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KR101326815B1 - Fabrication method of catalytic converter - Google Patents

Fabrication method of catalytic converter Download PDF

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KR101326815B1
KR101326815B1 KR1020110061775A KR20110061775A KR101326815B1 KR 101326815 B1 KR101326815 B1 KR 101326815B1 KR 1020110061775 A KR1020110061775 A KR 1020110061775A KR 20110061775 A KR20110061775 A KR 20110061775A KR 101326815 B1 KR101326815 B1 KR 101326815B1
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carrier
channel
catalyst
front surface
plugging
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KR20130000947A (en
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최성무
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현대자동차주식회사
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Priority to KR1020110061775A priority Critical patent/KR101326815B1/en
Priority to US13/313,997 priority patent/US9046023B2/en
Priority to DE102011056527A priority patent/DE102011056527A1/en
Priority to CN201110443426.0A priority patent/CN102828805B/en
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    • 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
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/0215—Coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • 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
    • B01J35/19—Catalysts containing parts with different compositions
    • 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
    • B01J35/57—Honeycombs
    • 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
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/0236—Drying, e.g. preparing a suspension, adding a soluble salt and drying
    • 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
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/08—Heat treatment

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Thermal Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Physics & Mathematics (AREA)
  • Biomedical Technology (AREA)
  • Environmental & Geological Engineering (AREA)
  • Analytical Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Catalysts (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)
  • Exhaust Gas After Treatment (AREA)

Abstract

본 발명의 실시예에 따른 촉매유닛의 방법은, 본 발명의 실시예에 따른 촉매유닛의 제조방법은, 담체의 전면(front surface) 일부에 마스킹부재를 덮어 채널의 일부를 덮는 단계, 및 상기 마스킹부재에 의해서 덮인 부분을 제외한 오픈된 채널 안으로 플러깅부재를 유입시키는 단계를 포함한다. 상기 플러깅부재를 유입시키는 단계에서, 롤러를 상기 담체의 전면을 따라서 굴림으로써, 상기 롤러에 부착된 상기 플러깅부재가 상기 오픈된 채널의 입구를 폐쇄하도록 한다. 상기 플러깅부재를 유입시키는 단계에서, 붓을 상기 담체의 전면을 따라서 이동함으로써, 상기 붓의 브러쉬에 부착된 상기 플러깅부재가 상기 오픈된 채널의 입구를 폐쇄하도록 한다.
따라서, 담체의 전면에서 중심부를 제외한 가장자리부를 용이하게 플러깅시킬 수 있다. 아울러, 배기가스의 흐름(유동)이 적은 데드존에 대응하는 부분에 형성되는 채널은 플러그로 폐쇄함으로써, 그 내부에 촉매코팅층을 형성하지 않는다. 따라서, 촉매성분에 대한 비용을 줄일 수 있고, 배기가스유동이 적은 부분만 폐쇄함으로써 배기가스 정화율은 일정하게 유지할 수 있다.In the method of the catalyst unit according to the embodiment of the present invention, the method of manufacturing the catalyst unit according to the embodiment of the present invention comprises the steps of covering a portion of the channel by covering a masking member on a portion of the front surface of the carrier, and the masking Introducing a plugging member into the open channel except for the portion covered by the member. In the step of introducing the plugging member, the roller is rolled along the front surface of the carrier so that the plugging member attached to the roller closes the inlet of the open channel. In the step of introducing the plugging member, by moving the brush along the front surface of the carrier, the plugging member attached to the brush of the brush to close the inlet of the open channel.
Therefore, the edge portion of the front surface of the carrier excluding the center portion can be easily plugged. In addition, the channel formed in the portion corresponding to the dead zone where the flow (flow) of the exhaust gas is small is closed by the plug, so that the catalyst coating layer is not formed therein. Therefore, the cost for the catalyst component can be reduced, and the exhaust gas purification rate can be kept constant by closing only the portion where the exhaust gas flow is small.

Description

촉매유닛의 제조방법{FABRICATION METHOD OF CATALYTIC CONVERTER}Manufacturing Method of Catalyst Unit {FABRICATION METHOD OF CATALYTIC CONVERTER}

본 발명은 배기가스에 포함된 유해물질을 저감시키도록 배기가스 유동특성에 따라서 채널이 형성되고, 이 채널에 촉매를 코팅함으로써 배기가스에 포함된 유해물질을 효율적으로 저감시키는 촉매유닛의 제조방법에 관한 것이다.The present invention relates to a method for producing a catalyst unit for efficiently reducing the harmful substances contained in the exhaust gas by forming a channel according to the flow characteristics of the exhaust gas so as to reduce the harmful substances contained in the exhaust gas. It is about.

