EP0840840B1 - A catalyst carrier arrangement - Google Patents

A catalyst carrier arrangement Download PDF

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Publication number
EP0840840B1
EP0840840B1 EP96911153A EP96911153A EP0840840B1 EP 0840840 B1 EP0840840 B1 EP 0840840B1 EP 96911153 A EP96911153 A EP 96911153A EP 96911153 A EP96911153 A EP 96911153A EP 0840840 B1 EP0840840 B1 EP 0840840B1
Authority
EP
European Patent Office
Prior art keywords
monolith
casing
metal
catalyst body
section
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Revoked
Application number
EP96911153A
Other languages
German (de)
French (fr)
Other versions
EP0840840A1 (en
Inventor
Sven Melker Nilsson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Dinex Ecocat Oy
Original Assignee
Kemira Metalkat Oy
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Application filed by Kemira Metalkat Oy filed Critical Kemira Metalkat Oy
Publication of EP0840840A1 publication Critical patent/EP0840840A1/en
Application granted granted Critical
Publication of EP0840840B1 publication Critical patent/EP0840840B1/en
Anticipated expiration legal-status Critical
Revoked legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
    • F01N3/2842—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration specially adapted for monolithic supports, e.g. of honeycomb type
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/02—Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal

Definitions

  • the subject invention concerns a carrier arrangement for catalytic converters.
  • metal substrates As substrates to be used to support the catalytic material in internal combustion engine exhaust systems ceramic materials are predominantly used. In latter years, metal substrates have, however, come into use to an increasingly large extent. The advantage of metal substrates is their ability to reach working temperatures more rapidly than do cermamic ones, as accordingly they begin their exhaust gases purification function at an earlier stage after start, which is a most essential feature. Moreover, metal substrates are more efficient thermal conductors, and thus they may be heated more quickly and the risk of local overheating is reduced. In addition, metal substrates support higher temperatures than ceramic ones.
  • metal monoliths As carrier members supporting the catalytic material so called metal monoliths are used. These consist of metal foils, preferably of stainless steel, wound into rolls wherein metal foils of flat configuration alternate with metal foils of corrugated configuration, whereby throughflow channels extending through the catalyst body are formed.
  • the foil thickness is small, normally only about 0.05 mm.
  • the catalyst body also includes a metal cover forming a jacket surrounding the monolith in contact with the latter. The cover thickness may amount to approximately 1 - 1.6 mm.
  • the thin carrier member foils are heated very rapidly.
  • the temperature quickly reaches between 500 and 800°C.
  • the temperature may rise to the range of up to between 1100 and 1200°C.
  • the temperature of the catalyst body rapidly sinks to the level of the ambient temperature.
  • the repeated temperature changes constitute a problem that affects the catalyst long-term durability.
  • the rapidly heated thin foils of the monolith also expand quickly.
  • the surrounding casing in abutment against the monolith but not in close contact with the exhausts and in addition having a larger material thickness, is heated and expands at a slower pace. During the heating, the casing thus prevents the monolith from expanding, which gives rise to considerable radial compressive forces that cause deformations to form in the monolith.
  • the strength of the metal also is reduced considerably, often down to about 10% of its strength at room temperature, which aggravates the deformations and reduces the monolith life further.
  • US 4,909,994 discloses a carrier arrangement for catalytic converters comprising a catalyst body which consists of a monolith of carrier members designed to support a catalytic material, said carrier members formed by superposed, alternately flat and corrugated metal foils which are helically wound to form through-flow channels extending through the catalyst body, and of a metal casing, the material thickness of which exceeds that of the metal foils and which casing encloses the monolith, whereby the interior width of the casing exceeds that of the monolith, whereby a gap forms between the casing and the monolith, and said gap is bridged at least in the area of a section by a radial bandlike depression of the casing extending circumferentially around the monolith.
  • the subject invention provides a simple, reliable and economical solution to the securement problem.
  • the solution functions both when applied to metal monoliths soldered together in the manner indicated above and when applied to metal monoliths joined together in some other manner, without soldering.
  • the characteristic features of the attachment arrangement appear from the appended claims.
  • the casing 2 is provided with at least one band-like depression 7, in accordance with the embodiment illustrated in the drawing figure with two such depressions, the gap 6 around the monolith 3 thus being eliminated in the area opposite said depressions.
  • the casing 2 and the monolith 3 are interconnected, preferably only at spaced intervals 8, for instance by means of soldering or welding.
  • the monolith 3 When the monolith 3 is heated by the exhaust gases flowing through it, the monolith 3 expands quicker than the casing 2, which is due partly to the more intimate contact of the monolith 3 with the hot exhaust gases, partly to the larger material thickness of the casing 2. The expansion may now take place essentially unimpededly, with the exception of in the area of the depressions 7 where a certain deformation of the outermost foil 4 of the monolith 3 will take place. Consequently, no compressive forces will generate along the major part of the surface of the monolith 3. When the casing and the monolith 3 again cool down, the monolith 3 may again retract and thus again open up a gap 6.
  • the catalyst body 1 may operate in an intact condition over a longer period than has hitherto been possible, with consequential increase of its serviceable life.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Catalysts (AREA)

