Ibiden Company Limited

Toyota Jidosha Kabushiki Kaisha

Fumiyuki Mutsuda

Yoshitaka Fujita

Hideyuki Komitsu

Shoji Ogimura

Yasutaka Ito

Takahiko Okabe

Satoru Kariya

Tomoyoshi Nakamura

Yuya Sugiura

The diffusing member of the present invention is disposed in an exhaust pipe to partially block exhaust gas flowing in from upstream of the exhaust pipe, the diffusing member including a ceramic member and a metal member, wherein the ceramic member surrounds the metal member in such a manner that the metal member is partially exposed, and the volume of the ceramic member constituting the diffusing member is larger than the volume of the metal member constituting the diffusing member.

Diffusing member, exhaust gas purification device, and use of diffusing member in exhaust gas purification device

The present invention provides a highly durable, electrically heated catalytic converter including an inner tube on which an insulation layer is formed, wherein the insulation layer is less susceptible to damage such as cracking and peeling even when thermal stress occurs in a curvature section of the inner tube where the insulation layer is formed. The present invention provides an electrically heated catalytic converter for purifying exhaust gas, the electrically heated catalytic converter including a catalyst carrier supporting a catalyst and configured to generate heat by energization; a case for accommodating the catalyst carrier; and an electrical insulation mat interposed between the catalyst carrier and the case, wherein the case includes an outer tube disposed at the outermost side and an inner tube disposed inside the outer tube; in a cross section upstream of the catalyst carrier taken along a plane including the central axis of the case, the inner tube includes one or more curvature sections curved so as to outwardly project and extended sections connected to the one or more curvature sections, an insulation layer including an amorphous inorganic material is formed at least on an inner surface of the one or more curvature sections and the extended sections of the inner tube, the one or more curvature sections include a first curvature section located closest to the catalyst carrier, the first curvature section has a first curvature section insulation layer formed thereon, the first curvature section insulation layer having a thickness of 100 to 400 &#x3bc;m, the extended sections include a first extended section connected to the first curvature section and adjacent to the catalyst carrier, the first extended section has a first extended section insulation layer formed thereon, and the thickness of the first curvature section insulation layer is greater than 1 time to less than 1.4 times the thickness of the first extended section insulation layer.

Electrically heated catalytic converter

A structure includes a surface coat layer of which the thickness on a bump such as a weld bead and a weld spatter or an edge portion, possibly formed on the surface of a base, is not greatly different from the thickness on a flat portion. The structure therefore has excellent properties including heat insulation properties and electrical insulation properties. The structure includes a base that is made of a metal, and has a flat portion and at least one of a bump and an edge portion on a surface; and a surface coat layer that is formed from an amorphous inorganic material and particles of a crystalline inorganic material, and covers the surface of the base, the surface coat layer including a first coat portion covering the flat portion and a second coat portion covering the at least one of a bump and an edge portion.

Structure and paint for forming surface coat layer

The present invention provides a highly durable, electrically heated catalytic converter including an insulation layer formed on an inner tube, wherein the insulation layer is less susceptible to cracking and peeling even when high thermal stress occurs in the insulation layer at and near the end portion of an inner tube, at upstream of a catalyst carrier. An electrically heated catalytic converter for purifying exhaust gas includes a catalyst carrier supporting a catalyst and configured to generate heat by energization; a case for accommodating the catalyst carrier; and an electrical insulation mat interposed between the catalyst carrier and the case, wherein the case includes an outer tube disposed at the outermost side and an inner tube disposed inside the outer tube; in a cross section upstream of the catalyst carrier taken along a plane including the central axis of the case, the inner tube is curved at least once so as to outwardly project and then obliquely extends toward the central axis of the case, an insulation layer having a thickness of 100 to 200 &#x3bc;m is formed in the range from an end portion of the inner tube to 10% of the length of the inner tube from the end portion of the inner tube to an end of the catalyst carrier, an insulation layer having a thickness of 100 to 400 &#x3bc;m is formed in the range from a point immediately after 10% of the length away from the end portion of the inner tube to 50% of the length of the inner tube from the end portion to the end of the catalyst carrier, and the insulation layer formed in the range from the end portion of the inner tube to 10% of the length is thinner than the insulation layer formed in the range from a point immediately after 10% of the length away from the end portion of the inner tube to 50% of the length.

The present invention provides a highly durable, electrically heated catalytic converter having a relatively simple structure while its inner tube is curved toward the central axis, wherein an insulation layer formed on the inner tube is less susceptible to cracking and peeling even when the inner tube is subjected to temperature changes or temperature gradients. An electrically heated catalytic converter for purifying exhaust gas includes a catalyst carrier supporting a catalyst and configured to generate heat by energization; a case for accommodating the catalyst carrier; and an electrical insulation mat interposed between the catalyst carrier and the case, wherein the case includes an outer tube disposed at the outermost side and an inner tube disposed inside the outer tube; in a cross section upstream of the catalyst carrier taken along a plane including the central axis of the case, the inner tube includes a first curved portion and a second curved portion formed in this order from the side closer to the catalyst carrier, the first curved portion is curved so as to outwardly project and the second curved portion is curved in the direction opposite to the curvature of the first curved portion so as to project toward the central axis, the second curved portion has a curvature radius larger than that of the first curved portion, and an insulation layer is formed on at least one portion of the inner tube.

An exhaust gas processing device includes a cylindrical metallic member and an insulating layer. The insulating layer has a thickness of about 20 &#x3bc;m to about 400 &#x3bc;m and is densely formed such that no through pores exist in a thickness direction of the insulating layer. The insulating layer is provided on an inner surface of the cylindrical metallic member.

Exhaust gas processing device

An exhaust gas processing device includes a honeycomb structure in a pillar shape including a honeycomb unit, a catalytic agent, an inorganic mat member, a cylindrical metallic member and an insulating layer. The honeycomb unit includes cell walls to define a plurality of cells which extend from a first end of the honeycomb unit to a second end of the honeycomb unit along a longitudinal direction. The catalytic agent is provided on the cell walls. The inorganic mat member is wound around an outer peripheral surface of the honeycomb structure. The cylindrical metallic member accommodates the honeycomb structure around which the inorganic mat member is wound. The insulating layer has a thickness of about 20 &#x3bc;m to about 400 &#x3bc;m and is densely formed. The insulating layer is provided between an inner surface of the cylindrical metallic member and the inorganic mat member.

An exhaust gas processing device includes a first cylindrical metallic member, an inorganic mat member, a second cylindrical metallic member, and an insulating layer. The inorganic mat member is wound around an outer periphery of the first cylindrical metallic member. The second cylindrical metallic member accommodates the first cylindrical metallic member around which the inorganic mat member is wound. The insulating layer have a thickness of about 20 &#x3bc;m to about 400 &#x3bc;m and is provided at at least one of a first part which is an inner surface of the first cylindrical metallic member, a second part between an outer surface of the first cylindrical metallic member and the inorganic mat member, and a third part between an inner surface of the second cylindrical metallic member and the inorganic mat member.

An exhaust gas processing device includes a pillar honeycomb structure, a first inorganic mat member, a first cylindrical metallic member, a second inorganic mat member, a second cylindrical metallic member, and an insulating layer. The insulating layer has a thickness of about 20 &#x3bc;m to about 400 &#x3bc;m and is provided at least one of a first part between an inner surface of the first cylindrical metallic member and the first inorganic mat member, a second part between an outer surface of the first cylindrical metallic member and the second inorganic mat member, and a third part between an inner surface of the second cylindrical metallic member and the second inorganic mat member.

Growing community of inventors

Ibi-gun, Japan

Fumiyuki Mutsuda