EP1529934A1 - Corps de catalyseur et son procédé de fabrication - Google Patents

Corps de catalyseur et son procédé de fabrication Download PDF

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Publication number
EP1529934A1
EP1529934A1 EP04405671A EP04405671A EP1529934A1 EP 1529934 A1 EP1529934 A1 EP 1529934A1 EP 04405671 A EP04405671 A EP 04405671A EP 04405671 A EP04405671 A EP 04405671A EP 1529934 A1 EP1529934 A1 EP 1529934A1
Authority
EP
European Patent Office
Prior art keywords
sheet metal
layers
coating
catalyst body
sheet
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.)
Granted
Application number
EP04405671A
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German (de)
English (en)
Other versions
EP1529934B1 (fr
Inventor
Pieter Delfina Dr. Steenackers
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Scambia Industrial Developments AG
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Scambia Industrial Developments AG
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Publication of EP1529934A1 publication Critical patent/EP1529934A1/fr
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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
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2807—Metal other than sintered metal
    • F01N3/281—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
    • 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
    • F01N2330/04—Methods of manufacturing
    • 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
    • F01N2330/14—Sintered material
    • 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
    • F01N2330/30—Honeycomb supports characterised by their structural details
    • F01N2330/32—Honeycomb supports characterised by their structural details characterised by the shape, form or number of corrugations of plates, sheets or foils
    • F01N2330/323—Corrugations of saw-tooth or triangular form
    • 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
    • F01N2330/30—Honeycomb supports characterised by their structural details
    • F01N2330/42—Honeycomb supports characterised by their structural details made of three or more different sheets, foils or plates stacked one on the other
    • 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
    • F01N2330/30—Honeycomb supports characterised by their structural details
    • F01N2330/44—Honeycomb supports characterised by their structural details made of stacks of sheets, plates or foils that are folded in S-form

Definitions

  • the invention relates to a process for the preparation a catalyst body for the catalytic treatment of Gas, in particular for the catalytic purification of exhaust gas an internal combustion engine.
  • a catalyst body for the catalytic treatment of Gas
  • an internal combustion engine Such for installation in a housing a catalyst provided catalyst body often referred to as a substrate.
  • the internal combustion engine can for example become an automobile or other Motor vehicle belong or be arranged stationary.
  • the sheet metal layers may therefore be in use the catalyst body due to the thermal stresses, Vibrations and other accelerations against each other move and thereby abrasion of the coating material cause. Furthermore, the compounds of the If necessary, loosen sheet metal layers over time. Furthermore have the according to the two mentioned documents produced catalyst body has the disadvantage that the Plain areas also between each other have adjoining wave crests lying sub-regions, which are quite wide and of course no catalytic ones Treatment of the exhaust gas result.
  • EP 0 049 489 A discloses a method for Production of a catalyst body from two sheet metal elements, namely from a sheet metal strip with trapezoidal waves and an originally flat tin band.
  • this Manufacturing process is first applied to the adhesive the wave crests existing, approximately flat Surface areas of the corrugated metal strip applied. Thereafter, a solder powder is sprayed against the corrugated tape, so that soldering powder on the previously provided with adhesive Adhered to surface areas.
  • Adhesive and solder powder provided corrugated sheet metal strip and the originally flat sheet metal strip are now merged and wound together to form a spiral winding, so that arise in pairs adjacent sheet metal layers, each of which is one turn of either Sheet metal strips exists.
  • the two metal bands are then at that formed by the plane surfaces of the wave crests Contact areas of the corrugated metal strip in a vacuum soldering oven soldered together. Thereafter, precious metal coatings on the soldered metal strips applied, so that a catalyst body is formed. at a catalyst body produced in this way extend the applied coatings right up to the corners between the ripples and the roughly flat vertices the corrugated sheet metal strip, where this one with the other Sheet metal strip is soldered. Since the application of the coatings only after soldering the metal strips done, the Coatings at and in said corners much thicker than with the rest, smooth, more or less flat or slightly curved surface areas of the two metal strips.
  • the thickness of the coatings often also varies in uncontrolled and unwanted way along the to the Waves parallel passages of the catalyst body. This is particularly the case when the bands along a have the width measured in the waves compared to the Cross sectional dimensions of the passages, i. to the wave height and to the wavelength or width of the waves, relatively large is. Uneven thicknesses of the coatings lead to the disadvantage that the catalytically active precious metal is not optimally distributed is and can be exploited badly. This in turn has as a result, that for the preparation of a catalyst body more expensive precious metal is needed than at one optimal, for example, uniform distribution of Noble metal and / or that the action of the catalyst body is reduced.
  • US 5 094 074 A discloses various catalysts with electrically heatable catalyst bodies and method for their production.
  • the catalyst body has a Sheet metal element consisting of a meandering band consists of flat, parallel sections. Between two adjacent, planar sections is each serving as a spacer, corrugated sheet metal element arranged.
