Spark ignition engine exhaust system

• US 5,396,764 A
• Filed: 02/14/1994
• Issued: 03/14/1995
• Est. Priority Date: 02/14/1994
• Status: Expired due to Fees

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Motor Company
• Inventors: Rao, Vemulapalli D. N., Cikanek, Harry A.
• Primary Examiner(s): Lazarus, Ira S.
• Assistant Examiner(s): O'CONNOR, DANIEL
• Application Number:
  US08/195,502
• Time in Patent Office: 393 Days
• Field of Search: 60/273, 60/274, 60/284, 60/286, 60/287, 60/297, 60/299, 60/300, 60/302, 60/303, 60/311
• US Class Current: 60/274
• CPC Class Codes: B01D 53/9481 Catalyst preceded by an adsorption device without catalytic function for temporary storage of contaminants, e.g. during cold start
• 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 13/107 More than one exhaust manifold or exhaust collector
• CPC Class Codes: F01N 2250/02 filtering and catalytic conversion
• CPC Class Codes: F01N 2250/12 absorption or adsorption, and catalytic conversion
• CPC Class Codes: F01N 2250/14 absorption or adsorption, and filtering
• CPC Class Codes: F01N 2330/06 Ceramic, e.g. monoliths
• CPC Class Codes: F01N 2330/10 Fibrous material, e.g. mineral or metallic wool
• CPC Class Codes: F01N 2410/00 By-passing, at least partially, exhaust from inlet to outlet of apparatus, to atmosphere or to other device
• CPC Class Codes: F01N 2410/12 in case of absorption, adsorption or desorption of exhaust gas constituents
• CPC Class Codes: F01N 2470/12 Tubes being corrugated
• CPC Class Codes: F01N 2570/14 Nitrogen oxides
• CPC Class Codes: F01N 3/0222 the structure being monolithic, e.g. honeycombs
• CPC Class Codes: F01N 3/023 using means for regenerating the filters, e.g. by burning trapped particles by electrically controlling the supply of combustible mixture or its constituents only F02D41/0235
• CPC Class Codes: F01N 3/031 having means for by-passing filters, e.g. when clogged or during cold engine start
• CPC Class Codes: F01N 3/035 with catalytic reactors , e.g. catalysed diesel particulate filters
• CPC Class Codes: F01N 3/0814 combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts
• CPC Class Codes: F01N 3/0821 combined with particulate filters catalysed diesel particulate filters F01N3/035
• CPC Class Codes: F01N 3/0835 Hydrocarbons
• CPC Class Codes: F01N 3/0878 : Bypassing absorbents or adsorbents
• CPC Class Codes: F01N 3/20 : specially adapted for catalytic conversion F01N3/22 takes precedence; Methods of operation or control of catalytic converters
• CPC Class Codes: F01N 3/2053 : By-passing catalytic reactors, e.g. to prevent overheating
• CPC Class Codes: F01N 3/2892 : Exhaust flow directors or the like, e.g. upstream of catalytic device
• 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: 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

Abstract

An exhaust system for a spark ignition engine on an automotive vehicle including an exhaust filter disposed downstream of a spark ignition engine for condensing hydrocarbons in exhaust gases from the engine during a first time period after start of the engine, a bypass structure for bypassing at least a portion of exhaust gases around the exhaust-filter to heat the exhaust filter during a second time period after the first time period and evaporate the condensed hydrocarbons, and a catalytic converter disposed downstream of the exhaust filter to oxidize the evaporated hydrocarbons and reduce NO_x in exhaust gases passing therethrough. A method is also provided.

Claims

1. An exhaust system for a spark ignition engine on an automotive vehicle comprising:

filter means disposed downstream of a spark ignition engine for condensing hydrocarbons in exhaust gases from the engine during a first time period after start of the engine;

bypass means for bypassing at least a portion of exhaust gases around said filter means to heat said filter means during a second time period after said first time period and evaporate the condensed hydrocarbons; and

a catalytic converter disposed downstream of said filter means to oxidize the evaporated hydrocarbons and reduce NO_x in exhaust gases passing therethrough.

2. An exhaust system as set forth in claim 1 wherein said filter means comprises a housing extending longitudinally and a substrate disposed within said housing having a plurality of walls forming a plurality of channels extending longitudinally with an inlet end and an outlet end.

3. An exhaust system as set forth in claim 2 wherein said substrate includes blocking means for blocking fluid flow alternatingly at said inlet end and said outlet end of said channels.

4. An exhaust system as set forth in claim 3 including a wash coat disposed on said walls of alternating said channels for allowing fluid flow to diffuse through said walls into the other of alternating said channels.

5. An exhaust system as set forth in claim 4 wherein said wash coat extends along said walls from said outlet end to a predetermined distance toward said inlet end.

6. An exhaust system as set forth in claim 5 wherein said wash coat is made of a catalytic material.

7. An exhaust system as set forth in claim 1 wherein said bypass means comprises a filter flange connected to an inlet end of said filter means and having a first plurality of apertures, a control flange disposed about said filter flange and having a second plurality of apertures, and control means for moving said control flange and said filter flange relative to each other for aligning and misaligning said first and second apertures.

8. An exhaust system as set forth in claim 7 wherein said control means comprises a bellows interconnecting said control flange and a housing.

9. An exhaust system as set forth in claim 7 wherein said control means comprises an actuator connected to said control flange for moving said control flange longitudinally relative to said filter flange.

10. An exhaust system as set forth in claim 7 wherein said control means comprises an actuator connected to said control flange for moving said control flange circumferentially relative to said filter flange.

11. A method of reducing hydrocarbons and NO_x in an exhaust system for a spark ignition engine on an automotive vehicle, said method comprising the steps of:

providing a filter downstream of a spark ignition engine and a catalytic converter downstream of the filter for an exhaust system;

condensing hydrocarbons in exhaust gases from the engine on the filter during a first time period after start of the engine;

bypassing at least a portion of exhaust gases around the filter to heat the filter during a second time period after the first time period and evaporate the condensed hydrocarbons; and

oxidizing the evaporated hydrocarbons and reducing NO_x in exhaust gases passing through the catalytic converter.

12. A method as set forth in claim 11 including the steps of providing the filter with a plurality of walls forming a plurality of channels extending longitudinally with an inlet end and an outlet end.

13. A method as set forth in claim 12 including the step of blocking fluid flow alternatingly at the inlet end and outlet end of the channels.

14. A method as set forth in claim 13 including the step of disposing a wash coat on the walls of alternating channels and allowing fluid flow to diffuse through the walls into the other of alternating channels.

15. A method as set forth in claim 14 including the step of extending the wash coat along the walls from the outlet end to a predetermined distance toward the inlet end.

16. A method as set forth in claim 15 wherein the wash coat is made of a catalytic material.

17. A method as set forth in claim 11 including the step of connecting a filter flange to an inlet end of the filter having a first plurality of apertures, disposing a control flange about the filter flange having a second plurality of apertures, and moving the control flange and the filter flange relative to each other for aligning and misaligning the first and second apertures.

18. A method as set forth in claim 17 including the step of connecting a bellows between the control flange and a housing of the filter and moving the control flange longitudinally relative to the filter flange.

19. A method as set forth in claim 17 including the step of connecting an actuator to the control flange and moving the control flange longitudinally relative to the filter flange.

20. A method as set forth in claim 17 including the step of connecting an actuator to the control flange and moving the control flange circumferentially relative to the filter flange.