EP1366274A1

EP1366274A1 - Exhaust processor with renewable particulate eliminator

Info

Publication number: EP1366274A1
Application number: EP02753702A
Authority: EP
Inventors: Paulo T. Lage
Original assignee: Individual
Current assignee: Individual
Priority date: 2001-02-07
Filing date: 2002-02-07
Publication date: 2003-12-03
Also published as: WO2002077425A1

Abstract

An exhaust processor (10, 210, 310, 310', 410, 410', 510, 610) comprises a housing (36, 236, 336, 436, 536, 636) formed to include an interior region (38, 238, 338, 438, 538, 638) and a first aperture (58, 258, 358, 458, 556, 658), a filter unit (12, 15, 415, 512, 612) adapted to filter particulate material from combustion product passing through the interior region, and a receptacle (32, 232, 332, 432, 532, 632) arranged to position the filter unit in the interio region. The receptacle extends into the first aperture to allow the filter unit to pass through the first aperture during insertion and removal of the filter unit into and out of the interior region.

Description

EXHAUST PROCESSOR WITH RENEWABLE PARTICULATE ELIMINATOR

BACKGROUND The present disclosure relates to an exhaust processor, and particularly to an apparatus for processing combustion product. More particularly, the present disclosure relates to an apparatus for pollution control and noise attenuation.

It is known to provide an exhaust processor to address combustion product generated by an engine, such as a diesel engine. The combustion product typically includes particulate material. To filter the particulate material from the combustion product, the exhaust processor may include a filter, sometimes referred to as a particulate trap. However, if the particulate trap becomes ineffective for filtering particulate material from the combustion product, it may be necessary to scrap the entire exhaust processor just to provide a new particulate trap for the combustion product.

SUMMARY

According to the present disclosure, an exhaust processor comprises a housing formed to include an interior region and a first aperture, a filter unit adapted to filter particulate material from combustion product passing through the interior region, and a receptacle arranged to position the filter unit in the interior region. The receptacle extends into the first aperture to allow the filter unit to pass through the first aperture during insertion and removal of the filter unit into and out of the interior region. This arrangement allows the filter unit to be replaced with another filter unit without having to scrap the entire exhaust processor.

In illustrative embodiments, the housing includes a first end cap, a second end cap, and a shell coupled to the first end cap and the second end cap. The first end cap, the second end cap, and the shell cooperate to define the interior region. The first end cap is formed to include an inlet. The second end cap is formed to include an outlet and the first aperture. In other illustrative embodiments, the shell is formed to include the outlet while the first aperture remains formed in the first end cap. In yet other illustrative embodiments, the second end cap is formed to include the outlet while the shell is formed to include the first aperture.

Additional aspects of the disclosure will become apparent to those skilled in the art upon consideration of the following detailed description of illustrative embodiments exemplifying the best mode as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description particularly refers to the accompanying figures in which: Fig. 1 is a perspective view of a first embodiment of an exhaust processor showing an elongated outer shell, a left-side inlet tube, a right-side outlet tube, and a removable cap attached to a right-side end plate of the exhaust processor and showing a replacement particulate trap unit that can be inserted into a receptacle formed in the exhaust processor after the cap has been removed and after removal of the old particulate trap unit contained in that receptacle;

Fig. 2 is an exploded view of the exhaust processor of Fig. 1 showing placement of two baffles within the interior region of the exhaust processor and showing a flow path of combustion product as it passes from the inlet tube, in sequence, through a catalyzed substrate mounted to communicate with the inlet tube, a central chamber located between the two interior baffles, a left-side chamber located between the left-side end plate and the first baffle, an interior uit containing the diesel particulate trap unit, and a right-side chamber located between the second baffle and the right-side end plate, and finally through an outlet tube coupled to the right-side end plate, and also showing an exploded view of the diesel particulate trap unit including a cylindrical mount mat, a ceramic particulate trap, a metal cylinder, an O- ring seal, and the removable cap;

Fig. 3 is a sectional view taken along line 3-3 of Fig. 1 showing placement of the inlet tube and outlet tube relative to the exhaust processor housing, the placement of the short-length catalyzed substrate in communication with the inlet tube and the central chamber located between the two interior baffles, the location of a short transfer conduit mounted in the first baffle to communicate combustion product from the central chamber to the left-side chamber, the placement of the receptacle containing the diesel particulate trap, the formation of the receptacle to receive a removable exterior cap and a series of flow apertures to allow combustion product exiting the diesel particulate trap to flow into the right-side chamber located between the second baffle and the right-side end plate, and the location of the outlet tube on the right-side end panel;

Fig. 4 is a partial view similar to Fig. 3 showing insertion of a replacement diesel particulate trap into an empty receptacle provided in the exhaust processor after removal of the removable exterior cap from its normal mounting spot on the right-side end plate; Fig. 5 is a perspective view of an exhaust processor in accordance with a second embodiment showing an elongated outer shell, a left-side inlet tube, a top wall outlet tube, and a removable cap attached to a right-side end plate of the exhaust processor and showing a replacement particulate trap unit that can be inserted into a receptacle formed in the exhaust processor after the cap has been removed and after removal of the old particulate trap unit contained in that receptacle;

Fig. 6 is an exploded view of the exhaust processor of Fig. 5 showing placement of two baffles within the interior region of the exhaust processor and showing a flow path of combustion product as it passes from the inlet tube, in sequence, through a catalyzed substrate mounted to communicate with the inlet tube, a right-side chamber located between the second baffle and the right-side end plate into a receptacle configured to receive a diesel particulate trap unit through a series of apertures formed in a right-side end of that receptacle, through a left-side chamber located between the left-side end plate and the first interior baffle, a transfer conduit mounted in the first interior baffle, a central chamber located between the two interior baffles, and finally through an outlet tube coupled to a top wall included in the elongated outer shell, and also showing an exploded view of the diesel particulate trap unit including a cylindrical mount mat, a ceramic particulate trap, a metal cylinder, an O-ring seal, and the removable cap;

Fig. 7 is a sectional view taken along line 7-7 of Fig. 5 showing placement of the inlet tube and outlet tube relative to the exhaust processor housing, the placement of the short-length catalyzed substrate in communication with the inlet tube and the right-side chamber located between the second interior baffle and the right-side end plate, the placement of the receptacle containing the diesel particulate trap, the formation of the receptacle to receive a removable exterior cap and a series of flow apertures to allow combustion product in the right-side chamber to flow into the receptacle, the location of an outlet end of the receptacle in the left-side chamber so that combustion product exiting the diesel particulate trap passes into the left-side chamber, the location of a short transfer conduit mounted in the first baffle to communicate combustion product from the left-side chamber to the central chamber, and the location of the outlet tube on the top wall of the outer shell; and

Fig. 8 is a partial view similar to Fig. 3 showing insertion of a replacement diesel particulate trap unit into an empty receptacle provided in the exhaust processor after removal of the removable exterior cap from its normal mounting spot on the right-side end plate.

Fig. 9 is a perspective view of an alternative embodiment of the first baffle of Fig. 1 showing the first baffle including a perforation field to permit fluid communication between the left-side chamber and the central chamber;

Fig. 10 is a sectional view of a variation of the exhaust processor of Fig. 3 showing the interior of the inlet tube without the catalyzed substrate and the diesel particulate trap unit replaced by a catalyzed soot filter unit configured to provide filtering and oxidizing functions; Fig. 11 is a perspective view of an exhaust processor in accordance with a third embodiment showing an elongated outer shell, a left-side inlet tube, a right-side outlet tube, and a removable cap attached to a side wall of the outer shell of the exhaust processor;

Fig. 12 is an exploded view of the exhaust processor of Fig. 11 showing placement of two baffles perpendicular to one another within the interior region of the exhaust processor, the inlet tube mounted to a left-side end plate, the outlet tube mounted to a right-side end plate, a short transfer conduit mounted to the first baffle, and a receptacle mounted to the second baffle and sized to receive a diesel particulate trap unit; Fig. 13 is a sectional view taken along line 13-13 of Fig. 11, with portions of the second baffle broken away, showing the inlet tube extending through the left-side end plate and the first baffle, the outlet tube extending through the right- side end plate, the catalyzed substrate positioned to lie inside of the inlet tube, the transfer conduit extending through the first baffle, and the diesel particulate trap positioned to lie inside of the receptacle which is mounted to the second baffle,

Fig. 14 is a sectional view taken along line 14-14 of Fig. 13 showing the first and second baffles positioned to lie perpendicular to one another, the interior region subdivided into a Helmholtz, first chamber located between the left-side end plate and the first baffle, a second chamber located between the first baffle and the right-side end plate and between a first side wall and the second baffle, and a third chamber positioned between the first baffle and the right-side end plate and between the second baffle and a second side wall, and further showing the flow path of combustion product through the catalyzed substrate in the inlet tube, the second chamber, the receptacle and the trap unit nested therein, a series of outlet apertures formed in the receptacle, the third chamber, and the outlet tube and a portion of the combustion product flowing through the transfer conduit from the second chamber to the Helmholtz, first chamber;

Fig. 15 is an exploded view of a variation of the exhaust process of Fig. 12 showing the first baffle arranged without a transfer conduit-receiving aperture to prohibit combustion product from flowing between the first chamber and the second chamber; Fig. 16 is a sectional view of the exhaust processor of Fig. 15 showing the flow path of combustion product through the inlet tube and catalyzed substrate nested therein, the second chamber, the diesel particulate trap unit nested in the receptacle, the third chamber, and the outlet tube;

Fig. 17 is a sectional view taken along line 17-17 of Fig. 16 showing the flow path of combustion product through the inlet tube and catalyzed substrate nested therein, the second chamber, the diesel particulate trap unit nested in the receptacle, the outlet flow apertures formed in the receptacle, the third chamber, and the outlet tube;

Fig. 18 is a sectional view of an exhaust processor in accordance with a fourth embodiment showing an elongated outer shell, a left-side inlet tube, an outlet tube mounted to a top wall of the outer shell, a baffle positioned to lie in the interior region of the exhaust processor to divide the interior region into a Helmholtz, left-side chamber filled with basalt wool absorbent material and a right-side chamber, a short transfer conduit mounted to the baffle to interconnect the left- and right-side chambers, an elongated receptacle sized to receive a catalyzed soot filter unit, and a spring configured to hold the filter unit in place when the removable cap is coupled to an end of the receptacle, and further showing the flow path of combustion product through the inlet tube, the receptacle and the filter unit nested therein, an outlet aperture formed in the receptacle, the right-side chamber, and the outlet tube and a portion of the combustion product flowing through the transfer conduit into the absorbent material in the left-side chamber; Fig. 19 is a sectional view similar to Fig. 18 except that the outlet tube is now coupled to the right-side end plate;

Fig. 20 is a sectional view similar to Figs. 18 and 19 except that the outlet tube is now coupled to a side wall of the outer shell;

Fig. 21 is a sectional view of a fifth embodiment exhaust processor showing the exhaust processor arranged to form a flow path through an inlet tube coupled to a left-side end plate and having an annular flange coupled to a metal cylinder which is coupled to a first interior baffle, a catalyzed substrate unit, a central chamber, a diesel particulate trap unit nested in a receptacle coupled to a deep drawn second interior baffle and a right-side end plate, a plurality of circumferentially spaced apertures formed in the receptacle, a right-side chamber, and an outlet tube coupled to the right-side end plate, and further showing a clamp and a ring seal cooperating to couple a removable cap to the right-side end plate to close a trap- receiving opening formed in the receptacle, and an annular stopper unit coupled to a left side of the receptacle and trap unit; Fig. 22 is an enlarged, partially exploded perspective view of the clamp of Fig. 21, the clamp including a split ring, a bolt, a nut, and a bolt mount including a first block coupled to the head of the bolt and a first end of the split ring and a second block coupled to the shank of the bolt and a second end of the split ring; Fig. 23 is an enlarged view of the clamp of Fig. 22, with portions broken away, showing the nut coupled to the bolt, the bolt coupled to the first and second blocks of the bolt mount, the first block coupled to the first end of the split ring, and the second block coupled to the second end of the split ring; Fig. 24 showing an enlarged sectional view of the stopper unit of Fig. 21 showing the stopper unit including a male ring welded to the receptacle and a female ring coupled to the male ring and welded to a metal cylinder of the trap unit; and Fig. 25 is a sectional view of a sixth embodiment showing an exhaust processor arranged to form a flow path in sequence through an inlet tube coupled to a left-side end plate, a catalyzed substrate nested in the inlet tube, an L-shaped ring coupled to the inlet tube and an extension conduit, the extension conduit coupled to a first interior baffle and a second interior baffle, a right-side chamber, a plurality of circumferentially spaced apertures formed in a receptacle coupled to the first and second baffles and a right-side end plate, a diesel particulate trap unit nested in the receptacle, a left-side chamber, a perforation field formed in the first baffle, a central chamber, and an outlet tube coupled to a top wall of a shell of the exhaust processor, and further showing a clamp and a ring seal cooperating to couple a removable cap to the right-side end plate to close a trap-receiving opening formed in the receptacle, and an annular stopper unit coupled to a left side of the receptacle and trap unit.

DETAILED DESCRIPTION OF THE DRAWINGS

An exhaust processor 10 is shown in Fig. 1 and is configured to remove particulate from combustion product generated by an engine and attenuate noise produced by the engine. The engine is, for example, a diesel engine for a vehicle. Exhaust processor 10 is particularly useful with diesel engines for heavy duty trucks.

Exhaust processor 10 includes a filter unit or diesel particulate trap unit 12 and a short-length catalyzed substrate unit 33 arranged in series therewith in a flow path 13 of combustion product inside of exhaust processor 10, as shown, for example, in Figs. 2-3, to filter diesel engine emissions.

Trap unit 12 can be easily replaced by a replacement particulate trap unit 12' after removing a removable cap 14 from a right-side end plate 24, as shown, for example, in Fig. 1. Replacement trap unit 12' is identical to trap unit 12 in structure and function. To replace trap unit 12, trap unit 12 is slid out of a trap unit- receiving receptacle 32, such as a sleeve, to remove trap unit 12 therefrom and replacement trap unit 12' is slid into receptacle 32 to insert replacement trap unit 12' therein, as shown, for example, in Fig. 4. In preferred embodiments, exhaust processor 10 is used in connection with a diesel engine on a heavy-duty truck and trap unit 12 is a diesel particulate trap unit. Exhaust processor 10 includes an elongated outer shell 16, an inlet tube

18, an outlet tube 20, a left-side end cap or plate 22, right-side end cap or plate 24, a first interior baffle 26, a second interior baffle 28, catalyzed substrate unit 33 mounted to inlet tube 18 therein, receptacle 32 sized to receive trap unit 12, and a transfer conduit 34, as shown, for example, in Figs. 2 and 3. Outer shell 16, inlet and outlet tubes 18, 20, left- and right-side end plates 22, 24, cap 14, and first and second baffles 26, 28 cooperate to define a housing 36.

Outer shell 16 and end plates 22, 24 cooperate to define an interior region 38. A left-side transition chamber 40 of interior region 38 is located between left-side end plate 22 and first baffle 26. A central inlet chamber 42 of interior region 38 is located between first and second baffles 26, 28. A right-side outlet chamber 44 is located between second baffle 28 and right-side end plate 24.

Exhaust processor 10 is arranged so that combustion product enters exhaust processor 10 through inlet tube 18 and exits exhaust processor 10 through outlet tube 20. Between inlet tube 18 and outlet tube 20, combustion product flows along flow path 13, in series, through catalyzed substrate unit 33, central chamber 42, transfer conduit 34, left-side chamber 40, receptacle 32 and trap unit 12 nested therein, and right-side chamber 44, as shown, for example, in Figs. 2 and 3.

Outer shell 16 includes a left end 48 and a right end 50, as shown, for example, in Figs. 1 and 3. Outer shell 16 is generally rectangular in cross-section. Each of end plates 22, 24 includes a generally rectangular perimeter edge 52.

Perimeter edge 52 of left-side end plate 22 is fixed to left end 48 and perimeter edge 52 of right-side end plate 24 is fixed to right end 50.

Left-side end plate 22 is spaced apart from right-side end plate 24 and baffles 26, 28. Left-side end plate 22 is formed to include a circular first inlet tube- receiving aperture 54 sized to receive and support an angled left inlet tube portion 55 of inlet tube 18, as shown, for example, in Figs. 2 and 3. Inlet tube 18 extends through and is mounted to aperture 54. Right-side end plate 24 is spaced apart from left-side end plate 22 and baffles 26, 28. Right-side end plate 24 is formed to include a circular outlet aperture or outlet tube-receiving aperture 56 and a circular first receptacle-receiving aperture 58. First receptacle-receiving aperture 58 is larger in diameter than and is positioned to lie above outlet-receiving aperture 56.

Outlet tube-receiving aperture 56 is sized to receive and support outlet tube 20 to support outlet tube 20. Outlet tube 20 extends through and is mounted to outlet tube-receiving aperture 56 to conduct combustion product from right-side chamber 44 outside of exhaust processor 10. First receptacle-receiving aperture 58 is sized to receive and support a right end 60 of receptacle 32. Right end 60 of receptacle 32 extends through and is mounted to first receptacle-receiving aperture 58.

First baffle 26 is spaced apart from end plates 22, 24 and second baffle 28. First baffle 26 includes a generally rectangular perimeter edge 62 and is formed to include a second inlet tube-receiving aperture 64, a second receptacle-receiving aperture 66, and transfer conduit-receiving aperture 68, as shown, for example, in Figs. 2-4. Perimeter edge 62 is sized to mate with an inner surface 70 of outer shell 16 therearound to form a gas-tight seal between first baffle 26 and outer shell 16.

Second inlet tube-receiving aperture 64 is sized to receive and support a right inlet tube portion 72 of inlet tube 18. Right inlet tube portion 72 extends through and is mounted to second inlet tube-receiving aperture 64. Second inlet tube- receiving aperture 64 is larger in diameter than first inlet tube-receiving aperture 54.

Second receptacle-receiving aperture 66 is sized to receive and support a left end 74 of receptacle 32. Left end 74 of receptacle 32 extends through and is mounted to second receptacle-receiving aperture 66. Second receptacle-receiving 66 aperture is positioned to lie above second inlet tube-receiving aperture 64.

