WO2006001807A2 - Automotive exhaust component and method of manufacture - Google Patents
Automotive exhaust component and method of manufacture Download PDFInfo
- Publication number
- WO2006001807A2 WO2006001807A2 PCT/US2004/019502 US2004019502W WO2006001807A2 WO 2006001807 A2 WO2006001807 A2 WO 2006001807A2 US 2004019502 W US2004019502 W US 2004019502W WO 2006001807 A2 WO2006001807 A2 WO 2006001807A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- intermediate section
- inlet
- catalytic
- outlet
- housing
- Prior art date
Links
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
- F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
- B01D53/9454—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific device
-
- 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
- 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
- F01N13/1844—Mechanical joints
- F01N13/185—Mechanical joints the connection being realised by deforming housing, tube, baffle, plate, or parts thereof
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
- F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
- F01N3/2857—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing the mats or gaskets being at least partially made of intumescent material, e.g. unexpanded vermiculite
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- 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
- F01N2310/00—Selection of sound absorbing or insulating material
- F01N2310/08—Exfoliated vermiculite, e.g. zonolite, coke, pumice
-
- 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
- F01N2350/00—Arrangements for fitting catalyst support or particle filter element in the housing
- F01N2350/02—Fitting ceramic monoliths in a metallic 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
- F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
- F01N2450/20—Methods or apparatus for fitting, inserting or repairing different elements by mechanical joints, e.g. by deforming housing, tube, baffle plate or parts thereof
-
- 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
-
- 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49345—Catalytic device making
Definitions
- Converter 10 further comprises catalytic element 28.
- catalytic element 28 comprises a generally cylindrical, frangible, heat-resistant ceramic honeycomb substrate 30 having a large number of passages 32 therethrough, each of the passages 32 running generally parallel to the cylindrical axes of both substrate 30 and intermediate section 22.
- Passages 32 are generally arranged in a honeycomb pattern or a similar array. Passages 32 extend completely through substrate 30, thereby allowing the passage of gas from one end 34 of element 28 to the other end 36 thereof.
- substrate 30 is composed of cordierite. Other ceramic materials having adequate strength, thermal shock resistance, heat resistance, and chemical compatibility both with the exhaust gas stream and catalyst material applied thereto may also be used.
- the interior surfaces of passages 32 are substantially covered with a substance catalytically active to induce the chemical reaction of substances present in engine exhaust for the purification thereof.
- catalytic element 28 may comprise a plurality of ceramic or other substrates arranged sequentially or in parallel, e.g.
- Ceramic substrate 30 is preferably supported and held securely in sealing contact within intermediate section 22 by a generally encircling mat 38.
- the mat is preferably resilient, insulative, and shock absorbent and may be composed of a gas impervious, vermiculite based material, available in the open market. Such a material is intumescent, that is, it expands substantially upon heating. Typically a mat having an initial thickness of approximately 1 A" is used.
- mat 38 is wrapped to substantially encircle the ceramic substrate 30 and cover at least a portion of its longitudinal or axial length.
- ferritic stainless steels are commonly used, including various 400-series alloys. Most commonly 409SS and SAE51409 alloys are employed.
- carbon steels are frequently used.
- austenitic and 300-series stainless steel alloys such as 304SS are generally employed.
- the catalytic converter of the invention may be manufactured in a wide range of sizes to accommodate the requirements of different engines, which may range from small engines of a few horsepower or less, such as might be used in lawn mowers, snow blowers, weed trimmers, and similar off- road, non-propulsion applications, to large diesel engines used in trucks.
- Automotive converters are typically about 9 to 20 inches in total length. Small, non-propulsion engines may employ substrates as small as 1-inch diameter or even less and may be only a few inches long.
- the minimum length of the substrate is generally determined by the flow velocity and the amount of time the exhaust gas must be at the catalytic surface to achieve a chemical reaction that sufficiently reduces the concentration of pollutants.
- the total length of the converter is then determined both by the length of the active catalyst and the required shaping of the transition sections and the inlet and outlet ports. Often the inlet and outlet ports of a converter are approximately half the diameter of the substrate to reduce exhaust flow impedance. The tapering of the inlet transition and outlet transition sections may range from very gradual to very abrupt.
- a further disadvantage of techniques such as spinning is the amount of work hardening that results in the reduced section.
- This work hardening is highly detrimental in that it leaves the inlet and outlet ports with a ductility level that is insufficient to allow the ports to be reliably and hermetically attached to other exhaust components by clamping.
- joints have to be made using welds or flanges, which are more expensive and difficult to implement, especially with after-market installations.
- the present catalytic converter may be manufactured in other configurations.
- the converter may incorporate a plurality of cascaded catalytic elements.
- Fig. 5 depicts such an embodiment 11 including two catalyst elements 28, 28' in a generally cylindrical converter. Each of the elements is of substantially similar size and is encircled by an intumescent mat 38.
- a subsequent swaging is then carried out to form subsection 74 and reshape temporary transition 75" into transition 75 having the desired shape, as shown in Fig. 6.
- Either of the formations shown in Figs. 7A-7B may be carried out before or after insertion of the catalytic elements.
- Other sequences may also be employed.
- the formation of subsections and the insertion of the associated catalytic elements can be carried out in alternation.
- Such a sequence is also preferably employed if the transitions include bends.
- the aforementioned swaging is preferred, since it ordinarily produces an inner surface that is smooth and substantially ridge-free, whereby flow disruption is minimized.
