CA2132294A1 - Radial flow exhaust catalytic converter - Google Patents
Radial flow exhaust catalytic converterInfo
- Publication number
- CA2132294A1 CA2132294A1 CA002132294A CA2132294A CA2132294A1 CA 2132294 A1 CA2132294 A1 CA 2132294A1 CA 002132294 A CA002132294 A CA 002132294A CA 2132294 A CA2132294 A CA 2132294A CA 2132294 A1 CA2132294 A1 CA 2132294A1
- Authority
- CA
- Canada
- Prior art keywords
- exhaust gas
- housing
- gas
- axial channel
- flow
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
- F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
- F01N3/2053—By-passing catalytic reactors, e.g. to prevent overheating
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2330/00—Structure of catalyst support or particle filter
- F01N2330/06—Ceramic, e.g. monoliths
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2330/00—Structure of catalyst support or particle filter
- F01N2330/10—Fibrous material, e.g. mineral or metallic wool
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
- F01N2450/24—Methods or apparatus for fitting, inserting or repairing different elements by bolts, screws, rivets or the like
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
- F01N2450/30—Removable or rechangeable blocks or cartridges, e.g. for filters
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Exhaust Gas After Treatment (AREA)
- Superconductors And Manufacturing Methods Therefor (AREA)
- Catalysts (AREA)
Abstract
An auxiliary catalytic converter (11) for treating exhaust gas pollutants from an internal combustion engine during warm-up comprises a housing (13) which defines an exhaust gas receiving chamber (15), an exhaust gas inlet (17) in one end of the housing and an exhaust gas outlet (19) at the other end of the housing, a hollow catalyst structure (23) having discrete channels or pores secured in the chamber spaced from the walls of the housing and aligned axially providing a passage (25) between the outer surface of the catalyst structure and the wall and an axial channel (27) in communication with the gas inlet and gas outlet, and valve means (41) adapted to be opened and closed in response to a predetermined condition, the valve means when in a closed position restraining exhaust gas flow in the axial channel causing the gas to flow radially through the catalyst structure into the passage and when in an open position permitting essentially unimpeded flow of gas from the gas inlet through the axial channel to the gas outlet.
Description
r r r ~ ~ ~ r FA-0551 r r ~~ r ~ ~ r r rr ~ r ~ 2 ~ 9 a~r TITLE
RAD~ LOU/ EXH~UST CAT~l YTIC CO~VERTER
FIEI,l) OFTHE II~Vr.i\TlC)~
Tllis invenlion r~ tes to cat;llytic conver~ers ~nr controllin~
cmission lcvcl.s rrom intern~l combustion enghlcs. Morc particul~rly, ~he inv~n~ion rcl;lles lo ;In ;luYili;lry c;lt;liylic convcrlcr for c~ntrolling emissiolls from an in~crnal comhuslit)n engilIc ~Illring lhe ~criod of en~ine warm-llp.
I~CI<(~ C)lJl~ln OFT~-ll II\VEI~ OI~
Thc L~rc;ltc.~l concel-lr~lioll Or ~tmosplleric contaminanls from the e~hau.ct Or an intcrllal coml~llstion enginc occurs imme~liately followin~
start-~lp of tlIc en~ine. ~'hile c~t,llytic convertcrs ,Ire required in the exh;lu.
system, such converters ~re essenti,llly inerreclive in controlling pollu~anls until they are hea~cd to elevate(~ temper~ture.~ by tllc hol exh,~lust gases from 15 the engine.
l~rror~ h~ve hcen m~dc to control thi.s prohlem using so c;llle~J
warm-up or "pup conver~cr~s" which are posiLioned ne,lr the exhal~st m;lnirnld in ~Yance Or ;, m~in, un~ler the floor, convcrter. In somc emhodiments the~se convertcrs ;Ire hc;llc~l electric~llly. Gener;llly Ihe exh,lust ~,~ses are 20 ~orced throu"h honeyconllle~l structurcs the surf~cc of which is coated wi~h catalyst. Wllile thesc cl~nv~rters (lo re~luce p()ll~ nt emi~si()ns foIlowing starf-up, thcy ;Irc p~)wcr ~In~ rucl (:onslllllcr!i l'hC n-,w of exh;lust ~ascs is imp~c(J throll~llollt the timc the enL~ine is opcr;lling. In a(l~ilion to!hi~
inefriciency, c;~t;llyst in tll~ convertcr conlinllc.~ ~o he de~cliv;lted ~s lon~ as 25 the engine i~ runnin~.
In accord;lllcc wilh this invenlioll ~h~rc i~ provide(l a unit;lry ,luxiliary ca~alytic conv~rter ~or an hltern~ll cl-n~l-u.~tion engine which ~chicves rapid ca~aly~ic aclivily wilhollt suhsl;ln~i;ll oper.l~ing pressure an~l 30 powcr k)sscx as!ioci;llcd witll known warm-llp convcrter systems. The syslem utili~.es a ra~ lo-v cat~ly~t system which i.~ placed adjacent or as a part o~
the exhaust manifolc3 at the coition or "Y" whcrc the cyIinder exhaust tubes corne together.
The converter of thi~i invention compri~es ~ housing defining ~
3s gas receiving chambcr an(l has an cxllaust gas inlet at one end of the housing SUBSTITUTE SHEET
r r 2 1~ 2 ~
adjaccnl or as a parl ol lhe exhaust m~nifold ;~nd ~n exhallst gas outlet ~I thcother end ()f the ho~ ing. The catalyst comprisc~i a c;lrtridge which ha.s an annular !itnlcturc an-l is ;~ligne(~ ~Lxially wilhill lhc housing. The stMcll~re h;ls multiplc ch;lllnel~ or pores through which ~ CS can pass from an internal to an cxtcrn;ll ~urr~cc. 1'hc cartridge is ali~llcd with the walls of the housing therel~y providinL~ ;l p;~ssa~c hetwccn the outcr surface (,r the cartri(lge andthe walls or, altcrn;l~iv~ly, thr()uy,h the channcls or pores in ~he cartri(lgc, an(l an axial challncl cxtelldin~3 fronl ;Idjacent the cxll~usl ~as inlet to an opening in the outle~. Valve Incans acljacent thc ga~ outlct ~re a~apted to be opencd ane~ closcd in re~p()n~c lo a pre~lctermine~l condilion of the exhaust ~
In opera(ioll the valve i~ in a clo~c(J p()~iliOIl re~trainin~, exhau~t gas flow throu~il tl-e .~ l channel ~uril~ tart ~p thereby causin~
the exhaust gas to flow ra(lially thro~lgh the c;ltaly~t structure ;Ind into the~nnular p~s~a~e alon,, Ihc outer walls of thc hou~ing. After enL~ine ignition has l~een ~u.~taincd for a prc~leicrmined pcriod ~n(J thc engine ha:s reache~ a satisf~ctory ~tablc con(lilion~ thc valve open~ removing the axial exhaust flow re~trictlon an~ permi~tin~, exh.~ t gasc~ to flow ~lown the axis and ~hrougl the cartri~J~c es.~cntiLllly ~lnrestriclc~]. In the~opcn posi~ion~ little pressllre drop occur~ iri the .LYial ch~mncl, all~l thcrc i.~ little or no signiricant catalyti~
activity. l'he (limen.~ions Or the axi;ll ch;~nn~l~ ;mnul.lr pas~age, inlct and outlet are dctcrmine~l to accommodatc prc~urc drop ~nd flow ratc based on ~he ~pecific rccluirclllcllt~ rl)r tlle l~articul.lr enginc involvcd.
I~Es(l? l PTlOi`~ ()F Tl~ R~Wl~GS.
FIG. l is a schem;llic cross-sectiollal view through a cat~lytic converter of this invcnti()n .shown as a portion of ~n cxhaust mainfold;
FIG. 2 i~ a ~ra~mentary, secti~lnal tnp view of the converter shown in FIG. 1, a~
FIG. 3 shows a sm;lll se,~,ment of a prelerre~ càtalyst cartri~lge structurc ror usc in this invcn~ion.
DETAll,I,D DE~iCRlPTI(~ FT~IE I~ TTQl~
Rcfcrrillg to FIG,l, caî;llytic convcrter 1 l is compri~e(l of a hou~in~ 13 the w.~ t-f ~vhich ~lefil1e an e~h;lu.~t ~,a~ rccciving chamber 15.
Housing l3 m~y i~c intçgr;l~ with or form an c,~ttension of exhaust manirokl l(lof an intcrn;ll comhu~tion engine, not shown. The engine may be a two or 35 ~ four cycle engine. The chamber has an exh;lu~it ~as inlet ~7 at one cnd of the ,:,i ~" ~
`~ SUBSTITUTE SH~T
r ~ ~ r ~ r r r ~ ~ r r r r1 ~ r r, I
r r ~ a ~ ~ 9 ~
hoLlsing .In~ n(l cxl~au.it ~.~s outlel 19 at thc o~her en(l of the housin- A
cat;llyst su~porl ring I i~ p(~siliol-cd hctwccn ~he inl~t and outlet.
Tl-e c;l~;llY.st strlJcturc is prerer;lllly in Ille form o~ an ~nnul~r c;lrlridgc 2~ lnd is ~;p;lCC i from ~l~c walls or lhe llousing ~n~ ~xi~lly ~ ne~i in 5 the ch.lnlher ~o provi(le a p.lS~ l~e 25 helwccn lhe o~ltcr !illrf.lcc of the c~t~lyst .~nd ll~e ~alls al~ n .Lxial ch Inncl ~7 in comm~lnic~tion with eYh IllS~
gas in]el 17 an i cYh;nl~ g;l.li outlet 19. Altcrn;llively p.lss.lge 27 co~lki be provided hy ch~nllcls or pores in the c~t;lly.s~ struc~urc ;~r(~vided sufficicnt ~;ls flow c~n b~ es~;lhli~she(J to outlct 19 lllrollgll thc ch.lnncl~s .nnd pores whcn 10 ~xial ch;lnnei 27 i~ cl~ ed.
Tlle c;l~.llYst str~lclure h.l~ m~lltiple sul7stanti;l11y di~crete channels .1l~(1 por~ Ihrollglloul. The slruclure is hcl~ in position be~wcen housing 13 ~1 inle~ 17 all i support ring ~ ~t o~lllct ]9. G.lskets no~ show may be uscd a~ cithcr end of ll~c s~ruclure ~o pr()vi ie a ~a.s tight seal. The support rin~ i.s .securcxl l~ctwecn fl Inge~ 29 an(J ~1 of holl;in~ 13 ~nd ou~let pipe 33 usin~ hOILS nuts 59 on 57 .lnd g;lskcts 3~ <all(J 31. ~ltern~tivcly ~he cvmponents m3y be wekle~l in place.
