Heater and catalytic converter

Abstract: An electrically conductive honeycomb body, preferably extruded from a metal powder slurry, is used to make a resistance heater by providing electrode sites (11). Such a heater may e.g. be placed upstream of a catalytic converter including a main catalyst. Or, a catalytic converter may include the electrodes (11) to energise it, in addition to catalyst carried on its honeycomb structure. The honeycomb body is formed with predetermined structural non-uniformities so as to influence its resistance characteristics between the electrodes (11). The non-uniformities may be slits (12) cut into the body. Other examples include variations of cell wall thickness through the body, variations of axial cell wall length over the body, and interruption of isolated cell walls at predetermined positions.

Description: The present invention relates to a resistance heating element and a catalytic converter including the resistance heating element. The element has a honeycomb structure. The invention also relates to a method of making a resistance heater. Honeycomb heaters of the above-described type can be employed as heaters for domestic use, such as hot air heaters, or as industrial heaters, such as preheaters used for control of automobile exhaust emission. The above-described catalytic converters can be applied for use in automobile exhaust emission control. Conventionally, porous ceramic honeycomb structures have been employed as catalysts or carriers for catalyst for removing, for example, nitrogen oxides, carbon monoxide and hydrocarbon present in the exhaust gas of internal combustion engines, such as automobiles, or filters for removing fine particles. Whereas porous ceramic honeycomb structures continue to be a popular and useful material in such environments, there has been a desire to develop materials exhibiting greater mechanical strength and thermal resistance in hostile environments. Apart from the above honeycomb structures, as restriction of exhaust emission has been intensified, there has been a demand for development of heaters for use in automobile exhaust emission control. Honeycomb structures have been proposed in, for example, United States Patent No. 4,758,272, Japanese Utility Model Laid-Open No.676⊘9/1988 and U.K. Patent 1492929. The honeycomb structure disclosed in United States Patent No. 4,758,272 has a composition essentially consisting, as analyzed in weight percent, of 5 to 5⊘% Aℓ, 3⊘ to 9⊘% Fe, ⊘ to 1⊘% Sn, ⊘ to 1⊘% Cu, ⊘ to 1⊘% Cr and no more than 1% Mg and/or Ca. This honeycomb structure has a porosity of 25 to 75% and a predetermined cell density, and is used as a diesel particulate filter. However, United States Patent No. 4,758,272 does not disclose the use of the above-described honeycomb structure as a heater or a catalytic converter. U.K. Patent 1492929 discloses the use of foil type metal honeycomb structure in a catalyst for use in automobile exhaust emission control. This honeycomb structure comprises a metal substrate produced by winding, together with a flat plate, a mechanically deformed, corrugated flat plate. This metal substrate has an oxide aluminum film formed on the surface thereof by the oxidation process. The catalyst for use in automobile exhaust emission control is manufactured by placing a high surface area oxide, such as alumina, on the oxide aluminum film of the metal substrate and by supporting a noble metal on the high surface area oxide. Japanese Utility Model Laid-Open No. 676⊘9/1988 discloses the use as a preheater of a electrically conductable metal monolith catalyst comprising a metal support and alumina coated thereon. In the foil-type metal honeycomb structure disclosed in U.K. Patent 1492929, however, the metal substrate with a coating formed thereon cannot be closely adhered to a catalyst layer because of its low porosity, and a ceramic catalyst readily peels off the metal substrate due to a difference in the thermal expansion between the ceramic catalyst and the metal substrate. Furthermore, telescope phenomenon readily occurs during the run cycle in which a metal to metal Join breaks and the metal substrate is deformed in such a manner that it protrudes in the direction of the flow of gas. This may disturb safe running of the vehicle. Furthermore, in the manufacture of the foil type metal honeycomb, yield of the rolling process is low, inviting high production cost. In the preheater proposed in Japanese Utility Model Laid-Open No. 676⊘9/1988, coated alumina readily peels off metal support due to a difference in thermal expansion between alumina and the metal support. Furthermore, a metal to metal join of the metal substrate breaks during the operation, generating an electrically insulating portion and, hence, non-uniform flow of current and non-uniform heating. The preheater disclosed in Japanese Utility Model Laid-Open No. 676⊘9/1988 is constructed such that a current is supplied between the inner periphery and the outer periphery of the foil type metal honeycomb structure to generate heat. However, we have noted that it is impossible to get an adjusted resistance (that is, the material, dimension and rib thickness of the honeycomb structure define the resistance but a desired resistance cannot be adjusted), and therefore exhibits insufficient temperature rising characteristics. Furthermore, since the electrodes are provided on the inner peripheral portion of the preheater, the central portion thereof does not act as a catalyst and pressure loss may be generated. Furthermore, the electrodes readily break due to the flow of gas. WO 89/10471 describes electrically conductive honeycomb bodies, used as heatable catalyst supports, made of metal sheets. The cell structure is composed of corrugated sheets lying between relatively flat sheets. Current flow is directed by insulating layers interposed between layers or spiral turns of this honeycomb structure. GB-A-2049377 describes ceramic honeycomb bodies made into electrical resistors for heating fluid, by applying electrically conductive coatings to the passage walls of the electrically resistive honeycomb structure. Current flow to heat the structure is thus generally perpendicular to the walls. It would be desirable to eliminate or at least reduce one or more of the above problems, in a heater and/or converter, and in particular provide the novel measure of resistance adjustment. In one aspect, the present invention provides a resistance heating element as set out in claim 1. In another aspect we provide a method of making a resistance heater comprising a honeycomb structure, as set out in claim 12. In yet another aspect, the invention provides a resistance heater having a honeycomb structure as set out in claim 15. The present invention further provides a catalytic converter which comprises a main monolith catalyst and the above-described heating element placed upstream of the main monolith catalyst. In the preferred form, the honeycomb structure is the one manufactured by extruding powders into a honeycomb configuration and by sintering the shaped body. Embodiments of the invention are described below with reference to the drawings. Fig. 1 to Fig. 5 are perspective views showing examples of heaters or catalytic converters embodying the present invention: Fig. 6 is a view showing another example of the present invention, Fig. 6 (a) is a perspective view, Fig. 6 (b) is a side view and Fig. 6 (c) is a plan view; Fig. 7 is a view showing further example of the present invention, Fig. 7 (a) is a perspective view and Fig. 7 (b) is a side view; and Fig. 9 is a partly enlarged view of passages of another type honeycomb structure usable in the invention. Fig. 1⊘ is an illustration of a square cell structure between adjacent slits in a heater embodying the invention. Fig. 11 is a perspective view of a heater catalyst A. Fig. 12 is a perspective view of a heater catalyst B. Fig. 13 is an illustration of an apparatus used for evaluation of performance of the heater catalyst. The present invention discloses a resistance adjusting type heater which comprises a honeycomb structure having a large number of passages, at least two electrodes for energizing the honeycomb structure, and a resistance adjusting means provided between the electrodes. That is, heat generation characteristics of the heater can be controlled by adjusting a resistance thereof, so the heater can be heated locally or in its entirety depending on its application. In the catalytic converter of the present invention, heat generation characteristics thereof can be controlled as in the case of the above heater. So, the catalytic converter can be heated locally or in its entirety depending on its application. The honeycomb structure employed in the present invention may be produced by extruding powders into a honeycomb configuration and by sintering the formed body. That is, the honeycomb structure may be the one manufactured using the powder metallurgy and extrusion. Therefore, the manufacture process is simple and low production cost can be attained. The use of a honeycomb structure (a unitary body) manufactured by using powders in the heater and catalytic converter contemplated in the present invention eliminates telescope phenomenon, and achieves uniform heating. In the present invention, it is preferable to form a slit or slits as the resistance adjusting means at a predetermined angle to the cell walls of the honeycomb structure rather than in the same direction as the cell walls. According to this arrangement, all the ribs (cell walls) between the electrodes are supplied with electric current so that the heat generating area and, hence, the heat exchanging area, is increased. By forming the slits 12 so as to make a predetermined angle to the cell walls 1⊘ of the honeycomb structure, the square cell structure 2 is arranged such that all the cell walls 1⊘ form a predetermined angle to the direction of flow of the electric current, as shown in Fig. 1⊘. In the resistance adjusting type heater contemplated in the present invention, coating of a heat-resistant metal oxide, such as Aℓ 2 O 3 or Cr 2 O 3 , on the surface of the cell walls and that of the pores of a metal honeycomb structure is preferred to enhance resistance to heat, oxidation and corrosion. Whereas any material, ceramic or metal, capable of generating heat when energized can be used as the material of the honeycomb structure which is the basic body of the invention, the use of metals enhances the mechanical strength. Examples of such metals include stainless steel and those having compositions of Fe-Cr-Aℓ, Fe-Cr, Fe-Aℓ, Fe-Ni, W-Co, and Ni-Cr. Among the above materials, Fe-Cr-Aℓ, Fe-Cr and Fe-Aℓ are preferred because of low cost and high resistance to heat, oxidation and corrosion. Foil type metal honeycomb structures may also be employed. The honeycomb structure employed in the present invention may be porous or may not be porous. In the case where a catalyst is carried on the honeycomb structure, however, a porous honeycomb structure is preferred because it is closely adhered to a catalyst layer and does not cause peeling off the catalyst due to a difference in the thermal expansion between the honeycomb structure and the catalyst. Even if a non-porous honeycomb structure is employed, since the heater of this invention has a resistance adjusting means which may be a slit, a thermal stress may be reduced while the possibility of-crack occurrence may be decreased. The method of manufacturing the metal honeycomb structure which can be employed in the present invention will now be exemplified. First, Fe powder, Aℓ powder and Cr powder, or alternatively powders of alloys of these metals, are mixed to prepare a metal powder mixture having a desired composition. Subsequently, the metal powder mixture is blended into an organic binder, such as methyl cellulose or polyvinylalcohol, and water to produce a readily formable mixture, and that mixture is then formed into a shape of a desired honeycomb configuration by the extrusion. When the metal powder mixture is blended into an organic binder and water, prior to the addition of water, an antioxidant, such as oleic acid, may be added to the metal powder mixture. Alternatively, powders of metals which are subjected to anti-oxidation process may be employed. Next, the formed honeycomb body is fired in a non-oxidizing atmosphere at a temperature ranging between 1⊘⊘⊘ and 145⊘°C. During the sintering in the non-oxidizing atmosphere containing hydrogen, the organic binder is decomposed and thereby removed with the aid of Fe or the like which acts as a catalyst, and a good sintered body can therefore be obtained. Sintering at a temperature lower than 1⊘⊘⊘°C achieves no sintering. Sintering conducted at a temperature higher than 145⊘°C causes deformation of the resulting sintered body. Preferably, a heat-resistant metal oxide is then coated on the surface of the cell walls and that of the pores of the obtained sintered body by any of the following methods wherein: (1) the metal honeycomb structure (the sintered body) is subjected to the heat-treatment in an oxidizing atmosphere at a temperature ranging between 7⊘⊘ to 11⊘⊘°C. (2) Aℓ or the like is plated (e.g., vapor plating) on the surface of the cell walls and that of the pores of the sintered body and that sintered body is then subjected to heat-treatment in an oxidizing atmosphere at a temperature between 7⊘⊘ and 11⊘⊘° C. (3) the sintered body is dipped into a molten metal, such as Aℓ, and that sintered body is then subjected to the heat-treatment in an oxidizing atmosphere at a temperature between 7⊘⊘ and 11⊘⊘°C. (4) alumina sol or the like is coated on the surface of the cell walls and that of the pores of the sintered body and that sintered body is then subjected to the heat-treatment in an oxidizing atmosphere at a temperature between 7⊘⊘ and 11⊘⊘° C. To enhance resistance to heat and oxidation, heat-treatment conducted at a temperature ranging between 9⊘⊘ and 11⊘⊘°C is preferred. Next, a resistance adjusting means of any form is provided on the obtained honeycomb structure between the electrodes thereof, which will be described later. The resistance adjusting means provided on the honeycomb structure may take on any of the following forms: (1) a slit or slits of any length, formed in any direction at any position (2) variations in the length of cell walls in the axial direction of the passages, and (3) a slit or slits formed in the cell wall (rib) of the honeycomb structure. Examples of the resistance adjusting means are typically shown in Figs. 1 to 7 and 9. In the drawings, each arrow indicates a current flow. A resistance adjusting type heater requires the provision of electrodes at the outer periphery or inside of the metal honeycomb structure obtained in the manner described above, e.g. by brazing or welding. As used herein, "electrode" means a general term of a terminal for energizing the heater and includes a terminal which is made by joining an outer periphery of the heater to a casing, or an earth, etc., unless the context requires otherwise. In the thus-obtained metal honeycomb structure designed for use as a heater, the resistance thereof will be preferably held between ⊘.⊘⊘1 Ω and ⊘.5 Ω. Also, a heater or catalytic converter can be produced by placing a catalyst on the surface of the obtained metal honeycomb structure. In such heater or catalytic converter, heat is generated due to reaction (oxidation) of the exhaust gas. The catalyst supported on the surface of the metal honeycomb structure may be of a carrier having a high surface area and a catalytic activating material supported on the carrier. Typical examples of the carriers having a high surface area include γ-Aℓ 2 O 3 , TiO 2 , SiO 2 -Aℓ 2 O 3 and perovskite. Examples of the catalytic activating material include noble metals, such as Pt, Pd and Rh, and base metals, such as Cu, Ni, Cr and Co. The preferred catalyst is the one in which from 1⊘ to 1⊘⊘ g/ft 3 noble metal is loaded on the carrier made of γ-Aℓ 2 O 3 . Whereas the honeycomb structure employed in the present invention may have any configuration, it is desirable that the cell density ranges from 6 to 15⊘⊘ cells-in 2 (⊘.9 to 233 cells/cm 2 ) with a wall thickness ranging from 5⊘ to 2⊘⊘⊘ µm. As stated above, the honeycomb structure employed in the present invention may be porous or may not be porous and may have any porosity. However, to achieve sufficient mechanical strength and resistance to oxidation and corrosion, the porosity of the metal honeycomb structure will preferably be held between ⊘ and 5⊘% by volume with most preferable porosity being less than 25% by volume. In a honeycomb structure designed to carry a catalyst thereon, the porosity will be held 5% or above to ensure strong adhesion between the honeycomb structure and catalyst layers. The term, "honeycomb structure" is employed in this application to refer to an integral body having a large number of passages partitioned by the walls. The passages may have any cross-sectional form (cell shape), e.g., a circular, polygonal or corrugated form. The present invention will further be illustrated in the following examples which are intended to be illustrative, but not limiting, of this invention. Example 1 Fe powder, Fe-Aℓ powder (Aℓ : 5⊘ wt%) and Fe-Cr powder (Cr : 5⊘ wt%), having average particle sizes of 1⊘, 2⊘ and 22 µm, were mixed to prepare a mixture having a composition of Fe-22Cr-5Aℓ (% by weight), and the obtained mixture was then blended into an organic binder (methyl cellulose), an antioxidant (oleic acid) and water to produce a readily formable body. That body was formed into a square cell honeycomb structure having a rib thickness of 4 mil and a cell density of 3⊘⊘ cpi 2 by the extrusion. The extruded honeycomb structure was dried and fired in H 2 atmosphere at 13⊘⊘°C. Thereafter, the obtained honeycomb structure was subjected to the heat-treatment in an atmosphere at 1⊘⊘⊘°C. The obtained honeycomb structure had a porosity of 22% by volume and an average pore diameter of 5 µm. Two electrodes 11 were provided on the outer wall of the thus-obtained honeycomb structure having an outer diameter of 9⊘ mmø and a length of 15 mm, as shown in Fig. 1. Also, six slits 12 having a length of 7⊘ mm were formed in the honeycomb structure in the axial direction of the passages (the slits provided at the two ends had a length of 5⊘ mm) at intervals of seven cells (about 1⊘ mm). Zirconia type heat-resistant inorganic adhesive was filled in an outer peripheral portion 13 of each slit 12 to form an insulating portion. The slits were parallel, from alternative sides. Example 2 γ-Aℓ 2 O 3 was coated on the honeycomb structure obtained in Example 1, and each 2⊘ g/ft 3 Pt and Pd were then loaded on this γ-Aℓ 2 O 3 . Thereafter, the whole honeycomb structure was fired at 6⊘⊘°C to obtain a honeycomb structure with a catalyst carried thereon. Thereafter, the electrodes 11 were provided on this honeycomb structure with a catalyst in the same manner as that of Example 1. Example 3 Three slits 12 were formed in the central portion of the honeycomb structure obtained in the same manner as that of Example 1, as shown in Fig. 2. The slits 12 were separated by intervals of three cells which were about 4.5 mm. The electrodes 11 were provided in the same manner as that of Example 1. Again, the slits were parallel to the structure axis. Example 4 Three slits 12 were formed in the honeycomb structure obtained in the same manner as that of Example 1 in a direction perpendicular to the axial direction of the passages (in the radial direction), as shown in Fig. 3. The slits 12 were separated from each other by 5 mm, and had a length of 7⊘ mm. The electrodes 11 were provided on the upper and lower end portions of the outer wall 1⊘ of the honeycomb structure, as shown in Fig. 3. Example 5 Six slits 12 (three slits in the upper portion and three slits in the lower portion) were formed in the honeycomb structure obtained in the same manner as that of Example 1 in the axial direction of the passages at intervals of seven cells (about 1⊘ mm), as shown in Fig. 4 The slit depth was 1⊘ mm. The electrodes 11 were provided on the honeycomb structure in the same manner as that of Example 1. Example 6 Six slits 12 (three slits in the upper portion and three slits in the lower portion) were formed in the honeycomb structure obtained in the same manner as that of Example 1 in such a manner that they were inclined at a predetermined angle with respect to the axis of the passage, as shown in Fig. 5. The slits 12 were separated from each other by seven cells (about 1⊘ mm). The slit depth was 12 mm. Example 7 A recess 14, having a depth of 4 mm, was formed in the honeycomb structure obtained in the same manner as that of Example 1 at the central portion of 5⊘ mmø at each end portion thereof, as shown in Figs. 6 (a) and (b), and two slits 12 were then formed, as shown in Fig. 6 (c). Thereafter, the electrodes 11 were provided on the honeycomb structure in the same manner as that of Example 1. Example 8 A recess 14, having a depth of 4 mm, was formed in the honeycomb structure obtained in the same manner as that of Example 1 at the central portion of 5⊘ mmø at each end portion thereof, as shown in Figs. 7 (a) and (b), and the two electrodes 11 were provided at the central portion of one of the recesses 14 and the outer wall 1⊘ of the honeycomb structure, respectively. Example 1⊘ Slits 15 were adequately formed in ribs 16 of the central portion of the honeycomb structure obtained in Example 9 to control heat generation characteristics thereof, as shown in Fig. 9. Such a honeycomb structure can also be easily manufactured using an extrusion die. Comparative Example 1 Electrodes were provided, in the same manner as that of example 1, on the honeycomb structure, having an outer diameter of 9⊘ mmø and a length of 15 mm, obtained in Example 1. This honeycomb structure had no slits. [Evaluation] (Checking of performance of a preheater for use in automobile exhaust emission control) In order to check the performance of a catalytic converter employing a three-way catalyst which was on sale when an engine was started, the conversion of the gas components of an exhaust was measured by introducing the exhaust into that catalytic converter in such a manner that the temperature of the inlet of the catalyst rose from 1⊘⊘oC to 42⊘°C in two minutes (at a fixed speed) and then that temperature was then maintained at 42⊘°C for 1 minute (data without heater). Thereafter, each of the samples of the Examples of the present invention was provided in front of the three-way catalyst as a preheater, and the conversion provided by that catalytic converter was measured in the same manner by introducing the exhaust thereinto while energizing the preheater. The preheater was used in a state in which it was energized for 1 minute by a battery of 12V. Table 1 shows the average conversion of the conversions obtained in three minutes for each of the gas components. Average Conversion (%) Sample CO HC NOx Without heater 5⊘ 37 47 Example 1 64 5⊘ 65 Example 2 7⊘ 55 68 Example 3 63 5⊘ 63 Example 4 63 51 64 Example 5 64 5⊘ 65 Example 6 63 48 61 Example 7 64 51 66 Example 8 63 5⊘ 64 Comparative Example 1 58 44 55 Example 11 Production of Sample A: Fe powder, Fe-Cr powder and Fe-Al powder were mixed to form a composition expressed by Fe-2⊘Cr-5Al(wt %). An organic binder (methyl cellulose), an anti-oxidation agent (Oleic acid) and water were added to this composition so as to form slurry. The slurry was extruded and dried so that a dried honeycomb body shown in Fig. 11 was obtained. The outside diameter and the thickness of the thus formed honeycomb body were 11⊘ mm and 3⊘ mm, respectively. The honeycomb structure had a multiplicity of square cells arranged at a density of 3⊘⊘ cells per square inch. Eleven slits 12 were formed in the honeycomb body such that six cells are included in the region between adjacent slits and such that the slits extend in the same direction as half 1a of the ribs (cell walls 1) defining the cells. Subsequently, the honeycomb body was fired in an H 2 gas atmosphere, whereby a honeycomb structure 3 was obtained to have an outside diameter of 92 mm and a thickness of 25 mm. The honeycomb structure 3 was coated with γ-Al 2 O 3 and precious metals Pt and Rh were loaded in amounts of 3⊘ g/ft 3 and 6g/ft 3 , respectively. The honeycomb structure was then fired at 6⊘⊘°C, whereby a honeycomb structure carrying catalyst was obtained. Then, a pair of electrodes 11 were set in the outer wall of the thus-obtained honeycomb structure, whereby a heater catalyst A was obtained. Production of Sample B: A honeycomb body of the same shape as that in Sample A was prepared from the same materials and through the same extrusion and drying process as in Sample A. Then, a honeycomb structure having the same number of slits 12 as Sample A was obtained. The length and pitch of the slits also were the same as those in Sample A. In this case, however, the slits were directed to form 45° to the cell walls 1⊘ of the cell, as shown in Fig. 12. The same process as that for the production of Sample A was applied to the above-mentioned honey-comb structure 3, whereby a heater catalyst B was obtained to have the same shape and heat generating area as Sample A. Thus, catalyst heater B was the same as the catalyst heater A except the angle of the slits to the cell walls of the cell. Before evaluating these heater catalysts A and B, electrical resistance of the heater catalysts A and B were measured. Both the heater catalysts A and B showed the same level of resistance of ⊘.⊘4 Ω. The effective volumes of the catalyst of both samples were 133 cm 3 and, hence, were equal. The evaluation of performance of the heater catalysts were conducted by using an apparatus shown in Fig. 13. More specifically, the exhaust gas from gasoline engine 2⊘ is cooled down to 12⊘°C through a cooler 21 and then introduced into the heater catalyst 22. Electric power was supplied to the heater catalyst 22 simultaneously with the commencement of evaluation from a 24V battery and the power supply was continued for 6⊘ seconds with an on-off control by controller 25 such that the temperature of the heater catalyst as measured by a thermo-couple is maintained at 35⊘°C. The mean cleaning rations for HC, CO and NOx during the period of 6⊘ seconds were measured by an exhaust gas measuring device 26. The values of the mean cleaning ratios as measured on heater catalysts A and B are shown in table 2. Mean Cleaning Ratio (%) HC CO NOx heater catalystA 34 52 58 heater catalystB 4⊘ 62 66

Claims: A resistance heating element comprising an electrically conductive honeycomb structure (10) having partition walls defining a large number of parallel passages for fluid flow extending in an axial direction and at least two-electrodes (11) on said honeycomb structure for passing electric current through the structure, wherein current flow for electrical resistance heating of said honeycomb structure (10) in use of the heater passes through the partition walls in general directions parallel to the faces of the partition walls, characterised in that said partition walls defining said parallel passages are planar and in that there is at least one slit (12) in said honeycomb structure which is open for axial fluid flow, said slit (12) extending through at least part of the axial length of the structure (10) parallel to said axial direction thereof and crossing the planes of a plurality of said planar partition walls. A resistance heating element according to claim 1 wherein there are a plurality of said slits (12) parallel to each other. A resistance heating element according to claim 2 having said two electrodes (11) on opposite sides of the honeycomb structure (10), there being a plurality of said slits (12) parallel to each other and extending inwardly of said honeycomb structure from opposite side or end regions thereof so that the or each said slit from a first said region overlaps at least one said slit from the opposite said region, thereby creating a sinuous general path for current flow between said electrodes (11). A resistance heating element according to any one of claims 1 to 3 wherein said honeycomb structure (10) is made by extrusion in said axial direction. A resistance heating element according to any one of claims 1 to 4 wherein said honeycomb structure (10) is a sintered honeycomb monolith. A resistance heating element according to any one of claims 1 to 5 wherein the or each said slit (12) extends the whole axial length of the honeycomb structure (10). A resistance heating element according to any one of claims 1 to 6 wherein the or each said slit (12) is planar. A resistance heating element according to any one of claims 1 to 7 wherein the or each said slit (12) has a width in a transverse direction perpendicular to said axial direction which is not more than the unit width of said parallel passages in said transverse direction. A catalytic converter comprising a main monolith catalyst and a resistance heating element according to any one of claims 1 to 8 arranged upstream of said main monolith catalyst in the flow direction of gas through the converter. A catalytic converter comprising a resistance heating element according to any one of claims 1 to 8 and a catalyst carried on said honeycomb structure. A catalytic converter comprising a main monolith catalyst and a resistance heating element according to any one of claims 1 to 8, said resistance heating element having a catalyst carried on the honeycomb structure thereof. A method of making a resistance heater having a honeycomb structure (10) which is electrically conductive and has a large number of parallel passages for axial fluid flow defined by partition walls having a general regular pattern throughout the structure (10), said heater having spaced electrodes (11) for passing electric current through said honeycomb structure, and wherein current flow for electrical resistance heating of said honeycomb structure (10) in use of the heater passes through the partition walls in general directions parallel to the faces of the partition walls, said method being characterised in that the honeycomb structure (10) is a monolith and in that the method includes the step of adjusting the electrical resistance characteristic of the structure. (10) by providing it with a local incorporated structural non-uniformity or non-uniformities (12,14,15) of said regular pattern in a predetermined manner, said structural non-uniformity or non-uniformities comprising: (i) a slit or slits (12) cut into the honeycomb structure and extending in a direction for a distance corresponding to a multiple of the dimension of said passages in said direction; (ii) a slit or slits (15) interrupting substantially isolated partition walls in the structure; or (iii) variations (14) in the partition wall axial length over the honeycomb structure. A method according to claim 12 in which the honeycomb structure is formed by extrusion of a powder composition. A method according to claim 13 wherein said powder composition is a metal powder. A resistance heater having a honeycomb structure (10) which is electrically conductive and has a large number of parallel passages for axial fluid flow defined by partition walls having a general regular pattern throughout the structure (10), said heater having spaced electrodes (11) for passing electric current through said honeycomb structure, and wherein current flow for electrical resistance heating of said honeycomb structure (10) in use of the heater passes through the partition walls in general directions parallel to the faces of the partition walls, characterised in that the honeycomb structure (10) is a monolith and has a local structural non-uniformity or non-uniformities (12,14,15) of said regular pattern incorporated in the structure in a predetermined manner, so as to determine the electrical resistance characteristic of the honeycomb structure, said structural non-uniformity or non-uniformities comprising: (i) a slit or slits (12) cut into the honeycomb structure and extending for a distance in a direction corresponding to a multiple of the dimension of said passages in said direction: (ii) a slit or slits (15) interrupting substantially isolated partition walls in the structure; or (iii) variations (14) in the partition wall axial length over the honeycomb structure. A resistance heater according to claim 15 in which the honeycomb structure has been formed by extrusion of a powder composition.

Inventors: ABE FUMIO, HARADA TAKASHI, KONDO TOMOHARU, MIZUNO HIROSHIGE, ABE, FUMIO, HARADA, TAKASHI, KONDO, TOMOHARU, MIZUNO, HIROSHIGE
Applicants: NGK INSULATORS LTD, NGK INSULATORS, LTD.
Application year: 1991
Main classification: F01N3
IPC codes: B01J35, F01N3, B22F3, H05B3, F02B1