EXHAUST GAS PROCESSING DEVICE

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 μm to about 400 μm 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. 1. An exhaust gas processing device comprising:a pillar honeycomb structure including a honeycomb unit which is electrically conductive and which has cells which are separated by a cell wall and extend from a first end surface to a second end surface along a longitudinal direction of the honeycomb structure, the cell wall carrying a catalytic agent;a first inorganic mat member wound around an outer periphery of the honeycomb structure;a first cylindrical metallic member accommodating the honeycomb structure around which the first inorganic mat member is wound;a second inorganic mat member wound around an outer periphery of the first cylindrical metallic member;a second cylindrical metallic member accommodating the first cylindrical metallic member around which the second inorganic mat member is wound; andan insulating layer having a thickness of about 20 μm to about 400 μm and 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.2. The exhaust gas processing device according ...

HOLDING SEALING MATERIAL, AND ELECTRICALLY HEATING EXHAUST GAS PURIFYING APPARATUS

A holding sealing material includes an inorganic fiber sheet having inorganic fibers interlaced with one another, and a water-proof insulation sheet containing a flaky inorganic material. An electrically heating exhaust gas purifying apparatus includes an exhaust gas-treating body made of a resistance heating body, a metal casing to house the exhaust gas-treating body and a holding sealing material. The exhaust gas purifying apparatus includes a first electrode and a second electrode. The first and second electrode each penetrate through the metal casing and the holding sealing material, and have a first end part bonded to the exhaust gas-treating body and a second end part exposed outside of the metal casing. The holding sealing material includes an inorganic fiber sheet which has inorganic fibers interlaced with one another, and a water-proof insulation sheet containing a flaky inorganic material. 1. A holding sealing material comprising:an inorganic fiber sheet having inorganic fibers interlaced with one another; anda water-proof insulation sheet containing a flaky inorganic material.2. The holding sealing material according to claim 1 ,wherein the flaky inorganic material is mica, vermiculite, montmorillonite, iron-montmorillonite, beidellite, saponite, hectorite, stevensite, nontronite, magadiite, ilerite, kanemite, smectite, layered titanate or a combination thereof.3. The holding sealing material according to claim 2 ,wherein the flaky inorganic material is mica.4. The holding sealing material according to claim 1 ,wherein the water-proof insulation sheet comprises an adhesive.5. The holding sealing material according to claim 4 ,wherein the adhesive includes silicones, polyethylene glycols, polyalkylene glycols, phosphoric acid esters, alkylbenzene, poly-α-olefins, polyol esters, alkylnaphthalene, halocarbons, polyallyl alkanes, polyphenyls, silicic acid esters, polyphenyl ethers or a combination thereof.6. The holding sealing material according to claim 5 , ...

STRUCTURE AND METHOD OF MANUFACTURING STRUCTURE

A structure includes a base material made of metal and a surface coating layer provided on a surface of said base material. The surface coating layer includes a first layer provided on the surface of said base material and a second layer provided directly or indirectly on the first layer as an outermost layer of said surface coating layer. The first layer contains an amorphous inorganic material. The second layer contains a crystalline inorganic material having a softening point of about 950° C. or higher. 1. A structure comprising:a base material made of metal; and a first layer provided on the surface of said base material and containing an amorphous inorganic material; and', 'a second layer provided directly or indirectly on the first layer as an outermost layer of said surface coating layer and containing a crystalline inorganic material having a softening point of about 950° C. or higher., 'a surface coating layer provided on a surface of said base material and comprising2. The structure according to claim 1 ,whereinsaid crystalline inorganic material contained in said second layer of the surface coating layer is one of zirconia and alumina.3. The structure according to claim 1 ,whereina total thickness of said first layer and said second layer of the surface coating layer is from about 1 μm to about 2000 μm.4. The structure according to claim 1 ,whereina thermal conductivity at room temperature of said first layer of the surface coating layer is from about 0.05 W/m·K to about 2 W/m·K.5. The structure according to claim 1 ,whereinsaid amorphous inorganic material contained in said first layer of the surface coating layer is a low melting point glass having a softening point of from about 300° C. to about 1000° C.6. The structure according to claim 1 ,whereinsaid first layer of the surface coating layer further contains a crystalline inorganic material.7. The structure according to claim 6 ,whereinsaid crystalline inorganic material contained in said first layer ...