V.llvc 41 is po~sitionc(l a~jacent the h~se of c;lt~lyst sur)p()rt rin~ 2]. A hall v llve ~vhich whcn opene(J prs)vidcs unrestricted fiow of 20 exhaJst~;ISC.~ ol cl1.un~cr 1~ throu~h :lxi;ll ch;lnl1el 7 m;~yheuse~l;
however o~hcr l;no~vl~ pcx Or v;llves xuch .~ butlerny v;llves m;ly be usc~. A
hutterlly v;ll~c .nrl-~n~el1~cl1l is shown in FIG. I m(J FIG 2. V~lve 4 l rcsls Ol1 se~ling surf;lccs 55 ;U1~ 55 when in thc clo.~e~ l)osition. ~s shown i~ FlG. 2 hcat sen.~i ~iv~: coil spri n~s 53 ~ncl 5~ re ~ v;~ e 4 1 i n the closed pOSi lion 25 whcn thc en~inc i.~ col~l ;m~l not runnin~. At .~l;lrl-llp ~iprin~x 53 ~n~ 5:~
prevent v;llvc froln opel~ xh;lust ~;IX el1lcrs ch Imher 15 and impin~e.i on the facc of the v;llve. ~ xhowl1 in FIG. 1 ll1e ~.ns p~scs throu~h c~rtri~l~c23 tg ~nn~ p;lx.~ e 25. /`.x ~hc xprin~s arc hedte(l to ~ predetermine(3 temper lturc ~y tl1e e.Yh;lllst ~;IS Il1e coil incrc;lxe.~ in len~lh c;lusin~ v~lve 41 30 to rot~tc t~ n opcll po.~i~ion. Thc v~lve is ~ ne~ in ch;lmber 25 in such ;~
m~nner xo th.lt ~nce il ix openc(l ~he e:~h~llst ~;ls flow c;l~lses i~ to self-cen~er in ;ln open position. Wllen the ~;ls flow CC;ISCS~ coil tcnxion returns Ihe v llve to ;l near clo~;e~l posilion. As thc coil cools~ ~he v;llve ~oe~ to I fully close(l position. Thi~ arran~emel1t is siml)le an~l parlicul~rly cost effective since it35 . captures the kine~ic energy of the xyxtem an~ rcquirex no external conlrol SUBSTll~lJTE S~ El ~ ~ r ~ ~ r ~ r ~
r ~ r 2 3L 3~ 2 9 ~ r, !
.
componen~s. 1~ is to ~ e no~e(l, ht)wevcr~ Ih.lt v;~ri()u~i altern~llives based on electric;~ nd m;l-metic ~pplic~tit~ns c~n he ~ pte~ ttl open and close the valve.
Rercrri~ nOw ~ ICi. 2, thc l);lsc 43 t)r ~hc c;llaly~t carlri~lyc is s ~hown ..u~-port(:~l On rinL~ 21 I-y wc(l~. 4~. V;JIVC 41 ~vhicll is intc~r;ll with sh;
39 pivots willlin tllc s~ )orl ring ;In(l is sllowll in thc closc{l postit)n th~hlockil~ c fl-.w of ~.~h;lusl g;lscs frt)lll ch;lnll~l 27. Mul~ lc opening~ 47 in ..upps)rt rin.~ ~ l ct)mml~ c;lîe wilh ;Innlll;lr p;l~ e ~ pernliltin~ ses 1() e~c.ll)e Ihrol~ xh;~ ;t ~ )ullet ~ t)le.~i(1 ;Irc provi(le(~ tt) ~cceptwcl~.
lO ~7 in ~.cllrrin& tl~c c;il;llysl .slruclurcs in thc .Isscllll-lc.
l hc c.al~lly~l slructure is Of thc ri~ yl)c m;l(lc from ;l reticul~le~ nllul;lr fornl omprisc~ f reinforcc(~ ccr~mic fibers. The .tructure c;lrrics ;l (;lt;lly~it all~l pr(~vi(Je~ le(~ rcsisl~nce to bo~h therm;ll shock an~ n!ecll;tnic.ll ~h(-cl;. ~Suit;lble ~tructurc!i <are ~lisclosed in lJ.S.
-~ 15 ~,~4n,109, IJ.S. ~,9x6,~?~, O.S. 4,(~ 4 ;In~l U.S. ~,()7()~0( 4. O~her s~ le tructures. .~uch ;~s cer<ll~ n~ mc~ fo~m.s wllic11 provi~c muliple ch;~nnels )r pore~ throu~h which ~,;lSC.S can p.ns~. m;ly l~e u~c~l. Procc.s~e~. for prcp.lrin~
other SUit;1171C S~rllCtllrC.'. ;Irc (li~.cl(~sccl itl Ellrnl)c;~n P;ltenl ~pplications 9~311~10.3 .In~l 91~1 I'J 1~.7~ file(l l~cccml-cr 2(), I~)')l.
~-: 20 I:IG. ~ sllows ;1 sc~ment of c~al;llyst c;lr~ri~l~e 2~. A series Of yers of y;trn A, B. (` ;uld D. whicll m;ly hc repc;.ltc~l m.lny ~ime~. form ;I w~ll ror a c:l~alys~ c~lrtrid~c. ~icl);lr;ltions "~ f tllc y:lrn~ form openin~s whicll permis the p;lSS.I~C Or cxh;lu~l ~;1S. I'rcfer~hly ~he fil-er~ rn;l~ing u~ ~e y~lrn.s ~re suh~t~llti;llly <llulllill.l ~,cn~r;llly h;lvin~ (liLllncler~; in thc r~n(~e of 0.~ to 2.() 2S 1~;1S (().0()~ ~0 ()Ø~ I11n~ rC:I1;1r~11;On Of rCrr;lCIOrY O.Y;de r;bCrS a11d ~h~;r precursors i~ disclo.ic~l in U.~ ,X()~,()15 ;In~l U.S. 3~ refr~csory oxi~le m~tl iX m.ly l~e ;Ipl~licd t() ;I wOUIl(] p;lcl~ ,c of tlIe y;lrns to provide mecil;lnic~ll slrellL,lll. Re~ic~ se~l lubc~ orc;lr~ri-l~csu.~eful in ~his invcn~ion e,Xhi~ C;IS;liytiC ;IClivily ill ct)nversioll of cxh~u~l ~;lses lo oxi(Jize c~rbon i ~ 30 monoxide, hydroc;~rhons ;lnd/or hy(lroc~rhon rcsi~l~lcs nr recluce nitro~e oxi~cs. Thi~ ~ctivity m;ly (lerive froln c~ll;llysic m;lleri~ls present in the componen~s Or ~he c;lrlrid~,e~ i.e. cer;llllic fiher!i~ cer;lmic ~inder or rerr~csory oxide mat~rix, or by :l~klition of cat;llysts to thc c;lrtri~l~e. The cat~lyst m~ly be ~--placed on the cartri~lge by a~ls()rption of ~ ~uitable compo~lnd of the ~c~ive ,~., ~,i ,,~, ,, , :
SU!~3$TI~UTE SH~El~
,.,,:~
r _ .. ' ~ ~ ' . r -r r ~ .. r r~ r ~
~,~ 2I~229ll component or imbibilion Or an active malerial or precur~or from a slurry form folic~wed by (Jryinl~ ~nd conver~;ion to the ac~ive material ÇU~STIT~E S~EE~
wo 93/19289 2 1 3 2 ~ 9 ~ Pcr/~JS92/02180 Suitable catalysts include the precious metals (Ru, Ph, Pd, Os, lr and Pt) in elemental or oxide form and oxides, vanadates, chromates, chromites, manganates, manganites, stannates, molybdates, tungstates, niobates or tantalates of Fe, Co, Ni, Cr, Mn, Cu, Zn, Ag and Cd, and the rare 5 earth salts.
In operation starting with a cold engine, valve 41 is in the closed position. The engine is started and the contaminated exhaust gas enters exhaust gas receiving chamber 15. The exhaust gas fills axial channel 27 and as pressure builds is forced radially through catalyst cartridge 23 10 which rapidly reaches activation temperature and serves to catalytically oxidize ultburned~ hydrocarbons and carbon monoxide. When the engine attatns an efficient operating temperature, coil springs lengthen in response to the hot gas causing`shaft 39 to turn and valve 41 to rotate to an open position. When the valve opens, the exhaust gases pass through axial channel 27 and out of chamber 15 through outlet 19 entering the normal exhaust systèm which includes an under the floor catalytic converter.
: ~ 1 :-:
, ,,,, ~, :
~, ,, , j -,':, ,, ~.
. ," .....
""~::
RAD~ LOU/ EXH~UST CAT~l YTIC CO~VERTER
FIEI,l) OFTHE II~Vr.i\TlC)~
Tllis invenlion r~ tes to cat;llytic conver~ers ~nr controllin~
cmission lcvcl.s rrom intern~l combustion enghlcs. Morc particul~rly, ~he inv~n~ion rcl;lles lo ;In ;luYili;lry c;lt;liylic convcrlcr for c~ntrolling emissiolls from an in~crnal comhuslit)n engilIc ~Illring lhe ~criod of en~ine warm-llp.
I~CI<(~ C)lJl~ln OFT~-ll II\VEI~ OI~
Thc L~rc;ltc.~l concel-lr~lioll Or ~tmosplleric contaminanls from the e~hau.ct Or an intcrllal coml~llstion enginc occurs imme~liately followin~
start-~lp of tlIc en~ine. ~'hile c~t,llytic convertcrs ,Ire required in the exh;lu.
system, such converters ~re essenti,llly inerreclive in controlling pollu~anls until they are hea~cd to elevate(~ temper~ture.~ by tllc hol exh,~lust gases from 15 the engine.
l~rror~ h~ve hcen m~dc to control thi.s prohlem using so c;llle~J
warm-up or "pup conver~cr~s" which are posiLioned ne,lr the exhal~st m;lnirnld in ~Yance Or ;, m~in, un~ler the floor, convcrter. In somc emhodiments the~se convertcrs ;Ire hc;llc~l electric~llly. Gener;llly Ihe exh,lust ~,~ses are 20 ~orced throu"h honeyconllle~l structurcs the surf~cc of which is coated wi~h catalyst. Wllile thesc cl~nv~rters (lo re~luce p()ll~ nt emi~si()ns foIlowing starf-up, thcy ;Irc p~)wcr ~In~ rucl (:onslllllcr!i l'hC n-,w of exh;lust ~ascs is imp~c(J throll~llollt the timc the enL~ine is opcr;lling. In a(l~ilion to!hi~
inefriciency, c;~t;llyst in tll~ convertcr conlinllc.~ ~o he de~cliv;lted ~s lon~ as 25 the engine i~ runnin~.
In accord;lllcc wilh this invenlioll ~h~rc i~ provide(l a unit;lry ,luxiliary ca~alytic conv~rter ~or an hltern~ll cl-n~l-u.~tion engine which ~chicves rapid ca~aly~ic aclivily wilhollt suhsl;ln~i;ll oper.l~ing pressure an~l 30 powcr k)sscx as!ioci;llcd witll known warm-llp convcrter systems. The syslem utili~.es a ra~ lo-v cat~ly~t system which i.~ placed adjacent or as a part o~
the exhaust manifolc3 at the coition or "Y" whcrc the cyIinder exhaust tubes corne together.
The converter of thi~i invention compri~es ~ housing defining ~
3s gas receiving chambcr an(l has an cxllaust gas inlet at one end of the housing SUBSTITUTE SHEET
r r 2 1~ 2 ~
adjaccnl or as a parl ol lhe exhaust m~nifold ;~nd ~n exhallst gas outlet ~I thcother end ()f the ho~ ing. The catalyst comprisc~i a c;lrtridge which ha.s an annular !itnlcturc an-l is ;~ligne(~ ~Lxially wilhill lhc housing. The stMcll~re h;ls multiplc ch;lllnel~ or pores through which ~ CS can pass from an internal to an cxtcrn;ll ~urr~cc. 1'hc cartridge is ali~llcd with the walls of the housing therel~y providinL~ ;l p;~ssa~c hetwccn the outcr surface (,r the cartri(lge andthe walls or, altcrn;l~iv~ly, thr()uy,h the channcls or pores in ~he cartri(lgc, an(l an axial challncl cxtelldin~3 fronl ;Idjacent the cxll~usl ~as inlet to an opening in the outle~. Valve Incans acljacent thc ga~ outlct ~re a~apted to be opencd ane~ closcd in re~p()n~c lo a pre~lctermine~l condilion of the exhaust ~
In opera(ioll the valve i~ in a clo~c(J p()~iliOIl re~trainin~, exhau~t gas flow throu~il tl-e .~ l channel ~uril~ tart ~p thereby causin~
the exhaust gas to flow ra(lially thro~lgh the c;ltaly~t structure ;Ind into the~nnular p~s~a~e alon,, Ihc outer walls of thc hou~ing. After enL~ine ignition has l~een ~u.~taincd for a prc~leicrmined pcriod ~n(J thc engine ha:s reache~ a satisf~ctory ~tablc con(lilion~ thc valve open~ removing the axial exhaust flow re~trictlon an~ permi~tin~, exh.~ t gasc~ to flow ~lown the axis and ~hrougl the cartri~J~c es.~cntiLllly ~lnrestriclc~]. In the~opcn posi~ion~ little pressllre drop occur~ iri the .LYial ch~mncl, all~l thcrc i.~ little or no signiricant catalyti~
activity. l'he (limen.~ions Or the axi;ll ch;~nn~l~ ;mnul.lr pas~age, inlct and outlet are dctcrmine~l to accommodatc prc~urc drop ~nd flow ratc based on ~he ~pecific rccluirclllcllt~ rl)r tlle l~articul.lr enginc involvcd.
I~Es(l? l PTlOi`~ ()F Tl~ R~Wl~GS.
FIG. l is a schem;llic cross-sectiollal view through a cat~lytic converter of this invcnti()n .shown as a portion of ~n cxhaust mainfold;
FIG. 2 i~ a ~ra~mentary, secti~lnal tnp view of the converter shown in FIG. 1, a~
FIG. 3 shows a sm;lll se,~,ment of a prelerre~ càtalyst cartri~lge structurc ror usc in this invcn~ion.
DETAll,I,D DE~iCRlPTI(~ FT~IE I~ TTQl~
Rcfcrrillg to FIG,l, caî;llytic convcrter 1 l is compri~e(l of a hou~in~ 13 the w.~ t-f ~vhich ~lefil1e an e~h;lu.~t ~,a~ rccciving chamber 15.
Housing l3 m~y i~c intçgr;l~ with or form an c,~ttension of exhaust manirokl l(lof an intcrn;ll comhu~tion engine, not shown. The engine may be a two or 35 ~ four cycle engine. The chamber has an exh;lu~it ~as inlet ~7 at one cnd of the ,:,i ~" ~
`~ SUBSTITUTE SH~T
r ~ ~ r ~ r r r ~ ~ r r r r1 ~ r r, I
r r ~ a ~ ~ 9 ~
hoLlsing .In~ n(l cxl~au.it ~.~s outlel 19 at thc o~her en(l of the housin- A
cat;llyst su~porl ring I i~ p(~siliol-cd hctwccn ~he inl~t and outlet.
Tl-e c;l~;llY.st strlJcturc is prerer;lllly in Ille form o~ an ~nnul~r c;lrlridgc 2~ lnd is ~;p;lCC i from ~l~c walls or lhe llousing ~n~ ~xi~lly ~ ne~i in 5 the ch.lnlher ~o provi(le a p.lS~ l~e 25 helwccn lhe o~ltcr !illrf.lcc of the c~t~lyst .~nd ll~e ~alls al~ n .Lxial ch Inncl ~7 in comm~lnic~tion with eYh IllS~
gas in]el 17 an i cYh;nl~ g;l.li outlet 19. Altcrn;llively p.lss.lge 27 co~lki be provided hy ch~nllcls or pores in the c~t;lly.s~ struc~urc ;~r(~vided sufficicnt ~;ls flow c~n b~ es~;lhli~she(J to outlct 19 lllrollgll thc ch.lnncl~s .nnd pores whcn 10 ~xial ch;lnnei 27 i~ cl~ ed.
Tlle c;l~.llYst str~lclure h.l~ m~lltiple sul7stanti;l11y di~crete channels .1l~(1 por~ Ihrollglloul. The slruclure is hcl~ in position be~wcen housing 13 ~1 inle~ 17 all i support ring ~ ~t o~lllct ]9. G.lskets no~ show may be uscd a~ cithcr end of ll~c s~ruclure ~o pr()vi ie a ~a.s tight seal. The support rin~ i.s .securcxl l~ctwecn fl Inge~ 29 an(J ~1 of holl;in~ 13 ~nd ou~let pipe 33 usin~ hOILS nuts 59 on 57 .lnd g;lskcts 3~ <all(J 31. ~ltern~tivcly ~he cvmponents m3y be wekle~l in place.
V.llvc 41 is po~sitionc(l a~jacent the h~se of c;lt~lyst sur)p()rt rin~ 2]. A hall v llve ~vhich whcn opene(J prs)vidcs unrestricted fiow of 20 exhaJst~;ISC.~ ol cl1.un~cr 1~ throu~h :lxi;ll ch;lnl1el 7 m;~yheuse~l;
however o~hcr l;no~vl~ pcx Or v;llves xuch .~ butlerny v;llves m;ly be usc~. A
hutterlly v;ll~c .nrl-~n~el1~cl1l is shown in FIG. I m(J FIG 2. V~lve 4 l rcsls Ol1 se~ling surf;lccs 55 ;U1~ 55 when in thc clo.~e~ l)osition. ~s shown i~ FlG. 2 hcat sen.~i ~iv~: coil spri n~s 53 ~ncl 5~ re ~ v;~ e 4 1 i n the closed pOSi lion 25 whcn thc en~inc i.~ col~l ;m~l not runnin~. At .~l;lrl-llp ~iprin~x 53 ~n~ 5:~
prevent v;llvc froln opel~ xh;lust ~;IX el1lcrs ch Imher 15 and impin~e.i on the facc of the v;llve. ~ xhowl1 in FIG. 1 ll1e ~.ns p~scs throu~h c~rtri~l~c23 tg ~nn~ p;lx.~ e 25. /`.x ~hc xprin~s arc hedte(l to ~ predetermine(3 temper lturc ~y tl1e e.Yh;lllst ~;IS Il1e coil incrc;lxe.~ in len~lh c;lusin~ v~lve 41 30 to rot~tc t~ n opcll po.~i~ion. Thc v~lve is ~ ne~ in ch;lmber 25 in such ;~
m~nner xo th.lt ~nce il ix openc(l ~he e:~h~llst ~;ls flow c;l~lses i~ to self-cen~er in ;ln open position. Wllen the ~;ls flow CC;ISCS~ coil tcnxion returns Ihe v llve to ;l near clo~;e~l posilion. As thc coil cools~ ~he v;llve ~oe~ to I fully close(l position. Thi~ arran~emel1t is siml)le an~l parlicul~rly cost effective since it35 . captures the kine~ic energy of the xyxtem an~ rcquirex no external conlrol SUBSTll~lJTE S~ El ~ ~ r ~ ~ r ~ r ~
r ~ r 2 3L 3~ 2 9 ~ r, !
.
componen~s. 1~ is to ~ e no~e(l, ht)wevcr~ Ih.lt v;~ri()u~i altern~llives based on electric;~ nd m;l-metic ~pplic~tit~ns c~n he ~ pte~ ttl open and close the valve.
Rercrri~ nOw ~ ICi. 2, thc l);lsc 43 t)r ~hc c;llaly~t carlri~lyc is s ~hown ..u~-port(:~l On rinL~ 21 I-y wc(l~. 4~. V;JIVC 41 ~vhicll is intc~r;ll with sh;
39 pivots willlin tllc s~ )orl ring ;In(l is sllowll in thc closc{l postit)n th~hlockil~ c fl-.w of ~.~h;lusl g;lscs frt)lll ch;lnll~l 27. Mul~ lc opening~ 47 in ..upps)rt rin.~ ~ l ct)mml~ c;lîe wilh ;Innlll;lr p;l~ e ~ pernliltin~ ses 1() e~c.ll)e Ihrol~ xh;~ ;t ~ )ullet ~ t)le.~i(1 ;Irc provi(le(~ tt) ~cceptwcl~.
lO ~7 in ~.cllrrin& tl~c c;il;llysl .slruclurcs in thc .Isscllll-lc.
l hc c.al~lly~l slructure is Of thc ri~ yl)c m;l(lc from ;l reticul~le~ nllul;lr fornl omprisc~ f reinforcc(~ ccr~mic fibers. The .tructure c;lrrics ;l (;lt;lly~it all~l pr(~vi(Je~ le(~ rcsisl~nce to bo~h therm;ll shock an~ n!ecll;tnic.ll ~h(-cl;. ~Suit;lble ~tructurc!i <are ~lisclosed in lJ.S.
-~ 15 ~,~4n,109, IJ.S. ~,9x6,~?~, O.S. 4,(~ 4 ;In~l U.S. ~,()7()~0( 4. O~her s~ le tructures. .~uch ;~s cer<ll~ n~ mc~ fo~m.s wllic11 provi~c muliple ch;~nnels )r pore~ throu~h which ~,;lSC.S can p.ns~. m;ly l~e u~c~l. Procc.s~e~. for prcp.lrin~
other SUit;1171C S~rllCtllrC.'. ;Irc (li~.cl(~sccl itl Ellrnl)c;~n P;ltenl ~pplications 9~311~10.3 .In~l 91~1 I'J 1~.7~ file(l l~cccml-cr 2(), I~)')l.
~-: 20 I:IG. ~ sllows ;1 sc~ment of c~al;llyst c;lr~ri~l~e 2~. A series Of yers of y;trn A, B. (` ;uld D. whicll m;ly hc repc;.ltc~l m.lny ~ime~. form ;I w~ll ror a c:l~alys~ c~lrtrid~c. ~icl);lr;ltions "~ f tllc y:lrn~ form openin~s whicll permis the p;lSS.I~C Or cxh;lu~l ~;1S. I'rcfer~hly ~he fil-er~ rn;l~ing u~ ~e y~lrn.s ~re suh~t~llti;llly <llulllill.l ~,cn~r;llly h;lvin~ (liLllncler~; in thc r~n(~e of 0.~ to 2.() 2S 1~;1S (().0()~ ~0 ()Ø~ I11n~ rC:I1;1r~11;On Of rCrr;lCIOrY O.Y;de r;bCrS a11d ~h~;r precursors i~ disclo.ic~l in U.~ ,X()~,()15 ;In~l U.S. 3~ refr~csory oxi~le m~tl iX m.ly l~e ;Ipl~licd t() ;I wOUIl(] p;lcl~ ,c of tlIe y;lrns to provide mecil;lnic~ll slrellL,lll. Re~ic~ se~l lubc~ orc;lr~ri-l~csu.~eful in ~his invcn~ion e,Xhi~ C;IS;liytiC ;IClivily ill ct)nversioll of cxh~u~l ~;lses lo oxi(Jize c~rbon i ~ 30 monoxide, hydroc;~rhons ;lnd/or hy(lroc~rhon rcsi~l~lcs nr recluce nitro~e oxi~cs. Thi~ ~ctivity m;ly (lerive froln c~ll;llysic m;lleri~ls present in the componen~s Or ~he c;lrlrid~,e~ i.e. cer;llllic fiher!i~ cer;lmic ~inder or rerr~csory oxide mat~rix, or by :l~klition of cat;llysts to thc c;lrtri~l~e. The cat~lyst m~ly be ~--placed on the cartri~lge by a~ls()rption of ~ ~uitable compo~lnd of the ~c~ive ,~., ~,i ,,~, ,, , :
SU!~3$TI~UTE SH~El~
,.,,:~
r _ .. ' ~ ~ ' . r -r r ~ .. r r~ r ~
~,~ 2I~229ll component or imbibilion Or an active malerial or precur~or from a slurry form folic~wed by (Jryinl~ ~nd conver~;ion to the ac~ive material ÇU~STIT~E S~EE~
wo 93/19289 2 1 3 2 ~ 9 ~ Pcr/~JS92/02180 Suitable catalysts include the precious metals (Ru, Ph, Pd, Os, lr and Pt) in elemental or oxide form and oxides, vanadates, chromates, chromites, manganates, manganites, stannates, molybdates, tungstates, niobates or tantalates of Fe, Co, Ni, Cr, Mn, Cu, Zn, Ag and Cd, and the rare 5 earth salts.
In operation starting with a cold engine, valve 41 is in the closed position. The engine is started and the contaminated exhaust gas enters exhaust gas receiving chamber 15. The exhaust gas fills axial channel 27 and as pressure builds is forced radially through catalyst cartridge 23 10 which rapidly reaches activation temperature and serves to catalytically oxidize ultburned~ hydrocarbons and carbon monoxide. When the engine attatns an efficient operating temperature, coil springs lengthen in response to the hot gas causing`shaft 39 to turn and valve 41 to rotate to an open position. When the valve opens, the exhaust gases pass through axial channel 27 and out of chamber 15 through outlet 19 entering the normal exhaust systèm which includes an under the floor catalytic converter.
: ~ 1 :-:
, ,,,, ~, :
~, ,, , j -,':, ,, ~.
. ," .....
""~::
Claims (6)
1. A unitary catalytic converter for treating exhaust gas pollutants from an internal combustion engine during engine warm-up comprising a) a housing (13) having walls defining an exhaust gas receiving chamber (15), an exhaust gas inlet (17)at one end of said housing and an exhaust gas outlet (19) at the other end of said housing, b) catalyst holding means (21) disposed in said chamber, c) an annular catalyst structure (23) having multiple channels or pores throughout said structure secured by said holding means, said structure being spaced from the walls of said housing and axially aligned in said chamber thereby providing a passage (25) between the outer surface of said catalyst structure and said walls and an axial channel (27) in communication with said exhaust gas inlet and said gas outlet, and d) valve means (41) adjacent said gas outlet adapted to be opened and closed in response to a predetermined condition, said valve means when in a closed position restraining exhaust gas flow in said axial channel causing said gas to flow radially through said catalyst structure into said passage, and when in an open position permitting essentially unimpeded flow of said gas from said gas inlet through said axial channel to said gas outlet.
2. The catalytic converter of Claim 1 wherein said valve is activated by a heat responsive means (53)(53').
3. The catalytic converter of Claim 1 wherein said catalyst structure is a reticulated hollow cartridge (23) having multiple channels or pores to permit exhaust gas to flow therethrough.
4. The catalytic converter of Claim 3 wherein said valve means includes heat responsive springs (53)(53') which open and close a valve (41).
5. The catalytic converter of Claim 4 wherein said catalyst structure (23) is held by compressive force between shoulders on said housing (13) and a support ring (21).
6. A unitary catalytic converter for treating exhaust gas pollutants from an internal combustion engine during engine warm-up comprising a) a housing (13) having walls defining an exhaust gas receiving chamber (15), an exhaust gas inlet (17)at one end of said housing and an exhaust gas outlet (19) at the other end of said housing, b) catalyst holding means (21) disposed in said chamber, c) an annular catalyst structure (23) having multiple channels or pores throughout said structure secured by said holding means, said structure being axially aligned in said chamber and having an axial channel (27) in communication with said exhaust gas inlet and said gas outlet, and d) valve means (41) adjacent said gas outlet adapted to be opened and closed in response to a predetermined condition, said valve means when in a closed position restraining exhaust gas flow in said axial channel causing said gas to flow through said catalyst structure into said outlet, and when in an open position permitting essentially unimpeded flow of said gas from said gas inlet through said axial channel to said gas outlet.
Priority Applications (12)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU22643/92A AU2264392A (en) | 1992-03-17 | 1992-03-17 | Radial flow exhaust catalytic converter |
| CA002132294A CA2132294A1 (en) | 1992-03-17 | 1992-03-17 | Radial flow exhaust catalytic converter |
| EP92914723A EP0631647B1 (en) | 1992-03-17 | 1992-03-17 | Catalytic converter |
| BR9207106A BR9207106A (en) | 1992-03-17 | 1992-03-17 | Catalytic converter for treatment of exhaust gas pollutants |
| AT92914723T ATE161612T1 (en) | 1992-03-17 | 1992-03-17 | CATALYTIC CONVERTER |
| JP5516484A JPH07504731A (en) | 1992-03-17 | 1992-03-17 | Radial flow type exhaust catalytic converter |
| DE69223807T DE69223807T2 (en) | 1992-03-17 | 1992-03-17 | CATALYTIC CONVERTER |
| RU94044335/06A RU94044335A (en) | 1992-03-17 | 1992-03-17 | Catalytic converter for radial exhaust-gas removal |
| CZ942276A CZ227694A3 (en) | 1992-03-17 | 1992-03-17 | Catalytic converter |
| ES92914723T ES2110506T3 (en) | 1992-03-17 | 1992-03-17 | CATALYTIC CONVERTER. |
| PCT/US1992/002180 WO1993019289A1 (en) | 1992-03-17 | 1992-03-17 | Radial flow exhaust catalytic converter |
| FI944313A FI944313A0 (en) | 1992-03-17 | 1994-09-16 | Exhaust catalytic converter with radial flow |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002132294A CA2132294A1 (en) | 1992-03-17 | 1992-03-17 | Radial flow exhaust catalytic converter |
| PCT/US1992/002180 WO1993019289A1 (en) | 1992-03-17 | 1992-03-17 | Radial flow exhaust catalytic converter |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2132294A1 true CA2132294A1 (en) | 1993-09-30 |
Family
ID=25677495
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002132294A Abandoned CA2132294A1 (en) | 1992-03-17 | 1992-03-17 | Radial flow exhaust catalytic converter |
Country Status (12)
| Country | Link |
|---|---|
| EP (1) | EP0631647B1 (en) |
| JP (1) | JPH07504731A (en) |
| AT (1) | ATE161612T1 (en) |
| AU (1) | AU2264392A (en) |
| BR (1) | BR9207106A (en) |
| CA (1) | CA2132294A1 (en) |
| CZ (1) | CZ227694A3 (en) |
| DE (1) | DE69223807T2 (en) |
| ES (1) | ES2110506T3 (en) |
| FI (1) | FI944313A0 (en) |
| RU (1) | RU94044335A (en) |
| WO (1) | WO1993019289A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US12060822B2 (en) * | 2017-04-13 | 2024-08-13 | Cummins Emission Solutions Inc. | Dosing module for use in aftertreatment systems for internal combustion engines |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1388637A (en) * | 1971-06-02 | 1975-03-26 | Gould Inc | Article for catalytic reduction of nox |
| GB1519343A (en) * | 1974-09-03 | 1978-07-26 | Matsushita Electric Ind Co Ltd | Gas purifying devices |
| DE3930380A1 (en) * | 1989-09-12 | 1991-03-21 | Porsche Ag | EXHAUST SYSTEM OF A MULTI-CYLINDER COMBUSTION ENGINE |
| DE9004614U1 (en) * | 1990-04-24 | 1991-03-14 | Kuck, Jürgen, 3300 Braunschweig | catalyst |
-
1992
- 1992-03-17 AU AU22643/92A patent/AU2264392A/en not_active Abandoned
- 1992-03-17 WO PCT/US1992/002180 patent/WO1993019289A1/en active IP Right Grant
- 1992-03-17 EP EP92914723A patent/EP0631647B1/en not_active Expired - Lifetime
- 1992-03-17 ES ES92914723T patent/ES2110506T3/en not_active Expired - Lifetime
- 1992-03-17 CA CA002132294A patent/CA2132294A1/en not_active Abandoned
- 1992-03-17 AT AT92914723T patent/ATE161612T1/en not_active IP Right Cessation
- 1992-03-17 JP JP5516484A patent/JPH07504731A/en active Pending
- 1992-03-17 DE DE69223807T patent/DE69223807T2/en not_active Expired - Fee Related
- 1992-03-17 RU RU94044335/06A patent/RU94044335A/en unknown
- 1992-03-17 CZ CZ942276A patent/CZ227694A3/en unknown
- 1992-03-17 BR BR9207106A patent/BR9207106A/en active Search and Examination
-
1994
- 1994-09-16 FI FI944313A patent/FI944313A0/en not_active Application Discontinuation
Also Published As
| Publication number | Publication date |
|---|---|
| BR9207106A (en) | 1995-12-05 |
| AU2264392A (en) | 1993-10-21 |
| EP0631647A1 (en) | 1995-01-04 |
| DE69223807D1 (en) | 1998-02-05 |
| ES2110506T3 (en) | 1998-02-16 |
| FI944313A (en) | 1994-09-16 |
| CZ227694A3 (en) | 1995-06-14 |
| ATE161612T1 (en) | 1998-01-15 |
| EP0631647B1 (en) | 1997-12-29 |
| WO1993019289A1 (en) | 1993-09-30 |
| DE69223807T2 (en) | 1998-07-23 |
| RU94044335A (en) | 1996-08-20 |
| FI944313A0 (en) | 1994-09-16 |
| JPH07504731A (en) | 1995-05-25 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |