JP2020124688A - 排ガス浄化用のメタル基材及びそれを用いた排ガス浄化装置 - Google Patents
排ガス浄化用のメタル基材及びそれを用いた排ガス浄化装置 Download PDFInfo
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- 229910052751 metal Inorganic materials 0.000 title claims abstract description 103
- 239000002184 metal Substances 0.000 title claims abstract description 103
- 239000000758 substrate Substances 0.000 title claims abstract description 17
- 238000000746 purification Methods 0.000 title claims description 31
- 239000011888 foil Substances 0.000 claims abstract description 225
- 239000000463 material Substances 0.000 claims description 84
- 239000003054 catalyst Substances 0.000 claims description 14
- 230000000052 comparative effect Effects 0.000 description 11
- 229910044991 metal oxide Inorganic materials 0.000 description 10
- 150000004706 metal oxides Chemical class 0.000 description 10
- 230000000694 effects Effects 0.000 description 6
- 229910000510 noble metal Inorganic materials 0.000 description 6
- 238000002474 experimental method Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000004080 punching Methods 0.000 description 5
- 238000002485 combustion reaction Methods 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 239000002243 precursor Substances 0.000 description 3
- 239000002002 slurry Substances 0.000 description 3
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 238000001354 calcination Methods 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 230000007774 longterm Effects 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 230000004323 axial length Effects 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 1
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 238000011056 performance test Methods 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000010970 precious metal Substances 0.000 description 1
- 229910001404 rare earth metal oxide Inorganic materials 0.000 description 1
- 229910052703 rhodium Inorganic materials 0.000 description 1
- 239000010948 rhodium Substances 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/10—Noble metals or compounds thereof
- B01D2255/102—Platinum group metals
- B01D2255/1021—Platinum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/10—Noble metals or compounds thereof
- B01D2255/102—Platinum group metals
- B01D2255/1023—Palladium
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/10—Noble metals or compounds thereof
- B01D2255/102—Platinum group metals
- B01D2255/1025—Rhodium
-
- 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
- F01N2330/02—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
- F01N2330/30—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)
-
- 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
- F01N2330/48—Honeycomb supports characterised by their structural details characterised by the number of flow passages, e.g. cell density
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Health & Medical Sciences (AREA)
- Combustion & Propulsion (AREA)
- Toxicology (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Biomedical Technology (AREA)
- Environmental & Geological Engineering (AREA)
- Analytical Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Catalysts (AREA)
- Exhaust Gas After Treatment (AREA)
- Exhaust Gas Treatment By Means Of Catalyst (AREA)
Abstract
Description
《態様1》
孔を有する波箔と孔を有する平箔とが積層されて筒状形状となっている排ガス浄化用の孔あきメタル基材であって、
前記波箔及び/又は前記平箔は、前記筒状形状の軸方向の全体にわたって孔を有する軸方向孔あき部分、及び前記筒状形状の軸方向の全体にわたって孔を有していない軸方向孔なし部分を有する、孔あきメタル基材。
《態様2》
前記波箔及び/又は前記平箔の前記軸方向孔なし部分の面積比率が、10%〜80%である、態様1に記載の孔あきメタル基材。
《態様3》
前記波箔及び/又は前記平箔の前記軸方向孔あき部分の開口率が、20〜80%である、態様1又は2に記載の孔あきメタル基材。
《態様4》
前記波箔及び前記平箔は、前記軸方向孔あき部分と前記軸方向孔なし部分とを有しており、前記波箔及び前記平箔の軸方向孔なし部分の面積比率が、それぞれ20%〜70%であり、かつ前記軸方向孔あき部分の開口率が、20〜80%である、態様1〜3のいずれか一項に記載の孔あきメタル基材。
《態様5》
前記波箔の軸方向孔なし部分の面積比率が、前記平箔の軸方向孔なし部分の面積比率よりも大きい、態様1〜4のいずれか一項に記載の孔あきメタル基材。
《態様6》
前記筒状形状の最外周に、前記軸方向孔なし部分が存在している、態様1〜5のいずれか一項に記載の孔あきメタル基材。
《態様7》
前記波箔及び/又は前記平箔の周方向の全体にわたって孔を有していない周方向孔なし部分が存在している、態様1〜6のいずれか一項に記載の孔あきメタル基材。
《態様8》
50個/平方インチ〜800個/平方インチのセルを有し、
前記波箔が、前記セルの平均開孔面積の2.0倍以上50倍以下の面積を有する複数の第1の孔を有し、
前記平箔が、前記セルの平均開孔面積の3.0倍以上100倍以下の面積を有する複数の第2の孔を有し、かつ
前記波箔の前記第1の孔の面積の平均値が、前記平箔の前記第2の孔の面積の平均値よりも小さい、
態様1〜7のいずれか一項に記載の孔あきメタル基材。
《態様9》
前記波箔の前記第1の孔の合計面積が、前記波箔の全ての孔の合計面積の60%以上であり、かつ/又は前記平箔の前記第2の孔の合計面積が、前記平箔の全ての孔の合計面積の60%以上である、態様8に記載の孔あきメタル基材。
《態様10》
触媒層がその表面に形成されている態様1〜9のいずれか一項に記載の孔あきメタル基材、及び前記メタル基材が挿入されている外筒を有する、排ガス浄化装置。
なお、本明細書において、軸方向の全体にわたって存在する軸方向孔あき部分と、周方向の全体にわたって存在する周方向孔なし部分とが重複する領域は、軸方向孔あき部分として考慮される。
図5(a)〜(d)に示されているような、軸方向孔なし部分の面積比率が0%の箔A(図5(a))、20%の箔B(図5(b))、47%の箔C(図5(c))、及び75%の箔D(図5(d))の箔を用意した。これらの箔は、20Cr−5Alのステンレス製で、50μmの厚みを有しており、図5(e)に示すように、パンチング孔の直径が4.5mmで、孔ピッチが6.2mmで、60°千鳥の孔配列であった。
以下の表2に記載の孔を有する波箔及び平箔を用いて、300個/平方インチのセル(セルの平均開孔面積:約2mm2)を有する孔あきメタル基材を製造した。さらに、これらの孔あきメタル基材に同一の触媒層を形成して、参考例1〜3及び比較参考例1〜9の排ガス浄化装置を製造した。比較参考例1〜5(グループA)では、波箔と平箔の孔を同じ大きさとした。比較参考例6〜7(グループB)では、波箔の孔を平箔の孔よりも大きくした。比較参考例8〜9(グループC)は、波箔の孔を平箔の孔よりも小さくしたものの、波箔の孔をセルの開孔径よりもわずかに大きい程度とした。なお、波箔及び平箔の孔は、円形で、かつそれぞれで同じ大きさとした。また、波箔及び平箔の開孔率は、50%であった。
1 波箔
1a 第1の孔
11 軸方向孔あき部分
12 軸方向孔なし部分
2 平箔
2a 第2の孔
21 軸方向孔あき部分
22 軸方向孔なし部分
23 端部分
24 周方向孔なし部分
3 セル
4 外筒
Claims (10)
- 孔を有する波箔と孔を有する平箔とが積層されて筒状形状となっている排ガス浄化用の孔あきメタル基材であって、
前記波箔及び/又は前記平箔は、前記筒状形状の軸方向の全体にわたって孔を有する軸方向孔あき部分、及び前記筒状形状の軸方向の全体にわたって孔を有していない軸方向孔なし部分を有する、孔あきメタル基材。 - 前記波箔及び/又は前記平箔の前記軸方向孔なし部分の面積比率が、10%〜80%である、請求項1に記載の孔あきメタル基材。
- 前記波箔及び/又は前記平箔の前記軸方向孔あき部分の開口率が、20〜80%である、請求項1又は2に記載の孔あきメタル基材。
- 前記波箔及び前記平箔は、前記軸方向孔あき部分と前記軸方向孔なし部分とを有しており、前記波箔及び前記平箔の軸方向孔なし部分の面積比率が、それぞれ20%〜70%であり、かつ前記軸方向孔あき部分の開口率が、20〜80%である、請求項1〜3のいずれか一項に記載の孔あきメタル基材。
- 前記波箔の軸方向孔なし部分の面積比率が、前記平箔の軸方向孔なし部分の面積比率よりも大きい、請求項1〜4のいずれか一項に記載の孔あきメタル基材。
- 前記筒状形状の最外周に、前記軸方向孔なし部分が存在している、請求項1〜5のいずれか一項に記載の孔あきメタル基材。
- 前記波箔及び/又は前記平箔の周方向の全体にわたって孔を有していない周方向孔なし部分が存在している、請求項1〜6のいずれか一項に記載の孔あきメタル基材。
- 50個/平方インチ〜800個/平方インチのセルを有し、
前記波箔が、前記セルの平均開孔面積の2.0倍以上50倍以下の面積を有する複数の第1の孔を有し、
前記平箔が、前記セルの平均開孔面積の3.0倍以上100倍以下の面積を有する複数の第2の孔を有し、かつ
前記波箔の前記第1の孔の面積の平均値が、前記平箔の前記第2の孔の面積の平均値よりも小さい、
請求項1〜7のいずれか一項に記載の孔あきメタル基材。 - 前記波箔の前記第1の孔の合計面積が、前記波箔の全ての孔の合計面積の60%以上であり、かつ/又は前記平箔の前記第2の孔の合計面積が、前記平箔の全ての孔の合計面積の60%以上である、請求項8に記載の孔あきメタル基材。
- 触媒層がその表面に形成されている請求項1〜9のいずれか一項に記載の孔あきメタル基材、及び前記メタル基材が挿入されている外筒を有する、排ガス浄化装置。
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
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JP2019019151A JP6742457B1 (ja) | 2019-02-05 | 2019-02-05 | 排ガス浄化用のメタル基材及びそれを用いた排ガス浄化装置 |
PCT/JP2020/004422 WO2020162510A1 (ja) | 2019-02-05 | 2020-02-05 | 排ガス浄化用のメタル基材、及びそれを用いた排ガス浄化装置 |
EP20753078.3A EP3922352A4 (en) | 2019-02-05 | 2020-02-05 | METALLIC BASE MATERIAL FOR EXHAUST GAS PURGE, AND EXHAUST GAS PURGE DEVICE USING THE SAME |
CN202080012114.1A CN113382802A (zh) | 2019-02-05 | 2020-02-05 | 排气净化用的金属基材和使用该金属基材的排气净化装置 |
US17/419,583 US20220080354A1 (en) | 2019-02-05 | 2020-02-05 | Metallic base material for exhaust purging, and exhaust purging device using same |
TW109103477A TWI813856B (zh) | 2019-02-05 | 2020-02-05 | 排氣淨化用的金屬基材、及使用該金屬基材的排氣淨化裝置 |
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- 2020-02-05 WO PCT/JP2020/004422 patent/WO2020162510A1/ja unknown
- 2020-02-05 EP EP20753078.3A patent/EP3922352A4/en active Pending
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TWI813856B (zh) | 2023-09-01 |
CN113382802A (zh) | 2021-09-10 |
EP3922352A4 (en) | 2022-10-26 |
JP6742457B1 (ja) | 2020-08-19 |
WO2020162510A1 (ja) | 2020-08-13 |
EP3922352A1 (en) | 2021-12-15 |
US20220080354A1 (en) | 2022-03-17 |
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