WO1997023273A1 - Ensemble et procede de fabrication de structures de convertisseurs catalytiques - Google Patents
Ensemble et procede de fabrication de structures de convertisseurs catalytiques Download PDFInfo
- Publication number
- WO1997023273A1 WO1997023273A1 PCT/US1996/017488 US9617488W WO9723273A1 WO 1997023273 A1 WO1997023273 A1 WO 1997023273A1 US 9617488 W US9617488 W US 9617488W WO 9723273 A1 WO9723273 A1 WO 9723273A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- leaves
- jacket
- catalytic converter
- foil
- leaf
- Prior art date
Links
- 230000003197 catalytic effect Effects 0.000 title claims abstract description 60
- 238000000034 method Methods 0.000 title description 12
- 239000011888 foil Substances 0.000 claims abstract description 56
- 229910052751 metal Inorganic materials 0.000 claims description 20
- 239000002184 metal Substances 0.000 claims description 20
- 239000012530 fluid Substances 0.000 claims description 4
- 239000000463 material Substances 0.000 claims description 4
- 230000002441 reversible effect Effects 0.000 claims description 2
- 238000012360 testing method Methods 0.000 description 18
- 229910045601 alloy Inorganic materials 0.000 description 11
- 239000000956 alloy Substances 0.000 description 11
- 229910001220 stainless steel Inorganic materials 0.000 description 9
- 238000000576 coating method Methods 0.000 description 8
- 238000005219 brazing Methods 0.000 description 7
- 239000011248 coating agent Substances 0.000 description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 4
- 230000001351 cycling effect Effects 0.000 description 4
- 229910001092 metal group alloy Inorganic materials 0.000 description 4
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 4
- 239000010935 stainless steel Substances 0.000 description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 239000003054 catalyst Substances 0.000 description 3
- 229910052804 chromium Inorganic materials 0.000 description 3
- 239000011651 chromium Substances 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 229910044991 metal oxide Inorganic materials 0.000 description 3
- 150000004706 metal oxides Chemical class 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 230000003647 oxidation Effects 0.000 description 3
- 238000007254 oxidation reaction Methods 0.000 description 3
- 229910052761 rare earth metal Inorganic materials 0.000 description 3
- 150000002910 rare earth metals Chemical class 0.000 description 3
- 239000003870 refractory metal Substances 0.000 description 3
- 238000003466 welding Methods 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 229910052746 lanthanum Inorganic materials 0.000 description 2
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 229910052697 platinum Inorganic materials 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 229910052703 rhodium Inorganic materials 0.000 description 2
- 239000010948 rhodium Substances 0.000 description 2
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 238000009628 steelmaking Methods 0.000 description 2
- 229910052727 yttrium Inorganic materials 0.000 description 2
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 2
- 229910052684 Cerium Inorganic materials 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- 229910052777 Praseodymium Inorganic materials 0.000 description 1
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 description 1
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 1
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 description 1
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- -1 e.g. Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000009863 impact test Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 229910052738 indium Inorganic materials 0.000 description 1
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 230000000873 masking effect Effects 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- 229910000510 noble metal Inorganic materials 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 229910052707 ruthenium Inorganic materials 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 229910001256 stainless steel alloy Inorganic materials 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 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
-
- 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
- F01N13/011—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 having two or more purifying devices arranged in parallel
- F01N13/017—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 having two or more purifying devices arranged in parallel the purifying devices are arranged in a single housing
-
- 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
Definitions
- the present invention relates to methods for the manufacture of metallic catalytic converters, and, more particularly, to such converters especially adapted for use in vehicular engines to control exhaust emissions, and to foil subassemblies useful in the practice of such methods.
- Catalytic converters containing a corrugated thin metal (stainless steel) monolith typically have been formed of a plurality of thin metal strips or foil leaves wound about a central pin or about spaced
- fixation points Such prior catalytic converters bodies, have supported both the outer and inner end of the individual layers by fixing them to the housing for the converter body and a central pin or post.