METAL MEMBER WITH COAT LAYER

The present invention provides a coated metal member including a metal base and a coat layer made of an amorphous inorganic material formed on the metal base, the coat layer containing pores and carbon particles. 1. A coated metal member comprising:a metal base; anda coat layer made of an amorphous inorganic material formed on the metal base,the coat layer containing pores and carbon particles.2. The coated metal member according to claim 1 ,wherein the carbon particles are particles of residual carbon derived from a pore-forming material used to form pores.3. The coated metal member according to claim 1 ,wherein the amount of the carbon particles is 0.005 to 1 part by weight relative to the total 100 parts by weight of the coat layer.4. The coated metal member according to claim 1 ,wherein the coat layer contains no large pores having a pore size larger than 45 μm.5. The coated metal member according to claim 1 ,wherein the coat layer further contains a crystalline inorganic material.6. The coated metal member according to claim 5 ,wherein the crystalline inorganic material is at least one oxide selected from the group consisting of zirconia, yttria, calcia, magnesia, ceria, alumina, titania, niobium oxide, and hafnia.7. The coated metal member according to claim 5 ,wherein the crystalline inorganic material is an oxide of at least one metal selected from the group consisting of manganese, iron, cobalt, copper, chromium, and nickel.8. The coated metal member according to claim 1 ,wherein the pores in the coat layer have an average pore size of 0.5 to 15 μm.9. The coated metal member according to claim 1 ,wherein the coat layer has a thickness of 50 to 1000 μm. The present invention relates to a coated metal member.In vehicles such as automobiles with engines, a large amount of heat is generated in the engine area. The generated heat is easily diffused into the surrounding area via engine components. The generated heat is not always fully utilized at the present ...

DIFFUSING MEMBER, EXHAUST GAS PURIFICATION DEVICE, AND USE OF DIFFUSING MEMBER IN EXHAUST GAS PURIFICATION DEVICE

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. 1. A diffusing member to be disposed in an exhaust pipe to partially block exhaust gas flowing in from upstream of the exhaust pipe , the diffusing member comprising:a ceramic member; anda metal member,wherein the ceramic member surrounds the metal member in such a manner that the metal member is partially exposed, andthe volume of the ceramic member constituting the diffusing member is larger than the volume of the metal member constituting the diffusing member.2. The diffusing member according to claim 1 ,wherein the exposed area of the ceramic member is larger than the exposed area of the metal member on an outermost surface of the diffusing member.3. The diffusing member according to claim 1 ,wherein pores are formed in the ceramic member.4. The diffusing member according to claim 3 ,wherein the ceramic member has a porosity of 5 to 60%.5. The diffusing member according to claim 3 ,wherein no continuous pores are formed in the ceramic member.6. The diffusing member according to claim 3 ,wherein the pores formed in the ceramic member are closed pores.7. The diffusing member according to claim 1 ,wherein the ceramic member comprises a crystalline inorganic material and/or an amorphous inorganic material.8. The diffusing member according to claim 7 ,wherein the crystalline inorganic material comprises at least one selected from the group consisting of alumina, silica, zirconia, zircon, yttria, calcia, magnesia, ceria, and hafnia.9. The diffusing member according to claim 7 ,wherein the ...

EXHAUST GAS PROCESSING DEVICE

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 μm to about 400 μm 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. 1. An exhaust gas processing device comprising:a first cylindrical metallic member;an inorganic mat member wound around an outer periphery of the first cylindrical metallic member;a second cylindrical metallic member accommodating the first cylindrical metallic member around which the inorganic mat member is wound; andan insulating layer having a thickness of about 20 μm to about 400 μm and 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.2. The exhaust gas processing device according to claim 1 ,wherein the insulating layer includes a glass layer.3. The exhaust gas processing device according to claim 1 ,wherein the insulating layer includes a mixed layer including an amorphous binder and crystalline metal oxide and has a thickness in a range of 50 to 400 μm.4. The exhaust gas processing device according to claim 1 ,wherein the insulating layer includes a glass layer and a mixed layer ...

