US20120055140A1 - Exhaust treatment system and method of assembly - Google Patents
Exhaust treatment system and method of assembly Download PDFInfo
- Publication number
- US20120055140A1 US20120055140A1 US13/095,194 US201113095194A US2012055140A1 US 20120055140 A1 US20120055140 A1 US 20120055140A1 US 201113095194 A US201113095194 A US 201113095194A US 2012055140 A1 US2012055140 A1 US 2012055140A1
- Authority
- US
- United States
- Prior art keywords
- internal combustion
- combustion engine
- insulating
- film laminate
- exhaust
- 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
Links
Images
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
-
- 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
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P2700/00—Indexing scheme relating to the articles being treated, e.g. manufactured, repaired, assembled, connected or other operations covered in the subgroups
- B23P2700/03—Catalysts 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
- 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
- Y10T29/49826—Assembling or joining
Definitions
- Exemplary embodiments of the present invention relate to exhaust systems for internal combustion engines and, more particularly, to an exhaust treatment system and method of assembly.
- a typical exhaust system for an internal combustion engine may involve the placement of an exhaust treatment system or assembly (typically an oxidation catalyst device) in close proximity to the exhaust manifold of the internal combustion engine.
- This exhaust treatment system in this example referred to as a close-coupled exhaust treatment system, is typically a catalytic device in which regulated exhaust constituents (ex. CO, HC, NO x , Particulates, etc.) may be converted to non-regulated compounds (ex. CO 2 , H 2 O, etc.).
- the close coupling to the engine exhaust manifold minimizes thermal loss from the exhaust gas, as it travels between the engine and the exhaust treatment system, resulting in higher temperatures and quicker catalytic activation. Minimizing thermal loss is important since the catalyst compounds that are typically used for treating engine exhaust gas operate at optimal efficiency at temperatures in excess of 350° C.
- the catalytic device may be disposed in a housing or canister that comprises a single piece cylindrical or near cylindrical member that is closed at each end by an inlet or an outlet cone that is in fluid communication with the exhaust system of the internal combustion engine.
- the catalytic device is typically constructed as a catalyst coated, flow-though substrate constructed of ceramic or metal that is supported within the canister by an insulating and cushioning mat material that is interposed between the perimeter of the flow-through substrate and an inner wall of the canister.
- Assembly of the exhaust treatment system may involve the use of a stuffing ram in which the catalyst coated, flow-through substrate is wrapped in the mat material and then axially inserted (i.e. “stuffed”) by the stuffing ram through a stuffing shoe and into the canister.
- the stuffing shoe compresses the mat material as it enters the canister allowing it to re-expand once the substrate is positioned properly in the canister. While the process can be effective for the assembly of the exhaust treatment system, the stuffing shoe may, at times, misalign or damage the mat causing durability issues during operation of the internal combustion engine.
- a method of assembling an exhaust treatment system for an internal combustion engine comprises a substrate disposed in a canister and an insulating and cushioning mat material interposed between an outer surface perimeter of the substrate and an inner wall of the canister comprising, inserting the insulating and cushioning mat material into a film laminate sleeve, subjecting the insulating and cushioning mat material to a compression process that compresses the mat material to a nominal thickness that is less that that of an uncompressed thickness, sealing the insulating and cushioning mat material in the film laminate sleeve and inserting the mat into the canister.
- an exhaust system for an internal combustion engine comprises an exhaust treatment system having a substrate disposed in a canister, an insulating and cushioning mat material interposed between an outer surface perimeter of the substrate and an inner wall of the canister and a film laminate sleeve compressing and sealing the insulating and cushioning mat material to a nominal thickness that is less than that of an uncompressed thickness.
- an exhaust treatment system for an internal combustion engine comprises an insulating and cushioning mat material disposed in the exhaust gas treatment system and a film laminate sleeve vacuum packed and sealing the insulating and cushioning mat material to a nominal thickness that is less than that of an uncompressed thickness.
- FIG. 1 is a front view of an internal combustion engine and associated exhaust gas treatment system embodying features of the invention
- FIG. 2 is a sectional view of the exhaust treatment system of FIG. 1 , embodying features of the invention
- FIG. 3 is an illustration of the insulating and cushioning mat material of the exhaust treatment system of FIG. 2 in an uncompressed state
- FIG. 4 is an illustration of the insulating and cushioning mat material of the exhaust treatment system of FIG. 2 in a compressed state, prior to installation therein;
- FIG. 5 is an illustration of an insulating and cushioning mat material and substrate assembly embodying features of the present invention.
- an exemplary embodiment is directed to an exhaust system 10 , for the reduction of regulated exhaust gas constituents of an internal combustion engine 12 .
- the internal combustion engine 12 may be one of various configurations and types, such as gas or diesel, in-line or V-configured.
- the internal combustion engine 12 includes a cylinder block 14 that is typically constructed of cast iron or a lighter weight alloy such as aluminum.
- the lower end of the cylinder block 14 is closed by an oil pan 16 while the upper end is closed by a cylinder head 18 and valve cover 20 .
- an exhaust treatment system 40 includes a canister 41 that is configured to support a catalyst substrate.
- the exhaust treatment system 40 is configured as a Split Volume Common Can (“SVCC”) Catalytic Converter having a first and a second catalyst substrate 44 and 45 , respectively.
- the catalyst substrates 44 , 45 may be constructed of a ceramic honeycomb, a metal honeycomb or other suitable structure.
- exhaust gas passages 46 that are essentially straight paths from the upstream fluid inlets 48 to the downstream fluid outlets 50 of each substrate 44 , 45 are defined by substantially longitudinally extending walls 52 on which various catalytic materials (not shown) are coated so that the exhaust gas 28 that passes through the catalyst substrates 44 and 45 contacts the catalytic material to thereby initiate a chemical conversion process.
- a precious metal or Platinum group metal catalyst compound including platinum group metals such as platinum (Pt), palladium (Pd), rhodium (Rh) or other suitable oxidizing catalysts, or combination thereof, catalyzes the oxidation of carbon monoxide (“CO”) to carbon dioxide (“CO 2 ”) in the presence of oxygen (“O 2 ”), as well as catalyzing the oxidation of various hydrocarbons, including gaseous HC and liquid HC particles including unburned fuel or oil as well as HC reductants that may have been introduced into the exhaust gas stream 28 to form H 2 O.
- platinum group metals such as platinum (Pt), palladium (Pd), rhodium (Rh) or other suitable oxidizing catalysts, or combination thereof
- Pt platinum
- Pd palladium
- Rh rhodium
- other suitable oxidizing catalysts or combination thereof
- a precious metal or Platinum group metal catalyst compound including platinum group metals such as platinum (Pt), palladium (Pd), rhodium (Rh) or other suitable oxidizing catalysts, or combination thereof, catalyzes the oxidation of any remaining (i.e. “slipped”) carbon monoxide (“CO”) to carbon dioxide (“CO 2 ”) in the presence of oxygen (“O 2 ”), as well as catalyzing the oxidation of various remaining hydrocarbons, including gaseous HC and liquid HC particles including unburned fuel or oil as well as HC reductants that may have been introduced into the exhaust gas stream 28 to form H 2 O.
- platinum group metals such as platinum (Pt), palladium (Pd), rhodium (Rh) or other suitable oxidizing catalysts, or combination thereof, catalyzes the oxidation of any remaining (i.e. “slipped”) carbon monoxide (“CO”) to carbon dioxide (“CO 2 ”) in the presence of oxygen (“O 2 ”), as well as catalyzing
- catalyst compounds such as a Selective Catalyst Reduction (“SCR”) catalyst
- SCR Selective Catalyst Reduction
- a single catalyst substrate may be installed in the canister 41 of the exhaust treatment system 40 in place of the first and second catalyst substrates 44 and 45 described above without affecting the scope or application of the invention.
- the substrate or substrates may include un-catalyzed filtration substrates as are commonly used in exhaust particulate traps also without affecting the scope or application of the invention.
- Closing a first inlet end 54 of the canister 41 is an inlet end cone 56 that is in fluid communication with the exhaust manifold 26 of the cylinder head 18 .
- the inlet cone 56 is configured to receive exhaust gas 28 for passage through the first and second catalyst substrates 44 and 45 , respectively.
- closing the second, outlet end 58 of the canister 41 is an outlet end cone 60 that may be configured in a cone or semi-conical configuration to provide a smooth transition of the exhaust gas 28 to an exhaust gas conduit 62 with which the outlet end cone 60 is in fluid communication.
- an insulating and cushioning mat material 64 is interposed between the outer surface 66 perimeter of the flow-through substrates 44 , 45 and the inner wall 68 of the canister 41 .
- the mat material 64 may be of the type commonly referred to as an intumescent mat or, may be a non-intumescent mat. The selection of the mat material 64 is dependent on the internal combustion engine 12 to which the exhaust treatment system 40 is applied as well as other considerations. Regardless of the type of insulating and cushioning mat material 64 selected, the mat material operates to support the first and second catalyst substrates 44 , 45 in the canister 41 against damage from external shock and movement of the substrates therein. In addition, the mat material 64 defines a thermal barrier between the catalyst substrates 44 , 45 and the inner wall 68 of the canister 41 the thereby reduce the temperature of the outer wall 70 of the canister 41 .
- each substrate is wrapped in a layer of insulating and cushioning mat material 64 .
- the insulating and cushioning mat material 64 is cut or otherwise formed to the external dimensions of the substrates 44 , 45 .
- the insulating and cushioning mat material 64 is inserted into a film laminate sleeve 72 and is subjected to compression of the mat material to a nominal thickness “t”, FIG. 4 that is less that that of its uncompressed thickness “T”, FIG. 3 .
