CATALYTIC CONVERTER COMPONENT AND PROCESS FOR ITS MANUFACTURE

• US 20140056780A1
• Filed: 08/20/2013
• Published: 02/27/2014
• Est. Priority Date: 08/24/2012
• Status: Active Grant

• Current Assignee: Advanced Technology Emission Solutions Inc
• Original Assignee: Advanced Technology Emission Solutions Inc
• Inventors: Crawford, Robin, Douglas, John
• Granted Patent: US 9,737,851 B2
• Time in Patent Office: Days
• US Class Current: 422/311
• CPC Class Codes: B01D 53/94 by catalytic processes
• CPC Class Codes: B28B 11/043 filling cavities or chambers of hollow blocks
• CPC Class Codes: B28B 11/241 using microwave heating means
• CPC Class Codes: B29C 48/0022 combined with cutting
• CPC Class Codes: B29C 48/022 characterised by the choice of material
• CPC Class Codes: B29C 48/11 comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped
• CPC Class Codes: B29C 48/30 Extrusion nozzles or dies extrusion characterised by the shape or cross-section of the extruded article B29C48/03
• CPC Class Codes: B29C 48/345 Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising
• CPC Class Codes: B29D 99/0089 Producing honeycomb structures consisting of porous ceramic ware C04B38/0006
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 2111/0081 as catalysts or catalyst carriers
• CPC Class Codes: C04B 26/02 Macromolecular compounds
• CPC Class Codes: C04B 35/195 Alkaline earth aluminosilicates, e.g. cordierite or anorthite
• CPC Class Codes: C04B 38/0012 characterised by the material used for sealing or plugging (some of) the channels of the honeycombs
• CPC Class Codes: C04B 38/0054 the pores being microsized or nanosized
• CPC Class Codes: C04B 40/0218 Microwaves
• CPC Class Codes: F01N 2510/02 for thermal insulation
• CPC Class Codes: F01N 3/0222 the structure being monolithic, e.g. honeycombs
• CPC Class Codes: H05B 6/108 for heating a fluid
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies
• CPC Class Codes: Y10T 29/49345 : Catalytic device making

Abstract

In a process for manufacturing a catalytic converter component, a ceramic unit is used that has been prepared by extruding green ceramic product through a die to form an extrusion having a honeycomb substrate structure in which tubular passages extend along the extrusion, the passages bounded by walls dividing adjacent passages from one another. The unit is obtained by cutting off a length of the extrusion and curing and firing it. The process further comprises flowing insulation material from one end of the unit into selected ones of the elongate passages, the insulating material then being cured by microwave irradiation. The passages are selected so that the cured insulation material forms an internal thermal insulating barrier between a core zone of the unit and a radially outer zone of the unit.

Claims

1. A process for manufacturing a component for a catalytic converter, comprising taking a ceramic unit prepared by extruding green ceramic product through a die to form an extrusion having a honeycomb substrate structure having a plurality of tubular passages extending along the length of the extrusion, the passages bounded by walls dividing adjacent passages from one another, the unit being obtained by cutting off a length of the extrusion and curing and firing the length of extrusion, the process further comprising flowing insulation material from an end of the unit to form an internal thermally insulating barrier between a core zone of the unit and a radially outer zone of the unit, and curing the flowed insulating material using microwave radiation.

2. A process as claimed in claim 1, in which the flowing insulation material from the end of the unit is such as to at least partially fill selected ones of the passages with the insulation material.

3. A process as claimed in claim 1, further comprising cutting away a part of the honeycomb structure, the flowing insulation material from the end of the unit being such as to at least partially fill the site of the cut away part of the honeycomb structure with the insulation material.

4. A process as claimed in claim 2, in which the insulation material is injected into the selected passages as a paste-like mixture of glass fibres, ceramic slurry, binder and water.

5. A process as claimed in claim 2, in which the insulation material flows into the selected passages under gravity as a powder of glass fibres, ceramic, and binder.

6. A process as claimed in claim 1, in which, following curing, the cured insulating material is predominantly a matrix of silica containing pores predominantly in the range 1.5 millimetres to 0.3 millimetres across.

7. A process as claimed in claim 1, the microwave radiation directed from both sides of the barrier layer.

8. A process as claimed in claim 1, the insulation material directed through a die to obtain a generally cylindrical thermal insulation barrier.

9. A process as claimed in claim 1, further comprising using a gasket layer on at least one end of the unit to limit incursion of insulation material into non-selected passages.

10. A process as claimed in claim 1, further comprising incrementally relatively moving an extrusion die and the unit to optimize registration of an exit aperture of the die to entrance openings of the selected passages.

11. A component for a catalytic converter comprising a unit of cured ceramic extrusion having a honeycomb substrate structure in which a plurality of passages extends along the unit, the passages bounded by walls dividing adjacent passages from one another, and an internal thermal insulation barrier between a core zone of the unit and a radially outer zone, the insulation material barrier composed of microwave radiation cured insulation material.

12. A component as claimed in claim 11, the thermal barrier formed by at least part of selected passages containing the microwave cured insulation material.

13. A component as claimed in claim 12, the microwave cured insulation material being cured from a past-like insulation material injected into the selected passages.

14. A component as claimed in claim 12, the microwave cured insulation material being cured from a powder insulation material gravity flowed into the selected passages.

15. A component as claimed in claim 12, in which the insulation material contains glass fibres, ceramic, and binder.

16. A component as claimed in claim 12, in which, following microwave curing, the cured insulating material is predominantly a matrix of silica containing pores predominantly in the range 1.5 millimetres to 0.3 millimetres across.

17. A component as claimed in claim 12, the component mounted within a casing, the casing having an inlet adaptor for entry of exhaust gases from an upstream exhaust pipe section to one end of the component for transmission along non-selected ones of the passages, and an outlet adaptor for exit of exhaust gases from the other end of the component to a downstream exhaust pipe section after transmission thereof along said non-selected passages, the core zone having a radial size substantially equal to the bore of the upstream exhaust pipe section.