Description

The subject invention concerns a carrier arrangement for catalytic converters.
As substrates to be used to support the catalytic material in internal combustion engine exhaust systems ceramic materials are predominantly used. In latter years, metal substrates have, however, come into use to an increasingly large extent. The advantage of metal substrates is their ability to reach working temperatures more rapidly than do cermamic ones, as accordingly they begin their exhaust gases purification function at an earlier stage after start, which is a most essential feature. Moreover, metal substrates are more efficient thermal conductors, and thus they may be heated more quickly and the risk of local overheating is reduced. In addition, metal substrates support higher temperatures than ceramic ones.
As carrier members supporting the catalytic material so called metal monoliths are used. These consist of metal foils, preferably of stainless steel, wound into rolls wherein metal foils of flat configuration alternate with metal foils of corrugated configuration, whereby throughflow channels extending through the catalyst body are formed. The foil thickness is small, normally only about 0.05 mm. The catalyst body also includes a metal cover forming a jacket surrounding the monolith in contact with the latter. The cover thickness may amount to approximately 1 - 1.6 mm.
When the hot exhaust gases flow through the monolith during the combustion engine operation the thin carrier member foils are heated very rapidly. Usually, the temperature quickly reaches between 500 and 800°C. In some types of engines, the temperature may rise to the range of up to between 1100 and 1200°C. As soon as the engine stops, the temperature of the catalyst body rapidly sinks to the level of the ambient temperature.
The repeated temperature changes constitute a problem that affects the catalyst long-term durability. The rapidly heated thin foils of the monolith also expand quickly. The surrounding casing, in abutment against the monolith but not in close contact with the exhausts and in addition having a larger material thickness, is heated and expands at a slower pace. During the heating, the casing thus prevents the monolith from expanding, which gives rise to considerable radial compressive forces that cause deformations to form in the monolith. When the abovementioned high temperature levels are reached, the strength of the metal also is reduced considerably, often down to about 10% of its strength at room temperature, which aggravates the deformations and reduces the monolith life further.
When the engine is stopped and the exhausts cool down the opposite phenomenon occurs, i.e. the monolith foils cool at a higher speed than the surrounding thicker casing. As a result, considerable tensile forces generate between the outermost part of the monolith and the cover.
For the reasons outlined in the aforegoing, considerable problems are involved as regards the attachment of metal monoliths in their casings. Several various solutions have been proposed and tested, but often with poor results. Some viable constructions have been developed, e.g. by the German company Emitec GmbH, but they are comparatively complex and expensive. A feature common to all these prior-art solutions is that they apply to monoliths wherein the various metal foil layers are interconnected by means of soldering, with the outermost layer being soldered to the surrounding jacket.
US 4,909,994 discloses a carrier arrangement for catalytic converters comprising a catalyst body which consists of a monolith of carrier members designed to support a catalytic material, said carrier members formed by superposed, alternately flat and corrugated metal foils which are helically wound to form through-flow channels extending through the catalyst body, and of a metal casing, the material thickness of which exceeds that of the metal foils and which casing encloses the monolith, whereby the interior width of the casing exceeds that of the monolith, whereby a gap forms between the casing and the monolith, and said gap is bridged at least in the area of a section by a radial bandlike depression of the casing extending circumferentially around the monolith.
The subject invention provides a simple, reliable and economical solution to the securement problem. The solution functions both when applied to metal monoliths soldered together in the manner indicated above and when applied to metal monoliths joined together in some other manner, without soldering. The characteristic features of the attachment arrangement appear from the appended claims.
The invention will be described in closer detail in the following with reference to the accompanying drawing, wherein
  • Fig. 1 is a broken schematical longitudinal sectional view through a catalyst body,
  • Fig. 1 illustrates a basic design of the inventive object. A catalyst body 1 comprises a metal casing 2 enclosing a so called monolith 3. The latter in turn consists of carrier members, designed to support a catalytic material and consisting of helically wound metal foils, arranged so that flat metal foils 4 alternate with corrugated metal foils, so as to form through-flow channels 5 extending through the catalyst body 1. The monolith 3 has a width or diameter that is slightly smaller than the internal width of the casing 2. Accordingly, a gap 6 forms between the casing 2 and the monolith 3, the size of which varies within different temperature ranges.
    • In accordance with the invention, the casing 2 is provided with at least one band-like depression 7, in accordance with the embodiment illustrated in the drawing figure with two such depressions, the gap 6 around the monolith 3 thus being eliminated in the area opposite said depressions. Along these depressions 7 the casing 2 and the monolith 3 are interconnected, preferably only at spaced intervals 8, for instance by means of soldering or welding.
    When the monolith 3 is heated by the exhaust gases flowing through it, the monolith 3 expands quicker than the casing 2, which is due partly to the more intimate contact of the monolith 3 with the hot exhaust gases, partly to the larger material thickness of the casing 2. The expansion may now take place essentially unimpededly, with the exception of in the area of the depressions 7 where a certain deformation of the outermost foil 4 of the monolith 3 will take place. Consequently, no compressive forces will generate along the major part of the surface of the monolith 3. When the casing and the monolith 3 again cool down, the monolith 3 may again retract and thus again open up a gap 6.
    Because the monolith 3 is exposed only to minor local deformations in the area of the depressions 7 and is allowed to expand and contract freely elsewhere, the catalyst body 1 may operate in an intact condition over a longer period than has hitherto been possible, with consequential increase of its serviceable life.
    Further improvements may be achieved by omitting to join one or some of the outermost foils 4 along the entire foil length to the foils immediately interiorly thereof but instead joining them to one another at points spaced laterally from the points 8 of attachment. When the monolith 3 cools down, with consequential contraction, the tensile forces at the points 8 of attachment will not be very pronounced because of the resiliency imparted to the outermost foils 4 between their interconnection points.
    The invention is not limited to the embodiments as shown and described but could be modified in a variety of ways within the scope of the appended claims.