Transfer conduit-receiving aperture 68 is sized to receive and support transfer conduit 34. Transfer conduit 34 extends through and is mounted to transfer conduit-receiving aperture 68 to conduct combustion product from central chamber 42 to left-side chamber 40.

Second baffle 28 is spaced apart from end plates 22, 24 and first baffle 26. Second baffle 28 includes a generally rectangular perimeter edge 76 and is formed to include a third receptacle-receiving aperture 78, as shown, for example, in Figs. 2-4. Perimeter edge 76 is sized to mate with inner surface 70 of outer shell 16 therearound to form a gas-tight seal between second baffle 28 and outer shell 16.

Third receptacle-receiving aperture 78 is sized to receive and support a middle portion 80 of receptacle 32, as shown, for example, in Figs. 3 and 4. Middle portion 80 of receptacle 32 extends through and is mounted to third receptacle- receiving aperture 78.

First, second, and third receptacle-receiving apertures 58, 66, 78 are substantially equal in diameter. In addition, apertures 58, 66, 78 are centered on a receptacle central axis 82, as shown in Figs. 3 and 4. A longitudinal axis 83 of trap unit 12 is coextensive with central axis 82.

Inlet tube 18 includes an inlet 84 of left portion 55, an outlet 86 of right portion 72, and a diffusion portion 87 interconnecting left and right portions 55, 72, as shown, for example, in Figs. 2 and 3. Inlet 84 is positioned to lie outside of interior region 38 and outlet 86 is positioned to lie inside of central chamber 42 so that inlet tube 18 extends from outside of interior region 38 through left-side chamber 40 to central chamber 42. Right portion 72 is larger in diameter than left portion 55. Catalyzed substrate unit 33 is centered on an inlet tube axis 46 inside of right portion 72. Inlet tube axis 46 is positioned to lie in parallel relation to receptacle axis 82. Combustion product enters exhaust processor 10 through inlet 84 and flows through left portion 55, catalyzed substrate unit 33, and right portion 72 and then exits inlet tube 18 through outlet 86 into central chamber 42, as shown, for example, in Fig. 3.

Transfer conduit 34 includes an inlet 91 and an outlet 92, as shown, for example, in Figs. 3 and 4. Inlet 91 is positioned to lie in central chamber 42 and outlet 92 is positioned to lie in left-side chamber 40 so that transfer conduit 34 conducts combustion product from central chamber 42 to left-side chamber 40.

Receptacle 32 is sized to receive and support trap unit 12 inside of receptacle 32 so that trap unit 12 is insertable in and removable from receptacle 32. Receptacle 32 is cylinder-shaped and extends from left-side chamber 40 through central chamber 42 and right-side chamber 44 to the outside of interior region 38. Receptacle 32 extends through and is mounted to first and second baffles 26, 28 and right-side end plate 24 as described above and shown, for example, in Figs. 3 and 4. Receptacle 32 includes right end 60, left end 74, middle portion 80, an inlet 93, a plurality of circular outlet flow apertures 94, an outer surface 95, an inner surface 96, and an end flange 97 and is formed to include an opening 98 at right end 60 to permit insertion and removal of trap unit 12 into and out of receptacle 32, as shown, for example, in Figs. 3 and 4. Trap unit 12 is positioned to lie inside of receptacle 32, as shown, for example, in Figs. 3 and 4, so that inner surface 96 contacts a sleeve or metal cylinder 99 of trap unit 12 circumferentially therearound. Stopper unit 122 is welded to metal cylinder 99 and left end 74 of receptacle 32. Receptacle 32, trap unit 12, and cap 14 cooperate to conduct combustion product from left-side chamber 40 to right-side chamber 44. Inlet 93 is positioned to lie in left-side chamber 40 so that combustion product flows from leftside chamber 40 through inlet 93 to an inlet end 101 of trap unit 12. Outlet flow apertures 94 extend circumferentially around receptacle 32 in an evenly spaced manner and are positioned to lie in right-side chamber 44 between right-side end plate 24 and an outlet end 100 of trap unit 12 so that cleaned combustion product exiting outlet end 100 of trap unit 12 flows from inside of receptacle 32 radially outwardly through outlet flow apertures 94 into right-side chamber 44.

End flange 97 is appended to and extends radially outwardly from right end 60 outside of interior region 38, as shown, for example, in Fig. 3. Cap 14 is coupled to end flange 97 to cover opening 98 to prevent combustion product from escaping from interior region 38 through opening 98 during operation of exhaust processor 10. A seal 114, such as an O-ring seal, is sandwiched between cap 14 and end flange 97. Thus, combustion product in left-side chamber 40 enters receptacle 32 through inlet 93 and flows through trap unit 12 for removal of particulate material therefrom and exits receptacle 32 through outlet flow apertures 94 into right-side chamber 44.

Outlet tube 20 includes an inlet 88 and an outlet 90, as shown, for example, in Fig. 3. Inlet 88 is positioned to lie in right-side chamber 44 and outlet 90 is positioned to lie outside of interior region 38. Combustion product enters outlet tube 20 through inlet 88 and exits outlet tube 20 through outlet 90.

Trap unit 12 is positioned to lie in receptacle 32 so that combustion product passes through trap unit 12 as it flows from left-side chamber 40 through receptacle 32 to right-side chamber 44. In this way, particulate material is filtered from combustion product by trap unit 12. Trap unit 12 is held in place in receptacle 32 by frictional engagement between inner surface 96 of receptacle 32 and metal cylinder 99. Trap unit 12 is positioned to lie in coaxial relation with receptacle 32 relative to receptacle axis 82 and is positioned to lie between outlet flow apertures 94 and inlet 93 of receptacle 32.

Trap unit 12 includes metal cylinder 99, an annular mat mount 110, and a cylinder-shaped ceramic particulate trap 112. Metal cylinder 99 contacts inner surface 96 of receptacle 32 and is sized to receive mat mount 110 and particulate trap 112. Mat mount 110 is nested within metal cylinder 99 and particulate trap 112 is nested within mat mount 110 such that mat mount 110 is sandwiched between metal cylinder 99 and particulate trap 112 is spaced apart radially from metal cylinder 99. Metal cylinder 99, mat mount 110, and particulate trap 112 are positioned to lie in coaxial relation with receptacle 32. Trap unit 12 is easily replaced by replacement trap unit 12', as shown, for example, in Fig. 4. To replace trap unit 12, cap 14 is removed from end flange 97 to open opening 98 and expose trap unit 12 inside of receptacle 32. Trap unit 12 is removed from receptacle 32 by sliding trap unit in direction 116 along receptacle axis 82 causing metal cylinder 99 to slide against inner surface 96 of receptacle 32. Replacement trap unit 12' is then inserted in empty receptacle 32 by sliding replacement trap unit 12' in direction 118 along receptacle axis 82 causing metal cylinder 99 to slide against inner surface 96 of receptacle 32. Once replacement trap unit 12' is located in place in receptacle 32, cap 14 is replaced back over end flange 97 to close opening 98 and conceal replacement trap unit 12' inside of receptacle 32. Catalyzed substrate unit 33 includes a catalyzed substrate 30 and an annular mat mount 31. Mat mount 31 is made of an intumescent material and is configured to support catalyzed substrate 30 in inlet tube 18.

Exhaust processor 10 includes an annular seal or stopper unit 122, as shown, for example, in Fig. 2. Stopper unit 122 is discussed below in detail as part of an exhaust processor 510, as shown, for example, in Figs. 21 and 24, wherein Fig. 24 shows an enlarged view of stopper unit 122. In preferred embodiments, exhaust processor 10 includes a first interior baffle 26' in place of first interior baffle 26, as shown, for example, in Fig. 9. Baffle 26' is similar to baffle 26 except as otherwise noted so that like reference numerals refer to like structures. Baffle 26' includes a perforation field 120 to permit combustion product to flow from central chamber 42 through perforation field 120 to left-side chamber 40 in lieu of transfer conduit-receiving aperture 68 and transfer conduit 34.

In other preferred embodiments, trap unit 12 is replaced by another filter unit or catalyzed soot filter unit 15 and catalyzed substrate unit 33 is omitted from exhaust processor 10, as shown, for example, in Fig. 10. Catalyzed soot filter unit 15 is configured to remove diesel particulate material, such as NO_x and HC, from combustion product. Catalyzed soot filter unit 15 is similar in construction to trap unit 12 so that like reference numerals refer to like structures. Catalyzed soot filter unit 15 includes a catalyzed soot filter 113 configured to provide filtering and oxidizing functions.

In other preferred embodiments, end flange 97 is omitted and cap 14 and O-ring 114 are replaced with a cap 514, a clamp 580, and a ring seal 581 as described in connection with exhaust processor 510 discussed below and as shown, for example, in Figs. 21-24. In other preferred embodiments, second baffle 28 is replaced with a second baffle 528 having an elongated perimeter edge 576 and a bowl-shaped aperture 556, as discussed in connection with exhaust processor 510 and shown, for example, in Fig. 21.

A second exhaust processor 210 configured to remove particulate from combustion product generated by a diesel engine and attenuate noise produced by the diesel engine is shown in Figs. 5-8. Exhaust processor 210 includes certain structures described above so that like reference numerals refer to like structures.

Exhaust processor 210 includes short-length catalyzed substrate unit 33 and diesel particulate trap unit 12 arranged in series therewith in a flow path 213 of combustion product inside of exhaust processor 210, as shown, for example, in Figs. 6 and 7, to filter diesel engine emissions. Exhaust processor 210 is aπanged so that combustion product exits exhaust processor 210 through an outlet tube 220 attached to an outlet aperture or outlet tube-receiving aperture 256 formed in top wall 217 of an elongated outer shell 218.

Similar to exhaust processor 10, trap unit 12 can be easily replaced by a replacement particulate trap unit 12' after removing removable cap 14 from a right- side end plate 224, as shown, for example, in Figs. 5 and 8. Exhaust processor 210 can be used in connection with a diesel engine on a heavy-duty truck.

Exhaust processor 210 includes outer shell 216, an inlet tube 218, outlet tube 220, a left-side end cap or plate 222, a right-side end cap or plate 224, a first interior baffle 226, a second interior baffle 228, catalyzed substrate unit 33 mounted to inlet tube 218 therein, a receptacle 232, such as a sleeve, sized to receive trap unit 12, and transfer conduit 34, as shown, for example, in Figs. 6 and 7. Outer shell 216, inlet and outlet tubes 218, 220, left- and right-side end plates 222, 224, cap 14, and first and second baffles 226, 228 cooperate to define a housing 236.

Outer shell 216 and end plates 222, 224 cooperate to define an interior region 238. A left-side transition chamber 240 of interior region 238 is located between left-side end plate 222 and first baffle 226. A central outlet chamber 242 of interior region 238 is located between first and second baffles 226, 228. A right-side inlet chamber 244 is located between second baffle 228 and right-side end plate 224.

Exhaust processor 210 is arranged so that combustion product enters exhaust processor 210 through inlet tube 218 and exits exhaust processor 210 through outlet tube 220 attached to top wall 217 of outer shell 216. Between inlet tube 218 and outlet tube 220, combustion product flows along flow path 213, in series, through catalyzed substrate unit 33, right-side chamber 244, receptacle 232 and trap unit 12 nested therein, left-side chamber 240, transfer conduit 34, and central chamber 242, as shown, for example, in Figs. 6 and 7.

Outer shell 216 includes a left end 248, a right end 250, and top wall 217, as shown, for example, in Figs. 5 and 7. Outer shell 216 is generally rectangular in cross-section. Each of end plates 222, 224 includes a generally rectangular perimeter edge 252. Perimeter edge 252 of left-side end plate 222 is fixed to left end 248 and perimeter edge 252 of right-side end plate 224 is fixed to right end 250.

Top wall 217 extends from left end 248 and right end 250. Top wall 217 is formed to include a circular outlet tube-receiving aperture 256 sized to receive and support outlet tube 220. Outlet tube 220 extends through and is mounted to outlet tube-receiving aperture 256 to conduct combustion product from central chamber 242 outside of exhaust processor 210.

Left-side end plate 222 is spaced apart from right-side end plate 224 and baffles 226, 228. Left-side end plate 222 is formed to include a circular first inlet tube-receiving aperture 254 sized to receive and support an angled left inlet tube portion 255 of inlet tube 218, as shown, for example, in Figs. 6 and 7. Inlet tube 218 extends through and is mounted to first inlet tube-receiving aperture 254.

Right-side end plate 224 is spaced apart from left-side end plate 222 and baffles 226, 228. Right-side end plate 224 is formed to include a circular first receptacle-receiving aperture 258. First receptacle-receiving aperture 258 is sized to receive and support a right end 260 of receptacle 232. Right end 260 of receptacle 232 extends through and is mounted to first receptacle-receiving aperture 258.

First baffle 226 is spaced apart from end plates 222, 224 and second baffle 228. First baffle 226 includes a generally rectangular perimeter edge 262 and is formed to include a second inlet tube-receiving aperture 264, a second receptacle- receiving aperture 266, and transfer conduit-receiving aperture 268, as shown, for example, in Figs. 6-8. Perimeter edge 262 is sized to mate with an inner surface 270 of outer shell 216 therearound to form a gas-tight seal between first baffle 226 and outer shell 216.

Second inlet tube-receiving aperture 264 is sized to receive and support a right inlet tube portion 272 of inlet tube 218. Right inlet tube portion 272 extends through and is mounted to second inlet tube-receiving aperture 264. Second inlet tube-receiving aperture 264 is larger in diameter than first inlet tube-receiving aperture 254.

Second receptacle-receiving aperture 266 is sized to receive and support a left end 274 of receptacle 232. Left end 274 of receptacle 232 extends through and is mounted to second receptacle-receiving aperture 266. Second receptacle-receiving 266 aperture is positioned to lie above second inlet tube- receiving aperture 264.

Transfer conduit-receiving aperture 268 is sized to receive and support transfer conduit 34. Transfer conduit 34 extends through and is mounted to transfer conduit-receiving aperture 268 to conduct combustion product from left-side chamber 240 to central chamber 240.

Second baffle 228 is spaced apart from end plates 222, 224 and first baffle 226. Second baffle 228 includes a generally rectangular perimeter edge 276 and is formed to include a third receptacle-receiving aperture 278 and a third inlet tube-receiving aperture 279, as shown, for example, in Figs. 6 and 7. Perimeter edge 276 is sized to mate with inner surface 270 of outer shell 216 therearound to form a gas-tight seal between second baffle 228 and outer shell 216. Third receptacle- receiving aperture 278 is positioned to lie above third inlet tube-receiving aperture 279.

Third receptacle-receiving aperture 278 is sized to receive and support a middle portion 280 of receptacle 232, as shown, for example, in Figs. 7 and 8. Middle portion 280 of receptacle 232 extends through and is mounted to third receptacle-receiving aperture 278. Third inlet tube-receiving aperture 279 is sized to receive and support right inlet tube portion 272 of inlet tube 218. Right inlet tube portion 272 extends through and is mounted to third inlet tube-receiving aperture 279. Third inlet tube- receiving aperture 279 is substantially equal in diameter to second inlet tube-receiving aperture 264 and larger in diameter than first inlet tube-receiving aperture 254. First, second, and third receptacle-receiving apertures 258, 266, 278 are substantially equal in diameter. In addition, apertures 258, 266, 278 are centered on a central receptacle axis 282, as shown in Figs. 7 and 8. A longitudinal axis 283 of trap unit 12 is coextensive with central axis 282.

Inlet tube 218 includes an inlet 284 of left portion 255, an outlet 286 of right portion 272, and a diffusion portion 287 interconnecting left and right portions 255, 272, as shown, for example, in Figs. 6 and 7. Inlet 284 is positioned to lie outside of interior region 238 and outlet 286 is positioned to lie inside of right-side chamber 244 so that inlet tube 218 extends from outside of interior region 238 through left-side chamber 240 and central chamber 242 to right-side chamber 244. Right portion 272 is larger in diameter than left portion 255. Catalyzed substrate unit 33 is centered on an inlet tube axis 246 inside of right portion 272. Inlet tube axis 246 is positioned to lie in parallel relation to receptacle axis 282. Thus, combustion product enters exhaust processor 210 through inlet 284 and flows through left portion 255, catalyzed substrate unit 33, and right portion 272 and then exits inlet tube 218 through outlet 286 into right-side chamber 244, as shown, for example, in Fig. 7. Transfer conduit 34 includes inlet 91 and outlet 92, as shown, for example, in Figs. 7 and 8. Inlet 91 is positioned to lie in left-side chamber 240 and outlet 92 is positioned to lie in central chamber 242 so that transfer conduit 34 conducts combustion product from left-side chamber 240 to central chamber 242.

Receptacle 232 is sized to receive and support trap unit 12 inside of receptacle 232 so that trap unit 12 is insertable in and removable from receptacle 232. Receptacle 232 is cylinder-shaped and extends from left-side chamber 240 through central chamber 242 and right-side chamber 244 to the outside of interior region 238. Receptacle 232 extends through and is mounted to first and second baffles 226, 228 and right-side end plate 224 as described above and shown, for example, in Figs. 7 and 8. Receptacle 232 includes right end 260, left end 274, middle portion

280, an outlet 293, a plurality of circular inlet flow apertures 294, an outer surface 295, an inner surface 296, and an end flange 297 and is formed to include an opening 298 at right end 260 to permit insertion and removal of trap unit 12 into and out of receptacle 232, as shown, for example, in Figs. 7 and 8. Trap unit 12 is positioned to lie inside of receptacle 232, as shown, for example, in Figs. 7 and 8, so that inner surface 296 contacts metal cylinder 99 of trap unit 12 circumferentially therearound. Stopper unit 122 is welded to left end 274 of receptacle 232 and metal cylinder 99.

Receptacle 232, trap unit 12, and cap 14 cooperate to conduct combustion product from right-side chamber 244 to left-side chamber 240. Inlet flow apertures 294 extend circumferentially around receptacle 232 in an evenly spaced manner and are positioned to lie in right-side chamber 244 between right-side end plate 224 and inlet end 101 of trap unit 12 so that combustion product flows from right-side chamber 244 radially inwardly through inlet flow apertures 294 to inlet end 101 of trap unit 12 inside of receptacle 232. Outlet 293 is positioned to lie in left-side chamber 240 so that combustion product exiting outlet end 100 of trap unit 12 flows through outlet 293 into left-side chamber 240. End flange 297 is appended to and extends radially outwardly from right end 260 outside of interior region 238, as shown, for example, in Fig. 7. Cap 14 is coupled to end flange 297 to cover opening 298 to prevent combustion product from escaping from interior region 238 through opening 298 during operation of exhaust processor 210. Seal 114 is sandwiched between cap 14 and end flange 297. Thus, combustion product in right-side chamber 244 enters receptacle 232 through inlet flow apertures 294 and flows through trap unit 12 for removal of particulate material therefrom and exits receptacle 232 through outlet 293 into left-side chamber 240. Outlet tube 220 includes an inlet (not shown) and an outlet 290, as shown, for example, in Fig. 6. The inlet of outlet tube 220 is positioned to lie in central chamber 242 and outlet 290 is positioned to lie outside of interior region 38. Combustion product exiting exhaust processor 210 flows from central chamber 242 through the inlet of outlet tube 220 and outlet 290. Trap unit 12 is positioned to lie in receptacle 232 so that combustion product passes through trap unit 12 as it flows from right-side chamber 244 through receptacle 232 to left-side chamber 240. In this way, particulate material is filtered from combustion product by trap unit 12. Trap unit 12 is held in place in receptacle 232 by frictional engagement between inner surface 296 of receptacle 232 and metal cylinder 99. Trap unit 12, including metal cylinder 99, mat mount 110, and particulate trap 112, is positioned to lie in coaxial relation with receptacle 232 relative to receptacle axis 282 and is positioned to lie between outlet 293 and inlet flow apertures 294 of receptacle 232.

Trap unit 12 of exhaust processor 210 is easily replaced by replacement trap unit 12', as shown, for example, in Fig. 8. To replace trap unit 12, cap 14 is removed from end flange 297 to open opening 298 and expose trap unit 12 inside of receptacle 232. Trap unit 12 is removed from receptacle 232 by sliding trap unit 12 in direction 116 along receptacle axis 282 causing metal cylinder 99 to slide against inner surface 296 of receptacle 232. Replacement trap unit 12' is then inserted in empty receptacle 232 by sliding replacement trap unit 12' in direction 118 along receptacle axis 282 causing metal cylinder 99 to slide against inner surface 296 of receptacle 232. Once replacement trap unit 12' is located in place in receptacle 232, cap 14 is replaced back over end flange 297 to close opening 298 and conceal replacement trap unit 12' inside of receptacle 232.

In other preferred embodiments, trap unit 12 is replaced by catalyzed soot filter unit 15 and catalyzed substrate unit 33 is omitted from exhaust processor 210.

In other preferred embodiments, end flange 297 is omitted and cap 14 and O-ring 114 are replaced with a cap 514, a clamp 580, and a ring seal 581 as described in connection with exhaust processor 510 discussed below and as shown, for example, in Figs. 21-24. In other preferred embodiments, second baffle 228 is replaced with second baffle 528 having elongated perimeter edge 576 and bowl- shaped aperture 556, as discussed in connection with exhaust processor 510 and shown, for example, in Fig. 21.

In other preferred embodiments, inlet tube 218 is replaced by a conduit coupled to and extending through inlet tube-receiving apertures 264, 279 and an inlet tube similar to an inlet tube 518 having an annular flange 554, as described in connection with exhaust processor 510 and shown, for example, in Fig. 21, such that annular flange 554 is coupled to the conduit. In other prefeπed embodiments, inlet tube 218 is replaced by an arrangement similar to what is described in connection with an exhaust processor 610 and shown in Fig. 24, so that the arrangement includes components similar to an inlet tube 618, an L-shaped ring 623, and extension conduit 619 coupled together in a manner similar to what is shown.

A third exhaust processor 310 configured to remove particulate from combustion product generated by a diesel engine and attenuate noise produced by the diesel engine is shown in Figs. 11-14. Exhaust processor 310 includes certain structures described above so that like reference numerals refer to like structures. Exhaust processor 310 includes diesel particulate trap unit 12, removable cap 14, transfer conduit 34, an outer shell 316, an inlet tube 318, an outlet tube 320, a left-side end cap or plate 322, a right-side end cap or plate 324, a first interior baffle 326, a second interior baffle 328, catalyzed substrate unit 33 mounted to inlet tube 318 therein, and a receptacle 332, such as a sleeve, sized to receive trap unit 12, as shown, for example, in Figs. 12-14. Outer shell 316, inlet and outlet tubes 318, 320, left- and right-side end plates 322, 324, cap 14, and first and second baffles 326, 328 cooperate to define a housing 336.

Catalyzed substrate unit 33 and diesel particulate trap unit 12 are arranged in series with one another in a flow path 313 of combustion product inside of exhaust processor 310, as shown, for example, in Figs. 13 and 14, to filter diesel engine emissions. Exhaust processor 310 is arranged so that combustion product enters exhaust processor 310 through inlet tube 318 and exits exhaust processor 310 through outlet tube 320 attached to an outlet aperture or outlet tube-receiving aperture 356 formed in right-side end plate 324. Similar to exhaust processor 10, trap unit 12 can be easily replaced by replacement particulate trap unit 12' after removing removable cap 14 from outlet tube-receiving aperture 356.

Outer shell 316 and end plates 322, 324 cooperate to define an interior region 338. A Helmholtz or first chamber 340 of interior region 338 is located between left-side end plate 322 and first baffle 326. A second chamber 342 of interior region 338 is located between first baffle 326 and right-side end plate 324 and between second baffle 328 and a first side wall 343. A third chamber 344 is located between first baffle 326 and right-side end plate 324 and between second baffle 328 and a second side wall 345.

Between inlet tube 318 and outlet tube 320, combustion product flows along flow path 313, in series, through catalyzed substrate unit 33, second chamber 342, receptacle 332 and trap unit 12 nested therein, and third chamber 344, as shown, for example, in Figs. 13 and 14. Combustion product can also flow from second chamber 342 to first chamber 340 through transfer conduit 34 which is coupled to a transfer conduit-receiving aperture 368 formed in first baffle 326. Outer shell 316 includes a left end 348, a right end 350, and first and second side walls 343, 345, as shown, for example, in Figs. 13 and 14. Outer shell 316 is generally rectangular in cross-section. Side walls 343, 345 extend from left end 348 to right end 350. Each of end plates 322, 324 includes a generally rectangular perimeter edge 352. Perimeter edge 352 of left-side end plate 322 is fixed to left end 348 and perimeter edge 352 of right-side end plate 324 is fixed to right end 350. Second side wall 345 is formed to include a first receptacle-receiving aperture 358. First receptacle-receiving aperture 358 is sized to receive and support receptacle 332, as shown, for example, in Fig. 14. Receptacle 332 extends through and is mounted to first receptacle-receiving aperture 358. Left-side end plate 322 is spaced apart from right-side end plate 324 and baffles 326, 328. Left-side end plate 322 is formed to include a circular first inlet tube-receiving aperture 354 sized to receive and support an angled left inlet tube portion 355 of inlet tube 318, as shown, for example, in Fig. 13. Inlet tube 318 extends through and is mounted to first inlet tube-receiving aperture 354. Right-side end plate 324 is spaced apart from left-side end plate 322 and first 326 but contacts second baffle 328. Right-side end plate 324 is formed to include outlet tube-receiving aperture 356.

First baffle 326 is positioned to lie in spaced apart, parallel relation to end plates 322, 324. First baffle 326 includes a generally rectangular perimeter edge 362 and is formed to include a second inlet tube-receiving aperture 364 and transfer conduit-receiving aperture 368, as shown, for example, in Figs. 12-14. Perimeter edge 362 is sized to mate with an inner surface 370 of outer shell 316 therearound to form a gas-tight seal between first baffle 326 and outer shell 316.

Second inlet tube-receiving aperture 364 is sized to receive and support a right inlet tube portion 372 of inlet tube 318. Right inlet tube portion 372 extends through and is mounted to second inlet tube-receiving aperture 364. Second inlet tube-receiving aperture 364 is larger in diameter than first inlet tube-receiving aperture 354.

Transfer conduit-receiving aperture 368 is sized to receive and support transfer conduit 34. Transfer conduit 34 extends through and is mounted to transfer conduit-receiving aperture 368 to conduct combustion product between second chamber 242 and first chamber 340, as shown, for example, in Figs. 13 and 14.

Second baffle 328 is positioned to lie in perpendicular relation to first baffle 326 and right-side end plate 324. In this way, second baffle 328 and first baffle 326 cooperate to form a T-shape. Similarly, second baffle 328 and right-side end plate 324 cooperate to form a T-shape. Second baffle 328 is positioned to lie in parallel relation to first and second side walls 343, 345. Second baffle 328 includes a generally rectangular perimeter edge 376 and is formed to include a second receptacle-receiving aperture 366, as shown, for example, in Figs. 12 and 14. Perimeter edge 376 contacts first baffle 326 and is sized to mate with inner surface 270 of outer shell 316 therearound to form a gas-tight seal between second baffle 328 and outer shell 316.

Second receptacle-receiving aperture 366 is sized to receive and support receptacle 332, as shown, for example, in Fig. 14. Receptacle 332 extends through and is mounted to second receptacle-receiving aperture 366.

First and second receptacle-receiving apertures 358, 366 are substantially equal in diameter. Apertures 358, 366 are centered on a central receptacle axis 382, as shown in Fig. 14. A longitudinal axis 383 of trap unit 12 is coextensive with central axis 382. Second side 345 and second baffle 328, along with any other necessary means, cooperate to support receptacle 332 as receptacle 332 extends through apertures 358, 366. Inlet tube 318 includes an inlet 384 of left portion 355, an outlet 386 of right portion 372, and a diffusion portion 387 interconnecting left and right portions 355, 372, as shown, for example, in Figs. 12-14. Inlet 384 is positioned to lie outside of interior region 338 and outlet 386 is positioned to lie inside of second chamber 342 so that inlet tube 318 extends from outside of interior region 338 through left-side end plate 322, first chamber 340, and first baffle 326 to second chamber 342. Catalyzed substrate unit 33 is centered on an inlet tube axis 346 inside of right portion 372. Thus, combustion product enters exhaust processor 310 through inlet 384 and flows through left portion 355, catalyzed substrate unit 33, and right portion 372 and then exits inlet tube 318 through outlet 386 into second chamber 342, as shown, for example, in Fig. 14.

Receptacle 332 is sized to receive and support trap unit 12 inside of receptacle 332 so that trap unit 12 is insertable in and removable from receptacle 332. Receptacle 332 is cylinder-shaped and extends from second chamber 342 through second receptacle-receiving aperture 366 of second baffle 328, third chamber 344, and first receptacle-receiving aperture 358 of second side wall 345 to the outside of interior region 338, as shown, for example, in Fig. 14. Receptacle 332 includes an inlet 393, a plurality of circular outlet flow apertures 394, an outer surface 395, an inner surface 396, and an end flange 397 and is formed to include an opening 398 to permit insertion and removal of trap unit 12 into and out of receptacle 332, as shown, for example, in Figs. 12-14. Inlet 393 is positioned to lie in second chamber 342. Outlet flow apertures 394 extend circumferentially around receptacle 332 in an evenly spaced manner and are positioned to lie in third chamber 344. Stopper unit 122 is welded to metal cylinder 99 and receptacle 332 adjacent to inlet 393.

Trap unit 12 is positioned to lie inside of receptacle 332 such that inner surface 396 contacts metal cylinder 99 of trap unit 12 circumferentially therearound. Trap unit 12, including metal cylinder 99, mat mount 110, and particulate trap 112, is positioned to lie in coaxial relation with receptacle 232 relative to a receptacle axis 382 and is positioned to lie between inlet 393 and outlet flow apertures 394. Receptacle axis 382 is positioned to lie in perpendicular relation to inlet tube axis 346.

Receptacle 332, trap unit 12, and cap 14 cooperate to conduct combustion product from second chamber 342 to third chamber 344, as show, for example, in Fig. 14. Combustion product flows from second chamber 342 through inlet 393, particulate trap 112 of trap unit 12, and radially outwardly through outlet apertures 394 to third chamber.

End flange 397 is appended to and extends radially outwardly from an end of receptacle 332 outside of interior region 338, as shown, for example, in Fig. 14. Cap 14 is coupled to end flange 397 to cover opening 398 to prevent combustion product from escaping from interior region 338 through opening 398 during operation of exhaust processor 310. Seal 114 is sandwiched between cap 14 and end flange 397.

Outlet tube 320 includes an inlet 388 and an outlet 390, as shown, for example, in Figs. 13 and 14. Inlet 388 is positioned to lie in third chamber 344 and outlet 390 is positioned to lie outside of interior region 338. In an alternative embodiment of exhaust processor 310, exhaust processor 310' eliminates transfer conduit 34 and transfer conduit-receiving aperture 368 of first baffle 326, as shown, for example, in Figs. 15-17. In this way, first chamber 340 is not in fluid communication with second chamber 342, thereby prohibiting combustion product from flowing from second chamber 342 to first chamber 340. Thus, combustion product flows along a flow path 313' through inlet tube 318 coupled to left-side end cap 322 and first baffle 326 and catalyzed substrate unit 33 nested in inlet tube 318 to second chamber 342. Combustion product then flows through inlet 393 of receptacle 332, trap unit 12, and outlet apertures 394 of receptacle 332 to third chamber 344. Combustion product exits exhaust processor 310 through outlet tube 320 coupled to right-side end cap 324.

In preferred embodiments of exhaust processors 310, 310', trap unit 12 is replaced by catalyzed soot filter unit 15 and catalyzed substrate unit 33 is omitted from respective exhaust processor 310, 310'.

In other preferred embodiments of exhaust processors 310, 310', cap 14 and O-ring 114 are replaced with a cap 514, end flange 397 is omitted and a clamp 580, and a ring seal 581 as described in connection with exhaust processor 510 discussed below and as shown, for example, in Figs. 21-24.

A fourth exhaust processor 410 configured to remove particulate from combustion product generated by a diesel engine and attenuate noise produced by the diesel engine is shown in Fig. 18. Exhaust processor 410 includes certain structures described above so that like reference numerals refer to like structures. Exhaust processor 410 includes a filter unit or catalyzed soot filter unit

415, removable cap 14, an outer shell 416 including a top wall 417 formed to include an outlet tube-receiving aperture 456, an inlet tube 418, an outlet tube 420, a left-side end cap or plate 422 coupled to outer shell 416 and formed to include an inlet tube- receiving aperture 454, a right-side end cap or plate 424 formed to include a first receptacle-receiving aperture 458, an interior baffle 426 coupled to outer shell 416 and formed to include a second receptacle-receiving aperture 466 and a transfer conduit-receiving aperture 468, a receptacle 432, such as a sleeve, sized to receive filter unit 415, a transfer conduit 434, basalt wool sound absorbent material 435, and a spring 437, as shown, for example, in Fig. 18. Outer shell 416, inlet and outlet tubes 418, 420, left- and right-side end plates 422, 424, cap 14, and baffle 426 cooperate to define a housing 436. Filter unit 415 includes a sleeve or metal cylinder 427, a mat mount 428, and a catalyzed soot filter 429. Outer shell 416 and end plates 422, 424 cooperate to define an interior region 438. A Helmholtz or left-side chamber 440 of interior region 438 is located between left-side end plate 422 and baffle 426. A right-side chamber 442 of interior region 438 is located between baffle 426 and right-side end plate 324. Inlet tube 418 is mounted to and extends through inlet tube-receiving aperture 454 into left-side chamber 440. Absorbent material is positioned to lie in left-side chamber 440. Transfer conduit 434 is mounted to and extends through transfer conduit-receiving aperture 468 to conduct combustion product between leftside chamber 440 and right-side chamber 442. Receptacle 432 is mounted to and extends through first and second receptacle-receiving apertures 458, 466. Receptacle 432 extends from left-side chamber 440 through right-side chamber 442 to the outside of interior region 438. Inlet tube 418 is coupled to a left end 474 of receptacle 432 in left-side chamber 440. Cap 14 is coupled to an end flange 497 at a right end 460 of receptacle 432. Receptacle 432 is formed to include an outlet aperture 494 positioned to lie in right- side chamber 442 between filter unit 415 and right-side end plate 424. Filter unit 415 is positioned to lie inside of receptacle 432 toward left end 474 between outlet aperture 494 and inlet tube 418.

Apertures 458, 466 are centered on a central receptacle axis 482, as shown in Fig. 18. A longitudinal axis 483 of filter unit 415 is coextensive with central axis 482.

Spring 437 is positioned to lie inside of receptacle 432 between catalyzed soot filter 429 and cap 14. Spring 437 is configured to maintain filter unit 415 in place inside of receptacle 432 when cap 14 is positioned on receptacle 432 during operation of exhaust processor 410.

Exhaust processor 410 is arranged so that combustion product enters exhaust processor 410 through inlet tube 418 and exits exhaust processor 410 through outlet tube 420 which is attached to outlet tube-receiving aperture 456 formed in top wall 417. Combustion product flows along flow path 413 through inlet tube 418, filter unit 415 nested in receptacle 432, and outlet aperture 494 formed in receptacle in 432 into right-side chamber 442. Combustion product then flows either through transfer conduit 434 into left-side chamber 440 or outlet tube 420. Upon removal of cap 14 from receptacle 432, filter unit 415 can be replaced by a replacement diesel trap unit. Spring 437 is removed so that filter unit 415 can be removed and the replacement diesel trap unit can be inserted in its place.

In preferred embodiments of exhaust processor 410, outlet tube 420 is attached to other locations. Two such alternative preferred embodiments are shown in Figs. 19 and 20.

An exhaust processor 410' is similar to exhaust processor 410, except as otherwise noted, so that like reference numerals refer to like structures, as shown, for example, in Fig. 19. A right-side end plate 424' is formed to include an outlet tube-receiving aperture 456' sized to receive outlet tube 420. Outlet tube 420 is mounted to and extends through outlet tube-receiving aperture 456' so that combustion product exits exhaust processor 410' through right-side end plate 424'.

