EP0959988B1 - Honeycomb body with cross-sectional area framed in the interior, particularly for small-power motors - Google Patents

Description

The present invention provides a catalyst in a home for an exhaust system of an internal combustion engine, in particular a small engine, wherein the catalyst is at least one structured, with a catalytic active material provided sheet, which is twisted, with exhaust gas flows through channels and at least partially on the dwelling is applied. Furthermore, a silencer for an exhaust system Internal combustion engine created and a method for producing a Catalyst carrier body, which is in an exhaust system of an internal combustion engine, arranged in particular in a silencer of a small engine becomes.

It is known to be catalysts for exhaust systems of an internal combustion engine Form honeycomb bodies. These are made from sheet metal layers that are twisted together or stacked. Other honeycomb bodies consist of sintered or extruded material. These catalysts should ensure that those that remain in the exhaust gas are realizable Gases continue to be implemented. Because of a multitude of always are increasingly strict exhaust gas regulations, especially for motor vehicles the catalysts are now designed to be almost perfect Conversion also over a longer operating period of the catalytic converter to ensure. The development of catalyst technology goes in particular to keep the catalytic surface as large as possible. Therefore, honeycomb bodies are used in particular, which have a high Number of channels have their cross-section. Besides this possibility the surface enlargement is also the length and the Volume of the catalyst and thus its cross section increased. This however, requires a large space for the catalyst in the exhaust system. Also, with increasing size of the catalyst, the working procedures more elaborate to manufacture. Furthermore, with large catalysts especially worry about their durability against mechanical and thermal changes in operation are carried, which requires special storage makes necessary.

Various configurations of catalysts are presented below, on their characteristics regarding the arrangement and shape of the Catalyst the present invention relates. From GB 2 231 283 a honeycomb body is known which has one layer. This location is out a flat sheet and a structured sheet and then spiral shaped into a multi-layer catalyst. This has one cylindrical inner free cross section, the size of which depends on the outer diameter of the honeycomb body. The multitude of superimposed, stabilizing layers should have sufficient rigidity of the thus formed Ensure the honeycomb body. Another is from DE 37 15 040 Catalyst known from a band with non-cutting stampings consists. These stampings are intended to enlarge the surface. The EP 0 473 081 discloses mounting a catalyst in the manifold Exhaust system of a motorcycle. A perforated sheet is used as the catalyst used. This can be straight or round. DE 24 36 559 in turn discloses a catalytic converter located directly in a manifold Internal combustion engine sits. The manifold itself is designed as a catalyst. In addition to a catalytic coating on the inside wall of the manifold additionally arranged catalytic, in particular helical shaped parts become. JP 61 61 940 shows a catalyst that is made of smooth and corrugated metal foils is built. Upstream of this full catalyst Another catalyst is arranged, which should be heatable. From the US 4 195 063 in turn is a main catalyst with an additional one upstream catalyst known. The main catalyst is from two catalytically coated nets, each between two mesh supports are supported. The catalyst is in the manifold, too can be arranged conically. The JP 61 096 120 shows two tubes that are close to an engine block are attached in a curved manner. The inside of the both tubes have holes. There is one between these two tubes arranged catalytically active layer.

A particularly preferred field of application of an inventive Catalyst is the field of small engines. Among small engines are said to following engines with a displacement of less than 250 cc his. Such engines occur particularly in lawn mowers, chainsaws, portable generators, two-wheelers and similar applications. For chainsaws, lawn mowers and other garden tools, the the person operating the device often over a long period of time directly in the Exhaust area of the small engine, which is why catalytic exhaust gas cleaning is particularly important there.

For the rest, reference is made to DE 38 29 668, in which the catalyst in a small motor in an approximately perpendicular to the flow direction extending partition is used. EP 0 470 113 also goes an arrangement of the catalyst in which this is spaced on all sides is arranged in an exhaust silencer for two-stroke engines. Farther is a method for producing a carrier matrix from EP 0 049 489 known for an exhaust gas catalytic converter. The ones disclosed in these three documents Features are also transferable to this invention.

An object of the present invention is now to provide a catalyst in a dwelling for an exhaust system of an internal combustion engine preferably for a small engine that can be manufactured in just a few steps, extremely compact and yet a sufficient catalytic surface provides so that legally prescribed limits for the exhaust behavior of an internal combustion engine is observed. A Another object of the invention is a housing for the catalyst to create the space gained by the compact catalyst does not annihilate again. In addition, a manufacturing process is said to a compact catalyst carrier body can be created, which a continuous production of the same while avoiding high production costs ensures.

This object is achieved with a catalyst with the features of the claim 1 and with a method with the features of the claim 28 solved. Further advantageous designs and features are in the dependent Claims specified.

