WO1997032119A1 - Ame catalytique de grande superficie pour pot catalytique de gaz d'echappement - Google Patents

Ame catalytique de grande superficie pour pot catalytique de gaz d'echappement Download PDF

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Publication number
WO1997032119A1
WO1997032119A1 PCT/US1997/001930 US9701930W WO9732119A1 WO 1997032119 A1 WO1997032119 A1 WO 1997032119A1 US 9701930 W US9701930 W US 9701930W WO 9732119 A1 WO9732119 A1 WO 9732119A1
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WO
WIPO (PCT)
Prior art keywords
core element
catalytic
catalytic converter
catalytic core
exhaust
Prior art date
Application number
PCT/US1997/001930
Other languages
English (en)
Other versions
WO1997032119B1 (fr
Inventor
Donald W. Graham
Samuel R. Hollingsworth, Jr.
Robert D. Burns
Michael D. Mitchel
Sokhorn Eam
Original Assignee
Astro Met, Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from US08/755,281 external-priority patent/US5937641A/en
Application filed by Astro Met, Inc. filed Critical Astro Met, Inc.
Priority to AU21186/97A priority Critical patent/AU2118697A/en
Publication of WO1997032119A1 publication Critical patent/WO1997032119A1/fr
Publication of WO1997032119B1 publication Critical patent/WO1997032119B1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
    • 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
    • F01N13/009—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 two or more separate purifying devices arranged in series
    • F01N13/0097—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 two or more separate purifying devices arranged in series the purifying devices are arranged in a single housing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • 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
    • 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
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2807—Metal other than sintered metal
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2882—Catalytic reactors combined or associated with other devices, e.g. exhaust silencers or other exhaust purification devices
    • F01N3/2885—Catalytic reactors combined or associated with other devices, e.g. exhaust silencers or other exhaust purification devices with exhaust silencers in a single housing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2490/00—Structure, disposition or shape of gas-chambers
    • F01N2490/02—Two or more expansion chambers in series connected by means of tubes
    • 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 subject invention relates to catalytic converters and particularly to catalytic converters for exhaust gases having a high surface area catalytic core element formed from rigid, reticulated or foam-like, metallic material.
  • Catalytic converters have been widely utilized with internal combustion engines, such as used in automobiles, to convert noxious exhaust gas components into harmless gases, with the intention being particularly directed to promoting the emission of carbon monoxide, hydrocarbons and oxides of nitrogen into carbon dioxide, water and nitrogen.
  • the principal components of a typical catalytic converter are a housing having exhaust gas inlet and outlet ports and a catalytic core element enclosed within the housing.
  • the catalytic core element of a conventional catalytic converter typically utilize a multichannel or honeycomb ceramic substrate having a catalyst deposited thereon; or catalyst coated refractory metal oxide beads or pellets; or a corrugated thin metal foil honeycomb monolith having a catalyst carried on or supported on its surface.
  • the catalyst typically used for catalytic converters is normally a noble metal, e.g. , platinum, palladium, rhodium, ruthenium, or a mixture or combination of two or more of such metals.
  • the catalyst catalyzes a chemical reaction, mainly oxidation, whereby the pollutant materials are converted to harmless by-products which then pass through the exhaust system into the atmosphere.
  • catalytic converters having catalytic core elements which utilize catalyst coated refractory metal oxide beads or pellets are bead or pellet fludization.
  • a catalytic converter must survive the turbulent hot exhaust stream and complete the combustion of the gases. During operation, the hot exhaust flow can agitate, swirl and grind the beads or pellets until the function of the converter significantly deteriorates. Accordingly, catalytic converters having such catalytic core elements utilizing catalyst coated refractory metal oxide beads or pellets often require repair or replacement which significantly increases the cost of their use.
  • pressure drop means the difference between the pressure at the inlet face and the outlet face of the catalytic core element.
  • the pressure drop across a catalytic core element of a catalytic converter generally used in the automotive industry is typically 2 inches of water at idle, and 12 to 15 inches of water at higher speeds. Higher pressure drops are undesirable, because the engine must expend extra energy to force the exhaust gas through the converter core element thereby reducing engine efficiency.
  • the prior art contains a variety of suggestions as to various substrates that may be used for catalytic core elements, including suggestions that a foam metal may be suitable as a substrate for a catalyst material.
