Upstream collimator for electrically heatable catalytic converter

• US 5,177,961 A
• Filed: 06/26/1991
• Issued: 01/12/1993
• Est. Priority Date: 06/26/1991
• Status: Expired due to Fees

• Current Assignee: Engelhard Corporation (BASF SE)
• Original Assignee: W R Grace & Company - CONN (WR Grace & Company)
• Inventors: Whittenberger, William A.
• Primary Examiner(s): Hart, Douglas
• Application Number:
  US07/722,607
• Time in Patent Office: 566 Days
• Field of Search: 60/300, 422/171, 422/174, 422/176
• US Class Current: 60/300
• CPC Class Codes: F01N 13/0097 the purifying devices are arranged in a single housing
• CPC Class Codes: F01N 2330/02 Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal
• CPC Class Codes: F01N 3/2026 directly electrifying the catalyst substrate, i.e. heating the electrically conductive catalyst substrate by joule effect
• CPC Class Codes: F01N 3/281 Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
• CPC Class Codes: F01N 3/2853 using mats or gaskets between catalyst body and housing
• CPC Class Codes: F01N 3/2892 Exhaust flow directors or the like, e.g. upstream of catalytic device
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

There is provided an improved electrically heatable catalytic converter formed of an electrically heatable corrugated thin metal monolith and having a collimator axially spaced upstream of the electrically heatable monolith, said collimator having the purpose of straightening and subdividing the gas flow to minimize the tendency of the leading edges of the corrugated thin metal monolith to be folded over in use.

Claims

1. An electrically heatable catalytic converter comprising (a) a corrugated thin metal polycellular monolith, said monolith having an upstream gas intercepting face, a plurality of gas transmitting cells opening in said face, and a catalyst deposited on the gas contacting surfaces of said cells, and (b) a porous ceramic disk collimator for said exhaust gas stream having gas transmitting openings of from 0.01" to 0.15" in diameter, said collimator being axially spaced upstream of said gas intercepting face, whereby the gas flow is straightened and subdivided prior to entry into the corrugated thin metal polycellular monolith.

2. An electrically heatable catalytic converter as defined in claim 1 wherein the ceramic disk is an extruded ceramic disk.

3. An electrically heatable catalytic converter as defined in claim 1 wherein the ceramic disk is an open pore cast ceramic disk.

4. An electrically heatable catalytic converter for treating exhaust gas emanating from an internal combustion engine to remove pollutant materials therefrom, said converter including (1) an outer metallic shell, (2) means at each end of said shell for adapting the configuration of the outer metallic shell for insertion into a conventional exhaust system for said internal combustion engine, (3) an insulating liner for the inner walls of said outer shell, (4) a core for said converter within said insulating liner including (5) a porous ceramic disk collimator having gas transmitting openings of from 0.01" to 0.15" in diameter, and axially spaced therefrom, (6) a core member comprising (a) at least one nonnesting corrugated thin stainless steel foil strip spirally wound about (b) an electrically conducting central metal post, and (c) a retaining shell tightly surrounding said core member and being electrically bonded thereto, (7) means for connecting said central post to one pole of a direct current voltage source, (8) means for connecting said retaining shell to the other pole of a direct current voltage source, and (9) a direct current voltage source rated at from 12 to 108 volts.