Porous metal structure

Abstract

Provided is a porous metal structure including: a case that is open at both ends; and first corrugated plates and second corrugated plates which are alternately stacked inside the case and form a passage through which air or gas passes. First upper vertices in contact with the lower surface of one of the second corrugated plates and first lower vertices in contact with the upper surface of one of the second corrugated plates are repeatedly formed in each of the first corrugated plates, and the distance between the first upper vertices and the second lower vertices forms a first pitch (L1). Second upper vertices in contact with the lower surface of one of the first corrugated plates and second lower vertices in contact with the upper surface of one of the first corrugated plates are repeatedly formed in each of the second corrugated plates, and the distance between the second upper vertices and the second lower vertices forms a second pitch (L2). The first pitch (L1) and the second pitch (L2) can be formed differently from each other to increase the surface area in contact with air or gas and improve performance.

Description

TECHNICAL FIELD

[0001] The present invention relates to a porous metal structure that has a plurality of passages through which air or gas passes and functions as a heater that heats air that passes therethrough or a catalyst to remove harmful substances from exhaust gas.BACKGROUND ART

[0002] In general, a porous metal structure forms a plurality of passage parts and performs a function of removing harmful substances from exhaust gas by reacting with a catalyst while the air or gas passes through the passage parts, or performs a function of heating air passing through the passage parts by being used as a heater.

[0003] As disclosed in Korean Patent No. 10-1886189 (registered on Jan. 1, 2018), a conventional porous metal structure has a structure in which a flat plate and a corrugated plate are alternately and repeatedly stacked to form a plurality of passage parts.

[0004] The porous metal structure having such a structure is used as a catalytic converter in which a catalyst material is coated on the surface of the flat plate and the corrugated plate, and since the catalytic material is coated on the surface of the flat plate, the catalytic material coating area is small, thereby deteriorating the performance of the catalytic converter.

[0005] In addition, when the porous metal structure is used as a heater, the heat generation area is small and the contact area with the air is small due to the flat plate shape, thereby deteriorating the heater performance.DISCLOSURETechnical Problem

[0006] Therefore, it is an object of the present invention to provide a porous metal structure which adopts a structure in which a corrugated plate and another corrugated plate are stacked instead of an existing structure of a corrugated plate and a flat plate, to maximize a contact area with air or gas, thereby increasing a catalyst coating area when used as a catalyst and increasing a heat generating area when used as a heater, thus improving the performance of the catalyst and the heater.

[0007] It is another object of the present invention to provide a porous metal structure having a structure in which a first corrugated plate and a second corrugated plate are alternately stacked to allow vertices of the first corrugated plate and the second corrugated plate to coincide with each other during assembly so that the two corrugated plates may be fixed by surface contact, thereby improving durability.Technical Solution

[0008] According to an aspect of the present invention, first corrugated plates and second corrugated plates that form a passage through which air or gas passes are alternately stacked inside a case that is open at both ends, wherein first upper vertices in contact with the lower surface of one of the second corrugated plates and first lower vertices in contact with the upper surface of one of the second corrugated plates are repeatedly formed in each of the first corrugated plates, and the distance between the first upper vertices and the second lower vertices forms a first pitch (L1), wherein second upper vertices in contact with the lower surface of one of the first corrugated plates and second lower vertices in contact with the upper surface of one of the first corrugated plates are repeatedly formed in each of the second corrugated plates, and the distance between the second upper vertices and the second lower vertices forms a second pitch (L2), and wherein the first pitch (L1) and the second pitch (L2) can be formed differently from each other.

[0009] Apexes of the first upper vertices and the second upper vertices may be in contact with each other.

[0010] The distance of the second pitch (L2) may be ½ of the distance of the first pitch (L1).

[0011] A first height (H1) between the first upper vertices and the first lower vertices may be formed three to five times greater than a second height (H2) between the second upper vertices and the second lower vertices.

[0012] A catalyst material may be coated on the surfaces of the first corrugated plates and the second corrugated plates.

[0013] The first corrugated plates and the second corrugated plates may be manufactured as heating coils that generate heat when power is applied thereto.Advantageous Effects

[0014] As described above, the present invention adopts a structure in which a corrugated plate and another corrugated plate are stacked instead of an existing structure of a corrugated plate and a flat plate, to maximize a contact area with air or gas, thereby increasing a catalyst coating area when used as a catalyst and increasing a heat generating area when used as a heater, thus improving the performance of the catalyst and the heater.

[0015] In addition, the present invention adopts a structure in which a first corrugated plate and a second corrugated plate are alternately stacked to allow vertices of the first corrugated plate and the second corrugated plate to coincide with each other during assembly so that the two corrugated plates may be fixed by surface contact, thereby improving durability.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 is a front view of a porous metal structure according to a first embodiment of the present invention.

[0017] FIG. 2 is an enlarged view of some portions of a porous metal structure according to the first embodiment of the present invention.

[0018] FIG. 3 is a front view of a porous metal structure according to a second embodiment of the present invention.

[0019] FIG. 4 is a cross-sectional view of an insulation connection member according to the present invention.BEST MODE

[0020] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. The sizes and shapes of the components shown in the drawings may be exaggerated for clarity and convenience.

[0021] Referring to FIG. 1, a porous metal structure according to a first embodiment of the present invention includes a case 10 formed in a circular or polygonal shape through which both sides are penetrated, and first corrugated plates 20 and second corrugated plates 30 alternately stacked on the case 10.

[0022] As shown in FIG. 1, the porous metal structure may be used as a metal catalyst carrier when a catalyst material for reacting with and purifying exhaust gas is coated on the surfaces of the first corrugated plates 20 and the second corrugated plates 30, and as shown in FIG. 3, when the first corrugated plates 20 and the second corrugated plates 30 may be manufactured as heating coils, which generate heat by power applied to the first corrugated plates 20 and the second corrugated plates 30, the porous metal structure may be used as a heater. Accordingly, when the first corrugated plates 20 and the second corrugated plates 30 may be manufactured as heating coils, and the catalyst material is coated on the surfaces of the heating coils, the porous metal structure may serve as a heater and a metal catalyst carrier at the same time.

[0023] The case 10 may have a cylindrical shape with both ends opened, or may be manufactured in a rectangular shape with both ends opened, and one opening of the case 10 may be a suction port through which air or gas is suctioned, and the other opening of the case 10 may be an outlet through which air or gas is discharged.

[0024] When the case 10 has a cylindrical shape, the first corrugated plates 20 and the second corrugated plates 30 may be arranged inside the case 10 in a wound shape, and when the case 10 has a rectangular shape, the first corrugated plates 20 and the second corrugated plates 30 may be arranged inside the case 10 in a shape where the first corrugated plates 20 and the second corrugated plates 30 are stacked one another in a vertical direction.

[0025] When the porous metal structure is applied as a metal catalyst carrier, as illustrated in FIG. 1, the first corrugated plates 20 and the second corrugated plates 30 may be alternately and repeatedly stacked, which may be wound in a circular shape, or may be vertically stacked.

[0026] In addition, when the porous metal structure is applied as a heater, as shown in FIG. 3, the first corrugated plates 20 and the second corrugated plates 30 are stacked by a predetermined number, and the first corrugated plates 20 and the second corrugated plates 30 which have been stacked one another are arranged at a predetermined interval (T1), thereby preventing a short circuit from occurring when power is applied to the first corrugated plates 20 and the second corrugated plates 30.

[0027] The first corrugated plates 20 each may be formed in a wavy shape or an uneven shape. Each of the upper sides of each of first corrugated plates 20 may be formed with a first upper vertex 22 contacting each of the lower surfaces of each of the second corrugated plate 30, and each of the lower sides may be formed with a first lower vertex 24 contacting each of the upper surfaces of each of the second corrugated plates 30. A distance between the first upper vertex 22 and a next first upper vertex may form a first pitch L1, and a height between the first upper vertex 22 and the first lower vertex 24 may form a first height H1.

[0028] The second corrugated plates30 each may be formed in a wavy shape or an uneven shape. Each of the upper sides of each of second corrugated plates 30 may be formed with a second upper vertex 32 contacting each of the lower surfaces of each of the first corrugated plate 20, and each of the lower sides may be formed with a second lower vertex 34 contacting each of the upper surfaces of each of the first corrugated plates 20. A distance between the second upper vertex 32 and a next second upper vertex may form a second pitch L2, and a height between the second upper vertex 32 and the second lower vertex 34 may form a second height H2.

[0029] The porous metal structure according to the present embodiment has a structure in which the first corrugated plates 20 and the second corrugated plates 30 are stacked to increase a surface area, thereby increasing a contact area with air or gas, thereby improving performance. That is, when applied as a metal catalyst support, a catalyst coating area may be increased to improve catalyst performance, and when applied as a heater, heating performance may be improved by increasing a heat generating area.

[0030] When the first corrugated plates 20 and the second corrugated plates 30 have the same waveform shape and size, it is difficult to assemble the first corrugated plates 20 and the second corrugated plates 30 when assembled, and the first pitch L1 of the first corrugated plates 20 and the second pitch L2 of the second corrugated plate 30 should be different from each other such that the first corrugated plates 20 and the second corrugated plates 30 are in surface contact with each other to increase the coupling force therebetween. The first height H1 and the second height H2 should also be formed to be different from each other.

[0031] That is, the first corrugated plates 20 and the second corrugated plates 30 should have a structure capable of increasing the coupling force between the first corrugated plates 20 and the second corrugated plates 30 when assembled while maximizing the contact area between the first corrugated plates 20 and the second corrugated plates 30.

[0032] Accordingly, when the first upper vertices 22 of each of the first corrugated plates 20 are fixed to coincide with the lower surfaces of the second upper vertices 32 of each of the second corrugated plates 30, and when the first lower vertices 24 of each of the first corrugated plates 20 are fixed to coincide with the upper surfaces of the second lower vertices 34 of each of the second corrugated plates 30, the first corrugated plates 20 and the second corrugated plates 30 are in surface contact with each other to improve the coupling force, thereby improving the durability of the porous metal structure.

[0033] Since the first pitch L1 of the first corrugated plates 20 and the second pitch L2 of the second corrugated plates 30 have different distances from each other, the second pitch L2 may be formed to be ½ of the first pitch L1 in order to match the first corrugated plates 20 and the second corrugated plates 30.

[0034] That is, the outer surface of each of the first upper vertices 22 of each of the first corrugated plates 20 may be arranged to be in contact with the inner surface of each of the second upper vertices 32 of each of the second corrugated plates 30 such that the apexes thereof coincide with each other to improve the coupling force between the first corrugated plates 20 and the second corrugated plates 30, and accordingly, deformation of the first corrugated plates 20 and the second corrugated plates 30 due to an external impact, vibration, pressure caused by passing of air or gas, thermal expansion due to a temperature change, or the like may be minimized.

[0035] The first height H1 of the first corrugated plates 20 and the second height H2 of the second corrugated plates 30 may be formed to be different from each other, and the first height H1 may be 3 to 5 times the second height H2 to increase the surface area of the first corrugated plates 20 and the second corrugated plates 30 while increasing the coupling force between the first corrugated plates 20 and the second corrugated plates 30.

[0036] When a heater and a catalytic converter are provided at the same time, the heater is provided in the front side to heat air or gas passing through the heater, and the heated air or gas passes through the catalytic converter so that the catalytic reaction is performed.

[0037] In this case, a space between the heater and the catalytic converter should be insulated, and to this end, an insulating connection member 50 is connected between the heater and the catalytic converter. As shown in FIG. 4, the insulating connection member 50 includes a first pin part 52 inserted into a passage part of the heater, a second pin part 54 inserted into a passage part of the catalytic converter, and an insulating body part 56 having one side fixed to the first pin part 52 and the other side to which the second pin part 54 is fixed.

[0038] As described above, since a plurality of insulating connection members 50 are inserted and connected between the heater and the catalytic converter, the heater and the catalytic converter are insulated from each other while being insulated from each other, and when the pin part is inserted, the assembly is completed, and thus assembly is easy and convenient.

[0039] While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, by way of illustration and example only, it is clearly understood that the present invention is not to be construed as limiting the present invention, and various changes and modifications may be made by those skilled in the art within the protective scope of the invention without departing off the spirit of the present invention.Industrial Applicability

[0040] According to the present invention, when a catalyst material is coated on the surfaces of the first corrugated plates and the second corrugated plates, the first corrugated plates and the second corrugated plates may be used as a catalytic converter, so that exhaust gas reacts with the catalyst material to remove harmful materials of the exhaust gas, and when the first corrugated plates and the second corrugated plates are manufactured as heating coils, the first corrugated plates and the second corrugated plates may be used as heaters for heating the passing air, and the first corrugated plates and the second corrugated plates are formed in a corrugated shape to maximize the surface area to improve performance.

Claims

1. A porous metal structure comprising:a case that is open at both ends; andfirst corrugated plates and second corrugated plates which are alternately stacked inside the case and form a passage through which air or gas passes,wherein first upper vertices in contact with the lower surface of one of the second corrugated plates and first lower vertices in contact with the upper surface of one of the second corrugated plates are repeatedly formed in each of the first corrugated plates, and the distance between the first upper vertices and the second lower vertices forms a first pitch (L1),wherein second upper vertices in contact with the lower surface of one of the first corrugated plates and second lower vertices in contact with the upper surface of one of the first corrugated plates are repeatedly formed in each of the second corrugated plates, and the distance between the second upper vertices and the second lower vertices forms a second pitch (L2), andwherein the first pitch (L1) and the second pitch (L2) are formed differently from each other.

2. The porous metal structure of claim 1, wherein apexes between the first upper vertices and the second upper vertices are in contact with each other to coincide with each other, apexes between the first lower vertices and the second lower vertices are in contact with each other to coincide with each other, and a surface-contact is made between the first corrugated plates and the second corrugated plates.

3. The porous metal structure of claim 1, wherein the distance of the second pitch (L2) is formed ½ of the distance of the first pitch (L1).

4. The porous metal structure of claim 1, wherein a first height (H1) between the first upper vertices and the first lower vertices is formed three to five times greater than a second height (H2) between the second upper vertices and the second lower vertices.

5. The porous metal structure of claim 1, wherein a catalyst material is coated on the surfaces of the first corrugated plates and the second corrugated plates.

6. The porous metal structure of claim 1, wherein the first corrugated plates and the second corrugated plates are manufactured as heating coils that generate heat when power is applied thereto.

7. The porous metal structure of claim 1, wherein the first corrugated plates and the second corrugated plates are manufactured as heating coils that generate heat when power is applied thereto, and a catalyst material is coated on the surfaces thereof.

8. The porous metal structure of claim 1, wherein the case is a circular or rectangular shape, and when the case is circular, the first corrugated plates and the second corrugated plates are stacked in a wound shape, and when the case has a rectangular shape, the first corrugated plates and the second corrugated plates are stacked in the vertical direction.

9. The porous metal structure of claim 1, wherein the first corrugated plates and the second corrugated plates include a heater that is manufactured by a heating coil that generates heat when power is applied thereto and heats air or gas that passes the heater, a catalytic converter arranged behind the heater and configured to receive air or gas having passed through the heater and react with the catalyst material, and an insulating connection member that connects the heater and the catalytic converter to each other.

10. The porous metal structure of claim 9, wherein the insulating connection member comprises: a first pin part fitted and coupled to a passage part of the heater; a second pin part fitted and coupled to a passage part of the catalytic converter; and an insulating body part having one end coupled to the first pin part and the other end to which the second pin part is coupled.

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