Catalytic Converter Apparatus

A catalytic converter apparatus includes a catalyst substrate that supports a catalyst for cleaning exhaust gas exhausted from an internal combustion engine, the catalyst substrate being heated by electrification; a case formed in a tubular shape, the catalyst substrate being accommodated inside the case and the case being attached to an exhaust pipe; an outer pipe provided at the case, the outer pipe being disposed at least at an upstream side of an exhaust gas flow direction relative to the catalyst substrate; an inner pipe provided at the case inside the outer pipe, an axial direction end portion of the inner pipe being formed in a tapered shape and a distal end face of the axial direction end portion being formed in a curved surface shape; and an insulating layer provided at least at an inner side face and the axial direction end portion of the inner pipe. 1. A catalytic converter apparatus comprising:a catalyst substrate that supports a catalyst for cleaning exhaust gas exhausted from an internal combustion engine, the catalyst substrate being heated by electrification;a case formed in a tubular shape, the catalyst substrate being accommodated inside the case and the case being attached to an exhaust pipe;an outer pipe provided at the case, the outer pipe being disposed at least at an upstream side of an exhaust gas flow direction relative to the catalyst substrate;an inner pipe provided at the case inside the outer pipe, an axial direction end portion of the inner pipe being formed in a tapered shape and a distal end face of the axial direction end portion being formed in a curved surface shape; andan insulating layer provided at least at an inner side face and the axial direction end portion of the inner pipe.2. The catalytic converter apparatus according to claim 1 , wherein claim 1 , if a radius of curvature of the distal end face of the axial direction end portion is represented by R claim 1 , chamfer machining is applied such that R≧0.5 mm.3. The ...

Exhaust gas processing device

An exhaust gas processing device includes a cylindrical metallic member and an insulating layer. The insulating layer has a thickness of about 20 μm to about 400 μm 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.

STRUCTURE AND PAINT FOR FORMING SURFACE COAT LAYER

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. 1. A structure comprising: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; anda 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,the surface coat layer having a thickness ratio of the second coat portion to the first coat portion (second coat portion thickness/first coat portion thickness) of from 0.4 to less than 1.0,the particles of the crystalline inorganic material constituting from 5 to 70% by weight of the whole of the surface coat layer.2. The structure according to claim 1 ,wherein the particles of the crystalline inorganic material constitute from 20 to 70% by weight of the whole of the surface coat layer.3. The structure according to claim 1 ,wherein the particles of the crystalline inorganic material have an average particle size of from 0.1 to 50 μm.4. The structure according to claim 3 ,wherein the particles ...

STRUCTURE AND PAINT FOR FORMING SURFACE COAT LAYER

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. 1. A structure comprising: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; anda 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,the surface coat layer having a thickness ratio of the second coat portion to the first coat portion (second coat portion thickness/first coat portion thickness) of from 0.4 to less than 1.0,the particles of the crystalline inorganic material having an average particle size of from 0.1 to 50 μm.2. The structure according to claim 1 ,wherein the particles of the crystalline inorganic material constitute from 5% by weight to less than 20% by weight of the surface coat layer.3. The structure according to claim 1 ,wherein the particles of the crystalline inorganic material have an average particle size of from 0.1 μm to less than 10 μm.4. The structure according to claim 1 ,wherein the first coat ...

STRUCTURE AND PAINT SET

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 covers the surface of the base, the surface coat layer including: a first surface coat layer that covers the flat portion, and contains an amorphous inorganic material, or a crystalline inorganic material and an amorphous inorganic material in combination. 1. A structure comprising: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; anda surface coat layer that covers the surface of the base,the surface coat layer including: a first surface coat layer that covers the flat portion, and comprises an amorphous inorganic material, or a crystalline inorganic material and an amorphous inorganic material in combination; and a second surface coat layer that covers the at least one of a bump and an edge portion, and comprises the crystalline inorganic material and the amorphous inorganic material,the second surface coat layer comprising a higher percentage by weight of the crystalline inorganic material than does the first surface coat layer.2. The structure according to claim 1 ,wherein the first surface coat layer is free from the crystalline inorganic material, or comprises the crystalline inorganic material in an amount of 0.1 to 5% by weight, andthe second surface coat layer comprises the crystalline inorganic material in an amount of 5 to 70% by weight.3. The structure according to claim 2 ,wherein second surface coat layer comprises the crystalline inorganic material in an amount of ...

STRUCTURE AND PAINT SET

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 covering the surface of the base, the surface coat layer including a first surface coat layer covering the flat portion and a second surface coat layer covering the at least one of a bump and an edge portion. 1. A structure comprising: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; anda surface coat layer covering the surface of the base,the surface coat layer including a first surface coat layer covering the flat portion and a second surface coat layer covering the at least one of a bump and an edge portion,the first surface coat layer and the second surface coat layer being formed from an amorphous inorganic material and particles of a crystalline inorganic material,the particles of the crystalline inorganic material in the second surface coat layer having an average particle size smaller than the particles of the crystalline inorganic material in the first surface coat layer.2. The structure according to claim 1 ,wherein the particles of the crystalline inorganic material in the second surface coat layer have an average particle size of from 0.1 to 50 μm, and the particles of the crystalline inorganic material in the first surface coat layer have an average particle size of from 1 to 51 μm.3. The structure according to claim 2 ,wherein the particles of the crystalline inorganic material in the second surface coat layer have an average particle size of from 0.1 to 10 μm.4. The ...

Electrically heated catalytic converter

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 μm, 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

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. 1. An electrically heated catalytic converter for purifying exhaust gas , the electrically heated catalytic converter comprising:a catalyst carrier supporting a catalyst and configured to generate heat by energization;a case for accommodating the catalyst carrier; andan electrical insulation mat interposed between the catalyst carrier and the case,wherein the case comprises 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 ...

ELECTRICALLY HEATED CATALYTIC CONVERTER

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 μm 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 μm 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. 1. An electrically heated catalytic converter for purifying exhaust gas , the electrically heated catalytic converter comprising:a catalyst carrier supporting a catalyst and configured to generate heat ...

PAINT AND EXHAUST SYSTEM COMPONENT WITH THE PAINT

A paint includes an amorphous inorganic material, crystalline inorganic material particles, and pore-forming material particles. The amorphous inorganic material contains silica. The crystalline inorganic material particles contain zirconia. The crystalline inorganic material particles have an average particle size of about 0.1 μm to about 150 μm. A weight of the crystalline inorganic material particles is about 30 parts by weight to about 180 parts by weight to 100 parts by weight of the amorphous inorganic material. The pore-forming material particles have an average particle size of about 0.1 μm to about 25 μm. A weight of the pore-forming material particles is about 0.001 parts by weight to about 1 parts by weight to 100 parts by weight of the amorphous inorganic material. 1. A paint comprising:an amorphous inorganic material containing silica;crystalline inorganic material particles containing zirconia and having an average particle size of about 0.1 μm to about 150 μm, a weight of the crystalline inorganic material particles being about 30 parts by weight to about 180 parts by weight to 100 parts by weight of the amorphous inorganic material; andpore-forming material particles having an average particle size of about 0.1 μm to about 25 μm, a weight of the pore-forming material particles being about 0.001 parts by weight to about 1 parts by weight to 100 parts by weight of the amorphous inorganic material.2. The paint according to claim 1 , wherein the pore-forming material comprises carbon claim 1 , a carbonate claim 1 , or a foaming agent.3. The paint according to claim 1 , wherein the pore-forming material gasifies at about 600° C. to about 1000° C.4. The paint according to claim 2 , wherein the pore-forming material gasifies at about 600° C. to about 1000° C.5. The paint according to claim 1 , wherein the crystalline inorganic material particles contain about 20% by weight or more of zirconia.6. The paint according to claim 1 , wherein the amorphous ...

STRUCTURE AND METHOD OF MANUFACTURING STRUCTURE

A structure includes a base material made of metal to be in a form of a tube and a surface coating layer provided on an inner face of the tube. The surface coating layer includes a first layer provided on the inner face and a second layer provided directly or indirectly on the first layer as an outermost layer of the surface coating layer. The first layer contains an amorphous inorganic material. The second layer contains a crystalline inorganic material having a softening point of about 950° C. or higher. 1. A structure comprising:a base material made of metal to be in a form of a tube; and a first layer provided on the inner face and containing an amorphous inorganic material; and', 'a second layer provided directly or indirectly on the first layer as an outermost layer of the surface coating layer and containing a crystalline inorganic material having a softening point of about 950° C. or higher., 'a surface coating layer provided on an inner face of the tube and comprising2. The structure according to claim 1 ,whereinsaid crystalline inorganic material contained in said second layer of the surface coating layer is one of zirconia and alumina.3. The structure according to claim 1 ,whereina total thickness of said first layer and said second layer of the surface coating layer is from about 1 μm to about 2000 μm.4. The structure according to claim 1 ,whereina thermal conductivity at room temperature of said first layer of the surface coating layer is from about 0.05 W/m·K to about 2 W/m·K.5. The structure according to claim 1 ,whereinsaid amorphous inorganic material contained in said first layer of the surface coating layer is a low melting point glass having a softening point of from about 300° C. to about 1000° C.6. The structure according to claim 1 ,whereinsaid first layer of the surface coating layer further contains a crystalline inorganic material.7. The structure according to claim 6 ,whereinsaid crystalline inorganic material contained in said first layer ...

Exhaust gas processing device

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 μm to about 400 μm 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.

Gas circulation member

Exhaust gas processing device

An exhaust gas processing device (100) including a pillar honeycomb structure (200) including a honeycomb unit that has cells separated by a cell wall carrying a catalytic agent; an inorganic mat member; and a cylindrical metallic member, wherein the honeycomb unit is electrically conductive, the exhaust gas processing device includes a first inorganic mat member (500) wound around the honeycomb structure, a first cylindrical metallic member (600) accommodating the honeycomb structure, a second inorganic mat member (510) wound around the first cylindrical metallic member, a second cylindrical metallic member (590) accommodating the first cylindrical metallic member, and an insulating layer (610A,610B,610C) of a thickness of 20 µm to 400 µm which is densely formed on at least one of a first part of an inner surface of the first cylindrical metallic member (600), a second part of an outer surface thereof, and a third part of an inner surface of the second cylindrical metallic member (590).

Structure, and paint set

The present invention provides a structure including 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 covers the surface of the base, the surface coat layer including: a first surface coat layer that covers the flat portion, and contains an amorphous inorganic material, or a crystalline inorganic material and an amorphous inorganic material in combination; and a second surface coat layer that covers the at least one of a bump and an edge portion, and contains the crystalline inorganic material and the amorphous inorganic material, the second surface coat layer containing a higher percentage by weight of the crystalline inorganic material than does the first surface coat layer.

Gas circulation member

The present invention provides a gas flow member capable of preventing a decrease in engine output and a decrease in exhaust gas purification performance even when the surface of a housing component of a turbo engine or the surface of an exhaust system component is a surface having high roughness or waviness. The gas flow member includes a metal base having a gas flow surface and a surface coat layer containing an amorphous inorganic material and a crystalline inorganic material, the gas flow surface of the base being coated with the surface coat layer, wherein the crystalline inorganic material contains at least one selected from the group consisting of calcia, magnesia, ceria, alumina, and zirconia, the gas flow surface of the base is a surface having a ten-point average roughness RzJIS of a roughness curve of 10 to 50 µm and having a maximum waviness height Wz of a waviness curve of 15 to 100 µm, roughness and waviness of the gas flow surface of the base are covered with the surface coat layer, the surface coat layer has an average thickness of more than 50 µm, and a coated gas flow surface which is a surface formed by covering the gas flow surface of the base with the surface coat layer is a smooth surface having a ten-point average roughness RzJIS of a roughness curve of 5 µm or less and is also a flat surface having a maximum waviness height Wz of a waviness curve of 10 µm or less.