  • a foam metal may be suitable as a substrate for a catalyst material.
  • the particular construction of a catalytic converter having a core element formed from a foam metal has not been disclosed.
  • foam metals formed from ferrous metals could not be made for commercial applications and the prior art does not disclose the particular construction or method of manufacture of the catalytic core element of the present invention.
  • the present invention is directed to a catalytic converter for converting a flow of exhaust gases into harmless gasses comprising a high surface area catalytic core element formed from rigid, reticulated or foam-like, metallic material.
  • the catalytic core element includes at least one longitudinally extending aperture therein for receiving the exhaust gases.
  • the catalytic core element includes a plurality of staggered, longitudinally extending apertures to reduce flow resistance.
  • the catalytic core element comprises a plurality of rigid, foam-like, metallic material segments arranged one after the other with their density decreasing in the direction of flow of the exhaust gases in order to reduce flow resistance.
  • the catalytic core element is mounted directly within the exhaust manifold of an internal combustion engine.
  • the catalytic core element is mounted directly within the exhaust pipe of an internal combustion engine. In another preferred embodiment of the invention, the catalytic core element is mounted within a housing having an exhaust gas inlet and an exhaust outlet.
  • the catalytic core element is mounted within a housing of a noise reducing muffler assembly.
  • the rigid, foam-like, metallic material is selected from the group consisting of alloys of aluminum, chromium. cobalt, columbium, iron, nickel, molybdenum, or precious metals including gold, silver, platinum, palladium, rhodium, rare earths, titanium, tantalum, tungsten, and their respective alloys.
  • the rigid, foam-like, metallic material may have a catalyst deposited thereon.
  • the catalytic core includes electrical conductors connected to the catalytic core element to form an electrical circuit such that a source of electrical potential may be connected across the electrical conductors whereby the catalytic core element may be electrically heated to a selected temperature.
  • a primary object of this invention is to provide a catalytic converter for exhaust gases which is capable of withstanding the thermal stresses and vibrations encountered in typical catalytic converter installations and applications.
  • Another primary object of this invention is to provide a catalytic converter for exhaust gases which has a simple design and is relatively inexpensive to manufacture.
  • Another primary object of this invention is to provide a catalytic converter for exhaust gases which has relatively long operating life.
  • Another primary object of this invention is to provide a catalytic converter for exhaust gases which has a relatively low pressure drop. Another primary object of this invention is to provide a catalytic converter for exhaust gases which requires the same or less space than conventional catalytic converters. Another primary object of this invention is to provide a catalytic converter for exhaust gases which can be manufactured having various cross-sectional configurations.
  • Another primary object of this invention is to provide a catalytic converter for exhaust gases having a catalytic core element comprising a rigid, foam-like,, material formed from a material selected from the group consisting of platinum, palladium and rhodium or a mixture or combination thereof.
  • Another primary object of this invention is to provide a catalytic converter for exhaust gases having a catalytic core element comprising a rigid, foam-like, material selected from the group consisting of alloys of aluminum, chromium, cobalt, columbium, iron, nickel, molybdenum, or precious metals including gold, silver, platinum, palladium, rhodium, rare earths, titanium, tantalum, tungsten, and their respective alloys.
  • Another primary object of this invention is to provide a catalytic converter for exhaust gases having a catalytic core element which may be heated to a selected temperature.
  • Another primary object of this invention is to provide a catalytic converter for exhaust gases having a catalytic core element which can be combined in a convenient package with a conventional muffler assembly.
  • FIG. 1 is a cross-sectional longitudinal view of a conventional catalytic converter for use with an internal combustion engine, having a catalytic core element comprising a multichannel or honeycomb ceramic substrate;
  • FIG. 2 is a pictorial view of a catalytic core element of the catalytic converter of the subject invention comprising a rigid, foam-like metallic segment;
  • FIG. 3 is an enlarged view of a portion of the catalytic core elements of FIG.
