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WO2006008222A1 - Procede pour produire au moins une zone d'une structure filtrante, destinee en particulier a un filtre a particules situe dans le systeme d'echappement d'un moteur a combustion interne - Google Patents

Procede pour produire au moins une zone d'une structure filtrante, destinee en particulier a un filtre a particules situe dans le systeme d'echappement d'un moteur a combustion interne Download PDF

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Publication number
WO2006008222A1
WO2006008222A1 PCT/EP2005/052958 EP2005052958W WO2006008222A1 WO 2006008222 A1 WO2006008222 A1 WO 2006008222A1 EP 2005052958 W EP2005052958 W EP 2005052958W WO 2006008222 A1 WO2006008222 A1 WO 2006008222A1
Authority
WO
WIPO (PCT)
Prior art keywords
film
filter
sintered metal
producing
structuring
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
PCT/EP2005/052958
Other languages
German (de)
English (en)
Inventor
Christoph Treutler
Uwe Glanz
Leonore Schwegler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Robert Bosch GmbH
Original Assignee
Robert Bosch GmbH
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Robert Bosch GmbH filed Critical Robert Bosch GmbH
Priority to EP05764002A priority Critical patent/EP1771236A1/fr
Priority to US11/632,737 priority patent/US20090016923A1/en
Priority to JP2007521933A priority patent/JP2008506523A/ja
Publication of WO2006008222A1 publication Critical patent/WO2006008222A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2027—Metallic material
    • B01D39/2031—Metallic material the material being particulate
    • B01D39/2034—Metallic material the material being particulate sintered or bonded by inorganic agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0001—Making filtering elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/52—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material
    • B01D46/521—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material
    • B01D46/522—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material with specific folds, e.g. having different lengths
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1103—Making porous workpieces or articles with particular physical characteristics
    • B22F3/1115—Making porous workpieces or articles with particular physical characteristics comprising complex forms, e.g. honeycombs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2279/00—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses
    • B01D2279/30—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses for treatment of exhaust gases from IC Engines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the invention relates to a method for producing at least one region of a filter structure, in particular for a particle filter in the exhaust system of an internal combustion engine.
  • sintered metal For the production of metallic filter mats sintered metal is suitable.
  • the processing of powdered metal is advantageous because of the particle size and
  • Particle size distribution of the powder used and on the sintering conditions can set a defined density and pore size of the sintered metal.
  • a carrier material for example an expanded metal or a metal fabric
  • the carrier or framework material fulfills two tasks: it helps to fix the sintered metal powder and later stabilizes the filter bag.
  • Such a filter device is known from DE 101 28 936 Al.
  • the particle filter shown there is installed in the exhaust system of a diesel internal combustion engine.
  • the filter walls in the known filter device are made of sintered metal and arranged so that wedge-shaped filter bags are formed.
  • the tapered wedge edges of the filter pockets show against the flow direction of the exhaust gas, the rear narrow side of a filter pocket seen in the flow direction is open.
  • the filter bags are arranged side by side in such a way that an overall rotationally symmetrical, annular filter structure is formed.
  • the filter walls are formed by labile sintered metal foils or sintered metal mats, which are connected to separate supporting or support structures, for example perforated plates, metal fabrics or the like.
  • a flowable paste or slurry can be prepared from sintered metal powder and an organic binder and by means of solvents.
  • the powder processed in this way can then be applied either by immersing the metal mesh or the expanded metal in the paste or the slip, or the metal mesh or the expanded metal can be cast in a casting process with the slip or overprinted with the paste (for example in screen printing technique) , In all variants of this process is a subsequent
  • Drying step required in which solvent is evaporated and the sintered metal powder is fixed on the metal framework.
  • a framework material significantly increases the weight and cost of a filter mat. It is therefore desirable to be able to dispense with a framework material and still produce defined, stable sintered metal foils. Object of the present invention is therefore to develop a method of the type mentioned so that a filter device with precisely defined properties can be produced inexpensively without the use of a support structure.
  • the use of a film has the advantage that its thickness, density and structuring of the sintered metal filling can be defined very precisely. These parameters allow the permeability of the sintered metal filter to be precisely predefined.
  • the structuring of the film allows the creation of a defined surface structure and thus the targeted enlargement of the active filter surface.
  • step b the film through
  • Film sheeting, tape casting or film extrusion is produced. All of these methods allow an exact adjustment of the film thickness and the production of a homogeneous, smooth and bubble-free sintered metal foil.
  • step b green films
  • step b multilayer green films
  • the structuring takes place in step c, preferably at a temperature in the range of 80-150 ° Celsius, preferably in the range of 80-90 ° Celsius.
  • the structuring temperature, at which the sintered metal foil is plastically deformable can be very well adjusted by an appropriate selection and amount of organic binder.
  • the specified temperature range is therefore particularly advantageous since the required energy input is limited and yet a good effect is already achieved with conventional organic and thermoplastic binders. This is especially true for the range of 80 - 90 ° Celsius.
  • the structuring is preferably carried out by means of stamping plates, which are placed on the film and pressed. It can also be a structured one. Laminierwalze be used, or it can be arranged several rollers in a row. Also, a two-sided arrangement of the rollers is possible.
  • both sides of the film are subjected to a structuring step.
  • a bilateral wafer structure of the film which has the advantage that not only surface is produced, but also the mechanical stability of the film is improved via suitable geometries (wafer structures, honeycomb structures, see below) becomes.
  • a plurality of differently structured films can be laminated together in order to increase the overall layer thickness or locally. This can take place before or after the embossing process, but advantageously several green sheets are first laminated together in order to achieve the desired layer thickness or even a desired gradient. Adjust powder size distribution and / or density distribution, and then embossed one or both surfaces.
  • films containing differently fine or coarse sintered metal powder may be combined together to influence the pore structure of the finished filter sheet.
  • coarse and fine powders have different tendencies to bond.
  • An equally important factor is the so-called green density of the films, that is, how close the particles are to each other and how quickly and how well they bond to each other.
  • laminate two films together one of which can be structured particularly well due to their composition, while the other is mechanically very stable, to allow in this way a safe handling in the production process. This is determined by the organics used in film production, i.e., the polymer binder used, the softening additives, etc.
  • a support structure In a further embodiment of the method according to the invention, it is possible to additionally connect the film to a support structure.
  • a metallic fabric, an expanded metal or a perforated plate is used as the support structure.
  • Optimum filter properties in particular when the filter device is used as a particle filter in the exhaust system of an internal combustion engine, are achieved if the sintered metal powder has a grain size of approximately 1-150 ⁇ m, preferably 40-70 ⁇ m, more preferably 50-60 ⁇ m.
  • step a the sintered metal powder with approximately 8% by weight of acrylate binder and butyl acetate as solvent is processed into a sacable slip.
  • Figure 1 is a schematic representation of an internal combustion engine with a
  • Figure 2 is a perspective view of the filter structure of Figure 1;
  • FIG. 3 shows two filter pockets of the filter structure of FIG. 1;
  • FIG. 4 shows a flowchart of a method for producing a filter wall of FIG
  • FIG. 5 shows a section through a sintered metal foil before the structuring step
  • FIG. 6 shows a section through the sintered metal foil from FIG. 5 after structuring with a first embossing plate
  • FIG. 7 shows a section through the sintered metal foil from FIG. 5 after structuring with a second embossing plate
  • FIG. 8 shows an embodiment of the structuring by means of weapon-shaped embossing plates
  • Figure 9 shows various embodiments of multilayer green sheets according to the invention.
  • an internal combustion engine carries the reference numeral 10. It includes an exhaust system 12, in which a particulate filter 14 is arranged. By means of this, for example, soot particles can be filtered out of the exhaust gas of the internal combustion engine 10.
  • the particulate filter 14 comprises a housing 16 and a filter structure 18 arranged in the housing 16.
  • the filter structure 18 is shown in more detail in Figure 2: It comprises a plurality of wedge-shaped filter pockets 20, which are arranged with their tapered wedge edge opposite to the flow direction of the exhaust gas.
  • the filter pockets 20 are arranged next to each other about an overall longitudinal axis, so that an overall rotationally symmetrical filter structure 18 is formed.
  • the radially inner and outer narrow sides of the filter pockets 20 are closed.
  • the downstream in the flow direction narrow sides of the filter bags 20 are open. In the area of their rear ends in the flow direction, the filter bags are interconnected.
  • FIG. 3 two adjacent filter pockets 20a and 20b are shown.
  • the exhaust gas enters an area between the two filter pockets 20a and 20b, passes through a lateral filter wall 22 and thus enters the interior of the respective filter pocket 20a and 20b.
  • the gasbgasstrom is shown by an arrow 24.
  • the particles are separated from the exhaust gas and deposited on the upstream surface of the side wall 22.
  • the walls, and in particular the side walls 22 of the filter pockets 20, are made of a porous sintered metal.
  • a method for producing, for example, the side walls 22 of the filter pockets 20 is shown in FIG. 4.
  • sintered metal powder 26 having a grain size of about 50-60 ⁇ m, preferably 53 ⁇ m, with about 2-8% by weight of acrylate binder 28 and a volatile organic compound Solvent, for example.
  • Butyl acetate or alcohol 30 processed by a device 32 to a squeegee slurry 34. This is processed with a film doctor blade 36 to a 100 - 500 .mu.m thick sintered metal foil 38 (green film). If so-called multi-layer green sheets 39 are produced from these single sheets, the thickness is preferably> 450 ⁇ m.
  • This metal foil or multilayer green sheets are then patterned by means of a device 40 using either embossing plates or a structured laminating roller.
  • the sintered films are heated to a temperature of about 80 0 C, there are various stamping plates placed and pressed.
  • the structure of the embossing plates was clearly visible after pressing on the corresponding blank 42.
  • the blank 42 is then sintered, creating a quasi-one-piece composite 46.
  • filter bags 22 are then produced by punching, folding and welding.
  • FIGS. 5, 6 and 7 show sections through a blank 42 used according to the invention.
  • FIG. 5 shows a blank 42 having a defined layer thickness and green density, which was produced by means of a comparatively thick sintered metal foil 38. Overall, the surface 52 of the sintered metal foil 38 is smooth.
  • the blank 42 drawn in FIG. 6 corresponds to that produced using the method described in FIG. 4: It can be seen that the surface structure of the stamping plate 40 is imaged on the surface 52 of the sintered metal foil 38.
  • FIG. 7 shows a blank 42 which has been produced with a differently structured embossing plate 40 and whose surface 52 has a correspondingly embossed pattern 54.
  • the mechanical stability of the film can be improved by means of suitable geometries.
  • a sintered metal foil with a high surface area and at the same time high mechanical stability can be produced by the production of a "waffle iron structure" described below.
  • sintered metal powder 26 with a grain size of approximately 50-60 ⁇ m, preferably 53 ⁇ m, with approximately 2-8% by weight of acrylate binder and a volatile organic solvent, for example butyl acetate or alcohol 30, is processed by means 32 into a squeegee 34 , This is processed with a film doctor blade 36 to a 100-500 .mu.m, preferably> 450 .mu.m thick sintered metal green sheet 38.
  • This foil is then structured, for example, by means of the embossing plates 56 shown in FIG. 8. For this purpose, the tool is heated to a temperature of about 8O 0 C, the green sheet 38 is inserted and closed the tool under pressure.
  • the green sheet 38 is removed again and has now adopted the structure of the stamping plates.
  • the blank is then sintered, whereby the geometry of the three-dimensionally structured film 38 is completely preserved.
  • the sintered metal powder in place of a defined film 38 in other geometries (tablets, roughly divided plates, flat breads, etc) in the form of a thermoplastic compound 58 (see Fig. 8).
  • the following example shows the production of high surface area sintered metal foils by using graded green sheets or multilayer films.
  • sintered metal powder 26 having a grain size of, for example, 50 ⁇ m, with about 2-8% by weight of acrylate binder and a volatile organic solvent, for example butyl acetate or alcohol 30, is processed by means 32 into a squeegee 34. This is processed with a film doctor blade 36 to a 100-500 .mu.m, preferably ⁇ 200 .mu.m thick sintered metal green sheet 38. Likewise, with powder, for example, the grain size of 30 microns and 80 microns, process.
  • green film variants are higher organics film compositions (e.g., 6-20 wt% acrylic binders), or films having pore-forming additives which completely volatilize in the sintering process. Films having different layer thicknesses are also possible variants, such as the use of defined powder mixtures (narrow monomodal, bi- or trimodal grain size distributions) or different powder types (e.g., spherical round powder types, irregular drop-shaped powder types, flaky powder types, etc.) in film production.
  • defined powder mixtures narrow monomodal, bi- or trimodal grain size distributions
  • different powder types e.g., spherical round powder types, irregular drop-shaped powder types, flaky powder types, etc.
  • These film variants 38 can be combined with one another in different ways to multilayer green films 39.
  • the porosity and the surface properties of the sintered filter foils 46 can be adjusted or defined in a targeted manner. For example, by laminating different film variants after sintering, a filter film with a coarse-pored and a fine-pored side can be achieved, or it is obtained when using films of different green density after sintering a filter film with very strong surface roughness, since the side with the lower green density shrinks inhomogeneously during sintering, and forms porous surface structures. In both cases sintered metal filters with graded porosity and high surface area are obtained.
  • the above-mentioned multi-layer green sheets 39 produced by laminating single sheets 38 are processed like the green sheets 38 and can be used as needed, such as Also, the films themselves 38 are laminated to a scaffold such as an expanded metal 62 and / or additionally mechanically structured by embossing.
  • FIG. 9 shows various possibilities for the design of multi-seed green films 39.
  • FIG. 9A shows a triple laminate 60 of three similar green sheets 38 with expanded metal 62 laminated on it as a support structure.
  • Fig. 9B shows a dual laminate 64 of two different green sheets 38 each having a fine and a coarse powder (66, 68). The surface of the coarse powder film 68 is further patterned by embossing to increase the filter surface area.
  • 9C shows a green sheet with so-called "waffle structure", produced using a multilayer green film 39 consisting of three layers (70, 72, 74) with different powder filling
  • FIG. 9D finally shows a double laminate 76 of two different green sheets 78, 80, FIG. wherein one film is highly filled, and the other has a lower degree of filling of metal powder and optionally also contains pore-forming additives .Alaminated expanded metal 62 is again shown in FIG.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Filtering Materials (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Powder Metallurgy (AREA)

Abstract

La présente invention concerne un procédé pour produire au moins une zone d'une structure filtrante, destinée en particulier à un filtre à particules situé dans le système d'échappement d'un moteur à combustion interne, le procédé comprenant les étapes suivantes : a. préparation d'un mélange à partir d'une poudre métallique frittée et d'un liant organique ; b. production d'un film à partir du mélange ; c. structuration du film ; et d. frittage.
PCT/EP2005/052958 2004-07-21 2005-06-24 Procede pour produire au moins une zone d'une structure filtrante, destinee en particulier a un filtre a particules situe dans le systeme d'echappement d'un moteur a combustion interne Ceased WO2006008222A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP05764002A EP1771236A1 (fr) 2004-07-21 2005-06-24 Procede pour produire au moins une zone d'une structure filtrante, destinee en particulier a un filtre a particules situe dans le systeme d'echappement d'un moteur a combustion interne
US11/632,737 US20090016923A1 (en) 2004-07-21 2005-06-24 Method for manufacturing at least one area of a filter structure, in particular for a particulate filter in the exhaust gas system of an internal combustion engine
JP2007521933A JP2008506523A (ja) 2004-07-21 2005-06-24 特に内燃機関の排ガスシステムにおける粒子フィルタのためのフィルタ構造体の少なくとも１つの領域を製造するための方法

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102004035311A DE102004035311A1 (de) 2004-07-21 2004-07-21 Verfahren zum Herstellen mindestens eines Bereichs einer Filterstruktur, insbesondere für einen Partikelfilter im Abgassystem einer Brennkraftmaschine
DE102004035311.5 2004-07-21

Publications (1)

Publication Number Publication Date
WO2006008222A1 true WO2006008222A1 (fr) 2006-01-26

Family

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Family Applications (1)

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PCT/EP2005/052958 Ceased WO2006008222A1 (fr) 2004-07-21 2005-06-24 Procede pour produire au moins une zone d'une structure filtrante, destinee en particulier a un filtre a particules situe dans le systeme d'echappement d'un moteur a combustion interne

Country Status (5)

Country Link
US (1) US20090016923A1 (fr)
EP (1) EP1771236A1 (fr)
JP (1) JP2008506523A (fr)
DE (1) DE102004035311A1 (fr)
WO (1) WO2006008222A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102008042415B3 (de) * 2008-09-26 2010-05-20 Andreas Hofenauer Metallisches Halbzeug, Verfahren zur Herstellung der Werkstoffe und Halbzeuge sowie deren Verwendungen
DE102013016226A1 (de) 2012-10-01 2014-04-03 Mann + Hummel Gmbh Metallisches Halbzeug

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT9339U1 (de) * 2006-07-06 2007-08-15 Plansee Se Verfahren zur herstellung eines extrudierten formkörpers
DE102011110633A1 (de) * 2011-07-29 2013-01-31 Fachhochschule Münster Verfahren zum Aufbringen einer Schutzschicht zum Schutz vor Schlagbeanspruchungen
US10494970B2 (en) * 2017-07-05 2019-12-03 Denso International America, Inc. Emissions control substrate
DE102019005071A1 (de) * 2019-04-27 2020-10-29 Deutz Aktiengesellschaft Schnellladestation und Verfahren zum Laden von elektrisch betriebenen Land-, Wasser-, Luftfahrzeugen und/oder Arbeitsmaschinen und/oder Batterien
CN115487604A (zh) * 2022-09-23 2022-12-20 东莞市名创传动科技有限公司 一种复合烧结过滤材料

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US4769212A (en) * 1985-03-29 1988-09-06 Hitachi Metals, Ltd Process for producing metallic sintered parts
WO1999054524A1 (fr) * 1998-04-17 1999-10-28 Gkn Sinter Metals Gmbh Procede de realisation d'une couche metallique frittee a porosite ouverte
DE10128936A1 (de) * 2001-06-18 2003-01-02 Hjs Fahrzeugtechnik Gmbh & Co Partikelfilter, insbesondere für Abgase von Dieselbrennkraftmaschinen

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US5132080A (en) * 1944-11-28 1992-07-21 Inco Limited Production of articles from powdered metals
US2792302A (en) * 1955-08-29 1957-05-14 Connecticut Metals Inc Process for making porous metallic bodies
US3489555A (en) * 1967-05-18 1970-01-13 Clevite Corp Method of slip casting titanium structures
AU640722B2 (en) * 1990-11-05 1993-09-02 Asahi Tec Corporation Method of producing a porous metal and a metal product using the same such as a catalyst carrier
US5592686A (en) * 1995-07-25 1997-01-07 Third; Christine E. Porous metal structures and processes for their production
US6843960B2 (en) * 2002-06-12 2005-01-18 The University Of Chicago Compositionally graded metallic plates for planar solid oxide fuel cells

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4769212A (en) * 1985-03-29 1988-09-06 Hitachi Metals, Ltd Process for producing metallic sintered parts
WO1999054524A1 (fr) * 1998-04-17 1999-10-28 Gkn Sinter Metals Gmbh Procede de realisation d'une couche metallique frittee a porosite ouverte
DE10128936A1 (de) * 2001-06-18 2003-01-02 Hjs Fahrzeugtechnik Gmbh & Co Partikelfilter, insbesondere für Abgase von Dieselbrennkraftmaschinen

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102008042415B3 (de) * 2008-09-26 2010-05-20 Andreas Hofenauer Metallisches Halbzeug, Verfahren zur Herstellung der Werkstoffe und Halbzeuge sowie deren Verwendungen
DE102013016226A1 (de) 2012-10-01 2014-04-03 Mann + Hummel Gmbh Metallisches Halbzeug

Also Published As

Publication number Publication date
DE102004035311A1 (de) 2006-02-16
EP1771236A1 (fr) 2007-04-11
US20090016923A1 (en) 2009-01-15
JP2008506523A (ja) 2008-03-06

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