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
  • F01N1/00—Silencing apparatus characterised by method of silencing
  • F01N1/02—Silencing apparatus characterised by method of silencing by using resonance
  • F01N1/04—Silencing apparatus characterised by method of silencing by using resonance having sound-absorbing materials in resonance chambers
• • 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
  • F01N1/00—Silencing apparatus characterised by method of silencing
  • F01N1/02—Silencing apparatus characterised by method of silencing by using resonance
• • 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
  • F01N13/00—Exhaust or silencing apparatus characterised by constructional features
  • F01N13/009—Exhaust or silencing apparatus characterised by constructional features having two or more separate purifying devices arranged in series
• • 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
  • F01N13/00—Exhaust or silencing apparatus characterised by constructional features
  • F01N13/009—Exhaust or silencing apparatus characterised by constructional features having two or more separate purifying devices arranged in series
  • F01N13/0093—Exhaust or silencing apparatus characterised by constructional features having two or more separate purifying devices arranged in series the purifying devices are of the same type
• • 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
  • F01N13/00—Exhaust or silencing apparatus characterised by constructional features
  • F01N13/011—Exhaust or silencing apparatus characterised by constructional features having two or more purifying devices arranged in parallel
• • 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
  • F01N3/24—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 constructional aspects of converting apparatus
  • F01N3/28—Construction of catalytic reactors
  • F01N3/2882—Catalytic reactors combined or associated with other devices, e.g. exhaust silencers or other exhaust purification devices
  • F01N3/2885—Catalytic reactors combined or associated with other devices, e.g. exhaust silencers or other exhaust purification devices with exhaust silencers in a single housing
• • 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
  • F01N2230/00—Combination of silencers and other devices
  • F01N2230/04—Catalytic converters
• • 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
  • F01N2490/00—Structure, disposition or shape of gas-chambers
  • F01N2490/15—Plurality of resonance or dead chambers
  • F01N2490/155—Plurality of resonance or dead chambers being disposed one after the other in flow direction

