CN1091836C - 一种内燃机用催化转化器的制造方法 - Google Patents

一种内燃机用催化转化器的制造方法 Download PDF

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CN1091836C
CN1091836C CN97121135A CN97121135A CN1091836C CN 1091836 C CN1091836 C CN 1091836C CN 97121135 A CN97121135 A CN 97121135A CN 97121135 A CN97121135 A CN 97121135A CN 1091836 C CN1091836 C CN 1091836C
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P·S·施米特
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    • 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
    • F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
    • F01N3/2857—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing the mats or gaskets being at least partially made of intumescent material, e.g. unexpanded vermiculite
    • 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
    • F01N13/16—Selection of particular materials
    • 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
    • F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and 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
    • F01N2330/06—Ceramic, e.g. monoliths
    • 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
    • F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
    • F01N2450/02—Fitting monolithic blocks into the 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
    • F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
    • F01N2450/22—Methods or apparatus for fitting, inserting or repairing different elements by welding or brazing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49345—Catalytic device making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49879—Spaced wall tube or receptacle
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49908—Joining by deforming
    • Y10T29/49915—Overedge assembling of seated part

Abstract

本发明公开了一种催化转化器的制造方法，该转化器具有一陶瓷蜂窝基体，其外包有支撑垫料，置于一座套内，其制造步骤如下：(1)加工成形一圆柱形金属筒体，具有均匀一致的曲率，并有一搭接部位具有与金属筒壳外表面基本上相同的曲率；(2)把该蜂窝包在足够量的支撑垫料内，再插入金属筒壳中；(3)把在已包好的蜂窝外的金属筒壳外的金属筒壳压紧封牢，使支撑垫料在蜂窝上产生基本上均匀的压应力。

