Exhaust system for a spark-ignited internal combustion engine

• US 8,127,537 B2
• Filed: 02/27/2007
• Issued: 03/06/2012
• Est. Priority Date: 02/28/2006
• Status: Active Grant

• Current Assignee: Johnson Matthey PLC
• Original Assignee: Johnson Matthey PLC
• Inventors: Clements, Marie Charlotte, Collins, Neil Robert, Arnold, Louise Clare, Morris, Darrell
• Primary Examiner(s): Denion, Thomas
• Assistant Examiner(s): Bradley, Audrey K
• Application Number:
  US12/280,939
• Publication Number:
  US 20080314034A1
• Time in Patent Office: 1,834 Days
• Field of Search: 602/76, 602/99, 422/168, 422/169, 422/170, 422/171, 422/177, 422/181, 422188-193, 422/600, 422/630, 422/631, 422/636
• US Class Current: 60/299
• CPC Class Codes: F01N 2240/20 a flow director or deflector
• CPC Class Codes: F01N 2330/30 Honeycomb supports characterised by their structural details
• CPC Class Codes: F01N 2510/0682 having a discontinuous, uneven or partially overlapping coating of catalytic material, e.g. higher amount of material upstream than downstream or vice versa
• CPC Class Codes: F01N 2560/02 the means being an exhaust gas sensor
• CPC Class Codes: F01N 2560/025 for measuring or detecting O2, e.g. lambda sensors
• CPC Class Codes: F01N 3/0864 Oxygen
• CPC Class Codes: F01N 3/2828 Ceramic multi-channel monoliths, e.g. honeycombs
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

An exhaust system for a spark-ignited internal combustion engine comprises a three-way catalyst composition including an oxygen storage component, which TWC composition is coated on a flow-through monolith substrate, which substrate comprising a plurality of channels, each channel having a length extending from an inlet end to an outlet end and a single lambda sensor, wherein the substrate comprises a portion of the plurality of channels wherein the TWC composition in at least a part of the length of channels extending from the inlet end has a reduced oxygen storage activity, or no oxygen storage activity, relative to the TWC composition in a remainder of the substrate, the arrangement being such that the single lambda sensor is contacted substantially only with exhaust gas that has first contacted the TWC composition having a reduced oxygen storage activity or no oxygen storage activity.

Claims

1. An exhaust system for a spark-ignited internal combustion engine comprising:

(a) a three-way catalyst (TWC) composition including an oxygen storage component, wherein the TWC composition is coated on a flow-through monolith substrate, the substrate comprises a plurality of channels, and each channel has a length extending from an inlet end to an outlet end; and

(b) a single lambda sensor,

wherein the substrate comprises a portion of the plurality of channels, wherein the portion of the plurality of channels is annular in shape, wherein the TWC composition in at least a part of the length of channels extending from the inlet end has a reduced oxygen storage activity, or no oxygen storage activity, relative to the TWC composition in a remainder of the substrate, the arrangement being such that the single lambda sensor is contacted substantially only with exhaust gas that has first contacted the TWC composition having a reduced oxygen storage activity or no oxygen storage activity.

2. An exhaust system according to claim 1, wherein the lambda sensor is disposed in a hole defined in part by an external wall of the flowthrough monolith substrate.

3. An exhaust system according to claim 1, wherein the TWC composition having reduced oxygen storage activity has one or both of:

(i) a lower oxygen storage component loading than the TWC composition in the remainder of the substrate;

or

(ii) a lower total platinum group metal loading than the TWC composition in the remainder of the substrate.

4. An exhaust system according to claim 1, wherein the TWC composition has no oxygen storage activity and has no oxygen storage component and/or no platinum group metals.

5. An exhaust system according to claim 1, wherein the TWC composition having reduced oxygen storage activity has both:

(i) a lower oxygen storage component loading than the TWC composition in the remainder of the substrate; and

(ii) a lower total platinum group metal loading than the TWC composition in the remainder of the substrate.

6. An exhaust system according to claim 1, wherein the portion of the plurality of channels extends from the inlet end to the outlet end of the substrate and the lambda sensor is located immediately downstream of the outlet end, the exhaust system comprising means substantially to prevent exhaust gas other than exhaust gas flowing in the portion of the plurality of channels from contacting the lambda sensor.

7. An exhaust system according to claim 6, wherein the means for substantially preventing contact of exhaust gas with the lambda sensor comprises a deflector for surrounding the lambda sensor, wherein the deflector is open at an upstream end and a downstream end.

8. An apparatus comprising a spark-ignited internal combustion engine and an exhaust system according to claim 1.

9. A vehicle comprising an apparatus according to claim 8.