WO2007028743A1 - Procede pour realiser un element filtrant et une structure de support destinee a un catalyseur a resistance thermique amelioree - Google Patents

Procede pour realiser un element filtrant et une structure de support destinee a un catalyseur a resistance thermique amelioree Download PDF

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Publication number
WO2007028743A1
WO2007028743A1 PCT/EP2006/065824 EP2006065824W WO2007028743A1 WO 2007028743 A1 WO2007028743 A1 WO 2007028743A1 EP 2006065824 W EP2006065824 W EP 2006065824W WO 2007028743 A1 WO2007028743 A1 WO 2007028743A1
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WO
WIPO (PCT)
Prior art keywords
fibers
filter element
ceramic
ceramic body
magnesium
Prior art date
Application number
PCT/EP2006/065824
Other languages
German (de)
English (en)
Inventor
Bernd Schumann
Joerg Jockel
Matthias Kruse
Original Assignee
Robert Bosch Gmbh
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Robert Bosch Gmbh filed Critical Robert Bosch Gmbh
Publication of WO2007028743A1 publication Critical patent/WO2007028743A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
    • C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
    • C04B35/195—Alkaline earth aluminosilicates, e.g. cordierite or anorthite
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2068—Other inorganic materials, e.g. ceramics
    • B01D39/2082—Other inorganic materials, e.g. ceramics the material being filamentary or fibrous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2068—Other inorganic materials, e.g. ceramics
    • B01D39/2093—Ceramic foam
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/628—Coating the powders or the macroscopic reinforcing agents
    • C04B35/62844—Coating fibres
    • C04B35/62876—Coating fibres with metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0471—Surface coating material
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3224—Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
    • C04B2235/3227—Lanthanum oxide or oxide-forming salts thereof
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3224—Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
    • C04B2235/3229—Cerium oxides or oxide-forming salts thereof
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
    • C04B2235/3244—Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5216—Inorganic
    • C04B2235/522—Oxidic
    • C04B2235/5224—Alumina or aluminates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5216—Inorganic
    • C04B2235/522—Oxidic
    • C04B2235/5228—Silica and alumina, including aluminosilicates, e.g. mullite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/526—Fibers characterised by the length of the fibers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5264—Fibers characterised by the diameter of the fibers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/602—Making the green bodies or pre-forms by moulding
    • C04B2235/6021—Extrusion moulding
    • 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
    • F01N2330/06—Ceramic, e.g. monoliths

