CN101044301A - 催化式排气净化器及其装配方法 - Google Patents

催化式排气净化器及其装配方法 Download PDF

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CN101044301A
CN101044301A CNA2005800262249A CN200580026224A CN101044301A CN 101044301 A CN101044301 A CN 101044301A CN A2005800262249 A CNA2005800262249 A CN A2005800262249A CN 200580026224 A CN200580026224 A CN 200580026224A CN 101044301 A CN101044301 A CN 101044301A
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sidepiece
intermediate portion
diameter
thermal shield
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彼得·克罗纳
詹姆斯·R·鲍曼
凯文·巴纳德
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Arvin Technologies Inc
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    • 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
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    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
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    • 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
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    • F01N2260/00—Exhaust treating devices having provisions not otherwise provided for
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    • F01N2470/00—Structure or shape of gas passages, pipes or tubes
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Abstract

一种催化式排气净化器，包括外管、一对位于外管中的催化衬底以及位于外管中催化衬底之间的隔热罩。本发明还披露了一种装配催化式排气净化器的方法。

Description

催化式排气净化器及其装配方法
技术领域
本发明涉及催化式排气净化器。
背景技术
催化式排气净化器用于处理从发动机或其它排气生成装置排出的排气中的排放物。这些排放物可能包括例如一氧化碳(CO)、未燃的碳氢化合物(HC)以及氮的氧化物(NOx)。催化式排气净化器可以用于在将排气排放到大气中之前将CO转化为二氧化碳(CO2)、将HC转化为水(H2O)以及将NOx转化为氮。
发明内容
本发明的一个方面提供一种催化式排气净化器，其包括没有经过任何焊接形成的外管、第一和第二催化衬底以及管状隔热罩。第一催化衬底固定在外管的管状第一侧部中。第二催化衬底固定在外管的管状第二侧部中。隔热罩位于第一侧部和第二侧部之间的管状中间部中，用于防止热量从中间部的排气中传递到中间部。氧传感器固定在中间部上，用于感应催化衬底之间的排气中的氧含量。
本发明另一个方面的装配催化式排气净化器的方法中，第一侧部的直径被减小以便将第一催化衬底固定在第一侧部中，而第二侧部的直径被减小以便将第二催化衬底固定在第二侧部中。这种对第一侧部和第二侧部中的一个或两个侧部的直径的减小发生在将隔热罩插入到中间部中之后。
附图说明
图1为催化式排气净化器的纵向截面图，其中显示了固定到外管的管状中间部的第一隔热罩和氧传感器，以及固定到外管的减小直径后的管状侧部的第一和第二催化衬底；
图2为沿图1的线2-2的横向截面图，其中显示了固定到中间部的第一隔热罩的内管的支座(standoffs)以及位于内管和中间部之间的第一隔热罩的绝缘层；
图3为图1中区域A的放大图，其中显示了位于内管和中间部之间的绝缘层；
图4为类似于图3的视图，其中显示了内管和中间部之间的气隙；
图5为类似图1的纵向截面图，其中显示了位于中间部并且通过减小第一和第二侧部的直径而被固定到外管的第二隔热罩；
图6为沿图5的线6-6的横向截面图；以及
图7为图5中区域B的放大图。
具体实施方式
虽然很容易对本发明进行各种修改和替换，但是下面将以示例的方式参照附图详细描述其特定的示例实施例。然而，应当理解，其目的并非将本发明限于所披露的这些具体实施例，相反，其目的在于覆盖落入所附的权利要求书中本发明的精神和范围之内的所有修改方案、等同方案以及替换方案。
参照图1，催化式排气净化器10用于处理从发动机(未显示)或其它排气生成装置中释放出的排气中的排放物。例如，净化器10用于将CO转化为CO2、将HC转化为H2O以及将NOx转化为氮。
净化器10包括外壳12、第一催化衬底14和第二催化衬底16、管状隔热罩18以及氧传感器20。催化衬底14和16用于处理排气中的排放物。每个催化衬底14、16包括例如由诸如堇青石的陶瓷材料制成的衬底，并且覆盖有诸如铂、钯和/或铑的催化剂。通过使用例如位于衬底14和第一侧部22之间并且由膨胀材料或玻璃纤维材料制成的第一支持垫26，将衬底14固定在外壳12的外管24的管状第一侧部22中。通过使用例如位于衬底16和第二侧部28之间并且由膨胀材料或玻璃纤维材料制成的第二支持垫30，将衬底16固定在外管24的管状第二侧部28中。隔热罩18绕外管24的纵向轴34位于外管24的中间部32中，用于防止热量从中间部32的排气中传递到中间部32。氧传感器20通过使用例如焊接到中间部32的传感器安装架36固定至中间部32上，用于感应衬底14和16之间所存在的排气的氧含量。
每个侧部22和28的直径小于中间部32的直径。在装配净化器10的期间，每个侧部22和28的直径减小以便将衬底14和16固定到侧部22和28中。
每一端盖38被固定至侧部22和28。外管34和端盖38一起提供外壳12。作为示例，端盖38焊接到外管24上。外管34和一个或两个端盖38构成为一个整体的实施例同样落入本发明的范围中。
参照图1-3，隔热罩18包括内管40以及位于内管40和中间部之间的管状绝缘层42。对于例如图4中所示的从隔热罩18中省去绝缘层42的实施例，同样也落入本发明的范围中。
内管40包括管状主体44、多个(例如3个)支座46以及相对的端部48，如图1和图2所示。支柱46径向地从主体44向外伸出到中间部32并且通过例如点焊固定到中间部32上。端部48从主体44径向地向内变细，以适应中间部分32和第一、第二侧部22、28之间的直径差异。限定在主体44中的孔50接纳有传感器安装架36，从而有助于氧传感器20感应氧。
在装配具有隔热罩18的净化器10期间，最初侧部22和28的直径与中间部32的直径相同。因此，最初的外管24是圆柱形的并且没有焊缝。
隔热罩18通过侧部22或28被插入到中间部32中并且被固定至中间部32。当隔热罩18包括绝缘层42时，绝缘层42在将隔热罩18固定到中间部32中之前被定位在内管40上。支座46通过点焊连接至中间部32，从而对隔热罩18进行固定。
催化衬底14和16被插入到侧部22和28中。第一催化衬底14被插入到第一侧部22中，第二催化衬底16被插入到第二侧部28中。
每个侧部22和28如箭头52所示从原来图1中以虚线表示的没有变形的位置被型锻或变形为图1中以实线表示的变形后的位置，从而减小每个侧部22、28的直径。侧部22和28的直径减小将支持垫26和30压靠衬底14和16，从而将衬底14和16固定在侧部22和28中。每个侧部22和28的直径可以在将隔热罩18插入到中间部32中之后以这种方式减小。在其它的实施例中，侧部22和28中的一个的直径可以在将隔热罩18插入到中间部32之前减小，而侧部22和28中的另一个的直径则可以在将隔热罩18插入到中间部32之后减小。
可以在减小侧部22和28的直径之前或之后，将传感器安装架36固定至中间部32，以及将氧传感器20固定至安装架36。
参照图5-7，净化器10包括一个替代隔热罩18的隔热罩118。隔热罩118以一种与隔热罩18固定至外管24的不同方式被固定到外管24上。具体地，作为减小侧部22和28的直径的结果，隔热罩118被固定至外管24。
隔热罩118包括内管140以及位于内管140和中间部32之间的管状绝缘层142。内管140包括主体144以及相对的第一端部148a和第二端部148b。作为减小侧部22和28的直径的结果，侧部22和28与相对的端部148a和148b接合并且使得端部148a和148b向内发生径向变形，从而构成第一侧部22和第一端部148a之间的机械锁以及第二侧部28和第二端部148b之间的机械锁。因此，内管140在无需任何焊接的情况下被固定至外管24。
应当理解，这里使用的术语“管”、“管状”、“直径”、“圆柱形”及类似术语包含了各种横截面形状。这些横截面形状包括，例如，圆形横截面形状、椭圆形横截面形状、矩形横截面形状以及其它闭合的曲线横截面形状。
虽然在附图及前面的描述中显示和描述了本发明的概念，但是这些显示和描述应当被认为是示例性的而非限制性的，应当理解，前面仅显示和描述了示例性的实施例，并且所有落入本发明范围的改变和修改都应当受到保护。
这里所描述的系统的多个特征使本发明概念具有许多优点。我们将会注意到，本发明各个系统的可选择实施例可能不包括描述的所有特征，但是仍然会从这些特征的至少一部分优点中受益。本领域技术人员可能会容易地设计出他们自已的系统实施方式，这些实施方式结合有本发明的一个或多个特征并且落入所附权利要求书限定的本发明的精神和范围中。

Claims (20)

