GB2268095A - Improvements in or relating to catalytic converters and diesel particulate traps - Google Patents
Improvements in or relating to catalytic converters and diesel particulate traps Download PDFInfo
- Publication number
- GB2268095A GB2268095A GB9213341A GB9213341A GB2268095A GB 2268095 A GB2268095 A GB 2268095A GB 9213341 A GB9213341 A GB 9213341A GB 9213341 A GB9213341 A GB 9213341A GB 2268095 A GB2268095 A GB 2268095A
- Authority
- GB
- United Kingdom
- Prior art keywords
- packing material
- knitted
- metal wire
- strip
- intumescent sheet
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—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
- F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
- F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
- F01N3/2857—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing the mats or gaskets being at least partially made of intumescent material, e.g. unexpanded vermiculite
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
- F02B3/00—Engines characterised by air compression and subsequent fuel addition
- F02B3/06—Engines characterised by air compression and subsequent fuel addition with compression ignition
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Exhaust Gas After Treatment (AREA)
Abstract
A packing material for mounting ceramic structures within a metallic container of a catalytic converter system or diesel particulate trap is disclosed. Such packing material is adapted to absorb mechanical shock as well as thermal shock and comprises an intumescent sheet material which is thermally resistant and is resilient after expansion, said material having a strip of knitted metal wire along at least the front edge of such intumescent sheet material.
Description
IMPROVEMENTS IN OR RELATING TO CATALYTIC CONVERTERS
AND DIESEL PARTICULATE TRAPS The present invention concerns improvements in or relating to catalytic devices or converters and diesel particulate traps. More particularly, the present invention is concerned with providing an improved catalytic converter and diesel particulate trap for use with automobiles, motor cycles or any internal combustion engine or diesel engine.
It is increasingly becoming recognised that catalytic devices and diesel particulate traps are required for oxidation of carbon monoxide and hydrocarbons and for reduction of the oxides of nitrogen in automobile exhaust systems or removal of soot particles in diesel exhausts in order to control pollution.
In view of the relatively high temperatures involved in the catalytic processes, ceramic material has been the natural choice for catalyst supports.
Particularly suitable supports have been provided by ceramic honeycomb structures. Such structures are usually coated with platinum or other suitable catalyst.
Such ceramic supports, duly coated with catalyst, are generally housed in a metal container, and such arrangement is generally termed a "catalytic converter".
In modern automobiles, it is possible to use a large catalytic converter or a plurality of smaller converters.
Ceramic bodies tend to be frangible and to have coefficients of thermal expansion which markedly differ from those of the metal containers in which they are encased. Thus, the mounting of the ceramic body or support in the container must provide resistance to mechanical shock due to impact and vibration as well as to thermal shock due to thermal cycling. Both thermal and mechanical shock may cause deterioration of the ceramic body or support which, once started, quickly accelerates and ultimately renders the catalytic device useless.
Accordingly, there is thus a need for providing a method of mounting ceramic structures in metal containers with resistance to mechanical and thermal shock.
In addition, due to the varying temperatures which can exceed 8000C, expansion and contraction of the metal container can take place. Moreover, when the container is attached to a vehicle which passes through water, then contraction of the metal casing can take place. Accordingly, a packing material is required which would be adapted to absorb mechanical shock as well as thermal shock.
It is known to provide a knitted metal wire, suitably produced on industrial knitting machines, and formed suitably from stainless steel and/or nickel alloys, which wire can be wrapped around the ceramic support and hold the support or body within the metal casing of the catalytic converter or diesel particulate trap.
A further packing material which has been utilised comprises intumescent sheet material or ceramic mat paper which is thermally resistant and is resilient after expansion. Such material has been used, for some years, as packing in positioning catalyst supports and bodies within metal containers. However, with the increasing power of automobiles, it has been discovered that such intumescent sheet material, which suitably has decreased negative expansion characteristics in the range of 2000C to 4000C and which is thermally resistant and is resilient after expansion, which is used as a support material between the ceramic support and the outer metal container of the catalytic converter, has been subjected to erosion at the front and, in certain instances, the rear thereof, due to action by exhaust gases.