電気加熱式触媒コンバータ

【課題】絶縁層を形成した内管の曲部に、熱応力が発生したとしても、絶縁層にクラックや剥れ等の破損が発生しにくい、耐久性に優れた電気加熱式触媒コンバータを提供する。 【解決手段】触媒が担持され、通電により発熱する触媒担体２０と、触媒担体を収容するケース３０と、触媒担体とケースとの間に介在する電気絶縁性のマット４０とを備えた排ガスを浄化するための電気加熱式触媒コンバータ１０であって、ケースは、最も外側に設けられた外管３１と、該外管の内側に設けられた内管３４とを備え、内管の内表面には絶縁層３６が形成されており、第１曲部３４ａ１に形成される第１曲部絶縁層３６ａ１の厚さは、１００〜４００μｍであり、第１曲部絶縁層の厚さは、第１曲部に連結している延在部のうち第１延在部３４ｂ１に形成される第１延在部絶縁層３６ｂ１の厚さの１倍を超えて、１．４倍未満であることを特徴とする電気加熱式触媒コンバータ。 【選択図】図１

Metal member with coat layer

構造体の製造方法及び構造体

【課題】 金属からなる基材の所定部分に充分な厚さのセラミックコート層が形成された構造体の製造方法を提供する。【解決手段】 金属からなる基材の表面の一部に被覆予定領域を決定する被覆予定領域決定工程と、上記被覆予定領域の外側に、上記被覆予定領域の境界と接するように凹部を形成する凹部形成工程と、軟化点が３００〜９００℃である低融点ガラス粉末を含むセラミック原料を上記被覆予定領域に塗布すると共に、上記セラミック原料を上記凹部に充填するセラミック原料塗布工程と、上記セラミック原料を上記基材の表面に上記軟化点よりも高い温度で焼き付けセラミックコート層を形成するセラミックコート層形成工程とを含むことを特徴とする構造体の製造方法。【選択図】 図５

構造体及び塗料セット

【課題】 表面に溶接ビードや溶接スパッタのような凸部が存在する場合や、エッジ部が存在する場合であっても、上記凸部やエッジ部にも、平坦部と厚さが大きく異ならない表面被覆層が形成され、断熱性や絶縁性等に優れる構造体を提供する。 【解決手段】 金属からなり、表面に平坦部と凸部及び／又はエッジ部とが形成された基材と、前記基材の表面に被覆された表面被覆層とを備えた構造体であって、 前記表面被覆層は、前記平坦部を被覆する第１表面被覆層と、前記凸部及び／又はエッジ部を被覆する第２表面被覆層とからなり、前記第１表面被覆層及び前記第２表面被覆層は、非晶性無機材及び結晶性無機材の粒子からなり、前記第２表面被覆層に含まれる結晶性無機材の粒子の平均粒子径は、前記第１表面被覆層に含まれる結晶性無機材の粒子の平均粒子径より小さいことを特徴とする構造体。 【選択図】 図１

構造体の製造方法及び構造体

【課題】金属からなる基材の所定部分に充分な厚さのセラミックコート層が形成された構造体の製造方法の提供。【解決手段】被覆予定領域を決定する被覆予定領域決定工程と、被覆予定領域の外側に、被覆予定領域の境界と接するように帯状の外方粗化面４０を形成する外方粗化面形成工程と、被覆予定領域に、内方粗化面４４を形成する内方粗化面形成工程と、軟化点が３００〜９００℃である低融点ガラス粉末を含むセラミック原料を被覆予定領域及び外方粗化面４０に塗布するセラミック原料塗布工程と、上記セラミック原料を上記基材の表面に上記軟化点よりも高い温度で焼き付けセラミックコート層５０を形成するセラミックコート層形成工程とを含み、上記外方粗化面形成工程では、上記外方粗化面の表面粗さを所定の値となる様にする構造体の製造方法。【選択図】図６

拡散部材、排ガス浄化装置及び排ガス浄化装置における拡散部材の使用

【課題】 排ガスの温度低下を抑制できる拡散部材を提供する。 【解決手段】 排気管内に設置されて、排気管上流から流入する排ガスの流れを一部阻害する拡散部材であって、金属からなる基材と、上記基材の表面上に形成されたセラミックコート層からなることを特徴とする拡散部材。 【選択図】 図１

Metal member with coat layer

Structure having a surface coat layer

ガラス粒子抄造シート、コート層付き金属基材及びコート層付き金属基材の製造方法

【課題】 金属基材の表面に、厚さばらつきが小さいコート層を簡便な工程で作製することができるガラス粒子抄造シートを提供する。【解決手段】 加熱溶融させて金属基材の表面にコート層を形成するためのガラス粒子抄造シートであって、上記ガラス粒子抄造シートはガラス粒子及び有機バインダを含み、有機繊維及び無機繊維の少なくとも一方を含むことを特徴とするガラス粒子抄造シート。【選択図】 図１

排ガス処理装置

【課題】ハニカム構造体に通電する際に、電流がハニカム構造体以外にリークすることを抑制することが可能な排ガス処理装置。 【解決手段】長手方向に沿って、第１の端面から第２の端面に延伸する複数のセルが触媒の担持されたセル壁によって区画されたハニカムユニットを有する柱状のハニカム構造体と、該ハニカム構造体の外周面に巻き回された無機マット材と、該無機マット材が巻き回されたハニカム構造体を収容する筒状金属部材と、を有する排ガス処理装置であって、前記ハニカムユニットは、導電性を有し、前記筒状金属部材の内表面の前記無機マット材と当接する部分には、厚さが２０μｍ〜４００μｍの緻密な絶縁層が形成されていることを特徴とする排ガス処理装置。 【選択図】図１

エンジンバルブ及びその製造方法

【課題】 断熱性が高く、エンジンバルブの傘部に形成されたガラスコート層が金属基材から剥離しにくいエンジンバルブを提供する。【解決手段】 軸部及び土台部からなる金属基材と、セラミック部材とからなるエンジンバルブであって、前記土台部は、柱状部と傘裾部とからなり、前記エンジンバルブの傘裏面の傘裾部以外の部分は前記セラミック部材により構成されており、前記セラミック部材の内側に形成された空間に前記柱状部が篏合されてエンジンバルブの傘部を構成しており、前記セラミック部材は、ガラスコート層を介して前記金属基材の傘裾部に接着され、一体化されてなることを特徴とするエンジンバルブ。【選択図】 図１

ガス流通部材

【課題】排気系部品の表面が面粗度の高い面やうねりを有する面であってもエンジンの出力の低下や排ガス浄化性能の低下を防止し得るガス流通部材を提供する。 【解決手段】ガス流通面３０を有する金属からなる基材２０と、上記基材２０の上記ガス流通面２１に被覆され、非晶性無機材及び結晶性無機材を含む表面被覆層３０とを備えたガス流通部材１０であり、上記結晶性無機材は、カルシア、マグネシア、セリア、アルミナ、及び、ジルコニアの群から選択された少なくとも１種からなり、上記基材２０の上記ガス流通面２１は、粗さ曲線における十点平均粗さＲｚＪＩＳが１０〜５０μｍであり、かつ、うねり曲線における最大高さうねりＷｚが１５〜１００μｍの面であり、上記表面被覆層３０の平均厚さは５０μｍを超えており、被覆ガス流通面４０は、上記十点平均粗さＲｚＪＩＳが５μｍ以下の平滑面、かつ、上記最大高さうねりＷｚが１０μｍ以下の平坦面である。 【選択図】図１

Electrically heated catalytic converter

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 μm, 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.

Structure and paint for forming surface coat layer

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.

Electrically heated catalytic converter

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 μm 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 μm 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.

Electrically heated catalytic converter

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.