EP1229219A2 - Device for purifying the exhaust gas from a combustion engine and manufacturing process - Google Patents

Device for purifying the exhaust gas from a combustion engine and manufacturing process Download PDF

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Publication number
EP1229219A2
EP1229219A2 EP02001466A EP02001466A EP1229219A2 EP 1229219 A2 EP1229219 A2 EP 1229219A2 EP 02001466 A EP02001466 A EP 02001466A EP 02001466 A EP02001466 A EP 02001466A EP 1229219 A2 EP1229219 A2 EP 1229219A2
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EP
European Patent Office
Prior art keywords
honeycomb body
washcoat
coating
longitudinal axis
liquid
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
EP02001466A
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German (de)
French (fr)
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EP1229219A3 (en
Inventor
Ekkehard Dr. Pott
Michael Dr. Zillmer
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Volkswagen AG
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Volkswagen AG
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Filing date
Publication date
Application filed by Volkswagen AG filed Critical Volkswagen AG
Publication of EP1229219A2 publication Critical patent/EP1229219A2/en
Publication of EP1229219A3 publication Critical patent/EP1229219A3/en
Ceased legal-status Critical Current

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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
    • F01N3/24—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
    • F01N3/2882—Catalytic reactors combined or associated with other devices, e.g. exhaust silencers or other exhaust purification devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional 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
    • 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
    • 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
    • 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
    • F01N13/08—Other arrangements or adaptations of exhaust conduits
    • F01N13/10—Other arrangements or adaptations of exhaust conduits of exhaust manifolds

Definitions

  • the invention relates to a device for cleaning exhaust gases Internal combustion engine according to the preamble of claim 1 and method for Manufacture of such a device according to the preambles of claims 3 and 5.
  • Modern motor vehicles generally have at least two catalytic converters, a so-called pre-catalytic converter being generally arranged directly behind the exhaust manifold. These pre-catalysts generally serve as NO x storage catalysts.
  • Such catalysts have a honeycomb body as a support structure (matrix), which carries the catalytically active layer.
  • This active layer consists of a washcoat layer, to which certain precious metals are applied.
  • the application of the Washcoats on the honeycomb body are usually done by dipping the Honeycomb body in the washcoat or by flooding the honeycomb body with the pasty washcoat.
  • This effect is particularly pronounced for gasoline engine exhaust with a high full-load residual oxygen content, because in addition to the thermal stress in the first zone of the Catalyst because of the good heat and mass transfer of the turbulent exhaust gas a disproportionately high catalytic conversion of pollutants and thus still higher energy input takes place in this catalyst zone.
  • At least one is located in the region of the end of the honeycomb body near the motor coating-free zone provided.
  • This coating-free zone means that Load on the catalyst with regard to the heat input, which is from the Heat transfer from the hot exhaust gas, and that which comes from the catalytic conversion results, at least partially decoupled.
  • the depth of the uncoated channel is reduced to the Reynolds number Matched full load. Ideally, it only becomes after the transition from turbulent to laminar Flow allows a coating within the respective channel.
  • Another object of the invention is a method for producing such To provide device.
  • the honeycomb body is immersed in coated liquid washcoat, the honeycomb body (10) not completely in the Washcoat (40) is immersed. This leaves part of the honeycomb body without Washcoat coating containing precious metals. This then forms the coating-free one Zone.
  • At least two diving operations are carried out, with the two dives the axis of the honeycomb body each different Liquid washcoat surface. This allows the shape of the coating-free zone can be defined more precisely.
  • the honeycomb body which is a plurality of each other has separate channels that extend parallel to a longitudinal axis, also coated by dipping in liquid washcoat. Part of the upper end face of the honeycomb body covered with a cover member, so that due to the air in the channels underneath the washcoat only up to a certain amount or not at all in these channels.
  • a multi-stage process is carried out, with which a more precise Definition of the coating-free zones can be achieved.
  • This method can include a variety of steps, so that any Number of coating-free zones can be generated, which in turn can have different shapes from one another.
  • FIGS. 2a and 2b The problem occurring in the prior art is shown in FIGS. 2a and 2b.
  • the four exhaust gas supply lines 31, 32, 33 and 34 combine in the collecting space 20. Exhaust pipes and plenum together form the so-called manifold. in the The example shown here forms the one flowing out of the fourth exhaust gas supply line 34 Exhaust a shot channel, so that in the subsequent catalytic converter a zone Z with high local pollution arises.
  • the problems outlined above occur.
  • the solution according to the invention is shown in FIG.
  • the honeycomb body 10 consists of a variety channels 12 parallel to one another, which are separated by channel walls 14.
  • the Channel walls 14, which are in the region of the coating-free zone 18, have the Height H no coating on.
  • the exhaust gas only flows up to this height through the channels without performing a catalytic reaction. This is true Transfer heat from the exhaust gas to the honeycomb body, but no additional Heat of reaction generated. Only below the height H does this close again coated zone 16 so that the catalytic conversion of the Exhaust gas takes place.
  • the height H should be such that it matches the route corresponds to what the exhaust gas needs to go from turbulent to laminar To flow over.
  • the catalyst which is to be produced is schematic in FIGS. 3a and 3b shown.
  • the honeycomb body is immersed in the liquid washcoat 40 parallel to its longitudinal axis AA to a first depth t 1 .
  • the longitudinal axis AA is perpendicular to the surface of the washcoat bath.
  • the axis AA can be tilted relative to the surface of the washcoat. This ensures that only the zone in the upper left corner of the honeycomb body remains uncoated.
  • Two dipping processes can also be carried out, the axis AA being perpendicular and once inclined with respect to the surface of the liquid washcoat 40.
  • This procedure is basically suitable for the production of catalysts, whose uncoated zones are said to have complex shapes.
  • An example of this is in the figures 4a and 4b.
  • This method can only be used if the honeycomb body has 10 channels 12 has that are completely separated from each other. However, this is usually the case.
  • the honeycomb body 10 is immersed in the washcoat to a first depth t 1 .
  • This cover element 51 must close the channels 12 lying beneath it in an essentially airtight and liquid-tight manner.
  • the honeycomb body 10 is now completely in the liquid Washcoat dipped.
  • the channels 12 that are not from the first Cover element 51 are covered, completely flooded. Because of the air column, which is in the covered channels, the washcoat cannot or only in these channels penetrate to a certain height. This forms below the Cover element 51 from a coating-free zone 18.
  • the cover member 51 can have any shape.
  • This embodiment is an extension of the second method example, which is expanded in that there are two separate coating-free zones 18 are generated.
  • the honeycomb body 10 is immersed in the washcoat 40 to a first depth t 1 .
  • a first area of the upper end face 10A of the honeycomb body 10 is then covered with the first cover element 51.
  • the honeycomb body 10 is lowered into the washcoat to a second depth t 2 .
  • a further part of the surface of the upper end face 10A is covered with a second cover element 52, whereupon the honeycomb body 10 is completely immersed in the washcoat.
  • FIGS. 5a and 5b two separate coating-free zones 18 with different shapes and heights have been created.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Catalysts (AREA)
  • Exhaust Gas After Treatment (AREA)

Abstract

The catalytic converter for IC engine exhaust comprises a honeycomb-shaped support (10) with a washcoat (16) and a coating-free zone (18) at the end nearest the engine. An Independent claim is included for a method for coating the support.

Description

Die Erfindung betrifft eine Vorrichtung zum Reinigen von Abgasen eines Verbrennungsmotors nach dem Oberbegriff des Anspruchs 1 sowie Verfahren zur Herstellung einer solchen Vorrichtung nach den Oberbegriffen der Ansprüche 3 und 5.The invention relates to a device for cleaning exhaust gases Internal combustion engine according to the preamble of claim 1 and method for Manufacture of such a device according to the preambles of claims 3 and 5.

Moderne Kraftfahrzeuge weisen in der Regel wenigstens zwei Katalysatoren auf, wobei ein sogenannter Vorkatalysator in der Regel unmittelbar hinter dem Abgaskrümmer angeordnet ist. Diese Vorkatalysatoren dienen in der Regel als NOx-Speicherkatalysatoren.Modern motor vehicles generally have at least two catalytic converters, a so-called pre-catalytic converter being generally arranged directly behind the exhaust manifold. These pre-catalysts generally serve as NO x storage catalysts.

Solche Katalysatoren besitzen einen Wabenkörper als Trägerstruktur (Matrix), welcher die katalytisch aktive Schicht trägt. Diese aktive Schicht besteht aus einer Washcoat-Schicht, auf die bestimmte Edelmetalle aufgebracht sind. Das Aufbringen des Washcoats auf den Wabenkörper geschieht in der Regel mittels Tauchen des Wabenkörpers in den Washcoat oder mittels Durchfluten des Wabenkörpers mit dem pastösen Washcoat.Such catalysts have a honeycomb body as a support structure (matrix), which carries the catalytically active layer. This active layer consists of a washcoat layer, to which certain precious metals are applied. The application of the Washcoats on the honeycomb body are usually done by dipping the Honeycomb body in the washcoat or by flooding the honeycomb body with the pasty washcoat.