- the interior support has been provided by looping the foil leaves about a fixed point or portions whereby the inner ends of the leaves have been supported by other foil leaves.
- the thin metal strips or leaves forming the multicellular honeycomb body also have been brazed together at points intermediate the ends to form a rigid honeycomb monolith.
- Various techniques such as soldering, welding, brazing, riveting, clamping, reverse wrapping or folding, or the like, have been used to secure the inner and outer ends , and usually the intermediate 5 portion, of the leaves or strips to the support member. While many techniques have been used to assemble the leaves into the housing and many leaf arrangements have been constructed, many arrangements have been unable to survive severe automotive industry tests known as the
- Hot Shake Test the Hot Cycling Test, combinations of these tests, cold vibration testing, water quench testing, and impact testing.
- the Hot Shake test involves oscillating (50 to 200 Hertz and 28 to 80 G inertial loading) the device in a
- Hot Shake Test and the Hot Cycling Test are sometimes combined, that is, the two tests are conducted simultaneously or superimposed one on the other.
- the Hot Shake Test and the Hot Cycling Test are hereinafter called "Hot Tests.” While they have proved very difficult to survive, the structures of the present invention are designed to survive these Hot Tests and other tests similar in nature and effect that are known in the industry.
- catalytic converter bodies and their method of manufacture have received considerable attention, particularly by the automotive industry, are complex in design and manufacture, and are in need of improvement.
- a catalytic converter comprising an outer jacket, and at least one nonradiating parallel grouping of non-nestable foil leaves having ends defining a leaf length to provide flow passages generally transverse to a leaf length.
- One end of each foil leaf is connected to the outer jacket and the other end of each leaf is unconnected to the outer jacket.
- Fig. 1 is a partial end view of an embodiment of a catalytic converter incorporating the teachings of the present invention
- Fig. 2 is a partial end view of an alternative embodiment of a catalytic converter incorporating the teachings of the present invention
- Fig. 2a is an alternative arrangement for the structure shown in Fig. 2;
- Fig. 3 is a partial end view of an alternative embodiment of a catalytic converter incorporating the 5 teachings of the present invention
- Fig. 3a is an alternative arrangement for the structure shown in Fig. 3;
- Fig. 4 is a partial end view in cross section of an alternative embodiment of a catalytic converter 10. incorporating the teachings of the present invention
- Fig. 4a is an alternative arrangement for the structure shown in Fig. 4;
- Fig. 5 is a perspective view of a continuous sheet of segments usable to construct catalytic converters 15 according to the claimed invention
- Fig. 6 is an end view of a pair of continuous strips shown in Fig. 5 and braised together;
- Fig. 7 is a partial end view in cross section of an alternative embodiment of a catalytic converter 0 incorporating the teachings of the present invention
- Fig. 8 is a partial end view in cross section of an alternative embodiment of a catalytic converter incorporating the teachings of the present invention.
- Fig. 9 is a partial end view in cross section of 5 an alternative embodiment of a catalytic converter incorporating the teachings of the present invention.
- Fig. 10 is a partial end view in cross section of an alternative embodiment of a catalytic converter incorporating the teachings of the present invention.
- One aspect of the present invention is based on a finding by the inventors that the structure of a metallic catalytic converter body can be improved by allowing the metal sheets, referred to as foil leaf core elements or foil leaves, to be compliant, move, flex, or float in the fluid stream. Whereas it was previously thought that rigidity was essential to prevent failure in the "Hot Tests, " it has been discovered that flexure or compliance of the foil heat core elements in response to thermal and fluid flow variations as well as mechanical vibration were desirable attributes in converter bodies used in various applications. This discovery has given rise to what is termed a "cantilever" converter body, namely, one in which the foil leaf elements forming the core are secured at one end only or are secured at their second end in a manner, so the individual foil leaf core elements are
- the foil leaf arrangement may be constructed from "ferritic" stainless steel such as that described in U.S. Patent 4,414,023 to Aggen.
