Exhaust Processor And Associated Method

• US 20070283680A1
• Filed: 05/12/2005
• Published: 12/13/2007
• Est. Priority Date: 05/12/2004
• Status: Abandoned Application

• Current Assignee: ET US Holdings LLC (Forvia SE)
• Original Assignee: ET US Holdings LLC (Forvia SE)
• Inventors: Arbuckle, Ivan, Abram, Kwin, Cook, Kenneth, Morales, Anthony, Callahan, Joseph, Willats, Robin, Ross, Gregory, Allen, Stephen, Smith, Aaron, Zimmer, John, Holtz, Glen
• Application Number:
  US11/568,836
• Publication Number:
  US 20070283680A1
• Time in Patent Office: Days
• US Class Current: 60/273
• CPC Class Codes: F01N 1/023 Helmholtz resonators
• CPC Class Codes: F01N 1/084 the gases flowing through the silencer two or more times longitudinally in opposite directions, e.g. using parallel or concentric tubes
• CPC Class Codes: F01N 1/10 in combination with sound-absorbing materials F01N1/125 takes precedence
• CPC Class Codes: F01N 1/165 for adjusting flow area
• CPC Class Codes: F01N 1/24 by using sound-absorbing materials F01N1/04, F01N1/06, F01N1/10, F01N1/14, F01N1/16 take precedence
• CPC Class Codes: F01N 2260/14 for modifying or adapting flow area or back-pressure
• CPC Class Codes: F01N 2430/02 by cutting out a part of engine cylinders
• CPC Class Codes: F01N 2470/02 Tubes being perforated

Abstract

An exhaust processor (12) comprises an isolated interior volume (16) that is defined in a housing (18) of the exhaust processor (12) so as to be isolated from exhaust gas in the housing (18). A motion converter (20) is positioned in the isolated interior volume (16) and is configured to convert in the isolated interior volume (16) linear movement of a linear valve actuator (22) into rotation of an exhaust valve (17). A cushioning pad (120, 122, 320, 420) can be used in a variety of exhaust processors (12, 212) to facilitate positioning of the exhaust valve (17). An associated method is disclosed.

Claims

1. A method, comprising the steps of:

treating exhaust gas in a housing of an exhaust processor,

isolating from exhaust gas an interior volume defined in the housing, and

converting in the isolated interior volume linear movement of a linear valve actuator into rotation of an exhaust valve mounted in the housing.

2. The method of claim 1, wherein the converting step comprises (i) moving a link in the isolated interior volume along an actuator axis in response to linear movement of the linear valve actuator along the actuator axis, (ii) rotating a lever in the isolated interior volume about a valve axis in response to movement of the link, and (iii) rotating the exhaust valve in response to rotation of the shaft.

3. The method of claim 2, wherein the lever-rotating step comprises rotating the lever from a first stop located in the isolated interior volume to a second stop located in the isolated interior volume so as to move the exhaust valve from a first valve position to a second valve position.

4. The method of claim 2, wherein:

the exhaust processor comprises a spring positioned in the isolated interior volume, and

the converting step comprises moving the lever from the second stop to the first stop with the spring upon de-energization of the linear valve actuator.

5. The method of claim 1,

wherein the interior volume is defined by an isolating enclosure included in a valve module comprising the exhaust valve, the linear valve actuator, and the motion converter,

further comprising the step of inserting the valve module into a shell of the housing such that a first portion of the isolating enclosure is positioned in the shell between first and second end caps of the housing and a second portion of the isolating enclosure extends from the first portion through the first end cap to a location outside the shell.

6. The method of claim 1, further comprising performing the converting step in response to changing operation of an engine between a first engine mode in which a first number of engine cylinders is active and a second engine mode in which a second number of engine cylinders different from the first number is active.

7. An exhaust processor, comprising:

an isolated interior volume that is defined in a housing of the exhaust processor so as to be isolated from exhaust gas in the housing,

an exhaust valve mounted in the housing for rotation relative thereto,

a linear valve actuator, and

a motion converter that is positioned in the isolated interior volume and that is configured to convert in the isolated interior volume linear movement of the linear valve actuator into rotation of the exhaust valve.

8. The exhaust processor of claim 7, wherein:

the linear valve actuator is configured for movement along an actuator axis,

the exhaust valve is configured for rotation about a valve axis, and

the actuator axis and the valve axis are transverse to one another.

9. The exhaust processor of claim 7, wherein:

the motion converter comprises a link secured to the linear valve actuator for movement of the link along an actuator axis in response to linear movement of the linear valve actuator along the actuator axis, a rotatable shaft secured to the valve to rotate the valve about a valve axis, and a lever secured to the link and the shaft to rotate the shaft in response to movement of the link, and

the link, the shaft, and the lever extend in the interior volume.

10. The exhaust processor of claim 9, wherein:

the motion converter comprises a first stop and a second stop,

the lever is configured to contact the first stop so as to position the valve in a first valve position and is configured to contact the second stop so as to position the valve in a second valve position, and

the first and second stops are positioned in the interior volume.

11. The exhaust processor of claim 10, wherein the motion converter comprises a spring that biases the lever toward the first stop and that is positioned in the interior volume.

12. The exhaust processor of claim 9, wherein:

the interior volume includes a first chamber and a second chamber in communication with the first chamber, and

the shaft and the lever extend in the first chamber, and

the link extends in the second chamber.

13. The exhaust processor of claim 9, wherein:

the isolated interior volume is defined by an isolating enclosure comprising a datum plate, a can, a link tube, a valve tube, and a shaft tube,

the can is secured to the datum plate to define therebetween a first chamber in which the shaft and the lever extend,

the link tube is secured to the datum plate and defines a second chamber that communicates with the first chamber through an opening defined in the datum plate,

the link extends in the first chamber,

the valve tube is secured to and extends through the datum plate, the first chamber, and the can,

the valve is positioned in the valve tube for rotation therein,

the shaft tube is secured to the datum plate and the valve tube and is positioned in the first chamber, and

the shaft is positioned in the shaft tube for rotation therein.

14. The exhaust processor of claim 13, wherein:

the motion converter comprises a first stop, a second stop, and a stop mounting plate to which the first and second stops are secured,

the lever is configured to contact the first stop so as to position the valve in a first valve position and is configured to contact the second stop so as to position the valve in a second valve position, and

the stop mounting plate is secured to the shaft tube.

15. The exhaust processor of claim 13, wherein:

the housing comprises a shell and first and second end caps coupled to opposite ends of the shell,

the datum plate and the can secured thereto are positioned between the end caps and within the shell,

the link tube extends through an opening defined in the first end cap to a location outside the shell,

the isolating enclosure comprises a cap secured to an end of the link tube, and

the link valve actuator comprises an actuator housing secured to the cap and an electrically actuatable piston extending from the actuator housing through the cap into the second chamber.

16. The exhaust processor of claim 7, wherein:

the housing comprises a shell and first and second end caps coupled to opposite ends of the shell,

the interior volume is defined by an isolating enclosure comprising a first enclosure portion and a second enclosure portion,

the first enclosure portion is positioned between the first and second end caps and is positioned within the shell so as to define a first chamber within the shell,

the second enclosure portion is secured to the first enclosure portion and extends through the first end cap to a location outside the shell so as to define a second chamber extending outside the shell and communicating with the first chamber,

the linear valve actuator is secured to the second enclosure portion, and and the motion converter extends through the first and second chambers.

17. The exhaust processor of claim 7, wherein:

the interior volume is defined by an isolating enclosure,

the linear valve actuator comprises an actuator housing positioned outside the interior volume and secured to the isolating enclosure, and

a sound abatement pad positioned between and contacting the actuator housing and the isolating enclosure so as to space the actuator housing apart from the isolating enclosure.

18. The exhaust processor of claim 7, further comprising an exhaust treatment device in the housing.

19. The exhaust processor of claim 18, wherein the exhaust treatment device is a sound attenuation arrangement positioned fluidly between the exhaust valve and a port of the housing.

20. The exhaust processor of claim 7, in combination with an engine and a cylinder control system, wherein:

the exhaust processor is fluidly coupled to the engine to receive exhaust gas therefrom,

the cylinder control system is coupled to the engine to selectively operate the engine in a first engine mode in which a first number of cylinders of the engine is active and a second engine mode in which a different second number of cylinders of the engine is active, and

the cylinder control system is operably coupled to the linear valve actuator so as to cause the motion converter to convert linear movement of the valve actuator into rotation of the valve to rotate the valve between a first valve position associated with the first engine mode and a second valve position associated with the second engine mode.

21-40. -40. (canceled)