1.一种装配催化式排气净化器的方法，所述催化式排气净化器包括第一催化衬底和第二催化衬底、管状隔热罩以及外管，所述外管包括管状的第一侧部和第二侧部以及位于所述第一侧部和第二侧部之间的管状中间部，所述方法包括以下步骤：
将所述隔热罩插入所述中间部，将所述第一催化衬底插入所述第一侧部，以及将所述第二催化衬底插入所述第二侧部，
在将所述第一催化衬底插入所述第一侧部之后，相对于所述中间部的直径减小所述第一侧部的直径，从而将所述第一催化衬底固定在所述第一侧部中，并且
在将所述隔热罩插入所述中间部以及将所述第二催化衬底插入所述第二侧部之后，相对所述中间部的直径减小所述第二侧部的直径，从而将所述第二催化衬底固定在所述第二侧部中。
2.根据权利要求1所述的方法，还包括将氧传感器固定至所述中间部的步骤。
3.根据权利要求1所述的方法，还包括在至少一个所述减小直径步骤之前，将所述隔热罩固定至所述中间部的步骤。
4.根据权利要求3所述的方法，其中，所述隔热罩包括内管，所述插入步骤包括将所述内管插入到所述中间部中，所述固定步骤包括在至少一个所述减小直径步骤之前，将所述内管固定至所述中间部。
5.根据权利要求4所述的方法，其中，所述内管包括支座，所述固定步骤包括在至少一个所述减小直径步骤之前，将所述支座焊接到所述中间部上。
6.根据权利要求1所述的方法，还包括因所述减小直径步骤而将所述隔热罩固定至所述第一侧部和所述第二侧部的步骤。
7.根据权利要求6所述的方法，其中，所述隔热罩包括内管，所述内管包括相对的第一端部和第二端部，所述插入步骤包括将所述内管插入到所述中间部中，所述固定步骤包括使所述第一端部和第二端部向内变形，从而因所述减小直径步骤而在所述第一端部和所述第一侧部之间以及在所述第二端部和所述第二侧部之间建立机械锁。
8.根据权利要求1所述的方法，其中，所述隔热罩包括内管，所述插入步骤包括在至少一个所述减小直径步骤之前，将所述内管插入到所述中间部中。
9.根据权利要求8所述的方法，其中，所述插入步骤包括在所述中间部以及被插入到中间部的内管之间设置气隙。
10.根据权利要求8所述的方法，其中，所述隔热罩包括环绕所述内管的管状绝缘层，所述插入步骤包括在至少一个减小直径步骤之前，将所述内管和所述环绕管状绝缘层一起插入到所述中间部中。
11.根据权利要求1所述的方法，其中，所述减小第一侧部直径的步骤包括将所述第一侧部的直径减小到小于所述中间部的直径，所述减小第二侧部直径的步骤包括将所述第二侧部的直径减小到小于所述中间部的直径。
12.根据权利要求1所述的方法，其中，所述减小第一侧部直径的步骤包括在将所述隔热罩插入到所述中间部以及将所述第一催化衬底插入到所述第一侧部之后，对所述第一侧部进行型锻；所述减小第二侧部直径的步骤包括在将所述隔热罩插入到所述中间部以及将所述第二催化衬底插入到所述第二侧部之后，对所述第二侧部进行型锻。
13.一种催化式排气净化器，包括：
没有经过任何焊接形成的外管，该外管包括管状第一侧部、管状第二侧部以及位于所述第一侧部和所述第二侧部之间的管状中间部，所述第一侧部和第二侧部的直径均小于所述中间部直径，所述外管具有纵向轴，
第一催化衬底和第二催化衬底，所述第一催化衬底固定在所述第一侧部中，所述第二催化衬底固定在所述第二侧部中，以及
管状隔热罩，其环绕所述纵向轴位于所述中间部中，用于阻止热量从所述中间部的排气中传递到所述中间部。
14.根据权利要求13所述的催化式排气净化器，还包括固定至所述中间部的氧传感器。
15.根据权利要求13所述的催化式排气净化器，其中，所述隔热罩包括位于所述中间部中的内管。
16.根据权利要求15所述的催化式排气净化器，其中，所述内管包括焊接到所述中间部上的支座。
17.根据权利要求15所述的催化式排气净化器，其中，所述内管包括主体以及从所述主体向内延伸的相对的第一端部和第二端部。
18.根据权利要求17所述的催化式排气净化器，其中，所述第一端部与所述第一侧部相接合，从而在它们之间建立机械锁；所述第二端部和所述第二侧部相接合，从而在它们之间建立机械锁。
19.根据权利要求13所述的催化式排气净化器，其中，所述隔热罩包括位于所述内管和所述中间部之间的管状绝缘层。
20.根据权利要求13所述的催化式排气净化器，其中，所述内管和所述中间部共同限定其间的气隙。
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