US20160061081A1 - Catalytic Converter Apparatus - Google Patents

Catalytic Converter Apparatus Download PDF

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Publication number
US20160061081A1
US20160061081A1 US14/801,017 US201514801017A US2016061081A1 US 20160061081 A1 US20160061081 A1 US 20160061081A1 US 201514801017 A US201514801017 A US 201514801017A US 2016061081 A1 US2016061081 A1 US 2016061081A1
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US
United States
Prior art keywords
upstream side
end portion
face
decreasing diameter
diameter portion
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US14/801,017
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English (en)
Inventor
Shoji Ogimura
Hideyuki Komitsu
Fumiyuki Mutsuda
Tomoyoshi Nakamura
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ibiden Co Ltd
Toyota Motor Corp
Original Assignee
Ibiden Co Ltd
Toyota Motor Corp
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Filing date
Publication date
Application filed by Ibiden Co Ltd, Toyota Motor Corp filed Critical Ibiden Co Ltd
Assigned to IBIDEN CO., LTD., TOYOTA JIDOSHA KABUSHIKI KAISHA reassignment IBIDEN CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KOMITSU, HIDEYUKI, Mutsuda, Fumiyuki, NAKAMURA, TOMOYOSHI, OGIMURA, SHOJI
Publication of US20160061081A1 publication Critical patent/US20160061081A1/en
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • F01N3/2006—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating
    • F01N3/2013—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating using electric or magnetic heating means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • F01N3/2006—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating
    • F01N3/2013—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating using electric or magnetic heating means
    • F01N3/2026—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating using electric or magnetic heating means directly electrifying the catalyst substrate, i.e. heating the electrically conductive catalyst substrate by joule effect
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/14—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having thermal insulation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/18—Construction facilitating manufacture, assembly, or disassembly
    • F01N13/1838—Construction facilitating manufacture, assembly, or disassembly characterised by the type of connection between parts of exhaust or silencing apparatus, e.g. between housing and tubes, between tubes and baffles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/18—Construction facilitating manufacture, assembly, or disassembly
    • F01N13/1861—Construction facilitating manufacture, assembly, or disassembly the assembly using parts formed by casting or moulding
    • F01N13/1866—Construction facilitating manufacture, assembly, or disassembly the assembly using parts formed by casting or moulding the channels or tubes thereof being made integrally with the housing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/005—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for draining or otherwise eliminating condensates or moisture accumulating in the apparatus
    • 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
    • F01N3/0892—Electric or magnetic treatment, e.g. dissociation of noxious components
    • 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
    • F01N2470/00—Structure or shape of gas passages, pipes or tubes
    • F01N2470/20—Dimensional characteristics of tubes, e.g. length, diameter
    • 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
    • F01N2470/00—Structure or shape of gas passages, pipes or tubes
    • F01N2470/24—Concentric tubes or tubes being concentric to housing, e.g. telescopically assembled
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the present invention relates to a catalytic converter apparatus that is provided at an exhaust pipe of an internal combustion engine.
  • JP-A Japanese Patent Application Laid-Open (JP-A) No. 2013-185573 discloses an electrically heated catalytic structure in which an inner pipe, in a shape that tapers to the upstream side of an exhaust gas flow direction, is provided at an outer pipe that accommodates a heat generating body (a catalyst substrate).
  • a heat generating body a catalyst substrate
  • an insulating layer is provided at the surface of the inner pipe.
  • the insulating layer may be formed by, for example, a material of the insulating layer being coated onto the surface of the inner pipe and fired.
  • the insulating layer at the surface of the inner pipe contracts in the firing process, cracks may form in the insulating layer at a distal end portion of the inner pipe.
  • an upstream side end portion of the inner pipe in a simply cut state has sharp corners, and it is likely that cracks form in the insulating layer starting from these corners.
  • the present invention provides a catalytic converter apparatus that may suppress the formation of cracks in an insulating layer at an axial direction end portion of an inner pipe.
  • a catalytic converter apparatus includes: a catalyst substrate that supports a catalyst for cleaning exhaust gas exhausted from an internal combustion engine, the catalyst substrate being heated by electrification; a case formed in a tubular shape, the catalyst substrate being accommodated inside the case and the case being attached to an exhaust pipe; an outer pipe provided at the case, the outer pipe being disposed at least at an upstream side of an exhaust gas flow direction relative to the catalyst substrate; an inner pipe provided at the case inside the outer pipe, an axial direction end portion of the inner pipe being formed in a tapered shape and a distal end face of the axial direction end portion being formed in a curved surface shape; and an insulating layer provided at least at an inner side face and the axial direction end portion of the inner pipe.
  • the catalyst substrate is accommodated inside the tubular case that is attached to the exhaust pipe, and the catalyst substrate inside the case is heated by electrification. As a result, exhaust gas exhausted from the internal combustion engine is cleaned.
  • the outer pipe and the inner pipe are provided in the case.
  • the outer pipe is disposed at least at the upstream side of the exhaust gas flow direction relative to the catalyst substrate.
  • the axial direction end portion of the inner pipe is formed in the tapered shape at the inside of the outer pipe.
  • the distal end face of the axial direction end portion of the inner pipe is formed in the curved surface shape. Because the insulating layer is provided at least at the inner side face and the axial direction end portion of the inner pipe, insulation between the catalyst substrate and the inner pipe may be maintained.
  • the distal end face of the axial direction end portion of the inner pipe is formed in the curved surface shape.
  • sharp corners at the distal end face of the inner pipe are removed. Therefore, the formation of cracks in the insulating layer at the distal end face of the inner pipe may be suppressed.
  • the insulating layer is formed by, for example, a material of the insulating layer being coated onto at least the inner side face and axial direction end portion of the inner pipe and fired.
  • chamfer machining is applied such that R ⁇ 0.5 mm.
  • the radius of curvature of the distal end face of the axial direction end portion of the inner pipe is represented by R
  • chamfering machining is applied such that R ⁇ 0.5 mm.
  • the distal end face of the axial direction end portion of the inner pipe is formed to a smoother curved surface shape.
  • the formation of cracks in the insulating layer at the distal end face of the axial direction end portion of the inner pipe may be more reliably suppressed.
  • the thickness of the insulating layer is specified to be at least 100 ⁇ m and at most 200 ⁇ m.
  • the thickness of the insulating layer is suitably specified, the formation of cracks in the insulating layer at the distal end face of the axial direction end portion of the inner pipe may be suppressed.
  • the thickness of the insulating layer is thinner than 100 ⁇ m, cracking of the insulating layer may be caused by contraction of the insulating layer during firing, and if the thickness of the insulating layer is more than 200 ⁇ m, it is difficult to form the insulating layer with a more uniform thickness.
  • FIG. 2 is a magnified sectional diagram showing an upstream end portion of an upstream side decreasing diameter portion employed in the catalytic converter apparatus shown in FIG. 1 .
  • FIG. 4 is a magnified sectional diagram, corresponding to FIG. 2 , showing an upstream end portion of an upstream side decreasing diameter portion employed in a catalytic converter apparatus in accordance with a third exemplary embodiment of the present invention.
  • FIG. 5B is a magnified sectional diagram illustrating the fabrication process of the upstream end portion of the upstream side decreasing diameter portion shown in FIG. 4 .
  • FIG. 5C is a magnified sectional diagram illustrating the fabrication process of the upstream end portion of the upstream side decreasing diameter portion shown in FIG. 4 .
  • the catalyst substrate 14 is formed of, for example, silicon carbide.
  • a catalyst platinum, palladium, rhodium or the like is adhered to surfaces of the catalyst substrate 14 and supported thereat.
  • the catalyst features an action that cleans substances (hydrocarbons and the like) from the exhaust gas flowing in the exhaust pipe 10 .
  • the case 28 is provided with an accommodation tube 30 in a circular tube shape and an upstream side decreasing diameter portion 32 .
  • the accommodation tube 30 has a constant diameter from the upstream side to the downstream side thereof.
  • the upstream side decreasing diameter portion 32 continues toward the upstream side from the upstream end of the accommodation tube 30 and serves as an inner pipe whose diameter is decreased in steps. That is, the upstream side decreasing diameter portion 32 is structured so as to form a shape that tapers toward the upstream side.
  • the upstream side decreasing diameter portion 32 decreases in diameter in two steps at two diameter reduction portions 32 C.
  • the number of the diameter reduction portions 32 C may be one or may be three or more.
  • the case 28 is provided with an upstream side conical member 20 and a connecting member 22 between the accommodation tube 30 and the upstream side exhaust pipe 10 A.
  • the upstream side conical member 20 and the connecting member 22 are disposed in this order from the upstream side of the exhaust gas flow direction.
  • the outer pipe of the present invention is structured by the upstream side conical member 20 and the connecting member 22 .
  • the upstream side conical member 20 includes a fixed tube 20 A and a fixed tube 20 B.
  • the fixed tube 20 A is fixed to the outer side of the upstream side exhaust pipe 10 A by welding or the like over the whole circumference thereof.
  • the fixed tube 20 B is fixed to the inner side of the connecting member 22 by welding or the like over the whole circumference thereof
  • the fixed tube 20 B has a larger diameter than the fixed tube 20 A.
  • a truncated cone portion 20 C connects between the fixed tube 20 A and the fixed tube 20 B.
  • the diameter of the truncated cone portion 20 C progressively increases from the fixed tube 20 A toward the fixed tube 20 B.
  • the upstream side exhaust pipe 10 A projects to the downstream side at the inner side of the truncated cone portion 20 C, structuring a projection portion 10 B.
  • the upstream side decreasing diameter portion 32 is disposed at the upstream side relative to the catalyst substrate 14 and at the downstream side relative to the truncated cone portion 20 C.
  • the upstream side decreasing diameter portion 32 is disposed inside the upstream side conical member 20 and connecting member 22 that serve as the outer pipe.
  • two truncated cone-shaped members (the truncated cone portion 20 C and the upstream side decreasing diameter portion 32 ) that increase in diameter from the upstream side toward the downstream side are provided successively in the exhaust gas flow direction.
  • An upstream end portion 32 D which is an axial direction end portion of the upstream side decreasing diameter portion 32 , is disposed at the downstream side relative to a downstream end portion 10 C of the upstream side exhaust pipe 10 A (the projection portion 10 B).
  • the upstream side exhaust pipe 10 A and the upstream side decreasing diameter portion 32 do not overlap (coincide) in the exhaust gas flow direction (the direction of arrow F 1 ).
  • a reservoir region 36 is structured between the upstream side conical member 20 and connecting member 22 and the upstream side decreasing diameter portion 32 .
  • the reservoir region 36 is a region in which condensed water (liquid water) that is condensed from moisture in the exhaust gas accumulates.
  • An inner diameter of the upstream end portion 32 D of the upstream side decreasing diameter portion 32 is larger than an inner diameter of the downstream end portion 10 C of the upstream side exhaust pipe 10 A.
  • a glass coating layer 40 that serves as an insulating layer is applied to a range reaching from an inner periphery face of the accommodation tube 30 of the case 28 over an inner periphery face (an inner side face) of the upstream side decreasing diameter portion 32 to the outer periphery face of the upstream side decreasing diameter portion 32 (substantially the whole surface of the upstream side decreasing diameter portion 32 ).
  • the glass coating layer 40 contains an inorganic substance such as a glass material or the like.
  • the glass coating layer 40 is formed of a material that has a lower thermal conductivity than the case 28 and is formed with a predetermined porosity.
  • the glass coating layer 40 is electrically insulative.
  • an insulating layer formed of an alternative material such as a ceramic or the like may be provided instead.
