Exhaust-gas aftertreatment device

• US 8,950,175 B2
• Filed: 11/08/2011
• Issued: 02/10/2015
• Est. Priority Date: 11/10/2010
• Status: Active Grant

• Current Assignee: Volvo Car Corporation (AB Volvo)
• Original Assignee: Volvo Car Corporation (AB Volvo)
• Inventors: Dahlgren, Jan, Ovesson, Staffan, Laurell, Mats
• Primary Examiner(s): Denion, Thomas
• Assistant Examiner(s): LEON JR, JORGE LUIS
• Application Number:
  US13/291,608
• Publication Number:
  US 20120110989A1
• Time in Patent Office: 1,190 Days
• Field of Search: 602/95, 602/96, 602/97, 602/99, 603/03, 603/09, 603/11, 603/20, 603/24
• US Class Current: 60/299
• CPC Class Codes: F01N 1/084 the gases flowing through the silencer two or more times longitudinally in opposite directions, e.g. using parallel or concentric tubes
• CPC Class Codes: F01N 2240/20 a flow director or deflector
• CPC Class Codes: F01N 2470/22 Inlet and outlet tubes being positioned on the same side of the apparatus
• CPC Class Codes: F01N 3/005 for draining or otherwise eliminating condensates or moisture accumulating in the apparatus F01N3/02 takes precedence
• 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 3/2013 using electric or magnetic heating means
• CPC Class Codes: F01N 3/2803 characterised by structure, by material or by manufacturing of catalyst support
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

An exhaust-gas aftertreatment device for an internal combustion engine includes a catalytic converter having a tubular member which defines a volume housing a catalytic converter substrate. The volume housing the catalytic converter substrate communicates with an inlet portion for receiving exhaust gas from the engine and with an outlet portion for discharging the exhaust gas after catalytic conversion thereof in the volume. The device further has a pipe member within the tubular member which connects the inlet portion with the volume in the tubular member and guides the exhaust gas from the inlet portion in a first direction of flow. The pipe member opens downstream into a deflector which deflects the exhaust gas into the volume of the tubular member in a second direction of flow other than the first direction of flow. Unburned liquid fuel contained in the exhaust gas is deposited on the deflector for later evaporation.

Claims

1. An exhaust-gas aftertreatment device for an internal combustion engine comprising:

a catalytic converter comprising a tubular member defining a volume housing a catalytic converter substrate, the volume in communication with an inlet portion to receive exhaust gas emissions from the internal combustion engine and with an outlet portion to discharge the exhaust gas emissions after catalytic conversion thereof in the volume;

an unobstructed pipe member within the tubular member and connecting the inlet portion with the volume and guiding the exhaust gas emissions from the inlet portion in a first direction of flow, the pipe member having an exit opening at a downstream end thereof in alignment with a longitudinal axis of the pipe member;

a dome-shaped deflector having a diameter substantially equal to a diameter of the tubular member and located at the downstream end of the pipe member such that a central portion of the deflector is directly opposite the pipe member exit opening and the exhaust gas emissions exiting the pipe member are directed onto the deflector central portion and deflected into the volume and in a second direction of flow other than the first direction of flow, so that liquid unburned fuel in the exhaust gas emissions reaches and is deposited on the deflector;

a layer of porous material having an open cell structure spaced from a surface of the deflector facing the flow of exhaust gas emissions; and

a collector positioned at a bottom of the deflector for collecting the liquid unburned fuel that drips from the deflector and/or the porous material after being deposited thereon.

2. The device of claim 1 wherein a cross-sectional area of the pipe member is less than a cross-sectional area of an inlet portion connected thereto.

3. The device of claim 1 wherein the pipe member is located centrally in the tubular member of the catalytic converter, extending in a longitudinal direction thereof.

4. The device of claim 1 wherein the pipe member has a length equal to a length of the tubular member of the catalytic converter.

5. The device of claim 1 wherein a cross-sectional area of the pipe member constitutes about 1-20% of a cross-sectional area of the tubular member of the catalytic converter.

6. An exhaust-gas aftertreatment device for an internal combustion engine comprising:

a catalytic converter comprising a tubular member defining a volume housing a catalytic converter substrate, wherein the volume communicates with an inlet portion to receive exhaust gas emissions from the internal combustion engine and with an outlet portion to discharge the exhaust gas emissions after catalytic conversion thereof in the volume;

an unobstructed pipe member within the tubular member and surrounded by the substrate, the pipe member connecting the inlet portion with the volume and guiding the exhaust gas emissions from the inlet portion in a first direction of flow, the pipe member having an exit opening at a downstream end thereof in alignment with a central axis of the pipe member;

a dome-shaped deflector having a central portion positioned directly opposite the pipe member exit opening such that exhaust gasses exiting the pipe member are directed onto the deflector central portion and deflected in a second direction of flow opposite to the first direction of flow and into the volume;

a layer of open cell porous material adjacent to and spaced from a surface of the deflector facing the flow of exhaust gas ; and

a liquid collector adjacent to a lower portion of the deflector and between the deflector and the porous material.

7. An exhaust-gas aftertreatment device for an internal combustion engine comprising:

a catalytic converter comprising a tubular member which defines a volume housing a catalytic converter substrate, the volume communicating with an inlet portion to receive exhaust gas emissions from the internal combustion engine and with an outlet portion to discharge the exhaust gas emissions after catalytic conversion thereof in the volume;

an unobstructed pipe member within the tubular member and connecting the inlet portion with the volume and guiding the exhaust gas emissions from the inlet portion in a first axial direction of flow, the pipe member having an exit opening at a downstream end thereof in alignment with a longitudinal axis of the pipe member;

a dome-shaped deflector having a central portion positioned directly opposite the pipe member exit opening such that the exhaust gas emissions exit the pipe member exit opening impinge directly onto the deflector central portion and are redirected in a second direction of flow opposite to the first direction of flow so that liquid unburned fuel in the exhaust gas emissions is deposited on the deflector prior to the exhaust gas emissions passing though the volume;

a layer of open cell porous material between the pipe member exit opening and the deflector central portion such that at least a portion of the exhaust gas emissions exiting the pipe member pass through the porous material before contacting the deflector; and

a drain cup located at a bottom of the deflector to collect the liquid unburned fuel that drips from the deflector and/or the layer of porous material.