Exhaust gas purification system for an internal combustion engine

• US 5,331,809 A
• Filed: 12/04/1990
• Issued: 07/26/1994
• Est. Priority Date: 12/06/1989
• Status: Expired due to Fees

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Takeshima, Sinichi, Hirota, Sinya, Katoh, Kenji
• Primary Examiner(s): Hart, Douglas
• Application Number:
  US07/625,893
• Time in Patent Office: 1,330 Days
• Field of Search: 60/286, 60/288, 60/298, 60/289, 60/290
• US Class Current: 60/288
• CPC Class Codes: F01N 2260/02 for cooling the device
• CPC Class Codes: F01N 2270/02 for cooling exhaust gases or the apparatus
• CPC Class Codes: F01N 2290/00 Movable parts or members in exhaust systems for other than for control purposes
• CPC Class Codes: F01N 2330/08 Granular material
• CPC Class Codes: F01N 2390/02 using electric components only
• CPC Class Codes: F01N 2410/02 in case of high temperature, e.g. overheating of catalytic reactor
• CPC Class Codes: F01N 2430/06 by varying fuel-air ratio, e.g. by enriching fuel-air mixture
• 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 3/2053 By-passing catalytic reactors, e.g. to prevent overheating
• 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 3/222 using electric valves only
• CPC Class Codes: F01N 3/28 Construction of catalytic reactors
• 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: F01N 9/00 Electrical control of exhaust gas treating apparatus monitoring or diagnostic devices for exhaust-gas treatment apparatus F01N11/00; conjoint electrical control of two or more combustion engine functions F02D43/00
• CPC Class Codes: F02B 1/04 with fuel-air mixture admission into cylinder
• 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
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

An exhaust gas purification system for an internal combustion engine includes a catalyst installed in an exhaust conduit of an engine and constructed of zeolite carrying at least one kind of metal selected from transition metals and noble metals to reduce nitrogen oxides included in the exhaust gas from the engine under an oxidizing gas condition and in the presence of hydrocarbons. The system further includes means for repeating a cycle of cooling the catalyst and then stopping the cooling to allow the catalyst to rise in temperature so that the temperature rising courses of the catalyst are positively and repeatedly produced. Since the catalyst can show a higher nitrogen oxides reducing ability in the temperature rising course than in the temperature lowering course, the NOx purification rate is greatly improved due to the positive production of the temperature rising courses.

Claims

1. A system for purifying exhaust gas from an internal combustion engine capable of executing fuel combustion at lean air-fuel ratios comprising:

a nitrogen oxide reducing catalyst installed in an exhaust conduit of the engine and constructed of zeolite carrying at least one kind of metal selected from transition metals and noble metals, wherein the catalyst produces active species through partial oxidation of the hydrocarbons in an oxidizing gas condition and causes the active species to react with nitrogen oxides included in the exhaust gas to reduce the nitrogen oxides, wherein said catalyst reduces nitrogen oxides more strongly in a catalyst temperature rising condition than in other catalyst temperature conditions; and

means for systematically producing a catalyst temperature rising condition while the engine is running by repeatedly executing a cycle of cooling the catalyst and then stopping the cooling to allow the catalyst to rise in temperature.

2. The exhaust gas purification system according to claim 1, and further comprising;

a bypass conduit connected to the exhaust conduit so as to bypass the catalyst;

a bypass valve adapted to switch exhaust gas flow between the catalyst and the bypass conduit;

engine operating condition detecting means for detecting an operating condition of the engine; and

catalyst temperature detecting means for detecting the temperature of the catalyst, and wherein the means for repeatedly producing a catalyst temperature rising condition includes bypass control means which switches on the bypass valve to cause the exhaust gas to flow through the bypass conduit when exhaust of nitrogen oxides from the engine is small and the catalyst temperature is equal to or higher then a first predetermined temperature and switches off the bypass valve to cause the exhaust gas to flow through the catalyst when the catalyst temperature is equal to or lower than a second predetermined temperature lower than the first predetermined temperature.

3. The exhaust gas purification system according to claim 1, and further comprising:

a bypass conduit connected to the exhaust conduit so as to bypass the catalyst;

a bypass valve adapted to switch flow of the exhaust gas between the catalyst and the bypass conduit;

engine operating condition detecting means for detecting an operating condition of the engine; and

catalyst temperature detecting means for detecting the temperature of the catalyst, and wherein the means for repeatedly producing a catalyst temperature rising condition includes bypass control means which switches on the bypass valve to cause the exhaust gas to flow through the bypass conduit when the engine operating condition is a condition where purification of nitrogen oxides can not be expected and the catalyst temperature is equal to or higher than a first predetermined temperature and switches off the bypass valve to cause the exhaust gas to flow through the catalyst when the catalyst temperature is equal to or lower than a second predetermined temperature lower than the first predetermined temperature.

4. The exhaust gas purification system according to claim 1, and further comprising:

a bypass conduit connected to the exhaust conduit so as to bypass the catalyst;

a bypass valve adapted to switch flow of the exhaust gas between the catalyst and the bypass conduit;

engine operating condition detecting means for detecting an operating condition of the engine; and

catalyst temperature detecting means for detecting the temperature of the catalyst, and wherein the means for repeatedly producing a catalyst temperature rising condition includes bypass control means which repeats switching on and switching off of the bypass valve at predetermined intervals in a temperature range above a predetermined catalyst temperature.

5. The exhaust gas purification system according to any one of claims 2 and 3, wherein the first predetermined temperature is 450°

C. and the second predetermined temperature is 300°

C.

6. The exhaust gas purification system according to claim 4, wherein the predetermined temperature is 300°

C.

7. The exhaust gas purification system according to any one of claims 2, 3 and 4, and further comprising a three-way catalyst installed in a portion of the exhaust conduit downstream of the nitrogen oxides reducing catalyst.

8. The exhaust gas purification system according to claim 1, wherein the catalyst is constructed in the form of pellets, and further comprising:

a catalytic converter case for housing catalyst pellets therein;

a cooling chamber communicating with the catalytic converter case;

circulating means for circulating the catalyst pellets between the converter case and the cooling chamber; and

circulating velocity control means for controlling the velocity of the catalyst pellet circulation, the means for repeatedly producing a catalyst temperature rising condition including the cooling chamber and the circulating means.

9. The exhaust gas purification system according to claim 8, wherein the circulating means includes a rotational screw driven by a motor.

10. The exhaust gas purification system according to claim 9, wherein the circulating velocity control means includes a variable resistance installed in an electrical circuit connecting the motor and a power source.

11. A system for purifying exhaust gas according to claim 1, further comprising:

engine operating condition detecting means for detecting an operating condition of the engine;

engine operating condition determining means for determining whether or not the detected engine operating condition is in a deceleration or idling condition, such that the amount of nitrogen oxides included in exhaust gas from the engine is small relative to the amount of nitrogen oxides included in exhaust gas when the engine operating condition is not in a deceleration or idling condition; and

secondary air supply means for introducing secondary air into a portion of the exhaust conduit upstream of the catalyst,

and, wherein the means for repeatedly producing a catalyst temperature rising condition includes means which operate the secondary air supply means to introduce secondary air into the engine exhaust conduit when the engine operating condition is determined to be in a decelerating or idling condition by the engine operating condition determining means.

12. A system for purifying exhaust gas according to claim 11, wherein the engine operating condition detecting means includes a throttle sensor for detecting a throttle valve opening degree.

13. The exhaust gas purification system according to claim 1, and further comprising:

a plurality of catalytic converter cases, the catalyst being divided into a plurality of portions and a portion of the catalyst being housed in each catalytic converter case;

a plurality of branch conduits each connected to a corresponding catalytic converter case;

a switching valve installed at a connecting portion of the branch conduits where all the branch conduits join each other so as to selectively direct the exhaust gas flow to any one of the branch conduits;

a plurality of secondary air inlets each provided in a portion of each branch conduit upstream of the catalytic converter case;

and wherein the means for repeatedly producing a catalyst temperature rising condition includes means which alternately switches the switching valve between the plurality of branch conduits when the exhaust gas temperature is high.

14. The exhaust gas purification system according to claim 1, and further comprising:

a single catalytic converter case, the catalyst being installed in an intermediate portion of an internal space of the catalytic converter case;

a dividing wall dividing a portion of the catalytic converter case internal space upstream of the catalyst into a plurality of sections so that the sections are in parallel with each other;

a plurality of secondary air inlets each provided for each section of the upstream portion of the catalytic converter case internal space,

and wherein the means for repeatedly producing a catalyst temperature rising condition includes means which alternately introduces secondary air through the secondary air inlet when the exhaust gas temperature is high.

15. The exhaust gas purification system according to any one of claims 13 and 14, and further comprising a three-way catalyst provided downstream of the nitrogen , oxides reducing catalyst.

16. The exhaust gas purification system according to claim 1, wherein the catalyst is divided into a first portion and a second portion arranged downstream of the first portion of the catalyst, and further comprising:

a bypass conduit bypassing the first portion of the catalyst;

a bypass valve adapted to switch flow of the exhaust gas between the first portion of the catalyst and the bypass conduit,

and wherein the means for repeatedly producing a catalyst temperature rising condition includes means which alternately switches the bypass valve between the first portion of the catalyst and the bypass conduit when the exhaust gas temperature exceeds a predetermined temperature.

17. The exhaust gas purification system according to claim 16, wherein the predetermined temperature is 700°

C.

18. The exhaust gas purification system according to claim 16, and further comprising a first three-way catalyst provided downstream of the first portion of the nitrogen oxides reducing catalyst and a second three-way catalyst provided downstream of the second portion of the nitrogen oxides reducing catalyst.

19. The exhaust gas purification system according to claim 1, wherein the catalyst is located at a position of the exhaust conduit where the catalyst temperature tends to rise above a temperature range between temperature T₁ and temperature T₂ at which the catalyst can show high NOx purification rates under a normal engine operating condition, and further comprising:

cooling means for cooling the catalyst;

catalyst temperature detecting means for detecting the temperature of the catalyst,

and wherein the means for repeatedly producing a catalyst temperature rising condition includes means which begins cooling of the catalyst by operating the cooling means when the catalyst temperature detected by the catalyst temperature detecting means rises above the temperature T₂ and stops the cooling when the catalyst temperature detected by the catalyst temperature detecting means lowers below the temperature T₁.

20. The exhaust gas purification system according to claim 1, wherein the catalyst is located at a position of the exhaust gas conduit where the catalyst temperature tends to rise to a temperature at which the catalyst can show a highest NOx purification rate under a normal engine operating condition, and further comprising:

cooling means for cooling the catalyst;

catalyst temperature detecting means for detecting the temperature of the catalyst;

and wherein the means for repeatedly producing a catalyst temperature rising condition includes means which begins cooling of the catalyst by operating the cooling means when the catalyst temperature detected by the catalyst temperature detecting means rises above the temperature T₀ and stops the cooling when the catalyst temperature detected by the catalyst temperature detecting means is lowered to a temperature equal to or lower than the temperature T₀.

21. The exhaust gas purification system according to any one of claims 19 and 20, wherein the cooling means includes secondary air supply means.

22. The exhaust gas purification system according to any one of claims 19 and 20, wherein the cooling means includes a bypass conduit bypassing the catalyst and a bypass valve for switching the exhaust gas flow between the catalyst and the bypass conduit.