Bei sehr hohen Katalysatortemperaturen, hohen Abgasmassenströmen und ungünstiger Krümmergeometrie kann es vorkommen, dass ein Vorkatalysator lokal mit sehr hohen Durchsätzen belastet wird, da eine oder mehrere Abgaszuleitungen sogenannte Schusskanäle ausbilden können, so dass das hieraus strömende Abgas den Vorkatalysator nur auf einer relativ kleinen Fläche trifft. In diesem Fall nimmt in dieser Katalysatorzone die thermische Belastung, insbesondere bei einer Volllast-Schub-Wechselbelastung, und die katalytische Umsetzung gegenüber dem Rest des Katalysators sehr stark zu und es kann zu einem lokalen Versagen des Katalysators kommen. Insbesondere bei Verwendung sogenannter Metallkatalysatoren ist hierbei die Auflösung der die Katalysatormatrix bildenden Folien untereinander möglich. Auch ein Ausbrechen von Washcoat- oder Trägermaterial oder Umformung der Matrix ist beobachtet worden. At very high catalyst temperatures, high exhaust gas mass flows and less favorable Exhaust manifold geometry can happen that a pre-catalyst locally with very high Throughputs are burdened because one or more exhaust gas lines are so-called Can form shot channels, so that the exhaust gas flowing from the Pre-catalytic converter only hits a relatively small area. In this case, this takes Catalyst zone the thermal load, especially in the case of a full-load shear alternating load, and the catalytic conversion over the rest of the Catalyst very strongly and there may be a local failure of the catalyst come. This is particularly the case when using so-called metal catalysts It is possible for the foils forming the catalyst matrix to dissolve among one another. Also a Breaking out of washcoat or carrier material or forming the matrix been observed.

Besonders ausgeprägt ist dieser Effekt bei Ottomotor-Abgas mit hohem Volllast-Restsauerstoffgehalt, da zusätzlich zur thermischen Belastung in der ersten Zone des Katalysators wegen der guten Wärme- und Stoffübertragung des turbulenten Abgases eine überproportional hohe katalytische Schadstoffumsetzung und damit ein noch höherer Energieeintrag in diese Katalysatorzone stattfindet.This effect is particularly pronounced for gasoline engine exhaust with a high full-load residual oxygen content, because in addition to the thermal stress in the first zone of the Catalyst because of the good heat and mass transfer of the turbulent exhaust gas a disproportionately high catalytic conversion of pollutants and thus still higher energy input takes place in this catalyst zone.

Ausgehend von diesem Stand der Technik ist es Aufgabe der Erfindung, einen gattungsgemäßen Katalysator dahingehend weiterzubilden, dass auch dann, wenn sich im Abgaskrümmer Schusskanäle ausbilden, ein lokales Versagen des Katalysators zuverlässig vermieden werden kann.Based on this prior art, it is an object of the invention to generic catalyst to further develop that even if Form shot channels in the exhaust manifold, a local failure of the catalytic converter can be reliably avoided.

Diese Aufgabe wird mit einer Vorrichtung mit den Merkmalen des Anspruchs 1 gelöst.This object is achieved with a device having the features of claim 1.

Hierbei wird im Bereich des motomahen Endes des Wabenkörpers wenigstens eine beschichtungsfreie Zone vorgesehen. Durch diese beschichtungsfreie Zone wird die Belastung des Katalysators bezüglich des Wärmeeintrags, welcher von der Wärmeübertragung des heißen Abgases stammt, und dessen, welcher sich aus der katalytischen Umsetzung ergibt, zumindest teilweise entkoppelt.In this case, at least one is located in the region of the end of the honeycomb body near the motor coating-free zone provided. This coating-free zone means that Load on the catalyst with regard to the heat input, which is from the Heat transfer from the hot exhaust gas, and that which comes from the catalytic conversion results, at least partially decoupled.

Beim Gaseintritt in die Kanäle des Katalysators erfolgt wegen der Turbulenz zunächst ein sehr guter Wärmeübergang zwischen Gas und der Katalysatormatrix, also dem Wabenkörper. Da die vordere Eintrittszone jedoch nicht katalytisch wirksam beschichtet ist, findet allenfalls eine geringe Schadstoffumsetzung statt. In dem Fall, dass der Wabenkörper aus Keramik besteht, findet nahezu keine Schadstoffumsetzung, in dem Fall, dass der Wabenkörper aus Metallfolien aufgebaut ist, nur eine geringe Schadstoffumsetzung statt. Da die Schadstoffumsetzung ein exothermer Prozess ist, wird dadurch die Erwärmung dieser Zone im Vergleich zum Stand der Technik verringert. Erst tiefer im Kanal des Katalysators befinden sich Washcoat und Edelmetall, so dass die Zone der katalytischen Schadstoffumsetzung von der Zone des besten Wärmeübergangs entkoppelt ist. Somit findet der Energieumsatz des Katalysators auf einer größeren Länge statt und das Risiko einer Strukturüberlastung wird verringert.When gas enters the channels of the catalytic converter, turbulence initially occurs a very good heat transfer between gas and the catalyst matrix, i.e. the Honeycombs. However, since the front entry zone is not coated catalytically effective there is at best a low conversion of pollutants. In the event that the Honeycomb body made of ceramic, finds almost no pollutant conversion in the If the honeycomb body is made of metal foils, only a small one Pollutant conversion instead. Since the pollutant conversion is an exothermic process, is the heating of this zone compared to the prior art reduced. Washcoat and precious metal are only deeper in the channel of the catalyst, so that the zone of catalytic pollutant conversion from the zone of the best Heat transfer is decoupled. Thus, the energy conversion of the catalyst is found longer and the risk of structural overload is reduced.

