例，对本发明的具体实施方式作进一步详细描述。以下实例用于说明本发明，但不用来限制本发明的范围。
在本发明的描述中，需要说明的是，除非另有明确的规定和限定，术语“安装”、“相连”、“连接”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或一体地连接；可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通。对于本领域的普通技术人员而言，可以具体情况理解上述术语在本发明中的具体含义。
如图1-图24所示，本发明公开一种抗热震非对称蜂窝陶瓷壁流式过滤器，其特征在于，包括：进口蜂窝陶瓷面和出口蜂窝陶瓷面，进口蜂窝陶瓷面和出口蜂窝陶瓷面均设有进口通道1和出口通道2，进口通道1与出口通道2连通，进口通道1的出口端和出口通道2的进口端封堵，进口通道1的内径大于出口通道2的内径；进口通道1的横截面为正方形，且设有圆角；或进口通道1的横截面为正方形，且相邻两条边由两条连接线连接，两条连接线之间为钝角；或进口通道1的横截面为正方形，且相邻两条边由两条连接线和圆弧连接，圆弧处于两条连接线之间，两条连接线之间为钝角。
蜂窝陶瓷过滤器具有进口通道1，让尾气进入；也具有出口通道2，让尾气流出。对进口通道1来说，其出口端被封堵，而进口端不堵；对出口通道2来说，其进口端被封堵，而出口端不堵。进口及出口通道2由多孔的壁隔开。一般来说，壁的气孔率在20％到70％之间。对汽油机及柴油机尾气过滤器，气孔平均尺寸在5到50微米间，优选10到30微米间。蜂窝陶瓷过滤器每平方英寸有50到350个格子，优选100到300个格子。壁厚可从0.05到0.5毫米，优选0.1到0.4毫米。
具体的，本发明的过滤器具有皮肤，此过滤器可以是圆形、椭圆形或其他形状。过滤器的组成是一系列的相互连接的多孔的壁构成的进口及出口通道2。进口及出口通道2一直延伸到整个过滤器的长度。此过滤器由挤出工艺形成。一般来说，此过滤器的材料是陶瓷材料，如堇青石，碳化硅，钛酸铝，及莫来石等，但也可是其它可挤出的材料，如玻璃，玻璃陶瓷，塑料，以及金属。
其中，进口通道1的内径与出口通道2的内径的比例范围为1.1-1.5。优选地，其比例范围为1.2-1.4。
本发明提供的一种抗热震非对称蜂窝陶瓷壁流式过滤器，对进口通道横截面进行圆角、双线或双线加圆弧改造，本过滤器具有兼顾良好的力学性能、低背压以及优异的抗热震性能。
以下实施例为本发明的几种情况。
实施例1：
如图1-图2所示，进口通道1的横截面为正方形，且设有圆角，相邻进口通道1的圆角之间的距离与壁厚的比例范围为0.8-1.4，优选地，其比例范围为0.9-1.3。优选地，圆角的半径大于壁厚的20％，且小于0.3mm。出口通道2的横截面为正方形。
实施例2：
如图3-图5所示，进口通道1的横截面为正方形，且设有圆角，相邻进口通道1的圆角之间的距离与壁厚的比例范围为0.8-1.4，优选地，其比例范围为0.9-1.3。优选地，圆角的半径大于壁厚的20％，且小于0.3mm。出口通道2的横截面为正方形，并设有圆角，圆角的半径大于壁厚的20％，且小于0.3mm。
实施例3：
如图6-图8所示，进口通道1的横截面为正方形，且设有圆角，相邻进口通道1的圆角之间的距离与壁厚的比例范围为0.8-1.4，优选地，其比例范围为0.9-1.3。优选地，圆角的半径大于壁厚的20％，且小于0.3mm。出口通道2的横截面为正方形，且设有倒角，所述倒角的斜边长度范围为所述出口通道2的横截面边长的5％-30％，优选地，倒角可为45°角，也可以为斜切角等。
实施例4：
如图9-10所示，进口通道1的横截面为正方形，且相邻两条边由两条连接线连接，两条连接线之间为钝角，其连接线与其相连的正方形边的夹角小于30°，优选地，夹角小于15°，根据实际需求，可选用更小的夹角。出口通道2的横截面为正方形。
实施例5：
如图11-13所示，进口通道1的横截面为正方形，且相邻两条边由两条连接线连接，两条连接线之间为钝角，其连接线与其相连的正方形边的夹角小于30°，优选地，夹角小于15°，根据实际需求，可选用更小的夹角。出口通道2的横截面为正方形，并设有圆角，圆角的半径大于壁厚的20％，且小于0.3mm。
实施例6：
如图14-图16所示，进口通道1的横截面为正方形，且相邻两条边由两条连接线连接，两条连接线之间为钝角，其连接线与其相连的正方形边的夹角小于30°，优选地，夹角小于15°，根据实际需求，可选用更小的夹角。出口通道2的横截面为正方形，且设有倒角，所述倒角的斜边长度范围为所述出口通道2的横截面边长的5％-30％，优选地，倒角可为45°角，也可以为斜切角等。
实施例7：
如图17-图18所示，进口通道1的横截面为正方形，且相邻两条边由两条连接线和圆弧组成的连接部连接，圆弧处于两条连接线之间，两条连接线之间为钝角，圆弧长度小于连接部长度的30％，优选地，长度小于15％。出口通道2的横截面为正方形。
实施例8：
如图19-图21所示，进口通道1的横截面为正方形，且相邻两条边由两条连接线和圆弧组成的连接部连接，圆弧处于两条连接线之间，两条连接线之间为钝角，圆弧长度小于连接部长度的30％，优选地，长度小于15％。出口通道2的横截面为正方形，并设有圆角，圆角的半径大于壁厚的20％，且小于0.3mm。
实施例9：
如图22-图24所示，进口通道1的横截面为正方形，且相邻两条边由两条连接线和圆弧组成的连接部连接，圆弧处于两条连接线之间，两条连接线之间为钝角，圆弧长度小于连接部长度的30％，优选地，长度小于15％。出口通道2的横截面为正方形，且设有倒角，所述倒角的斜边长度范围为所述出口通道2的横截面边长的5％-30％，优选地，倒角可为45°角，也可以为斜切角等。
依据以上实施例，将进口通道1及出口通道2的结构设计组合起来，从而改善背压，增加力学及热力学强度。优选地，以上实施例的进口通道1的横截面可以为正方形。
本发明提供的一种抗热震非对称蜂窝陶瓷壁流式过滤器，对进口通道1横截面进行圆角、双线或双线加圆弧改造，进一步结合对出口通道2横截面正方、倒角或圆角改造，本过滤器具有兼顾良好的力学性能、低背压以及优异的抗热震性能。
以上仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (4)

1.一种抗热震非对称蜂窝陶瓷壁流式过滤器，其特征在于，包括：进口蜂窝陶瓷面和出口蜂窝陶瓷面，所述进口蜂窝陶瓷面和所述出口蜂窝陶瓷面均设有进口通道(1)和出口通道(2)，所述进口通道(1)与所述出口通道(2)连通，所述进口通道(1)的出口端和所述出口通道(2)的进口端封堵，所述进口通道(1)的内径与所述出口通道(2)的内径的比例范围为1.1-1.5；
所述进口通道(1)的横截面为正方形，且设有圆角，相邻所述进口通道(1)的圆角之间的距离与壁厚的比例范围为0.8-1.4，所述圆角的半径大于壁厚的20％，且小于0.3mm；
或所述进口通道(1)的横截面为正方形，且相邻两条边由两条连接线连接，所述两条连接线之间为钝角，且所述连接线与其相连的正方形边的夹角小于30°；
或所述进口通道(1)的横截面为正方形，且相邻两条边由两条连接线和圆弧连接，所述圆弧处于所述两条连接线之间，所述两条连接线之间为钝角，所述圆弧长度小于所述连接部长度的30％。
2.如权利要求1所述的抗热震非对称蜂窝陶瓷壁流式过滤器，其特征在于，所述出口通道(2)的横截面为正方形。
3.如权利要求1所述的抗热震非对称蜂窝陶瓷壁流式过滤器，其特征在于，所述出口通道(2)的横截面为正方形，并设有圆角，所述圆角的半径大于壁厚的20％，且小于0.3mm。
4.如权利要求1所述的抗热震非对称蜂窝陶瓷壁流式过滤器，其特征在于，所述出口通道(2)的横截面为正方形，且设有倒角，所述倒角的斜边长度范围为所述出口通道(2)的横截面边长的5％-30％。
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