  • a distal end face 33 of the upstream end portion 32 D of the upstream side decreasing diameter portion 32 is formed in a curved surface shape (a rounded surface shape). That is, in a simply cut state, the upstream end portion 32 D of the upstream side decreasing diameter portion 32 has corners with substantially right-angled shapes, but the sharp corners are removed by chamfering machining of the corners to the curved surface shape (the rounded surface shape).
  • a plate thickness t of the upstream side decreasing diameter portion 32 is set at, for example, 1.4 to 1.9 mm.
  • the thickness of the glass coating layer 40 is preferably set to at least 100 ⁇ m and at most 200 ⁇ m, and is more preferably set to to at least 120 ⁇ m and at most 180 ⁇ m.
  • the thickness of the glass coating layer 40 is set in a suitable range, the formation of cracks in the glass coating layer 40 at the distal end face 33 of the upstream end portion 32 D of the upstream side decreasing diameter portion 32 may be more effectively suppressed.
  • the thickness of the glass coating layer is thinner than 100 ⁇ m, cracks in the glass coating layer at the distal end face of the upstream end portion may be caused by the contraction of the glass coating layer during firing. In addition, it may not be possible to assure satisfactory electrical insulation. If the thickness of the glass coating layer is more than 200 ⁇ m, it is difficult to form the glass coating layer with a more uniform thickness.
  • the catalytic converter apparatus 12 moisture is included in the exhaust gas.
  • the moisture may condense and form water droplets inside the exhaust pipe 10 at the upstream side relative to the catalytic converter apparatus 12 .
  • the upstream side exhaust pipe 10 A and the upstream side decreasing diameter portion 32 do not overlap in the exhaust gas flow direction. Therefore, water condensing from the exhaust gas passes between the upstream side exhaust pipe 10 A and the upstream side decreasing diameter portion 32 and accumulates in the reservoir region 36 that is between the upstream side conical member 20 and connecting member 22 and the upstream side decreasing diameter portion 32 .
  • adherence of condensed water to the catalyst substrate 14 is suppressed. Therefore, short circuits between the electrodes 16 A and 16 B caused by condensed water are suppressed. Therefore, electric current amounts in the catalyst substrate 14 are assured and the catalyst substrate 14 is effectively raised in temperature.
  • the upstream side decreasing diameter portion 32 projects integrally from the accommodation tube 30 and there is no joint between the upstream side decreasing diameter portion 32 and the accommodation tube 30 . Therefore, water that has accumulated in the reservoir region 36 does not ingress through a joint between the upstream side decreasing diameter portion 32 and the accommodation tube 30 to the side thereof at which the catalyst substrate 14 is disposed.
  • the inner diameter of the upstream end portion 32 D of the upstream side decreasing diameter portion 32 is larger than the inner diameter of the downstream end portion 10 C of the upstream side exhaust pipe 10 A.
  • the diameter of the upstream side decreasing diameter portion 32 decreases toward the upstream side. Therefore, eddies form in the exhaust gas flowing at the inner side of the upstream side decreasing diameter portion 32 , and the upstream side decreasing diameter portion 32 more easily absorbs heat from the exhaust gas. Thus, the temperature of the upstream side decreasing diameter portion 32 may be raised more easily, and combustion of carbon adhering to the upstream side decreasing diameter portion 32 may be promoted.
  • the case 28 is attached partway along the exhaust pipe 10 (between the upstream side exhaust pipe 10 A and the downstream side exhaust pipe that is not shown in the drawings) so as to be coaxial with the exhaust pipe 10 .
  • exhaust gas passes through the interior of the catalyst substrate 14 , substances in the exhaust gas (hydrocarbons) and the like are cleaned by the catalyst supported at the catalyst substrate 14 .
  • the catalyst substrate 14 is electrified by the terminals 18 A and 18 B and the electrodes 16 A and 16 B, and the catalyst substrate 14 is heated.
  • the catalyst supported by the catalyst substrate 14 is raised in temperature and may exhibit the cleaning action more effectively. For example, if the temperature of the exhaust gas is low, just after starting of the engine or the like, because the catalyst substrate 14 is already electrified and heated, the cleaning performance of the catalyst may be assured in an initial period when the engine starts.
