EP1685313B1 - Konverter für abgase von verbrennungsmotoren - Google Patents

Konverter für abgase von verbrennungsmotoren Download PDF

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Publication number
EP1685313B1
EP1685313B1 EP04769659A EP04769659A EP1685313B1 EP 1685313 B1 EP1685313 B1 EP 1685313B1 EP 04769659 A EP04769659 A EP 04769659A EP 04769659 A EP04769659 A EP 04769659A EP 1685313 B1 EP1685313 B1 EP 1685313B1
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EP
European Patent Office
Prior art keywords
panels
converter according
metallic
converter
converting system
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Expired - Fee Related
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EP04769659A
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English (en)
French (fr)
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EP1685313A1 (de
Inventor
Paolo Della Porta
Giovanni Salvago
Stefano Zilio
Giorgio Vergani
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SAES Getters SpA
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SAES Getters SpA
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Priority claimed from ITMI20032210 external-priority patent/ITMI20032210A1/it
Priority claimed from ITMI20040847 external-priority patent/ITMI20040847A1/it
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Publication of EP1685313A1 publication Critical patent/EP1685313A1/de
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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
    • 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
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • 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
    • F01N3/18—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 methods of operation; Control
    • F01N3/20—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 methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • 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
    • 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
    • F01N3/2817—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates only with non-corrugated sheets, plates or foils
    • 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
    • F01N3/2821—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates the support being provided with means to enhance the mixing process inside the converter, e.g. sheets, plates or foils with protrusions or projections to create turbulence
    • 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
    • F01N3/2835—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support fibrous
    • 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
    • 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
    • F01N2330/10—Fibrous material, e.g. mineral or metallic wool
    • 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
    • F01N2330/10—Fibrous material, e.g. mineral or metallic wool
    • F01N2330/101—Fibrous material, e.g. mineral or metallic wool using binders, e.g. to form a permeable mat, paper or the like
    • 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
    • F01N2330/38—Honeycomb supports characterised by their structural details flow channels with means to enhance flow mixing,(e.g. protrusions or projections)

