Fixed Contact Bed Type With Resilient Or Differential Thermal Expansion Compensating Bed Support Means Patents (Class 422/221)
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Patent number: 5902557Abstract: In an electrically heated catalyst support, when necessary, reinforcing layers are formed on the inner circumference and the outer circumference of a honeycomb body. On an end surface of the honeycomb body on the downstream side of exhaust gas, there are provided a plurality of insulating ceramic bars on the outer circumferential layer and/or the inner circumferential layer in such a manner that the insulating ceramic bars cross a non-reinforcing layer of the honeycomb body. End portions of the ceramic bars are held on the reinforcing layer by pins or a ring-shaped holding member joined to an external metallic cylinder. Due to the foregoing arrangement, telescoping of the honeycomb body in the direction of gas flow and damage of the metallic foil can be prevented without obstructing the generation of heat when electricity is supplied. Accordingly, durability of the catalyst support can be remarkably enhanced.Type: GrantFiled: April 15, 1997Date of Patent: May 11, 1999Assignees: Nippon Steel Corporation, Toyota Jidosha Kabushiki KaisaInventors: Kouki Yotsuya, Takuzou Kako, Shogo Konya, Yuuji Nakashima, Kouji Yoshizaki, Kazuhiro Sakurai, Masahiko Ogai
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Patent number: 5888457Abstract: A catalytic converter including a cylindrical catalyst carrier having a catalyst carried therein, a retaining mat wound around an outer peripheral surface of the catalyst carrier, and a casing including a cylindrical carrier retaining portion for retaining the catalyst carrier with the retaining mat compressed. The cylindrical carrier retaining portion is an assembly which is constructed of diametrically split halves whose axially extending opposite-side edges are fitted over each other with fitted portions bonded to each other. The cylindrical carrier retaining portion has an oval cross-sectional shape with a longer diameter between both the fitted portions. Thus, the density of the retaining mat in the circumferential direction of the catalyst carrier after being compressed can be varied in an increased manner to compensate for the decreasing variation in urging force provided by the cylindrical carrier retaining portion.Type: GrantFiled: October 10, 1996Date of Patent: March 30, 1999Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Shinichi Tosa, Kouichi Fujimori
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Patent number: 5882608Abstract: A pollution control device has a metal housing, a solid pollution control device disposed within the metal housing, and a mounting mat disposed between the pollution control element and the housing for positioning the pollution control element and for absorbing mechanical and thermal shock. The mounting mat includes a layer of intumescent material having at least one insert formed of a resilient, flexible, fibrous non-intumescent material. The insert is positioned along at least a portion of at least one lateral edge of the mounting mat to prevent erosion of the intumescent material and to provide a seal between the pollution control element and the housing.Type: GrantFiled: June 18, 1996Date of Patent: March 16, 1999Assignee: Minnesota Mining and Manufacturing CompanyInventors: Stephen M. Sanocki, Loyd R. Hornback, III, Richard P. Merry, Joel H. Sabean, Paul D. Stroom
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Patent number: 5876469Abstract: A reformed gas composed mainly of hydrogen and carbon monoxide to be used for a fuel cell is produced by using a multi-tubular reformer provided with bayonet type double-wall catalyst tubes and feeding hydrocarbon gas such as natural gas and steam to the reformer. Porous media of a ceramic material are arranged in such a manner in a shell side flue gas inlet part of the interior of the reformer as to envelop the leading end parts of the catalyst tubes. The transfer of heat from the flue gas to the catalyst tubes is enhanced because the porous media accumulate the heat from the flue gas and radiate the accumulated heat in the direction of the walls of the outer tubes of the catalyst tubes. The otherwise possible uneven transfer of heat to the catalyst tubes is prevented because the wall effect and the channelling of the flue gas are repressed. This invention, therefore, permits effective utilization of the thermal energy of the flue gas for the reforming reaction and enables the reformer to be stably operated.Type: GrantFiled: November 14, 1996Date of Patent: March 2, 1999Assignee: Chiyoda CorporationInventors: Nobuo Moriya, Takao Kawai, Hiroshi Yagi, Ryosuke Shimizu, Yasumasa Morita
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Patent number: 5869010Abstract: The invention provides an intumescent sheet material comprising 20 to 80 dry weight percent of at least one unexpanded intumescent material, 10 to 40 dry weight percent of at least one processed vermiculite selected from ground expanded vermiculite and delaminated vermiculite, greater than 0 to 5 dry weight percent of inorganic fibers having diameters greater than 5 microns, and greater than 0 to 10 dry weight percent of organic fibers; wherein said sheet material comprises substantially no ceramic fibers of less than 5 microns.Type: GrantFiled: March 10, 1997Date of Patent: February 9, 1999Assignee: Minnesota Mining and Manufacturing CompanyInventor: Roger L. Langer
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Patent number: 5866079Abstract: A ceramic honeycomb catalytic converter having a novel canning structure capable of stably retaining a thin-walled ceramic honeycomb catalyst within a metal casing for a long period. A retainer member in the form of a ceramic fiber mat is disposed between an inner peripheral surface of the casing and an outer peripheral surface of the honeycomb catalyst, in a compressed state to generate a surface pressure for retaining the honeycomb catalyst in place. The ceramic fiber mat is composed of heat resistant and non-intumescent ceramic fibers, and has a compression characteristic which is substantially free from a significant increase or decrease over an operative temperature range of the catalytic converter. The casing may be provided with at least one locking member for locking the ceramic fiber mat in a flow direction of exhaust gas passed through the honeycomb catalyst.Type: GrantFiled: August 31, 1994Date of Patent: February 2, 1999Assignee: NGK Insulators, Ltd.Inventors: Minoru Machida, Toshio Yamada, Toshihiko Hijikata, Yukihito Ichikawa
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Patent number: 5866077Abstract: A honeycomb support structure of an electrically-heated catalyst apparatus is disclosed, in which a support member of retainers for preventing an electrically-heated catalyst moving backward is coupled to an outer cylinder while causing the support member to follow the thermal deformation of the outer cylinder thereby to suppress the deformation of the support member due to the thermal stress. A metal foil laminate having a corrugated foil and a tabular foil superposed one on the other is spirally wound to form a cylindrical honeycomb unit, which is accommodated in a metal outer cylinder and is heated by being supplied with power. The honeycomb unit support structure includes a plurality of ceramic bars and at least a support member having a plurality of recesses for holding the ceramic bars at such a position as to traverse the end surface of the honeycomb unit downstream of the exhaust gas flow and in such a manner as to follow the deformation of the outer cylinder.Type: GrantFiled: February 5, 1997Date of Patent: February 2, 1999Assignees: Toyota Jidosha Kabushiki Kaisha, Nippon Steel Corp.Inventors: Kazuhiro Sakurai, Takuzou Kako
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Patent number: 5857140Abstract: A catalytic converter in which a catalyst coated substrate is positioned within a housing and is constructed with end portions thereof extending into close proximity to the end members attached to the housing so as to improve the durability of a mat of intumescent material that is wrapped around and serving to support the substrate within the housing.Type: GrantFiled: October 3, 1997Date of Patent: January 5, 1999Assignee: General Motors CorporationInventor: Michael Ralph Foster
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Patent number: 5853675Abstract: A composite for mounting a catalytic converter or diesel particulate filter. The composite comprises a flexible mat and a layer of an intumescent paste comprising an intumescent material. A catalytic converter element and diesel particulate filter comprising such a composite are also described.Type: GrantFiled: June 30, 1995Date of Patent: December 29, 1998Assignee: Minnesota Mining and Manufacturing CompanyInventor: Gary F. Howorth
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Patent number: 5851496Abstract: Device for cleaning exhaust gases by a metallic catalyst carrier that is installed in an exhaust gas passage and is contained in a metallic outer cylinder, wherein a structure for absorbing a difference in the thermal expansion between the metallic catalyst carrier and the outer cylinder is realized without causing stress to the metallic catalyst carrier and without requiring strict tolerance in production. A cushioning material made of a heat-resistant wire gauze is arranged between the metallic catalyst carrier and the metallic outer cylinder, and the cushioning material, metallic carrier and metallic outer cylinder are conductively joined. The cushioning material is compressed between the metallic catalyst carrier and the outer cylinder, and the cushioning material is joined to the metallic catalyst carrier and to the outer cylinder. Here, the junction is accomplished locally without overlapping one upon the other in the axial direction of the outer cylinder.Type: GrantFiled: January 23, 1997Date of Patent: December 22, 1998Assignee: Toyota Jidosha Kabushiki KaishaInventor: Kazuhiro Sakurai
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Patent number: 5849250Abstract: The present invention provides an auxiliary catalytic converter having a back pressure relief device being disposed after the main catalytic converter or after the muffler system which further reduces vehicle exhaust emissions from exhaust emission systems and that will meet the more stringent emission requirements of state and federal government regulations. The auxiliary catalytic converter includes a ceramic or steel housing of relatively small size, having a diameter in the range of 1 inch to 8 inches and a length of 4 inches to 11 inches. The housing includes a matrix core of catalytic layered materials which react with the gaseous exhaust emission pollutants, such as NO.sub.x, NHMC, HC, and CO. These pollutants are further reduced and oxidized by the auxiliary catalytic converter using typical catalytic materials of platinum, palladium, rhodium, or the like contained within the honeycombed or meshed layers of the matrix core.Type: GrantFiled: February 3, 1997Date of Patent: December 15, 1998Inventor: Mark Timko
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Patent number: 5849251Abstract: A catalytic converter for a tailpipe which further reduces vehicle exhaust emissions from exhaust emission systems and that will meet the more stringent emission requirements of state and federal government regulations. The tailpipe catalytic converter includes a ceramic or steel housing which includes a matrix core of catalytic layered materials which react with the exhaust emission pollutants, such as NO.sub.x, NMHC, HC, and CO. These pollutants are further reduced and oxidized by the catalytic converter in the tailpipe by the typical catalytic materials of platinum, palladium, rhodium, or the like contained within the honeycombed or meshed layers of the matrix core. The catalytic converter is lodged within the interior of the tailpipe adjacent the open end or as an extension to the end of the tailpipe. The tailpipe catalytic converter is held in place by any suitable device, such as a clamp, mounting screws, or mounting brackets.Type: GrantFiled: February 3, 1997Date of Patent: December 15, 1998Inventor: Mark Timko
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Patent number: 5827485Abstract: A reactor, for example, for adsorption processes, is described which is designed essentially cylindrically and is symmetrical with respect to an essentially vertical axis. The reactor is bounded by a shell. A circular bed filled with free-flowing material (e.g., an adsorbent or catalyst) is positioned inside the shell. The free-flowing material is contained within an inner basket and an outer basket and supported by a bottom support member from below. Both baskets are rigidly connected in the radial direction and rigidly connected at their lower end to the shell. At least one of the two baskets is both expandable in the axial direction and rigidly connected at its upper end to the shell.Type: GrantFiled: June 18, 1990Date of Patent: October 27, 1998Assignee: Linde AktiengesellschaftInventors: Klaus Libal, Walter Fierlbeck, Ulrich Von Gemmingen
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Patent number: 5820834Abstract: The flexible catalyst mounting system employing a "v" notch for holding flexible catalyst elements. Between any pair of rings a flexible catalyst element or plurality of elements, a stack, are placed. The rings placed between flexible catalyst elements or stacks are designed such that linear compression of a ring forces the ring to axially expand, thereby providing a radial seal to prevent gases from bypassing the flexible catalyst element or stack. The flexible catalyst mounting system can be used with flexible catalyst elements of varying ductility.Type: GrantFiled: March 31, 1997Date of Patent: October 13, 1998Assignee: Precision Combustion Inc.Inventors: Michael Joseph DiGiovanni, John Frederick Bianchi
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Patent number: 5811063Abstract: A device for the treatment of exhaust gases such as a catalytic converter, a diesel particulate trap and the like, includes a housing having an inlet at one end and an outlet at its opposite end through which exhaust gases flow; a structure resiliently mounted within the housing, the structure having an outer surface and an inlet end surface at one end in communication with the inlet of the housing and an outlet end surface at an opposite end in communication with the outlet of the housing; and mounting element, disposed between the structure and the housing, for selectively exerting substantially stable mounting pressure against the housing and the structure over a temperature range of from about 20.degree. C. to at least about 1200.degree. C., wherein the mounting element is a flexible mounting mat including an integral, substantially non-expanding sheet comprising ceramic fibers, wherein the fibers are substantially shot free. The mat has flexible, structural integrity.Type: GrantFiled: September 8, 1997Date of Patent: September 22, 1998Assignee: Unifrax CorporationInventors: John W. Robinson, Alan R. Lebold, Mark Travers
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Patent number: 5770165Abstract: An improved structural support system for a regenerator used with a regenerative thermal oxidizer, including a perforated and corrugated rigid beam resting on a support surface. The perforated beam supports heat exchange materials either directly, or indirectly using a perforated grid. The beam includes a plurality of perforations permitting upward gas flow from the underside of the beam and through the heat exchange materials. The air distribution plenums under the beam are reduced in height from that of conventional systems. The novel structure results in a more reliable and efficient regenerator.Type: GrantFiled: May 17, 1996Date of Patent: June 23, 1998Assignee: Smith Engineering CompanyInventors: Thomas James Truppi, Erwin Hendricks, Gary Lee Martin, Melanius D'Souza
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Patent number: 5759500Abstract: A fluid-reactor, heat exchange device and method of reacting a fluid in the device. The device embodies a bundle of heat-exchange tubes mounted internally of an elongated reactor shell to a stationary tubesheet attached to the reactor shell near one end of the shell. The heat-exchange tubes are also mounted to a floating tubesheet which is located near the other end of the shell. Attached to the floating tubesheet is a catalyst basket which when the device is in operation will contain catalyst. The catalyst is supported in the basket, and the fluid to be reacted will enter the shell near the point of attachment to the stationary tubesheet, where it will contact the heat exchange tubes. The fluid will flow along the outside of the tubes and into the catalyst basket where it will contact the catalyst and react. The fluid will then pass into the heat exchange tubes and finally be removed from the device near the end of the reactor where it was introduced.Type: GrantFiled: January 16, 1996Date of Patent: June 2, 1998Assignee: E. I. du Pont de Nemours and CompanyInventors: John Byron Garner, James Olden Hester, Geoffry Wallar Smith
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Patent number: 5746986Abstract: A catalytic converter for stand-alone application or for use with a novel silencer. The silencer includes a catalytic converter formed from a central housing of a size to house at least one catalytic converter element, an inlet portion connected to the inlet side of the central housing and an outlet portion connected to the outlet side of the central housing. The silencer is formed from a cylindrical housing which is secured on one end to the catalytic converter and on the opposite end to an exhaust pipe of an internal combustion engine. The cylindrical housing has at least one baffle plate transversely mounted therein. The baffle plate has a plurality of perforated conical members positioned opposite each other on each side of the baffle plate. The perforated conical members redirect the flow of exhaust gas through the silencer.Type: GrantFiled: January 2, 1997Date of Patent: May 5, 1998Assignee: Waukesha-Pearce Industries, Inc.Inventors: Bobby G. Pollock, Terry A. Segal, John E. Dusek, Jr., Alvin L. Bodin, Cyde D. Maas, Edward C. Coen, Randall A. Pinter
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Patent number: 5744104Abstract: An electrically heated catalytic converter having a substrate for a catalyst, a rod-like metal electrode connected to the substrate, and a casing accommodating the substrate. The substrate for the catalyst is formed as a scroll-like cylindrical laminated assembly of thin metal sheets wound around the electrode. The electrode extends from the laminated assembly along the central axis, bends towards the wall of the casing and penetrates the casing. The electrode is fixed to the casing via an insulating material at the point where it penetrates the casing. When the electricity is fed to the electrode, electric current flows through the electrode to the laminated assembly, and to the casing, and heat is generated in the substrate by the electric current and the temperature of the catalyst carried by the substrate quickly reaches the activating temperature. The rod-like electrode of the present invention is formed as a hollow pipe.Type: GrantFiled: February 22, 1995Date of Patent: April 28, 1998Assignee: Toyota Jidosha Kabushiki KaishaInventors: Kazuhiro Sakurai, Koji Shimoji, Tohru Yoshinaga, Kiyohiko Watanabe
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Patent number: 5736109Abstract: The invention provides a catalytic converter or diesel particulate filter comprising: (a) a housing; (b) a catalytic converter element or diesel particulate filter element disposed within said housing; and (c) a flexible intumescent sheet material disposed between said catalytic converter element and said housing; wherein said flexible intumescent sheet material comprises 1 to 70 dry weight percent of at least one unexpanded intumescent material, from greater than 20 to 50 dry weight percent of organic binder, 5 to less than 79 dry weight percent of inorganic binder, and 0 to 70 dry weight percent of one or more fillers.Type: GrantFiled: June 30, 1995Date of Patent: April 7, 1998Assignee: Minnesota Mining and Manufacturing CompanyInventors: Gary F. Howorth, John J. Rogers, Toshiyuki Watanabe
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Patent number: 5730843Abstract: A contact structure, useful as a distillation structure, has a rigid frame made of two substantially vertical duplicate grids spaced apart and held rigid by a plurality of substantially horizontal rigid members and a plurality of substantially horizontal wire mesh tubes mounted to the grids to form a plurality of fluid pathways among the tubes. For use as a catalytic distillation structure, which serves as both the distillation structure and the catalyst, at least a portion of the wire mesh tubes contain a particulate catalytic material. The catalyst within the tubes provides a reaction zone where catalytic reactions may occur and the wire mesh provides mass transfer surfaces to effect a fractional distillation. The spacing elements provide for a variation of the catalyst density and loading and structural integrity.Type: GrantFiled: December 29, 1995Date of Patent: March 24, 1998Assignee: Chemical Research & Licensing CompanyInventors: Willibrord A. Groten, Derwyn Booker, Clifford S. Crossland
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Patent number: 5707593Abstract: A reactor that can be attached to the exhaust manifold of an internal combustion engine to oxidize and burn carbon soot particles, carbon monoxide, and unburned hydrocarbons, and to dissociate nitrogen and sulfur oxides. The reactor has a reaction zone that contains porous heat-retaining foam cells and that is bounded by a porous heat-retaining zone, which in turn is surrounded by ceramic insulation materials to minimize energy losses. Engine exhaust at elevated temperatures and containing some oxygen (air) enters the reaction chamber. By means of impinging heat transfer, thermal radiation enhancement, energy trapping and combustion of engine emissions, temperatures sufficient to oxidize carbon soot particles, carbon monoxide, and unburned hydrocarbons are attained. Steam or atomized water droplets are introduced to improve the efficiency of the reactor through gasification, regasification, water shift reactions, methanation, and hydrocracking reactions. Harmless product of the oxidation reactions, H.sub.Type: GrantFiled: December 31, 1996Date of Patent: January 13, 1998Inventor: Chi S. Wang
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Patent number: 5674461Abstract: An exhaust gas purifying device includes a cylindrical carrier carrying a catalyst, the carrier having a number of holes in the cylindrical wall thereof, an exhaust pipe into which the cylindrical carrier is inserted, an elastic member set radially compressed between a part of the outer cylindrical surface of at least one end portion of the carrier and a recess formed in the inner cylindrical surface of the exhaust pipe which is confronted with the part of the outer cylindrical surface, pressing pieces protruded from the outer cylindrical surface of the carrier so as to engage with the inner end face of the elastic member as viewed in the direction of axis thereof, the pressing pieces cooperating with the end of the recess to compress the elastic member axially, and a valve chamber formed in the exhaust pipe, the valve chamber having a valve body which includes a valve shaft penetrating the valve chamber in a direction of diameter, and a valve body fixedly mounted on the valve shaft.Type: GrantFiled: April 24, 1996Date of Patent: October 7, 1997Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Hiroshi Kato, Mitsuo Kusa, Kensuke Suzuki, Takahito Sekita
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Patent number: 5618500Abstract: A reactor that can be attached to the exhaust manifold of a diesel or gasoline engine, or other internal combustion engines such as a jet engine or a gas turbine to oxidize and burn carbon soot particles, carbon monoxide, and unburned hydrocarbons, and to dissociate nitrogen and sulfur oxides. The reactor has a reaction zone that contains porous heat-retaining foam cells and that is bounded by a porous heat-retaining zone, which in turn is surrounded by ceramic insulation materials to minimize energy losses. Engine exhaust at elevated temperatures and containing some oxygen (air) enters the reaction chamber. By means of impinging heat transfer, thermal radiation enhancement, energy trapping and combustion of engine emissions, temperatures sufficient to oxidize carbon soot particles, carbon monoxide, and unburned hydrocarbons are attained. Harmless product of the oxidation reactions, H.sub.2 O and CO.sub.2 are released from the reactor.Type: GrantFiled: August 21, 1995Date of Patent: April 8, 1997Inventor: Chi-Shang Wang
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Patent number: 5614155Abstract: A heater unit including a honeycomb heater, a metallic casing for holding the honeycomb heater, and a gas flow-controlling means for controlling flow of exhaust gas through the heater unit, such that about 2 to 20% of the total amount of exhaust gas flows outside the honeycomb heater, between the honeycomb heater and the metallic casing. The honeycomb heater may be attached inside the metallic casing via several appropriate devices including supporting, buffer and connecting devices.Type: GrantFiled: March 28, 1995Date of Patent: March 25, 1997Assignee: NGK Insulators, Ltd.Inventors: Fumio Abe, Shigeharu Hashimoto, Tomoharu Kondo
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Patent number: 5614156Abstract: A thermoelectric reactor for the chemical destruction of heavy-molecule volatile organic compounds (VOCs), semi-volatile organic compounds, or hydrogen sulfide contained in a gaseous feed. The reactor contains a hollow core containing energy sources. This reactor core surrounded by several ceramic walls and insulating zones. Uniform, high temperatures, up to at least 1900.degree. C., are obtained in the reactor core not only from direct radiant heat from the energy sources, but also from energy reflected and emitted from the surrounding zones. Reaction rates are enhanced by non-equilibrium conditions caused by electromagnetic threes derived from the energy sources. Further chemical destruction is accomplished in a porous energy retaining zone after passage through the reactor core. Ionizing gases and ionization seed material may be added to the gaseous feed material to increase electric conductivity and promote dissociation and ionization in the reactor core.Type: GrantFiled: February 13, 1996Date of Patent: March 25, 1997Inventor: Chi S. Wang
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Patent number: 5599509Abstract: In a metal catalyst converter configured of the metal catalyst carrier that holds the catalyst into the honeycomb body created by alternately winding flat sheet and corrugated sheet, a plurality of slit matrix that extend in the direction perpendicular to the exhaust gas direction were arranged on at least one part of the upstream side of the exhaust gas passage. By that a low heat capacity and high heat transfer area in regard to the downstream side of the exhaust gas passage was formed. The upstream portion of the metal catalyst converter on which slit matrix was formed was configured to be covered by outer casing having an air insulation layer. The upstream side of this outer casing was held and fixed to the exhaust gas passage.Type: GrantFiled: April 4, 1995Date of Patent: February 4, 1997Assignee: Nippondenso Co., Ltd.Inventors: Tetsuya Toyao, Toshiki Matsumoto, Hiromasa Aoki, Tatsuya Fujita, Senta Tojo
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Patent number: 5580532Abstract: A device for the treatment of exhaust gases such as a catalytic converter, a diesel particulate trap and the like, includes a housing having an inlet at one end and an outlet at its opposite end through which exhaust gases flow; a structure resiliently mounted within the housing, the structure having an outer surface and an inlet end surface at one end in communication with the inlet of the housing and an outlet end surface at an opposite end in communication with the outlet of the housing; and mounting means, disposed between the structure and the housing, for selectively exerting substantially stable mounting pressure against the housing and the structure over a temperature range of from about 20.degree. C. to at least about 1200.degree. C., wherein the mounting means is a flexible mounting mat including an integral, substantially non-expanding sheet comprising ceramic fibers, wherein the fibers are substantially shot free. The mat has flexible, structural integrity.Type: GrantFiled: November 3, 1994Date of Patent: December 3, 1996Assignee: Unifrax CorporationInventors: John W. Robinson, Alan R. Lebold, Mark Travers
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Patent number: 5578277Abstract: A modular catalytic converter and muffler is used to purify exhaust from a relatively large diesel engine. The device includes various structural components that are mounted in the exhaust flow path within a housing having an inlet and an outlet. A plate mounted within the housing divides the housing into an inlet chamber and an outlet chamber. A plurality of catalytic converter sub-cans are mounted across the plate between the inlet chamber and the outlet chamber. A flow distributor is mounted within the housing upstream of the catalytic converter sub-cans. The flow distributor divides and directs a portion of the exhaust to each of the catalytic converter sub-cans. Some muffler structure is mounted within the housing between the catalytic converter sub-cans and the outlet in order to attenuate noise in the exhaust.Type: GrantFiled: October 17, 1995Date of Patent: November 26, 1996Assignee: Caterpillar Inc.Inventors: Scott T. White, Aaron L. Smith, Daniel J. Learned, Randy N. Peterson, William H. Lane
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Patent number: 5569441Abstract: A process and apparatus for accelerating the rate of heating of a fixed bed catalyst to a light-off temperature for a catalytic reaction is disclosed. Supplementary energy from an external energy source is provided to a predetermined area of the catalyst bed for a limited period of time. The fixed bed catalyst may be present as a solid body or in bulk form and has a gas inlet area defined by a cross-section of the flow through channels of the reaction media. The supplementary energy is supplied to one or more isolated sections of the gas inlet area of the catalyst. Such a system significantly reduces the energy required in order to effectuate at least partial conversion of harmful emissions during initial operation of the converter.Type: GrantFiled: December 5, 1994Date of Patent: October 29, 1996Assignee: Degussa AktiengesellschaftInventors: Bernd Engler, Egbert Lox, Andreas Niemann-Weber
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Patent number: 5569455Abstract: Method of forming a catalytic bonding layer by chemical vapor deposition (CVD) onto carrier structures including internal combustion engine exhaust system and catalytic converter components, in order to bond a catalyst layer thereto, thereby providing a structure wherein additionally the bonding layer can be energized to promote catalytic conversion-activating preheating of the catalyst. In an electromagnetic induction catalytic preheating system, a ceramic lattice or a metallic network can form the base structure of the catalytic converter, wherein at least the latter is encompassed by an electrical/thermal insulating layer; around either induction coiling is wrapped and secured by a thermally insulating material. Upon engine start, current is electromagnetically induced in the catalytic bonding layer or the metallic network through the induction coiling.Type: GrantFiled: January 3, 1995Date of Patent: October 29, 1996Assignees: Shimadzu Corporation, Mazda Motor CorporationInventors: Isao Fukui, Masamitsu Takahashi, Kazunori Ihara, deceased, Hiroshi Murakami, Tetsuhiro Tanaka, Shinobu Miyaura, Shinichi Kuroda, Masahiro Hiraishi, Koji Inoue
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Patent number: 5547549Abstract: A vibrating bed pyrolysis system has a vibrating bed which is supplied with hot solid particles. Dry coal particles are rapidly heated by the hot solid particles to drive off hydrocarbon vapors. The vapors are condensed in a jet condenser, and products are flowed to a header tank. A portion of the liquid product is stored at room temperature for later use. A small portion of the liquid product is pumped from the header tank and cooled to ambient temperature and is sprayed in the jet condenser, which is positioned above the vibrating pyrolysis bed. A dryer bed vibrated by the same vibrating machine which vibrates the pyrolysis bed is supplied with hot solid particles and the crushed coal. Moisture in the coal particles is evaporated, and water vapors entrain coal fines before the coal particles are passed to the pyrolysis bed. The hot solid particles are taken from a fluidized bed combustor and are returned to the combustor with the coal char particles by entrainment into the gas lift system.Type: GrantFiled: June 2, 1995Date of Patent: August 20, 1996Inventor: Arthur P. Fraas
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Patent number: 5540899Abstract: A reactor arrangement and process for indirectly contacting a reactant stream with a heat exchange stream uses multiple passes of the heat exchange stream in a transverse flow arrangement to control temperature conditions over the width and length of channels through which the reactant passes. The heat transfer coefficient may be varied by changing the number and/or the arrangement of the corrugations along the plates or adding a heat adjustment plate to a channel containing the heat exchange fluid. The reactor arrangement and process of this invention may be used to operate a reactor under isothermal or other controlled temperature conditions. The variation in corrugation arrangements within a single heat exchange section is highly useful in maintaining a desired temperature profile in an arrangement having a cross-flow of heat exchange medium relative to reactants. The corrugations arrangement eliminates or minimizes the typical step-wise approach to isothermal conditions.Type: GrantFiled: December 22, 1994Date of Patent: July 30, 1996Assignee: UOPInventor: William J. Koves
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Patent number: 5523059Abstract: The invention provides an intumescent sheet material comprising 25 to 60 dry weight percent of at least one unexpanded intumescent material, 25 to 60 dry weight percent of ceramic fibers, 0.5 to 5 dry weight percent of glass fibers having a diameter of less than about 2 microns, and 0.1 to 15 dry weight percent of organic binder, wherein said intumescent sheet material has a cold erosion rate of less than 0.05 grams/hour. The invention also provides catalytic converters and diesel particulate filters containing the sheet material.Type: GrantFiled: June 30, 1995Date of Patent: June 4, 1996Assignee: Minnesota Mining and Manufacturing CompanyInventor: Roger L. Langer
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Patent number: 5512251Abstract: There is provided an improved converter body core element having a corrugated thin metal strip having, parallel to and close to a longitudinal marginal edge thereof, a recess dimensioned and configured to receive a heater band. In specific embodiments, the heater band is desirably lightly corrugated, i.e., having an amplitude of the corrugations which is from one tenth to one third the amplitude of the corrugations in the strip containing the recess, and the heater band is dimensioned and configured to fit into the recess.Type: GrantFiled: July 29, 1994Date of Patent: April 30, 1996Assignee: W. R. Grace & Co.-Conn.Inventors: Gordon W. Brunson, William A. Whittenberger
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Patent number: 5501846Abstract: A catalytic process and apparatus which is mechanically manipulated to increase the operating efficiency thereof. Provision is made for the application of an electric current during mechanical manipulation of the catalyst such as may be useful in certain instances.Type: GrantFiled: August 8, 1994Date of Patent: March 26, 1996Inventors: Richard Pavelle, Paul Burstein, Leon Ferber, Ronald M. Latanision
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Patent number: 5501842Abstract: A metal honeycomb heater is protectively mounted in an axially assembled enclosure comprising opposing tubular enclosure sections incorporating internal bore stops and a resilient mounting material to support the heater. An axial force of predetermined magnitude is applied to the sections during assembly, preloading the resilient mounting material and generating a selected spring tension and preloading force on the honeycomb. The sections are fastened together under this force so that the preloading force and spring tension are retained during subsequent use of the assembly.Type: GrantFiled: August 30, 1994Date of Patent: March 26, 1996Assignee: Corning IncorporatedInventors: Lawrence S. Rajnik, Paul S. Schmitt
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Patent number: 5494642Abstract: An electrically heated catalytic converter having a substrate for a catalyst which is formed as a scroll-like cylindrical laminated assembly, a rod like metal center electrode connected to the laminated assembly, and a casing accommodating the laminated assembly which also acts as an outer electrode. The center electrode extends from the laminated assembly along the central axis, bends towards the wall of the casing and penetrates the casing. The center electrode is fixed to the casing via an insulating material at the point where it penetrates the casing. Four buffer members are interposed between the laminated assembly and the casing, each of buffer members being made of a metal plate, one end of the respective buffer members being fixed to the casing at the portion near the penetration point of the center electrode, the other end of the respective buffer members being fixed to the outside of the laminated assembly.Type: GrantFiled: December 21, 1994Date of Patent: February 27, 1996Assignee: Toyota Jidosha Kabushiki KaishaInventor: Masakatsu Sanada
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Patent number: 5486338Abstract: A metal catalyst carrier for exhaust gas purification, comprising: a columnar metal honeycomb composed by spirally winding a laminate of a flat metal foil and a corrugated metal foil; a columnar metal case enclosing the metal honeycomb with a space remaining therebetween; and a cushion member disposed in the space and joined to the metal honeycomb and to the metal case alternately with respect to the column circumferential direction.Type: GrantFiled: September 27, 1993Date of Patent: January 23, 1996Assignees: Nippon Steel Corporation, Toyota Jidosha Kabushiki KaishaInventors: Hitoshi Ota, Masao Yashiro, Koki Yotsuya, Takuzo Kako, Yuzi Nakashima
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Patent number: 5482686Abstract: A flexible, resilient, intumescent mat material comprising fiber, binder, and an intumescent agent which includes a mixture of unexpanded vermiculite and expandable graphite undergoes intumescence at a lower temperature, with an enhanced degree of expansion and with a lesser degree of contraction upon prolonged heating. The intumescent mat can be employed in catalytic converters for motor vehicles and as a firestop material.Type: GrantFiled: November 18, 1994Date of Patent: January 9, 1996Inventors: Alan R. Lebold, John D. Ten Eyck
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Patent number: 5482685Abstract: A catalyst 1 is provided in a gas passage 4 for communicating between a gas flow-in unit 12 and a gas flow-out unit 13, and the catalyst 1 is heated by a heater 2, and a temperature sensor 3 for detecting the temperature of the heater 2 is provided inside the heater 2. By feeding power to the heater 2, the wall temperature of the heater 2 is raised to heat the catalyst 1, and then malodorous gas containing odor substances is passed in from the gas flow-in unit 12. The malodorous gas passes through the catalyst 1 in the gas passage 4 to be oxidized to be harmless and odorless, and is discharged from the gas flow-out unit 13.Type: GrantFiled: April 11, 1994Date of Patent: January 9, 1996Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Tatsuo Fujita, Syuzo Tokumitsu, Hirofumi Nishida, Tadashi Suzuki, Yukiyoshi Ono, Tetsuo Terashima, Takeshi Tomizawa, Jiro Suzuki, Syuji Asada, Yukiyoshi Nishikori
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Patent number: 5441716Abstract: A chemisorption reaction process is carried out under conditions in which the volumetric expansion of the complex compound reaction product is restricted, and at half-cycle reaction periods of less than 30 minutes each, and/or in a reaction chamber having a maximum mean mass diffusion path length of less than about 15 mm, and/or a maximum heat diffusion path length of less than 1.5 mm.Type: GrantFiled: August 9, 1993Date of Patent: August 15, 1995Assignee: Rocky ResearchInventor: Uwe Rockenfeller
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Patent number: 5439651Abstract: A catalytic exhaust treatment system for an outboard motor wherein a catalyst bed is supported within the exhaust pipe on a support plate that permits the catalyst bed to expand and contract relative to the surrounding exhaust pipe from which it is spaced. The exhaust gases can flow through the catalyst bed and, around the catalyst bed for complete treatment.Type: GrantFiled: September 24, 1993Date of Patent: August 8, 1995Assignee: Sanshin Kogyo Kabushiki KaishaInventor: Masahiko Kato
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Patent number: 5417935Abstract: An SCR reactor (50) is disclosed which permits ready removal of a catalyst bed (58) from the SCR reactor and provides an effecting sealing mechanism between the catalyst bed (58) and the frame (52) of the SCR reactor. The frame is provided with side rails (54, 56) which have individual indentations spaced therealong. The catalyst bed is provided with wheels (60A, 60B, 60C) along its length which permit the catalyst bed to be rolled along the side rails until the catalyst bed is moved into its installed position whereupon the wheels descend into the indentations (62), causing the weight of the catalyst bed to form an effective seal between a downwardly face edge (64) on the catalyst bed and the frame (52).Type: GrantFiled: May 21, 1993Date of Patent: May 23, 1995Assignee: Peerless Manufacturing CompanyInventors: Leslie P. Jaynes, Kenneth D. Thomas
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Patent number: 5409670Abstract: An SCR reactor sealing mechanism is disclosed which utilizes a clamping plate (34) to urge a side sealing flange (24) on a member (20) containing the catalyst (22) against a mating sealing surface (32) on the supporting internal frame (12) to prevent exhaust gas from bypassing the catalyst. The sealing mechanism has an advantage in permitting the member and catalyst to be removed from the internal frame by simply loosening the clamping plate (34) and slid out of or into the internal frame.Type: GrantFiled: August 13, 1993Date of Patent: April 25, 1995Assignee: Peerless Manufacturing CompanyInventors: Leslie P. Jaynes, Kenneth D. Thomas
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Patent number: 5403558Abstract: A metallic carrier composed of an end face portion formed in at least one of the axial end portions of a honeycomb body and an outer circumferential reinforcing layer in which foils in a range from the outermost layer to a quarter of the total number of layers are joined together in the axial intermediate portion. Thus, the metallic carrier is flexible in expansion and shrinkage. Further, the honeycomb body and a jacket are joined to each other mainly at the outer circumference of the outer circumferential reinforcing layer of the honeycomb body, to reduce thermal stress developed between the honeycomb body and jacket while maintaining the strength against a high temperature, to thereby prevent the metallic carrier from being ruptured.Type: GrantFiled: July 6, 1993Date of Patent: April 4, 1995Assignees: Nippon Steel Corporation, Toyota Jidosha Kabushiki Kaisha, Nippon Kinzoku Co., Ltd.Inventors: Takuo Kono, Mikio Yamanaka, Takashi Tanaka, Yasushi Ishikawa, Yutaka Sadano, Masao Yashiro, Tatuo Sugiura, Tadanobu Komai, Shinichi Matsumoto, Toshihiro Takada, Shinji Shibata, Hikaru Aoyagi, Masaaki Ohashi, Yoshio Nishizawa, Akihiko Kasahara
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Patent number: 5399321Abstract: A tubular pressurized catalytic hydrocarbon converter provided with a cylindrical casing (1) containing vertical gas exhaust pipes (4) around which are arranged reaction tubes (2) which are coaxially placed in sleeves (3). The lower portions of these tubes are connected to the vertical pipes by "pig-tails" and have a novel design since the aim is to increase the converter's reliability and working life by eliminating reaction tube deformation and facilitating "pig-tail" assembly and maintenance. To this end, the converter is provided with a transverse wall attached to the lower ends of the sleeves and provided with openings in which the lower ends of the tubes and vertical pipes are freely inserted. It is also provided with plates (7) having movable covers (8) and attached to the lower ends of the vertical pipes which are in turn connected to the "pig-tails".Type: GrantFiled: December 13, 1991Date of Patent: March 21, 1995Assignee: Compagnie Francaise d'Etudes et de Construction TechnipInventors: Mikail H. Sosna, Vladimir P. Semenov, Valentin V. Harlamov, Leonid Y. Krotov, Boris S. Zats, Isaak M. Zinger, Isaak E. Bondar, Galina N. Jakusheva, Lidya Z. Nikolova, Vladimir F. Efankin, Gennadii F. Kiselev, Vladimir K. Chubukov, deceased, Vladimir P. Gavrilin, deceased
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Patent number: 5385873Abstract: A high temperature resistant material including between approximately 28 and 60 dry weight percent of high temperature resistant ceramic fibers and between approximately 20 and 50 dry weight percent of high aspect ratio vermiculite.Type: GrantFiled: April 7, 1993Date of Patent: January 31, 1995Assignee: ACS Industries, Inc.Inventor: Gerald F. MacNeill
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Patent number: 5384101Abstract: Reaction rates in chemisorption reactions involving solid reactants and gaseous ligands are improved by maintaining optimized solid density throughout the reaction. Methods and apparatus which restrict volumetric solid expansion, compression of the solid reactant, and mixture with inert solid porous or particulate materials are disclosed.Type: GrantFiled: June 16, 1992Date of Patent: January 24, 1995Assignee: Rocky ResearchInventor: Uwe Rockenfeller
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Patent number: 5372792Abstract: The present invention provides a cylindrical reactor vessel having a top end with an inlet and a bottom end with an outlet end. A refractory insulating lining is applied on the interior of the wall of the vessel. A cylindrical vertically disposed first inner basket having a generally closed top first end and an open second end in communication with the outlet conduit and having fluid pervious sidewalls surrounded by a vertically disposed outer cylindrical second basket defining a space therebetween for containment of subdivided contact material. The cylindrical second basket also has a top end, which is closed, and fluid pervious sidewalls. The cylindrical second basket is spaced away from the refractory lining of the vessel at a sufficient distance, to provide an annular space for fluid, admitted through the inlet, to progress downwardly through the annular space and then radially inwardly through the contact material contained in the space between the first and second basket.Type: GrantFiled: February 3, 1992Date of Patent: December 13, 1994Assignee: Exxon Research & Engineering Co.Inventors: Rodney T. Mueller, Catherine M. Murray, Donald F. Shaw, Robert F. Tammera