WO1997032119B1 - Catalytic converter for exhaust gases having a high surface area catalytic core element - Google Patents
Catalytic converter for exhaust gases having a high surface area catalytic core elementInfo
- Publication number
- WO1997032119B1 WO1997032119B1 PCT/US1997/001930 US9701930W WO9732119B1 WO 1997032119 B1 WO1997032119 B1 WO 1997032119B1 US 9701930 W US9701930 W US 9701930W WO 9732119 B1 WO9732119 B1 WO 9732119B1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- core element
- catalytic converter
- catalytic
- catalytic core
- foam
- Prior art date
Links
- 230000003197 catalytic Effects 0.000 title claims abstract 82
- 239000007789 gas Substances 0.000 title claims 15
- 239000007769 metal material Substances 0.000 claims abstract 15
- 238000002485 combustion reaction Methods 0.000 claims abstract 4
- 230000003247 decreasing Effects 0.000 claims abstract 3
- 230000001788 irregular Effects 0.000 claims abstract 2
- 239000011148 porous material Substances 0.000 claims abstract 2
- KDLHZDBZIXYQEI-UHFFFAOYSA-N palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims 32
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims 32
- 239000000463 material Substances 0.000 claims 21
- 229910052763 palladium Inorganic materials 0.000 claims 16
- 229910052697 platinum Inorganic materials 0.000 claims 16
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 claims 16
- 229910052703 rhodium Inorganic materials 0.000 claims 16
- 239000010948 rhodium Substances 0.000 claims 16
- 238000010438 heat treatment Methods 0.000 claims 15
- 239000002002 slurry Substances 0.000 claims 15
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims 14
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims 14
- 239000000956 alloy Substances 0.000 claims 12
- 229910045601 alloy Inorganic materials 0.000 claims 12
- 239000011230 binding agent Substances 0.000 claims 10
- 239000011368 organic material Substances 0.000 claims 10
- OZAIFHULBGXAKX-UHFFFAOYSA-N precursor Substances N#CC(C)(C)N=NC(C)(C)C#N OZAIFHULBGXAKX-UHFFFAOYSA-N 0.000 claims 10
- 239000000203 mixture Substances 0.000 claims 9
- 229910052804 chromium Inorganic materials 0.000 claims 7
- VYZAMTAEIAYCRO-UHFFFAOYSA-N chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims 7
- 239000011651 chromium Substances 0.000 claims 7
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims 7
- 239000010941 cobalt Substances 0.000 claims 7
- 229910052803 cobalt Inorganic materials 0.000 claims 7
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims 7
- 229910052737 gold Inorganic materials 0.000 claims 7
- 239000010931 gold Substances 0.000 claims 7
- 229910052742 iron Inorganic materials 0.000 claims 7
- ZOKXTWBITQBERF-UHFFFAOYSA-N molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims 7
- 229910052750 molybdenum Inorganic materials 0.000 claims 7
- 239000011733 molybdenum Substances 0.000 claims 7
- 229910052759 nickel Inorganic materials 0.000 claims 7
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 claims 7
- 239000010955 niobium Substances 0.000 claims 7
- 239000010970 precious metal Substances 0.000 claims 7
- -1 rare earths Chemical compound 0.000 claims 7
- 229910052709 silver Inorganic materials 0.000 claims 7
- 239000004332 silver Substances 0.000 claims 7
- BQCADISMDOOEFD-UHFFFAOYSA-N silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims 7
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 claims 7
- 229910052715 tantalum Inorganic materials 0.000 claims 7
- 239000010936 titanium Substances 0.000 claims 7
- RTAQQCXQSZGOHL-UHFFFAOYSA-N titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims 7
- 229910052719 titanium Inorganic materials 0.000 claims 7
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims 7
- 229910052721 tungsten Inorganic materials 0.000 claims 7
- 239000010937 tungsten Substances 0.000 claims 7
- 229910052782 aluminium Inorganic materials 0.000 claims 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminum Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims 5
- 239000003575 carbonaceous material Substances 0.000 claims 5
- 229910052751 metal Inorganic materials 0.000 claims 5
- 239000002184 metal Substances 0.000 claims 5
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims 5
- 235000019422 polyvinyl alcohol Nutrition 0.000 claims 5
- 229920002451 polyvinyl alcohol Polymers 0.000 claims 5
- 239000000843 powder Substances 0.000 claims 5
- 239000003344 environmental pollutant Substances 0.000 claims 4
- 231100000719 pollutant Toxicity 0.000 claims 4
- 239000006227 byproduct Substances 0.000 claims 2
- 239000011248 coating agent Substances 0.000 claims 2
- 238000000576 coating method Methods 0.000 claims 2
- 238000003780 insertion Methods 0.000 claims 2
- 238000007599 discharging Methods 0.000 claims 1
- 230000001473 noxious Effects 0.000 claims 1
- 239000004020 conductor Substances 0.000 abstract 3
- 230000004913 activation Effects 0.000 abstract 1
- 238000004519 manufacturing process Methods 0.000 abstract 1
- 230000035882 stress Effects 0.000 abstract 1
Abstract
