STRUCTURES FOR CATALYTIC CONVERTERS
1. A catalytic convertor device, comprising:
- a housing with an inlet and an outlet; and
a catalytic convertor core with an inlet and an outlet, the catalytic convertor core being formed from a gas permeable material, wherein the catalytic convertor core is longitudinally pleated to create a plurality of pleats of the gas permeable material inside the housing.
Various structures for catalytic convertors are disclosed herein. The device includes an outer housing enclosing a catalytic core. The catalytic core can be formed in a myriad of ways. Flow paths through the core are constructed so that they are not straight-line paths from the inlet of the device to the outlet of the device. Pleated conformations and stacked core arrays are described that maximize the catalytic surface area in a given volume of housing. The application of the core to exhaust from diesel engines is also disclosed.
- 1. A catalytic convertor device, comprising:
a housing with an inlet and an outlet; and a catalytic convertor core with an inlet and an outlet, the catalytic convertor core being formed from a gas permeable material, wherein the catalytic convertor core is longitudinally pleated to create a plurality of pleats of the gas permeable material inside the housing.
- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20)
- 11. A catalytic convertor device, comprising:
a housing with an inlet and an outlet; and a catalytic convertor core with an inlet and an outlet, the catalytic convertor core comprising openings therein that form fluid flow paths, the openings being staggered from the inlet to the outlet so that no fluid flow path is a straight line, the catalytic convertor core being longitudinally pleated to create a plurality of pleats inside the housing.
This application claims the priority benefit of U.S. patent application Ser. No. 16/172,732, filed on Oct. 27, 2018, of which this application is a continuation-in-part, and the priority benefit of U.S. Provisional Application 62/917,497, filed on Dec. 11, 2018. The disclosures of the aforementioned applications are hereby incorporated by reference in their entireties, including all references and appendices cited therein, for all purposes.
The present disclosure relates generally to fluidic architectures for the conversion of harmful gases to gases that are not harmful, and more specifically to the catalytic conversion of exhaust gases from internal combustion engines.
In various embodiments of the present disclosure, catalytic convertor devices include a housing and a convertor core. The convertor core includes at least one catalytic core. Both the convertor core and the housing have an inlet side and an outlet side. The convertor core further includes at least one catalytic core, the catalytic core having openings that form fluid flow paths. The openings are staggered from the inlet side to the outlet side so that no fluid flow path is a straight line. This maximizes exposure of inlet harmful gases to catalytic surfaces by minimizing a boundary layer and providing configurations that maximize the exposure of virgin harmful gases to the catalytic surfaces in the catalytic core, the catalytic core having openings that form fluid flow paths. The openings are staggered from the inlet side to the outlet side so that no fluid flow path is a straight line. This maximizes exposure of inlet harmful gases to catalytic surfaces by minimizing a boundary layer and providing configurations that maximize the exposure of virgin harmful gases to the catalytic surfaces in the catalytic core. The catalytic core structure can be deployed in any catalytic conversion process. In various embodiments, the structures can be used in internal combustion engines including those employing the Otto cycle and diesel type engines.
In various embodiments, the convertor core is made from catalyzed pleated surfaces situated in a conical array. Each of the catalytic surfaces has a plurality of openings therein that form fluid flow paths.
The accompanying drawings, wherein like reference numerals refer to identical or functionally similar elements throughout the separate views, together with the detailed description below, illustrate embodiments of concepts that include the claimed disclosure, and explain various principles and advantages of those embodiments.
The present disclosure is generally directed to configurations of catalytic surfaces that are utilized to convert harmful exhaust gases to harmless gases in a more efficient manner and at a lower cost than current art devices. The configurations of catalytic surfaces disclosed herein result in more efficient conversion of harmful exhaust gases to harmless gases both during normal operation and warmup. Catalytic materials are much more efficient at converting harmful gasses at elevated temperatures. The reduced mass and the fluidic architecture disclosed herein result in catalytic convertor devices that require significantly less time to reach efficient conversion temperatures. The lower cost of the devices is due in part to a reduction in the mass of the devices and also to the more efficient utilization of the precious metals used in the catalytic converter core devices.
Referring first to
Exhaust gases from internal combustion engines typically contain a small amount of gases that are harmful to humans and the environment. When the catalytic converter assembly 50 is cold, the harmful exhaust gases can pass thought the catalytic converter assembly 50 without being converted to harmless gases. The gases exit the catalytic converter assembly 50 at the outlet 12. When the conversion components within the catalytic converter assembly 50 reach operational temperature, a significant fraction of the harmful exhaust gases are converted to harmless gases.
The catalytic material is typically a precious metal carried in a porous ceramic material called a washcoat. Washcoats comprise a porous ceramic material to create maximum surface area to act as a carrier for the actual catalytic material. Some examples known to those skilled in the art of washcoat materials are aluminum oxide, titanium dioxide and silicon dioxide, or a mixture of silica and alumina. Some known catalytic materials are platinum, palladium, rhodium, etc. The engineering of the specific catalytic material used for catalytic conversion is not discussed herein, inasmuch as one skilled in the art of catalytic conversion materials and their reaction with exhaust gases could apply the known art to any of the fluidic structures described in this disclosure.
Nearly all of the exhaust gases that flow through the conical catalytic core 51 are converted from harmful gases to harmless gases (presuming an operable temperature range in the catalytic core) as the inlet gases react with the catalytic material on the surfaces of the conical catalytic panel 51.
Referring now to
To ensure that exhaust gases do not bypass the porous material 202, end plate 203 is mated to the porous material 202. End plate 203 is sized to fill the inlet of the housing (not shown) so that the exhaust gas is forced to flow over the porous catalytic material 202. The end plate 203 ensures that all of the exhaust gas flows through the pleated conical catalytic converter core 200. The outside surface of the plate 203 seals against the inside of the housing in practice.
Referring now to
The technology disclosed herein addresses improved configurations for catalytic convertors. The improvements disclosed are independent of the actual catalytic material used for the catalytic conversion. There are a myriad of choices that would suffice as the material from which to form the catalytic cores described. Porous metal, screens, fiberglass, or porous ceramic materials could be deployed to create a catalytic core embodying the teachings of this disclosure—keeping the boundary layer to a minimum while facilitating virgin harmful gases being brought into contact with the catalytic surfaces. Further, the type of material used to create the catalytic cores is not limited to ceramics or metals. Glass or other materials that can withstand high operating temperatures could also be deployed. Cores with square or round holes—indeed openings of nearly any conformation—could as well be deployed. It should be noted that in general, smaller core openings, smaller pitch, and thinner thickness of material deliver improved performance. Thinner material typically leads to less mass in the device. Less mass relates to lower weight, cost of manufacturing, and faster warmup of the catalytic surfaces. Smaller pores with smaller pitch results in lower overall velocity between the pores which lead to greater conversion rates. It should be self-evident that one skilled in the art of catalytic materials could engineer a specific catalytic material to be installed in a catalytic convertor to be used in a given application.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the present disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the present disclosure. Exemplary embodiments were chosen and described in order to best explain the principles of the present disclosure and its practical application, and to enable others of ordinary skill in the art to understand the present disclosure for various embodiments with various modifications as are suited to the particular use contemplated.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the technology. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. The descriptions are not intended to limit the scope of the invention to the particular forms set forth herein. To the contrary, the present descriptions are intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims and otherwise appreciated by one of ordinary skill in the art. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments.