JP2021037439A - 電気加熱式担体、排気ガス浄化装置及び排気ガス浄化装置の製造方法 - Google Patents
電気加熱式担体、排気ガス浄化装置及び排気ガス浄化装置の製造方法 Download PDFInfo
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- JP2021037439A JP2021037439A JP2019158991A JP2019158991A JP2021037439A JP 2021037439 A JP2021037439 A JP 2021037439A JP 2019158991 A JP2019158991 A JP 2019158991A JP 2019158991 A JP2019158991 A JP 2019158991A JP 2021037439 A JP2021037439 A JP 2021037439A
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- electrode
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- honeycomb structure
- exhaust gas
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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
- F01N3/18—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
- F01N3/2006—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating
- F01N3/2013—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating using electric or magnetic heating means
-
- 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
- F01N3/2006—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating
- F01N3/2013—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating using electric or magnetic heating means
- F01N3/2026—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating using electric or magnetic heating means directly electrifying the catalyst substrate, i.e. heating the electrically conductive catalyst substrate by joule effect
-
- 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
-
- B01J35/56—
-
- 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
- F01N13/18—Construction facilitating manufacture, assembly, or disassembly
-
- 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
-
- 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
- F01N3/2825—Ceramics
-
- 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
- F01N3/2825—Ceramics
- F01N3/2828—Ceramic multi-channel monoliths, e.g. honeycombs
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
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Abstract
Description
(1)外周壁と、前記外周壁の内側に配設され、一方の端面から他方の端面まで貫通して流路を形成する複数のセルを区画形成する隔壁と、を有するセラミックス製の柱状ハニカム構造体と、
前記柱状ハニカム構造体の外周壁の表面に配設された電極層と、
前記電極層上に設けられた、金属製コネクタに接続可能な電極接続部と、
を備え、
前記電極接続部は、独立した立ち上がり部位を少なくとも1つ有し、前記電極接続部の前記電極層の表面からの高さが1〜6mmである電気加熱式担体。
(2)缶体と嵌合可能な電気加熱式担体であって、
前記電気加熱式担体が、
外周壁と、前記外周壁の内側に配設され、一方の端面から他方の端面まで貫通して流路を形成する複数のセルを区画形成する隔壁と、を有するセラミックス製の柱状ハニカム構造体と、
前記柱状ハニカム構造体の外周壁の表面に配設された電極層と、
前記電極層上に設けられた、金属製コネクタに接続可能な電極接続部と、
を備え、
前記電極接続部は、独立した立ち上がり部位を少なくとも1つ有し、前記電極接続部の前記電極層の表面からの高さが、前記電気加熱式担体を前記缶体と嵌合したときに生じる前記缶体と前記電極層との隙間の高さ以下である電気加熱式担体。
(3)(1)または(2)に記載の電気加熱式担体と、
前記電気加熱式担体の外周面に嵌合される缶体と、
前記電極接続部と電気的に接続された金属製コネクタと、
を有する排気ガス浄化装置。
(4)(3)の排気ガス浄化装置の製造方法であって、前記製造方法が、
前記電気加熱式担体を前記缶体に嵌合する工程、及び
前記電極接続部に、前記金属製コネクタを電気的に接続する工程、
をこの順に有する排気ガス浄化装置の製造方法。
図2は、本発明の実施形態における電気加熱式担体20の柱状ハニカム構造体10の外観模式図を示すものである。図3は、本発明の実施形態における一方の電極層14a、14bに正対したときの電気加熱式担体20の平面図である。図4は、図3の電気加熱式担体20を側方から見たときの電気加熱式担体20の平面図である。
柱状ハニカム構造体10は、外周壁12と、外周壁12の内側に配設され、一方の端面から他方の端面まで貫通して流路を形成する複数のセル15を区画形成する隔壁13とを有する。
柱状ハニカム構造体10は、外周壁12の表面に、電極層14a、14bが配設されている。電極層14a、14bは、一方の電極層が、他方の電極層に対して、柱状ハニカム構造体10の中心軸を挟んで対向するように設けられている一対の電極層であってもよい。なお、当該電極層は、上述のように一対設けなくてもよく、例えば柱状ハニカム構造体10の外周壁12の表面において、上述の一方のみ(電極層14aまたは電極層14bのいずれか一方のみ)設けられていてもよい。
電極接続部30は、電極層14a、14b上に設けられ、電気的に接合されている。電極接続部30は、後述の金属製コネクタ41に接続可能に形成されており、金属製コネクタ41が外部電源に電気的に接続されている。これにより、電極接続部30に電圧を印加すると通電してジュール熱により柱状ハニカム構造体10を発熱させることが可能である。このため、柱状ハニカム構造体10はヒーターとしても好適に用いることができる。印加する電圧は12〜900Vが好ましく、48〜600Vが更に好ましいが、印加する電圧は適宜変更可能である。
金属としては、単体金属又は合金のいずれでもよく、例えばシリコン、アルミニウム、鉄、ステンレス、チタン、タングステン、Ni合金、Ni−Cr合金、Ni−Co合金などを好適に用いることができる。金属化合物としては、酸化物セラミックス以外の物であって、金属酸化物、金属窒化物、金属炭化物、金属珪化物、金属ほう化物、複合酸化物等が挙げられ、例えばFeSi2、CrSi2などを好適に用いることができる。金属と金属化合物は、いずれも、単独一種でもよく、二種以上を併用しても良い。
酸化物セラミックスとしては、具体的には、ガラス、コージェライト、ムライトなどがある。
ガラスは、B、Mg、Al、Si、P、Ti及びZrからなる群から選択される少なくとも1種の成分からなる酸化物を更に含んでも良い。上記群より選択される少なくとも1種を更に含んでいると、電極層の強度がより向上する点で更に好ましい。
次に、本発明に係る電気加熱式担体20を製造する方法について例示的に説明する。本発明の電気加熱式担体20の製造方法は一実施形態において、電極層形成ペースト付き未焼成柱状ハニカム構造体を得る工程A1と、電極層形成ペースト付き未焼成柱状ハニカム構造体を焼成して柱状ハニカム構造体を得る工程A2と、柱状ハニカム構造体に電極接続部を接合する工程A3とを含む。
上述した本発明の各実施形態に係る電気加熱式担体20は、それぞれ図9に示すような排気ガス浄化装置40に用いることができる。排気ガス浄化装置40において、電気加熱式担体20は、エンジンからの排気ガスを流すための排気ガス流路の途中に設置される。
次に、本発明の実施形態に係る排気ガス浄化装置40の製造方法について詳述する。まず、本発明の実施形態に係る電気加熱式担体20に触媒を担持させる。触媒は前述の貴金属系触媒又はこれら以外の触媒などを使用することができる。続いて、缶体42内に、可撓性を有する断熱部材などで構成された保持材を介して、触媒が担持された電気加熱式担体20を押し込みキャニングによって嵌合する。
12 外周壁
13 隔壁
14a、14b 電極層
15 セル
16 中間層
19 分離帯
20、50 電気加熱式担体
30、36、39 電極接続部
31 溶接部位
32 立ち上がり部位
34、37 柱状部
35、38 連結部
40 排気ガス浄化装置
41 金属製コネクタ
42、53 缶体
43 先端部
44、54 開口部
52 電極
Claims (23)
- 外周壁と、前記外周壁の内側に配設され、一方の端面から他方の端面まで貫通して流路を形成する複数のセルを区画形成する隔壁と、を有するセラミックス製の柱状ハニカム構造体と、
前記柱状ハニカム構造体の外周壁の表面に配設された電極層と、
前記電極層上に設けられた、金属製コネクタに接続可能な電極接続部と、
を備え、
前記電極接続部は、独立した立ち上がり部位を少なくとも1つ有し、前記電極接続部の前記電極層の表面からの高さが1〜6mmである電気加熱式担体。 - 前記電極接続部は、少なくとも表面が金属で構成されている請求項1に記載の電気加熱式担体。
- 前記電極接続部は、全体が金属で構成されている請求項2に記載の電気加熱式担体。
- 前記電極接続部が、前記電極層上に起立するように設けられた柱状電極接続部である請求項1〜3のいずれか一項に記載の電気加熱式担体。
- 前記電極接続部が円柱状または多角柱状である請求項4に記載の電気加熱式担体。
- 前記電極接続部が外径1〜20mmの円柱状である請求項5に記載の電気加熱式担体。
- 前記電極接続部は、前記電極層上に起立するように設けられた複数の柱状部と、前記複数の柱状部の下端を連結する連結部とを有する請求項1〜3のいずれか一項に記載の電気加熱式担体。
- 前記電極接続部は、前記電極層上に起立するように設けられた複数の柱状部と、前記複数の柱状部の上端を連結する連結部とを有する請求項1〜3のいずれか一項に記載の電気加熱式担体。
- 前記電極接続部は、下端が前記柱状ハニカム構造体の外周壁に埋め込まれている請求項1〜8のいずれか一項に記載の電気加熱式担体。
- 前記電極層と前記電極接続部との間に、少なくとも1層の中間層が設けられている請求項1〜8のいずれか一項に記載の電気加熱式担体。
- 前記中間層が、酸化物セラミックス、または、金属若しくは金属化合物と酸化物セラミックスとの混合物で構成されている請求項10に記載の電気加熱式担体。
- 前記電極層が、前記柱状ハニカム構造体の外周壁の表面に、前記柱状ハニカム構造体の中心軸を挟んで対向するように配設された一対の電極層であり、
前記電極接続部は、前記一対の電極層上に形成されている請求項1〜11のいずれか一項に記載の電気加熱式担体。 - 缶体と嵌合可能な電気加熱式担体であって、
前記電気加熱式担体が、
外周壁と、前記外周壁の内側に配設され、一方の端面から他方の端面まで貫通して流路を形成する複数のセルを区画形成する隔壁と、を有するセラミックス製の柱状ハニカム構造体と、
前記柱状ハニカム構造体の外周壁の表面に配設された電極層と、
前記電極層上に設けられた、金属製コネクタに接続可能な電極接続部と、
を備え、
前記電極接続部は、独立した立ち上がり部位を少なくとも1つ有し、前記電極接続部の前記電極層の表面からの高さが、前記電気加熱式担体を前記缶体と嵌合したときに生じる前記缶体と前記電極層との隙間の高さ以下である電気加熱式担体。 - 請求項1〜13のいずれか一項に記載の電気加熱式担体と、
前記電気加熱式担体の外周面に嵌合される缶体と、
前記電極接続部と電気的に接続された金属製コネクタと、
を有する排気ガス浄化装置。 - 前記金属製コネクタと前記電極接続部とを接合する溶接接点部又は溶射部を有する請求項14に記載の排気ガス浄化装置。
- 請求項14または15に記載の排気ガス浄化装置の製造方法であって、前記製造方法が、
前記電気加熱式担体を前記缶体に嵌合する工程、及び
前記電極接続部に、前記金属製コネクタを電気的に接続する工程、
をこの順に有する排気ガス浄化装置の製造方法。 - 前記電気加熱式担体を前記缶体に嵌合する方法が、押し込みキャニングである請求項16に記載の排気ガス浄化装置の製造方法。
- 前記電極接続部に前記金属製コネクタを電気的に接続する方法が、溶融金属法、固相接合法、及び機械的接合法からなる群より選択される少なくとも一種である請求項16または17に記載の排気ガス浄化装置の製造方法。
- 前記溶融金属法が、溶接、ろう付け、液相拡散接合、及び共晶接合からなる群より選択される少なくとも一種である請求項18に記載の排気ガス浄化装置の製造方法。
- 前記溶接が、レーザー溶接、EB溶接、TIG溶接、MIG溶接、プラズマ溶接、抵抗溶接、及びコンデンサ溶接からなる群より選択される少なくとも一種である請求項19に記載の排気ガス浄化装置の製造方法。
- 前記固相接合法が、拡散接合、焼結法、摩擦撹拌接合、及び超音波接合からなる群より選択される少なくとも一種である請求項18に記載の排気ガス浄化装置の製造方法。
- 前記機械的接合法が、焼き嵌め、圧入、ねじ止め、及び塑性結合法からなる群より選択される少なくとも一種である請求項18に記載の排気ガス浄化装置の製造方法。
- 前記電気加熱式担体を前記缶体に嵌合する工程の前に、前記電気加熱式担体に触媒を担持させる工程を有する請求項16〜22のいずれか1項に記載の排気ガス浄化装置の製造方法。
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WO2012063353A1 (ja) * | 2010-11-11 | 2012-05-18 | トヨタ自動車株式会社 | 電気加熱型触媒 |
JP2013158714A (ja) * | 2012-02-06 | 2013-08-19 | Denso Corp | 電気加熱式触媒装置 |
JP2015107452A (ja) * | 2013-12-04 | 2015-06-11 | トヨタ自動車株式会社 | 通電加熱式触媒装置及びその製造方法 |
JP2016186262A (ja) * | 2015-03-27 | 2016-10-27 | トヨタ自動車株式会社 | 電気加熱式触媒コンバーター |
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