Description

一种内燃机用催化转化器的制造方法
本发明涉及内燃机排气净化用的催化转化器的生产方法，更具体地涉及利用具有基本均匀曲率的预制矩形金属板来生产该催化转化器的方法。
众所周知，内燃机(尤其是机动车辆上的)所用的排气净化系统通常采用一种蜂窝室结构陶瓷元件作为催化剂的载体来完成其对排气的净化作用。更确切地说，该蜂窝室结构涂有一种含贵金属的催化剂，能在有O2的存在下把排气中所含的有毒成分如HC和CO转化为CO2和H2O。这种蜂窝室的结构被安置在“气密”的板金属或铸造金属的耐热座套或筒器内。
目前用的典型的蜂窝结构含有一种陶瓷材料，例如堇青石，是一种机械强度很有限的脆性材料。为此缘故，今天所用的催化转化器一般都含有撑垫材料包在该蜂窝周围。这种能使任何压力均匀地分布到陶瓷上去的弹性材料，当温度升高时它一般会膨胀。这样就能使蜂窝上所受支撑压力随高温而增加。且能在一定程度上补偿金属外壳的热膨胀。因为金属外壳的热膨胀大于包在内部的陶瓷蜂窝，因此这种撑垫材料的热膨胀防止了温度升高时该蜂窝在管壳内的松动。
本领域对上述催化器已知有很多种的加工方法，包括把外包垫料的蜂窝按紧配合地插入管件外壳中(例见美国专利No.4,093,423(Neumann))，以及用两个“半剖”金属壳体拼合在外包垫料的蜂窝外面，然后焊牢，例见美国专利No.5,273,724(Bos)。另一种加工方法，通常称为“止血带式”包扎法(tourniquet wrap)，是把一金属矩形平板卷成搭接式的圆筒。再把外包垫料的蜂窝松弛地插入该筒中，然后将整体一起拉拢以形成必要的撑垫压力，最后再将搭接处焊牢。这样就能使该筒内保持必要的压力同时又能防止漏气，例见美国专利No.5,082,479(Miller)。
上述把矩形平板卷成圆筒形的加工方法通常是利用三辊板金工辊轧技术。这种预轧金属制件的固有缺陷是圆筒两端与圆筒中部的曲率不相一致。用了这种不均匀曲率金属圆筒的后果是：在蜂窝结构与金属圆筒之间会形成不规则空隙。虽有撑垫的作用能够降低一些这种不均匀，但它会对蜂窝结构造成不均匀的压力载荷。在空隙最小区域的点载荷会导致蜂窝结构的局部压损，也即把脆性的蜂窝结构压碎。
因此，本发明的一个目的是克服目前制造催化转化器所用的“止血带式包扎法”的缺点。换言之，即提供一种制造催化转化器的方法，它能在蜂窝结构上得到基本均匀的压力载荷，从而避免蜂窝的局部压损(即压碎)。
这一目的以及可从后文明显看到的其它一些目的，本发明是采用具有基本均匀曲率的金属板圆筒来完成的。具体地说，这是一种具有蜂窝陶瓷结构的催化转换器，外包撑垫，并放置在座套之内，其制造方法包括下列诸步骤：(1)加工成形一金属圆筒，其内外表面基本上都具有均匀曲率，且有一搭接部位，其内表面具有与金属壳体外表面基本相同的曲率；(2)把蜂窝结构包复在足够量的撑垫材料中，包复后插进金属壳体内；(3)在压力下把包复在蜂窝外的金属壳体封好后，从而通过撑垫材料在蜂窝上产生一基本均匀的压应力。
图1是按上述加工方法制成的具有蜂窝结构的催化转化器的纵向剖面简图。
图2是图1沿A-A剖面线的剖视图。
图3是图1和2中的均匀曲率预制金属圆筒在蜂窝尚未插入前的示图。
参见图1和2，所示催化转换器含有一陶瓷蜂窝结构，其作用就是载有催化剂的结构或即其载体。催化转换器10是由圆筒形陶瓷蜂窝14以及包于其外的金属外壳或筒器12所组成。制造筒器12的材料要能够耐车底盐垢、耐高温和耐腐蚀，通常选用铁基不锈钢，最好如SS-409、SS-439牌号等级，最近还有SS-441。材料的选择决定于废气种类、最高温度等条件。蜂窝14是由陶瓷材料(例如堇青石)挤压成形。筒器12具有入口16和出口18。来自入口的废气流经蜂窝14的各个蜂窝室后即自出口18排出。陶瓷蜂窝14具有正方形的蜂窝室；虽也可采用其它形状如三角形、矩形等等，但考虑到挤压模型等的加工成本，通常还是采用正方形状的蜂窝室。
陶瓷蜂窝14是利用陶瓷纤维撑垫或纤维丝网24支撑在筒器12内，撑垫起着吸震作用。撑垫24一般由陶瓷纤维材料形成，可以是一种简单的非膨胀型陶瓷材料，或一种泡沸材料，例如含有一种蛭石成份，它受热膨胀，当钢制外壳从陶瓷单块向外膨胀时它能维持牢固的受压状态，也可以是兼含该两种成份的撑垫材料。可接受的非膨胀型陶瓷纤维材料包括例如MN州Minneapolis，“3M”公司以“NEXTEL”商标出售的陶瓷材料，或NY州Niagara Carborundum(金刚砂)公司以“FIBERFRAX”商标出售的陶瓷材料。可接受的泡沸陶瓷材料包括MN州Minneapolis“3M”公司以“INTERAM”商标出售的陶瓷材料。纤维垫料24的宽度基本上等于蜂窝14的长度，插于14间，并经适当的热定形。定形后的纤维垫料紧压着蜂窝的外围，故能抵住气流的拖拽力而使蜂窝固定。支座块20和22从筒器12内周壁上伸出，能挡住纤维垫料24因受气流的拖拽力或相关的振动加速度而沿筒器12的纵向移动。
图1和2所示催化转换器的制造方法通常包括下列各步骤：(1)加工成型一金属圆筒壳，它具有基本均匀一致的曲率并有一搭接部分；(2)把蜂窝基层包在足够量的支撑垫料中并将包好后的蜂窝插进金属筒壳内；(3)把金属筒壳以紧压状态封闭于包好的蜂窝外周，使得支撑垫料在蜂窝上产生一基本均匀一致的压应力；(4)在搭接处把筒器两边固定牢以保持紧压状态。
参见图3，图中所示为未受压前的“均匀曲率”圆柱形筒壳12，即是在尚未把包好的蜂窝插入筒内再把该金属筒壳紧压封牢以形成催化转化器之前的状态。如图3所示，该金属筒壳的内外表面26和28在其整个长度上都具有基本均匀一致的曲率。圆柱形金属筒壳12还有一搭接部位30，该处的内表面具有与金属筒壳外表面28基本上相同的曲率。搭接内表面32与金属筒壳外表面28两曲率基本上相似，能使该两表面在压紧封牢阶段有效地和顺利地相互作用。换言之，在整个压紧封牢阶段，由于两者曲率实质上相同，故金属筒壳外表面28能沿搭接内表面顺利滑动以形成催化转化器，而不会沿着搭接接头部位产生出任何上述的不希望有的点载荷，而且进一步还可表明该实质上相似曲率的另一个效果是：由支撑垫料施加于陶瓷蜂窝上的合成压应力在搭接接头上是均匀的。
关于最后一步把筒壳两边搭牢的办法，最好是把搭接的内表面与金属筒壳的外表面焊牢，达到“气密”的密封效果并维持压应力。
另外对未压前圆柱形金属筒壳希望要有的特性如下：(1)圆柱形金属筒壳的尺寸与其外部搭接长度两者的组合应使净内径足以容纳包好的未受压蜂窝可以插进；(2)圆柱形金属筒壳的搭接长度应使在封筒时搭接前端不要触及连接该搭接部位与金属圆柱筒壳的(径向)台阶34。
至于“均匀曲率”圆柱金属筒壳的加工方法，采用什么样的技术来形成壳体是不重要的，重要的是该方法的结果应能使所形成的内外表面要有实质上均匀一致的曲率，并使其搭接部位内表面具有与壳体外表面实质上相同的曲率。
一个建议用来形成圆柱金属筒壳的方法为：用“线切割”一对冲压模，成为一对能精确互相配合的同形模具副，能将金属板各端冲压成所要的曲率。具体地可制成一副冲压模用来冲压圆柱金属板的一端，另用第二副冲压模(曲率稍有不同)来冲压圆柱金属板另一端的搭接部位。在使用了上述冲压模以保证两端能具有要求的曲率之后，圆柱形金属板的中部就可用上述在技术上大家熟知的三辊轧压法来加工完成了。
应该理解本发明并不局限于上述实施方法，熟悉这方面技术的任何人员能在不背离本发明范围和精神下进行各种变动和变异。

Claims (1)

1.一种用来净化内燃机排气的催化转化器的制造方法，该转化器具有单块的陶瓷基体，其外包有支撑垫料，置于座套内，其制造方法包括以下步骤：加工成型一圆柱形金属筒壳，筒壳内外表面各具有基本上均匀的曲率，并有一搭接部位，搭接的内表面具有与金属筒壳外表面基本上相同的曲率；把该基体包在足够量的支撑垫料中，再把包好的基体插入金属筒壳中；然后把金属筒壳压紧封牢在包好的基体之外，使这样形成的催化转化器中由支撑垫料对基体产生基本上均匀的压应力；最后把搭接部位的内表面牢固连接于金属筒体的外表面上，以获得“气密”的封口，并保持其压应力。
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CN1938500B (zh) * 2004-03-25 2010-05-05 株式会社梦可思 催化转化器的制造方法、催化转化器、以及催化转化器的控制方法
CN101257962B (zh) * 2005-05-02 2011-07-27 弗利特加尔公司 用于制造排气系统的方法

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DE69712149D1 (de) 2002-05-29
TW347368B (en) 1998-12-11
EP0837229A1 (en) 1998-04-22
US6000131A (en) 1999-12-14
JPH10121953A (ja) 1998-05-12
CN1181452A (zh) 1998-05-13

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