Combination catalytic converter and heat exchanger that maintains a catalyst substrate within an efficient operating temperature range for emmisions reduction
First Claim
1. A catalytic conversion system for removing pollutants from exhaust emissions generated by an engine, said system comprising:
- a catalytic converter;
an exhaust emissions inlet port allowing exhaust emissions to enter the catalytic converter;
an exhaust emissions outlet port allowing the exhaust emissions to exit the catalytic converter;
a plurality of tubes aligned with the inlet port and the outlet port, each of said tubes including a catalyst material formed on a substrate such that the exhaust emissions pass through the tubes and contact the catalyst material when travelling from the inlet port to the outlet port, wherein the plurality of tubes include more than one catalyst material where each catalyst material includes a different effective operating temperature; and
a heat exchange system, said heat exchange system causing a cooling fluid to flow around the plurality of tubes so as to cool the catalyst material within the tubes.
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Accused Products
Abstract
A combination catalytic converter and heat exchanger unit that controls the temperature of one or more catalytic converters within their efficient conversion operating temperature ranges. The unit includes a plurality of spaced apart tubes through which the exhaust emissions flow through the unit. Each of the plurality of tubes includes a substrate on which is formed a catalyst that reduces or eliminates harmful by-products in the exhaust emissions. A cooling system, such as a fan, forces a cooling fluid, such as air, around the tubes to cool the catalyst to be within its efficient operating temperature range. The tubes have a suitable diameter that allows the center of the tubes to be effectively cooled. The speed of the fan is controlled to variably adjust the temperature of the exhaust emissions in response to various input data, such as the temperature of the exhaust emissions at different locations in the exhaust path, engine speed and load, and the type of catalyst being used. The plurality of tubes can incorporate two or more catalysts that have different operating ranges so as to control the effectiveness of the conversion for increased efficiency and reduction of energy consumption. It is also possible to provide supplemental electrical heat to the plurality of tubes to extend the duration whereby the catalytic converter is operating within its efficient conversion window.
114 Citations
26 Claims
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1. A catalytic conversion system for removing pollutants from exhaust emissions generated by an engine, said system comprising:
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a catalytic converter; an exhaust emissions inlet port allowing exhaust emissions to enter the catalytic converter; an exhaust emissions outlet port allowing the exhaust emissions to exit the catalytic converter; a plurality of tubes aligned with the inlet port and the outlet port, each of said tubes including a catalyst material formed on a substrate such that the exhaust emissions pass through the tubes and contact the catalyst material when travelling from the inlet port to the outlet port, wherein the plurality of tubes include more than one catalyst material where each catalyst material includes a different effective operating temperature; and a heat exchange system, said heat exchange system causing a cooling fluid to flow around the plurality of tubes so as to cool the catalyst material within the tubes. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A catalytic converter comprising:
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an exhaust emission inlet port allowing exhaust emissions to enter the catalytic converter; an exhaust emissions outlet port allowing the exhaust emissions to exit the catalytic converter; and a plurality of tubes aligned with the inlet port and the outlet port, each of the plurality of tubes being spaced from each other so that they are not in contact, each tube including a catalyst material formed on a catalyst substrate, wherein the plurality of tubes includes a plurality of different catalyst materials where at least two of the catalyst materials have different effective operating temperatures. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17)
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18. A method of converting exhaust emissions in a catalytic converter, said method comprising the steps of:
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providing a plurality of tubes including a catalyst material formed on a substrate, each of said tubes being spaced apart from each other, wherein the step of providing the plurality of tubes includes providing the plurality of tubes with more than one catalyst material where each catalyst material includes a different effective operating temperature; directing the exhaust emissions into the catalytic converter and through the plurality of tubes; and directing a cooling fluid around the plurality of tubes within the catalytic converter to cool the catalyst material within the plurality of tubes. - View Dependent Claims (19, 20, 21, 22)
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23. A catalytic conversion system for removing pollutants from exhaust emissions generated by an engine, said conversion system comprising:
a plurality of catalytic converters, each of the catalytic converters including an exhaust emissions inlet port allowing exhaust emissions to enter the catalytic converter; an exhaust emissions outlet port allowing the exhaust emissions to exit the catalytic converter; a plurality of tubes aligned with the inlet port and the outlet port, each of said tubes including a catalyst material formed on a substrate such that the exhaust emissions pass through the tubes and contact the catalyst material when travelling from the inlet port to the outlet port; and a heat exchange system, said heat exchange system causing a cooling fluid to flow around the plurality of tubes so as to cool the catalyst material within the tubes.
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24. A catalytic conversion system for removing pollutants from exhaust emissions generated by an engine, said conversion system including a catalytic converter, said system comprising:
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an exhaust emissions inlet port allowing exhaust emissions to enter the catalytic converter; an exhaust emissions outlet port allowing the exhaust emissions to exit the catalytic converter; a plurality of tubes aligned with the inlet port and the outlet port, each of said tubes including a catalyst material formed on a substrate such that the exhaust emissions pass through the tubes and contact the catalyst material when travelling from the inlet port to the outlet port; and a heat exchange system, said heat exchange system causing a cooling fluid to flow around the plurality of tubes so as to cool the catalyst material within the tubes, said heat exchange system including a heating element to heat the exhaust emissions within the catalytic converter.
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25. A catalytic converter comprising:
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an exhaust emission inlet port allowing exhaust emissions to enter the catalytic converter; an exhaust emissions outlet port allowing the exhaust emissions to exit the catalytic converter; and a plurality of tubes aligned with the inlet port and the outlet port, each of the plurality of tubes being spaced from each other so that they are not in contact, each tube including a catalyst material formed on a catalyst substrate, wherein a first group of the plurality of tubes includes a first catalyst material and a second group of the plurality of tubes includes a second catalyst material.
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26. A catalytic converter comprising:
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an exhaust emission inlet port allowing exhaust emissions to enter the catalytic converter; an exhaust emissions outlet port allowing the exhaust emissions to exit the catalytic converter; and a plurality of tubes aligned with the inlet port and the outlet port, each of the plurality of tubes being spaced from each other so that they are not in contact, each tube including a catalyst material formed on a catalyst substrate, wherein some of the plurality of tubes includes a first catalyst material for a predetermined length of the tube nearest the inlet port and a second catalyst material for the remaining length of the tube nearest the outlet port.
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Specification