    Claims (2)

    1. A carrier arrangement for catalytic converters, comprising a catalyst body (1) which consists of a monolith (3) of carrier members designed to support a catalytic material, said carrier members formed by superposed, alternately flat and corrugated metal foils (4) which are helically wound to form through-flow channels (5) extending through the catalyst body (1), and of a metal casing (2), the material thickness of which exceeds that of the metal foils (4) and which casing encloses the monolith (3), whereby the interior width of the casing (2) exceeds that of the monolith (3), whereby a gap (6) forms between the casing (2) and the monolith (3), and said gap (6) is bridged at least in the area of a section (7) by a radial bandlike depression of the casing (2) extending circumferentially around the monolith (3),
      characterized in that said monolith (3) being soldered or welded to the casing (2) along said section (7).
    2. An arrangement as claimed in claim 1,
      characterized in that in the area of said section (7) the monolith (3) is attached to the casing (2) only in some points (8) circumferentially around the monolith.
    EP96911153A 1995-04-27 1996-04-18 A catalyst carrier arrangement Revoked EP0840840B1 (en)

    Applications Claiming Priority (3)

    Application Number Priority Date Filing Date Title
    SE9501556A SE506670C2 (en) 1995-04-27 1995-04-27 Catalyst mounting arrangement
    SE9501556 1995-04-27
    PCT/SE1996/000499 WO1996034188A1 (en) 1995-04-27 1996-04-18 A catalyst carrier arrangement

    Publications (2)

    Publication Number Publication Date
    EP0840840A1 EP0840840A1 (en) 1998-05-13
    EP0840840B1 true EP0840840B1 (en) 2003-07-23

    Family

    ID=20398107

    Family Applications (1)

    Application Number Title Priority Date Filing Date
    EP96911153A Revoked EP0840840B1 (en) 1995-04-27 1996-04-18 A catalyst carrier arrangement

    Country Status (9)

    Country Link
    EP (1) EP0840840B1 (en)
    JP (1) JPH11504094A (en)
    KR (1) KR19990008026A (en)
    CN (1) CN1084429C (en)
    AU (1) AU5412096A (en)
    DE (1) DE69629196T2 (en)
    ES (1) ES2203689T3 (en)
    SE (1) SE506670C2 (en)
    WO (1) WO1996034188A1 (en)

    Families Citing this family (7)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    CZ295523B6 (en) * 1997-03-21 2005-08-17 Ecocat Oy Catalytic reactor
    CN1096542C (en) * 1997-03-21 2002-12-18 凯米拉梅塔尔卡特公司 Improvements in catalytic reactors
    SE508622C2 (en) * 1997-11-21 1998-10-19 Nilcon Eng Ab Catalyst with cam flange for clamping
    SE522537C2 (en) 2000-03-21 2004-02-17 Kemira Metalkat Oy Catalyst support with jacket
    EP1230978B1 (en) * 2001-02-12 2005-09-28 Ecocat Oy Method for manufacturing a corrugated metal reactor packing
    JP5080306B2 (en) * 2008-02-14 2012-11-21 エコキャット オサケユイチア Improved catalytic reactor
    DE102018201738A1 (en) 2018-02-05 2019-08-08 Continental Automotive Gmbh Catalyst and process for its preparation

    Citations (4)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    US4909994A (en) * 1987-07-10 1990-03-20 Nissan Motor Co., Ltd. Catalytic converter
    DE3926072A1 (en) * 1989-08-07 1991-02-21 Behr Gmbh & Co Catalyser for purifying IC engine exhausts - has circumferential corrugation impressed into jacket surrounding catalyst support matrix
    DE3930680A1 (en) * 1989-09-14 1991-03-28 Behr Gmbh & Co Radial and axial movements of expanding exhaust purifier - matrix in housing are permitted by fixed and mobile supports incorporating spring strips
    US5079210A (en) * 1989-11-16 1992-01-07 Toyota Jidosha Kabushiki Kaisha Metallic support for exhaust gas purifying catalyst

    Family Cites Families (2)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    ATE44582T1 (en) * 1985-07-25 1989-07-15 Interatom BRACKET FOR A METALLIC EXHAUST CATALYST SUPPORT BODY AND METHOD OF MANUFACTURE.
    DE8812762U1 (en) * 1988-10-11 1989-06-29 Emitec Gesellschaft für Emissionstechnologie mbH, 5204 Lohmar Catalyst with double jacket system

    Patent Citations (4)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    US4909994A (en) * 1987-07-10 1990-03-20 Nissan Motor Co., Ltd. Catalytic converter
    DE3926072A1 (en) * 1989-08-07 1991-02-21 Behr Gmbh & Co Catalyser for purifying IC engine exhausts - has circumferential corrugation impressed into jacket surrounding catalyst support matrix
    DE3930680A1 (en) * 1989-09-14 1991-03-28 Behr Gmbh & Co Radial and axial movements of expanding exhaust purifier - matrix in housing are permitted by fixed and mobile supports incorporating spring strips
    US5079210A (en) * 1989-11-16 1992-01-07 Toyota Jidosha Kabushiki Kaisha Metallic support for exhaust gas purifying catalyst

    Also Published As

    Publication number Publication date
    CN1182468A (en) 1998-05-20
    KR19990008026A (en) 1999-01-25
    SE9501556D0 (en) 1995-04-27
    DE69629196T2 (en) 2004-02-19
    SE506670C2 (en) 1998-01-26
    CN1084429C (en) 2002-05-08
    EP0840840A1 (en) 1998-05-13
    AU5412096A (en) 1996-11-18
    WO1996034188A1 (en) 1996-10-31
    DE69629196D1 (en) 2003-08-28
    ES2203689T3 (en) 2004-04-16
    SE9501556L (en) 1996-10-28
    JPH11504094A (en) 1999-04-06

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