A catalyst with a housing for an exhaust system of an internal combustion engine, especially a small motor, has at least one structured, sheet provided with a catalytically active material. This is twisted, forms channels through which exhaust gas can flow and at least lies partly at the dwelling. The the sheet forms a layer together with the dwelling or a sheet a smooth and a structured sheet metal closed channels, so structuring, that viewed across a cross-section of the dwelling through the closed Channels framed cross-sectional area at least half of the total cross-section of the dwelling, the catalyst being a maximum of two Layers. The structured sheet is around an at least partially curved, elongated Body wound at an angle. By limiting the catalyst to a maximum of two Layers an extremely compact catalyst can be achieved with little space requirement. For this purpose, it is expedient that the structuring of the sheet is so extensive is carried out that in addition to the channel effect of the catalyst also sufficient catalytic surface is available. Also relieved Using a maximum of two layers to heat the catalyst its usable temperature because it has less mass to be heated than other, elaborately designed catalysts. Furthermore, the limitation proven to be advantageous on a maximum of two layers in order to In addition to flexibility, catalyst also high stability and Give form stability. For the preferred applications in the small engine sector the catalyst provides an at least satisfactory catalytic one Implementation of the exhaust gas available. An improvement in catalytic Implementation occurs when the framed cross-sectional area is at least Accounts for 2/3 of the total cross-section of the dwelling. If that with catalytic Active material provided sheet is so wound that the structuring comes to the opposite, it is achieved that the channeled Cross-sectional area in an area around the center of the catalyst located while the center point is not within a remaining one completely channeled area is arranged. This is for flattened Cross-sectional areas of the catalyst as well as round, oval or polygonal Catalysts achievable. This concentration of the framed cross-sectional area allowed around the midpoint, pointing to that midpoint The outside of the sewer must also be fully exposed to exhaust gas. Farther the structuring of the maximum of two layers can then be particularly advantageous interpret so that the flow resistance to the trained Channels is not larger than that of the not fully channeled Cross section.

One embodiment of the catalyst provides that the opposite Structures intertwine without mutually touch. In this way, the free space becomes quasi-canal Brought geometry. Through the opposite structuring it is possible that the framed cross-sectional area is at least 3/4 of the Total cross-sectional area of the dwelling.

Especially with small devices that may have to be moved manually, it is important to this from the design with small dimensions and light weight. The catalyst can contribute to this by it has a stabilizing reinforcement. This secures the catalyst its shape retention without restricting its elasticity too much. The stabilizing reinforcement can also be designed to be load-bearing Functions for the small device. As a result, the catalyst is fully in this integrable. The dwelling and the catalyst are then in the Location, included in the design of the statics and torsional rigidity to become.

A particularly stable against shocks, shocks and vibrations Catalyst is created in that each channel-forming sheet of the Catalyst is present on a reinforcement. The stability can still can be further reinforced by the channel-forming sheet, which is a Has a top and a bottom, each with the top and bottom reinforcement is pending. Another way of using a catalyst to maintain high dimensional stability but also high elasticity in this one from a location with an unstructured and a structured To build up sheet metal. This is a stabilizing agent Combination can be combined. A preferred embodiment of a catalyst has an unstructured sheet with a top and a bottom on, with a structured one on the top and one on the bottom Sheet are arranged. The structuring is in particular a corrugation. Curvature, serration or folding of the sheet. This can continue Show microstructures as well as small incisions and openings. On in this way, the catalytically active surface can also be enlarged. Regarding the structuring, the type and shape of the location will be discussed all to EP 0 484 364, WO 93/20339, EP 0 152 560 and referred to DE 29 611 143.

By building the catalyst from three joined sheets, the is extremely structured, it is possible to use the catalyst alone due to a clamping force of this outer sheet in a dwelling holders. Such a bracket is facilitated if at least part of a layer of the catalyst is flexible. This is a particular one Part of the location, which is on a reinforcement, especially a wall supports the dwelling or the small device or the internal combustion engine.

In order to achieve a high stability of the catalyst, this shows in a Another embodiment, the formation of a layer with a first sheet and a second sheet. The first sheet is preferably around a factor between 1.5 to 5, in particular between 2 to 4 thicker than the second sheet. When using metal foil between 20 µm and 100 µm allows this, the thinner particularly favorable for structuring To be able to use film without the thought of a self-stabilized To give up catalyst. Therefore, it is preferred that the first Sheet is unstructured and the second sheet is structured. Another education of the catalyst provides this with a flattened cross section. It is known in which directions the external forces are applied the catalyst will work, can with a flattened cross section create a catalyst that is particularly stable in this direction having. The catalyst can also be designed so that it acts on external forces preferred directions towards which it is elastic and possibly also necessarily reacted plastically. Through defined areas of the Catalytic converter, which is subject to plastic deformation when subjected to excessive loads to absorb and adsorb the acting forces can be Destruction can be prevented.

According to an advantageous embodiment of a catalyst according to the invention is an area of the catalyst opposite an area of the dwelling, adapted to the area of the dwelling.

According to a further advantageous embodiment of a catalyst according to the invention this has a profiled outer surface to prevent unwanted Moving the catalyst in the dwelling. Particularly preferred is in this context that the profiling is directed, in particular is a helical tooth profile.

The catalyst can be arranged in an exhaust system, which is usually leads away from this in internal combustion engines. It is exactly the same Catalyst also applicable in exhaust systems in the housing of the Internal combustion engine are housed. For both, it is useful that the housing of the catalyst is part of the exhaust system. To this In this way, the heat flow of the heating catalyst to the outside be ensured. The dwelling can be a manifold or component a silencer of the exhaust system. This makes the compact Installation of the catalyst ensured without an additional for this Space is needed.

According to another aspect of the invention, the compact Space utilization a silencer for an exhaust system of an internal combustion engine, used in particular a small engine in that the silencer Has means for receiving the previously described catalyst. This is for example a suitably equipped and above all adapted housing, the housing of the catalyst and its fixation there easier. This is by means of a casing pipe as a dwelling as well as through an appropriate interior design in the housing of the Internal combustion engine achievable. The combination silencer / catalytic converter enables especially small engines whose exhaust systems keep small to be able to.

It is preferred that part of the muffler means for fixing the Has catalyst. This can include teeth, notches, crossbars, Folds, grooves or similar constructive means. Will teeth or Used the same, they come into effect with at least the opposite Sheet. Teeth engage in it and thereby hold it entire catalyst.

Depending on the operating mode of the internal combustion engine and its area of application also the life of the catalyst. The engine just keeps going used for a short time, the engine becomes large, external forces exposed, this all shortens the life of the catalyst. thats why it is expedient to use the catalyst interchangeably. With the silencer For example, the catalyst can be in an upper and lower housing be arranged. One of the two housing halves preferably has one Reinforcement by which a force, in particular a clamping force the catalyst is exercisable. The reinforcement can be a crossbar in the silencer just like one of the sound absorbing constructions of the Be silencer. Another way to put the catalyst in the muffler to hold, consists in at least part of the catalyst in the Squeeze the silencer so that the catalytic converter is immobile. A further embodiment of a silencer, which is particularly suitable for Small engines is suitable, has at least two parts, an upper and a Under housing. A partition divides the silencer into a first and a second area. The partition and / or the silencer have means for holding a catalyst in each of each other separate areas. The partition is largely parallel to a flow direction arranged the muffler. In this way there is the possibility of two To accommodate catalysts in a silencer. This is not mandatory. Only a single catalyst or even more than two catalysts can be used his.

According to a further advantageous embodiment of a catalyst according to the invention with a silencer made of two parts, the two parts have one interlocking locking mechanism to hold the catalyst used wind.

• ein strukturiertes Blech um einen zumindest teilweise gewölbten, länglichen Körper schräg aufgewickelt,
• nachfolgend zumindest ein Teil des länglichen Körpers mit dem aufgewickelten Blech in mehrere Abschnitte zertrennt und
• jeweils ein Abschnitt ein Katalysator-Trägerkörper wird.

According to a further idea of the invention, a method for producing a catalyst carrier body, which is arranged in an exhaust system of an internal combustion engine, in particular a silencer of a small engine, is also provided, wherein

• a structured sheet is wound diagonally around an at least partially curved, elongated body,
• subsequently at least part of the elongated body with the wound sheet is divided into several sections and
• a section becomes a catalyst carrier body.

This method is particularly suitable for a continuous manufacturing process, the structured sheet being unwound from an endless belt can be. The elongated body in turn can be a pipe or else a correspondingly long other body. For a special one high space utilization to achieve a large catalytic effect The surface of the body has a hollow interior in which a further structured sheet metal is arranged. The catalytic one Surface is then created in that the sheet and / or Body coated with a catalytic layer before winding be or in that after the separation of the separated Section is coated with a catalytically active layer. Depending on Fastening the sheets to each other, this can be done by soldering, welding, Gluing or similar means are also done by a Internal stress of one of the sheets is to be selected when the catalytic acting layer is most appropriately applied.

To achieve a high stability of the section it is provided that as A sheet metal is used that is thicker than the one to be wound Sheet. Favorable stability values are achieved when the thicker sheet is about one to five times thicker than the sheet to be wound. After this Process, a compact catalyst can be made from the catalyst carrier body, as described above, produce particularly inexpensive.

Fig. 1

ein strukturiertes Blech in einer Behausung,

Fig. 2

ein weiteres strukturiertes Blech in einer Behausung,

Fig. 3

einen eineinhalblagigen Katalysator in einer Behausung,

Fig. 4

mehrere Anordnungen von Katalysatoren in einem Abgassystem eines Verbrennungsmotors,

Fig. 5

eine Anordnung von zwei Katalysatoren in einem Schalldämpfer,

Fig. 6

einen weiteren eineinhalblagigen Katalysator,

Fig. 7

einen eineinhalblagigen Katalysator mit auf ihn wirkenden Kräften,

Fig. 8

eine weitere Anordnung von zwei Katalysatoren in einer Behausung eines Abgassystemes,

Fig. 9

ein Herstellungsverfahren für einen Katalysatorträgerkörper,

Fig. 10

ein Herstellungsverfahren entsprechend dem der Fig. 9 gezeigten,

Fig. 11

ein weiteres Herstellungsverfahren,

Fig. 12

eine Anordnung für ein Herstellungsverfahren entsprechend dem der Fig. 11 gezeigten,

Fig. 13

ein anderes Herstellungsverfahren,

Fig. 14

noch ein anderes Herstellungsverfahren,

Fig. 15

eine weitere Behausung für einen Katalysator,

Fig. 16

eine Ausgestaltung einer Außenfläche eines Katalysators,

Fig. 17

eine Anordnungsmöglichkeit von Katalysatoren in einer anderen Behausung und

Fig. 18

wiederum eine Behausung.

Further advantages and features of the invention are illustrated in the following description of the drawing. Additional advantageous refinements can be achieved by combining the previously disclosed features with the following. Show it:

Fig. 1

a structured sheet in a dwelling,

Fig. 2

another structured sheet in a dwelling,

Fig. 3

a one and a half-layer catalyst in a dwelling,

Fig. 4

several arrangements of catalysts in an exhaust system of an internal combustion engine,

Fig. 5

an arrangement of two catalysts in a silencer,

Fig. 6

another one and a half layer catalyst,

Fig. 7

a one and a half-layer catalyst with forces acting on it,

Fig. 8

a further arrangement of two catalysts in a housing of an exhaust system,

Fig. 9

a manufacturing process for a catalyst carrier body,

Fig. 10

a manufacturing method corresponding to that shown in FIG. 9,

Fig. 11

another manufacturing process,

Fig. 12

an arrangement for a manufacturing method corresponding to that shown in FIG. 11,

Fig. 13

another manufacturing process,

Fig. 14

yet another manufacturing process

Fig. 15

another dwelling for a catalyst,

Fig. 16

an embodiment of an outer surface of a catalytic converter,

Fig. 17

a possibility of arranging catalysts in another dwelling and

Fig. 18

another dwelling.

1 shows a catalytic converter 1 which has a sheet 2. The sheet 2 is arranged in a dwelling 3 of an exhaust system and has a catalytic Coating 4 on. The sheet 2 is structured. The structure is one Corrugation. This allows the sheet 2 in under its own stress to arrange dwelling 3. This residual stress is sufficient for the catalyst 1 to be fixed in dwelling 3. The structuring of the sheet 2 is chosen so that channels 5 are formed in interaction with the dwelling 3 become. The channels 5 enclose part of the total cross-sectional area to a framed cross-sectional area. The remaining one, not area 6 enclosed by the channels in the dwelling 3 is due to the corrugation is less than 50% of the total cross-section of the dwelling shown. This area 6 is dashed for better clarity highlighted.

FIG. 2 again shows a structured sheet 2, which has a catalyst 1 forms, in a dwelling 3. The sheet 2 has a corrugated structure, which is chosen so that a first wave crest 7 in an opposite engages first trough 8. On the one hand, this leads to another Reduction of the area 6 and thus an enlargement of the framed Cross sectional area. On the other hand, the first wave crest is 7 with one second wave crest 9 not tangled. So can the catalyst 1 react elastically to external forces by changing the distance between the first wave crest 7 and the second wave crest 9 as leeway is available. The elasticity behavior of the catalyst 1 is can be influenced by the type of connection of the sheet 2 with the dwelling 3. For example, every second wave trough with the dwelling 3 connected, which is indicated by the connection points 10, remains Although catalyst 1 is fixed, it is still movably held in the dwelling 3. The connection point 10 can cover the entire axial Extend the length of the catalyst 1, but also only point by point or in sections. This is indicated by the connection points 10.1, which exist as plumb points on both sides of a wave trough and there run in the axial direction of the catalyst. The connection points 10.2, however, are for example as spot or longitudinal welding consider.

Fig. 3 shows a preferred one and a half layer catalyst 1 in one Housing 3. A layer 11 becomes a first 12 and a second Sheet 13 formed. The first sheet 12 is unstructured. The second sheet 13 has a fold as a structuring. Layer 11 is so twisted that it forms a closed body 14. In this body 14 is a third sheet 15 is arranged, which is the first sheet 12 with supports its structuring. The third sheet 15 does not einkanalte area 6 again significantly reduced. At the same time it poses additional catalytic surfaces are available. To achieve a special elasticity but also strength of the catalyst 1 is unstructured first sheet 12 thicker than the second sheet 13 and that third plate 15. The two structured plates 13 and 15 are therefore found with the first sheet 12 a static counterpart to the dwelling 3.

FIG. 4 shows an internal combustion engine 16 to which an exhaust system 17 connected. The exhaust system 17 has a manifold area 18, one Silencer 19 and connecting lines 20. In the manifold area 18 are a first catalyst 21, a second catalyst 22 and a third Catalyst 23 in each case in a line discharging from a cylinder arranged. The first catalyst 21 is conical, the second Catalyst 22 also. The third catalytic converter 23, on the other hand, has one Curvature, its cross-section remaining essentially constant. On fourth catalyst 24 is arranged in a connecting line 20. This has a regular cross-section that extends over its axial Length does not change. There is also a fifth one in the silencer 19 Catalyst 25. This is adapted to its dwelling 3 and vice versa. For this purpose, the silencer 19 has holding means 26, such as one Bulge 27 shown. The catalyst fits into this bulge 27 25 due to its size. This makes it possible for the fifth catalytic converter 25 is connected solely due to its internal stress with the bulge 27 in the silencer 19 holds.

