Metal Foam Catalyst Support with Corrugated Sheath
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Solution Overview
Problem
Metallic honeycomb catalyst support bodies have a smooth surface, making it difficult to coat with a porous carrier material, requiring high binder levels which can negatively affect catalyst activity.
Innovation Solution
A catalyst support body with a honeycomb body composed of at least three metal layers wound in a spiral form, using metal foam layers with a corrugated sheath between sectionally planar layers, allowing for improved adhesion and reduced binder usage, while maintaining mechanical strength and increased surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic honeycomb bodies with smooth surfaces are used, then mechanical stability and shapability are improved, but adhesion of porous carrier material deteriorates
Solution Approach 1:
The patent applies local quality by creating surface corrugations only on the inner walls of the honeycomb body channels while maintaining the overall mechanical integrity of the metallic structure. This localized surface modification provides anchoring points for the porous carrier material without compromising the global mechanical stability of the honeycomb body.
Solution Approach 2:
The patent introduces curved corrugations undulating along the channel length, transforming the smooth planar surface into a curved undulating surface. This curvature creates peaks and valleys that mechanically interlock with the porous carrier material, significantly improving adhesion while maintaining the metallic structure's strength.
2Ease of manufacture
If high binder levels are used to achieve sufficient adhesion, then adhesion of porous carrier material is improved, but catalyst activity deteriorates
Solution Approach 1:
The patent performs preliminary action by pre-modifying the honeycomb body surface with corrugations before applying the porous carrier material and binder. This pre-created rough surface structure provides mechanical anchoring that reduces the reliance on high binder levels, allowing for reduced binder content while maintaining sufficient adhesion and preserving catalyst activity.
3Ease of manufacture
If ceramic honeycomb bodies are used, then adhesion of porous carrier material is improved, but mechanical stability and response under cold-start conditions deteriorate
Solution Approach 1:
The patent changes the material parameter from ceramic to metallic foam, which fundamentally alters the thermal properties. Metallic foam has higher thermal conductivity than ceramic, enabling faster heat transfer and quicker catalyst activation under cold-start conditions, while the introduced surface corrugations compensate for the lower surface roughness by providing mechanical interlocking.
4Area of moving object
If metal foam layers are used instead of planar metal layers, then surface area is increased, but structural complexity increases
Solution Approach 1:
The patent transitions from planar two-dimensional metal layers to three-dimensional metal foam structures. This dimensional change inherently increases the surface area within the same volume, providing more active sites for catalysis while the regular corrugation pattern maintains a degree of structural predictability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enables firm bonding of the porous carrier material with minimal binder, enhancing catalyst activity and mechanical stability, and provides a larger surface area for exhaust gas flow, reducing pressure loss and mechanical stress on the washcoat, leading to improved catalytic performance and weight reduction.
Implementation Method 1
the metal layers consist of a metal foam
Implementation Method 2
Metallic honeycomb catalyst support bodies have a smooth surface, making it difficult to coat with a porous carrier material
Data Source
AI summary
The present invention relates to a catalyst support body (100) with a longitudinal axis (103) comprising a honeycomb body (101) and a housing (102), wherein the honeycomb body (101) consists of at least three metal layers (104) arranged one above the other, which are wound with their end surfaces in each case starting from a common centre into layers lying one above the other in the form of a spiral and are secured in the sleeve of the housing (102), wherein the metal layers consist of metal-foam layers, and wherein a metal-foam layer developed as a corrugated sheath (107) is arranged between two planar metal-foam layers (105, 106), wherein attachment sections (108) on the outside of the corrugated sheath (107) connect it to the planar metal-foam layers (105, 106).