An exhaust processor 410" is similar to exhaust processor 410, except as otherwise noted, so that like reference numerals refer to like structures, as shown, for example, in Fig. 20. A side wall 419 is formed to include an outlet tube-receiving aperture 456" sized to receive outlet tube 420. Outlet tube 420 is mounted to and extends through outlet tube-receiving aperture 456" so that combustion product exits exhaust processor 410" through side wall 419.

In other preferred embodiments of exhaust processor 410, transfer conduit 434 and transfer conduit-receiving aperture 468 is omitted so that left- and right-side chambers 440, 442 are not in fluid communication with one another. As a result, left-side chamber 440 acts no longer as a Helmholtz chamber.

In preferred embodiments of exhaust processors 410, 410', 410", stopper unit 122 is coupled to left end 474 and metal cylinder 427. In other preferred embodiments of 410, 410', 410", filter unit 415 is replaced with catalyzed substrate unit 33 described above.

In other preferred embodiments of exhaust processors 410, 410', 410", end flange 497 is omitted and cap 14 and O-ring 114 are replaced with a cap 514, a clamp 580, and a ring seal 581 as described in connection with exhaust processor 510 discussed below and as shown, for example, in Figs. 21-23.

In other preferred embodiments of exhaust processors 410, 410', 410", inlet tube 418 is replaced by an inlet tube similar to inlet tube 518 having annular flange 554, as described in connection with exhaust processor 510 and shown, for example, in Fig. 21, such that annular flange 554 is coupled to receptacle 432. In other preferred embodiments, inlet tube 418 is replaced by an aπangement similar to what is described in connection with an exhaust processor 610 and shown in Fig. 24, so that the arrangement includes components similar to inlet tube 618 and L-shaped ring 623, wherein ring 623 is coupled to inlet tube 618 and receptacle 432.

A fifth exhaust processor 510 configured to remove particulate from combustion product generated by a diesel engine and attenuate noise produced by the diesel engine is shown in Fig. 18. Exhaust processor 510 includes certain structures described above so that like reference numerals refer to like structures.

Exhaust processor 510 includes a catalyzed substrate unit 533 mounted in a metal cylinder 548, a filter unit or diesel particulate trap unit 512, a removable cap 514, an outer shell 516, an inlet tube 518, an outlet tube 520, a left-side end cap or plate 522, a right-side end cap or plate 524, a first interior baffle 526, a second interior baffle 528, a receptacle 532, such as a sleeve, sized to receive trap unit 512, and annular stopper unit 122 coupled to a left end 574 of receptacle 532 and trap unit 512, as shown, for example, in Fig. 21. Outer shell 516, inlet and outlet tubes 518, 520, left- and right- end plates 522, 524, cap 514, and first and second baffles 526, 528 cooperate to define a housing 536. Outer shell 516 and end plates 522, 524 cooperate to define an interior region 538, as shown, for example, in Fig. 21. A left-side chamber 540 of interior region 538 is located between left-side end plate 522 and first baffle 526. A central inlet chamber 542 of interior region 538 is located between first and second baffles 526, 528. A right-side outlet chamber 544 of interior region 538 is located between second baffle 528 and right-side end plate 524.

Catalyzed substrate unit 533 includes a mat mount 549 and a catalyzed substrate 550. Trap unit 512 includes a metal cylinder 551, a mat mount 552, and a diesel particulate trap 553.

Inlet tube 518 is coupled to an inlet tube-receiving aperture 547 formed in left-side end plate 522 and includes an annular flange 554 coupled to metal cylinder 548, as shown, for example, in Fig. 21. Annular flange 554 is designed to prohibit combustion product from contacting a left end of mat mount 549 to protect the integrity of mat mount 549.

First baffle 526 is formed to include a trap-receiving aperture 555 sized to receive metal cylinder 548, as shown, for example, in Fig. 21. Metal cylinder 548 is coupled to trap-receiving aperture 555.

Second baffle 528 includes an elongated perimeter edge 576 and is formed to include a bowl-shaped first receptacle-receiving aperture 556, as shown, for example, in Fig. 21. Elongated perimeter edge 576 is coupled to shell 516 and extends to a right end of shell 516. Receptacle 532 extends through and is coupled to first receptacle-receiving aperture 556.

Right-side end plate is formed to include a second receptacle-receiving aperture 557 and an outlet tube-receiving aperture 558. Second receptacle-receiving aperture 557 is sized to receive a right end 560 of receptacle 532. Outlet tube 520 is coupled to outlet tube-receiving aperture 558. Apertures 556, 557 are centered on a central receptacle axis 578, as shown in Fig. 21. A longitudinal axis 579 of trap unit 512 is coextensive with central axis 578.

Receptacle is formed to include a plurality of outlet apertures 594. Outlet apertures 594 are positioned to lie between trap unit 512 and right-side end plate 524 in right-side chamber 544.

Annular seal or stopper unit 122 is shown in Figs. 21 and 24. Stopper unit 122 includes a male ring 124 and a female ring 126 sized to receive male ring 124. Male ring 124 is welded to left end 574 of receptacle 532 by weld 127. Female ring 126 is welded to metal cylinder 551. Female ring 126 receives male ring 124 when trap unit 512 is inserted in receptacle 532. Female ring 126 decouples from male ring 124 when trap unit 512 is removed from receptacle 532. Female ring 126 blocks combustion product from infiltrating a left end of mat mount 552 to protect the integrity of mat mount 552.

Exhaust processor 510 includes a clamp 580 and a ring seal 581 to couple cap 514 to right-side end plate 524, as shown, for example, in Fig. 21. Clamp 580 includes a split ring 582, a bolt 583, a nut 584 coupled to bolt, and a bolt mount 585. Bolt mount 585 includes a first block 586 coupled to a first end 587 of ring 582 and a second block 588 coupled to a second end 589 of ring 582. Bolt 583 is welded to first block 586 and extends through second block 585. Nut 84 is used tighten and loosen ring 82.

Exhaust processor 510 is arranged so that combustion product enters exhaust processor 510 through inlet tube 518 and exits exhaust processor 510 through outlet tube 520. Combustion product flows along a flow path 513 in sequence through inlet tube 518, catalyzed substrate unit 533 nested in metal cylinder 548, central chamber 542, trap unit 512 nested in receptacle 532, outlet apertures 594, right-side chamber 544, and outlet tube 520. Trap unit 512 can be replaced by another diesel particulate trap unit.

To do so, clamp 580 is loosened and cap 514 is removed to expose receptacle 532.

Trap unit 512 is removed from receptacle 532 and a replacement is inserted into receptacle 532. Cap 514 is then reattached to right-side end plate 524 by tightening clamp 580 therearound. In preferred embodiments, trap unit 512 can be replaced by catalyzed soot filter unit 15. In this case, catalyzed substrate unit 533 is omitted from exhaust processor 510.

In other preferred embodiments, inlet tube 518 is replaced by an arrangement similar to what is described in connection with an exhaust processor 610 and shown in Fig. 24, such that the arrangement includes components similar to inlet tube 618 and L-shaped ring 623, wherein ring 623 is coupled to inlet tube 618 and metal cylinder 548.

A sixth exhaust processor 610 configured to remove particulate from combustion product generated by a diesel engine and attenuate noise produced by the diesel engine is shown in Fig. 24. Exhaust processor 610 includes certain structures described above so that like reference numerals refer to like structures.

Exhaust processor 610 includes a filter unit or diesel particulate trap unit 612, a removable cap 614, an outer shell 616 including a top wall 617 formed to include an outlet tube-receiving aperture 659, an inlet tube 618, an outlet tube 620, a left-side end cap or plate 622 formed to include an inlet tube-receiving aperture 647, a right-side end cap or plate 624 formed to include a first receptacle-receiving aperture

658, a first interior baffle 626 formed to include a first conduit-receiving aperture 664, a perforation field 621, and a second receptacle-receiving aperture 666, a second interior baffle 628 including an elongated perimeter edge 676 and being formed to include a second conduit-receiving aperture 665 and a third receptacle-receiving aperture 678, a receptacle 632, such as a sleeve, sized to receive trap unit 612 and being formed to include a plurality of inlet apertures 694, conduit 619, L-shaped ring 623 interconnecting inlet tube 618 and conduit 619, annular stopper 122 coupled to receptacle 632 and trap unit 612, clamp 580, ring seal 581, and catalyzed substrate unit 33 positioned to lie inside of inlet tube 618, as shown, for example, in Fig. 25. Shell 616, end plates 622, 624, baffles 626, 628, cap 614, clamp 580, and ring seal 581 cooperate to form a housing 636, as shown, for example, in Fig. 25. Shell 616, end plates 622, 624, clamp 580, and rings seal 581 cooperate to define an interior region 638. Baffles 626, 628 are positioned to lie in interior region 638 to divide interior region 638 into a right-side inlet chamber 644 positioned between baffle 628 and right-side end plate 624, a left-side transition chamber 642 between left-side end plate 622 and baffle 626, and a central outlet chamber 644 between baffles 626, 628.

Apertures 658, 666, 678 are centered on a central receptacle axis 682, as shown in Fig. 25. A longitudinal axis 683 of trap unit 612 is coextensive with central axis 682. Extension conduit 619 extends through and is coupled to first and second conduit-receiving apertures 664, 665 as it extends from left-side chamber 640 through central chamber 642 to right-side chamber 644.

Ring 623 is L-shaped in cross-section to its longitudinal extent, as shown, for example, in Fig. 24. Ring 623 includes an axially extending flange 679 coupled to extension conduit 619 and a radially extending flange 680 coupled to inlet tube 618. Radially extending flange 680 abuts catalyzed substrate unit 33 as it extends radially inwardly from inlet tube 618 to catalyzed substrate 30. Radially extending flange blocks combustion product from infiltrating the adjacent end of mat mount 31 to help protect the integrity of mat mount 31. Exhaust processor 610 is arranged so that combustion product enters exhaust processor 610 through inlet tube 618 and exits exhaust processor 610 through outlet tube 620. Combustion product flows along a flow path 613 in sequence through inlet tube 618 and catalyzed substrate unit 33 nested therein, ring 623, extension conduit 619, right-side chamber 644, inlet apertures 694, trap unit 612 nested in receptacle 632, left-side chamber 640, perforation field 621 formed in first baffle 626, central chamber 642, and outlet tube 620. Trap unit 612 can be replaced by loosening clamp 580 and removing cap 614 to expose trap unit 612. After a replacement is installed, cap 614 is reattached by tightening clamp 580 therearound.

In preferred embodiments, trap unit 612 is replaced by catalyzed soot filter unit 15 and catalyzed substrate unit 33 is omitted from exhaust processor 610. In other preferred embodiments, inlet tube 618 and L-shaped ring 623 are replaced by an inlet tube similar to inlet tube 518 having annular flange 554, as described in connection with exhaust processor 510 and shown, for example, in Fig. 21, such that annular flange 554 is coupled to extension conduit 619.

Claims

WHAT IS CLAIMED IS:

1. An exhaust processor comprising a housing including a first end cap, a second end cap, and a shell coupled to the first end cap and the second end cap, the first end cap, the second end cap, and the shell cooperating to define an interior region, the first end cap being formed to include an inlet, the second end cap being formed to include an outlet and a first aperture, a filter unit adapted to filter particulate material from combustion product passing from the inlet through the interior region to the outlet, and a receptacle arranged to position the filter unit in the interior region, the receptacle extending into the first aperture to allow the filter unit to pass through the first aperture during insertion and removal of the filter unit into and out of the interior region.

2. The exhaust processor of claim 1 , wherein the housing includes a first baffle positioned in the interior region, the first baffle is formed to include a second aperture, and the receptacle extends into the second aperture.

3. The exhaust processor of claim 2, wherein the housing includes a second baffle positioned in the interior region, the second baffle is formed to include a third aperture, and the receptacle extends into the third aperture.

4. The exhaust processor of claim 3, wherein the shell, the first end cap, the second end cap, the first baffle, and the second baffle cooperate to define an inlet chamber positioned between the first baffle and the second baffle, a transition chamber positioned between the second baffle and the second end cap, and an outlet chamber positioned between the first baffle and the first end cap and in communication with the outlet.

5. The exhaust processor of claim 4, wherein the housing includes an inlet conduit extending through the inlet and a fourth aperture formed in the second baffle to introduce combustion product into the inlet chamber.

6. The exhaust processor of claim 4, wherein the second baffle is formed to include a fourth aperture to allow combustion product to flow from the inlet chamber to the transition chamber.

7. The exhaust processor of claim 4, wherein the receptacle is formed to include an inlet aperture positioned in communication with the transition chamber and an outlet aperture positioned in communication with the outlet chamber.

8. The exhaust processor of claim 7, wherein the filter unit is positioned within the receptacle between the inlet aperture and the outlet aperture.

9. The exhaust processor of claim 1, wherein the housing includes a removable cap to prevent access to the interior region through the first aperture during operation of the exhaust processor.

10. The exhaust processor of claim 1, further comprising a spring positioned within the receptacle and engaging the filter unit.

11. The exhaust processor of claim 1 , further comprising a catalyzed substrate unit positioned to lie in the interior region between the inlet and an inlet aperture of the receptacle to treat combustion product flowing from the inlet to the inlet aperture of the receptacle.

12. The exhaust processor of claim 11, further comprising means for positioning the catalyzed substrate unit in the interior region so that combustion product flows from the inlet through the catalyzed substrate unit to the inlet aperture of the receptacle.

13. An exhaust processor comprising a housing including a first end cap, a second end cap, and a shell coupled to the first end cap and the second end cap, the first end cap, the second end cap, and the shell cooperating to define an interior region, the first end cap being formed to include an inlet, the second end cap being formed to include a first aperture, the shell being formed to include an outlet, a filter unit adapted to filter particulate material from combustion product passing from the inlet through the interior region to the outlet, and a receptacle arranged to position the filter unit in the interior region, the receptacle extending into the first aperture to allow the filter unit to pass through the first aperture during insertion and removal of the filter unit into and out of the interior region.

14. The exhaust processor of claim 13, wherein the housing includes a first baffle positioned in the interior region, the first baffle is formed to include a second aperture, and the receptacle extends into the second aperture.

15. The exhaust processor of claim 14, wherein the housing includes a second baffle positioned in the interior region, the second baffle is formed to include a third aperture, and the receptacle extends into the third aperture.

16. The exhaust processor of claim 15, wherein wherein the shell, the first end cap, the second end cap, the first baffle, and the second baffle cooperate to define an inlet chamber positioned between the first end cap and the first baffle, a transition chamber positioned between the second end cap and the second baffle, and an outlet chamber positioned between the first baffle and the second baffle and in communication with the outlet.

17. The exhaust processor of claim 16, wherein the housing includes an inlet conduit extending through the inlet, a fourth aperture formed in the second baffle, and a fifth aperture formed in the first baffle to introduce combustion product into the inlet chamber.

18. The exhaust processor of claim 16, wherein the receptacle is formed to include an inlet aperture positioned in communication with the inlet chamber and an outlet aperture positioned in communication with the transition chamber.

19. The exhaust processor of claim 18, wherein the filter unit is positioned within the receptacle between the inlet aperture and the outlet aperture.

20. The exhaust processor of claim 14, further comprising sound- absorbent material positioned between the second end cap and the first baffle.

21. The exhaust processor of claim 13, further comprising a catalytic substrate unit positioned in the interior region.

22. An exhaust processor comprising a housing including a first end cap, a second end cap, and a shell coupled to the first end cap and the second end cap, the first end cap, the second end cap, and the shell cooperating to define an interior region, the first end cap being formed to include an inlet, the second end cap being formed to include an outlet, the shell being formed to include a first aperture, a filter unit adapted to filter particulate material from combustion product passing from the inlet through the interior region to the outlet, and a receptacle arranged to position the filter unit in the interior region, the receptacle extending into the first aperture to allow the filter unit to pass through the first aperture during insertion and removal of the filter unit into and out of the interior region.

23. The exhaust processor of claim 22, wherein the housing includes a first baffle positioned in the interior region, the first baffle is formed to include a second aperture, and the receptacle extends into the second aperture.

24. The exhaust processor of claim 23, wherein the housing includes a second baffle positioned in the interior region, and the receptacle and the second baffle are spaced apart from one another.

25. The exhaust processor of claim 24, further comprising an inlet conduit extending into the inlet and a third aperture formed in the second baffle.

26. The exhaust processor of claim 24, wherein the first baffle and the second baffle are perpendicular to one another.

27. An exhaust processor comprising a housing formed to include an inlet, an outlet, and an interior region, a filter unit positioned in the interior region and adapted to filter particulate material from combustion product passing from the inlet through the interior region to the outlet, and means for supporting the filter unit during operation of the exhaust processor and removal of the filter unit out of the interior region to facilitate replacement of the filter unit with another filter unit.

28. An exhaust processor comprising a housing formed to include an interior region and a first aperture, a filter unit adapted to trap particulate material from combustion product passing through the interior region, the filter unit having a longitudinal axis and a receptacle arranged to position the filter unit in the interior region, the receptacle having a central axis that is coextensive with the longitudinal axis of the filter unit and extends through the first aperture to allow the filter unit to pass through the first aperture during insertion and removal of the filter unit into and out of the interior region.

29. The exhaust processor of claim 28, wherein the housing includes a removable cap to prevent access to the interior region through the first aperture during operation of the exhaust processor.

30. The exhaust processor of claim 28, wherein the filter unit includes a sleeve engaging the receptacle, a particulate trap, and a mount aπanged to position the particulate trap within the sleeve.

31. The exhaust processor of claim 28, wherein the receptacle includes a sleeve surrounding the filter unit.

32. The exhaust processor of claim 31 , wherein the sleeve extends from the interior region into the first aperture.

33. The exhaust processor of claim 31 , wherein the sleeve includes a first end formed to include a second aperture through which the filter unit passes during insertion and removal of the filter unit into and out of the interior region.

34. The exhaust processor of claim 33, wherein the sleeve includes a second end formed to include a third aperture through which combustion product passes during operation of the exhaust processor.

35. The exhaust processor of claim 34, wherein the sleeve is formed to include a fourth aperture through which combustion product passes during operation of the exhaust processor.