It is accordingly an object of the present invention to provide a suitable packing material for ceramic supports located in the metal casing of a catalytic converter or diesel particulate trap, which at least minimises the problems associated with previously utilised packing material.
According to the present invention there is provided a packing material for mounting ceramic structures within a metallic container of a catalytic converter system or diesel particulate trap, wherein such packing material is adapted to absorb mechanical shock as well as thermal shock, said packing material comprising an intumescent sheet material which is thermally resistant and is resilient after expansion, said material having a strip of knitted metal wire along at least the front edge, and possibly also the rear edge, of such intumescent sheet material.
The provision of such an arrangement will enable erosion of the front edge, and also the rear edge where applicable, of the intumescent sheet material to be prevented, when such material is utilised as packing material for mounting a ceramic structure or body in a metal container of a catalytic converter system or diesel particulate trap.
The flexible, resilient intumescent sheet material is suitably formed from unexpanded intumescent material and an inorganic binder, possibly together with inorganic fibrous material.
In a preferred embodiment of the present invention there is utilised a flexible knitted strip of metal wire having asymmetrical interlocking loops, such strip being formed into a U-section, and placing such Usection along at least the front, and also the rear, if necessary, edge of the intumescent sheet material, where same will be exposed to exhaust gases.
Any suitable form of flexible knitted metal wire may be utilised and may be formed from an anti-corrosive nickel alloy such as Iconel, or from stainless steel.
The wire can be in single or double or multiple wire form as desired.
The knitted metal wire, will generally be manufactured on an industrial knitting machine. In one embodiment of the invention, it is possible to knit a sock or tube of knitted wire mesh on an industrial knitting machine. Thereafter, the tube or sock is removed therefrom and passed through flattening rollers.
Such flattened material can then be bent over to form the desired U-section form of the flexible knitted strip utilised in the present invention.
The strip of knitted metal wire may be attached to the front edge and, if necessary, rear edge of the intumescent sheet material by stitching. In this connection, it is possible to stitch through the strip and the intumescent sheet material, also known as ceramic mat paper, with a thread of low temperature material which will burn off thereby allowing the ceramic mat paper to expand and secure the strip to the intumescent sheet material. Alternatively, it is possible to utilise a high temperature thread when stitching which will keep the strip of knitted metal wire attached to the intumescent sheet material.
The provision of the seal by utilising a knitted metal wire arrangement as described above, will at least slow down, and in many instances prevent, erosion or migration of the intumescent sheet material. In addition, it is also believed that the manner of attachment referred to above should assist in production during assembly of catalytic converters since the modified packing material in accordance with this new invention can be applied in the form of one component, rather than utilising a plurality of components.
It is believed that the packing material of the present invention will provide the necessary support for catalyst structures utilised in catalytic converters and diesel particulate traps. Moreover, it is believed that since most catalytic converters and diesel particulate traps will need to provide a 100,000 - 120,000 mile guarantee, then the modified packing material of the present invention should enable an appropriate system to be produced. Moreover, with the increasing power of vehicles, particularly in relation to high performance vehicles, it is believed that the modified packing material of the present invention will enable catalytic converters and diesel particulate traps to be produced wherein the intumescent sheet material utilised will not erode at its front and possibly rear edges.
It is to be understood that various modifications can be effected in relation to the form of knitted metal wire which can utilised in the present invention and that any suitable form of intumescent sheet material or ceramic paper material can be utilised.
Claims (14)
1. A packing material for mounting ceramic structures within a metallic container of a catalytic converter system or diesel particulate trap, wherein such packing material is adapted to absorb mechanical shock as well as thermal shock, said packing material comprising an intumescent sheet material which is thermally resistant and is resilient after expansion, said material having a strip of knitted metal wire along at least the front edge of such intumescent sheet material.
2. A packing material as claimed in claim 1, in which a strip of knitted metal wire is provided along both the front and the rear edge of said intumescent sheet material.
3. A packing material as claimed in claim 2, in which the flexible, resilient, intumescent sheet material is formed from unexpanded intumescent material and an organic binder.
4. A packing material as claimed in claim 3, in which said intumescent sheet material also includes inorganic fibrous material.
5. A packing material as claimed in any preceding claim, in which the strip of metal wire is in the form of a flexible knitted strip of metal wire having asymmetrical interlocking loops, such strip being formed into a U-section, said U-section, in use, being placed along at least the front edge of the intumescent sheet material, where same, in use, will be exposed to exhaust gases.
6. A packing material as claimed in any preceding claim, in which the knitted metal wire is formed from an anti-corrosive nickel alloy or from stainless steel.
7. A packing material as claimed in any preceding claim, in which the knitted metal wire is in single or double or multiple wire form.
8. A packing material as claimed in any preceding claim, in which the knitted metal wire is manufactured on an industrial knitting machine.
9. A packing material as claimed in claim 8, in which, in use, a sock or tube of knitted wire mesh is knitted on an industrial knitted machine, the tube or sock thereafter being removed therefrom and passed through flattening rollers, such flattened material being bent over to form a U-section form of flexible knitted wire strip.
10. A packing material as claimed in any preceding claim, in which the strip of knitted metal wire is attached to at least the front edge of the intumescent sheet material by stitching.
11. A packing material as claimed in claim 10, in which a thread of low temperature material is stitched through the knitted metal wire strip and the intumescent sheet material.
12. A packing material as claimed in claim 10 in which a thread of high temperature material is stitched through the knitted metal wire strip and the intumescent sheet material.
13. A packing material as claimed in any preceding claim, substantially as hereinbefore described.
14. A catalytic converter or diesel particulate trap including a packing material as claimed in any proceding claim.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9213341A GB2268095A (en) | 1992-06-24 | 1992-06-24 | Improvements in or relating to catalytic converters and diesel particulate traps |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9213341A GB2268095A (en) | 1992-06-24 | 1992-06-24 | Improvements in or relating to catalytic converters and diesel particulate traps |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB9213341D0 GB9213341D0 (en) | 1992-08-05 |
| GB2268095A true GB2268095A (en) | 1994-01-05 |
Family
ID=10717605
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB9213341A Withdrawn GB2268095A (en) | 1992-06-24 | 1992-06-24 | Improvements in or relating to catalytic converters and diesel particulate traps |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2268095A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2314034A (en) * | 1996-06-15 | 1997-12-17 | Catalytic Support Syst Ltd | Support and seal for a catalytic converter |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4397817A (en) * | 1980-08-20 | 1983-08-09 | Honda Giken Kogyo Kabushiki Kaisha | Catalytic converter |
| EP0366484A2 (en) * | 1988-10-28 | 1990-05-02 | Minnesota Mining And Manufacturing Company | Erosion resistant mounting composite for catalytic converter |
-
1992
- 1992-06-24 GB GB9213341A patent/GB2268095A/en not_active Withdrawn
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4397817A (en) * | 1980-08-20 | 1983-08-09 | Honda Giken Kogyo Kabushiki Kaisha | Catalytic converter |
| EP0366484A2 (en) * | 1988-10-28 | 1990-05-02 | Minnesota Mining And Manufacturing Company | Erosion resistant mounting composite for catalytic converter |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2314034A (en) * | 1996-06-15 | 1997-12-17 | Catalytic Support Syst Ltd | Support and seal for a catalytic converter |
| GB2314034B (en) * | 1996-06-15 | 2000-04-12 | Catalytic Support Syst Ltd | A seal assembly |
Also Published As
| Publication number | Publication date |
|---|---|
| GB9213341D0 (en) | 1992-08-05 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |