JP2021190401A - 電気加熱式触媒装置の製造方法、電気加熱式触媒装置の電極用金属薄板、及び電気加熱式触媒装置 - Google Patents
電気加熱式触媒装置の製造方法、電気加熱式触媒装置の電極用金属薄板、及び電気加熱式触媒装置 Download PDFInfo
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Abstract
Description
以下、電気加熱式触媒装置の第1実施形態を、図1〜図7を参照して詳細に説明する。
図1に示すように、電気加熱式触媒装置10は、車載用の内燃機関の排気管11の内部に設置される触媒担体12を備えている。触媒担体12は、多孔質の電気伝導体により形成されており、その外形は円柱状をなしている。なお、以下の説明では、円筒形状をなす触媒担体12の円柱中心線に平行な方向を同触媒担体12の軸方向と記載する。また、以下の説明では、円柱中心線に対する周回方向を触媒担体12の周方向と、円柱中心線に直交する方向を触媒担体12の径方向と、それぞれ記載する。
電極15は、触媒担体12の外周面上に設けられた表面電極層20を有している。表面電極層20は、溶射によって触媒担体12の外周面に形成される多孔質金属の膜となっており、ニクロム・クロム合金等の高温下での耐酸化性に優れた金属材料で形成されている。本実施形態の電気加熱式触媒装置10における表面電極層20は、触媒担体12の軸方向に長辺が延び、周方向に短辺が延びる矩形状に形成されている。
(1)溶射により固定層25を形成して表面電極層20の表面に配線部23を固定する際に、撓み無く張った状態で配線部23を表面電極層20の表面に押し付けるために張力Tを加えるための把持手となる偽端子部32が金属薄板30に設けられている。そのため、表面電極層20の表面上に配線部23を容易かつ的確に固定でき、金属電極層21の配線部23と表面電極層20との接触不良が生じ難くなる。
(第2実施形態)
次に、電気加熱式触媒装置の第2実施形態を、図8及び図9を併せ参照して詳細に説明する。なお本実施形態にあって、上記実施形態と共通する構成については、同一の符号を付してその詳細な説明は省略する。
(4)金属薄板130の不要部分の切除は、溶断部位が十分に加熱したときに偽端子部132を引っ張って不要部分を切り離すことで行われる。第1実施形態の場合のように溶断部位が複数存在する場合には、各溶融部位が切り離し可能に加熱される時期がばらつくことがあり、切り離しを行う時期の見極めが難しくなる。これに対して本実施形態の場合には、溶断部位が一箇所のみであるため、金属薄板130の不要部分の切り離し作業が容易となる。
・触媒担体12や表面電極層20、金属電極層21、固定層25の構成材料を適宜変更してもよい。
12…触媒担体
15…電極
20…表面電極層
21…金属電極層
22,122…第1の基部
23,123…配線部
23A…先端(溶断された部分)
24,124…端子部
25…固定層
30,130…金属薄板
31,131…第2の基部
131A…溶断された部分
32,132…偽端子部
33,133…狭小部
Claims (9)
- 触媒が担持された電気伝導体からなる円筒形状の触媒担体と、前記触媒担体の外周面上に設けられた膜状の表面電極層と、薄板状の金属材料からなる金属電極層であって、基部と、同基部から前記触媒担体の周方向にそれぞれ延出されており、かつ前記表面電極層の表面上に前記触媒担体の軸方向に並んで配置された複数の配線部と、前記触媒担体の周方向における前記基部の両端のうち、同基部から見て前記配線部が位置する側と逆側の端から延出された端子部と、を有した金属電極層と、前記配線部を挟んで前記表面電極層の表面に固定された固定層と、を備える電気加熱式触媒装置を製造する方法であって、
前記複数の配線部、前記基部、及び前記端子部を有するとともに、前記複数の配線部における前記基部に接続された側と逆側の端部にそれぞれ接続された第2の基部と、前記配線部の延伸方向における前記第2の基部の両端のうち、同第2の基部から見て前記配線部が位置する側と逆側の端から延出された偽端子部と、を有した金属薄板を前記金属電極層の材料として用いるとともに、
前記触媒担体の外周面上に形成された前記表面電極層の表面に、前記端子部及び前記偽端子部をそれぞれ把持して前記金属薄板に張力を加えた状態で前記複数の配線部を押し付ける行程と、
前記複数の配線部を前記表面電極層の表面に押し付けた状態で、前記固定層を溶射により形成する行程と、
前記金属薄板の中で前記配線部の延伸方向に直交する断面の面積が最小となる部分を最小断面積部としたとき、前記固定層の形成後に前記金属薄板の前記端子部と前記偽端子部との間に電流を流すとともに、その通電に伴うジュール熱による前記最小断面積部の溶断を通じて、前記金属薄板における前記最小断面積部よりも前記偽端子部の先端側の部分を切除することで前記金属電極層を形成する行程と、
を行う電気加熱式触媒装置の製造方法。 - 前記複数の配線部における前記第2の基部に近い側の端部には、前記配線部の延伸方向に直交する断面の面積が当該配線部の中で最小となった狭小部がそれぞれ形成されており、かつ前記配線部のそれぞれの前記狭小部が形成された部分が前記金属薄板の前記最小断面積部とされている請求項1に記載の電気加熱式触媒装置の製造方法。
- 前記配線部の延伸方向における前記偽端子部の両端部のうち、前記第2の基部に近い側の端部には、前記配線部の延伸方向に直交する断面の面積が同偽端子部の中で最小となった狭小部が形成されており、かつ同狭小部が形成された部分が前記金属薄板の前記最小断面積部となっている請求項1に記載の電気加熱式触媒装置の製造方法。
- 触媒が担持された電気伝導体からなる円筒形状の触媒担体と、前記触媒担体の外周面上に設けられた膜状の表面電極層と、薄板状の金属材料からなる金属電極層であって、基部と、同基部から前記触媒担体の周方向にそれぞれ延出されており、かつ前記表面電極層の表面上に前記触媒担体の軸方向に並んで配置された複数の配線部と、前記触媒担体の周方向における前記基部の両端のうち、前記基部から見て前記配線部が位置する側と逆側の端から延出された端子部と、を有した金属電極層と、前記配線部を挟んで前記表面電極層の表面に固定された固定層と、を備える電気加熱式触媒装置における前記金属電極層の材料として用いられる金属薄板であって、
前記複数の配線部、前記基部、及び前記端子部を有するとともに、
前記複数の配線部における前記基部に接続された側と逆側の端にそれぞれ接続された第2の基部と、
前記配線部の延伸方向における前記第2の基部の両端のうち、前記配線部が接続された側とは逆側の端から延出された偽端子部と、
を有しており、かつ当該金属薄板の中で前記配線部の延伸方向に直交する断面の面積が最小となる部分を最小断面積部としたとき、前記複数の配線部のそれぞれにおける前記基部に接続される側の端部よりも前記偽端子部の先端に近い位置に前記最小断面積部が設けられている
電気加熱式触媒装置の電極用金属薄板。 - 前記複数の配線部のそれぞれにおける前記第2の基部に接続される側の端部には、前記配線部の延伸方向に直交する断面の面積が前記配線部の他の部位よりも小さくされた狭小部が形成されており、前記配線部のそれぞれの前記狭小部が形成された部分が前記金属薄板の前記最小断面積部となっている請求項4に記載の電気加熱式触媒装置の電極用金属薄板。
- 前記配線部の延伸方向における前記偽端子部の両端部のうち、前記第2の基部に近い側の端部には、前記配線部の延伸方向に直交する断面の面積が同偽端子部の中で最小となった狭小部が形成されており、かつ同狭小部が形成された部分が前記金属薄板の前記最小断面積部となっている請求項4に記載の電気加熱式触媒装置の電極用金属薄板。
- 触媒が担持された電気伝導体からなる円筒形状の触媒担体と、
前記触媒担体の外周面上に形成された膜状の表面電極層と、
薄板状の金属材料からなる金属電極層であって、基部と、同基部から前記触媒担体の周方向にそれぞれ延出されており、かつ前記表面電極層の表面上に前記触媒担体の軸方向に並んで配置された複数の配線部と、前記触媒担体の周方向における前記基部の両端のうち、同基部から見て前記配線部が位置する側と逆側の端から延出された端子部と、を有した金属電極層と、
前記配線部を間に挟み込んだ状態で前記表面電極層の表面に固定された固定層と、
を備えており、
前記触媒担体の周方向における前記金属電極層の両端のうち、前記基部から見て前記端子部が位置する側と逆側の端に溶断された部分が存在し、かつ前記溶断された部分の面積は、前記金属電極層の中で前記触媒担体の周方向に直交する断面の面積が最小となる部分の同断面の面積以下の面積となっている
電気加熱式触媒装置。 - 前記複数の配線部のそれぞれの先端が前記溶断された部分となっている請求項7に記載の電気加熱式触媒装置。
- 前記金属電極層は、前記触媒担体の周方向における前記配線部の両端のうち、同配線部から見て前記基部が位置する側と逆側の端において前記複数の配線部のそれぞれと接続される第2の基部を有しており、かつ前記触媒担体の周方向における前記第2の基部の両端のうち、同第2の基部から見て前記配線部が位置する側と逆側の端に前記溶断された部分が設けられている請求項7に記載の電気加熱式触媒装置。
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