  • FIG. 4 is a cross-sectional longitudinal view of the catalytic core element of the subject invention comprising more than one individual segment;
  • FIG. 5 is a cross-sectional longitudinal view of a catalytic converter in accordance with the present invention and showing electrical connectors connected to the catalytic core element;
  • FIG. 6 is a cross-sectional longitudinal view of another embodiment of a catalytic converter in accordance with the present invention showing the catalytic core element of FIG. 5 having an enlarged inlet surface and a reduced thickness;
  • FIG. 7 is a pictorial view of the catalytic core element of FIG. 2 having a longitudinally extending central aperture
  • FIG. 8 is a pictorial view of the catalytic core element of FIG. 2 having a plurality of staggered longitudinally extending apertures;
  • FIG. 9 is a cross-sectional view of one configuration of a catalytic converter having the catalytic core element of FIG. 7;
  • FIG. 10 is a cross-section view of one configuration of a catalytic converter having the catalytic core element of FIG. 8;
  • FIG. 11 is a cross-sectional longitudinal view of an exhaust manifold of a typical internal combustion engine showing another embodiment of the catalytic converter installed therein; and FIG. 12 is a cross-sectional longitudinal view of another embodiment of the catalytic converter of the present invention installed in a catalytic converter and muffler assembly having a catalytic converter region and a acoustical or attenuation region.
  • the principal components of a typical catalytic converter for use with an internal combustion engine are a catalytic core element 102 enclosed in a housing 104 having exhaust gas inlet 106 and outlet 108 ports.
  • the catalytic core element 102 typically utilize a multichannel or honeycomb ceramic substrate (as shown) having a catalyst deposited thereon or a plurality of catalyst coated refractory metal oxide beads or pellets; or a corrugated thin metal foil honeycomb monolith having a catalyst carried on or supported on its surface.
  • the catalytic core element of the subject invention comprises at least one rigid, porous substrate or segment of reticulated or foam-like, high temperature, metallic material having relatively high mechanical strength and thermal shock resistance and is constructed in accordance with the manner and materials as disclosed in commonly owned and copending application Serial No. 08/607,768 filed February 25, 1996 and incorporated herein by reference.
  • rigid, porous substrate or segment of reticulated or foam-like, high temperature, metallic material forming the catalytic core element 202 of the subject invention comprising interconnecting metallic walls 204 which define an open pattern of micronically sized interconnected pores 206 which join together to form irregular passages extending through the catalytic core element 202 from one end 208 to the other end 210.
  • a continuing concern in the catalytic converter industry, particularly in the automotive field, is the fact that excessive flow resistance or pressure loss reduces engine efficiency and performance. Thus, reducing pressure loss while maintaining effective emission control is a continuing industry goal.
  • the pores 206 are sufficiently large and numerous to trap exhaust particles while permitting the relatively free flow of exhaust gases through the porous catalytic core element 202 between the exhaust inlet port and the exhaust outlet port of the catalytic converter. Further, the numerous changes in direction of the gas as it flows through the catalytic core element 202 operates to evenly distribute particulates throughout the catalytic core element 202 thereby reducing the possibility of pressure drop buildup.
  • the catalytic core element 302 comprises at least two individual segments 304 arranged one after the other and contacting one another with their density decreasing sequentially in the direction of the gas flow F. In this way, the flow resistance or pressure drop across the catalytic core element may be controlled or further reduced. By the production process according to the present invention, such segments having differing density may be produced without difficulty.
  • the catalytic core element of the subject invention is provided with a platinum, palladium, rhodium or a combination thereof coating or may be formed of a material selected from the group consisting of platinum, palladium, rhodium and a combination thereof for imparting a catalytic action on the pollutant exhaust gases entering the catalytic converter such that the pollutant gases are converted to harmless by-products which then pass out through the catalytic converter to be discharged into the atmosphere.
  • chromium such as chromium, cobalt, columbium, iron, nickel, molybdenum, or precious metals including gold, silver, rare earths, titanium, tantalum, tungsten, and their respective alloys may be selected to form the catalytic core element to achieve the desired catalytic reactions.
  • materials such as chromium, cobalt, columbium, iron, nickel, molybdenum, or precious metals including gold, silver, rare earths, titanium, tantalum, tungsten, and their respective alloys may be selected to form the catalytic core element to achieve the desired catalytic reactions.
  • the rigid, foam-like catalytic core element of the subject invention By forming the rigid, foam-like catalytic core element of the subject invention from material such as platinum, palladium, rhodium or a combination thereof as disclosed hereinabove, eliminates or reduces the need for coating the element with a catalyst thereby permitting the catalytic converter of the subject invention to be manufactured with significantly less time and cost than conventional catalytic converters. It is known to a person skilled in the art that this catalytic action only proceeds in the desired manner if a particular stoichiometric composition of the exhaust gases exists. Non-illustrated devices for controlling the composition of the exhaust gasses which are not, however, the subject of the present invention are also assumed to be known.
  • one embodiment of the catalytic converter 400 of the present invention comprising a catalytic core element 402 enclosed within a housing 404 having an exhaust inlet 406 and an exhaust outlet 408.
  • a catalytic core element 402 enclosed within a housing 404 having an exhaust inlet 406 and an exhaust outlet 408.
  • the catalytic core element 402 is electrically isolated from the housing 404 by insulation 410. Electrical conductors 412 are connected to the catalytic core element 402 to form an electrical circuit such that a source of electrical potential (not shown) may be connected across the electrical conductors 412.
  • the rigid, foam-like metallic catalytic core element 402 serves as a resistance between the electrical conductors 412 and. when a source of electrical potential is applied, the catalytic core element heats rapidly to a selected temperature. While the foregoing description describes a particular method of heating one or more catalytic core elements, it should be apparent to one skilled in the art that other conventional methods of heating one or more catalytic core elements, such as for example by inserting heating elements into the core, may be utilized.
  • the flow resistance or pressure drop of the exhaust gas traveling through the catalytic core element depends on the velocity of the flow, the inlet surface area, the density and thickness or length of the catalytic core element.
  • FIG. 6 another arrangement of the catalytic converter 500 of the subject invention is shown where the area A of the inlet surface 503 of the catalytic core element 502 is significantly enlarged and the thickness T of the catalytic core element 502 is significantly reduced.
  • the flow resistance or pressure drop may be controlled or reduced. Since the catalytic core element of the present invention is not susceptible to fracture, the particular dimensions of the catalytic core element may be varied to accommodate the desired purposes and may be produced without difficulty by the production process according to the present invention.
  • the flow resistance or pressure drop of the exhaust gas traveling through the catalytic core element may be reduced by providing the catalytic core element 602 with a longitudinally extending aperture 607 (FIG. 7) or a plurality of staggered apertures (Fig. 8) such that a number of apertures 609a extend longitudinally inwardly from the inlet surface 603 of the catalytic core element 602 and a number of apertures 609b extend longitudinally inwardly from the outlet surface 605 of the catalytic core element 602.
  • the catalytic converter can be configured such that the flow through the catalytic core element 602 can be radial, through a lateral portion of the catalytic core element or axial through the end portion.
  • FIG. 9 One such configuration is shown in Fig. 9 whereby the catalytic core element 602 of FIG. 7 is positioned within, and spaced from, a housing 604 to form an annulus 611 therebetween.
  • arrows 610 representing the flow of exhaust gases
  • exhaust gases are directed from the exhaust inlet 606 through the longitudinally extending aperture 607, radially outwardly from the aperture 607 through the catalytic core element 602 to the annulus 611, and out through the exhaust outlet 608.
  • the catalytic core element 602 of FIG. 8 is positioned within a housing 604.
  • Exhaust gases are directed into said catalytic core element 602 through apertures 609a, radially outwardly from the apertures 609a through the catalytic core element 602 to apertures 609b, and out of the catalytic core element 602.
  • the catalytic housing may be appropriately configured.
  • the housing may be configured with an outer flow channel to permit treated exhaust flow passing radially outwardly through the catalytic core element to exit axially out through an outlet port to be discharged into the atmosphere.
  • Catalytic converters for use in automobiles and small appliances and equipment often encounter severe space limitations. Since the catalytic core element according to the subject invention is not susceptible to fracture, the catalytic converter assembly itself may be made simpler in structure. Further, since the particular dimensions and shape of the catalytic core element may be varied to accommodate the desired purposes and may be produced without difficulty by the production process according to the present invention, the catalytic converter housing may be eliminated by directing positioning the catalytic core element within the exhaust manifold or exhaust pipe or tail pipe of the internal combustion engine. Referring to FIG.
  • a cross-sectional view of an exhaust manifold 700 of a typical internal combustion engine is shown having a right exhaust manifold section 704, a left exhaust manifold section 706, a crossover pipe 708, and an outlet connection 710 connected to the exhaust pipe 712.