  • the glass coating layer 40 is applied in the range reaching from the inner periphery face of the accommodation tube 30 of the case 28 over the inner periphery face of the upstream side decreasing diameter portion 32 to the outer periphery face of the upstream side decreasing diameter portion 32 (substantially the whole surface of the upstream side decreasing diameter portion 32 ).
  • insulation of the case 28 (the accommodation tube 30 and the upstream side decreasing diameter portion 32 ) is improved. Therefore, current leakages to the case 28 (the accommodation tube 30 and the upstream side decreasing diameter portion 32 ) when the catalyst substrate 14 is electrified are suppressed. As a result, electric current amounts in the catalyst substrate 14 may be assured and the catalyst substrate 14 may be raised in temperature effectively.
  • the distal end face 33 of the upstream end portion 32 D of the upstream side decreasing diameter portion 32 is formed in the curved surface shape (the rounded surface shape). If the radius of curvature of the distal end face 33 of the upstream end portion 32 D is represented by R, it is preferable to apply chamfering machining such that R ⁇ 0.5 mm. In the present exemplary embodiment, the radius of curvature R of the distal end face 33 of the upstream end portion 32 D is set to approximately 0.75 mm (R0.75).
  • the glass coating layer 40 is formed by firing of the materials.
  • the distal end face 33 of the upstream end portion 32 D of the upstream side decreasing diameter portion 32 has been formed to the curved surface shape (machined to curved chamfers) and sharp corners of the distal end face 33 have been removed, cracking of the glass coating layer 40 starting from sharp corners, due to contraction of the glass coating layer 40 during the firing, is suppressed. Therefore, the formation of cracks in the glass coating layer 40 at the distal end face 33 of the upstream end portion 32 D of the upstream side decreasing diameter portion 32 may be suppressed as a result.
  • the upstream end portion of the upstream side decreasing diameter portion in a simply cut state, has sharp corners at the distal end face thereof
  • the glass coating layer contracts during firing, cracks may form in the glass coating layer starting from these corners.
  • regions that may not insulate are produced and, because of short circuits, it may not be possible to assure electric current amounts in the catalyst substrate.
  • the distal end face 33 of the upstream end portion 32 D of the upstream side decreasing diameter portion 32 is formed in the curved surface shape (machined to curved chamfers), even when the glass coating layer 40 at the distal end face 33 of the upstream end portion 32 D contracts during firing, the formation of cracks in the glass coating layer 40 may be suppressed.
  • the thickness of the glass coating layer 40 is set to at least 100 ⁇ m and at most 200 ⁇ m.
  • the thickness of the glass coating layer 40 may be formed to a substantially uniform thickness. For example, if there is a sharp corner at the upstream end portion of an upstream side decreasing diameter portion, the thickness of a glass coating layer may be thinner in the vicinity of the corner.
  • FIG. 3 shows a magnified sectional diagram of an upstream end portion of an upstream side decreasing diameter portion of a case employed in a catalytic converter apparatus according to a second exemplary embodiment of the present invention.
  • Structural portions that are the same as in the first exemplary embodiment described above are assigned the same reference numerals, and descriptions thereof are not given.
  • an upstream side decreasing diameter portion 52 serves as an inner pipe of the case.
  • the upstream side decreasing diameter portion 52 is provided with curved chamfer portions 53 A and 53 B at which two locations, at corner portions of a distal end face 53 of an upstream end portion 52 A of the upstream side decreasing diameter portion 52 , are formed into curved surface shapes in a side sectional view (machined to curved chamfers, which may also be referred to as “curve machining”). That is, in the side sectional view, in a cut state, the upstream end portion 52 A of the upstream side decreasing diameter portion 52 includes corners with substantially right-angled shapes at two locations, upper and lower, in FIG. 3 .
  • FIG. 4 shows a magnified sectional diagram of an upstream end portion of an upstream side decreasing diameter portion of a case employed in a catalytic converter apparatus according to a third exemplary embodiment of the present invention.