- One usable ferritic stainless steel alloy contains 20% chromium, 5% aluminum, and from 0.002% to 0.05% of at least one rare earth metal selected from cerium, lanthanum, neodymium, yttrium, and praseodymium, or a mixture of two or more of such rare earth metals, balance iron and trace steel making impurities.
- a ferritic stainless steel is commercially available from Allegheny Ludlum Steel Co. under the trademark "Alfa IV.
- Haynes 214 alloy Another usable commercially available stainless steel metal alloy is identified as Haynes 214 alloy. This alloy and other useful nickeliferous alloys are described in U.S. Patent 4,671,931 dated 9 June 1987 to Herchenroeder et al . These alloys are characterized by high resistance to oxidation and high temperatures. A specific example contains 75% nickel, 16% chromium, 4.5% aluminum, 3% iron, optionally trace amounts of one or more rare earth metals except yttrium, 0.05% carbon, and steel making impurities. Haynes 230 alloy, also useful herein has a composition containing 22% chromium, 14% tungsten, 2% molybdenum, 0.10% carbon, a trace amount of lanthanum, balance nickel.
- the ferritic stainless steels, and the Haynes alloys 214 and 230, all of which are considered to be stainless steels, are examples of high temperature resistive, oxidation resistant (or corrosion resistant) metal alloys that are useful for use in making the foil leaf core elements or leaves of the present invention, as well as the multicellular honeycomb converter bodies thereof.
- Suitable metal alloys must be able to withstand "high" temperature, e.g., from 900 degrees C. to 1200 degrees C. (1652 degrees F. to 2012 degrees F.) over prolonged periods.
- the housings, or jacket, hereof are of stainless steel and have a thickness of from about 0.03" to about 0.08", preferably, 0.04" to 0.06".
- the multicellular converter bodies of the present invention preferably are formed from foil leaves precoated before assembly, such as described in U.S. Patent 4,711,009 Cornelison et al .
- the converter bodies of the invention may be made solely of corrugated foil core elements which are non-nesting, or of alternating corrugated and flat foil core elements, or of other non ⁇ nesting arrangements or of other arrangements providing cells, flow passages, or a honeycomb structure when assembled.
- the foil leaves, which will be used as core elements are precoated before assembly. The ends are masked or cleansed to maintain them free of any coating so as to facilitate brazing or welding to the housing or to an intermediate sleeve.
- the coating is desirably a refractory metal oxide, e.g., alumina, alumina/ceria, titania, titania/alumina, silica, zirconia, etc., and if desired, a catalyst may be supported on the refractory metal oxide coating.
- the catalyst is normally a noble metal, e.g., platinum, palladium, rhodium, ruthenium, indium, or a mixture of two or more of such metals, e.g., platinum/rhodium.
- the refractory metal oxide coating is generally applied in an amount ranging from about 10 mgs/square inch to about 80 mgs/ square inch.
- corrugations preferably have an amplitude of from about 0.01 inch to about 0.15 inch, and a pitch of from about 0.02 inch to about 0.25 inch.
- the amplitude and pitch of the corrugations determine cell density, that is, the number of cells per unit of cross-sectional area in the converter body. Typically, the cell density is expressed in cells per square inch (cpsi) and may vary from about 50 cpsi to 2-000 cpsi.
- the corrugations are generally patterned, e.g., a herringbone pattern or a chevron pattern, or skewed pattern. in a "skewed pattern", the corrugations are straight, but at an angle of from 3 degrees to about 10 degrees to the parallel marginal edges of the strips.
- the latter foil leaf core elements may be layered without nesting.
- straight-through corrugations may be conveniently used, these exhibiting the lowest pressure drop at high flow in fluid flowing through the converter body.
- the straight-through corrugations are usually oriented along a line normal to the longitudinal marginal edges of the foil leaves, although, as indicated above, the corrugations may be oriented along a line oblique to the longitudinal marginal edges of the leaves.
- the "flat" foil leaf core elements preferably are lightly corrugated to have corrugations with an amplitude of from about 0.002" to about 0.01", e.g., 0.005" and a pitch of from about 0.02" to about 0.2", e.g., 0.1".
- the coated corrugated and flat foil leaves that form the working gas flow passageways in the converter body of the invention constitute the major metal foil content thereof and are preferably formed of the lower cost ferritic stainless steel alloys. Because of its greater strength, albeit higher cost, he nickeliferous stainless steel alloys may be used in the converter of the invention particularly in the center area and other areas where the requirement for foil strength justifies the higher cost of these alloys. In the ensuing description and in the appended claims, the latter foil alloys may be referred to generically as "high strength" foil and may be uncoated to facilitate joining by spot welding, for example.
- a honeycomb structure for use as a catalytic convertor structure or catalyst carrier body including a jacket and at least one non-radiating parallel grouping of non-nestable foil leaves having ends defining a leaf length to provide flow passage to its generally transverse to the leaf length.
- One end of each foil leaf is connected to the jacket tube, and the other end of each leaf is unconnected to the jacket.
- a catalytic converter structure 20 includes an jacket, 22, preferably made from a metal sheet formed into a tube.
- the non-nestable foil leaves preferably include an alternating series of corrugated metal strips 24 and flat metal strips 26, which together are non-nestable and provide flow passages 28 generally transverse to a leaf length.
- Each sheet has two ends.
- the left end 30 of each flat leaf 26 is connected to the left side of the jacket 22 and the right end 32 of each flat leaf 64 is proximate to but spaced from and unconnected to the right side 33 of jacket 22.
- a stack of foil leaves 24 and 26 form a single nonradiating parallel grouping of metal sheets that extend along flat paths.
- the leaves extend along nonradiating paths because the paths of the leaves do not generally radiate from a center or central area.
- the remaining portion inside the jacket 22 of the arrangement shown in Fig. 1 is filled with flat and corrugated sheets in a manner similar to those shown in place. Alternatively, the remaining space may be filled with another arrangement of sheets.
- a completed arrangement of non-nestable sheets in a jacket may be used alone as a catalytic converter structure or it may be used as a catalytic converter structure within a larger catalytic converter structure. For example, one use of the structure shown in Fig.
- a catalytic converter could be central core of a catalytic converter from which additional foil leaves may be attached and radiate outward to another j cket.
- bodies of other shapes such as elliptical shapes, may also be constructed according to the teachings of the invention.
- a number of methods may be used to construct the arrangement shown in Fig. 1.
- a continuous sheet of metal may be formed into alternating corrugated and flat pieces with intermediate segments, which are either masked when the sheet is coated with catalytic material, or subsequently cleaned of the catalytic coating before assembly and connection to the jacket.
- the alternating corrugated and flat pieces may be either cut to the proper lengths for any geometric configuration such as various chord lengths spanning a jacket, or folded to form that geometric configuration, and the stack is inserted into a jacket lined with brazing foil.
- the foil leaves may also be individually inserted into a jacket.
- the ends of the alternating strips are then secured to the jacket, preferably by a brazing method using induction heat.
- the folded portions on one side of the jacket may be brazed while the portions on the other side of the jacket are not brazed, to allow a cantilevered arrangement.
- every other folded portion around the periphery of the outer jacket may be connected to allow for folded ends that cantilever in alternating left and right directions.
- An example of an accordion folded stack of foils is shown in Fig. 2 where folded portions 138 can be selectively connected to outer jacket 122 by brazing in a manner to obtain the desired amount of compliance for a particular application according to the present invention.
- folds 138a, c, e, and g can be connected to outer jacket 122, while folds 138 b, d, f, and h are left free and unconnected to outer jacket 122.
- folds 138a, d, e, and h may be connected to outer jacket 122 while folds 138b, c, f, and g are allowed to be free from connection to outer jacket 123.
- the folds 138 are made at the areas where catalytic coating is not present, either by masking during the coating process or removal after the coating process.
- the foil arrangement shown in Fig. 3 is formed to provide a flat and corrugated segment in each leaf length and each leaf length is configured so that when juxtaposed, a flat segment in one leaf length is coextensive with a corrugated segment in an adjacent leaf length.
- flat segment 226a extends over the left half of the body and continues to provide corrugated segment 224a over the right half of the body.
- the right end of leaf segment 224a is folded at fold 238a and continues back as a flat segment 226b juxtaposed to adjacent corrugated leaf segment 224a.
- Flat segment 226b of leaf length b continues to the left and becomes corrugated leaf segment 224b, which is juxtaposed to flat leaf segment 226a.
- leaf length a starts with corrugated section 324a, becomes flat section 326a and then corrugated section 324a', which is folded at fold 328a to form leaf lenth b, where it becomes flat segment 326b, corrugated section 324b and flat section 326b" , and then folds again at 328b to form the next row.
- the same kind of selective connection process can be employed to braze the foil ends to the outer jacket where desired for the proper amount of compliancy.
- both foil ends of all or selected leaf lengths may be connected to 5 the jacket in a rigid and/or compliant manner, either by the design of the connection and/or the end portions of the leaves themselves.
- Figs. 3, 4, 9, and 10 it may be desirable to connect both ends in some applications. It is preferable in a number of
- a continuous strip of metal sheet which forms the foil leaves, includes several
- corrugated portions 424 which alternate with flat portions 426.
- Each of these segments may be separated by a margin 425, which has no catalytic material and which forms a good surface for brazing to an outer jacket. In other alternatives, some margins may contain 0 catalytic material.
- two sets of leaves made by the process of Fig. 5 can be juxtaposed and brazed together at 427 in some or all of margins 425 in a desired manner to change the stiffness and compliancy of the leaf structure.
- Figs. 2a, 3a, and 4a, 5 show these arrangements relating to the respective figures with brazing 227 and 327 respectively in the margins.
- Figs. 2a, 3a, and 4a also show an arrangement of folds 138, 238, and 338 along respective margins 125, 225, and 325.
- Fig. 7 shows a catalytic converter with two groupings of leaves, group 531 on the left half and group 532 on the right half.
- One end 530 and 534 of each of the leaves 524 and 526 are connected to the left side 531 of outer jacket 532.
- One end 532 and 536 of the leaves 524 and 526a are connected to the other opposite side of jacket 522, namely the right side 533.
- the leaves in both groupings extend across the outer jacket to a common diametral line 540 where the cantilevered ends are narrowly spaced from each other.
- Another arrangement is shown in Fig. 8, where the leaves are in four groupings, 640, 641, 642, and 643.
- One end of each of the leaves is connected to outer jacket 622 and the free ends of the leaves extend to perpendicular diametral lines 650 and 651, where they are spaced from the leaves of the adjacent segment.
- Fig. 9 shows a catalytic converter where the leaves 724 and 726 extend along curved paths that are parallel and nonradiating, in that they do not radiate to or from a central point or define a central point in the converter.
- Fig. 10 shows a catalytic converter in which the nonradiating parallel grouping of foil leaves extend along reversely curved paths. In these two instances, the foils are symmetric along center lines
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (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)
Abstract
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU76021/96A AU7602196A (en) | 1995-12-22 | 1996-10-31 | Assembly and method for making catalytic converter structure |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US57761895A | 1995-12-22 | 1995-12-22 | |
US08/577,618 | 1995-12-22 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1997023273A1 true WO1997023273A1 (fr) | 1997-07-03 |
Family
ID=24309475
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1996/017488 WO1997023273A1 (fr) | 1995-12-22 | 1996-10-31 | Ensemble et procede de fabrication de structures de convertisseurs catalytiques |
Country Status (2)
Country | Link |
---|---|
AU (1) | AU7602196A (fr) |
WO (1) | WO1997023273A1 (fr) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2007031122A1 (fr) * | 2005-06-17 | 2007-03-22 | Emitec Gesellschaft Für Emissionstechnologie Mbh | Production d'un corps en nid d'abeilles, en particulier de grandes dimensions, pour le traitement ulterieur mobile de gaz d'echappement |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3890104A (en) * | 1970-11-03 | 1975-06-17 | Getters Spa | Catalytic cartridge |
US3966646A (en) * | 1973-11-08 | 1976-06-29 | United Kingdom Atomic Energy Authority | Fabricating bodies |
US4832998A (en) * | 1986-05-12 | 1989-05-23 | Interatom Gmbh | Honeycomb body, especially a catalyst carrier body having sheet metal layers twisted in opposite directions and a method for producing the same |
US5118477A (en) * | 1989-05-08 | 1992-06-02 | Usui Kokusai Sangyo Kabushiki Kaisha | Exhaust gas cleaning device |
US5240682A (en) * | 1991-05-06 | 1993-08-31 | W. R. Grace & Co.-Conn | Reinforced corrugated thin metal foil strip useful in a catalytic converter core, a catalytic converter core containing said strip and an electrically heatable catalytic converter containing said core |
US5366700A (en) * | 1991-04-16 | 1994-11-22 | Emitec Gesellschaft Fuer Emissionstechnologie Mbh | Apparatus for catalytically decontaminating exhaust gases and method for producing the apparatus |
-
1996
- 1996-10-31 AU AU76021/96A patent/AU7602196A/en not_active Abandoned
- 1996-10-31 WO PCT/US1996/017488 patent/WO1997023273A1/fr active Application Filing
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3890104A (en) * | 1970-11-03 | 1975-06-17 | Getters Spa | Catalytic cartridge |
US3966646A (en) * | 1973-11-08 | 1976-06-29 | United Kingdom Atomic Energy Authority | Fabricating bodies |
US4832998A (en) * | 1986-05-12 | 1989-05-23 | Interatom Gmbh | Honeycomb body, especially a catalyst carrier body having sheet metal layers twisted in opposite directions and a method for producing the same |
US5118477A (en) * | 1989-05-08 | 1992-06-02 | Usui Kokusai Sangyo Kabushiki Kaisha | Exhaust gas cleaning device |
US5366700A (en) * | 1991-04-16 | 1994-11-22 | Emitec Gesellschaft Fuer Emissionstechnologie Mbh | Apparatus for catalytically decontaminating exhaust gases and method for producing the apparatus |
US5240682A (en) * | 1991-05-06 | 1993-08-31 | W. R. Grace & Co.-Conn | Reinforced corrugated thin metal foil strip useful in a catalytic converter core, a catalytic converter core containing said strip and an electrically heatable catalytic converter containing said core |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2007031122A1 (fr) * | 2005-06-17 | 2007-03-22 | Emitec Gesellschaft Für Emissionstechnologie Mbh | Production d'un corps en nid d'abeilles, en particulier de grandes dimensions, pour le traitement ulterieur mobile de gaz d'echappement |
KR100917740B1 (ko) * | 2005-06-17 | 2009-09-15 | 에미텍 게젤샤프트 퓌어 에미시온스테크놀로기 엠베하 | 자동차 배기 가스 사후 처리를 위한 특히 큰 허니콤 몸체의제조 |
US7789947B2 (en) | 2005-06-17 | 2010-09-07 | Emitec Gesellschaft Fur Emissionstechnologie Mbh | Honeycomb body, in particular large honeycomb body, for mobile exhaust-gas aftertreatment, process for producing a honeycomb body, process for treating exhaust gas and exhaust gas assembly |
CN101198405B (zh) * | 2005-06-17 | 2011-08-10 | 排放技术有限公司 | 蜂窝体、用于制造蜂窝体的方法及其应用 |
Also Published As
Publication number | Publication date |
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AU7602196A (en) | 1997-07-17 |
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