Vorzugsweise wird die Tiefe des nicht beschichteten Kanals auf die Reynolds-Zahl bei Volllast abgestimmt. Idealerweise wird erst nach Übergang von turbulenter zu laminarer Strömung eine Beschichtung innerhalb des jeweiligen Kanals zugelassen. Preferably, the depth of the uncoated channel is reduced to the Reynolds number Matched full load. Ideally, it only becomes after the transition from turbulent to laminar Flow allows a coating within the respective channel.

Eine weitere Aufgabe der Erfindung ist es, ein Verfahren zur Herstellung einer solchen Vorrichtung zur Verfügung zu stellen.Another object of the invention is a method for producing such To provide device.

Diese Aufgabe wird durch die Verfahren mit den Merkmalen der Ansprüche 3 oder 7 gelöst.This object is achieved by the method with the features of claims 3 or 7 solved.

Bei einem Verfahren nach Anspruch 3 wird der Wabenkörper mittels Eintauchen in flüssigen Washcoat beschichtet, wobei der Wabenkörper (10) nicht vollständig in den Washcoat (40) eingetaucht wird. Hierdurch bleibt ein Teil des Wabenkörpers ohne edelmetallhaltige Washcoatbeschichtung. Diese bildet dann die beschichtungsfreie Zone.In a method according to claim 3, the honeycomb body is immersed in coated liquid washcoat, the honeycomb body (10) not completely in the Washcoat (40) is immersed. This leaves part of the honeycomb body without Washcoat coating containing precious metals. This then forms the coating-free one Zone.

Nach Anspruch 6 werden wenigstens zwei Tauchvorgänge durchgeführt, wobei bei den beiden Tauchvorgängen die Achse des Wabenkörpers jeweils unterschiedlich zur Oberfläche des flüssigen Washcoats steht. Hierdurch kann die Form der beschichtungsfreien Zone genauer definiert werden.According to claim 6 at least two diving operations are carried out, with the two dives the axis of the honeycomb body each different Liquid washcoat surface. This allows the shape of the coating-free zone can be defined more precisely.

Nach Anspruch 7 wird der Wabenkörper, welcher eine Vielzahl von voneinander getrennten Kanälen aufweist, die sich parallel zu einer Längsachse erstrecken, ebenfalls durch einen Tauchvorgang in flüssigen Washcoat beschichtet. Hierbei wird ein Teil der oberen Stirnfläche des Wabenkörpers mit einem Abdeckelement abgedeckt, so dass aufgrund der in den darunter liegenden Kanälen stehenden Luft der Washcoat nur bis zu einer gewissen Höhe oder überhaupt nicht in diese Kanäle eindringen kann.According to claim 7, the honeycomb body, which is a plurality of each other has separate channels that extend parallel to a longitudinal axis, also coated by dipping in liquid washcoat. Part of the upper end face of the honeycomb body covered with a cover member, so that due to the air in the channels underneath the washcoat only up to a certain amount or not at all in these channels.

Nach Anspruch 8 wird ein mehrstufiges Verfahren durchgeführt, womit eine genauere Definition der beschichtungsfreien Zonen erreicht werden kann.According to claim 8, a multi-stage process is carried out, with which a more precise Definition of the coating-free zones can be achieved.

Dieses Verfahren kann eine Vielzahl von Schritten umfassen, so dass eine beliebige Anzahl beschichtungsfreier Zonen erzeugt werden können, welche wiederum untereinander unterschiedliche Formen aufweisen können.This method can include a variety of steps, so that any Number of coating-free zones can be generated, which in turn can have different shapes from one another.

Die Erfindung wird nun anhand von Ausführungsbeispielen mit Bezug auf die Figuren näher erläutert. Es zeigen:

Fig. 1
einen Abgaskrümmer und einen sich daran anschließenden Katalysator im Längsschnitt,
Fig. 2a
einen Abgaskrümmer und einen sich daran anschließenden Katalysator im Längsschnitt gemäß dem Stand der Technik,
Fig. 2b
den Katalysator aus Fig. 2a in der Draufsicht,
Fig. 3a
eine Draufsicht auf einen Katalysator,
Fig. 3b
einen Längsschnitt durch einen Katalysator,
Fig. 3c
ein Verfahren zur Herstellung des in den Figuren 3a und 3b dargestellten Katalysators,
Fig. 4a
eine Draufsicht auf einen Katalysator,
Fig. 4b
den Katalysator der Fig. 4a im Längsschnitt,
Fig. 4c
ein Verfahren zur Herstellung des in den Fign. 4a und 4b dargestellten Katalysators,
Fig. 5a
eine Draufsicht auf einen Katalysator,
Fig. 5b
einen Längsschnitt durch den in Fig. 5a dargestellten Katalysator,
Fig. 5c
ein Verfahren zur Herstellung des in den Fign.5a und 5b dargestellten Katalysators.
The invention will now be explained in more detail using exemplary embodiments with reference to the figures. Show it:
Fig. 1
an exhaust manifold and a subsequent catalyst in longitudinal section,
Fig. 2a
an exhaust manifold and an adjoining catalyst in longitudinal section according to the prior art,
Fig. 2b
2a in top view,
Fig. 3a
a top view of a catalyst,
Fig. 3b
a longitudinal section through a catalyst,
Fig. 3c
a method for producing the catalyst shown in Figures 3a and 3b,
Fig. 4a
a top view of a catalyst,
Fig. 4b
4a in longitudinal section,
Fig. 4c
a method for producing the in the Fign. 4a and 4b shown catalyst,
Fig. 5a
a top view of a catalyst,
Fig. 5b
6 shows a longitudinal section through the catalyst shown in FIG. 5a,
Fig. 5c
a method of making the catalyst shown in Figures 5a and 5b.

In den Figuren 2a und 2b ist das im Stand der Technik auftretende Problem dargestellt. Die vier Abgaszuleitungen 31, 32, 33 und 34 vereinigen sich im Sammelraum 20. Abgaszuleitungen und Sammelraum bilden zusammen den sogenannten Krümmer. Im hier dargestellten Beispiel bildet das aus der vierten Abgaszuleitung 34 strömende Abgas einen Schusskanal, so dass im sich anschließenden Katalysator eine Zone Z mit hoher lokaler Belastung entsteht. Hier können die oben dargestellten Probleme auftreten.The problem occurring in the prior art is shown in FIGS. 2a and 2b. The four exhaust gas supply lines 31, 32, 33 and 34 combine in the collecting space 20. Exhaust pipes and plenum together form the so-called manifold. in the The example shown here forms the one flowing out of the fourth exhaust gas supply line 34 Exhaust a shot channel, so that in the subsequent catalytic converter a zone Z with high local pollution arises. Here are the problems outlined above occur.

In Figur 1 ist die erfindungsgemäße Lösung dargestellt. In dem Bereich, in dem der Schusskanal S auf den Wabenkörper 10 auftrifft, befindet sich eine beschichtungsfreie Zone 18. Diese hat die Höhe H. Der Wabenkörper 10 besteht aus einer Vielzahl zueinander paralleler Kanäle 12, welche durch Kanalwände 14 getrennt sind. Die Kanalwände 14, die im Bereich der beschichtungsfreien Zone 18 liegen, weisen über die Höhe H keine Beschichtung auf. Dadurch strömt das Abgas bis zu dieser Höhe lediglich durch die Kanäle ohne eine katalytische Reaktion durchzuführen. Hierbei wird zwar Wärme vom Abgas auf den Wabenkörper übertragen, jedoch keine zusätzliche Reaktionswärme erzeugt. Erst unterhalb der Höhe H schließt sich auch hier wieder die beschichtete Zone 16 an, so dass in diesem Bereich die katalytische Umsetzung des Abgases erfolgt. Idealerweise sollte die Höhe H so bemessen sein, dass sie der Strecke entspricht, die das Abgas braucht, um von einer turbulenten zu einer laminaren Strömung überzugehen.The solution according to the invention is shown in FIG. In the area where the Shot channel S strikes the honeycomb body 10, there is a coating-free Zone 18. This has the height H. The honeycomb body 10 consists of a variety channels 12 parallel to one another, which are separated by channel walls 14. The Channel walls 14, which are in the region of the coating-free zone 18, have the Height H no coating on. As a result, the exhaust gas only flows up to this height through the channels without performing a catalytic reaction. This is true Transfer heat from the exhaust gas to the honeycomb body, but no additional Heat of reaction generated. Only below the height H does this close again coated zone 16 so that the catalytic conversion of the Exhaust gas takes place. Ideally, the height H should be such that it matches the route corresponds to what the exhaust gas needs to go from turbulent to laminar To flow over.

Im Folgenden werden Verfahren vorgeschlagen, wie ein solcher Katalysator mit wenigstens einer beschichtungsfreien Zone hergestellt werden kann.In the following, methods are proposed, such as using such a catalyst at least one coating-free zone can be produced.

