Heat-resistant metal monolith
AssigneeNGK Insulators, Ltd.
InventorsTakashi Harada, Hiroshige Mizuno, Fumio Abe, Tsuneaki Ohashi
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Abstract
A heat-resistant metallic monolith, manufactured by forming metal powders into a honeycomb structure and by sintering the structure, has a heat-resistant metal oxide coated on the surface of the cell walls and that of the pores thereof. Such a heat-resistant metallic monolith is manufactured by mixing metal powders, an organic binder and water to prepare a mixture, by forming the mixture into a shape of a desired honeycomb configuration, by sintering the shape in a non-oxidizing atmosphere at a temperature between 1000.degree. and 1450.degree. C. and then by coating a heat-resistant metal oxide on a surface of the cell walls and that of the pores of the obtained sintered body.
Claims20
A heat-resistant metallic monolith comprising:
- a porous sintered metal monolith comprising an outer shell and a matrix of intersecting porous partition walls thereby defining a plurality of honeycomb passages, said partition walls and outer shell being integrally formed together to form a unitary structure, said metal monolith containing Fe, Cr and Al, wherein 10<Cr.ltoreq.25 wt %, 3<Al.ltoreq.20 wt %, the balance being substantially Fe;
- and
- a heat-resistant metal oxide coated on a surface of the partition walls and surfaces of pores in said metal monolith.
A honeycomb heater comprising:
- a porous sintered heat-resistant metal monolith comprising an outer shell and a matrix of intersecting porous partition walls thereby defining a plurality of honeycomb passages, said partition walls and outer shell being integrally formed together to form a unitary structure, said metal monolith containing Fe, Cr and Al, wherein 10<Cr.ltoreq.25 wt %, 3<Al.ltoreq.20 wt %, the balance being substantially Fe;
- a heat-resistant metal oxide coated on a surface of the partition walls and surfaces of pores in said metal monolith;
- and
- electrodes provided on said metal monolith.
A catalytic converter arranged to be in a stream of gas, comprising:
- a main monolith catalyst arranged to be in such a stream of gas;
- a heater arranged to be in such a stream of gas, adjacent to and upstream of said main monolith catalyst, said heater comprising (a) a porous sintered heat-resistant metal monolith comprising an outer shell and a matrix of intersecting porous partition walls thereby defining a plurality of honeycomb passages, said partition walls and outer shell being integrally formed together to form a unitary structure, said metal monolith containing Fe, Cr and Al, wherein 10<Cr.ltoreq.25 wt %, 3.ltoreq.Al.ltoreq.20 wt %, the balance being substantially Fe, and (b) electrodes provided on said metal monolith;
- a heat-resistant metal oxide coated on a surface of the partition walls and surfaces of pores in said metal monolith;
- and
- inlet means and outlet means for allowing passage of such a stream of gas through said main monolith catalyst and said heater.
A catalytic converter arranged to be in a stream of gas comprising:
- a main monolith catalyst arranged to be in such a stream of gas;
- a heater arranged to be in such a stream of gas, adjacent to and upstream of said main monolith catalyst, said heater comprising (a) a porous sintered heat-resistant metallic monolith comprising an outer shell and a matrix of intersecting porous partition walls thereby defining a plurality of honeycomb passages, said partition walls and outer shell being integrally formed together to form a unitary structure, said metal monolith containing Fe, Cr and Al, wherein 10<Cr.ltoreq.25 wt %, 3.ltoreq.Al.ltoreq.20 wt %, the balance being substantially Fe, and (b) electrodes provided on said metal monolith;
- a heat-resistant metal oxide coated on a surface of the partition walls and surfaces of pores in said metal monolith;
- a catalyst supported on said heat-resistant metallic monolith;
- and
- inlet means and outlet means for allowing passage of such a stream of gas through said main monolith catalyst and said heater.
A catalytic converter comprising:
- a heater comprising (a) a porous sintered heat-resistant metal monolith an outer shell and a matrix of intersecting porous partition walls thereby defining a plurality of honeycomb passages, said partition walls and outer shell being integrally formed together to form a unitary structure, said metal monolith containing Fe, Cr and Al, wherein 10<Cr.ltoreq.25 wt %, 3.ltoreq.Al.ltoreq.20 wt %, the balance being substantially Fe, and (b) electrodes provided on said metal monolith;
- a heat-resistant metal oxide coated on a surface of the partition walls and surfaces of pores in said metal monolith;
- and
- a catalyst supported on said heat-resistant metallic monolith.
Dependencies are inferred from the claim text.