- the insulating and cushioning mat material 64 is sealed in the film laminate sleeve 72 in order to maintain the mat in its compressed state.
- the compression of the mat material is through application of a vacuum to the film laminate sleeve 72 with subsequent sealing of the sleeve while under vacuum.
- An alternative to vacuum compression of the mat material is mechanical compression utilizing a suitable press.
- the film laminate sleeve 72 comprises a Low Organic Film Laminate (“LOFL”) that is subject to vaporization, combustion or other form of dissipation when heated to the temperatures experienced by the exhaust treatment system 40 .
- LOFL Low Organic Film Laminate
- the selected film laminate sleeve 72 is selected from a group of laminates that will substantially completely vaporize, combust or otherwise dissipate during heating/operation of the exhaust system 10 to thereby allow the insulating and cushioning mat material 64 to expand to a dimension that provides full support and thermal insulation of the substrates 44 , 45 within the canister 41 .
- the compressed mat material 64 is wrapped around the substrate or substrates 44 , 45 and the mat and substrate assembly is axially inserted into the canister 41 . Insertion of the mat and substrate assembly may be through the use of a stuffing ram, as is commonly known. However, in the case of the mat and substrate assembly utilizing the invention disclosed, the insulating and cushioning mat material 64 will require little or no compression by a stuffing shoe, resulting in a low risk of damage thereto.
- the LOFL film laminate sleeve 72 Upon operation of the internal combustion engine, the LOFL film laminate sleeve 72 will vaporize, combust or otherwise dissolve in the hot exhaust gas environment and the insulating and cushioning mat material 64 will expand to fill the gap between the outer surfaces 66 of the substrates 44 , 45 and the inner wall 68 of the canister 41 . Expansion of the cushioning mat material 64 supports the catalyst substrates 44 , 45 in the canister 41 against damage from external shock and movement of the substrates therein and defines a thermal barrier between the catalyst substrates 44 , 45 and the inner wall 68 of the canister 40 , reducing the temperature of the outer wall 70 of the canister 41 .
- the insulating and cushioning mat material 64 may be wrapped around the catalyst substrates 44 , 45 in an uncompressed state such as is illustrated in FIG. 3 .
- the mat and substrate assembly 74 may be placed in a film laminate sleeve 72 and vacuum packed to compress the insulating and cushioning mat material 64 about the outer surface 66 of the substrate.
- the mat and substrate assembly 74 is sealed in the film laminate sleeve 72 at seams 76 , for instance, in order to maintain the insulating and cushioning mat material 64 in its compressed state until the mat and substrate assembly 74 is installed into the canister 41 of the exhaust treatment system 40 .
Abstract
An exhaust treatment system for an internal combustion engine comprises an insulating and cushioning mat material disposed in the exhaust treatment system and a film laminate sleeve vacuum packed and sealing the insulating and cushioning mat material therein.
Description
- This patent application claims priority to U.S. Provisional Patent Application Ser. No. 61/379,538 filed Sep. 2, 2010, which is incorporated herein by reference in its entirety.
- Exemplary embodiments of the present invention relate to exhaust systems for internal combustion engines and, more particularly, to an exhaust treatment system and method of assembly.
- A typical exhaust system for an internal combustion engine may involve the placement of an exhaust treatment system or assembly (typically an oxidation catalyst device) in close proximity to the exhaust manifold of the internal combustion engine. This exhaust treatment system, in this example referred to as a close-coupled exhaust treatment system, is typically a catalytic device in which regulated exhaust constituents (ex. CO, HC, NOx, Particulates, etc.) may be converted to non-regulated compounds (ex. CO2, H2O, etc.). The close coupling to the engine exhaust manifold minimizes thermal loss from the exhaust gas, as it travels between the engine and the exhaust treatment system, resulting in higher temperatures and quicker catalytic activation. Minimizing thermal loss is important since the catalyst compounds that are typically used for treating engine exhaust gas operate at optimal efficiency at temperatures in excess of 350° C.
- In an exemplary embodiment of the exhaust treatment system discussed, the catalytic device may be disposed in a housing or canister that comprises a single piece cylindrical or near cylindrical member that is closed at each end by an inlet or an outlet cone that is in fluid communication with the exhaust system of the internal combustion engine. The catalytic device is typically constructed as a catalyst coated, flow-though substrate constructed of ceramic or metal that is supported within the canister by an insulating and cushioning mat material that is interposed between the perimeter of the flow-through substrate and an inner wall of the canister.
- Assembly of the exhaust treatment system may involve the use of a stuffing ram in which the catalyst coated, flow-through substrate is wrapped in the mat material and then axially inserted (i.e. “stuffed”) by the stuffing ram through a stuffing shoe and into the canister. The stuffing shoe compresses the mat material as it enters the canister allowing it to re-expand once the substrate is positioned properly in the canister. While the process can be effective for the assembly of the exhaust treatment system, the stuffing shoe may, at times, misalign or damage the mat causing durability issues during operation of the internal combustion engine.
- In an exemplary embodiment of the present invention, a method of assembling an exhaust treatment system for an internal combustion engine comprises a substrate disposed in a canister and an insulating and cushioning mat material interposed between an outer surface perimeter of the substrate and an inner wall of the canister comprising, inserting the insulating and cushioning mat material into a film laminate sleeve, subjecting the insulating and cushioning mat material to a compression process that compresses the mat material to a nominal thickness that is less that that of an uncompressed thickness, sealing the insulating and cushioning mat material in the film laminate sleeve and inserting the mat into the canister.
- In another exemplary embodiment of the present invention, an exhaust system for an internal combustion engine comprises an exhaust treatment system having a substrate disposed in a canister, an insulating and cushioning mat material interposed between an outer surface perimeter of the substrate and an inner wall of the canister and a film laminate sleeve compressing and sealing the insulating and cushioning mat material to a nominal thickness that is less than that of an uncompressed thickness.
- In yet another exemplary embodiment of the present invention, an exhaust treatment system for an internal combustion engine comprises an insulating and cushioning mat material disposed in the exhaust gas treatment system and a film laminate sleeve vacuum packed and sealing the insulating and cushioning mat material to a nominal thickness that is less than that of an uncompressed thickness.
- The above features and advantages, and other features and advantages of the present invention are readily apparent from the following detailed description of the invention when taken in connection with the accompanying drawings.
- Other objects, features, advantages and details appear, by way of example only, in the following detailed description of the embodiments, the detailed description referring to the drawings in which:
-
FIG. 1 is a front view of an internal combustion engine and associated exhaust gas treatment system embodying features of the invention; -
FIG. 2 is a sectional view of the exhaust treatment system ofFIG. 1 , embodying features of the invention; -
FIG. 3 is an illustration of the insulating and cushioning mat material of the exhaust treatment system ofFIG. 2 in an uncompressed state; -
FIG. 4 is an illustration of the insulating and cushioning mat material of the exhaust treatment system ofFIG. 2 in a compressed state, prior to installation therein; and -
FIG. 5 is an illustration of an insulating and cushioning mat material and substrate assembly embodying features of the present invention. - The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
- Referring now to
FIG. 1 , an exemplary embodiment is directed to anexhaust system 10, for the reduction of regulated exhaust gas constituents of aninternal combustion engine 12. It is appreciated that theinternal combustion engine 12 may be one of various configurations and types, such as gas or diesel, in-line or V-configured. For ease of description and discussion, the disclosure will be discussed in the context of the in-line four cylinder gasoline engine shown. Theinternal combustion engine 12 includes acylinder block 14 that is typically constructed of cast iron or a lighter weight alloy such as aluminum. The lower end of thecylinder block 14 is closed by anoil pan 16 while the upper end is closed by acylinder head 18 andvalve cover 20. - In an exemplary embodiment, the
cylinder head 18 is associated with anexhaust manifold 26 that is configured to conduct combustion constituents orexhaust gas 28 therefrom. Referring toFIGS. 1 and 2 , in an exemplary embodiment, anexhaust treatment system 40 includes acanister 41 that is configured to support a catalyst substrate. In the exemplary embodiment illustrated in the Figures, theexhaust treatment system 40 is configured as a Split Volume Common Can (“SVCC”) Catalytic Converter having a first and asecond catalyst substrate catalyst substrates - In an exemplary embodiment,
exhaust gas passages 46, that are essentially straight paths from theupstream fluid inlets 48 to thedownstream fluid outlets 50 of eachsubstrate walls 52 on which various catalytic materials (not shown) are coated so that theexhaust gas 28 that passes through thecatalyst substrates exhaust gas 28 traverses the length of the first catalyst substrate 44 a precious metal or Platinum group metal catalyst compound, including platinum group metals such as platinum (Pt), palladium (Pd), rhodium (Rh) or other suitable oxidizing catalysts, or combination thereof, catalyzes the oxidation of carbon monoxide (“CO”) to carbon dioxide (“CO2”) in the presence of oxygen (“O2”), as well as catalyzing the oxidation of various hydrocarbons, including gaseous HC and liquid HC particles including unburned fuel or oil as well as HC reductants that may have been introduced into theexhaust gas stream 28 to form H2O. As theexhaust gas 28 traverses the length of the second catalyst substrate 45 a precious metal or Platinum group metal catalyst compound, including platinum group metals such as platinum (Pt), palladium (Pd), rhodium (Rh) or other suitable oxidizing catalysts, or combination thereof, catalyzes the oxidation of any remaining (i.e. “slipped”) carbon monoxide (“CO”) to carbon dioxide (“CO2”) in the presence of oxygen (“O2”), as well as catalyzing the oxidation of various remaining hydrocarbons, including gaseous HC and liquid HC particles including unburned fuel or oil as well as HC reductants that may have been introduced into theexhaust gas stream 28 to form H2O. Other combinations of catalyst compounds, such as a Selective Catalyst Reduction (“SCR”) catalyst, are of course contemplated and will be selected based on various parameters such as the type of engine (ex. diesel or gasoline) as well as the application of theinternal combustion engine 12 and/or the vehicle type in which the engine is operated. It is, of course, contemplated that a single catalyst substrate may be installed in thecanister 41 of theexhaust treatment system 40 in place of the first andsecond catalyst substrates - Closing a