The subject invention is a novel catalytic converter (400, 500) having a catalytic core element (202, 302, 402, 502, 602, 702, and 802) which is capable of withstanding the thermal stresses and vibrations encountered in typical catalytic converter applications. The catalytic core element is relatively easy and inexpensive to manufacture, has a relatively long operating life, has a relatively low pressure drop, and can be manufactured having various cross section configurations. The catalytic converter (400, 500) includes a catalytic core element (202, 302, 402, 502, 602, 702, and 802) comprising a rigid, foam-like, metallic material having interconnecting walls (204) defining an open pattern of interconnected pores (206) which join together to form irregular passages extending through the catalytic core element. In order to reduce flow resistance or pressure drop across the catalytic core element (302), the catalytic core element may be formed of 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 order to decrease the activation time of the foam-like metallic material forming the catalytic core element (402), electrical conductors (412) may be connected to the catalytic core element to form an electric circuit whereby a source of electrical potential may be connected across the electrical conductors so that during operation the catalytic core element serves as a resistance between the electrical conductors to rapidly heat the catalytic core element to a selected temperature. The catalytic core element (202, 302, 402, 502, 602, 702, and 802) may be formed into various sizes and configurations and may be placed within the exhaust manifold (700), exhaust pipe (712), or the muffler assembly (804) of an internal combustion engine.
Claims
1. A catalytic converter comprising: a housing having at least one exhaust gas inlet port and at least one exhaust gas outlet port; and a catalytic core element formed from a rigid, foam-like, high temperature metallic material prepared by the steps of: selecting an organic reticulated precursor material having a predetermined cell size; preparing a slurry of binder and metal powder, said binder being selected from the family of phenolic or PVA; impregnating said organic reticulated precursor material with said slurry; curing the impregnated organic material; heating the cured impregnated organic material and the slurry, retaining the shape of the original organic structure; heating the remaining material structure to remove the presence of any carbonaceous material; and heating the remaining structure to sinter the structure.
2. The catalytic converter of claim 1 wherein said rigid, foam-like, high temperature metallic material is selected from the group consisting of platinum, palladium, rhodium or a combination thereof.
3. The catalytic converter of claim 1 wherein said rigid, foam-like, high temperature metallic material is selected from the group consisting of chromium, cobalt, columbium, iron, nickel, molybdenum, or precious metals including gold, silver, platinum, palladium, rhodium, rare earths, titanium, tantalum, tungsten, and their respective alloys.
4. The catalytic converter of claim 3 wherein said rigid, foam-like, high temperature metallic material includes a platinum, palladium, rhodium, or a combination thereof, coating for imparting a catalytic action on the pollutant exhaust gases entering through said exhaust inlet port such that the pollutant gases are converted to harmless by-products which then pass out through said exhaust outlet port to be discharged into the atmosphere.
5. The catalytic converter of claim 1 further comprising means to heat said catalytic core element to a desired temperature.
6. A catalytic converter comprising a housing having at least one exhaust gas inlet port and at least one exhaust gas outlet port; and a catalytic core element comprising more than one individual segment formed from rigid foam-like, high temperature metallic material prepared by the steps of: selecting an organic reticulated precursor material having a predetermined cell size; preparing a slurry of binder and metal powder, said binder being selected from the family of phenolic or PVA; impregnating said organic reticulated precursor material with said slurry; curing the impregnated organic material; heating the cured impregnated organic material and the slurry, retaining the shape of the original organic structure; heating the remaining material structure to remove the presence of any carbonaceous material; and heating the remaining structure to sinter the structure.
7. The catalytic converter of claim 6 wherein said rigid, foam-like, high temperature metallic material is selected from the group consisting of platinum, palladium, rhodium or a combination thereof.
AHENDfcD SHEET (ARTICLE 19) 21
8. The catalytic converter of claim 6 wherein said rigid, foam-like, high temperature metallic material is selected from the group consisting of chromium, cobalt, columbium, iron, nickel, molybdenum, or precious metals including gold, silver, platinum, palladium, rhodium, rare earths, titanium, tantalum, tungsten, and their respective alloys.
9. The catalytic converter of claim 6 wherein said rigid, foam-like, high temperature metallic material includes a platinum, palladium, rhodium, or a combination thereof, coating for imparting a catalytic action on the pollutant exhaust gases entering through said exhaust inlet port such that the pollutant gases are converted to harmless by-products which then pass out through said exhaust outlet port to be discharged into the atmosphere.
10. The catalytic converter of claim 6 wherein said catalytic element further comprises means to electrically heat at least one of said individual segment to a desired temperature.
11. A catalytic converter for converting a flow of exhaust gases into harmless gases, the catalytic converter comprising a catalytic core element formed from at least one rigid, foam-like, metallic segment having at least one longitudinally extending aperture therein for receiving the exhaust gases.
12. The catalytic converter of claim 11 further comprising a housing having an exhaust gas inlet port for receiving the exhaust gases an exhaust gas outlet port for discharging the exhaust gases, wherein said catalytic core element is positioned within, and spaced from, said housing to form an annulus therebetween, whereby the exhaust gases are directed from said exhaust inlet port, through said longitudinally extending aperture, radially outwardly from said aperture through the catalytic core element to said annulus, and out through said exhaust outlet port.
13. The catalytic converter of claim 11 wherein said catalytic core element comprises a plurality of staggered, longitudinally extending apertures.
14. The catalytic converter of claim 13 wherein said catalytic core element further comprises an inlet surface and an outlet surface, wherein a fixed number of said apertures are directed inwardly into said catalytic core element from said inlet surface and a fixed number of said apertures are directed inwardly into said catalytic core element from said outlet surface, whereby the exhaust gases are directed into said catalytic core element through said inlet surface and said apertures which are directed inwardly from said inlet surface, radially outwardly from said apertures through said catalytic core element to said apertures which are directed inwardly from said outlet surface, and out of said catalytic core element through said apertures.
15. The catalytic converter of claim 11 wherein said metallic segment is formed from a material selected from the group consisting of platinum, palladium, rhodium, or a combination thereof.
16. The catalytic converter of claim 11 wherein said 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. 23
17. The catalytic converter of claim 11 wherein said catalytic core element is formed of more than one rigid, foam-like, metallic segments arranged one after the other with their density decreasing in the direction of flow of the exhaust gases.
18. The catalytic converter of claim 11 further comprising means to heat said catalytic core element to a desired temperature.
19. A catalytic converter for converting noxious exhaust gas components into harmless gases, the catalytic converter comprising: a housing having an exhaust gas inlet and an exhaust gas outlet and defining an enclosed space therebetween, said space being separated into a catalytic converter region and an attenuation region; a catalytic core element disposed within said catalytic converter region, wherein said catalytic core element comprises at least one rigid, foam-like, metallic segment; and a sound attenuation means disposed within said attenuation region for sound attenuation therein; wherein said rigid, foam-like, metallic segment is prepared by the steps of: selecting an organic reticulated precursor material having a predetermined cell size; preparing a slurry of binder and metal powder, said binder being selected from the family of phenolic or PVA; impregnating said organic reticulated precursor material with said slurry; curing the impregnated organic material; heating the cured impregnated organic material and the slurry, retaining the shape of the original organic structure; heating the remaining material structure to remove the presence of any carbonaceous material; and heating the remaining structure to sinter the structure. 24
20. The catalytic converter of claim 19 wherein said catalytic core element includes at least one longitudinally extending aperture.
21. The catalytic converter of claim 19 wherein said catalytic core element includes a plurality of staggered longitudinally extending apertures.
22. The catalytic converter of claim 19 wherein said metallic segment is formed from a material selected from the group consisting of platinum, palladium, rhodium, or a combination thereof.
23. The catalytic converter of claim 19 wherein said 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.
24. The catalytic converter of claim 19 wherein said catalytic core element is formed of more than one rigid, foam-like, metallic segments arranged one after the other with their density decreasing in the direction of flow of the exhaust gases.
25. A catalytic converter for insertion in an exhaust manifold of an internal combustion engine comprising a catalytic core element formed from at least one rigid, foam-like, metallic segment having a configuration for placement within the exhaust manifold; wherein each said foam-like, metallic segment is prepared by the steps of: selecting an organic reticulated precursor material having a predetermined cell size; preparing a slurry of binder and metal powder, said binder being selected from the family of phenolic or PVA; impregnating said organic reticulated precursor material with said slurry; curing the impregnated organic material; heating the cured impregnated organic material and the slurry, retaining the shape of the original organic structure; 25
heating the remaining material structure to remove the presence of any carbonaceous material; and heating the remaining structure to sinter the structure.