  • the catalytic core element 702 is shown configured to be coaxially disposed within the exhaust manifold 700.
  • the catalytic converter of the subject invention eliminates the space requirement necessary for conventional catalytic converters and may be manufactured with significantly less time and cost than conventional catalytic converters requiring an outer housing. Further, by positioning the catalytic core element in the exhaust manifold the permits the rapid activation of the catalytic catalyst without the need of a secondary heating system.
  • FIG. 12 another embodiment of the catalytic converter 800 of the present invention is shown whereby the catalytic converter is placed within a catalytic converter and muffler assembly 804 having a catalytic converter region 806 and a downstream acoustical or attenuation region 808.
  • the principals of operation are found in known muffler constructions and are well known in the noise attenuation industry.
  • the catalytic converter 800 of the subject invention is positioned within the catalytic converter region 806 of the catalytic converter and muffler assembly 804 and includes a catalytic core element 802 enclosed within a housing 810 having an outer end wall 812 having an inlet port 814 for receiving one end of an exhaust pipe 816 and an inner end wall 818 that also forms an end wall of the adjacent attenuation region 808 and includes an outlet port 820.
  • exhaust gases are delivered from the engine by the exhaust pipe 816 to the catalytic converter and muffler assembly 804.
  • the exhaust gases pass through the catalytic core element 802 and are directed through outlet port 820 into the acoustical or attenuation region 808 where the transmission of sound in the exhaust gas is conventionally reduced.
  • catalytic converter having a catalytic core comprising at least one catalytic core element formed of a rigid, porous body or substrate of foam-like, high temperature, metallic material which is capable of withstanding the thermal stresses and vibrations encountered in typical catalytic converter installations and applications.
  • Catalytic converters utilizing such foam-like, high temperature, metallic materials are relatively easy and inexpensive to manufacture, have relatively long operating life, and require the same or less space than conventional catalytic converters.
  • catalytic core elements formed from such rigid, foam-like, high temperature, metallic materials may be configured to be easily incorporated into the exhaust manifold or exhaust pipe of an internal combustion engine or incorporated into a muffler assembly thereby reducing the overall size of an exhaust system.
  • foam-like, high temperature, metallic material selected from the group consisting of platinum, palladium, rhodium and a combination thereof eliminates or greatly reduces the need for catalytic coatings thereby simplifying and decreasing time and expense of manufacture.
  • the catalytic core elements may be electrically heated to substantially activate the catalytic action.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Catalysts (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)

Abstract

La présente invention concerne un pot catalytique (400, 500) pourvu d'une âme catalytique (202, 302, 402, 502, 602, 702 et 802) capable de résister aux contraintes et vibrations habituelles dans le cas des pots catalytiques. Cette âme catalytique, qui est relativement facile et économique à fabriquer, est caractérisée par une durée de vie relativement élevée pour une chute de pression relativement basse. Cette âme catalytique peut également se fabriquer sous des configurations correspondant à diverses sections en coupe. Le pot catalytique (400, 500) inclut une âme catalytique (202, 302, 402, 502, 602, 702 et 802) constituée d'une mousse métallique rigide pourvue de parois d'interconnexion (204) définissant une structure ouverte de pores interconnectés (206) qui se réunissent pour former des canaux irréguliers traversant l'âme catalytique. Pour limiter la résistance à l'écoulement ou la chute de pression lors de la traversée de l'âme catalytique (302), celle-ci peut être constituée d'au moins deux unités (304) disposées l'une après l'autre et en contact l'une avec l'autre, la densité des unités décroissant séquentiellement selon le sens d'écoulement des gaz (F). Pour réduire la période d'inefficacité de la mousse métallique formant l'âme catalytique (402), il est possible de lui connecter des conducteurs électriques (412) de façon à constituer un circuit électrique, une source de potentiel électrique étant raccordée aux bornes des conducteurs électriques. En cours de fonctionnement, les conducteurs électriques constituent avec l'âme catalytique une résistance électrique chauffant rapidement l'âme catalytique jusqu'à une température déterminée. L'âme catalytique (202, 302, 402, 502, 602, 702 et 802), qui peut se présenter sous différentes cotes et configurations, peut se placer à l'intérieur du collecteur d'échappement (700), du pot d'échappement (712), ou de l'ensemble pot de détente (804) d'un moteur à combustion interne.