first inlet end 54 of thecanister 41 is aninlet end cone 56 that is in fluid communication with theexhaust manifold 26 of thecylinder head 18. Theinlet cone 56 is configured to receiveexhaust gas 28 for passage through the first andsecond catalyst substrates outlet end 58 of thecanister 41 is anoutlet end cone 60 that may be configured in a cone or semi-conical configuration to provide a smooth transition of theexhaust gas 28 to anexhaust gas conduit 62 with which theoutlet end cone 60 is in fluid communication. - Referring to particularly to
FIGS. 2 , 3 and 4, an insulating andcushioning mat material 64 is interposed between theouter surface 66 perimeter of the flow-throughsubstrates inner wall 68 of thecanister 41. Themat material 64 may be of the type commonly referred to as an intumescent mat or, may be a non-intumescent mat. The selection of themat material 64 is dependent on theinternal combustion engine 12 to which theexhaust treatment system 40 is applied as well as other considerations. Regardless of the type of insulating andcushioning mat material 64 selected, the mat material operates to support the first andsecond catalyst substrates canister 41 against damage from external shock and movement of the substrates therein. In addition, themat material 64 defines a thermal barrier between thecatalyst substrates inner wall 68 of thecanister 41 the thereby reduce the temperature of theouter wall 70 of thecanister 41. - In an exemplary embodiment, and referring particularly to
FIGS. 3 and 4 , prior to insertion of the first andsecond catalyst substrates canister 41, each substrate is wrapped in a layer of insulating and cushioningmat material 64. The insulating andcushioning mat material 64 is cut or otherwise formed to the external dimensions of thesubstrates cushioning mat material 64 is inserted into afilm laminate sleeve 72 and is subjected to compression of the mat material to a nominal thickness “t”,FIG. 4 that is less that that of its uncompressed thickness “T”,FIG. 3 . The insulating andcushioning mat material 64 is sealed in thefilm laminate sleeve 72 in order to maintain the mat in its compressed state. In an exemplary embodiment the compression of the mat material is through application of a vacuum to thefilm laminate sleeve 72 with subsequent sealing of the sleeve while under vacuum. An alternative to vacuum compression of the mat material is mechanical compression utilizing a suitable press. In an exemplary embodiment, thefilm laminate sleeve 72 comprises a Low Organic Film Laminate (“LOFL”) that is subject to vaporization, combustion or other form of dissipation when heated to the temperatures experienced by theexhaust treatment system 40. While not limited to an LOFL, the selectedfilm laminate sleeve 72 is selected from a group of laminates that will substantially completely vaporize, combust or otherwise dissipate during heating/operation of theexhaust system 10 to thereby allow the insulating and cushioningmat material 64 to expand to a dimension that provides full support and thermal insulation of thesubstrates canister 41. - In an exemplary embodiment, following the vacuum process that compresses the insulating and cushioning
mat material 64 to a nominal thickness “t”, thecompressed mat material 64 is wrapped around the substrate orsubstrates canister 41. Insertion of the mat and substrate assembly may be through the use of a stuffing ram, as is commonly known. However, in the case of the mat and substrate assembly utilizing the invention disclosed, the insulating and cushioningmat material 64 will require little or no compression by a stuffing shoe, resulting in a low risk of damage thereto. - Upon operation of the internal combustion engine, the LOFL
film laminate sleeve 72 will vaporize, combust or otherwise dissolve in the hot exhaust gas environment and the insulating and cushioningmat material 64 will expand to fill the gap between theouter surfaces 66 of thesubstrates inner wall 68 of thecanister 41. Expansion of thecushioning mat material 64 supports the catalyst substrates 44, 45 in thecanister 41 against damage from external shock and movement of the substrates therein and defines a thermal barrier between the catalyst substrates 44, 45 and theinner wall 68 of thecanister 40, reducing the temperature of theouter wall 70 of thecanister 41. - Referring now to
FIG. 5 , it is also contemplated that the insulating andcushioning mat material 64 may be wrapped around the catalyst substrates 44, 45 in an uncompressed state such as is illustrated inFIG. 3 . Following the application of the insulating andcushioning mat material 64 to the catalyst substrates 44, 45 the mat andsubstrate assembly 74 may be placed in afilm laminate sleeve 72 and vacuum packed to compress the insulating andcushioning mat material 64 about theouter surface 66 of the substrate. The mat andsubstrate assembly 74 is sealed in thefilm laminate sleeve 72 atseams 76, for instance, in order to maintain the insulating andcushioning mat material 64 in its compressed state until the mat andsubstrate assembly 74 is installed into thecanister 41 of theexhaust treatment system 40. - While the invention has been described with respect to the application of an insulating and cushioning mat material disposed between the catalyst substrate and the canister of an exhaust treatment system, it is contemplated that, as such, the invention will apply equally to any areas of an exhaust treatment system that require the disposition of such a mat.
- While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed for carrying out this invention, but that the invention will include all embodiments falling within the scope of the present application.
Claims (19)
1. A method of assembling an exhaust treatment system for an internal combustion engine comprising a substrate disposed in a canister and an insulating and cushioning mat material interposed between an outer surface perimeter of the substrate and an inner wall of the canister comprising:
inserting the insulating and cushioning mat material into a film laminate sleeve;
subjecting the insulating and cushioning mat material to a compression process that compresses the mat material to a nominal thickness that is less that that of an uncompressed thickness;
sealing the insulating and cushioning mat material in the film laminate sleeve; and
inserting the mat into the canister.
2. The method for assembly of an exhaust treatment system of claim 1 , further comprising:
operating the internal combustion engine to vaporize, combust or otherwise dissolve the film laminate sleeve in a hot exhaust gas environment to expand the insulating and cushioning mat material.
3. The method for assembly of an exhaust treatment system of claim 1 , wherein the compression process comprises applying a vacuum to the insulating and cushioning mat material containing film laminate sleeve.
4. The method for assembly of an exhaust treatment system of claim 1 , further comprising:
wrapping the compressed insulating and cushioning material around the substrate prior to inserting the mat into the canister; and
inserting the mat wrapped substrate into the canister.
5. The method for assembly of an exhaust treatment system of claim 1 , further comprising:
wrapping the uncompressed insulating and cushioning material around the substrate;
subjecting the mat wrapped substrate to a compression process that compresses the mat material to a nominal thickness that is less that that of an uncompressed thickness;
sealing the mat wrapped substrate in the film laminate sleeve; and
inserting the mat wrapped and laminate sealed substrate into the canister.
6. An exhaust system for an internal combustion engine comprising:
an exhaust treatment system having a substrate disposed in a canister;
an insulating and cushioning mat material interposed between an outer surface perimeter of the substrate and an inner wall of the canister; and
a film laminate sleeve compressing and sealing the insulating and cushioning mat material to a nominal thickness that is less than that of an uncompressed thickness.
7. The exhaust system for the internal combustion engine of claim 6 , wherein the compressing and sealing the insulating and cushioning mat material comprises applying a vacuum to the film laminate sleeve.
8. The exhaust system for the internal combustion engine of claim 6 , wherein the film laminate sleeve comprises a film laminate that vaporizes and/or combusts when heated.
9. The exhaust system for the internal combustion engine of claim 6 , wherein the film laminate sleeve comprises a Low Organic Film Laminate.
10. The exhaust system for the internal combustion engine of claim 6 , wherein the substrate comprises a catalyst coated substrate.
11. The exhaust system for the internal combustion engine of claim 6 , wherein the catalyst comprises a precious metal or Platinum group metal catalyst compound, including platinum group metals such as platinum (Pt), palladium (Pd), rhodium (Rh) or other suitable oxidizing catalysts, or combination thereof.
12. The exhaust system for the internal combustion engine of claim 6 , wherein the canister further comprises:
a first, inlet end closed by an inlet end cone that is in fluid communication with an exhaust manifold of a cylinder head of the internal combustion engine; and
a second, outlet end closed by an outlet end cone that is in fluid communication with an exhaust gas conduit of the exhaust system.
13. An exhaust treatment system for an internal combustion engine comprising:
an insulating and cushioning mat material disposed in the exhaust gas treatment system; and
a film laminate sleeve vacuum packed and sealing the insulating and cushioning mat material to a nominal thickness that is less than that of an uncompressed thickness.
14. The exhaust treatment system for the internal combustion engine of claim 13 , wherein the film laminate sleeve comprises a film laminate that vaporizes and/or combusts when heated.
15. The exhaust treatment system for the internal combustion engine of claim 13 , wherein the film laminate sleeve comprises a Low Organic Film Laminate.
16. The exhaust treatment system for the internal combustion engine of claim 13 , wherein the film laminate sleeve is vacuum packed and seals the insulating and cushioning mat material and a catalyst substrate therein.
17. The exhaust treatment system for the internal combustion engine of claim 16 , wherein the substrate comprises a catalyst coated substrate.
18. The exhaust treatment system for the internal combustion engine of claim 17 , wherein the catalyst comprises a precious metal or Platinum group metal catalyst compound, including platinum group metals such as platinum (Pt), palladium (Pd), rhodium (Rh) or other suitable oxidizing catalysts, or combination thereof.
19. The exhaust treatment system for the internal combustion engine of claim 16 , further comprising:
a canister housing the film laminate sleeve, the insulating and cushioning mat material and the catalyst substrate therein;
a first canister inlet end closed by an inlet end cone that is in fluid communication with an exhaust manifold of a cylinder head of the internal combustion engine; and
a second, outlet end closed by an outlet end cone that is in fluid communication with an exhaust gas conduit of an exhaust system.
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/095,194 US20120055140A1 (en) | 2010-09-02 | 2011-04-27 | Exhaust treatment system and method of assembly |
DE112011102569T DE112011102569T5 (en) | 2010-09-02 | 2011-09-02 | Exhaust treatment system and assembly method |
PCT/US2011/050328 WO2012039913A2 (en) | 2010-09-02 | 2011-09-02 | Exhaust treatment system and method of assembly |
CN2011800423829A CN103080492A (en) | 2010-09-02 | 2011-09-02 | Exhaust treatment system and method of assembly |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US37953810P | 2010-09-02 | 2010-09-02 | |
US13/095,194 US20120055140A1 (en) | 2010-09-02 | 2011-04-27 | Exhaust treatment system and method of assembly |
Publications (1)
Publication Number | Publication Date |
---|---|
US20120055140A1 true US20120055140A1 (en) | 2012-03-08 |
Family
ID=45769628
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/095,194 Abandoned US20120055140A1 (en) | 2010-09-02 | 2011-04-27 | Exhaust treatment system and method of assembly |
Country Status (4)
Country | Link |
---|---|
US (1) | US20120055140A1 (en) |
CN (1) | CN103080492A (en) |
DE (1) | DE112011102569T5 (en) |
WO (1) | WO2012039913A2 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20140228610A1 (en) * | 2013-02-14 | 2014-08-14 | Basf Se | Installing monoliths in a reactor for conducting heterogeneously catalyzed gas phase reactions |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102018119599A1 (en) * | 2018-08-13 | 2020-02-13 | Volkswagen Aktiengesellschaft | Exhaust aftertreatment system and method for exhaust aftertreatment of an internal combustion engine |
Citations (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3921273A (en) * | 1973-10-09 | 1975-11-25 | Toyota Motor Co Ltd | Method of filling a casing with heat insulating fibers |
US4127556A (en) * | 1975-09-29 | 1978-11-28 | Toyota Jidosha Kogyo Kabushiki Kaisha | Ceramic fiber molding for manifold reactors |
GB2171180A (en) * | 1985-02-19 | 1986-08-20 | W F J Refractories Limited | Fibrous material packages, method of making same and their use |
US4746570A (en) * | 1984-09-20 | 1988-05-24 | Toyota Jidosha Kabushiki Kaisha | Heat-resistant, highly expansible sheet material for supporting catalyst carrier and process for the preparation thereof |
US4929429A (en) * | 1988-02-11 | 1990-05-29 | Minnesota Mining And Manufacturing Company | Catalytic converter |
JPH11117728A (en) * | 1997-10-17 | 1999-04-27 | Ibiden Co Ltd | Catalytic converter for exhaust emission control, and manufacture thereof |
JPH11173141A (en) * | 1997-12-05 | 1999-06-29 | Ibiden Co Ltd | Manufacture of sealant for catalyst converter |
JPH11173142A (en) * | 1997-12-05 | 1999-06-29 | Ibiden Co Ltd | Manufacture of sealant for catalyst converter |
US6484397B1 (en) * | 2000-07-11 | 2002-11-26 | Corning Incorporated | Method of assembling a catalytic converter for use in an internal combustion engine |
US20100247399A1 (en) * | 1997-05-09 | 2010-09-30 | 3M Innovative Properties Company | Self-supporting insulating end cone liner and pollution control device |
US20110023430A1 (en) * | 2007-08-31 | 2011-02-03 | Amit Kumar | Multiple Layer Substrate Support and Exhaust Gas Treatment Device |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4999168A (en) * | 1989-05-01 | 1991-03-12 | The Carborundum Company | Crack resistant intumescent sheet material |
KR100414539B1 (en) * | 1995-04-13 | 2004-05-07 | 미쓰비시 가가꾸 가부시키가이샤 | Manufacturing method of monolith support material |
JP3084556B2 (en) * | 1998-11-02 | 2000-09-04 | 藤壷技研工業株式会社 | Exhaust gas purification device for engine |
DE102005017946B4 (en) * | 2005-04-18 | 2007-11-22 | J. Eberspächer GmbH & Co. KG | Exhaust treatment device and associated exhaust system |
-
2011
- 2011-04-27 US US13/095,194 patent/US20120055140A1/en not_active Abandoned
- 2011-09-02 WO PCT/US2011/050328 patent/WO2012039913A2/en active Application Filing
- 2011-09-02 DE DE112011102569T patent/DE112011102569T5/en not_active Withdrawn
- 2011-09-02 CN CN2011800423829A patent/CN103080492A/en active Pending
Patent Citations (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3921273A (en) * | 1973-10-09 | 1975-11-25 | Toyota Motor Co Ltd | Method of filling a casing with heat insulating fibers |
US4127556A (en) * | 1975-09-29 | 1978-11-28 | Toyota Jidosha Kogyo Kabushiki Kaisha | Ceramic fiber molding for manifold reactors |
US4746570A (en) * | 1984-09-20 | 1988-05-24 | Toyota Jidosha Kabushiki Kaisha | Heat-resistant, highly expansible sheet material for supporting catalyst carrier and process for the preparation thereof |
GB2171180A (en) * | 1985-02-19 | 1986-08-20 | W F J Refractories Limited | Fibrous material packages, method of making same and their use |
US4929429A (en) * | 1988-02-11 | 1990-05-29 | Minnesota Mining And Manufacturing Company | Catalytic converter |
US20100247399A1 (en) * | 1997-05-09 | 2010-09-30 | 3M Innovative Properties Company | Self-supporting insulating end cone liner and pollution control device |
JPH11117728A (en) * | 1997-10-17 | 1999-04-27 | Ibiden Co Ltd | Catalytic converter for exhaust emission control, and manufacture thereof |
JPH11173141A (en) * | 1997-12-05 | 1999-06-29 | Ibiden Co Ltd | Manufacture of sealant for catalyst converter |
JPH11173142A (en) * | 1997-12-05 | 1999-06-29 | Ibiden Co Ltd | Manufacture of sealant for catalyst converter |
US6484397B1 (en) * | 2000-07-11 | 2002-11-26 | Corning Incorporated | Method of assembling a catalytic converter for use in an internal combustion engine |
US20110023430A1 (en) * | 2007-08-31 | 2011-02-03 | Amit Kumar | Multiple Layer Substrate Support and Exhaust Gas Treatment Device |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20140228610A1 (en) * | 2013-02-14 | 2014-08-14 | Basf Se | Installing monoliths in a reactor for conducting heterogeneously catalyzed gas phase reactions |
US9616406B2 (en) * | 2013-02-14 | 2017-04-11 | Basf Se | Installing monoliths in a reactor for conducting heterogeneously catalyzed gas phase reactions |
Also Published As
Publication number | Publication date |
---|---|
WO2012039913A3 (en) | 2012-06-21 |
CN103080492A (en) | 2013-05-01 |
DE112011102569T5 (en) | 2013-05-29 |
WO2012039913A2 (en) | 2012-03-29 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US10544724B2 (en) | Vehicle exhaust system component having an insulating heat shield assembly with encapsulated pockets | |
JP4557976B2 (en) | Contamination control element holding material and contamination control device | |
US6299843B1 (en) | Catalytic converter for use in an internal combustion engine and a method of making | |
US8795598B2 (en) | Exhaust treatment device with independent catalyst supports | |
US6491878B1 (en) | Catalytic converter for use in an internal combustion engine | |
US20060277900A1 (en) | Service joint for an engine exhaust system component | |
US8793978B2 (en) | Exhaust system having thermally conductive dosing channel | |
US20100239469A1 (en) | Monolithic exhaust treatment unit for treating an exhaust gas | |
FR2947004A1 (en) | Exhaust line for diesel engine, of motor vehicle, has injection unit and nitrogen oxide treating device inserted in hot conduit in upstream of mechanical decoupling element | |
JP5815036B2 (en) | Matte with tapered cut edges | |
US20120055140A1 (en) | Exhaust treatment system and method of assembly | |
CN103228335B (en) | Method of installing a multi-ayer batt, blanket or mat in an exhaust gas aftertreatment or acoustic device | |
WO2014133511A1 (en) | Exhaust manifold with turbo support | |
US8839517B2 (en) | Spin formed catalyst | |
CN201574805U (en) | Composite ternary catalyst | |
EP1308607B1 (en) | End cones for exhaust emission control devices and methods of making | |
US20120240562A1 (en) | Exhaust Treatment Device for an Internal Combustion Engine | |
JP2014521875A (en) | Method of winding bat, blanket or mat in exhaust gas aftertreatment or silencer | |
JP2005083304A (en) | Exhaust emission control device of internal combustion engine | |
FR3018310A1 (en) | CATALYST THREE WAYS | |
JP2001254618A (en) | Catalytic converter for exhaust emission control and manufacturing method therefor |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: GM GLOBAL TECHNOLOGY OPERATIONS LLC, MICHIGAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:JOHNSON, RICHARD LORENZE;REEL/FRAME:026187/0626 Effective date: 20110421 |
|
AS | Assignment |
Owner name: WILMINGTON TRUST COMPANY, DELAWARE Free format text: SECURITY AGREEMENT;ASSIGNOR:GM GLOBAL TECHNOLOGY OPERATIONS LLC;REEL/FRAME:028466/0870 Effective date: 20101027 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |