Exhaust component and method for producing an exhaust component

• US 6,555,070 B1
• Filed: 10/04/1999
• Issued: 04/29/2003
• Est. Priority Date: 10/05/1998
• Status: Expired due to Term

• Current Assignee: Bosal Emission Control Systems Nv (Bosal International NV)
• Original Assignee: Scambia Industrial Developments AG
• Inventors: Krüger, Klaus Gerhard
• Primary Examiner(s): TRAN, HIEN THI
• Application Number:
  US09/413,909
• Time in Patent Office: 1,303 Days
• Field of Search: 422/171, 422/177, 422/179, 422/180, 602/99, 603/00, 603/01, 602/72, 603/23, 603/22, 603/02
• US Class Current: 422/179
• CPC Class Codes: F01N 13/008 Mounting or arrangement of exhaust sensors in or on exhaust apparatus sensor arrangements for engine control F02D41/1439
• CPC Class Codes: F01N 13/102 having thermal insulation
• CPC Class Codes: F01N 13/14 having thermal insulation exhaust manifolds F01N13/102
• CPC Class Codes: F01N 13/1844 Mechanical joints
• CPC Class Codes: F01N 13/185 the connection being realised by deforming housing, tube, baffle, plate, or parts thereof
• CPC Class Codes: F01N 13/1888 the housing of the assembly consisting of two or more parts, e.g. two half-shells
• CPC Class Codes: F01N 2310/02 Mineral wool, e.g. glass wool, rock wool, asbestos or the like
• CPC Class Codes: F01N 2450/20 by mechanical joints, e.g. by deforming housing, tube, baffle plate or parts thereof
• CPC Class Codes: F01N 2450/22 by welding or brazing
• CPC Class Codes: F01N 3/2853 using mats or gaskets between catalyst body and housing
• CPC Class Codes: F01N 3/2864 the mats or gaskets comprising two or more insulation layers

Abstract

The exhaust component has an exhaust manifold with at least two inlet lines, and, for example, also a catalytic converter and a wall with two composite wall elements. The two wall elements together, in cross section, surround interior spaces of all the inlet lines and, if appropriate, also the catalyst means of the catalytic converter. Each wall element has two single-piece metal shells and a layer of heat-insulating material which is arranged between these shells, so that each wall element provides good thermal insulation. During the production of a wall element, the shells belonging to this element, as well as the layer of insulating material arranged between them, are together subjected to plastic deformation. This allows inexpensive production of the wall.

Claims

1. An exhaust component, comprising at least two inlet lines for connection to an internal combustion engine and each having an inner line;

and a wall having two wall elements,

wherein each wall element having two metal shells and a layer of heat-insulating material which is located between the shells,

wherein the two wall elements have edge sections which are connected to one another, and together, in cross section, surround the inner lines of all the inlet lines,

wherein each inner line is, in cross section, at least partially separated by a hollow intermediate space, from the wall elements which surround the inner line in cross section and delimit an exhaust passage,

wherein the exhaust component further comprises an inner collection wall which is mostly separated by the hollow intermediate space from the wall elements which surround the inner collection wall in cross section, and which delimit an inner collection space, wherein the inner line of each inlet line has an inlet end section rigidly connected to the two wall elements, and an outlet end section connected to the inner collection wall, and

wherein at least one of the outlet end section of each inner line and the inner collection wall is displaceable, respectively, relative to the inner collection wall and relative to the wall elements,

wherein the exhaust component further comprises an exhaust manifold including said inlet lines, and a catalytic converter containing catalyst means for catalytic treatment of the exhaust gas and connected to the inner lines.

2. The exhaust component as claimed in claim 1, wherein the layer of heat-insulating material is microporous and has a structure which is substantially formed of grains.

3. The exhaust component as claimed in claim 1, wherein the layer of heat-insulating material is at least 2 mm thick.

4. The exhaust component as claimed in claim 1, wherein each shell is a single piece, wherein the shells which belong to the same wall element are connected to one another essentially along an entire circumference thereof and are designed to be sufficiently strong for the connected wall elements to be self-supporting, and wherein at least a substantial part of the wall comprises exclusively the wall elements.

5. The exhaust component as claimed in claim 1, wherein all the shells of the two wall elements which are connected to one another at the edge sections are in contact with one another at the edge sections, at least in pairs, and are joined to one another so that they are connected at least approximately tightly together by at least one of welding, brazing, adhesive bonding, and flanging.

6. The exhaust component as claimed in claim 1, wherein the wall elements, at least in most of the wall, define an outer limit of the exhaust component.

7. The exhaust component as claimed in claim 1, wherein one of said two wall elements and two additional wall elements, which are connected to the wall elements surrounding the inner lines and have each a pair of metal shells and a layer of heat-insulating material provided between these shells, surround catalyst means in cross section.

8. The exhaust component as claimed in claim 7, wherein the two additional wall elements are directly and rigidly connected to the wall elements which surround the interior spaces of the inlet lines.

9. The exhaust component as claimed in claim 1, wherein the wall elements have finger-shaped sections which are separated from one another by intermediate spaces and together in pairs surround the inner lines of different ones of the inlet lines.

10. The exhaust component as claimed in claim 1, wherein the inner collection wall is rigidly connected to at least one of the wall elements by a bush adapter for supporting a lambda probe that projects through the bush adapter into the inner collection space.

11. The exhaust component as claimed in claim 1, further comprising an inlet port for each inlet line, and an outlet,

wherein the wall elements together tightly limit an interior space in which the inner lines and at least a substantial part of the inner collection wall are located, and wherein the interior space forms the intermediate space containing at least one of a substantially stationary exhaust gas and air.

12. An exhaust component, comprising at least two inlet lines for connection to an internal combustion engine and each having an inner line;

and a wall having two wall elements,

wherein each wall element has two metal shells and a layer of heat-insulating material which is located between the shells, wherein the two wall elements have edge sections which are connected to one another and together, in cross section, surround the inner lines of all the inlet lines,

wherein each inner line is, in cross section, at least partially separated by a hollow intermediate space from the wall elements which surround the inner line in cross section and delimit an exhaust passage,

wherein the exhaust component further comprises an inner collection wall which is mostly separated by the hollow intermediate space from the wall elements which surround the inner collection wall in cross-section, and which delimits an inner collection space,

wherein the inner collection wall is rigidly connected to at least one of the wall elements by a bush adapter to support a lambda probe that projects into an inner collection space defined by the inner collection wall, and

wherein the inner line of each inlet line has an inlet end section rigidly connected to the two wall elements, and an outlet end section connected to the inner collection wall and displaceable with respect to inner collection wall, and

wherein the exhaust component further comprises an exhaust manifold including said inlet lines.

13. The exhaust component as claimed in claim 12, wherein each shell is a single piece, wherein the shells which belong to the same wall element are connected to one another essentially along an entire circumference of each shell and are designed to be sufficiently strong for the connected wall elements to be self-supporting, and wherein at least a substantial part of the wall comprises exclusively the wall elements.

14. The exhaust component as claimed in claim 12, wherein all the shells of the two wall elements which are connected to one another at the edge sections are in contact with one another, at the edge sections, at least in pairs and are joined to one another so that they are connected at least approximately tightly together by welding.

15. The exhaust component as claimed in claim 12, further comprising catalyst means for catalytic treatment of the exhaust gas, and wherein one of said two wall elements and two additional wall elements which are connected to the wall elements surrounding the inner lines and have each a pair of metal shells and a layer of heat-insulating material which is provided between these shells, surround catalyst means in cross section.

16. The exhaust component as claimed in claim 12, wherein the two additional wall elements are directly and rigidly connected to the wall elements which surround the interior spaces of the inlet lines.

17. The exhaust component as claimed in claim 12, further comprising an inlet port for each inlet line, and an outlet, and wherein the wall elements together tightly limit an interior space in which the inner lines and at least a at substantial part of the inner collection wall are located, and wherein the internal space forms the intermediate space containing at least one of substantially stationary exhaust gas and air.

18. The exhaust component as claimed in claim 12, further comprising a catalytic converter containing catalyst means for catalytic treatment of the exhaust gas, and wherein the two wall elements in addition to surrounding the inner lines, also surround the catalytic means in cross-section.

19. The exhaust component as claimed in claim 18, wherein each shell is a single piece, wherein the shells which belong to the same wall element are connected to one another essentially along an entire circumference of each shell and are designed to be sufficiently strong for them together to be self-supporting, and wherein all the shells of the two wall elements which are connected to one another at the edge sections are in contact with one another, at the edge sections, at least in pairs and are joined to one another.

20. The exhaust component as claimed in claim 18, further comprising an inlet port for each inlet line, and an outlet, and wherein the wall elements together tightly limit an interior space in which the inner lines and at least a substantial part of the inner collection wall are located, and wherein the interior space forms the intermediate space containing at least one of substantially stationary exhaust gas and air.

21. The exhaust component as claimed in claim 12, further comprising a catalytic converter containing catalyst means for catalytic treatment of the exhaust gas, and two additional wall elements connected to the two wall elements, the two additional wall elements having each a pair of metal shells and a layer of a heat-insulating material provided between the metal shells, the additional wall elements surrounding the catalyst means in cross-section.

22. The exhaust component as claimed in claim 21, wherein each shell is a single piece, wherein the shells which belong to the same wall element are connected to one another essentially along an entire circumference of each shell and are designed to be sufficiently strong for them together to be self-supporting, and wherein all the shells of the two wall elements which are connected to one another at the edge sections are in contact with one another, at the edge sections, at least in pairs, and are joined to one another.

23. The exhaust component as claimed in claim 21, further comprising an inlet port for each inlet line, and an outlet, and wherein the wall elements together tightly limit an interior space in which the inner lines and at least a substantial part of the inner collection wall are located, and form the intermediate space containing at least one of substantially stationary exhaust gas and air.