Exhaust purifying apparatus and method for internal combustion engine

• US 20010011455A1
• Filed: 01/16/2001
• Published: 08/09/2001
• Est. Priority Date: 02/03/2000
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Itou, Keiji, Tanaka, Hiroshi, Katoh, Kenji, Itou, Takaaki, Ichinose, Hiroki, Harima, Kenji
• Granted Patent: US 6,378,298 B2
• Time in Patent Office: Days
• US Class Current: 60/288
• CPC Class Codes: F01N 13/009 having two or more separate purifying devices arranged in series
• CPC Class Codes: F01N 13/0097 the purifying devices are arranged in a single housing
• CPC Class Codes: F01N 13/011 having two or more purifying devices arranged in parallel
• CPC Class Codes: F01N 2240/02 a heat exchanger
• CPC Class Codes: F01N 2430/06 by varying fuel-air ratio, e.g. by enriching fuel-air mixture
• CPC Class Codes: F01N 2570/04 Sulfur or sulfur oxides
• CPC Class Codes: F01N 2570/12 Hydrocarbons
• CPC Class Codes: F01N 2570/14 Nitrogen oxides
• CPC Class Codes: F01N 3/05 by means of air, e.g. by mixing exhaust with air silencers working by addition of air to exhaust F01N1/14; arrangements for the supply of additional air for the thermal or catalytic conversion of noxious components of exhaust F01N3/30 ; in tailpipes F01N13/082
• CPC Class Codes: F01N 3/0807 by using absorbents or adsorbents
• CPC Class Codes: F01N 3/0814 combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts
• CPC Class Codes: F01N 3/0835 Hydrocarbons
• CPC Class Codes: F01N 3/0842 Nitrogen oxides
• CPC Class Codes: F01N 3/085 Sulfur or sulfur oxides
• CPC Class Codes: F01N 3/0871 Regulation of absorbents or adsorbents, e.g. purging by electrically controlling the supply of combustible mixture or its constituents only F02D41/0235
• CPC Class Codes: F01N 3/0878 Bypassing absorbents or adsorbents
• CPC Class Codes: F01N 3/0885 Regeneration of deteriorated absorbents or adsorbents, e.g. desulfurization of NOx traps
• CPC Class Codes: F01N 3/2006 Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating by electrically controlling the supply of combustible mixture or its constituents only F02D41/0235
• CPC Class Codes: F01N 3/2046 Periodically cooling catalytic reactors
• CPC Class Codes: F01N 3/22 Control of additional air supply only, e.g. using by-passes or variable air pump drives
• CPC Class Codes: F01N 3/30 : Arrangements for supply of additional air control, e.g. using by-passes or variable air pump drives, F01N3/22
• CPC Class Codes: Y02A 50/20 : Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

An exhaust purifying apparatus for an internal combustion engine includes a catalyst that purifies exhaust gas from the engine, a first passage that allows exhaust gas to flow from the engine to the catalyst, and a second passage that allows exhaust gas to flow from the engine to the catalyst. The first passage includes an accelerated cooling portion whose cross section is designed so that a relatively large quantity of heat is released from the exhaust gas in the first passage, and the second passage has a cross section designed so that a relatively small quantity of heat is released from the exhaust gas in the second passage. The apparatus further includes a flow amount controller that controls amounts of exhaust gas flowing through the first and second passages, such that the amount of exhaust gas flow through the first passage is made larger than that through the second passage when the temperature of exhaust gas emitted from the engine is to be lowered by a relatively large degree before reaching the catalyst, and such that the amount of exhaust gas flow through the second passage is made larger than that through the first passage when the temperature of exhaust gas emitted from the engine is to be lowered by a relatively small degree before reaching the catalyst.

Claims

1. An exhaust purifying apparatus for an internal combustion engine, the exhaust purifying apparatus comprising:

a catalyst that purifies exhaust gas emitted from the internal combustion engine;

a first passage disposed between the engine and the catalyst to allow exhaust gas to flow therethrough from the engine to the catalyst, said first passage including an accelerated cooling portion having a cross section that permits a first quantity of heat to be released from the exhaust gas in the first passage;

a second passage disposed between the engine and the catalyst to allow exhaust gas to flow therethrough from the engine to the catalyst, said second passage having a cross section that permits a second quantity of heat that is smaller than said first quantity of heat to be released from the exhaust gas in the second passage; and

a flow amount controller that controls amounts of exhaust gas flowing through the first passage and through the second passage, such that;

(i) the amount of exhaust gas flowing through the first passage is made larger than the amount of exhaust gas flowing through the second passage when a temperature of exhaust gas emitted from the engine is to be lowered by a relatively large degree before the exhaust gas flows into the catalyst, and (ii) the amount of exhaust gas flowing through the second passage is made larger than the amount of exhaust gas flowing through the first passage when the temperature of exhaust gas emitted from the engine is to be lowered by a relatively small degree before the exhaust gas flows into the catalyst.

