CN1523206A - 汽车用陶瓷催化剂载体的一体型圆形单元结构 - Google Patents
汽车用陶瓷催化剂载体的一体型圆形单元结构 Download PDFInfo
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Abstract
本发明是关于汽车用陶瓷催化剂载体的一体型圆形单元结构，其通过挤压成型工序，在催化剂载体的内侧上，将形成有涂敷层的多个贯通部形成为蜂窝形状，该涂敷层边使排气通过边发挥氧化和还原作用，被单元通路间隔分隔的由贯通部和涂敷层构成的单元，分布为与催化剂载体形成为一体型的圆形结构。在使涂敷层分布均匀的同时，减小单元行间的垂直高度，从而增大单元密度，由此可充分确保催化剂载体与排气间的接触反应条件，并能提高催化剂转换器的整体排气净化效率。
Description
技术领域
本发明是关于汽车用陶瓷催化剂载体的一体型圆形单元结构，更详细讲，是关于在以蜂窝形状构成形成涂敷层的数个贯通部的汽车用陶瓷催化剂载体的单元结构中，将单元挤压成型为与催化剂载体形成一体型的圆形结构，使涂敷层形成均匀的分布度，同时，减小单元行间的垂直高度，以相对增大单元的密度，由此可提高整个催化剂转换器排气的净化效率的汽车用陶瓷催化剂载体的一体型圆形单元结构。
背景技术
一般讲，汽车使用挥发性油等矿物燃料产生驱动所需要的动力，但就其结构特性讲，由于燃料的不完全燃烧，而产生象一氧化碳和氮氧化物等对人体有害的排气，故在因燃料的不完全燃烧而产生有害成分的车体的各部分中，具有使挥发性油等燃料燃烧的燃烧室、将空气和燃料混合的吸气系统和排出排气的排气系统等多样的装置，以最大限度地抑制上述有害气体的产生量。
尤其是，在汽车将排气向外部排出的排气管间，附着有催化剂转换器以去除排气中的有害成分，但是，上述催化剂转换器使用将排气中的一氧化碳(CO)和碳氢化合物(HC)氧化，转化成二氧化碳(CO2)和水(H2O)的氧化催化剂，和将氮化物(NOx)分别还原成氮(N2)和二氧化碳(CO2)的还原催化剂，为了满足反应所需要的温度和排气滞留时间等要件，在加大催化剂转换器的有效面积的同时，还要在壳体内安装其表面附着催化剂的粒子状催化剂载体。
一方面，上述催化剂载体形成特定的结构体，在该结构体表面上，涂敷能引起排气中有害成分氧化和还原反应的催化剂。
因此，经由上述排气管流入壳体内部的排气，与涂敷在催化剂载体上的催化剂进行催化反应，随后进入流出口。
作为这种催化剂载体实例，可举出日本特开昭56-147637号公报中公开的，单元截面形状为三角形、四角形(图2)、六角形，在各单元的角部设有规定大小的圆角部(fillet)的蜂窝结构体。
在日本特开昭62-225250号公报中公开了一种在六角形单元的单元右部上设有弯曲部(1mm以上)的蜂窝结构体。
同样，在日本特开平7-39760号公报中公开了在间隔厚度为0.05～0.15mm、开口率为0.65～0.95的确定了高密度上下限的蜂窝结构体中，使用了六角形单元。在日本特开平8-193512号公报中，公开了一种由配置在发动机附近的六角形单元形成的蜂窝结构体，在日本特开平11-320723号公报中，公开了一种轴压缩破坏强度比平均为0.9以上的六角单元的蜂窝结构体(图3)。
图4和图5是表示900cpsi(Cell per square inch)/2.5mil(mili inch)密度的催化剂载体的四角形单元结构的照片，在单元140和单元通路间隔110之间，涂敷了含有贵金属的涂敷层(例如氧化铝(Al2O3)等)130，如上所述，现有的由四角形和六角形单元结构形成的催化剂载体100，就其结构讲，涂敷层130集中在各个贯通部120的角部分上，这种分布存在不均匀的问题，由此，存在的不足之处是排气集中在某一部位，或者偏重于一方等，催化剂载体100不能充分发挥自身的功能。
如图6～图8所示，四角形单元结构和六角形单元结构的单元通路间隔110，是由形成恒定壁厚的直线形结构所构成，存在的问题是由排气(氧化铁)可腐蚀的部位遍及整体。
尤其是，现有的六角形单元结构，为了制作形成高密度，必须制作单元密度大的类型，由于结构的问题，而带来的问题是难以制作600cpsi以上的高密度型。
因此，为解决由现有的多角形单元结构产生的问题，在日本特开平7-243322号公报中，提出一种由圆形单元结构形成的金属载体(Metallic support)，如图9所示，上述金属载体是将由圆形形成的数个金属材料管110′形成捆状的载体，结构是将涂敷成分涂敷在上述金属材料管110′的内径和外径上。
然而，上述圆形单元结构的金属载体存在如下问题，第一，就材料特性方面讲，由于没有气孔，所以涂敷成分不能紧密地黏附在载体表面上，为了克服此问题，必须进行表面蚀刻，然而如图9所示，由于是由细小金属材料管110′的结合所构成，所以存在的问题是上述表面蚀刻不容易进行，而且费用也增加。
第二，取出最小厚度的金属材料管110′，将其进行积层后，制作成载体，所以管与管结合的边界部位的单元厚度增加，由此，相对减小了贯通部分(OFA：Open Frontal Area)111′的面积。
这种贯通部分111′的减小，延长了催化剂活性化的温度，降低了催化剂的净化效率，同时，由于排气难以排出，而导致背压上升。
为了制作与陶瓷催化剂载体相同的贯通部111′，使金属材料管110′的厚度减小时，当暴露在900℃以上的排气中时，上述金属材料管110′的很薄部分产生熔化的问题。
第三，根据上述理由，必须加大单元的厚度，由此带来的问题是延迟了催化剂活性化的到达时间。
第四，当上述金属材料管110′的内径和外径全部涂敷时，在金属材料管110′外径上的涂敷量远远多于内径上的涂敷量，由此管与管的外径形成的贯通部112′的截面积减小，截面的形状也不再是圆形，形成排气不能通过的结构，同时也形成作为催化剂的贵金属的活性度非常低的结构。
在金属材料管110′的外径上不涂布涂敷成分时，在外径形成的贯通部112′中，排气在未净化的情况下就被排出，结果导致催化剂整体的净化效率降低。
为了防止这种现象，将上述贯通部112′隔断，导致加工过程非常复杂，诱发费用升高的问题。
第五，就上述金属载体100′的制作而言，必须将管与管形成积层而制作，尤其是，在密度为900cpsi/2.5mil，直径为110mm的催化剂时，单元数可达到13500。
将它们焊接或利用其他方法成捆制作载体时，存在的问题是导致生产单价的极大升高。
发明内容
本发明就是为解决上述问题而提出的，其目的是提供一种汽车用陶瓷催化剂载体的一体型圆形单元结构。将汽车催化剂载体的单元结构形成为圆形结构的陶瓷一体型单元结构，在使涂敷层形成均匀分布的同时，减小单元行间的垂直高度，以增大单元密度，由此充分确保催化剂载体与排气之间接触的反应条件，从而提高催化剂转换器整体排气的净化效率。
以下对为达到上述目的的本发明特征进行说明。
本发明的特征是通过挤压成型工序，以蜂窝形状构成形成有涂敷层130的数个贯通部120，该涂敷层130使排气一边通过催化剂载体100的内侧，一边进行氧化和还原作用，在如此构成的汽车用陶瓷催化剂载体的单元结构中，被单元通路间隔11分隔的由贯通部12和涂敷层13构成的单元14，以与催化剂载体10形成一体型的圆形结构进行分布。
本发明的另一特征是，上述单元14的配列是以等间距、连续重复的正规交错配列所形成的。
本发明的另一特征是，形成上述单元通路间隔11的最小厚度范围，在单元14密度为400cpsi以上的范围内，具有165μm以下的厚度。
附图说明
图1是本发明汽车用陶瓷催化剂载体的一体型图形单元结构的图。
图2是现有的催化剂载体的四角形单元结构的图。
图3是现有的催化剂载体的六角形单元结构的图。
图4是现有的密度为900cpsi/2.5mil的催化剂载体的四角形单元结构的照片。
图5是已知涂敷层分布的图4的放大图。
图6是现有四角形单元结构的单元通路间隔的破坏状态的图。
图7是现有四角形单元结构的单元通路间隔的破坏状态的图。
图8是现有六角形单元结构的单元通路间隔的破坏状态的图。
图9是现有圆形单元结构的金属载体的图。
符号说明：10催化剂载体；11单元通路间隔；12贯通部；13涂敷层；14单元。
具体实施方式
以下参照附图详细说明本发明的构成。
图1是本发明的汽车用陶瓷催化剂载体的一体型圆形单元结构示意图。
根据本发明的具体实例，是将陶瓷原料供入挤压器内由模具挤出，形成具有一定截面的连续体的、通过挤压成型工序而制作的催化剂载体10，截面形状呈蜂窝形状，可最大限度地确保与排气的接触面积，通过利用上述蜂窝形状的贯通部12，使排气通过，通过接触引发氧化和还原作用，以提高排气的净化性能，尤其是由单元通路间隔11形成分隔的单元结构，因其形状和材质的差异，会产生很大的不同。
如图1所示，本发明是通过挤压成型工序，由与催化剂载体10形成一体型的圆形单元结构构成，由上述圆形结构形成的贯通部12的内径，含有许多气孔，所以含有贵金属的涂敷层13很容易附着在催化剂载体10的表面上，并且由能耐高温排气的陶瓷材质形成。
如上所述，由圆形构成的贯通部12的内径，使涂敷层13容易附着，上述涂敷层13也会和单元形状一样形成圆形的环状结构，只在排气通过的内径部位上涂敷，进而可形成很薄的涂敷层13，所以与现有的圆形单元结构的金属载体100′相比，其长处是贵金属的活性应用程度非常高，由此可节省涂敷剂。
现有的单元结构是以四角形或六角形形成，涂敷层130的分布集中或偏重于其贯通部120的角处，这不仅降低了贵金属活性应用程度，还具有催化剂净化效率低下的问题，通过本发明这种状况得以解决。
一方面，上述单元通路间隔11，共有单元14和单元14，即两个单元14，所以与现有的圆形单元结构的金属载体比较，可形成厚度很薄的单元通路间隔11。由此，其长处是可减少催化剂达到活性化的到达时间，在某种程度上提高了排气的净化性能。
在本发明的优选具体实例中，在单元14密度为400cpsi以上的范围内，形成的上述单元通路间隔11的最小厚度范围，优选具有165μm以下的厚度。
上述单元通路间隔11具有在单元14和单元14之间，中央部具有最小间隔、两侧部具有最大的间隔的结构，与现有的由一定直线形结构形成的多角形结构的催化剂载体相比，由排气(氧化铁)可破坏的部位(强度弱的部位)是上述具有最小间隔的中央部位，整体狭窄地形成，故在机械特性方面，从单元结构的强度方面发挥了优良的效果。
上述圆形单元结构，与上述催化剂载体10构成一体型，其配列是由等间隔、连续重复的正规交错配列形成，通过缩小单元14间的垂直高度，所以增大了单元密度。如图1所示，a表示单元14的直径，t表示单元通路间隔11的厚度。单元14的行间垂直高度h2，采用三角比的定理(a+t)sin60°、即，以
表示。
单元14间的间隔比现有的多角形结构催化剂载体中的单元间隔要小，这就是增大单元密度的原因。由此，可充分确保催化剂载体10与排气之间的接触反应条件，并能提高催化剂转换器整体的排气净化效率。
如上所述，本发明汽车用陶瓷催化剂载体的一体型圆形单元结构，使涂敷层的分布度均匀，降低了单元的垂直高度，从而增大了单元的密度，从而充分确保了催化剂载体与排气间的接触反应条件，不仅提高了催化剂的整体排气净化效率，而且也能获得为了同等净化排气而减少催化剂贵金属量的效果。
Claims (3)
1.一种汽车用陶瓷催化剂载体的一体型圆形单元结构，其通过挤压成型工序，将形成有涂敷层(130)的多个贯通部(120)形成为蜂窝形状，该涂敷层(130)使排气一边通过催化剂载体(100)的内侧，一边发挥氧化和还原作用，其特征在于，
被单元通路间隔(11)分隔的由贯通部(12)和涂敷层(13)构成的单元(14)，分布为与催化剂载体(10)形成为一体型的圆形结构。
2.如权利要求1所述的汽车用陶瓷催化剂载体的一体型圆形单元结构，其特征在于，所述单元(14)的配列是由以等间隔、连续重复的正规交错配列所形成。
3.如权利要求1所述的汽车用陶瓷催化剂载体的一体型圆形单元结构，其特征在于，所述单元通路间隔(11)的最小厚度范围形成为：在单元(14)的密度为400cpsi以上的范围内，具有165μm以下的厚度。
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| KR10-2003-0009715 | 2003-02-17 | ||
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| KR10-2003-0050876A KR100527970B1 (ko) | 2003-02-17 | 2003-07-24 | 자동차용 세라믹 촉매담체의 일체형 원형셀구조 |
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| CN102979605A (zh) * | 2012-04-09 | 2013-03-20 | 周正祥 | 内燃机尾气净化装置 |
| US9808794B2 (en) | 2013-09-23 | 2017-11-07 | Corning Incorporated | Honeycomb ceramic substrates, honeycomb extrusion dies, and methods of making honeycomb ceramic substrates |
| CN104316539A (zh) * | 2014-09-01 | 2015-01-28 | 苏州德创测控科技有限公司 | 三元催化器检测系统、检测器及检测方法 |
| CN104324726B (zh) * | 2014-10-13 | 2016-08-10 | 上海大学 | 一种金属载体整体式催化剂的制备方法 |
| JP6579894B2 (ja) * | 2015-10-01 | 2019-09-25 | 三菱日立パワーシステムズ株式会社 | 一酸化窒素分解装置、発電システム |
| CN108025301A (zh) | 2015-10-02 | 2018-05-11 | 托普索公司 | 用于尾气或废气净化的含催化剂的陶瓷过滤器的制备方法 |
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| DE1442587A1 (de) * | 1965-04-22 | 1968-10-31 | Schneider & Co | Traeger fuer Katalysatorstoffe |
| US3930522A (en) * | 1973-05-02 | 1976-01-06 | General Refractories Company | Structural ceramic article and method of making same |
| US6116014A (en) * | 1995-06-05 | 2000-09-12 | Catalytica, Inc. | Support structure for a catalyst in a combustion reaction chamber |
| JP3489049B2 (ja) * | 1999-07-15 | 2004-01-19 | 日産自動車株式会社 | 排気ガス浄化用触媒 |
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| CN108204267A (zh) * | 2018-03-21 | 2018-06-26 | 吉林大学 | 一种电场强化的三元催化器 |
| CN108204267B (zh) * | 2018-03-21 | 2024-04-16 | 吉林大学 | 一种电场强化的三元催化器 |
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