- a housing that is not cylindrically symmetric is far easier and more efficient to form using swaging than spin forming or other similar processes.
- the forming process is carried out semicontinuously. Seamless tubes having substantially the diameters desired for the intermediate section (or the largest of its subsections) are supplied in long lengths. From these tubes are cut preforms adapted to be formed into the catalytic converter housing. Ceramic substrates are provided having the desired diameter and length. Each substrate is wrapped with an intumescent mat to form the catalytic element. The mat is compressed and the combined assembly inserted into the free end of the supply tube. The supply tube is then gripped circumferentially and its free end is swaged to form the inlet port and inlet transition section.
- the preform with its substrate, is then placed in a hydraulic ram assembly having swaging dies coaxially aligned and adapted to be forced compressively over each of the preform's ends, thereby simultaneously swaging each end.
- a plurality of dies are sequenced into a hydraulic ram and used stepwise to accomplish the desired reduction to the final inlet and outlet port diameters and to form the inlet and outlet transition sections.
- a plurality of rams are used, with the preform being indexed between rams, which are appointed with a desired sequence of dies to progressively swage the ends in a plurality of graduated swaging stages.
- a tube preform having approximately the diameter of the largest subsection 72 of the cascaded arrangement of intermediate section 70.
- Catalytic substrate 78 encircled by intumescent mat 80 is first inserted into section 72.
- an end of the preform is end-formed by forcibly inserting the preform into swaging die 92 adapted to reduce the diameter of the preform to create temporary subsection 74' and transition 73.
- the workpiece is removed from die 92 and catalytic substrate 82 encircled by intumescent mat 80 is disposed in temporary subsection 74' at a preselected location.
- gripping dies that simultaneously reduce a tube diameter beneficially improves the efficiency of a tube fabrication process by eliminating a step in many known forming processes.
- gripping operations capable of opposing the substantial axial forces required are frequently required for successful end forming.
- a separate step for reducing the diameter of an intermediate portion of the tube has been required.
- dies that accomplish both the required gripping and reduction eliminates a process step.
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP04755589A EP1791620A4 (en) | 2004-06-15 | 2004-06-18 | Automotive exhaust component and method of manufacture |
CN2004800438059A CN101547731B (en) | 2004-06-15 | 2004-06-18 | Automotive exhaust component and method of manufacture |
CA002570842A CA2570842A1 (en) | 2004-06-15 | 2004-06-18 | Automotive exhaust component and method of manufacture |
JP2007516452A JP4482585B2 (en) | 2004-06-15 | 2004-06-18 | Automotive exhaust components and manufacturing method |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/867,925 US7323145B2 (en) | 2002-03-26 | 2004-06-15 | Automotive exhaust component and method of manufacture |
US10/867,925 | 2004-06-15 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2006001807A2 true WO2006001807A2 (en) | 2006-01-05 |
WO2006001807A3 WO2006001807A3 (en) | 2009-04-02 |
Family
ID=35782199
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2004/019502 WO2006001807A2 (en) | 2004-06-15 | 2004-06-18 | Automotive exhaust component and method of manufacture |
Country Status (6)
Country | Link |
---|---|
US (1) | US7323145B2 (en) |
EP (1) | EP1791620A4 (en) |
JP (1) | JP4482585B2 (en) |
CN (1) | CN101547731B (en) |
CA (1) | CA2570842A1 (en) |
WO (1) | WO2006001807A2 (en) |
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US20070294891A1 (en) * | 2006-06-23 | 2007-12-27 | Haimian Cai | Method of forming a catalytic converter from a radially deformed pre-form member |
US20080000084A1 (en) * | 2006-06-23 | 2008-01-03 | Haimian Cai | Method of spin forming a catalytic converter |
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CN107218107B (en) * | 2017-06-02 | 2023-10-31 | 河南科技大学 | Catalyst and internal combustion engine and vehicle using same |
GB2568900B (en) * | 2017-11-29 | 2020-09-02 | Perkins Engines Co Ltd | Exhaust gas treatment assembly comprising a gas permeable block and a housing, and method of assembly |
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2004
- 2004-06-15 US US10/867,925 patent/US7323145B2/en not_active Expired - Fee Related
- 2004-06-18 EP EP04755589A patent/EP1791620A4/en not_active Withdrawn
- 2004-06-18 CA CA002570842A patent/CA2570842A1/en not_active Abandoned
- 2004-06-18 CN CN2004800438059A patent/CN101547731B/en not_active Expired - Fee Related
- 2004-06-18 JP JP2007516452A patent/JP4482585B2/en not_active Expired - Fee Related
- 2004-06-18 WO PCT/US2004/019502 patent/WO2006001807A2/en active Search and Examination
Non-Patent Citations (1)
Title |
---|
See references of EP1791620A4 * |
Also Published As
Publication number | Publication date |
---|---|
EP1791620A4 (en) | 2010-07-07 |
JP2008511776A (en) | 2008-04-17 |
JP4482585B2 (en) | 2010-06-16 |
US7323145B2 (en) | 2008-01-29 |
WO2006001807A3 (en) | 2009-04-02 |
EP1791620A2 (en) | 2007-06-06 |
CN101547731A (en) | 2009-09-30 |
CN101547731B (en) | 2012-07-04 |
CA2570842A1 (en) | 2006-01-05 |
US20040265191A1 (en) | 2004-12-30 |
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