1.Verfahrensbeispiel1.Verfahrensbeispiel

In den Figuren 3a und 3b ist der Katalysator, welcher erzeugt werden soll, schematisch dargestellt.The catalyst which is to be produced is schematic in FIGS. 3a and 3b shown.

Der Wabenkörper wird parallel zu seiner Längsachse A-A bis zu einer ersten Tiefe t1 in den flüssigen Washcoat 40 eingetaucht. Hierbei steht die Längsachse A-A senkrecht zur Oberfläche des Washcoat-Bades. Alternativ kann die Achse A-A gegenüber der Oberfläche des Washcoats verkippt werden. Hierdurch wird erreicht, dass nur die Zone in der oberen linken Ecke des Wabenkörpers unbeschichtet bleibt. Es können auch zwei Tauchvorgänge durchgeführt werden, wobei die Achse A-A einmal senkrecht und einmal schräg bezüglich der Oberfläche des flüssigen Washcoats 40 steht.The honeycomb body is immersed in the liquid washcoat 40 parallel to its longitudinal axis AA to a first depth t 1 . The longitudinal axis AA is perpendicular to the surface of the washcoat bath. Alternatively, the axis AA can be tilted relative to the surface of the washcoat. This ensures that only the zone in the upper left corner of the honeycomb body remains uncoated. Two dipping processes can also be carried out, the axis AA being perpendicular and once inclined with respect to the surface of the liquid washcoat 40.

2. Verfahrensbeispiel2. Process example

Diese Vorgehensweise eignet sich grundsätzlich zur Herstellung von Katalysatoren, deren unbeschichtete Zonen komplexe Formen aufweisen sollen. Ein Beispiel hierfür ist in den Fign. 4a und 4b dargestellt.This procedure is basically suitable for the production of catalysts, whose uncoated zones are said to have complex shapes. An example of this is in the figures 4a and 4b.

Dieses Verfahren ist nur dann anwendbar, wenn der Wabenkörper 10 Kanäle 12 aufweist, die voneinander vollständig getrennt sind. Dies ist jedoch in der Regel der Fall.This method can only be used if the honeycomb body has 10 channels 12 has that are completely separated from each other. However, this is usually the case.

Zunächst wird der Wabenkörper 10 bis zu einer ersten Tiefe t1 in den Washcoat eingetaucht. Anschließend wird das Gebiet der oberen Stirnfläche 10A des Wabenkörpers 10, unter welchem die beschichtungsfreie Zone 18 erzeugt werden soll, mit einem ersten Abdeckelement 51 abgedeckt. Dieses Abdeckelement 51 muss die unter ihm liegenden Kanäle 12 im wesentlichen luft- und flüssigkeitsdicht verschließen. First, the honeycomb body 10 is immersed in the washcoat to a first depth t 1 . The area of the upper end face 10A of the honeycomb body 10, under which the coating-free zone 18 is to be created, is then covered with a first covering element 51. This cover element 51 must close the channels 12 lying beneath it in an essentially airtight and liquid-tight manner.

In einem dritten Schritt wird nun der Wabenkörper 10 vollständig in den flüssigen Washcoat eingetaucht. Hierbei werden die Kanäle 12, die nicht vom ersten Abdeckelement 51 abgedeckt sind, vollständig geflutet. Auf Grund der Luftsäule, welche in den abgedeckten Kanälen steht, kann der Washcoat in diese Kanäle nicht oder nur bis zu einer gewissen Höhe eindringen. Hierdurch bildet sich unterhalb des Abdeckelementes 51 eine beschichtungsfreie Zone 18 aus. Das Abdeckelement 51 kann hierbei beliebige Formen haben.In a third step, the honeycomb body 10 is now completely in the liquid Washcoat dipped. Here, the channels 12 that are not from the first Cover element 51 are covered, completely flooded. Because of the air column, which is in the covered channels, the washcoat cannot or only in these channels penetrate to a certain height. This forms below the Cover element 51 from a coating-free zone 18. The cover member 51 can have any shape.

3. Verfahrensbeispiel3. Process example

Dieses Ausführungsbeispiel ist eine Erweiterung des zweiten Verfahrensbeispiels, welches dahingehend erweitert ist, dass hier zwei getrennte beschichtungsfreie Zonen 18 erzeugt werden.This embodiment is an extension of the second method example, which is expanded in that there are two separate coating-free zones 18 are generated.

Zunächst wird der Wabenkörper 10 bis zu einer ersten Tiefe t1 in den Washcoat 40 eingetaucht. Anschließend wird ein erster Bereich der oberen Stirnfläche 10A des Wabenkörpers 10 mit dem ersten Abdeckelement 51 abgedeckt. Im weiteren wird der Wabenkörper 10 bis zu einer zweiten Tiefe t2 in den Washcoat abgesenkt. Nun wird ein weiterer Teil der Oberfläche der oberen Stirnfläche 10A mit einem zweiten Abdeckelement 52 abgedeckt, woraufhin der Wabenkörper 10 ganz in den Washcoat eingetaucht wird. Hierbei sind, wie aus den Figuren 5a und 5b ersichtlich, zwei getrennte beschichtungsfreie Zonen 18 mit unterschiedlicher Form und Höhe entstanden.First, the honeycomb body 10 is immersed in the washcoat 40 to a first depth t 1 . A first area of the upper end face 10A of the honeycomb body 10 is then covered with the first cover element 51. Furthermore, the honeycomb body 10 is lowered into the washcoat to a second depth t 2 . Now a further part of the surface of the upper end face 10A is covered with a second cover element 52, whereupon the honeycomb body 10 is completely immersed in the washcoat. Here, as can be seen from FIGS. 5a and 5b, two separate coating-free zones 18 with different shapes and heights have been created.

Es versteht sich von selbst, dass dieses Verfahren auf eine beliebige Anzahl von beschichtungsfreien Zonen erweitert werden kann. It goes without saying that this method can be used on any number of coating-free zones can be expanded.

BEZUGSZEICHENLISTELIST OF REFERENCE NUMBERS

1010
Wabenkörperhoneycombs
10A10A
obere Stirnfläche des Wabenkörpersupper end face of the honeycomb body
1212
Kanälechannels
1414
Kanalwändechannel walls
1616
beschichtete Zonecoated zone
1818
beschichtungsfreie Zonecoating-free zone
2020
Sammelraumplenum
3131
erste Abgaszuleitungfirst exhaust pipe
3232
zweite Abgaszuleitungsecond exhaust pipe
3333
dritte Abgaszuleitungthird exhaust pipe
3434
vierte Abgaszuleitungfourth exhaust pipe
4040
flüssiger Washcoatliquid washcoat
5151
erstes Abdeckelementfirst cover element
5252
zweites Abdeckelementsecond cover element
SS
Schusskanalfiring channel
ZZ
Zone hoher BelastungHigh stress zone
t1 t 1
erste Eintauchtiefefirst immersion depth
t2 t 2
zweite Eintauchtiefesecond immersion depth
HH
Höheheight
A-AA-A
Längsachse des WabenkörpersLongitudinal axis of the honeycomb body

Claims (9)

Vorrichtung zum Reinigen von Abgasen eines Verbrennungsmotors bestehend aus einem Wabenkörper (10) mit einem motomahen und einem motorfernen Ende und einer auf diesen Wabenkörper aufgebrachten aktiven Beschichtung,
dadurch gekennzeichnet, dass sich im Bereich des motornahen Endes des Wabenkörpers wenigstens eine beschichtungsfrei (18) Zone befindet.Device for cleaning exhaust gases from an internal combustion engine consisting of a honeycomb body (10) with an end near the engine and an end remote from the engine and an active coating applied to this honeycomb body,
characterized in that there is at least one coating-free (18) zone in the region of the end of the honeycomb body near the engine. Vorrichtung nach Anspruch 1, dadurch gekennzeichnet, dass die aktive Beschichtung eine Washcoat-Schicht aufweist.Device according to claim 1, characterized in that the active coating has a washcoat layer. Verfahren zur Beschichtung eines sich entlang einer Längsachse (A-A) erstreckenden Wabenkörpers (10) durch wenigstens einmaliges Eintauchen des Wabenkörper in einen flüssigen Washcoat (40),
dadurch gekennzeichnet, dass wenigstens ein Tauchvorgang durchgeführt wird, bei dem der Wabenkörper (10) nicht vollständig in den Washcoat (40) eingetaucht wird.Method for coating a honeycomb body (10) extending along a longitudinal axis (AA) by immersing the honeycomb body in a liquid washcoat (40) at least once,
characterized in that at least one dipping process is carried out in which the honeycomb body (10) is not completely immersed in the washcoat (40). Verfahren nach Anspruch 3, dadurch gekennzeichnet, dass während des wenigstens einen Eintauchvorgangs die Längsachse (A-A) des Wabenkörpers (10) im wesentlichen senkrecht bezüglich der Oberfläche des flüssigen Washcoats (40) steht.A method according to claim 3, characterized in that during the at least one immersion process, the longitudinal axis (AA) of the honeycomb body (10) is substantially perpendicular to the surface of the liquid washcoat (40). Verfahren nach Anspruch 3, dadurch gekennzeichnet, dass während des wenigstens einen Eintauchvorgangs die Längsachse (A-A) des Wabenkörpers (10) schräg bezüglich der Oberfläche des flüssigen Washcoats (40) steht.A method according to claim 3, characterized in that during the at least one immersion process, the longitudinal axis (AA) of the honeycomb body (10) is inclined with respect to the surface of the liquid washcoat (40). Verfahren nach den Ansprüchen 3 bis 5, dadurch gekennzeichnet, dass wenigstens zwei Eintauchvorgänge durchgeführt werden, wobei während eines Eintauchvorgangs die Längsachse (A-A) des Wabenkörpers (10) im wesentlichen senkrecht bezüglich der Oberfläche des flüssigen Washcoats (40) und während eines weiteren Eintauchvorgangs im wesentlichen schräg bezüglich der Oberfläche des flüssigen Washcoats (40) steht. Method according to claims 3 to 5, characterized in that at least two immersion processes are carried out, the longitudinal axis (AA) of the honeycomb body (10) being substantially perpendicular to the surface of the liquid washcoat (40) and during a further immersion process during an immersion process is substantially oblique with respect to the surface of the liquid washcoat (40). Verfahren zur Beschichtung eines sich entlang einer Längsachse (A-A) erstreckenden, zwei Stirnflächen aufweisenden Wabenkörpers (10), welcher voneinander getrennte Kanäle (12) aufweist, die sich parallel zur Längsachse (A-A) erstrecken, durch wenigstens einmaliges Eintauchen des Wabenkörper in einen flüssigen Washcoat (40),
dadurch gekennzeichnet, dass
vor dem Eintauchvorgang ein Teil der oberen Stirnfläche (10A) des Wabenkörpers (10) mit einem Abdeckelement (51, 52) im wesentlichen dichtend abgedeckt wird.Method for coating a honeycomb body (10) which extends along a longitudinal axis (AA) and has two end faces and which has channels (12) which are separate from one another and which extend parallel to the longitudinal axis (AA), by immersing the honeycomb body in a liquid washcoat at least once (40)
characterized in that
before the immersion process, a part of the upper end face (10A) of the honeycomb body (10) is covered essentially sealingly with a cover element (51, 52). Verfahren nach Anspruch 5, dadurch gekennzeichnet, dass vor dem Abdecken des Teils der oberen Stirnfläche (10A) ein Eintauchvorgang durchgeführt wird, wobei der Wabenkörper (10) nicht vollständig in den flüssigen Washcoat (40) eingetaucht wird.A method according to claim 5, characterized in that before the part of the upper end face (10A) is covered, an immersion process is carried out, the honeycomb body (10) not being completely immersed in the liquid washcoat (40). Verfahren nach einem der Ansprüche 3 bis 6, dadurch gekennzeichnet, dass während oder nach der Beschichtung mit Washcoat eine Beschichtung mit wenigstens einem Edelmetall durchgeführt wird.Method according to one of claims 3 to 6, characterized in that during or after the coating with washcoat, a coating is carried out with at least one noble metal.
EP02001466A 2001-02-02 2002-01-22 Device for purifying the exhaust gas from a combustion engine and manufacturing process Ceased EP1229219A3 (en)

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DE10104751A DE10104751A1 (en) 2001-02-02 2001-02-02 Device for cleaning exhaust gases from an internal combustion engine and method for its production
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WO2007073807A2 (en) * 2005-12-24 2007-07-05 Umicore Ag & Co. Kg Method for catalytically coating ceramic honeycomb bodies
DE102007026442A1 (en) 2007-06-06 2008-12-11 Robert Bosch Gmbh Method for feeding a coating substance into a molding body of an exhaust gas branch component comprises inserting the molding body into an immersion bath for an immersion time and rotating the molding body about a longitudinal axis
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WO2007073807A2 (en) * 2005-12-24 2007-07-05 Umicore Ag & Co. Kg Method for catalytically coating ceramic honeycomb bodies
WO2007073807A3 (en) * 2005-12-24 2007-08-23 Umicore Ag & Co Kg Method for catalytically coating ceramic honeycomb bodies
CN101370583B (en) * 2005-12-24 2010-06-16 乌米科雷股份两合公司 Method for catalytically coating ceramic honeycomb bodies
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DE102007002903B4 (en) * 2007-01-19 2009-06-04 Süd-Chemie AG Process for coating a catalyst support
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FR2941999A1 (en) * 2009-02-12 2010-08-13 Peugeot Citroen Automobiles Sa CATALYST FOR THE TREATMENT OF EXHAUST GASES OF A COMBUSTION ENGINE AND PROCESS FOR OBTAINING SUCH A CATALYST
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CN102317590B (en) * 2009-02-12 2013-10-16 标致·雪铁龙汽车公司 Catalyst for treating the exhaust gases of a combustion engine, and method for obtaining such a catalyst
DE102011018259A1 (en) * 2011-04-20 2012-10-25 Süd-Chemie AG Coating catalyst shaped body, by providing substrate having first end surface, second end surface and flow channels, and introducing suspension and/or solution in flow channels starting from first end surface

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