Fig. 5 shows another silencer 19. This is inside through a partition 28 into an upper region 29 and into a lower one Area 30 divided. A fluidic connection between the upper area 29 and lower area 30 for through the silencer 19 flowing exhaust gas flow 31 is through a perforation 32 in the partition 28 ensured. The muffler 19 has an upper housing 33 and a lower housing 34, which are connected by connecting means 35 can be fixed with the partition wall 28. The partition 28, the The upper housing 33 and the lower housing 34 have holding means 26 for the Silencer 19 located upper catalyst 36 and lower Catalyst 37 on. The holding means 26 are, for example, grooves 38, teeth 39 or also transverse webs 40. They occur at least with the outside lying plate of the upper 36 or lower 37 catalyst in contact. The one or more holding means 26 can also be arranged so that at least a part an end face 41 of the upper 36 and / or lower catalyst 37 for Fixation is used. The silencer 19 shown is extremely compact and preferably intended for use especially in small engines. The exhaust gas connections 42 provided for the exhaust gas flow 31 are dependent on Installation position of the silencer 19 can be arranged differently. While the Exhaust ports 42.1 for connection in a straight-line exhaust system are suitable, the exhaust ports 42.2 are on the side of the silencer 19 scheduled. This brings a fluidic advantage because the redirection to the upper catalyst 36 or the redirection from lower catalyst 37 on the exhaust port 42 is omitted.

Fig. 6 shows a circular catalyst 1. This is one and a half layers built up. It has two thicker, structured sheets, an inner sheet 43 and an outer panel 44. Between the inner panel 43 and the outer Sheet 44 is an unstructured sheet 45. As structuring the inner sheet 43 and the outer sheet 44 became a curl selected. Are the wave troughs or wave crests of both structured sheets 43 and 44 arranged at approximately the same distance, is the unstructured Sheet 45 is able to absorb acting forces and through an elastic Deformation to adsorb the energy. Furthermore, the interior Sheet 43 additional half structures 46. These already divide them existing channels 5 or channel further cross-sectional areas of the otherwise free area 6. The half structures 46 are, for example formed by incisions in the inner sheet 43, the incised Material depending on the location in the structure to the outside or is turned inside. Another way to half-structures 46 To provide, for example, is the arrangement of additional sheet metal sections on the inner sheet 43. The use of semi-structures or the like supports the large-area single-channel end of the catalytic converter 1 to achieve a small free area 6 and thus a large framed Cross sectional area.

Fig. 7 also shows a one and a half-layer catalyst 1, on the outer Forces 47 act. The external forces 47 can operate the catalyst 1 can be absorbed by deformation of the outer sheet 44. However, these can also be deliberately applied, for example, during the manufacturing process, around an otherwise round catalyst 1 into a catalyst 1 with a flattened cross section. You can also look at the Take advantage of external forces 47 to the catalyst 1 in a dwelling use. There he is then through his own generated tensions held.

Fig. 8 shows an extremely compact arrangement of an upper catalyst 36 and a lower catalyst 37 in a dwelling 3. Both catalysts 36 and 37 are adapted to the shape of the dwelling 3 and allow an axial flow of an exhaust gas flow 31. This is particularly important so feasible that he first the upper catalyst 36 and then flows through the lower catalyst 37. The dwelling 3 with the two Catalysts 36 and 37 are therefore particularly space-saving, for example in use a silencer. Furthermore, it can also like that Provide catalysts 36, 37 with a catalytically active coating his. This applies not only to the one shown, but also to other dwellings. There are also other applications for this trained package 48. Because it is easy to put in and out due to its construction is to be expanded, it is suitable, for example, as a replacement part for exhaust systems of internal combustion engines. The necessary for large exhaust gas flows The catalytically active surface is then through the successive flow of the upper catalyst 36 and lower catalyst 37 met.

In this way, a number of packages 48 can also be arranged one behind the other in order to clean the exhaust gas stream 31.

9 shows a method for producing a catalyst carrier body. A structured sheet 49 is wrapped around an at least partially curved, elongated body 50 wound obliquely. The body 50 and the structured For this purpose, sheet 49 executes a relative movement. This is for example by rotating the arched body 50 and advancing the same achievable that the structured sheet 49 is drawn onto the body 50. This is illustrated by the arrows on the sheet 49 or on the body 50. The structured sheet 49 is connected to the body 50. Subsequently, at least a portion of the elongated body 50 is joined to the wound sheet 49 separated into several sections 51. As a separation unit 52 a laser is used here. This is able to cut the sections 51 cleanly separated from the body 50. The separation process can in particular be carried out so that a post-treatment of the section 51 omitted. The section 51 as a finished catalyst body can then can then be used as catalyst 1. This is the section 51 either subsequently provided with a catalytically active coating or this coating has the sheet 49 or the body 50 at Already winding up.

10 shows a further production method for a catalyst carrier body. An endless roller 53 becomes one with a catalytic one Coated sheet 54 led to a deflection roller 55. Of there the sheet 54 is guided to a first profiling roller 56 which is engaged with a second profiling roller 57. The flank geometry of the two profiling rollers 56, 57 determines the structuring of the sheet 54. This is then applied to a hollow body 58. This hollow body 58 has an internal, structured second sheet 59, which also already has a catalytic effect Coating is provided. The hollow body 58 and the second sheet 59 are for example before applying the sheet 54 from a formed layer producible, which is then twisted at an angle. This Twist is indicated by the dashed line 60. The hollow body 58 can also be a tube into which the second sheet 59 is inserted has been. In a slightly different process, the structured second Sheet 59 not before separating sections 51 but only after separation is used.

11 shows a further production method for a catalyst carrier body. Here too, an endless roller 53 (not shown) is used for this sheet 54 provided with a catalytically active coating on the hollow body 58 applied. The hollow body 58 is made from a layer that is wound obliquely with itself. The twist is recognizable by the butt seam 60 between adjacent areas of the twisted layer. The twist is particularly so that channels 5, dashed here indicated, not interrupted by the twist in its course become. The same also applies to the channels 5 of the sheet to be applied 54. In that the butt seam 60 in the sheet 54 to be applied is at an angle to that of the hollow body 58, is a resultant Catalyst carrier body can be formed particularly stable. An advantage of It is angularity of the butt joints to each other that the later catalyst carrier body has no axially extending circumferential seam. The burden in the seam is rather distributed over the entire circumference. It can also The sheet 54 is applied in such a way that the position of the hollow body 58 is almost clamped. The connection between the sheet 54 and the Hollow body 58 can be soldered directly after application or also only in a later step. For example, it is possible that the sheet 54 is also glued on and later soldered. The same also applies to the connection of the position of the hollow body 58. With something Another manufacturing process turns the layer back into a hollow body 58 designed according to FIG. 11. This time, however, the situation will change formed to the hollow body that an overlap area 61, dash-dotted indicated, is trained. The overlap area 61 then stabilizes the hollow body 58. At the same time, it can also be used to connect manufacture. To this end, the overlap region 61 has one embodiment an adhesive to which solder is then applied. In A corresponding procedure is also followed with the sheet 54 to be applied. The then elongated hollow body 58 with applied Sheet 54 as a whole is heated to appropriate temperatures in a soldering furnace brought so that the solder material in the overlap area 61 a permanent Establishes connection. The connection from the hollow body 58 to the applied one Sheet 54 is also made by soldering. After that, only individual sections 51 separated.

FIG. 12 shows a method such as that described in FIG. 11 Catalyst carrier body can be produced. From the endless roll 53 it will wide sheet 54 to a first 56 and second 57 profiling roller guided. After profiling, the sheet 54 is divided into four individual sheets 54.1, 54.2, 54.3 and 54.4 cut. This is done by the cutting device 62, which has cutting knife 63. From there the separated ones get Sheets 54.1 to 54.4 for respective hollow bodies 58.1 to 58.4. To this they are wound up each time. The direction of advance of the hollow body 58.1 to 58.4 is indicated by the respective arrows. The manufacturing process shown is suitable for a continuous workflow because the Hollow bodies 58.1 to 58.4 in a similar manner in an upstream station can also be produced continuously.

FIG. 13 also shows a production method for a catalyst 1. A structured sheet 65 and an unstructured one are placed in a rotating body 64 Sheet 66 as in a sardine can opener in a slot 67 of Introduced rotating body 64. When the rotating body 64 rotates two sheets 65, 66 wound as a layer. The shape of the resulting Catalyst 1 is dependent on the geometry of the rotating body 64. The one in Inside the resulting catalyst 1 can be formed cavity Rather large or small depending on the respective requirements being held. An additional, in particular structured sheet metal can be introduced. The rotating body 64 is in such a further development of the manufacturing process leave the catalyst 1 in this and then serves because of it Material thickness as stabilization.

FIG. 14 shows another manufacturing process for a catalyst 1. The catalyst 1 arises from the fact that structured sheets 65 and unstructured Sheets 66 can be stacked on top of each other. That way the catalyst 1 at most two layers 11 with one inside framed and completed channeled area 6. The over the actual later catalyst 1 protruding ends 68 of the structured and unstructured sheets 65, 66 are along the direction of the arrow bent so that a jacket around the catalyst 1 is formed. The bending the ends 68 are advantageously not only for a single sheet but for all sheets together in one work step. This is regardless of whether it is structured sheets 65 or unstructured Sheets 66 deals. An advantageous method for this is the structured one Sheets 65 and unstructured sheets 66 without folding the ends 68 to stack first. Only then are the ends 68 folded down. This can be done in one direction, but also in opposite directions. This can the entire stack can be rotated or deforming devices engage on the outside at ends 68 and bend them over.

FIG. 15 shows a further dwelling 3 for a catalytic converter 1 Housing 3 can be used as a silencer housing. It has a basic body 69 and has corrugations 70 which are designed so that they in corresponding savings 71 of the arranged in the interior of the dwelling 3 Attack catalyst 1 and fix it. The base body 69 consists of a first part 69.1 and a second part 69.2, each have a folded end 72. The ends 72 can be together be connected, for example by a weld or by soldering. Then there is a one-piece base body 69. Otherwise this is in two pieces, in which case it then interacts with the engagement of the ends 68 is held together in the catalyst 1. For side cover and Prevention of the outflow of the flowing through the catalyst 1 Gas flow 73 are a first cover 74 on the base body 69 and a second cover 75. In the first cover 74 there are bulges 76, which engage in corresponding savings 71 of the catalytic converter 1. This gives the catalyst 1 a lateral fixation. This type of closure the dwelling 3 by means of a lid to be attached laterally allows the Replace catalytic converter 1 by pushing it in and out of the base housing 69 to be able to.

FIG. 16 shows an embodiment of an outer surface 77 of a catalytic converter 1. The outer surface 77 is profiled and thereby prevents unwanted Moving the catalyst 1 in a dwelling, which is not shown here is. The profiling 78 can be non-directional or aligned. In any case The profiling 78 ensures that, for example, due to vibrations slowly pushing the catalyst 1 out of the Dwelling is prevented. Helical tooth profiling has been found to be advantageous proved. On the one hand, this can be aligned so that a preferred direction regarding the inhibition of shifting arises. For example, by Add a mechanical stop device to the dwelling this opposite direction ensures that a removal of the catalyst 1 from the dwelling only after the release of Way through the mechanical stop device is possible. One like just now Profiling described can not only the catalyst 1 but also have the dwelling 3 or a silencer 19 itself.

FIG. 17 shows a possibility of arranging a first 21, a second 22 and third 23 catalyst in another dwelling 3. The dwelling 3, for example a silencer 19, has an upper housing 33 and a lower housing 34. The upper housing 33 is with the Lower housing 34 via an interlocking locking mechanism 79 closed and held. End regions 80 of the walls of the upper case 33 and lower housing 34 each form a type of hook. These hooks 81 are designed so that when pressing the upper housing 33 on the Lower housing 34, the end regions 80 of the upper housing 33 to the inside and the end regions 80 of the lower housing 34 are pressed outwards. As a result, the hooks 81 located opposite one another can then interlock. The inner shape of the dwelling 3 is for the person or persons to be arranged there Catalysts 21, 22 and 23 can be used differently. During the first catalytic converter 21, which is shown in section, alone in the dwelling 3 shows the arrangement of the second 22 and third Catalyst, such as the body geometry of the upper case 33 and lower case 34 with their hook design for holding one of the two Catalysts in the upper region 29 or lower region 30 is used. With the first catalytic converter 21, on the other hand, part of the closing mechanism engages 79 into the catalyst 21 itself and fixes it in the dwelling Third

FIG. 18 again shows a dwelling 3. The dwelling 3 also has an upper case 33 and a lower case 34, which are so formed are that it is the catalyst or catalysts to be placed inside fix due to their shape. The catalyst itself can not only more or less square but also concave or convex be designed. Other shapes are also possible, be it hexagonal or other polygonal configurations as well as curved or other complicated geometries.

The present invention primarily provides a catalyst as well as a Process for producing a catalyst carrier body, from which this Catalyst is producible, but it has a simple, compact structure offers effective benefits in terms of its emission control behavior. On The preferred field of application for such a catalytic converter is small engines.

LIST OF REFERENCE NUMBERS

1

catalyst

2

sheet

3

habitation

4

catalytic coating

5

channel

6

not completely channeled and framed area

7

first wave crest

8th

first wave valley

9

second wave crest

10

junction

10.1

soldered point

10.2

Spot or longitudinal welding

11

location

12

first sheet

13

second sheet

14

body

15

third sheet

16

internal combustion engine

17

exhaust system

18

bend region

19

silencer

20

connecting line

21

first catalyst

22

second catalyst

23

third catalyst

24

fourth catalyst

25

fifth catalyst

26

holding means

27

bulge

28

partition wall

29

upper area

30

lower area

31

exhaust gas flow

32

perforation

33

upper housing

34

lower case

35

connecting means

36

top catalyst

37

lower catalyst

38

groove

39

tooth

40

crosspiece

41

face

42,42.1,42.2

exhaust port

43

inner, thicker sheet

44

outer, thicker sheet

45

unstructured sheet

46

half structure

47

external force

48

package

49

structured sheet metal

50

elongated, arched body

51

severed section

52

separation unit

53

continuous roll

54

Sheet with a catalytic coating

55

idler pulley

56

first profiling roller

57

second profiling roller

58

hollow body

59

structured second sheet

60

butt seam

61

overlap area

62

cutter

63

separating knife

64

rotating body

65

structured sheet metal

66

unstructured sheet

67

slot

68

end up

69

base housing

69.1

first part of the basic housing

69.2

second part of the basic housing

70

Einwellung

71

saving

72

folded end

73

gas flow

74

first lid

75

second lid

76

concavity

77

outer surface

78

profiling

79

closing mechanism

80

End of the wall

81

hook

Claims (34)

1. Catalytic converter (1; 21, 22, 23, 24, 25; 36; 37) with a housing (3) for an exhaust gas system (17) of an internal combustion engine (16), in particular a small engine, wherein the catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) has at least one structured sheet (2; 13) which is provided with a catalytically active material and which is wound and which forms passages (5) through which exhaust gas can flow and which at least partially bears against the housing (3), wherein closed passages (5) are formed by the structuring of the sheet (2, 13) and the housing (3) or a sheet of a layer having a smooth and a structured sheet, so that, as considered over a cross-section of the housing (3) a cross-sectional area which is bordered in by said closed passages (5) constitutes at least half of the total cross-sectional area of the housing (3), wherein the catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) has utmost two layers (11), characterized in that the structured sheet (49) is wound on inclined around an at least partially curved elongate body (50).
2. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to claim 1, characterized in that the bordered cross-sectional area constitutes at least two-thirds of the total cross-section of the housing (3).
3. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to claim 1, characterized in that the sheet (2; 13) is wound in a manner, that the structuring comes to lay on mutually opposite relationship.
4. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to claim 3, characterized in that the oppositely disposed structuring are interlaced which each other without touching each other.
5. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to claim 3 or 4, characterized in that the bordered cross-sectional area constitutes at least three quarters of the total cross-sectional area of the housing (3).
6. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims characterized in that the catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) has a stabilizing reinforcement.
7. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims characterized in that each passage-forming sheet of the catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) bears against a reinforcement.
8. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims characterized in that the passage-forming sheet (2; 13) has a top-side and an underside, wherein the top-side and the underside of the sheet each bears against a respective reinforcement.
9. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims characterized in that it comprises a layer (11) with an unstructured sheet (12) and a structured sheet (13).
10. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims, characterized in that the catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) comprises an unstructured sheet (13) with a top-side and an underside, wherein a respective structured sheet (12, 14) is arranged at each of the topside and the underside.
11. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims, characterized in that the structuring is a corrugation configuration, a bend configuration or a scallop configuration.
12. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims, characterized in that at least a part of a layer (11) of the catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) is flexible, in particular a part of a layer which bears against a reinforcement, in particular a wall.
13. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims, characterized in that a first sheet (12) with a second sheet (13) forms a layer (11), wherein the first sheet (12) is thicker than the second sheet (13), preferably by a factor of between 1.5 and 5, in particular between 2 and 4.
14. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to claim 13, characterized in that said first sheet (12) is unstructured and the second sheet (13) is structured.
15. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims, characterized in that it is of a flattened cross-section.
16. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims, characterized in that a surface (71) of the catalytic converter (1) which is disposed in opposite relationship to a surface (70, 76) of the housing (3), is adapted to the surface (70, 76) of the housing (3).
17. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims, characterized in that it has a profiled external surface (77) to prevent unintended displacement of the catalytic converter (1) in the housing (3).
18. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to claim 17, characterized in that the profiling (78) is directed, that it is in particular an inclined tooth profiling.
19. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims, characterized in that it is so arranged that the housing (3) is part of the exhaust gas system (17).
20. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to claim 19, characterized in that the housing (3) is a manifold pipe or a component of a silencer (19) of the exhaust gas system (17).
21. Catalytic converter (1, 21, 22, 23, 24, 25, 36, 37) according to one of the preceding claims comprising a silencer (19) for an exhaust gas system of an internal combustion engine (16), in particular a small engine, characterized in that the silencer (19) has means (26) for receiving a catalytic converter (1; 21,22,23,24,25;36,37).
22. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims comprising a silencer (19) according to claim 21, characterized in that part of the silencer (19) has means (26, 27; 38, 39, 40) for fixing the catalytic converter (1; 21, 22, 23, 24, 25; 36, 37).
23. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims comprising a silencer (19) according to claim 21 or 22, characterized in that the catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) is interchangeably insertable.
24. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims comprising a silencer (19) according to one of claims 21 to 23, characterized in that the silencer (19) has a reinforcement through which a force, in particular a clamping force, is exertable on the catalytic converter (1; 21, 22, 23, 24, 25; 36, 37).
25. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims comprising a silencer (19) according to one of claims 21 to 24, characterized in that a part of the catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) is squeezed by the silencer (19).
26. Catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of the preceding claims comprising a silencer (19) having at least two parts (33, 34) according to one of the preceding claims, characterized in that a partitioning wall (28) divides the silencer (19) into a first region (29) and a second region (30), wherein the partitioning wall (28) and/or the silencer (19) has means (26, 27; 38, 39, 40) for holding a catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) in each respective region (29, 30) and the partitioning wall is arranged substantially parallel to a through-flow direction through the silencer (19).
27. Catalytic converter according to one of claims 21 to 26 comprising a silencer having at least two parts, characterized in that said two parts (33, 34) comprise an intermeshing locking mechanism (79) which is used for holding the catalytic converter (21,22,23).
28. A process for the production of a catalytic converter carrier body which is arranged in an exhaust gas system (17) of an internal combustion engine (16), in particular in a silencer (19) of small engine, wherein

    a structured sheed (49) is wound on inclinedly around an at least partially curved elongate body (50),

    subsequently at least a part of the elongate body (50) with the wound sheet (49) is divided up into a plurality of portions (51), and

    a respective portion (51) becomes a catalytic converter carrier body.
29. A process according to claim 28, characterized in that the body (51, 58) has a hollow cavity therein, in which a further structured sheet (59) is arranged.
30. A process according to claim 28 or 29, characterized in that the sheet (49; 54; 59) and/or the body (50; 58) are coated with a catalytically active layer (4) prior to the winding-on operation.
31. A process according to claim 28 or 29, characterized in that the portion (51) is coated with a catalytically active layer (4).
32. A process according to one of claims 28 to 31, characterized in that the body (50; 58) is a sheet which is thicker than the sheet (49; 54; 59) which is to be wound on, and in particular is about 1 to 5 times thicker.
33. A process according to one of claims 28 to 32, characterized in that the sheet (49; 54; 59) which is to be wound on is unwound from an endless sheet strip (53).
34. A process according to one of claims 28 to 33, characterized in that a catalytic converter (1; 21, 22, 23, 24, 25; 36, 37) according to one of claims 1 to 27 is made from the catalytic converter carrier body wherein due to the structuring of the sheet (2; 13) in addition with the housing (3) or a sheet of a layer closed passages (5) are formed such that, considered over a cross-section of the housing (3) a cross-sectional area which is bordered by the closed passages (5) constitutes at least half of the total cross-sectional area of the housing (3).

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