2. An exhaust purifying apparatus according to

claim 1

, wherein the cross section of the accelerated cooling portion of the first passage is generally arcuate, and the cross section of the second passage is generally circular.

3. An exhaust purifying apparatus according to

claim 2

, wherein the accelerated cooling portion of the first passage substantially surrounds the second passage.

4. An exhaust purifying apparatus according to

claim 1

, wherein the first passage and the second passage have substantially equal lengths.

5. An exhaust purifying apparatus according to

claim 1

, wherein the first passage and the second passage have cross-sectional areas that are substantially equal.

6. An exhaust purifying apparatus according to

claim 1

, wherein the catalyst comprises a lean NOx catalyst capable of purifying exhaust gas with a lean air-fuel ratio of NOx.

7. An exhaust purifying apparatus according to

claim 1

, wherein the flow amount controller controls the amounts of exhaust gas flowing through the first passage and through the second passage, based on a catalyst midbed temperature of the catalyst or a parameter effecting the catalyst midbed temperature.

8. An exhaust purifying apparatus according to

claim 7

, wherein the flow amount controller controls the amounts of exhaust gas flowing through the first passage and through the second passage so as to control a catalyst midbed temperature of the catalyst to be within a predetermined temperature range in which the catalyst provides a purification efficiency of not lower than a specified value.

9. An exhaust purifying apparatus according to

claim 1

, wherein the flow amount controller controls the amount of exhaust gas flowing through the second passage to be larger than the amount of exhaust gas flowing through the first passage during an S-poisoning recovery process for releasing SOx that has been absorbed by the catalyst.

10. An exhaust purifying apparatus according to

claim 9

, further comprising an exhaust air-fuel controller that controls an air-fuel ratio of exhaust gas that flows into the catalyst during the S-poisoning recovery process to be substantially equal to or richer than a stoichiometric air-fuel ratio.

11. An exhaust purifying apparatus according to

claim 9

, wherein the flow amount controller controls the amounts of flow so as to increase a proportion of the exhaust gas flowing through the first passage immediately after completion of the S2 poisoning recovery process.

12. An exhaust purifying apparatus according to

claim 1

, further comprising an HC adsorbent provided in the first passage, wherein the flow amount controller causes all the exhaust gas to flow through the first passage during a start of the internal combustion engine.

13. An exhaust purifying apparatus according to

claim 12

, wherein the HC adsorbent is disposed downstream of the accelerated cooling portion of the first passage.

14. An exhaust purifying apparatus according to

claim 12

, wherein the catalyst comprises a selective reduction type NOx catalyst that reduces or decomposes NOx in the presence of hydrocarbon in an oxygen-excess atmosphere, said second passage being provided with an occlusion-reduction type NOx catalyst that absorbs NOx when incoming exhaust gas has a lean air-fuel ratio, and releases and reduces the absorbed NOx into N₂ when the concentration of oxygen contained in the incoming exhaust gas is reduced, said flow amount controller causes exhaust gas to flow mainly through the first passage when the engine is operating with a high load.

15. An exhaust purifying apparatus according to

claim 14

, further comprising a common passage located upstream of the first passage and the second passage, said common passage allowing exhaust gas to flow therethrough before entering the first and second passages, said common passage being provided with an additional selective reduction type NOx catalyst that reduces or decomposes NOx in the presence of hydrocarbon in an oxygen-excess atmosphere.

16. An exhaust purifying apparatus according to

claim 1

, further comprising:

a temperature sensor disposed at one of;

(i) a joint passage into which a downstream portion of the first passage and a downstream portion of the second passage merge, (ii) an exhaust passage disposed downstream of the joint passage, and (iii) the catalyst; and

a diagnostic unit that determines whether the flow amount controller operates normally or not, based on a change in the temperature detected by the temperature sensor when the flow amount controller is operated to change a ratio of the amounts of exhaust gas flowing through the first passage and through the second passage.

17. An exhaust purifying apparatus according to

claim 1

, further comprising:

a pressure sensor disposed in the first passage to detect a pressure of exhaust gas; and

a diagnostic unit that determines whether the flow amount controller operates normally or not, based on a change in the pressure detected by the pressure sensor when the flow amount controller is operated to change a ratio of the amounts of exhaust gas flowing through the first passage and through the second passage.

18. A method of purifying exhaust emitted from an internal combustion engine by utilizing a catalyst that purifies exhaust gas emitted from the internal combustion engine, the method comprising:

disposing a first passage between the engine and the catalyst to allow exhaust gas to flow through the first passage from the engine to the catalyst, the first passage including an accelerated cooling portion having a cross section that permits a first quantity of heat to be released from the exhaust gas in the first passage;

disposing a second passage between the engine and the catalyst to allow exhaust gas to flow through the second passage from the engine to the catalyst, the second passage having a cross section that permits a second quantity of heat that is smaller than the first quantity of heat to be released from the exhaust gas in the second passage; and

controlling amounts of exhaust gas flowing through the first passage and through the second passage, including;

(i) making the amount of exhaust gas flowing through the first passage larger than the amount of exhaust gas flowing through the second passage when a temperature of exhaust gas emitted from the engine is to be lowered by a relatively large degree before the exhaust gas flows into the catalyst, and (ii) making the amount of exhaust gas flowing through the second passage larger than the amount of exhaust gas flowing through the first passage when the temperature of exhaust gas emitted from the engine is to be lowered by a relatively small degree before the exhaust gas flows into the catalyst.

19. A method according to

claim 18

, further comprising making the cross section of the accelerated cooling portion of the first passage generally arcuate, and making the cross section of the second passage generally circular.

20. A method according to

claim 19

, wherein the accelerated cooling portion of the first passage is disposed to substantially surround the second passage.

21. A method according to

claim 18

, further comprising making a length of the first passage substantially equal to a length of the second passage.

22. A method according to

claim 18

, further comprising making cross-sectional areas of the first passage and of the second passage substantially equal.

23. A method according to

claim 18

, wherein the amounts of exhaust gas flowing through the first passage and through the second passage are controlled based on a catalyst midbed temperature of the catalyst or a parameter effecting the catalyst midbed temperature.

24. A method according to

claim 23

, wherein the amounts of exhaust gas flowing through the first passage and through the second passage are controlled so as to control a catalyst midbed temperature of the catalyst to be within a predetermined temperature range in which the catalyst provides a purification efficiency of not lower than a specified value.

25. A method according to

claim 18

, wherein the amount of exhaust gas flowing through the second passage is controlled to be larger than the amount of exhaust gas flowing through the first passage during an S-poisoning recovery process for releasing SOx that has been absorbed by the catalyst.

26. A method according to

claim 25

, further comprising controlling an air-fuel ratio of exhaust gas that flows into the catalyst during the S-poisoning recovery process to be substantially equal to or richer than a stoichiometric air-fuel ratio.

27. A method according to

claim 25

, wherein the amounts of flow are controlled so as to increase a proportion of the exhaust gas flowing through the first passage immediately after completion of the S-poisoning recovery process.

28. A method according to

claim 18

, wherein an HC adsorbent is provided in the first passage, and wherein all the exhaust gas is controlled to flow through the first passage during a start of the internal combustion engine.

29. A method according to

claim 28

, wherein:

the catalyst comprises a selective reduction type NOx catalyst that reduces or decomposes NOx in the presence of hydrocarbon in an oxygen-excess atmosphere;

the second passage is provided with an occlusion-reduction type NOx catalyst that absorbs NOx when incoming exhaust gas has a lean air-fuel ratio, and releases and reduces the absorbed NOx into N₂ when the concentration of oxygen contained in the incoming exhaust gas is reduced; and

the controlling step causes exhaust gas to flow mainly through the first passage when the engine is operating with a high load.

30. A method according to

claim 18

, further comprising:

sensing a temperature at one of;

(i) a joint passage into which a downstream portion of the first passage and a downstream portion of the second passage merge, (ii) an exhaust passage disposed downstream of the joint passage, and (iii) the catalyst; and

determining whether the flow amount controlling step is being performed normally or not, based on a change in the sensed temperature when the controlling step changes a ratio of the amounts of exhaust gas flowing through the first passage and through the second passage.

31. A method according to

claim 18

, further comprising:

detecting a pressure of exhaust gas in the fist passage; and

determining whether the flow amount controlling step is being performed normally or not, based on a change in the detected pressure when the controlling step changes a ratio of the amounts of exhaust flowing through the first passage and the second passage.