Definitions

  • a method of manufacturing a filter element and a support structure for a catalyst having improved temperature resistance is provided.
  • the invention relates to processes for the production of ceramic bodies with improved temperature resistance and ceramic bodies, in particular filter elements and support structures for exhaust aftertreatment devices of an internal combustion engine.
  • Filter elements for particulate filters of diesel engines and the support structures of catalysts for internal combustion engines are often made of cordierite. Pure cordierite has a very small thermal expansion coefficient and thus has a good resistance to sudden temperature changes (thermal shocks).
  • temperatures of over 1,000 ° Celsius can occur because the regeneration of soot is exothermic. Since the soot distribution within the filter element is not homogeneous and also the possibilities of heat dissipation locally are different, caused during regeneration local temperature differences in the filter element.
  • the local temperature differences in the filter element result in thermal stresses that can lead to the destruction of the filter element by cracks.
  • the invention has for its object to provide a method for producing a filter element and a filter element, which is more robust in terms of thermal stresses than conventional ceramic body made of cordierite.
  • This object is achieved in a method for producing bodies of magnesium-aluminum-silicate, preferably cordierite, or a body of another ceramic material, wherein the starting materials of magnesium-aluminum-silicate or other ceramic material to a moldable mass be mixed, the moldable mass fibers are added. From this fiberized moldable mass, a body is then formed and subjected to a heat treatment.
  • the ceramic body produced by the process according to the invention has a fiber-reinforced structure, which is mechanically very resilient and has a good internal damping. As a result, naturally increases the temperature resistance of the body produced by the process according to the invention.
  • An advantage of the method according to the invention is that, with the exception of the addition of the fibers to the moldable mass, no further process-related expense is required compared to the production of a cordierite ceramic body according to the prior art.
  • the inventive method is very inexpensive and effective.
  • the mechanical strength of the body produced by the method of the invention can be further increased by coating the fibers before adding them to the moldable mass.
  • the fibers are coated with iron, cobalt, nickel, palladium, platinum and / or titanium. It has been shown in practical experiments that by the coating of the fibers in the finished ceramic body a direct
  • thermo-mechanical stability of the ceramic body produced by the method according to the invention is based on an improved vibration damping by the fibers. This vibration damping is particularly effective when there is a cavity around the fibers that can absorb and dampen vibration present in the ceramic body.
  • the coatings of the invention act as a release agent between the fibers and the ceramic material. It has proven to be advantageous if the body is formed by extrusion, since in this method, in particular prismatic body with honeycomb-shaped cross-section can be made quickly and inexpensively.
  • the fibers consist of magnesium-aluminum-silicate, preferably cordierite, or a material with similar properties, and that the material of the fibers is doped with a material which suppresses the sintering. This doping suppresses the sintering in the calcination process, so that the fibers remain as such after the calcination process.
  • Zirconium, lanthanum and / or cerium have proven to be suitable materials for doping the fibers.
  • the fibers consist of other ceramic materials.
  • a thickness of 3 .mu.m-6 .mu.m, more preferably of 3 .mu.m-5 .mu.m has proven.
  • For the length of the fibers have dimensions of 10 .mu.m - 100 .mu.m, more preferably from 10 .mu.m - 20 .mu.m, proved.
  • Figure 1 is a schematic representation of a
  • FIG. 2 shows a longitudinal section of a filter element according to the invention
  • FIG. 3 shows a flow diagram of an exemplary embodiment of the method according to the invention.
  • Figure 4 shows the structure of a body according to the invention.
  • an internal combustion engine carries the reference numeral 10.
  • the exhaust gases are discharged via an exhaust pipe 12, in which a filter device 14 is arranged. With this, soot particles are filtered out of the exhaust gas flowing in the exhaust pipe 12. This is particularly necessary in diesel engines to comply with legal requirements.
  • the filter device 14 comprises a cylindrical housing 16, in which one in the present embodiment rotationally symmetrical, also a total cylindrical filter element 18 is arranged.
  • FIG. 2 shows a cross-section of a filter element 18 according to the prior art.
  • the filter element 18 is manufactured as an extruded shaped body from a ceramic material, such as cordierite.
  • the filter element 18 is flowed through in the direction of the arrows 20 of not shown exhaust gas.
  • An entrance surface has the reference numeral 22 in FIG. 2, while an exit surface in FIG. 2 has the reference numeral 24.
  • the inlet channels 28 are at the
  • the sealing plugs are shown in FIG. 2 without reference numerals.
  • the outlet channels 30 are open at the outlet surface 24 and closed in the region of the inlet surface 22.
  • the flow path of the unpurified exhaust gas thus leads into one of the inlet channels 28 and from there through a filter wall (without reference numeral) into one of the outlet channels 30. This is illustrated by the arrows 32 by way of example.
  • FIG. 3 is a flow chart of a
  • a first step 34 the materials required for producing a ceramic body are mixed together in the desired composition. Thereafter, temperature-resistant ceramic fibers are added to this mixture. Subsequently, in a third Step 38 of the mass given the desired shape in a molding process.
  • the shaping can be effected by extrusion.
  • the body resulting from the shaping process 38 is subjected to a heat treatment, in particular a sintering process, in a further step 40.
  • the fibers retain their shape and structure and increase the mechanical strength of the ceramic material.
  • a small air cushion forms between the ceramic material and the fibers, which further increases the internal damping of the ceramic body produced by the process according to the invention.
  • FIG. 4 schematically shows the structure of a ceramic body produced by the method according to the invention.
  • the ceramic workpiece is shown in Figure 4 by hatching.
  • Fibers 42 are incorporated in this matrix.
  • This structure is interrupted by various pores 44, which ensure the required for a filter element porosity of the ceramic body.
  • some of the fibers 42 protrude into the pores 44. This effect is desirable because it increases the storage capacity of the filter element, in particular for soot. If the fibers 42 have been provided with a suitable coating, the ends of the fibers 42 which protrude into the pores 44 may also have a catalytic effect.
  • a dashed line 46 indicates by way of example that an air cushion 48 forms between the hatched ceramic body and the fibers 42 due to the coating of the fibers 42 before the sintering process.
  • This air cushion 48 increases the internal damping of ceramic material and is therefore advantageous.