PCT/US1997/001930 1996-02-27 1997-02-25 Ame catalytique de grande superficie pour pot catalytique de gaz d'echappement WO1997032119A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU21186/97A AU2118697A (en) 1996-02-27 1997-02-25 Catalytic converter for exhaust gases having a high surface area catalytic core element

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US60738996A 1996-02-27 1996-02-27
US60776896A 1996-02-27 1996-02-27
US08/607,768 1996-02-27
US08/607,389 1996-02-27
US08/755,281 1996-11-22
US08/755,281 US5937641A (en) 1996-11-22 1996-11-22 Catalytic converter for exhaust gases having a high surface area catalytic core element

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Publication Number Publication Date
WO1997032119A1 true WO1997032119A1 (fr) 1997-09-04
WO1997032119B1 WO1997032119B1 (fr) 1997-10-09

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AU (1) AU2118697A (fr)
WO (1) WO1997032119A1 (fr)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998056503A1 (fr) * 1997-06-09 1998-12-17 Emitec Gesellschaft Für Emissionstechnologie Mbh Support metallique pour catalyseur d'epuration d'un courant de gaz d'echappement, en particulier d'un petit moteur
US5857326A (en) * 1997-11-24 1999-01-12 General Motors Corporation Exhaust poison trap
US5857328A (en) * 1997-11-24 1999-01-12 General Motors Corporation Exhaust manifold catalytic converter
US6062020A (en) * 1997-11-12 2000-05-16 General Motors Corporation Exhaust manifold converter apparatus
WO2007134735A1 (fr) * 2006-05-23 2007-11-29 Emcon Technologies Germany (Augsburg) Gmbh Elément de tourbillonnement pour un système d'échappement des gaz
DE102007008823A1 (de) * 2007-02-22 2008-08-28 Alantum Gmbh & Co. Kg Katalysatorträgerkörper
FR3103517A1 (fr) * 2019-11-22 2021-05-28 Faurecia Systemes D'echappement Dispositif de chauffage de gaz d’échappement à élément chauffant en mousse métallique
GB2593810A (en) * 2020-03-02 2021-10-06 Diesekt3 Ltd Components and assemblies for treating exhaust emissions
US20220349326A1 (en) * 2021-04-28 2022-11-03 Faurecia Systemes D'echappement Exhaust gas heating element

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Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998056503A1 (fr) * 1997-06-09 1998-12-17 Emitec Gesellschaft Für Emissionstechnologie Mbh Support metallique pour catalyseur d'epuration d'un courant de gaz d'echappement, en particulier d'un petit moteur
JP2002503143A (ja) * 1997-06-09 2002-01-29 エミテク・ゲゼルシャフト・フュール・エミシオーンテクノロギー・ミット・ベシュレンクテル・ハフツング 排気ガスフロー、特に小型エンジンからの排気ガスフローを清浄化するための触媒コンバータ
US6062020A (en) * 1997-11-12 2000-05-16 General Motors Corporation Exhaust manifold converter apparatus
US5857326A (en) * 1997-11-24 1999-01-12 General Motors Corporation Exhaust poison trap
US5857328A (en) * 1997-11-24 1999-01-12 General Motors Corporation Exhaust manifold catalytic converter
WO2007134735A1 (fr) * 2006-05-23 2007-11-29 Emcon Technologies Germany (Augsburg) Gmbh Elément de tourbillonnement pour un système d'échappement des gaz
DE102007008823A1 (de) * 2007-02-22 2008-08-28 Alantum Gmbh & Co. Kg Katalysatorträgerkörper
FR3103517A1 (fr) * 2019-11-22 2021-05-28 Faurecia Systemes D'echappement Dispositif de chauffage de gaz d’échappement à élément chauffant en mousse métallique
US11713701B2 (en) 2019-11-22 2023-08-01 Faurecia Systemes D'echappement Exhaust gas heating device, having a metal foam heating element
GB2593810A (en) * 2020-03-02 2021-10-06 Diesekt3 Ltd Components and assemblies for treating exhaust emissions
US20220349326A1 (en) * 2021-04-28 2022-11-03 Faurecia Systemes D'echappement Exhaust gas heating element

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