Device for purifying exhaust gas of engine

• US 6,014,859 A
• Filed: 08/19/1998
• Issued: 01/18/2000
• Est. Priority Date: 08/25/1997
• Status: Expired due to Term

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Itou, Takaaki, Yoshizaki, Kouji
• Primary Examiner(s): Denion, Thomas
• Assistant Examiner(s): TRAN, BINH Q
• Application Number:
  US09/136,766
• Time in Patent Office: 517 Days
• Field of Search: 60/285, 60/286, 60/287, 60/295, 60/297, 60/300, 60/303, 60/284, 60/274, 123/443
• US Class Current: 60/285
• CPC Class Codes: B01D 53/9495 Controlling the catalytic process
• CPC Class Codes: F01N 13/009 having two or more separate purifying devices arranged in series
• CPC Class Codes: F01N 13/011 having two or more purifying devices arranged in parallel
• CPC Class Codes: F01N 2570/04 Sulfur or sulfur oxides
• CPC Class Codes: F01N 3/0814 combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts
• CPC Class Codes: F01N 3/0842 Nitrogen oxides
• CPC Class Codes: F01N 3/0871 Regulation of absorbents or adsorbents, e.g. purging by electrically controlling the supply of combustible mixture or its constituents only F02D41/0235
• CPC Class Codes: F01N 3/0885 Regeneration of deteriorated absorbents or adsorbents, e.g. desulfurization of NOx traps
• 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 3/30 Arrangements for supply of additional air control, e.g. using by-passes or variable air pump drives, F01N3/22
• CPC Class Codes: F02D 41/027 to purge or regenerate the exhaust gas treating apparatus
• CPC Class Codes: F02D 41/028 Desulfurisation of NOx traps or adsorbent
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

An engine has a plurality of the cylinders. The cylinders are divided into a first cylinder group and a second cylinder group, and each cylinder group is connected, via a corresponding branch exhaust passage, to a common interconnecting exhaust passage. In the interconnecting exhaust passage, an exhaust gas purifying catalyst is arranged. The air-fuel ratio of the exhaust gas of the first cylinder group is made lean to feed oxygen to the exhaust gas purifying catalyst, and the air-fuel ratio of the second cylinder group is made rich to feed fuel for heating to the exhaust gas purifying catalyst, so that the oxygen and the fuel for heating react with each other to heat the exhaust gas purifying catalyst to reactivate the exhaust gas purifying catalyst when the reactivation of the exhaust gas purifying catalyst is must be performed. In each branch exhaust passage, a start catalyst is arranged.

Claims

1. A device for purifying the exhaust gas of an engine having an exhaust passage, the device comprising:

an exhaust gas purifying catalyst arranged in the exhaust passage;

a start catalyst arranged in the exhaust passage upstream of the exhaust gas purifying catalyst;

means for forming a gas including oxygen;

means for forming a gas including a reducing agent;

means for forming at least one of the gas including oxygen and the gas including the reducing agent from the exhaust gas of the engine;

means for mixing the gas including oxygen and the gas including the reducing agent and feeding the gas mixture to the exhaust gas purifying catalyst without the gas mixture flowing into the start catalyst;

judging means for judging whether the exhaust gas purifying catalyst is poisoned, wherein a reactivation of the exhaust gas purifying catalyst is performed when the exhaust gas is judged to be poisoned; and

means for obtaining a cumulative fuel amount of the fuel fed to the engine during the usual engine operation, wherein the exhaust gas purifying catalyst is judged to be poisoned when the cumulative fuel amount is larger than a predetermined amount.

2. A device according to claim 1, wherein, when the reactivation of the exhaust gas purifying catalyst must be performed, the gas including oxygen and the gas including the reducing agent are formed and fed to the exhaust gas purifying catalyst so that the oxygen and the reducing agent react with each other to heat the exhaust gas purifying catalyst to reactivate the exhaust gas purifying catalyst.

3. A device according to claim 2, further comprising means for controlling the air-fuel ratio of the exhaust gas flowing to the exhaust gas purifying catalyst, and wherein the air-fuel ratio of the exhaust gas flowing to the exhaust gas purifying catalyst is made rich when the reactivation of the exhaust gas purifying catalyst must be performed.