  • FIG. 5A to FIG. 5C illustrate a fabrication process of the upstream end portion of the upstream side decreasing diameter portion shown in FIG. 4 .
  • Structural portions that are the same as in the first exemplary embodiment described above are assigned the same reference numerals, and descriptions thereof are not given.
  • the corners 64 A and 64 B at the two locations of the distal end face 64 are chamfer-machined (straight chamfer machining) to substantially flat surface shapes in diagonal directions in the side sectional view, to form straight chamfer portions 66 at the two locations.
  • a length D of each straight chamfer portion 66 in a direction orthogonal to the axial direction of the upstream side decreasing diameter portion 62 is set to 0.5 mm (2-C0.5).
  • the distal end face 64 of the upstream end portion 62 A has corners 66 A, 66 B, 66 C and 66 D at four locations in the side sectional view.
  • curved chamfer machining which may also be referred to as “curve machining”.
  • curve machining curved chamfer machining
  • curved chamfer portions 63 A, 63 B, 63 C and 63 D are formed.
  • the distal end face 63 is formed with a smooth curved surface shape at the upstream end portion 62 A (see FIG. 4 ).
  • the curved chamfer portions 63 A, 63 B, 63 C and 63 D are chamfer-machined such that a radius of curvature R of each is approximately 0.5 mm (4-R0.5).
  • Other structures of this catalytic converter apparatus are the same as in the first exemplary embodiment.
  • the glass coating layer 40 is formed by firing of the materials.
  • the distal end face 63 of the upstream end portion 62 A of the upstream side decreasing diameter portion 62 has been formed into a smooth curved surface shape by the straight chamfer machining followed by the curved chamfer machining.
  • sharp corners of the distal end face 63 of the upstream end portion 62 A of the upstream side decreasing diameter portion 62 are removed. Therefore, cracking of the glass coating layer 40 starting from sharp corners, due to contraction of the glass coating layer 40 during the firing, is suppressed. As a result, the formation of cracks in the glass coating layer 40 at the distal end face 63 of the upstream end portion 62 A of the upstream side decreasing diameter portion 62 may be suppressed.
  • FIG. 6 shows results of inspections for the presence or absence of chipping (cracking) of a glass coating layer in accordance with the shapes of upstream end portions of upstream side decreasing diameter portions.
  • FIG. 7 shows a graph of relationships between the shapes of upstream end portions of upstream side decreasing diameter portions and maximum tensile stresses.
  • a first comparative example (BL) is a situation in which a distal end face of an upstream end portion of an upstream side decreasing diameter portion has sharp corners in a block shape that is simply cut off.
  • a second comparative example (C0.2) is a situation in which, in side sectional view, straight chamfer machining (C0.2 chamfering) is applied to two locations at the corners of the distal end face of the upstream end portion of an upstream side decreasing diameter portion.
  • a third comparative example (C0.5) is a situation in which, in side sectional view, straight chamfer machining (C0.5 chamfering) is applied to two locations at the corners of the distal end face of the upstream end portion of an upstream side decreasing diameter portion.
  • a second example (R0.5) is a situation in which, in side sectional view, curve machining (curved chamfer machining) is applied to two locations at the corners of the distal end face of the upstream end portion of an upstream side decreasing diameter portion such that the radius of curvature R is 0.5 mm.
  • the maximum tensile stresses (MPa) in FIG. 7 are results predicted by computer numerical analyses of thermal stresses produced during cooling of the upstream end portions of the upstream side decreasing diameter portions.
  • the maximum tensile stress may be reduced by around 25% compared to the situation of the first comparative example (BL) that has sharp corners at the distal end face of the upstream end portion of the upstream side decreasing diameter portion.
  • the maximum tensile stress may be reduced by 50% or more compared to the situation of the first comparative example (BL) that has sharp corners at the distal end face of the upstream end portion of the upstream side decreasing diameter portion.
  • the maximum tensile stress may be reduced by around 50% or more by making the radius of curvature R of the distal end face of the upstream end portion of the upstream side decreasing diameter portion at least 0.5 mm.
  • the shape of the distal end face of the upstream end portion of an upstream side decreasing diameter portion is not limited by the first to third exemplary embodiments but may be modified to an alternative shape provided it is formed as a curved surface shape.
  • the present invention is not limited by the first to third exemplary embodiments.
  • the present invention may also be applied to a case in which an insulating layer is provided at a distal end face of an axial direction end portion (a downstream end portion) of a downstream side decreasing diameter portion that is disposed at the downstream side of a catalyst substrate inside a case and structures an inner pipe of the case.
  • the present invention may further be applied to a case in which insulating layers are provided at distal end faces of both an upstream side decreasing diameter portion and a downstream side decreasing diameter portion.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)
US14/801,017 2014-09-02 2015-07-16 Catalytic Converter Apparatus Abandoned US20160061081A1 (en)

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JP2014-177982 2014-09-02

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20160115843A1 (en) * 2014-10-28 2016-04-28 Toyota Jidosha Kabushiki Kaisha Electrically heated catalytic converter
US10598068B2 (en) 2015-12-21 2020-03-24 Emissol, Llc Catalytic converters having non-linear flow channels
US10927736B2 (en) * 2018-10-30 2021-02-23 Faurecia Emissions Control Technologies, Germany Gmbh Catalyst body, electrically heated catalyst and motor vehicle with a catalyst
US20220010716A1 (en) * 2016-08-19 2022-01-13 Kohler Co. System and method for low co emission engine
FR3138164A1 (fr) * 2022-07-25 2024-01-26 Renault S.A.S Convertisseur catalytique, système de traitement de gaz d’échappement et véhicule associés.

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Publication number Priority date Publication date Assignee Title
JP6408865B2 (ja) 2014-10-28 2018-10-17 イビデン株式会社 電気加熱式触媒コンバータ

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Publication number Priority date Publication date Assignee Title
GB671159A (en) * 1950-03-09 1952-04-30 George Bromhead Walker An improved silencer or muffler for engine and other gas exhausts
JP2010050440A (ja) * 2008-07-23 2010-03-04 Hitachi Metals Ltd Ｒ−Ｆｅ−Ｂ系焼結磁石ユニットおよびそれを用いたリニアモータ用磁気回路並びにそれらの製造方法
EP2419613B1 (en) * 2009-04-17 2016-08-17 Unifrax I LLC Exhaust gas treatment device
JP5316707B2 (ja) * 2011-03-10 2013-10-16 トヨタ自動車株式会社 内燃機関の排気浄化装置
JP5508338B2 (ja) * 2011-05-20 2014-05-28 日本特殊陶業株式会社 ガスセンサ素子の製造方法
JP2013185573A (ja) * 2012-03-12 2013-09-19 Toyota Motor Corp 電気加熱式触媒

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20160115843A1 (en) * 2014-10-28 2016-04-28 Toyota Jidosha Kabushiki Kaisha Electrically heated catalytic converter
US9506387B2 (en) * 2014-10-28 2016-11-29 Ibiden Co., Ltd. Electrically heated catalytic converter
US10598068B2 (en) 2015-12-21 2020-03-24 Emissol, Llc Catalytic converters having non-linear flow channels
US10815856B2 (en) 2015-12-21 2020-10-27 Mansour Masoudi Catalytic converters having non-linear flow channels
US20220010716A1 (en) * 2016-08-19 2022-01-13 Kohler Co. System and method for low co emission engine
US11643962B2 (en) * 2016-08-19 2023-05-09 Kohler Co. System and method for low CO emission engine
US10927736B2 (en) * 2018-10-30 2021-02-23 Faurecia Emissions Control Technologies, Germany Gmbh Catalyst body, electrically heated catalyst and motor vehicle with a catalyst
FR3138164A1 (fr) * 2022-07-25 2024-01-26 Renault S.A.S Convertisseur catalytique, système de traitement de gaz d’échappement et véhicule associés.

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