Definitions

  • the present invention relates to a converter for internal combustion engines, and in particular to a device which can be employed for oxidation of the exhaust gases of these engines.
  • US patent 5,294,411 discloses a device for treating exhaust gases, which comprises a honeycomb structure rolled up like a spiral, which has a catalytically active continuous surface on a ceramic or metallic substrate, in which the flow of the exhaust gases follows linear paths, flowing in a multiplicity of channels defined by the structure itself, all parallel to each other and to the direction of said flow.
  • a device of this kind essentially presents two problems: first, the total surface available for the contact with gases, which corresponds to the development of the spiral structure, is not particularly wide and the ratio between the volume of the device and the geometrical surface over which the catalyst is spread is not advantageous; second, the strictly linear geometry of the channels is such that the gas flow through the structure is prevalently laminar, thereby not allowing an optimal exploitation of the catalyst.
  • Patent application WO 97/02092 discloses a device for treating exhaust gases obtained from a perforated metallic sheet or a metallic net onto which is deposited a ceramic porous layer preferably made of alumina or zirconia, which is subsequently impregnated with a solution or suspension of a catalyst precursor. Also in this case, however, the available catalytic surface is not very wide, and therefore the conversion efficiency is limited. It is therefore an object of the present invention to provide a converter for exhaust gases which is free from said disadvantages.
  • a converter for exhaust gases of internal combustion engines comprising a housing which is provided with at least one inlet opening for the exhaust gases to be converted and with at least one outlet opening for the converted gases and includes a converting system, characterized in that said converting system comprises a plurality of panels of fibers comprising a metallic core covered with a layer of oxides over which catalytically active metals are present, said panels being arranged with an edge facing the inlet opening and with another edge facing the outlet opening, essentially parallel to each other, and kept spaced apart by means of metallic spacers.
  • the metallic panels of the invention functionalized with catalysts, have a contact surface notably increased with respect to the perforated plates and metallic nets of the known devices.
  • the arrangement according to the invention comprising panels and spacers, causes a turbulent gas flow in the converter, such that the gas in its path between the inlet and the outlet is compelled to pass, at least partially, through said panels.
  • FIG 1 shows an exploded view of a converter of the invention, 10, including a converting system 11 comprising a plurality of panels 12; converter 10 comprises in a known way a housing 13 having at least an inlet opening 14 for the exhaust gases to be treated coming from an internal combustion engine, and at least an outlet opening 15 for the gases treated by system 11.
  • the panels are preferably surrounded by metallic elements 16 (not shown in this figure) forming a frame fixed to the panel edges by any suitable means, for instance by mechanical crimping: this frame helps in keeping the flatness of panel 12 during thermal cycling (both the thermal treatments for oxidizing and functionalizing the panels, and the thermal cycling due to operation downstream the engine), and to avoid the loss of fibers at the panel edges.
  • Converter 10 may comprise a flange around the perimeter of the outlet 15 (not shown in this figure).
  • system 11 comprises a plurality of panels 12 kept at the desired distance by metallic spacers.
  • the inventors have found that good results are obtained if this distance is kept in the range between about 1 and 4 mm. With distances lower than 1 mm the packing of panels gets too crowded and system 11 causes a too high gas pressure drop.
  • too high distances have the drawback of reducing the number of panels of kind 12, and thus the catalytic surface active in gas treatment; besides, if the distance between panels is too high, the effect of generating a turbulent motion in the gas flow is reduced, and at least a part of the gas could cross system 11 without getting in contact with the catalyst placed on the panels of kind 12.
  • Optimal values of the distance between adjacent panels are in the range between about 2 and 3 mm.
  • FIG. 2 shows a panel 12 used in the system of the invention, in the preferred embodiment comprising surrounding metallic elements 16.
  • the panel is a mat of metallic fibers, that are generally caused to adhere to each other by sintering.
  • the fibers may be made of steel or, preferably, of an alloy containing iron, chrome and aluminum, plus small percentages of other elements, known as Fecralloy ® (trademark registered by UKAEA, Didcot, Great Britain). This alloy turned out to be particularly suitable for the prolonged use at high temperatures, as in the uses intended for catalytic converters or filters for internal combustion engines.
  • Panels made of Fecralloy ® fibers can be obtained from the company N.V. Bekaert SA, of Zwevegem, Belgium, and are marketed with the name Bekipor ® ; these panels can be shaped according to different geometries and adapted to the different kinds of use.
  • Figure 3 shows in section a fiber used in making panel 12 (the parts of the fiber are shown not in scale); in the figure, it is shown a fiber with a rectangular cross-section, as this is the most typical form of Fecralloy ® fibers, but obviously the fibers could have other sections, e.g. circular.
  • Fiber 30 comprises a Fecralloy ® core 31 covered with a layer of oxides, 32, that carries the catalyst 33.
  • the layer of oxides is generally a multilayer made up of two or three layers of oxide, different from each other as to chemical composition or physical properties.
  • a first oxide layer, 32' is grown on the surface of the Fecralloy ® fibers by means of a high temperature treatment in an oxidizing atmosphere: the oxide layer formed with this treatment consists mainly of aluminum oxide whiskers, having length generally comprised between 0.5 and 5 microns ( ⁇ m), depending upon time and temperature of the treatment; preferably the whiskers have length lower than 3 ⁇ m.
  • the oxide forming these whiskers is generally very dense and uniform.
  • the subsequent step of the process consists of forming a second oxide layer, 32", over the first one.
  • This second oxide layer unlike the first one, is porous and has a high specific surface; this may consist again of aluminum oxide, or may be a different oxide.
  • the second oxide layer can be obtained by spraying onto the mat of sintered metallic fibers a solution of a precursor compound of the oxide, or by immersing the mat in the same solution followed by thermal decomposition of the precursor.
  • the second oxide layer can be obtained by immersing the mat into a liquid suspension of precursor particles and a subsequent calcination.
  • a third layer of oxides, 32"' is formed onto the second oxide layer. This layer too has a high specific surface.
  • Optional layer 32"' generally consists of a mixed oxide of cerium and zirconium (with the optional addition of lanthanum), and has the property of limiting the sintering of the catalytic metals, thereby ensuring their dispersion over time and thus helping to keep a high efficiency of the converter, as well as of being a reservoir of oxygen for the oxidation of the unburned gases leaving the engine.
  • the outer oxide layer (either 32" or 32"'), thanks to its porous structure, is an optimal support for the catalytic metals, assuring the dispersion of the metal and its good anchoring to the fiber surface.
  • the functionalization of the oxide layer with the catalyst 33 is necessary for the intended use of the fibrous panel.
  • the catalyst is preferably one or more noble metals chosen among those of the eighth group of the periodic table or their compounds; preferred is the use of platinum.
  • FIG 4 shows a partial exploded view of a first possible embodiment of system 11.
  • system 11 comprises a stacking of panels 12 alternate to metallic sheets 40 (only two panels and one metallic sheet are shown; metallic elements of kind 16 are not shown); these sheets present a plurality of protrusions, 41, 41', ..., extending from both faces of a sheet.
  • the protrusions are all of same height, so as to offer a plurality of contact points onto which two panels 12 (one per side of sheet 40) can lay.
  • Sheets 40 are made with high-temperature resistant metals; preferably these sheets too are made with the same Fecralloy ® used for producing the fibers of panels 12. These sheets are generally as thin as possible, compatibly with the necessary mechanical resistance at high temperatures; optimal thickness values are comprised between 0.15 and 0.45 mm.
  • Figure 5 shows, in a view similar to that of figure 4, a slightly different embodiment of system 11; in this case sheets 50 (analogous to sheets 40) present, besides protrusions 51, 51', ..., a plurality of holes 52, 52', ...; this arrangement helps in enhancing the turbulence of motion of the gas in its passage across system 11, thereby increasing the efficiency of the contact between the gas and panels 12, and as a consequence the efficiency of system 11 in gas treatment; in figure 5 the holes are shown circular, but their shape could be essentially any. In a system 11 comprising sheets of kind 50, it is preferable that holes do not take more than 50% of the surface of the sheet, in order not to cause structural problems to this latter when system 11 works at high temperatures
  • FIG. 6 is an example of this embodiment.
  • sheet 60 has openings 61 obtained by partially cutting the sheet obtaining "wings” 62 joined to the sheet along at least a margin, and bending these "wings” along said margin; the dimensions of the "wings” and their bending angle with respect to the sheet plane will determine the distance between the surface of sheet 60 and that of the adjacent panel 12, so that these "wings” constitute the spacers in this embodiment; figure 6 shows rectangular “wings” (and openings), but obviously any other suitable form could be adopted. Cuts on sheet 60 defining these "wings” may be practiced by mechanical shearing, laser cutting or any other known method.
  • the various kinds of systems 11 so far described are preferably inserted into a metallic casing, surrounding the system on all sides but inlet and outlet sides, which is then in turn inserted into housing 13; preferably, between this metallic casing and housing 13, ceramic fibers plates are disposed for thermal insulation reasons.
  • Figure 7 shows a panel 12 that can be used for still another embodiment of system 11 of the invention; for the sake of representation clarity, this figure shows the assembly of the panel with a few spacers.
  • the spacers 70 are metallic sheets having a geometric area that is a small fraction of the geometric area of panels 12 (contrary to sheets 40, 50 and 60), and rolled up in a such fashion that any contact points with adjacent panels are curved and smooth.
  • Spacers 70 are kept in place by fixing them (e.g., by spot welding) onto metallic tapes 71; tapes 71 are as narrow as possible, compatibly with the needs of being enough mechanically strong and of offering a sufficient area for fixing spacers 70.
  • tapes 71 are kept in place by fixing them (e.g., again by spot welding) to two metallic elements of kind 16, fixed by crimping to the two lateral edges of panel 12 (with respect to the gas flow direction in converter 10, indicated by the arrow); while the other two elements of kind 16 (the ones facing inlet 14 and outlet 15 of converter 10) could be joined to the panel before the thermal oxidation treatments of the fibers, the two lateral elements of kind 16 are better added to panel 12 at the end of its production, in order to avoid their oxidation and guarantee good welding characteristics to tapes 71.
  • spacers of kind 70 are present on the other face, hidden in the figure, of panel 12: the spacers are preferably placed in the same positions on all panels of the converter system, so that by stacking a plurality of panels the spacers form a kind of pillar, having an overall effect of strengthening the structure.
  • Figure 8 shows in an exploded view the preferred assembly of system 11 when spacers of kind 70 are used: for the sake of clarity, no spacers are shown in this figure.
  • the panels are better inserted in two lateral holding members, 80, 80', having the shape of a Greek fret.
  • Panels 12 can be fixed to members 80, 80' by mechanical crimping of the sections of the fret onto lateral elements of kind 16, the same elements bearing tapes 71.
  • the assembly made up of panels and holding members is in turn inserted in a metallic casing 81, surrounding the four faces of the assembly parallel to the flow of gases, but open at the inlet and outlet sides.
  • passageways 82 are filled with a high-temperature resistant glue (not shown in figure); these glue normally comprise metallic powders (e.g., steel powders) in an inorganic binder; a suitable glue is Durabond 954, sold by COTRONICS Corp. of Brooklyn, NY (USA).
  • a high-temperature resistant glue normally comprise metallic powders (e.g., steel powders) in an inorganic binder; a suitable glue is Durabond 954, sold by COTRONICS Corp. of Brooklyn, NY (USA).
  • the assembly is completed by joining on its back and front faces two frames, 83, 83', that concur in ensuring that no passageways are left for gases coming from the engine to by-pass the system 11; frames 83, 83', are joined to front and back elements of kind 16 of panels 12, to the ends of holding members 80, 80', and possibly to casing 81 again by means of gluing.
  • the converter according to the invention by comprising panels produced with metal fibers, is particularly suitable for its arrangement as close as possible to the motor (configuration known in the field as "Close Coupled Catalyst" or CCC), i.e. in the position ensuring that the converter works at the maximum temperature, thus obtaining a high conversion efficiency.
  • CCC Compact Coupled Catalyst
  • the converter of the invention can tolerate sudden changes of temperature, as those expected in the modem systems for abating pollutants coming from internal combustion engines.
  • converter system of the invention Another important advantage offered by the converter system of the invention is the low weight of the support material compared to a honeycomb converter systems of the prior art occupying the same volume (and thus having about the same amount of catalytic metals and essentially the same conversion efficiency).
  • the inventors have prepared different kinds of converter systems of the invention and, by measuring their weights and volumes, it has been found that these have on average a weight of 0.28 grams per cubic centimeter of the system; on the other hand, a similar measure on prior art systems has revealed an average weight of about 0.62 grams per cubic centimeter.

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

Claims (15)

  1. Konverter (10) für die Abgase von Verbrennungsmotoren, welcher ein Gehäuse (13) umfasst, das mit mindestens einer Einlassöffnung (14) für die umzuwandelnden Abgase und mit mindestens einer Auslassöffnung (15) für die umgewandelten Gase versehen ist und ein Umwandlungssystem (11) enthält, dadurch gekennzeichnet, dass das Umwandlungssystem eine Vielzahl von Platten (12) aus Fasern (30) umfasst, die einen Metallkern (31), der mit einer Schicht (32) aus Oxiden überzogen ist, auf welcher katalytisch aktive Metalle (33) vorhanden sind, umfassen, wobei die Platten so angeordnet sind, dass sie im Wesentlichen parallel zueinander mit einer Kante zur Einlassöffnung und einer anderen Kante zur Auslassöffnung gerichtet sind und von metallischen Abstandshaltern (41, 41'; 51, 51'; 62; 70) voneinander beabstandet gehalten werden.
  2. Konverter nach Anspruch 1, wobei der Kern (31) aus den Fasern (30) aus einer Eisen, Chrom und Aluminium enthaltenden Legierung hergestellt und mit einer Mehrfachschicht (32) aus Oxiden bedeckt ist, die eine erste Schicht (32') aus Aluminiumoxid, die sich mit der Legierung in Berührung befindet, eine zweite Oxidschicht (32") und wahlweise eine dritte Schicht (32''') aus Cer-, Zirconium- und wahlweise Lanthanoxid umfasst.
  3. Konverter nach Anspruch 2, wobei die Mehrfachschicht (32) mit einem oder mehreren Katalysatoren (33) beschichtet ist, die aus den Edelmetallen der achten Gruppe des Periodensystems oder ihren Verbindungen ausgewählt sind.
  4. Konverter nach Anspruch 3, wobei der Katalysator aus Platin besteht.
  5. Konverter nach Anspruch 1, wobei das Umwandlungssystem (11) aus von Metallelementen (16) umgebenen Platten (12) hergestellt ist.
  6. Konverter nach Anspruch 1, wobei der Abstand zwischen zwei einander benachbarten Platten (12) des Umwandlungssystems (11) 1 bis 4 mm beträgt.
  7. Konverter nach Anspruch 1, wobei der Abstand zwischen zwei einander benachbarten Platten (12) des Umwandlungssystems (11) 2 bis 3 mm beträgt.
  8. Konverter nach Anspruch 1, wobei das Umwandlungssystem (11) eine abwechselnde Übereinander-Anordnung von Platten (12) und auf beiden Seiten Vorsprünge (41, 41') aufweisenden Metallblechen (40) umfasst.
  9. Konverter nach Anspruch 1, wobei das Umwandlungssystem (11) eine abwechselnde Übereinander-Anordnung von Platten (12) und Metallblechen (50) umfasst und diese Bleche Vorsprünge (51, 51') auf beiden Seiten und Löcher (52, 52'), die den Durchgang der umzuwandelnden Gase von einer Seite des Blechs zur anderen erlauben, aufweisen.
  10. Konverter nach Anspruch 9, wobei die Vorsprünge und die Löcher übereinstimmen und durch Anbringen von Einschnitten in den Blechen (60), wodurch Klappen (62) erhalten wurden, die entlang mindestens eines Randes mit dem Blech verbunden sind, und Aufbiegen der Klappen entlang dieses Randes, wodurch die Löcher (61) erhalten wurden, gebildet worden sind.
  11. Konverter nach Anspruch 5, wobei das Umwandlungssystem (11) einen Stapel aus Platten (12) umfasst, die auf den gewünschten Abstand von Abstandshaltern (70) gehalten werden, die Metallbleche sind, welche eine geometrische Fläche haben, die kleiner als diejenige der Platten ist, und welche derart aufgewickelt worden sind, dass die Berührungspunkte mit den benachbarten Platten gekrümmt und glatt sind.
  12. Konverter nach Anspruch 11, wobei die Abstandshalter (70) an ihrer Stelle durch Befestigung an Metallbändern (71) gehalten werden, die ihrerseits durch Befestigung an zwei die Platte umgebenden Metallelementen (16) an ihrer Stelle gehalten werden.
  13. Konverter nach Anspruch 12, wobei die zwei Metallelemente (16) diejenigen an den zu dem Gasstrom im Konverter parallel stehenden Seiten der Platte sind.
  14. Konverter nach Anspruch 13, wobei die zu dem Gasstrom im Konverter parallel stehenden Seiten der Platte von zwei seitlichen Haltemitteln (80, 80') mit der Form eines Mäanders gehalten werden, die aus Platten (12) und Haltemitteln (80, 80') aufgebaute Einheit in einen Metallkasten (81) eingebaut ist, der die zu dem Gasstrom in dem Konverter parallel stehenden vier Seiten der Einheit umgibt, aber auf der Einlass- und der Auslassseite offen ist, die Durchgänge (82) zwischen den Haltemitteln (80, 80') und dem Kasten (81) mit einem hochtemperaturbeständigen Klebstoff ausgefüllt sind und zwei Metallrahmen (83, 83') mit den vorderseitigen und rückseitigen umgebenden Elementen (16) der Platten (12), den Enden der Haltemittel (80, 80') und wahlweise dem Kasten (81) verbunden sind.
  15. Konverter nach einem der vorhergehenden Ansprüche, wobei das Umwandlungssystem (11) in einen Kasten (81) eingebaut ist, der in dem Gehäuse (13) des Konverters (10) angeordnet ist, wobei zwischen dem Kasten und dem Gehäuse Keramikplatten eingefügt sind.
EP04769659A 2003-11-14 2004-10-18 Konverter für abgase von verbrennungsmotoren Expired - Fee Related EP1685313B1 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
ITMI20032210 ITMI20032210A1 (it) 2003-11-14 2003-11-14 Convertitore di gas di scarico di motori a combustione interna.
ITMI20040847 ITMI20040847A1 (it) 2004-04-28 2004-04-28 Convertitore di gas di scarico di motori a combustione interna
PCT/IB2004/003398 WO2005047664A1 (en) 2003-11-14 2004-10-18 Converter for exhaust gases of internal combustion engines

Publications (2)

Publication Number Publication Date
EP1685313A1 EP1685313A1 (de) 2006-08-02
EP1685313B1 true EP1685313B1 (de) 2006-12-27

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EP04769659A Expired - Fee Related EP1685313B1 (de) 2003-11-14 2004-10-18 Konverter für abgase von verbrennungsmotoren

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EP (1) EP1685313B1 (de)
JP (1) JP2007511699A (de)
KR (1) KR20060121190A (de)
DE (1) DE602004003975T2 (de)
WO (1) WO2005047664A1 (de)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018078587A1 (en) * 2016-10-28 2018-05-03 Basf Corporation Catalytic and sorptive articles comprising metal fiber felt substrates
KR102039518B1 (ko) * 2018-02-26 2019-11-01 희성촉매 주식회사 촉매의 시공간 방출 평가를 위한 고효율 차량 시험장치

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4280926A (en) * 1978-09-12 1981-07-28 Sakai Chemical Industry Co., Ltd. Method for producing a catalyst and a carrier therefor
JPS57174145A (en) * 1981-04-20 1982-10-26 Kawasaki Heavy Ind Ltd Platelike catalytic body for denitration
US5102745A (en) * 1989-11-13 1992-04-07 Auburn University Mixed fiber composite structures
JPH0685877B2 (ja) * 1991-01-23 1994-11-02 株式会社荏原製作所 触 媒
AU3520000A (en) * 1999-03-09 2000-09-28 Abb Lummus Global Inc. Exhaust gas catalytic converter
JP2002191986A (ja) * 2000-12-26 2002-07-10 Babcock Hitachi Kk 排ガス浄化用触媒構造体およびその形成に用いるメタルラス板
JP2003071286A (ja) * 2001-09-03 2003-03-11 Toyota Central Res & Dev Lab Inc 低温有害ガス浄化触媒
JP3872675B2 (ja) * 2001-10-22 2007-01-24 三菱重工業株式会社 排煙処理装置

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DE602004003975D1 (de) 2007-02-08
KR20060121190A (ko) 2006-11-28
JP2007511699A (ja) 2007-05-10
EP1685313A1 (de) 2006-08-02
DE602004003975T2 (de) 2007-10-18
WO2005047664A1 (en) 2005-05-26

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