Abstract

La présente invention concerne un procédé pour réaliser un élément filtrant, et un élément filtrant destiné à un dispositif de post-traitement de gaz d'échappement d'un moteur à combustion interne, dont la résistance thermique et la charge mécanique admissible suite à des contraintes thermiques, sont supérieures à celles des corps céramiques de l'état de la technique. L'élément filtrant est fait de magnésium-aluminum-silicate et contient des fibres (42), de préférence des fibres revêtues.
PCT/EP2006/065824 2005-09-06 2006-08-30 Procede pour realiser un element filtrant et une structure de support destinee a un catalyseur a resistance thermique amelioree WO2007028743A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE200510042209 DE102005042209A1 (de) 2005-09-06 2005-09-06 Verfahren zur Herstellung eines Filterelements und einer Trägerstruktur für einen Katalysator mit verbesserter Temperaturbeständigkeit
DE102005042209.8 2005-09-06

Publications (1)

Publication Number Publication Date
WO2007028743A1 true WO2007028743A1 (fr) 2007-03-15

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PCT/EP2006/065824 WO2007028743A1 (fr) 2005-09-06 2006-08-30 Procede pour realiser un element filtrant et une structure de support destinee a un catalyseur a resistance thermique amelioree

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DE (1) DE102005042209A1 (fr)
WO (1) WO2007028743A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8789400B2 (en) 2006-11-16 2014-07-29 Johnson Controls Technology Company Modular seat back
CN111203034A (zh) * 2019-12-31 2020-05-29 汉格斯特滤清系统(昆山)有限公司 一种耐高温滤筒的制备方法

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109851328A (zh) * 2019-02-15 2019-06-07 江苏埃梯恩膜过滤技术有限公司 一种高性能陶瓷平板膜支撑体的制备工艺

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US4921822A (en) * 1988-11-07 1990-05-01 General Electric Company Ceramic composite
JPH04357179A (ja) * 1991-06-04 1992-12-10 Matsushita Electric Ind Co Ltd 耐熱性無機組成物及びそれを用いた多孔質耐熱材の製造方法
EP0562597A1 (fr) * 1992-03-27 1993-09-29 Nippon Soken, Inc. Corps poreux renforcé de fibres et filtre de séparation de particules composé de cela
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US4921822A (en) * 1988-11-07 1990-05-01 General Electric Company Ceramic composite
JPH04357179A (ja) * 1991-06-04 1992-12-10 Matsushita Electric Ind Co Ltd 耐熱性無機組成物及びそれを用いた多孔質耐熱材の製造方法
US5552352A (en) * 1991-06-17 1996-09-03 General Electric Company Silicon carbide composite with coated fiber reinforcement
EP0562597A1 (fr) * 1992-03-27 1993-09-29 Nippon Soken, Inc. Corps poreux renforcé de fibres et filtre de séparation de particules composé de cela
US20020081445A1 (en) * 1997-01-29 2002-06-27 Shingo Kadomura Composite material manufacturing method thereof, substrate processing apparatus and manufacturing method thereof, substrate mouting stage and manufacturing method thereof, and substrate processing method

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R.J. KERANS ET AL.: "Interface design for oxidation -resistant ceramic composite", J. AMER. CERAM. SOCIETY, vol. 85, no. 11, 2002, pages 2599 - 2632, XP002407397 *
WENDORFF J ET AL: "PLATINUM AS A WEAK INTERPHASE FOR FIBER-REINFORCED OXIDE-MATRIX COMPOSITES", JOURNAL OF THE AMERICAN CERAMIC SOCIETY, BLACKWELL PUBLISHING, MALDEN, MA, US, vol. 81, no. 10, October 1998 (1998-10-01), pages 2738 - 2740, XP000784975, ISSN: 0002-7820 *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8789400B2 (en) 2006-11-16 2014-07-29 Johnson Controls Technology Company Modular seat back
CN111203034A (zh) * 2019-12-31 2020-05-29 汉格斯特滤清系统(昆山)有限公司 一种耐高温滤筒的制备方法

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