4. A device according to claim 3, wherein the exhaust gas purifying catalyst comprises a NO_X absorbent, the NO_X absorbent absorbing NO_X therein when the air-fuel ratio of the inflowing exhaust gas is lean, and releasing the absorbed NO_X therefrom when the oxygen concentration in the inflowing exhaust gas becomes lower, and wherein the reactivation of the NO_X absorbent is performed when the NO_X absorbent is poisoned by sulphur containing components.

5. A device according to claim 4, wherein the air-fuel ratio of the exhaust gas flowing to the NO_X absorbent is made lean during the usual engine operation, and wherein the air-fuel ratio of the exhaust gas flowing to the NO_X absorbent is made stoichiometric temporarily when the reactivation of the NO_X absorbent must be stopped.

6. A device according to claim 5, wherein a time in which the air-fuel ratio of the exhaust gas flowing to the NO_X absorbent must be made stoichiometric becomes longer as the amount of the exhaust gas flowing through the NO_X absorbent during the previous reactivation of the NO_X absorbent became larger.

7. A device according to claim 4, wherein the air-fuel ratio of the exhaust gas flowing through the NO_X absorbent is made temporarily rich to release the absorbed NO_X from the NO_X absorbent and reduce the NO_X.

8. A device according to claim 4, further comprising means for finding the amount of the reducing agent fed to the NO_X absorbent during the reactivation of the NO_X absorbent, wherein the reactivation of the NO_X absorbent is finished when the amount of the reducing agent fed to the NO_X absorbent is larger than a predetermined amount.

9. A device according to claim 4, wherein the NO_X absorbent is comprised of at least one substance selected from alkali metals including potassium, sodium, lithium, and cesium, alkali earth metals including barium and calcium, rare earth metals including lanthanum and yttrium, and of precious metals including platinum, palladium, rhodium, and iridium, which are carried on a carrier.

10. A device according to claim 2, wherein the air-fuel ratio of the exhaust gas flowing to the exhaust gas purifying catalyst is made lean during the usual engine operation.

11. A device according to claim 1, wherein the judging means judges whether the exhaust gas purifying catalyst is poisoned by at least one of sulphur containing components, a soluble organic fraction, and lead.

12. A device according to claim 1, further comprising means for detecting the temperature of the exhaust gas purifying catalyst, wherein the reactivation of the exhaust gas purifying catalyst is performed when the exhaust gas purifying catalyst is judged to be poisoned and the temperature of the exhaust gas purifying catalyst is higher than a predetermined temperature.

13. A device according to claim 1, wherein the start catalyst comprises a three-way catalyst.

14. A device according to claim 13, wherein the air-fuel ratio of the exhaust gas of engine is made stoichiometric to make the air-fuel ratio of the exhaust gas flowing to the three-way catalyst stoichiometric during the engine starting operation.

15. A device according to claim 1, wherein the air-fuel ratio of the exhaust gas of the engine is made lean to form the gas including oxygen.

16. A device according to claim 15, wherein the engine has a plurality of cylinders, the cylinders being divided into a plurality of cylinder groups, wherein the air-fuel ratio of the exhaust gas of a part of the cylinder groups is made lean to form the gas including oxygen, and the air-fuel ratio of the exhaust gas of at least one of the remaining cylinder groups is made rich to form the gas including the reducing agent.

17. A device according to claim 16, wherein each cylinder group is connected, via a corresponding branch exhaust passage, to a common interconnecting exhaust passage, start catalysts being arranged in each branch exhaust passage, an exhaust gas purifying catalyst being arranged in the interconnecting exhaust passage, and wherein the gas including oxygen and the gas including the reducing agent are mixed in the interconnecting passage after they pass through the start catalysts.

18. A device according to claim 16, wherein each cylinder group is connected to a common interconnecting exhaust passage, the start catalyst and the exhaust gas purifying catalyst being arranged in the interconnecting exhaust passage, and wherein the device further comprises bypass means for communicating the cylinder groups and the exhaust gas purifying catalyst by bypassing the start catalyst.

19. A device according to claim 18, wherein the bypass means comprises:

a bypass passage connecting the interconnecting passage upstream of the start catalyst and the interconnecting passage between the start catalyst and the exhaust gas purifying catalyst; and

a bypass valve for introducing the exhaust gases of the cylinder groups selectively to one of the bypass passage and the start catalyst, wherein the bypass valve introduces the exhaust gases of the cylinder groups into the bypass passage when the gas including oxygen and the gas including the reducing agent must be fed to the exhaust gas purifying catalyst.

20. A device according to claim 16, wherein the air-fuel ratio of the air-fuel mixture burned in the at least one of the remaining cylinder groups is made rich to form the gas including the reducing agent.

21. A device according to claim 16, wherein the cylinder has a fuel injector directly injecting fuel into the cylinder, and wherein the fuel injector of the at least one of the remaining cylinder groups injects fuel secondarily at the combustion stroke or the exhaust stroke of the engine to form the gas including the reducing agent.

22. A device according to claim 16, wherein the cylinders are divided into a first cylinder group and a second cylinder group, and wherein the air-fuel ratio of the exhaust gas of the first cylinder group is made lean to form the gas including oxygen, and the air-fuel ratio of the exhaust gas of the second cylinder group is made rich to form the gas including the reducing agent.

23. A device according to claim 15, further comprising a reducing agent injector arranged in the exhaust passage between the start catalyst and the exhaust gas purifying catalyst for injecting the reducing agent to the exhaust gas purifying catalyst, and wherein the air-fuel ratio of the exhaust gas of the engine is made lean to form the gas including oxygen and the reducing agent is injected by the reducing agent injector to form the gas including the reducing agent.

24. A device according to claim 1, wherein the air-fuel ratio of the exhaust gas of the engine is made rich to form the gas including the reducing agent.

25. A device according to claim 24, further comprising an oxygen injector arranged in the exhaust passage between the start catalyst and the exhaust gas purifying catalyst for injection oxygen to the exhaust gas purifying catalyst, and wherein the air-fuel ratio of the exhaust gas of the engine is made rich to form the gas including the reducing agent and oxygen is injected by the oxygen injector to form the gas including oxygen.

26. A device according to claim 1, wherein the reducing agent comprises hydrocarbon.

27. A device for purifying the exhaust gas of an engine having an exhaust passage, the device comprising:

an exhaust gas purifying catalyst arranged in the exhaust passage;

a start catalyst arranged in the exhaust passage upstream of the exhaust gas purifying catalyst;

means for forming a gas including oxygen;

means for forming a gas including a reducing agent;

means for forming at least one of the gas including oxygen and the gas including the reducing agent from the exhaust gas of the engine; and

means for mixing the gas including oxygen and the gas including the reducing agent disposed upstream of the start catalyst and feeding the gas mixture to the exhaust gas purifying catalyst without the gas mixture flowing into the start catalyst.

28. A device for purifying the exhaust gas of an engine having an exhaust passage, the device comprising:

an exhaust gas purifying catalyst arranged in the exhaust passage;

a start catalyst arranged in the exhaust passage upstream of the exhaust gas purifying catalyst;

means for forming a gas including oxygen;

means for forming a gas including a reducing agent;

means for forming at least one of the gas including oxygen and the gas including the reducing agent from the exhaust gas of the engine; and

means for mixing the gas including oxygen and the gas including the reducing agent and feeding the gas mixture to the exhaust gas purifying catalyst without the gas mixture flowing into the start catalyst;

wherein the engine has a plurality of cylinders, the cylinders being divided into a plurality of cylinder groups, wherein the air-fuel ratio of the exhaust gas of a part of the cylinder groups is made lean to form the gas including oxygen, and the air-fuel ratio of the exhaust gas of at least one of the remaining cylinder groups is made rich to form the gas including the reducing agent, and each cylinder has a fuel injector directly injecting fuel into the cylinder, and wherein the fuel injector of the at least one of the remaining cylinder groups injects fuel secondarily at the combustion stroke or the exhaust stroke of the engine to form the gas including the reducing agent.