  • the sheet metal elements together form one Stack of alternating successive, level and corrugated sheet metal layers that at the wave crests on abut each other. All sheet metal elements have one metallic core and coatings.
  • a Catalyst body In the production of a Catalyst body is at least that of a meandering band existing sheet metal element before the Assembling with the corrugated sheet metal elements so with Coatings of electrically insulating ceramics provided that these coatings both surfaces of the metallic core of the Cover the band completely and the metallic core of the Tape after assembly with the corrugated sheet metal elements electrically isolate against their metallic cores.
  • the invention is based on the object, a method to create for the preparation of a catalyst body, the allows to avoid disadvantages of the known methods.
  • the catalyst body should be simple and economical can be manufactured and assembled.
  • the sheet metal layers of the finished catalyst body be stable and permanently connected.
  • the invention further relates to a catalyst body according to claim 11.
  • the sheet metal layers are according to the Erfingung so prepared and assembled into a catalyst body, that after putting them together in non-coated areas with formed by these, preferably metallic, bare Surfaces of contact areas abut each other.
  • the Sheet metal elements can then through the contact areas a joint connection, namely preferably by welding or possibly by brazing or sintering, cohesively joined together and firm and insoluble with each other get connected.
  • the sheet metal layers by Resistance welding without additional welding material connected with each other.
  • Resistance welding can a short electrical surge with high current through the sheet metal layers and their contact areas be passed through. This surge can, for example by discharging a previously charged electrical Condenser can be generated.
  • a Resistance welding process can the sheet element layers at the contact areas on the for welding required temperature while the remaining Regions of the sheet metal layers remain relatively cool. The Resistance welding therefore allows the sheet metal elements fast and gentle and with relatively little Energy consumption solid, solid and durable to connect with each other.
  • each catalyst body may be a stack Of sheet metal layers have, each of which consists of a consists of separate sheet metal element.
  • the sheet metal layers can but also by turns from two to one winding be formed wound sheet metal elements.
  • the catalyst body may also include a stack of sheet metal layers in which either one each of two each other adjacent sheet metal layers or all sheet metal layers through sections of a meandering curved and / or folded sheet metal element are formed.
  • catalyst body 1 is used for the catalytic treatment and purification of gas, namely exhaust gas of an internal combustion engine, and has an im General cuboid or cube-shaped stack 3 of Sheet metal layers, each of which is separate Sheet metal element 5 or 7 exists.
  • the stack points alternately successive first, smooth and even and in particular, wave-free sheet metal elements 5 and second, corrugated sheet metal elements 7 on.
  • the sheet metal elements are still in merged together and fixed as well as undetachably connected to each other, so that the stack 3 a forms solid block.
  • the stack 3 is in one, for example in cross-section substantially quadrangular, namely rectangular or square shaped, open at both ends, metallic sleeve 9 is arranged and fixed.
  • a spray device 11 partly visible in FIG has at least one spray nozzle 13 and preferably at least two spray nozzles 13 to a first metal strip 15 to spray that leads to the formation of at least a first Sheet metal element 5 and preferably of a plurality of first sheet metal elements 5 serves.
  • the spraying device 11 does not yet have drawn transport on to the first metal strip 15th in the transport direction 19 indicated by an arrow to transport between the spray nozzles 13 therethrough.
  • FIG. 4 also shows a spray device 11, to spray a second metal strip 17, the formation of at least one second sheet metal element 7 and preferably of several such serves.
  • the apparent in Figure 4 Sprayer 11 also has at least two Spray nozzles 13 and transport on and can for example, by the same spraying device as in Figure 1 drawn sprayer or by a separate Sprayer be formed.
  • the or each Sprayer 11 further includes means to the To supply at least one coating material spray nozzles and the Spraying, for example, more or less similar to one Control the printing process of an inkjet printer, in particular to turn on and off.
  • the first metal band 15 and the second metal band 17 have identical widths and thicknesses, consist of sheet metal the same material, such as stainless steel, and can, for example, not shown supply rolls or also unwound successively from the same supply roll become.
  • the two metal bands are in the area of Sprayer 11 smooth and, for example, even. If the Metal bands 15, 17 moved past the spray nozzles 13 over For example, at least one of them sprays one aqueous solution and / or dispersion existing Cover material on the two opposite sides or surfaces of the metal bands on, so that on this successive coatings along the metal bands arise, the first metal strip 15 as the first coatings 21 and the second metal strip as second coatings 23rd designated and also in the figures 2 and 5 can be seen.
  • the coatings 21, 23 consist as usual for the most part at least one porous metal oxide, for example Aluminum oxide, which forms a so-called "wash coat".
  • the Coatings also contain catalytically active material, namely at least one precious metal, for example platinum and Rhodium.
  • the "wash coat” and the precious metals can at Spraying the coatings, for example, in one and the same Solution and / or dispersion may be included and together the metal bands are sprayed on. It is, however possible, first a first, the "wash coat” containing Cover material and then a second, the precious metals to spray containing coating material. Maybe you can even the different precious metals sprayed separately become.
  • the coatings 21, 23 extend over the whole Widths of the metal bands and have for example in Substantially everywhere about the same thicknesses and the same compositions.
  • the spraying could, however possibly also be controlled so that the thickness of the Coatings and / or the concentration of precious metals in the Coatings and / or the precious metal composition locally vary.
  • the Thickness of the coatings or at least the per unit area of the Surfaces of the metal strips contained in the coatings Precious metal amount at least along a part of itself resulting in the use of the catalyst body, general flow path of the exhaust gas changes and for example in the general flow direction of the exhaust gas increases or decreases.
  • the metal strips are sprayed in such a way that between the on their two surfaces in the Lengthwise successive coatings strip-shaped, blank, i. Coating-free metallic Areas arise. These are perpendicular to the Longitudinal edges of the metal bands.
  • the first metal band 15 are the bare, non-coated areas designated 25 and all have the same in the longitudinal direction of the first Metal bands measured width s.
  • the second metal band 17 follow along the metal band alternately bare, non-coated Areas 33 and 35 on each other, in the longitudinal direction of the metal band measured, different widths t or u have.
  • the width u of the strip-shaped regions 35 is larger, e.g. at least 30% and e.g.
  • FIG. 1 and 2 is still a grid spacing a of first metal bands drawn in the longitudinal direction of the metal strip, for example, from center to center of successive, bright, coating-free areas 25 is measured.
  • Figures 4 and 5 is a grid spacing b of the second metal strip drawn, for example, from Middle to middle of successive, bare, coating-free areas 33, 35 is measured.
  • the first and the second metal band 15 and 17 both have the same Width c and the same thickness.
  • the first metal band 15 are on the two opposite sides or surfaces of the metal strip applied coatings and accordingly also on the both sides or surfaces existing bare, plating-free Areas 25 by half a grid spacing, ie to the distance a / 2 offset from each other.
  • the one on the bottom Side of the first metal strip existing bare areas 25 So are in the middle between two on the top of the metal band consecutive, bare Regions 25.
  • the second metal band 17 overlap the on the lower and upper side of the metal band existing, bare areas 33, 35 in pairs, so that the Centerlines of a stacked pair of bare areas 33, 35 in one to the surfaces of the Metal bands vertical projection coincide.
  • the pitches a and b are, for example, approximately same size, but could also be different from each other be and be expediently at least 2 mm, conveniently at most 5 mm and for example approximately 3 mm.
  • the width c can - depending on the size of the to be prepared catalyst body - within wide limits be varied and is normally at least 20 mm, usually not more than 100 mm and, for example, approximately 30 mm.
  • the width s of the bare areas of the first Metal bands 15 is preferably at least 0.05 mm, preferably at most 0.3 mm and, for example, about 0.15 mm to 0.2 mm.
  • the widths of the bare areas 33 and 35 of the second metal bands are preferably at least 0.05 mm, preferably at most 0.3 mm and for example about 0.1 mm and about 0.15 mm, respectively.
  • the thickness of the Coating-free metal bands 15, 17 is, for example about 50 ⁇ m.
  • the thicknesses of the coatings 21 and 23 are preferably in the range of 15 microns to 50 microns and amount to Example about 30 ⁇ m.
  • the second metal band 17 is, for example, before the Applying the coatings to the subsequently to be formed bare, coating-free areas 33, 35 provided with holes 31, the For example, be formed by punching. It becomes the Example for each pair later facing each other Areas 33, 35 a straight line across the width of the Metal bands 17 distributed holes 31 formed. Perhaps However, each couple could face each other Areas just two each near one of the longitudinal edges holes arranged in the metal band or even only one single hole or no hole can be formed.
  • the second metal strip 17 is after applying the Coatings 23 are so corrugated, i. by forming with waves Provide that the waves and their crests are vertical to the longitudinal edges of the metal strip and that each Wave crests at a pair of opposing. bare, coating-free areas 33, 35 is located.
  • the holes 31 may be in forming the second metal strip be used to by means of a suitable device the to ensure proper positioning of the metal strip, so that the wave crests precisely at bare areas 33, 35 arise.
  • first metal strip 15 and the coated with coatings 23 and waves second metal strip 17 are with a not shown cutting device in first sheet metal elements 5 and second sheet metal elements 7 cut so that the sheet metal elements a to be formed Catalyst body 1 have corresponding length, which in wide Borders can be varied.
  • Each sheet metal element has in one Top view a quadrangular, namely preferably rectangular or square outline. Every sheet metal element accordingly has four pairs to each other parallel edges.
  • One of the second corrugated sheet metal elements is separate in Figure 6 shown. Further, sections are of first Sheet metal elements 5 and a second sheet metal element 7 in the Figures 8 and 9 can be seen. Every second sheet metal element 8 has Shafts with wave crests 37 and wave flanks 39. The Wave crests 37 run parallel to two edges of the Sheet metal element and are bent in cross section and / or Angled and - as it is particularly clear in Figures 8 and Figure 9 shows - at the highest and lowest, respectively Make the outside flattened so that they are there - i. on the Outside of the respective upper or lower Wave crest forming half-wave - a narrow, have strip-shaped, at least approximately flat surface.
  • the Wave flanks 39 are at least for the most part approximate even, so that each wave is approximately the shape of a triangle having.
  • the second metal strip 15 is in the formation of the Waves otherwise remodeled in such a way that on the same side of the second metal strip 15 and on the same side of one of them cut off, second Sheet metal element 7, consecutive Wave crests 37 from each other have a distance e, the equal to the pitch a of the first metal strip 15 and one of which is cut off, first sheet metal element 5.
  • Each first sheet metal element 5 has a metallic core, that of the original, non-overlapping part of the first Metal bands 15 formed and in the figures 8, 9 with 41 is designated. Each first sheet metal element 5 also has first Covers shown in Figures 8 and 9 as the coatings of first metal bands are denoted by 21. Every first Sheet metal element further has bright, coating-free areas, which are designated as 25 as in the first metal band.
  • each second sheet metal element 7 has a metallic core 43, from the original, coating-free part of the second metal strip 17 is formed, second coatings 23 and bare, coating-free Areas 33 and 35. The narrower, bare areas 33rd are located on the inner side of the wave crest 37. The wider, bare areas 35 are located on the outer side of the wave crest.
  • first and second sheet metal elements For the formation of a catalyst body be alternately first and second sheet metal elements to each other stacked, so that the apparent in Figure 7 stack 3rd arises.
  • the sheet metal elements are stacked on top of each other arranged so that the on the outside of the wave crest 37 of the second sheet metal elements 7 existing, bare, Plain-free areas 35 on bare, non-coated Rests areas 25 of first sheet metal elements, as in Figures 8 and 9 can be seen.
  • the strip-shaped, bare, non-coated areas 25 and 35 then form Touch areas in which the successive touch resting sheet metal elements in pairs. These Touch areas are accordingly over their whole Lengths and especially over the entire length of the Wave crest metallic bright.
  • the contact areas of adjacent sheet metal elements 5, 7 are in to the Wave crests perpendicular cross sections narrower than the they form coating-free areas 25 and 35, respectively Plain-free area 35 extends into the Wave crests 37 vertical directions on both sides of him having wave crest on the in this Wave crest existing touch area.
  • a wave crest 37 according to the figures 8 and 9 at least approximately in the middle of a coating-free Area 25 of a first sheet metal element 5 on this rests, also covers the coating-free area 25 in to the apex vertical directions on both sides the wave crest beyond this.
  • the ones from Wave crest to wave crest measured wave height is preferably at least 0.5 mm, preferably at most 3 mm and for example 1 mm to 2 mm.
  • FIG 7 are still parts of an electrical Welding device 51 can be seen, the electric Resistance welding is formed.
  • the welding device For example, 51 has a fixed one below Electrode 53 and above an electrode 55, the vertical is adjustable and pressed against the lower electrode 53 can be.
  • the two electrodes are flat, each other facing surfaces.
  • the stack formed from sheet metal elements 3 is disposed between the two electrodes 53, 55 and has preferably at the lowest and uppermost each a second wavy Sheet metal element 7, which is located on the lower or upper Side of the sheet metal element concerned, bare Regions 35 on the facing surfaces of the Electrodes rests.
  • the adjustable electrode 55 will now in the direction of the arrows 57 against the stack 3 and the Electrode 53 is pressed, whereby the sheet metal elements 5 and 7 of the stack 3 are pressed against each other.
  • the Welding device 51 then generates an electrical Power surge, so that briefly a large electric current flows through the stack 3 of sheet metal elements.
  • the power surge For example, by discharging a previously charged, electrical capacitor can be generated.
  • the capacitor can, for example, to an electrical voltage of about Charged 3 kV, then within a few Milliseconds at least largely and at least for be discharged for the most part. This will all Sheet metal elements at all wave crests, in which Sheet metal elements rest on each other over the entire length the wave crest welded together.
  • the stack 3 forms a solid unit after this welding process and can now, for example, in the already mentioned, in FIG 10 apparent sleeve 9 used and in this on any a way, for example, by some welding connections be fixed. Since the stack 3 of sheet metal elements already itself forms a solid, stable unit, the sleeve can be very thin-walled and, for example, have wall thicknesses, less than 1 mm and, for example, at most or approximately 0.5 mm.
  • the sleeve 9 has an axis and four parallel to this, essentially flat walls that together form a continuous Limit the hole whose axis coincides with that of the sleeve coincides.
  • the stack 3 is in the sleeve 9 arranged a pair of edges of each sheet metal element and the Wave crest of the corrugated sheet metal elements parallel to the axis and run to the hole of the sleeve.
  • the catalyst body 1 then points from the adjacent sheet metal elements limited passages parallel to the waves for the exhaust gas on.
  • the catalyst body 1 can be used alone or together with at least one other, the same or similarly formed catalyst body to form a Catalyst used and installed in a housing, having an inlet and an outlet for the exhaust gas.
  • the catalyst 1 is very stable and durable. Further are the adjacent to the passages, in use the catalyst body in contact with the exhaust gas passing Surface sections of the sheet metal elements virtually complete by the catalytically active material-containing coatings formed, so that the catalyst body also an effective catalytic treatment and purification of the exhaust gas results.
  • the apparent in Figure 11 stack 73 of sheet metal elements has alternately successive first, flat sheet metal elements 75 and second, corrugated sheet metal elements 77 on.
  • the Waves of the latter are not in cross-section, however triangular, but at the wave crests and for example, even more curved at the flanks and For example, they could be approximately sinusoidal.
  • the sheet metal stack 73 may be similar like the sheet metal stack 3.
  • Each sheet metal element 83, 85 has a quadrangular, im Essentially rectangular or square outline and accordingly four pairs parallel to each other edges.
  • the waves and crests of each sheet metal element are parallel to two of the edges of the sheet metal element and perpendicular to the other two edges of the sheet metal element.
  • the out Sheet metal elements formed stack of such is in a sleeve 9 arranged that the crests of each wave a sheet metal element of each pair of adjacent and In places adjacent to each other sheet metal elements parallel to the walls of the sleeve and the axis of the sleeve as well in particular to the axis of this in cross section enclosed hole.
  • the waves and wave crests the other sheet metal elements then run course perpendicular to the walls and to the axis of the sleeve. Every couple of adjacent sheet metal elements then limits one generally parallel to the axis and wave crests the passage extending the sheet metal elements for the exhaust gas.
  • Figure 13 is a part of a catalyst body seen in the place of a stack of sheet metal elements a winding 93 which, by winding a first, smooth, wave-free sheet metal element 95 and a second, corrugated sheet metal element 97 is formed.
  • the first, smooth wave-free sheet metal element 95 is then not flat, but curved in a spiral.
  • the second corrugated sheet metal element is at least in large part between two successive turns of the first sheet metal element and lies with the wave crests on these turns of the first Sheet metal element.
  • the winding can be full in cross section or have a cavity in the central area. Of the The latter can be approximately in cross section, for example circular or approximately oval and / or for example be flattened in places.
  • each turn of one of the two sheet metal elements 95, 97 forms a sheet metal element location.
  • the two have Sheet metal coatings and partially touching, bare, non-coated areas and are among those of these formed contact areas firmly connected, for example, welded. Welding can - depending on the type and shape of the winding - for example sector by sector or possibly in a single operation done by resistance welding.
  • the catalyst body partially shown in FIG has a stack 103 of sheet metal elements, the one first, smooth, undulating, meandering curved and / or folded sheet metal element 105 and a plurality of second, corrugated sheet metal elements 107 has.
  • the first sheet metal element forms loops with flat sections.
  • the second, corrugated sheet metal elements are - apart from at best located at the two ends of the stack, second Sheet metal elements - each between two flat sections of the first, non-corrugated sheet metal element arranged.
  • This Catalyst body forms each planar section of the Sheet metal member 105 and each plate member 107 a Sheet metal element layer.
  • the sheet metal elements in turn have coatings and bare touch areas where they touch each other abut and welded together.
  • Fig. 15 shows parts of a device 131 for Treat a metal strip 135, which is used to form an in Fig. 17 shown catalyst body 121 is used.
  • Catalyst body 121 has a stack 123 of sheet metal elements 125, 127 on.
  • the latter include alternately successive first sheet metal elements 125 and second Sheet metal elements 127 and each form a sheet metal element location.
  • the first and second sheet metal elements are all corrugated but different ones, under each other Angles crossing waves.
  • the stack 123 of sheet metal elements 125, 127 is firmly seated in a metallic sleeve 129th
  • the metal band 135 consists of one before the treatment with the device 131 blank sheet, namely, for example made of stainless steel.
  • the metal band 135 was in bare Condition and before treatment with the device 131 curled.
  • the metal strip 135 has mutually parallel longitudinal edges and waves. The waves form with the longitudinal direction and the longitudinal edges of the metal strip one of 90 ° different angles ⁇ .
  • the device 131 has a device to in places, namely at the wave crests 161 of the waves of the metal band 135, an anti-adhesive agent on the metal band 135 to raise.
  • This device has, for example, two Rollers 137 facing each other at a distance 137, which are parallel to each other and to the longitudinal edges of the metal strip 135 vertical axes are rotatable.
  • the Both roles have cylindrical peripheral surfaces whose Diameter are much larger than the wavelength of the wavy metal bands.
  • the closest to each other located circumferential locations of these cylindrical peripheral surfaces stand at a distance from each other, about equal to that measured from wave crest to wave crest Wave height of the corrugated metal strip 135 is such that this can be moved between the two roles and while touching the two rollers at the wave crests.
  • the Both rollers 137 are used in treating the corrugated Metal bands by a not shown drive device in opposite directions of rotation indicated by arrows 141 turned so that they put the metal band together with additional, not subscribed, for example Transport rollers having transport in the by an arrow designated transport direction 143 in the Fig. 15 from left to right transport.
  • the device 131 further includes a supply device not shown to supply the two rollers 137 with an antiblocking agent.
  • the non-stick agent comes with the two rollers 137 at the wave crests 161 on the outside of the applied wave peak forming half wave.
  • the non-stick agent then forms non-stick pads 145, which the outer surfaces of the crest forming and / or comprehensive surface areas of the metal strip 135 via its entire width, i. along the whole length of the Cover wave crests.
  • the device 131 also has a spraying device 151 with at least one spray nozzle 153 and namely with at least two on different sides of the metal strip 131 arranged spray nozzles 153 to the metal strip 135 to spray.
  • the two spray nozzles are in relation to the transport direction 143 arranged behind the rollers 137. If that Metal strip is moved past the spray nozzles 153, spray these at least one of an aqueous solution and / or Dispersion existing coating material on the two opposite sides or surfaces of the metal strip 131 on.
  • the coating material 155 contains at least one for Formation of a porous "washcoat" metal oxide and catalytically active material, namely at least one Precious metal.
  • the at least one metal oxide and the at least one precious metal in one and the same Solution and / or dispersion may be included as well as together the metal strip 135 are sprayed on. It is, however possible, the at least one metal oxide and the at least a precious metal in succession with different spray nozzles to spray on the metal band.
  • the am Metal tape adhering coating material is then dried and then forms solid coatings 157.
  • the coating material 155 for example, be sprayed so that the Coats 157 are roughly the same everywhere and everywhere have about the same composition.
  • the spraying it may also be done in such a way that the thicknesses the coatings and / or the per unit area existing Quantities of the catalytically active material in one vary in the desired, predetermined manner.
  • the anti-adhesive pads 145 are after spraying and drying the coating material 155 and before joining the already mentioned Sheet metal elements 125, 127 and / or possibly when connecting the Sheet metal elements removed again. Removing the anti-adhesive pads For example, with the help of a solvent or by heating and melting and possibly Evaporation and / or burning take place.
  • the provided with the coatings 157 corrugated metal strip 135 is used before or after removing the non-stick pads cut into pieces that are all the same size and the first sheet metal elements 125 and second sheet metal elements 127th form.
  • Three of the sheet metal elements 125, 127 are partially in the Figures 16 and 18 can be seen.
  • the waves of the sheet metal elements have Wave crests, those in Figs. 16-18 like those of the metal strip 135 in Fig. 15 are designated 161.
  • the Shafts also have wave flanks 163.
  • Each sheet metal element 125, 127 has one of the originally bare metal band 135th formed, metallic core 167, applied to this Covers that like those of the metal band with 157 and coating-free areas 159.
  • the two fine surfaces of each sheet metal element in its Wave crests two mutually parallel planes.
  • Each of the Sheet metal elements 125, 127 is in a vertical plan view on the planes defined by the wave crests square, namely rectangular or square and has accordingly, four edges, two of which Longitudinal edges of the metal strip 135 are formed and in Below also as longitudinal edges or first edges of the Be designated sheet metal element.
  • the longitudinal edges or first Edges of each sheet metal element 125, 127 are corrugated.
  • each sheet metal element extends in the top view at right angles to the longitudinal edges or first edges of the sheet metal element.
  • the coatings 157 and the Plain-free regions 159 extend from one Longitudinal edge or first edge to the opposite longitudinal edge or first edge of the sheet metal elements 125, 127. Further form the non-overlapping areas of course the same as the Wave crest 161 with a different angle of 90 ° ⁇ the longitudinal edges or first edges of the sheet metal elements.
  • the cut sheet metal elements 125, 127 are in the in such a way indicated in Fig. 16 to a stack 123 arranged that alternately a first sheet metal element 125 and a second plate member 127 follow each other and one each form first and second sheet-metal element layer and that the Waves and in particular the wave crests 161 of each other pairs of adjacent sheet metal elements intersect each other. If the sheet metal elements 125, 127 brought to abut each other be, they touch each other in pairs at touch areas, schematically shown in Fig. 17 and with 165 and part of the outside on the Wave crests existing, coating-free areas 159 are formed.
  • the stack 123 formed by the sheet metal elements 125, 127 is analogous to that shown in Fig. 7 stack 3 of Sheet metal elements 5 and 7 between two electrodes of a Welding device arranged and compressed. Then become the sheet metal elements by resistance welding welded together.
  • the needed for welding Electricity can be used, for example - as was the case with the Description of Fig. 7 was mentioned - by unloading a electrical capacitor can be generated.
  • the stack 123 of then welded together sheet metal elements 125, 127 is then in the metallic, in Fig. 17 apparent sleeve 129th used. This is similar to that shown in Fig. 10 Sleeve 9 is formed like this has four walls, is at both Ends open and rectangular or square in cross-section.
  • the stack 123 is thereby inserted into the sleeve 129, that the longitudinal direction of the four walls of the sleeve 129 and the from this limited, through hole perpendicular to the previously defined longitudinal edges or first edges of Sheet metal elements 125, 127 are.
  • the stack 123 is in the sleeve 129 fixed, for example, in some places with this welded.
  • the Waves and wave crests 161 of the pairs together adjacent sheet metal elements 125, 127 and sheet metal layers together together form a peak different from 90 ° Angle ⁇ .
  • the waves and wave crests 161 of each other neighboring and in places in pairs welded sheet metal elements 125, 127 form with the general passage direction 171 and / or general Exhaust gas flow direction 171 the angle ⁇ / 2.
  • the exhaust gas is therefore, when flowing through a passage through the shafts and the present in the passage at the contact areas 165 Welded connections from the general passage direction 171 and / or general exhaust gas flow direction locally distractedly different.
  • the angle ⁇ between the Wave crests 161 and the longitudinal edges or first edges the sheet metal elements is preferably at least 60 °, preferably at most 85 ° and for example 70 ° to 80 °.
  • Angle ⁇ / 2 is then preferably at least 5 °, preferably at most 30 ° and for example 10 ° to 20 °.
  • angle ⁇ is preferably at least 10 °, preferably at most 60 ° and for example 20 ° to 40 °.
  • the coatings 157 and coating-free areas 159 of Sheet metal elements 125, 127 are particularly clear in FIG. 18 seen. To this figure is still to be noted that the Sheet metal elements in this figure along a cutting plane are cut, which forms the angle ⁇ / 2 with the waves and so not at right angles to the waves runs.
  • the Wave crests 161 have on their outside at their highest point a narrow surface section, which in one vertical section to the wave crests as well as in the Fig. 18 apparent section bent rather flat and almost even or even - as in the in Figures 8, 9 apparent wave crests 37 - is exactly the same.
  • the bare, non-coated areas 159 extend in these cuts and directions especially on both sides of the contact areas A little bit beyond this, right up to the curved ones Transition portions which the wave crest 161 with the these adjoining corrugations connect, and / or even a little bit into the ripples. Since the bare, non-coated areas 159 of the surfaces of the corrugated sheet metal elements 125, 127 over the entire length of the Waves and wave crests 161 extend, the Plain areas also in the to the waves as well Wave crest parallel direction of the sheet metal element in question a greater extent than the contact areas. The coating-free regions 159 therefore protrude at all Touch areas 165 that are not exactly on one edge a sheet metal element to the whole area of contact around beyond this.
  • the coatings are at the wave crests 161 only on the outer, convex side of the Wave crest forming half wave by a coating-free Area 159 interrupted.
  • the inner, concave side of the crest a section of a Coating present with the coating sections on the inner, facing sides of the concerned with the Wave crest 161 contiguous wave edges 163 related.
  • the methods and the catalyst bodies produced can still be changed in other ways. It could be for Example certain features of various described Process and the prepared catalyst body parts be combined with each other. So can the formation of corrugated metal elements serving metal bands also in the With reference to the figures 1 to 14 described embodiments may be curled before the coatings be applied. The partially shown in Fig. 13 Winding could take place from an unwashed and a corrugated sheet metal element of two corrugated sheet metal elements with be formed crossing each other waves. Instead of the Formation of coatings coating material in one of Based on the figures 1, 4, 15 described species Spraying metal strips may be similar to the cover material as with other printing processes known from printing technology be printed or applied on metal bands such that the desired coatings and coating-free areas arise.
  • the described with reference to FIGS 15 to 18 The described with reference to FIGS 15 to 18 The method could be modified so that the separate pieces existing sheet metal elements 125, 127 through alternately consecutive, first and second Sheet metal layers are replaced, which consist of sections of a single continuous sheet metal element consist, the analog as shown in Fig. 14, the first sheet metal element 105th bent zigzag or meandering and / or folded is. Furthermore, the corrugated sheet metal elements 125, 127 - analogous as it already has as a possibility for the corrugated Sheet metal elements 83, 85 was mentioned - only in the Touch areas and in the vicinity of this Contact areas should be free of coating.
  • the coating-free Areas would not be over the entire length of the Wave crests extend, but should preferably also in The direction of the crests a slightly larger dimension as the touch areas have and anyway so sized be that the sheet metal elements with bare, metallic Surfaces rest on each other.
  • the Sheet metal elements may be replaced by resistance welding by another cohesive joining method, for Example by another welding process or by Brazing or sintering at the contact areas joined together and fixed by joining connections as well inextricably linked together. So you could go to Example in the partially shown in Fig. 13 winding 93 provide the sheet metal elements instead of by welding through Brazing together.

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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)
  • Catalysts (AREA)
EP04405671A 2003-11-05 2004-11-03 Corps de catalyseur et son procédé de fabrication Expired - Lifetime EP1529934B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CH19012003 2003-11-05
CH19012003 2003-11-05

Publications (2)

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EP1529934A1 true EP1529934A1 (fr) 2005-05-11
EP1529934B1 EP1529934B1 (fr) 2007-08-22

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EP (1) EP1529934B1 (fr)
AT (1) ATE371102T1 (fr)
DE (1) DE502004004710D1 (fr)
ZA (1) ZA200408957B (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1918011A1 (fr) * 2006-10-23 2008-05-07 Scambia Industrial Developments AG Dispositif pour la conversion catalytique et pour la filtration de particules contenues dans un gas d'échappement
EP1721694B1 (fr) * 2005-05-11 2008-05-28 Scambia Industrial Developments Aktiengesellschaft Procédé de fabrication d'au moins un élément métallique en tôle, procédé de fabrication d'au moins un corps catalytique, élément métallique en tôle et corps catalytique
WO2010122006A1 (fr) * 2009-04-22 2010-10-28 Emitec Gesellschaft Für Emissionstechnologie Mbh Procédé de production d'un corps en nid d'abeilles revêtu

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0049489A1 (fr) * 1980-10-07 1982-04-14 INTERATOM Gesellschaft mit beschränkter Haftung Procédé de fabrication d'une garniture interieure d'un catalysateur d'echappement
US5094074A (en) * 1990-02-23 1992-03-10 Nissan Motor Co., Ltd. Catalytic converter with metallic carrier and method for producing same
EP0674944A1 (fr) * 1994-03-31 1995-10-04 Degussa Aktiengesellschaft Procédé de fabrication d'un support métallique monolithique revêtu
US20020197580A1 (en) * 2001-04-30 2002-12-26 Richard Carroni Device for burning a gaseous fuel/oxidant mixture
EP1300555A2 (fr) * 2001-08-08 2003-04-09 ALSTOM (Switzerland) Ltd Catalyseur

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0049489A1 (fr) * 1980-10-07 1982-04-14 INTERATOM Gesellschaft mit beschränkter Haftung Procédé de fabrication d'une garniture interieure d'un catalysateur d'echappement
US5094074A (en) * 1990-02-23 1992-03-10 Nissan Motor Co., Ltd. Catalytic converter with metallic carrier and method for producing same
EP0674944A1 (fr) * 1994-03-31 1995-10-04 Degussa Aktiengesellschaft Procédé de fabrication d'un support métallique monolithique revêtu
US20020197580A1 (en) * 2001-04-30 2002-12-26 Richard Carroni Device for burning a gaseous fuel/oxidant mixture
EP1300555A2 (fr) * 2001-08-08 2003-04-09 ALSTOM (Switzerland) Ltd Catalyseur

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1721694B1 (fr) * 2005-05-11 2008-05-28 Scambia Industrial Developments Aktiengesellschaft Procédé de fabrication d'au moins un élément métallique en tôle, procédé de fabrication d'au moins un corps catalytique, élément métallique en tôle et corps catalytique
EP1918011A1 (fr) * 2006-10-23 2008-05-07 Scambia Industrial Developments AG Dispositif pour la conversion catalytique et pour la filtration de particules contenues dans un gas d'échappement
WO2010122006A1 (fr) * 2009-04-22 2010-10-28 Emitec Gesellschaft Für Emissionstechnologie Mbh Procédé de production d'un corps en nid d'abeilles revêtu
CN102414411A (zh) * 2009-04-22 2012-04-11 排放技术有限公司 用于制造带涂层的蜂窝体的方法
JP2012524652A (ja) * 2009-04-22 2012-10-18 エミテック ゲゼルシヤフト フユア エミツシオンス テクノロギー ミツト ベシユレンクテル ハフツング コーティングされたハニカム体を製造するための方法
US8444741B2 (en) 2009-04-22 2013-05-21 Emitec Gesellschaft Fuer Emissionstechnologie Mbh Coated honeycomb body and method for producing a coated honeycomb body
KR101308287B1 (ko) 2009-04-22 2013-09-13 에미텍 게젤샤프트 퓌어 에미시온스테크놀로기 엠베하 코팅된 허니콤 몸체 제조 방법
RU2536739C2 (ru) * 2009-04-22 2014-12-27 Эмитек Гезельшафт Фюр Эмиссионстехнологи Мбх Способ изготовления снабженного покрытием сотового элемента

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ZA200408957B (en) 2005-07-27
DE502004004710D1 (de) 2007-10-04
ATE371102T1 (de) 2007-09-15
EP1529934B1 (fr) 2007-08-22

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