26. The catalytic converter of claim 25 wherein said metallic segment is formed from a material selected from the group consisting of platinum, palladium, rhodium, or a combination thereof.
27. The catalytic converter of claim 25 wherein said 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.
28. A catalytic converter for insertion in an exhaust pipe of an internal combustion engine comprising a catalytic core element formed from at least one rigid, foam-like, metallic segment having a configuration for placement within the exhaust pipe; wherein each said rigid, foam-like, metallic segment is prepared by the steps of: selecting an organic reticulated precursor material having a predetermined cell size; preparing a slurry of binder and metal powder, said binder being selected from the family of phenolic or PVA; impregnating said organic reticulated precursor material with said slurry; curing the impregnated organic material; heating the cured impregnated organic material and the slurry, retaining the shape of the original organic structure; heating the remaining material structure to remove the presence of any carbonaceous material; and heating the remaining structure to sinter the structure. 26
29. The catalytic converter of claim 28 wherein said metallic segment is formed from a material selected from the group consisting of platinum, palladium, rhodium, or a combination thereof.
30. The catalytic converter of claim 28 wherein said 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.
31. A catalytic converter for use with the exhaust system of an internal combustion engine, the catalytic converter comprising: a catalytic core element comprising at least one segment comprising a rigid, foam-like, material having interconnecting walls defining an open pattern of interconnected pores which join together to form irregular passages extending through the catalytic core element; wherein said catalytic core element having a configuration for placement within the exhaust system.
32. The catalytic converter of claim 31 wherein said metallic segment is formed from a material selected from the group consisting of platinum, palladium, rhodium, or a combination thereof.
33. The catalytic converter of claim 31 wherein said 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.
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 | |
| US08/607,389 | 1996-02-27 | ||
| US08/607,768 | 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 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| WO1997032119A1 WO1997032119A1 (en) | 1997-09-04 |
| WO1997032119B1 true WO1997032119B1 (en) | 1997-10-09 |
Family
ID=27416973
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US1997/001930 WO1997032119A1 (en) | 1996-02-27 | 1997-02-25 | Catalytic converter for exhaust gases having a high surface area catalytic core element |
Country Status (2)
| Country | Link |
|---|---|
| AU (1) | AU2118697A (en) |
| WO (1) | WO1997032119A1 (en) |
Families Citing this family (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5857328A (en) * | 1997-11-24 | 1999-01-12 | General Motors Corporation | Exhaust manifold catalytic converter |
| DE19724289A1 (en) * | 1997-06-09 | 1998-12-10 | Emitec Emissionstechnologie | Catalyst for cleaning an exhaust gas stream, especially from a small engine |
| 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 |
| DE102006024199A1 (en) * | 2006-05-23 | 2007-11-29 | Arvinmeritor Emissions Technologies Gmbh | Turbulator for exhaust system |
| DE102007008823A1 (en) * | 2007-02-22 | 2008-08-28 | Alantum Gmbh & Co. Kg | Catalyst support body |
| FR3103517B1 (en) * | 2019-11-22 | 2021-10-29 | Faurecia Systemes Dechappement | Exhaust gas heater with metal foam heating element |
| GB202002983D0 (en) * | 2020-03-02 | 2020-04-15 | Diesekt3 Ltd | Components and assemblies for treating exhaust emissions |
| FR3122453B1 (en) * | 2021-04-28 | 2023-12-29 | Faurecia Systemes Dechappement | Exhaust heating element |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2135620B1 (en) * | 1971-05-05 | 1973-07-13 | Chrysler Uk | |
| JPS5618254B2 (en) * | 1974-04-08 | 1981-04-27 | ||
| JPS5710319A (en) * | 1980-06-23 | 1982-01-19 | Toyota Motor Corp | Exhaust gas filter for internal combustion engine |
| JPS62193650A (en) * | 1986-02-19 | 1987-08-25 | Hitachi Zosen Corp | Catalyst carrier using foamed metal |
| JPH086582B2 (en) * | 1986-10-31 | 1996-01-24 | マツダ株式会社 | Engine exhaust gas purification catalytic device |
| DE3729126A1 (en) * | 1987-09-01 | 1989-04-06 | Mototech Motoren Umweltschutz | Diesel soot-particle filter and process for the production thereof |
| JP2618764B2 (en) * | 1991-04-26 | 1997-06-11 | 本田技研工業株式会社 | Method and apparatus for purifying exhaust gas of an internal combustion engine |
-
1997
- 1997-02-25 WO PCT/US1997/001930 patent/WO1997032119A1/en active Application Filing
- 1997-02-25 AU AU21186/97A patent/AU2118697A/en not_active Abandoned
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