자동차에서 배기가스를 정화하기 위하여 주로 쓰이는 장치가 삼원촉매(three way catalyst)를 사용한 촉매컨버터인데, 이는 배기 파이프 도중에 장착되며, 차량에 따라 배기가스 배출량이 다르기 때문에 촉매의 사양은 다르다.The most commonly used device for purifying exhaust gas in automobiles is a catalytic converter using a three way catalyst, which is installed in the middle of an exhaust pipe, and the specification of the catalyst is different because the exhaust gas emission varies depending on the vehicle.

상기 삼원촉매는 배기가스의 유해성분인 일산화탄소, 질소산화물 및 탄화수소계 화합물과 동시에 반응하여 이들 화합물을 제거하는 촉매를 의미하며, 주로 Pt/Rh, Pd/Rh 또는 Pt/Pd/Rh계의 삼원촉매가 이용된다.The three-way catalyst refers to a catalyst that removes these compounds by reacting simultaneously with the harmful components of the exhaust gas such as carbon monoxide, nitrogen oxides and hydrocarbon-based compounds, and is mainly a three-way catalyst of Pt / Rh, Pd / Rh or Pt / Pd / Rh system. Is used.

한편, 유해 배기가스의 배출이 상대적으로 많은 디젤 차량의 경우, 연비, 출력면에서 우수함에도 불구하고 가솔린 차량과는 달리 배기가스 내에 질소산화물과 입자상물질(Particulate Matter, PM)이 상당히 많이 함유되어 있다.On the other hand, diesel vehicles, which have relatively high emissions of harmful exhaust gases, have high amounts of nitrogen oxides and particulate matter (Particulate Matter (PM)) in the exhaust gases, unlike gasoline vehicles, despite excellent fuel economy and output. .

이와 같이 디젤 차량에 있어서는 공기가 대부분의 운전조건에서 충분한 상태로 연소되기 때문에 일산화탄소와 탄화수소는 가솔린 차량에 비해 아주 적게 배출되나, 질소산화물과 입자상물질이 많이 배출된다.As such, in a diesel vehicle, carbon monoxide and hydrocarbons are emitted much less than gasoline vehicles because air is sufficiently burned under most driving conditions, but nitrogen oxides and particulate matter are emitted.

최근 디젤 차량의 배출기준 강화에 대응하기 위하여 후처리기술로 디젤매연여과필터의 연구가 매우 활발히 진행되고 있으며, 이 디젤매연여과필터를 실제 차량에 적용하기 위해서는 아직 연구되어야 할 부분이 많다.Recently, research on diesel particulate filter as an aftertreatment technology is actively conducted in order to cope with the emission standard of diesel vehicles, and there are many areas to be studied in order to apply the diesel particulate filter to actual vehicles.

디젤산화촉매(Diesel Oxidation Catalyst, DOC)에 백금(Pt)을 사용하고 이와 별도로 디젤매연여과필터(Diesel Particulate Filter, DPF)를 사용하는 구조(DOC+DPF, CPF)가 최근 유럽의 자동차 메이커에서 개발되어 양산됨으로써, 많은 신뢰도 향상과 매출을 올리고 있는 상황에 있다.The structure (DOC + DPF, CPF) that uses platinum (Pt) for diesel oxidation catalyst (DOC) and diesel particulate filter (DPF) separately developed by European car maker recently By mass production, there is a lot of reliability improvement and sales.

그리고, 촉매를 코팅한 구조의 디젤매연여과필터, 즉 디젤매연촉매여과필터(Diesel Catalyzed Particulate Filter)가 개발된 바 있다. 한편, 기존 코디어라이트 담체에 이종 농도의 촉매를 코팅하는 방식으로는 여러 가지 방법들이 알려져 있으며, 이미 많은 선행기술들이 있다.In addition, a diesel particulate filter having a catalyst coated structure, that is, a diesel particulate filter has been developed. On the other hand, a variety of methods are known as a method of coating a heterogeneous catalyst on the existing cordierite carrier, there are many prior art.

예를 들면, 코디어라이트 담체를 서로 다른 농도의 촉매용액에 담갔다가 빼는 방식(dipping)이 있고, 담체의 일측 단부를 촉매용액에 담가서 세운 뒤 반대쪽 타측 단부 위에서 흡입기를 이용해 진공압을 걸어 촉매용액을 흡입하고 이어 담체를 거꾸로 세워 타측 단부를 농도가 상이한 촉매용액에 담근 뒤 다시 그 반대쪽 일측 단부 위에서 진공압을 걸어 촉매용액을 흡입하는 방식이 있다.For example, the dilution of the cordierite carrier in different concentrations of the catalyst solution is followed by dipping.The one end of the carrier is immersed in the catalyst solution, erected, and the vacuum solution is applied on the other end of the catalyst using an inhaler. Then, the carrier is inverted and then the other end is immersed in a catalyst solution having a different concentration, and then the vacuum solution is applied on the opposite end to suck the catalyst solution.

한편, 촉매유닛을 제작할 때, 배기가스의 유동특성과 상관없이 담체 전체에 귀금속을 코팅하고 있는데, 이는 배기가스의 유동에 따라서 귀금속을 효율적으로 사용하지 못하는 문제점이 있다.On the other hand, when manufacturing a catalyst unit, regardless of the flow characteristics of the exhaust gas is coated with a noble metal throughout the carrier, which has a problem that can not use the precious metal efficiently according to the flow of the exhaust gas.

따라서, 본 발명은 배기가스의 유동이 적은 담체의 특정부위는 촉매성분을 코팅하지 않음으로써, 원가를 절감할 수 있도록 하는 촉매유닛의 제조방법을 제공하는 것이다.Accordingly, the present invention is to provide a method for producing a catalyst unit that can reduce the cost by not coating the catalyst component on a specific portion of the carrier with a low flow of exhaust gas.

본 발명의 실시예에 따른 촉매유닛의 제조방법은, 담체의 전면(front surface) 일부에 마스킹부재를 덮어 채널의 일부를 덮는 단계, 및 상기 마스킹부재에 의해서 덮인 부분을 제외한 오픈된 채널 안으로 플러깅부재를 유입시키는 단계를 포함한다. A method of manufacturing a catalyst unit according to an embodiment of the present invention includes covering a portion of a channel by covering a masking member on a portion of a front surface of a carrier, and plugging the member into an open channel except for a portion covered by the masking member. Including the step of introducing.

상기 플러깅부재를 유입시키는 단계에서, 롤러를 상기 담체의 전면을 따라서 굴림으로써, 상기 롤러에 부착된 상기 플러깅부재가 상기 오픈된 채널의 입구를 폐쇄하도록 한다. In the step of introducing the plugging member, the roller is rolled along the front surface of the carrier so that the plugging member attached to the roller closes the inlet of the open channel.

상기 플러깅부재를 유입시키는 단계에서, 붓을 상기 담체의 전면을 따라서 이동함으로써, 상기 붓의 브러쉬에 부착된 상기 플러깅부재가 상기 오픈된 채널의 입구를 폐쇄하도록 한다. In the step of introducing the plugging member, by moving the brush along the front surface of the carrier, the plugging member attached to the brush of the brush to close the inlet of the open channel.

상기 마스킹부재를 제거하는 단계, 및 상기 오픈된 채널을 폐쇄한 상기 플러깅부재를 건조 소성기키는 단계를 포함한다. Removing the masking member, and drying the plugging member closing the open channel.

가장자리 부분에 상기 오픈된 채널이 위치하도록 상기 마스킹부재는 상기 담체의 전면에서 중심부를 커버한다. The masking member covers a central portion at the front of the carrier so that the open channel is located at an edge portion.

앞에서 기재된 바와 같이 본 발명에 따른 촉매유닛의 제조장치 및 이의 제조방법에서, 담체의 전면에서 중심부를 제외한 가장자리부를 용이하게 플러깅시킬 수 있다. As described above, in the apparatus for producing a catalyst unit and a method for manufacturing the same according to the present invention, it is possible to easily plug the edge portion of the front surface of the carrier except for the center portion.

아울러, 배기가스의 흐름(유동)이 적은 데드존에 대응하는 부분에 형성되는 채널은 플러그로 폐쇄함으로써, 그 내부에 촉매코팅층을 형성하지 않는다. 따라서, 촉매성분에 대한 비용을 줄일 수 있고, 배기가스유동이 적은 부분만 폐쇄함으로써 배기가스 정화율은 일정하게 유지할 수 있다.In addition, the channel formed in the portion corresponding to the dead zone where the flow (flow) of the exhaust gas is small is closed by the plug, so that the catalyst coating layer is not formed therein. Therefore, the cost for the catalyst component can be reduced, and the exhaust gas purification rate can be kept constant by closing only the portion where the exhaust gas flow is small.

도 1은 본 발명의 실시예에 따른 촉매유닛의 개략적인 사시도이다.
도 2는 본 발명의 실시예에 따른 촉매유닛에 채널플러깅부를 형성하는 방법을 보여주는 사시도이다.
도 3은 본 발명의 실시예에 따른 촉매유닛을 채널플러깅부를 형성하는 방법을 보여주는 측면도이다.
도 4는 본 발명의 실시예에 따른 촉매유닛의 개략적인 측 단면도이다.
도 5는 본 발명의 실시예에 따른 촉매유닛에 촉매코팅층을 형성하는 방법을 보여주는 측 단면도이다.
도 6은 본 발명의 실시예에 따른 촉매유닛의 제조방법을 보여주는 플로우차트이다.
도 7은 본 발명의 실시예에 따른 촉매유닛이 장착된 상태를 보여주는 개략적인 단면도이다.1 is a schematic perspective view of a catalyst unit according to an embodiment of the present invention.
Figure 2 is a perspective view showing a method for forming a channel plugging portion in the catalyst unit according to an embodiment of the present invention.
Figure 3 is a side view showing a method for forming a channel plugging unit catalyst unit according to an embodiment of the present invention.
4 is a schematic side cross-sectional view of a catalyst unit according to an embodiment of the present invention.
5 is a side cross-sectional view showing a method of forming a catalyst coating layer on a catalyst unit according to an embodiment of the present invention.
6 is a flowchart showing a method of manufacturing a catalyst unit according to an embodiment of the present invention.
7 is a schematic cross-sectional view showing a state in which a catalyst unit is mounted according to an embodiment of the present invention.

이하, 본 발명의 바람직한 실시예를 첨부한 도면에 의거하여 상세하게 설명하면 다음과 같다.Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

도 1은 본 발명의 실시예에 따른 촉매유닛의 개략적인 사시도이다.1 is a schematic perspective view of a catalyst unit according to an embodiment of the present invention.

도 1을 참조하면, 촉매유닛(100)은 담체(102)를 포함한다.Referring to FIG. 1, the catalyst unit 100 includes a carrier 102.

상기 담체(102)에는 전체적으로 원통형 구조이며, 전면에서 후면으로 배기가스가 통과하도록 채널(112)들이 형성된다. 본 발명의 실시예에서, 상기 채널(112)은 두 가지로 구분되는데, 그 입출구가 개방된 채널오프닝부(110)와 입출구중 하나가 폐쇄된 채널플러깅부(120)를 포함한다. The carrier 102 has a generally cylindrical structure, and channels 112 are formed to allow exhaust gas to pass from the front side to the rear side. In the exemplary embodiment of the present invention, the channel 112 is divided into two types, and includes a channel opening part 110 in which an inlet and an outlet are open, and a channel plugging unit 120 in which one of the inlets and outlets is closed.

상기 채널오프닝부(110)는 상기 채널(112)의 입구와 출구가 모두 개방되고, 상기 채널플러깅부(120)는 상기 채널(112)의 입구 또는 출구가 플러그(122)로 폐쇄된 구조이다. 아울러, 상기 채널오프닝부(110)에서 그 내측면에는 배기가스에 포함된 유해물질을 저감시키는 촉매코팅층(114)이 형성된다. The channel opening part 110 has both an inlet and an outlet of the channel 112 open, and the channel plugging part 120 has a structure in which the inlet or the outlet of the channel 112 is closed by the plug 122. In addition, a catalyst coating layer 114 is formed on the inner side of the channel opening 110 to reduce harmful substances contained in the exhaust gas.

도시한 바와 같이, 상기 담체(102)의 전면에서 중심부에는 상기 채널오프닝부(110)가 형성되고, 상기 중심부를 제외한 가장자리부에 상기 채널플러깅부(120)가 형성된다. 상기 채널플러깅부(120)를 형성하기 위한 방법에 대해서는 도 2 및 도 3을 참조하여 설명한다. As shown, the channel opening part 110 is formed at the center of the front surface of the carrier 102, and the channel plugging part 120 is formed at the edge of the carrier 102. A method for forming the channel plugging unit 120 will be described with reference to FIGS. 2 and 3.

도 2는 본 발명의 실시예에 따른 촉매유닛에 채널플러깅부를 형성하는 방법을 보여주는 사시도이다. Figure 2 is a perspective view showing a method for forming a channel plugging portion in the catalyst unit according to an embodiment of the present invention.

도 2를 참조하면, 촉매유닛(100)을 제작하기 위한 담체(102)가 준비되고, 상기 담체(102)는 전면에서 후면으로 채널(112)들이 형성된 구조를 갖는다. 여기서, 채널(112)들의 입구와 출구는 모두 개방된 상태이다. Referring to FIG. 2, a carrier 102 for preparing the catalyst unit 100 is prepared, and the carrier 102 has a structure in which channels 112 are formed from the front side to the rear side. Here, both the inlet and the outlet of the channels 112 are open.

도시한 바와 같이, 상기 담체(102)의 전면에 마스킹부재(200)를 덮는다. 여기서, 상기 마스킹부재(200)는 상기 담체(102)의 전면에서 중심부에 배치되고, 가장자리부는 덮지 않는다. 따라서, 가장자리부의 상기 채널(112)들은 그 입구가 개방된다. As shown, the masking member 200 is covered on the front surface of the carrier 102. Here, the masking member 200 is disposed at the center of the front surface of the carrier 102, the edge portion is not covered. Thus, the channels 112 at the edges are open at their inlets.

도 3은 본 발명의 실시예에 따른 촉매유닛을 채널플러깅부를 형성하는 방법을 보여주는 측면도이다. Figure 3 is a side view showing a method for forming a channel plugging unit catalyst unit according to an embodiment of the present invention.

도 3을 참조하면, 상기 담체(102)의 전면에 상기 마스킹부재(200)가 덮이고, 상기 담체(102)의 전면에 롤러(300)를 굴린다. 여기서, 상기 롤러(300)에는 플러깅부재(320)가 부착되어 있고, 상기 플러깅부재(320)가 상기 마스킹부재(200)로 덮이지 않은 채널(112)들로 유입된다. 여기서, 상기 플러깅부재(320)는 액상으로 상기 채널(112)의 안으로 유입된다.Referring to FIG. 3, the masking member 200 is covered on the front surface of the carrier 102, and the roller 300 is rolled on the front surface of the carrier 102. Here, a plugging member 320 is attached to the roller 300, and the plugging member 320 flows into the channels 112 that are not covered by the masking member 200. Here, the plugging member 320 is introduced into the channel 112 in the liquid phase.

본 발명의 실시예에서, 상기 담체(102)의 전면에 플러깅부재(320)를 바르는 방법은 붓(310)을 이용할 수 있다. 상기 붓(310)의 브러쉬에 부착된 상기 플러깅부재(320)가 상기 담체(102)의 채널(112)들로 유입된다. In an embodiment of the present invention, the method of applying the plugging member 320 to the front surface of the carrier 102 may use a brush 310. The plugging member 320 attached to the brush of the brush 310 flows into the channels 112 of the carrier 102.

도 4는 본 발명의 실시예에 따른 촉매유닛의 개략적인 측 단면도이다. 4 is a schematic side cross-sectional view of a catalyst unit according to an embodiment of the present invention.

도 4를 참조하면, 도 3에서 상기 마스킹부재(200)를 제거하면, 상기 담체(102)의 전면에서 중심부에는 상기 채널오프닝부(110)가 형성된다. 아울러, 상기 붓(310)이나 상기 롤러(300)에 의해서 형성된 상기 플러깅부재에 의해서 상기 담체(102)의 전면의 가장자리부에는 상기 채널플러깅부(120)가 형성된다.Referring to FIG. 4, when the masking member 200 is removed in FIG. 3, the channel opening 110 is formed at the center of the front surface of the carrier 102. In addition, the channel plugging portion 120 is formed at an edge portion of the front surface of the carrier 102 by the plugging member formed by the brush 310 or the roller 300.

도 5는 본 발명의 실시예에 따른 촉매유닛에 촉매코팅층을 형성하는 방법을 보여주는 측 단면도이다. 5 is a side cross-sectional view showing a method of forming a catalyst coating layer on a catalyst unit according to an embodiment of the present invention.

도 5를 참조하면, 가장자리부에 상기 채널플러깅부(120)가 형성되고, 상기 흡입기(510)를 이용하여 상기 담체(102)의 상기 채널오프닝부(110)를 통해서 워시코트(500)를 흡입한다. Referring to FIG. 5, the channel plugging part 120 is formed at an edge portion, and the washcoat 500 is sucked through the channel opening part 110 of the carrier 102 using the inhaler 510. do.

따라서, 상기 채널오프닝부(110)에 대응하는 상기 채널(112)의 내측면에는 도 1에 도시한 바와 같이 촉매코팅층(114)이 형성된다. Accordingly, the catalyst coating layer 114 is formed on the inner surface of the channel 112 corresponding to the channel opening 110.

도 6은 본 발명의 실시예에 따른 촉매유닛의 제조방법을 보여주는 플로우차트이다. 6 is a flowchart showing a method of manufacturing a catalyst unit according to an embodiment of the present invention.

도 6을 참조하면, S600에서 전면에서 후면으로 오픈된 채널(112)들이 형성된 담체(102)가 준비되고, S610에서, 상기 마스킹부재(200)를 이용하여 전면의 중심부를 덮는다.Referring to FIG. 6, a carrier 102 having channels 112 opened from front to back in S600 is prepared, and in S610, the center of the front surface is covered using the masking member 200.

S620에서, 상기 롤러(300) 또는 상기 붓(310)으로 상기 마스킹부재(200)를 제외한 상기 담체(102)의 가장자리부의 상기 채널(112)을 플러깅부재(320)로 플러깅한다. In S620, the channel 300 of the edge of the carrier 102 excluding the masking member 200 is plugged into the plugging member 320 by the roller 300 or the brush 310.

아울러, S630에서, 상기 마스킹부재(200)를 제거하고, 추후 소성과정을 통해서 상기 채널(112)로 유입된 플러깅부재(320)를 단단하게 응고시켜, 도 1의 플러그(122)를 생성한다.In addition, in S630, the masking member 200 is removed, and the plugging member 320 introduced into the channel 112 through the firing process is solidified, thereby generating the plug 122 of FIG.

도 7은 본 발명의 실시예에 따른 촉매유닛이 장착된 상태를 보여주는 개략적인 단면도이다.7 is a schematic cross-sectional view showing a state in which a catalyst unit is mounted according to an embodiment of the present invention.

도 7을 참조하면, 배기라인에는 컨버터하우징(730)이 배치되고, 상기 컨버터하우징(730) 내부에 상기 촉매유닛(100)(담체)이 배치된다.Referring to FIG. 7, a converter housing 730 is disposed in an exhaust line, and the catalyst unit 100 (carrier) is disposed inside the converter housing 730.

도시한 바와 같이, 상기 배기라인(700)과 인접하여 상기 컨버터하우징(730)에는 그 내부 직경이 커지는 컨버터콘부(720)가 형성되고, 상기 촉매유닛(100)의 가장자리부는 상기 컨버터콘부(720)에 의해서 일부 지지되는 구조를 갖는다. As shown in the drawing, the converter housing 730 is formed in the converter housing 730 adjacent to the exhaust line 700. The converter cone portion 720 having an inner diameter thereof is increased, and the edge portion of the catalyst unit 100 is the converter cone portion 720. It has a structure that is partially supported by.

따라서, 상기 촉매유닛(100)에서 상기 컨버터콘부(720)와 대응하는 부분에는 배기가스가 거의 흐르지 않는 데드존(710)(dead zone)이 형성된다.Therefore, a dead zone 710 in which exhaust gas hardly flows is formed in a portion of the catalyst unit 100 corresponding to the converter cone portion 720.

본 발명의 실시예에서, 상기 데드존(710)에 대응하는 담체(100)의 가장자리에 형성된 채널의 입구 또는 출구를 상기 플러그(122)로 폐쇄함으로써, 그 내부에는 촉매성분을 형성하지 않는다. 따라서, 배기가스의 정화율을 저하시키지 않으면서, 촉매성분을 효율적으로 사용할 수 있다.In the embodiment of the present invention, by closing the inlet or outlet of the channel formed at the edge of the carrier 100 corresponding to the dead zone 710 with the plug 122, it does not form a catalyst component therein. Therefore, the catalyst component can be used efficiently without lowering the purification rate of the exhaust gas.

본 발명의 실시예에서는, 원통형 촉매(담체)를 기준으로 설명되었으나, 오벌타입 촉매(oval type catalyst)와 레이스트랙타입촉매(race track type catalyst) 등 다양한 형태를 갖는 촉매에도 적용될 수 있다.In the embodiment of the present invention, although described based on a cylindrical catalyst (carrier), it can be applied to a catalyst having various forms such as an oval type catalyst and a race track type catalyst.

이상으로 본 발명에 관한 바람직한 실시예를 설명하였으나, 본 발명은 상기 실시예에 한정되지 아니하며, 본 발명의 실시예로부터 당해 발명이 속하는 기술분야에서 통상의 지식을 가진 자에 의한 용이하게 변경되어 균등하다고 인정되는 범위의 모든 변경을 포함한다.While the present invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, And all changes to the scope that are deemed to be valid.

100: 촉매유닛
102: 담체
110: 채널오프닝부
112: 채널
114: 촉매코팅층
120: 채널플러깅부
122: 플러그
200: 마스킹부재
300: 롤러
310: 붓
320: 플러깅부재
500: 워시코트
510: 흡입기100: catalytic unit
102: carrier
110: channel opening
112: channel
114: catalyst coating layer
120: channel plugging unit
122: plug
200: masking member
300: roller
310: brush
320: plugging member
500: washcoat
510: inhaler

Claims (5)

담체의 전면(front surface) 일부에 마스킹부재를 덮어 채널의 일부를 덮는 단계; 및
상기 마스킹부재에 의해서 덮인 부분을 제외한 오픈된 채널 안으로 플러깅부재를 유입시키는 단계; 를 포함하고,
가장자리 부분에 상기 오픈된 채널이 위치하도록 상기 마스킹부재는 상기 담체의 전면에서 중심부를 커버하는 촉매유닛의 제조방법.Covering a portion of the channel by covering a masking member on a portion of the front surface of the carrier; And
Introducing a plugging member into an open channel except for a portion covered by the masking member; Lt; / RTI >
The masking member manufacturing method of the catalyst unit to cover the central portion in front of the carrier so that the open channel is located at the edge portion. 제1항에서,
상기 플러깅부재를 유입시키는 단계에서,
롤러를 상기 담체의 전면을 따라서 굴림으로써, 상기 롤러에 부착된 상기 플러깅부재가 상기 오픈된 채널의 입구를 폐쇄하도록 하는 촉매유닛의 제조방법. In claim 1,
In the step of introducing the plugging member,
And rolling the roller along the front surface of the carrier so that the plugging member attached to the roller closes the inlet of the open channel. 제1항에서,
상기 플러깅부재를 유입시키는 단계에서,
붓을 상기 담체의 전면을 따라서 이동함으로써, 상기 붓의 브러쉬에 부착된 상기 플러깅부재가 상기 오픈된 채널의 입구를 폐쇄하도록 하는 촉매유닛의 제조방법. In claim 1,
In the step of introducing the plugging member,
And moving the brush along the front surface of the carrier so that the plugging member attached to the brush of the brush closes the inlet of the open channel. 제1항에서,
상기 마스킹부재를 제거하는 단계; 및
상기 오픈된 채널을 폐쇄한 상기 플러깅부재를 건조 소성기키는 단계; 를 포함하는 촉매유닛의 제조방법. In claim 1,
Removing the masking member; And
Dry firing the plugging member closing the open channel; Method for producing a catalyst unit comprising a. 삭제delete
KR1020110061775A 2011-06-17 2011-06-24 Fabrication method of catalytic converter Expired - Fee Related KR101326815B1 (en)

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KR1020110061775A KR101326815B1 (en) 2011-06-24 2011-06-24 Fabrication method of catalytic converter
US13/313,997 US9046023B2 (en) 2011-06-17 2011-12-07 Catalytic converter and fabrication method thereof
DE102011056527A DE102011056527A1 (en) 2011-06-17 2011-12-16 CATALYST AND MANUFACTURING METHODS THEREOF
CN201110443426.0A CN102828805B (en) 2011-06-17 2011-12-27 Catalyst and its manufacture method
US14/707,345 US9617896B2 (en) 2011-06-17 2015-05-08 Catalytic converter and fabrication method thereof

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Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2008055346A (en) * 2006-08-31 2008-03-13 Denso Corp Method for plugging ceramic honeycomb structure

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2008055346A (en) * 2006-08-31 2008-03-13 Denso Corp Method for plugging ceramic honeycomb structure

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