Definitions

• the present invention relates generally to automobile exhaust emission control, and more specifically to a device combining a catalytic exhaust converter and a resonator installed within the exhaust system for the reduction of exhaust noise.
• a device combining a catalytic exhaust converter and a resonator installed within the exhaust system for the reduction of exhaust noise.
• the resonator As the resonator is adapted to attenuate different frequencies than the muffler, and operates on a different principle, it is generally placed elsewhere in the exhaust system, somewhat forwardly of the muffler. This is also the general area in which catalytic converters are typically installed in an automobile, in order to avoid excessive exhaust heat while still accepting sufficient exhaust heat to function. While resonators do not generate internal heat due to chemically reacting the exhaust products, as do catalytic converters, they still must be structured to accept a relatively high exhaust temperature due to their location relatively near the engine. However, heretofore no combining of a catalytic converter and a resonator has been accomplished, to the knowledge of the present inventor.
• the device may be installed in a conventional automobile exhaust system, between the engine and a conventional muffler and/or tailpipe.
• Different embodiments may be provided for single and dual exhaust systems, each of which may include one or more catalytic converter elements or "bricks.”
• a muffler for further sound attenuation may not be required, depending upon the particular automobile, engine, and exhaust system.
• the device is essentially a cylindrical container with a series of cup-shaped catalytic converter elements arranged therein.
• the elements are each relatively thin, due to the cup-like shape of each element, and thus do not present a significant cross sectional area to the exhaust gases passing therethrough. Thus, a great many such elements are required, unlike the present catalytic converter and resonator combination.
• the exhaust gas flow through the device is not axial, but passes radially through a plurality of lateral openings in a conical inlet pipe, unlike the straight through, axial flow configuration of the present system.
• Japanese Patent Publication No. 55-43262 published on March 27, 1980 illustrates an exhaust gas purifier in which the catalytic converter unit includes a baffle within its inlet end to preclude interference between exhaust gases alternatingly entering the converter from the no. 1 and no. 4 cylinders, and the no. 2 and no. 3 cylinders. No muffler, resonator, or other sound attenuating means is apparent, as is provided in the present catalytic converter and resonator combination invention.
• a "protector 37" (per the English abstract) , apparently comprising an outer shell spaced apart from the inner housing containing the catalytic converter, is welded over the remainder of the assembly, unlike the present catalytic converter and resonator combination with its single shell or housing. No disclosure is apparent regarding any provision for a straight through, free flow resonator, as provided by the present invention.
• Figure 1 is a perspective view in partial section of a single exhaust catalytic converter and resonator combination of the present invention, showing its structure and features.
• Figure 5 is a perspective view in partial section of an alternative embodiment of the device of Figure 4, incorporating dual concentric catalytic converter elements therein.
• Figure 6 is a detailed front elevation view of the substrate element and flow passages, of the present catalytic converter element showing the thinner walls and larger passages therethrough.
• the present invention comprises several different embodiments of a catalytic converter and resonator combination.
• the present invention includes at least one (or more) catalytic converter element (s) within the same canister or shell used to house an exhaust resonator, which is normally used for the attenuation or canceling of exhaust noise or sound in a relatively narrow frequency range.
• Such resonators generally include a plurality of relatively small perforations therein, with the size of the perforations being configured according to the frequency or frequencies which are to be attenuated or canceled.
• Resonators are not mufflers, in that they do not serve to attenuate or cancel a broad range of exhaust frequencies, but rather reduce or eliminate certain objectionable frequencies or levels which are more difficult to attenuate using a conventional muffler.
• the catalytic converter element 24 includes a substrate 28 having a plurality of longitudinal passages 30 therethrough, with each of the passages 30 being defined by a plurality of walls 32, as shown in detail in Figure 6. These walls 32 may be generally horizontally and vertically oriented to form a honeycomb or grid-like configuration when viewed in lateral cross section, as shown in Figure 6. Each of the walls 32 is coated with one or more catalytically reactive elements or materials, e. g., noble metals such as platinum, palladium, rhodium, etc., as is known in the art .
• catalytically reactive elements or materials e. g., noble metals such as platinum, palladium, rhodium, etc.
• the efficiency of the present converter 24 is increased by constructing the substrate 28 with the walls 32 having a relatively thin cross section and the passages 30 therebetween being relatively wide, in order to reduce the restriction to exhaust gas flow as much as possible.
• the walls W of conventional substrates, such as the substrate S shown in Figure 7, are relatively thick due to the need for structural strength at the elevated temperatures occurring within catalytic converters. These walls W are normally somewhat thicker than required for structural strength at normal temperatures, but due to the extremely elevated temperatures occurring within a catalytic converter, they must be made even thicker to provide the required structural strength at such elevated temperatures where most materials are weakened.
• the catalytic converter 24 of the present catalytic converter and resonator combination 10 preferably uses a ceramic material for the substrate walls 32.
• ceramic materials provide excellent resistance to heat, but a relatively strong material is required in order to provide the required structural strength, particularly in the case of the relatively thin substrate walls 32 of the present invention.
• a ceramic material known as Dow-Corning XT (tm) manufactured by the Dow-Corning Company, has been found to be suitable for the construction of such thin wall catalytic converter substrates 28 of the present invention.
• Other materials providing sufficient structural strength at the elevated temperatures experienced within an operating catalytic converter may be used as desired.
• the essentially equal diameters 22 of the catalytic converter element 24 and inner surface of the forward portion 16 of the canister 12 serve to affix the catalytic converter element 24 concentrically within the canister 12.
• the tight fit of the catalytic converter element 24 within the forward portion 16 of the canister 12 provides a tight seal between the catalytic converter element 24 and forward portion 16 of the canister 12, thereby precluding any bypass flow of exhaust gases therebetween.
• the toroidal plates 48 and 50 serve to secure the resonator pipe element 34 concentrically within the rearward portion 18 of the canister 12, with the tight fit of the catalytic converter element 24 within the forward portion 16 of the canister 12 serving to secure the converter element 24 concentrically therein.
• all of the above elements i. e., the canister 12 with its inlet and outlet ends 14 and 20, catalytic converter 24, and resonator element 34 with its hollow core 36, are disposed concentrically relative to one another and are axially aligned with one another to provide a straight through, low restriction, free flow path for engine exhaust through the catalytic converter and resonator combination 10.
• the canister rearward portion 68 includes a resonator element 72 installed therein, constructed generally in the same manner as that described for the resonator element 34 of the embodiment 10 of Figure 1.
• the resonator element 72 of the embodiment 68 of Figure 2 has a hollow core 74, a forward end 76, and an opposite rearward end 78, which also comprises the rear or outlet pipe for the converter and resonator combination embodiment 60 of Figure 2.
• the forward portion of the resonator element 72 is formed essentially identically to the resonator element 34 of the device 10 of Figure 1, having a plurality of relatively small sound attenuating perforations or passages 80 formed through the wall thereof.
• the forward end 76 of the resonator 72 is secured concentrically within the canister rearward portion 68 by a forward plate 82.
• the remainder of the catalytic converter and resonator combination 60 of Figure 2 is constructed similarly to the embodiment 10 of Figure 1, with the resonator element 72 having an outer diameter substantially less than the inner diameter of the rear portion 68 of the canister 62. This difference between the inner diameter of the canister rearward portion 68 and the outer diameter of the resonator element 72, defines a sound attenuating plenum 86 therebetween.
• a forward sound attenuating plenum 88 is also defined between the rear of the catalytic converter element 24 and the forward end 76 of the resonator element 72 and its supporting front plate 82, within the outer shell 62 of the combination catalytic converter and resonator device 60.
• the toroidal front plate 82 along with the necked down rearward end 84 of the conical rearward portion 70 of the shell 62, serve to secure the resonator pipe element 72 concentrically within the rearward portion 68 of the canister 62, with the tight fit of the catalytic converter element 24 within the forward portion 66 of the canister 62 serving to secure the converter element 24 concentrically therein.
• inventions each include a single resonator tube element 34 or 72 with a single catalytic converter element 24 concentric therewith.
• additional catalytic converter elements may be added in series with the single element 24 of the devices 10 and 60 respectively of Figures 1 and 2, if so desired, for further efficiency.
• Figure 3 discloses such an alternate embodiment, designated as catalytic converter and resonator combination 100.

Landscapes

• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Combustion & Propulsion (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Health & Medical Sciences (AREA)
• Toxicology (AREA)
• Exhaust Silencers (AREA)
• Exhaust Gas After Treatment (AREA)

Applications Claiming Priority (3)

Publications (2)

Family

ID=22469754

Family Applications (1)

Country Status (4)

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• 1999
  • 1999-08-13 EP EP99941093A patent/EP1108121A4/de not_active Withdrawn
  • 1999-08-13 CA CA002336979A patent/CA2336979A1/en not_active Abandoned
  • 1999-08-13 AU AU54812/99A patent/AU5481299A/en not_active Abandoned
  • 1999-08-13 WO PCT/US1999/018343 patent/WO2000011328A1/en not_active Ceased

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