Fixed Bed With Resilient Or Differential Thermal Expansion Compensating Bed Support Means Patents (Class 422/179)
  • Patent number: 5866079
    Abstract: 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: Grant
    Filed: August 31, 1994
    Date of Patent: February 2, 1999
    Assignee: NGK Insulators, Ltd.
    Inventors: Minoru Machida, Toshio Yamada, Toshihiko Hijikata, Yukihito Ichikawa
  • Patent number: 5866077
    Abstract: 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: Grant
    Filed: February 5, 1997
    Date of Patent: February 2, 1999
    Assignees: Toyota Jidosha Kabushiki Kaisha, Nippon Steel Corp.
    Inventors: Kazuhiro Sakurai, Takuzou Kako
  • Patent number: 5857140
    Abstract: 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: Grant
    Filed: October 3, 1997
    Date of Patent: January 5, 1999
    Assignee: General Motors Corporation
    Inventor: Michael Ralph Foster
  • Patent number: 5853675
    Abstract: 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: Grant
    Filed: June 30, 1995
    Date of Patent: December 29, 1998
    Assignee: Minnesota Mining and Manufacturing Company
    Inventor: Gary F. Howorth
  • Patent number: 5851496
    Abstract: 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: Grant
    Filed: January 23, 1997
    Date of Patent: December 22, 1998
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventor: Kazuhiro Sakurai
  • Patent number: 5849250
    Abstract: 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: Grant
    Filed: February 3, 1997
    Date of Patent: December 15, 1998
    Inventor: Mark Timko
  • Patent number: 5849251
    Abstract: 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: Grant
    Filed: February 3, 1997
    Date of Patent: December 15, 1998
    Inventor: Mark Timko
  • Patent number: 5829132
    Abstract: A method is provided for assembling an exhaust processor including a housing formed from a tube having an inlet end and an outlet end, an internal inlet cone shield, a substrate, and an internal outlet cone shield. The housing includes an inlet end and an outlet end. The inlet end of the tube is sized down to a desired inlet diameter to form the inlet end of the housing. The internal inlet cone shield is installed into the tube through the outlet end of the tube. The substrate is inserted into the tube through the outlet end of the tube. The internal outlet cone shield is installed into the tube through the outlet end of the tube. The outlet end of the tube is sized down to a desired outlet diameter to form the outlet end of the housing.
    Type: Grant
    Filed: August 7, 1996
    Date of Patent: November 3, 1998
    Assignee: Arvin Industries, Inc.
    Inventors: Mark Allen Sickels, James Dale Quackenbush
  • Patent number: 5827485
    Abstract: 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: Grant
    Filed: June 18, 1990
    Date of Patent: October 27, 1998
    Assignee: Linde Aktiengesellschaft
    Inventors: Klaus Libal, Walter Fierlbeck, Ulrich Von Gemmingen
  • Patent number: 5820834
    Abstract: 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: Grant
    Filed: March 31, 1997
    Date of Patent: October 13, 1998
    Assignee: Precision Combustion Inc.
    Inventors: Michael Joseph DiGiovanni, John Frederick Bianchi
  • Patent number: 5811063
    Abstract: 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: Grant
    Filed: September 8, 1997
    Date of Patent: September 22, 1998
    Assignee: Unifrax Corporation
    Inventors: John W. Robinson, Alan R. Lebold, Mark Travers
  • Patent number: 5800787
    Abstract: An electrically heatable honeycomb body includes a plurality of passages which are each defined by partition walls made of an electroconductive material and which are substantially parallel to the direction of a gas flowing through the honeycomb body, and two ends which are the gas inlet and outlet sides of honeycomb body, wherein the heat generation of the honeycomb body by electrification is controlled by adjusting the flow of electricity therein and wherein those cells each constituted by a passage and partition walls, present in the vicinity of each current-concentrating portion are formed in such a structure that the stress caused by current concentration can be reduced. This honeycomb body can reduce the stress caused by current concentration and thereby can prevent the rupture of its cells.
    Type: Grant
    Filed: March 25, 1996
    Date of Patent: September 1, 1998
    Assignee: NGK Insulators, Ltd.
    Inventors: Yasushi Kato, Shigeharu Hashimoto, Yoshinobu Watanabe
  • Patent number: 5787584
    Abstract: A catalytic converter structure comprising: cylindrical catalyst substrate; a first cylindrical tube covering a first end of the substrate; a second cylindrical tube covering a second end of the substrate; a support mat surrounding a central portion of the substrate and portions of the first and second cylindrical tubes; and a housing having a cylindrical shape, within which the substrate, first and second cylindrical tubes and the support mat are located, wherein the housing has a central body and first and second housing ends, wherein the housing ends each have a first diameter less than a second diameter of the central body, wherein the first and second housing ends engage the first and second cylindrical tubes, respectively. The structure requires few components, is easy to tool and easy to adapt to different engine implementations.
    Type: Grant
    Filed: August 8, 1996
    Date of Patent: August 4, 1998
    Assignee: General Motors Corporation
    Inventors: Michael Richard Shea, Robert Anthony Lawrence, Eric Hans Andersen
  • Patent number: 5782089
    Abstract: In a honeycomb catalytic converter having a metal case, a honeycomb catalyst mounted in the metal case, and a securing member used for mounting the honeycomb catalyst in the metal case and arranged between an outer surface of the honeycomb catalyst and an inner surface of the metal case, at lest one of an inlet portion and outlet portion of the honeycomb catalyst has a double cone structure in which an inner cylindrical member is arranged in the metal case. The honeycomb catalytic converter mentioned above can mount the honeycomb catalyst stably in the metal case for a long period of time even when exposed to high temperatures.
    Type: Grant
    Filed: January 24, 1996
    Date of Patent: July 21, 1998
    Assignee: NGK Insulators, Ltd.
    Inventors: Minoru Machida, Toshihiko Hijikata, Masashi Yano
  • Patent number: 5766559
    Abstract: An exhaust gas management apparatus including: an air flow directing body forming a bypass passage including an inlet end and an outlet end and defining a low pressure region between the inlet end and the outlet end having a first diameter less than second and third diameters of the inlet and outlet ends, respectively; a hydrocarbon adsorber mounted radially exterior of the air flow directing body; an air source located downstream in an exhaust flow path of the low pressure region of the air flow body; and an air pump forcing air through the air source wherein, during activation of the pump, the bypass passage is valved shut at the low pressure region, wherein less air is required to valve shut the bypass passage than would be required at another location within the bypass passage.
    Type: Grant
    Filed: February 3, 1997
    Date of Patent: June 16, 1998
    Assignee: General Motors Corporation
    Inventors: Scott Christopher Blanchet, Wayne Richard Moore
  • Patent number: 5746986
    Abstract: 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: Grant
    Filed: January 2, 1997
    Date of Patent: May 5, 1998
    Assignee: 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
  • Patent number: 5744104
    Abstract: 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: Grant
    Filed: February 22, 1995
    Date of Patent: April 28, 1998
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Kazuhiro Sakurai, Koji Shimoji, Tohru Yoshinaga, Kiyohiko Watanabe
  • Patent number: 5736109
    Abstract: 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: Grant
    Filed: June 30, 1995
    Date of Patent: April 7, 1998
    Assignee: Minnesota Mining and Manufacturing Company
    Inventors: Gary F. Howorth, John J. Rogers, Toshiyuki Watanabe
  • Patent number: 5716586
    Abstract: An exhaust gas purifier includes a filter for collecting particulates, a heater for firing collected particulates, a blower for feeding air, and a controller for controlling power supplied to the heater and air flow rate of the blower. The air flow rate is varied in a regeneration period for improving the regeneration efficiency and for protecting the filter. In one embodiment, the air flow rate is initially reduced in the burning period and increased after burning in the radial direction at the downstream portion of the filter. The burning propagation speed, the heat generation and the increase of the temperature of the filter are limited by suppressing the air flow rate in the burning period. The particulates remaining in the downstream portion of the filter due to the suppressed air flow rate supplied in the burning period can be burned subsequently by supplying an increased air flow rate after the burning period.
    Type: Grant
    Filed: July 18, 1995
    Date of Patent: February 10, 1998
    Assignee: Kabushiki Kaisha Toyoda Jidoshokki Seisakusho
    Inventor: Hiroyuki Taniguchi
  • Patent number: 5707593
    Abstract: 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: Grant
    Filed: December 31, 1996
    Date of Patent: January 13, 1998
    Inventor: Chi S. Wang
  • Patent number: 5683660
    Abstract: A method for uniting an exhaust treatment body (2) surrounded by a bedding mat (6) with a metal case (8) forming a housing for the exhaust treatment body, characterized in that one or two preformed metal blanks are pressed by means of a form tool (10) against the exhaust treatment body (2) surrounded by the bedding mat (6) and thereby brought into the final case form; and the thus formed metal blank or blanks are welded to the case (8) along one or two longitudinal seams (28). An afflux funnel (44) and a discharge funnel are preferably welded on by means of a special triple seam (56).
    Type: Grant
    Filed: December 29, 1994
    Date of Patent: November 4, 1997
    Assignee: J. Eberspacher GmbH & Co.
    Inventors: Georg Wirth, Siegfried Worner, Peter Zacke
  • Patent number: 5674461
    Abstract: 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: Grant
    Filed: April 24, 1996
    Date of Patent: October 7, 1997
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Hiroshi Kato, Mitsuo Kusa, Kensuke Suzuki, Takahito Sekita
  • Patent number: 5656244
    Abstract: A process and system for reducing cold start NO.sub.x, carbon monoxide, and hydrocarbon emissions from mobile source engine exhaust utilizes adsorption and desorption of NO.sub.x compounds on a regenerable sorbent material. Molecules of NO.sub.x are adsorbed onto the sorbent material during the ineffective warm up period of a three-way catalytic converter. When the catalytic converter reaches operating temperatures, the NO.sub.x molecules are thermally desorbed from the sorbent material and delivered to the catalytic converter for effective reduction to molecular nitrogen.
    Type: Grant
    Filed: November 2, 1995
    Date of Patent: August 12, 1997
    Assignee: Energy and Environmental Research Corporation
    Inventor: Jerald A. Cole
  • Patent number: 5656245
    Abstract: The disclosure relates to a catalytic converter for cleaning exhaust gas generated from automobiles or the like and more particularly to a structure for securing a catalyst carrier to a casing.In the converter, a casing for embracing, supporting and securing the catalyst carrier is provided with at least one end cover at the one end of the casing in the longitudinal direction thereof, the catalyst carrier is secured to the one end cover, but not secured to the remainder of the casing. The catalyst carrier may be secured to the end cover by sandwiching the flange portion of the catalyst carrier between the vertical step portion of the end cover and a pushing ring via buffering members. Alternatively, the catalyst carrier may be secured to the end cover by pushing a taper bushing having a wedge-shaped cross section into the space between the concave recessed portion provided on the surface of the catalyst carrier and the short pipe portion of the end cover.
    Type: Grant
    Filed: November 14, 1995
    Date of Patent: August 12, 1997
    Assignee: Nippon Reinz Co., Ltd.
    Inventors: Katsuhide Fujisawa, Masakatsu Takahashi, Makoto Tajima
  • Patent number: 5648050
    Abstract: It is the primary object of the present invention to provide a catalyst converter which can hold a sufficient amount of catalyst to raise the temperature thereof to the catalyst activation temperature in a short time without enlarging the metal carrier itself. The metal carrier 1 is arranged in the course of an exhaust manifold 3 of an engine 2 and is composed of an alternating winding of a flat sheet 7 and a corrugated sheet 8, wherein slit parts 9 are formed in the flat sheet 7 and the corrugated sheet 8 of the metal carrier 1 in an end portion thereof, on the side the engine 2.
    Type: Grant
    Filed: March 16, 1994
    Date of Patent: July 15, 1997
    Assignee: Nippondenso Co., Ltd.
    Inventors: Toshiki Matsumoto, Tetsuya Toyao, Tetsuya Nakamura, Shigeru Maehara, Hiromasa Aoki, Tatsuya Fujita, Senta Tojo, Kinji Hodaira, Takeshi Matsui, Yushi Fukuda
  • Patent number: 5618500
    Abstract: 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: Grant
    Filed: August 21, 1995
    Date of Patent: April 8, 1997
    Inventor: Chi-Shang Wang
  • Patent number: 5614155
    Abstract: 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: Grant
    Filed: March 28, 1995
    Date of Patent: March 25, 1997
    Assignee: NGK Insulators, Ltd.
    Inventors: Fumio Abe, Shigeharu Hashimoto, Tomoharu Kondo
  • Patent number: 5614156
    Abstract: 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: Grant
    Filed: February 13, 1996
    Date of Patent: March 25, 1997
    Inventor: Chi S. Wang
  • Patent number: 5599509
    Abstract: 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: Grant
    Filed: April 4, 1995
    Date of Patent: February 4, 1997
    Assignee: Nippondenso Co., Ltd.
    Inventors: Tetsuya Toyao, Toshiki Matsumoto, Hiromasa Aoki, Tatsuya Fujita, Senta Tojo
  • Patent number: 5589144
    Abstract: The present invention relates to a thermal barrier coating applied to the inside surface of a catalytic converter and intake pipe between the manifold of an internal combustion engine and the catalytic converter. The catalytic converter and intake pipes are generally formed in two halves to facilitate an effective means by which the thermal barrier coating can be sprayed onto the inside surface by an arc plasma source prior to combining the individual halves of the catalytic converter or intake pipe.
    Type: Grant
    Filed: May 1, 1990
    Date of Patent: December 31, 1996
    Inventors: John E. Filippi, John A. Golen
  • Patent number: 5580532
    Abstract: 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: Grant
    Filed: November 3, 1994
    Date of Patent: December 3, 1996
    Assignee: Unifrax Corporation
    Inventors: John W. Robinson, Alan R. Lebold, Mark Travers
  • Patent number: 5578277
    Abstract: 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: Grant
    Filed: October 17, 1995
    Date of Patent: November 26, 1996
    Assignee: Caterpillar Inc.
    Inventors: Scott T. White, Aaron L. Smith, Daniel J. Learned, Randy N. Peterson, William H. Lane
  • Patent number: 5569441
    Abstract: 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: Grant
    Filed: December 5, 1994
    Date of Patent: October 29, 1996
    Assignee: Degussa Aktiengesellschaft
    Inventors: Bernd Engler, Egbert Lox, Andreas Niemann-Weber
  • Patent number: 5569455
    Abstract: 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: Grant
    Filed: January 3, 1995
    Date of Patent: October 29, 1996
    Assignees: Shimadzu Corporation, Mazda Motor Corporation
    Inventors: Isao Fukui, Masamitsu Takahashi, Kazunori Ihara, deceased, Hiroshi Murakami, Tetsuhiro Tanaka, Shinobu Miyaura, Shinichi Kuroda, Masahiro Hiraishi, Koji Inoue
  • Patent number: 5555621
    Abstract: A method of making a catalytic converter for an automotive internal combustion engine comprises a cylindrical honeycomb catalyst carrier made of a ceramic and carrying a catalytic material. The catalyst carrier is encased within a cylindrical container upon being axially supported at its opposite end faces between oppositely disposed annular metal caps through cushioning materials. The metal caps are fixedly secured to the inner peripheral surface of the container by plug welding. In production of the catalytic converter, the plug welding is made in a state in which the metal caps are being biased to the catalyst carrier at a predetermined pressure by a pair of pressing jigs which respectively abut the metal caps.
    Type: Grant
    Filed: July 5, 1994
    Date of Patent: September 17, 1996
    Assignee: Calsonic Corporation
    Inventors: Hiroshi Tanabe, Tsutomu Imamura, Katsumi Amada, Yuji Shimada
  • Patent number: 5554342
    Abstract: An electrical heating type catalytic device having a metallic catalyst carrier constituted by layering metallic foils, surfaces of the metallic foils being coated by an insulation film, adjoining metallic foils being joined conductively in only some regions of the metallic catalyst carrier.
    Type: Grant
    Filed: June 1, 1995
    Date of Patent: September 10, 1996
    Assignees: Toyota Jidosha Kabushiki Kaisha, Nippon Soken, Inc., Nippondenso Co., Ltd.
    Inventors: Hiroshi Hirayama, Kouji Yoshizaki, Kouhei Igarashi, Keiji Ito, Tohru Yoshinaga, Kiyohiko Watanabe, Yukihiro Shinohara, Osamu Fujishiro
  • Patent number: 5525308
    Abstract: An exhaust gas purifier arrangement for an internal combustion engine includes a gas adsorber and a catalyzer located downstream from the adsorber in the direction of exhaust gas flow and a burner providing hot burner gases to heat the catalyzer through a burner pipe which traverses the adsorber, and also includes an arrangement for controlling the heat transfer between the burner pipe and the gas adsorber so that heating the adsorber to its desorption temperature is accelerated at low ambient temperatures.
    Type: Grant
    Filed: February 10, 1995
    Date of Patent: June 11, 1996
    Assignee: Volkswagen AG
    Inventor: Polat Oser
  • Patent number: 5523059
    Abstract: 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: Grant
    Filed: June 30, 1995
    Date of Patent: June 4, 1996
    Assignee: Minnesota Mining and Manufacturing Company
    Inventor: Roger L. Langer
  • Patent number: 5512251
    Abstract: 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: Grant
    Filed: July 29, 1994
    Date of Patent: April 30, 1996
    Assignee: W. R. Grace & Co.-Conn.
    Inventors: Gordon W. Brunson, William A. Whittenberger
  • Patent number: 5501842
    Abstract: 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: Grant
    Filed: August 30, 1994
    Date of Patent: March 26, 1996
    Assignee: Corning Incorporated
    Inventors: Lawrence S. Rajnik, Paul S. Schmitt
  • Patent number: 5494642
    Abstract: 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: Grant
    Filed: December 21, 1994
    Date of Patent: February 27, 1996
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventor: Masakatsu Sanada
  • Patent number: 5490382
    Abstract: 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: Grant
    Filed: April 17, 1995
    Date of Patent: February 13, 1996
    Assignee: Sanshin Kogyo Kabushiki Kaisha
    Inventor: Masahiko Kato
  • Patent number: 5488826
    Abstract: A catalytic reactor for reducing pollutants in the exhaust gas from an internal combustion engine includes a catalyst element and a heat shield exterior to the catalyst element. The heat shield and catalyst element are mounted within an exhaust pipe so that two annular insulation spaces exist between the catalyst element and the exhaust pipe. The first annular insulation space is located between the interior wall of the exhaust pipe and the exterior wall of the heat shield. The second annular insulation space is located between the interior wall of the heat shield and the catalyst element itself. A spring washer positioned between one end of the catalytic reactor and an axial retaining flange on the exhaust pipe allows the catalytic reactor to expand axially as it heats to operating temperature. A layer of ceramic material may be deposited on the exterior surface of the heat shield to further reduce heat transfer to the exhaust pipe.
    Type: Grant
    Filed: July 19, 1993
    Date of Patent: February 6, 1996
    Assignee: Dry Systems Technologies
    Inventor: Norbert Paas
  • Patent number: 5486338
    Abstract: 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: Grant
    Filed: September 27, 1993
    Date of Patent: January 23, 1996
    Assignees: Nippon Steel Corporation, Toyota Jidosha Kabushiki Kaisha
    Inventors: Hitoshi Ota, Masao Yashiro, Koki Yotsuya, Takuzo Kako, Yuzi Nakashima
  • Patent number: 5482686
    Abstract: 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: Grant
    Filed: November 18, 1994
    Date of Patent: January 9, 1996
    Inventors: Alan R. Lebold, John D. Ten Eyck
  • Patent number: 5482685
    Abstract: 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: Grant
    Filed: April 11, 1994
    Date of Patent: January 9, 1996
    Assignee: 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
  • Patent number: 5476640
    Abstract: Low temperature apparatus for the destruction of low volume time varying organic air toxins in air streams utilizing non-catalytic glass beads in parallel conduits heated by hot gas flow around the conduits and flowing the air stream through the conduits and controlling the hot gas flow in response to toxin levels in the air stream.
    Type: Grant
    Filed: August 25, 1994
    Date of Patent: December 19, 1995
    Assignee: The United States of America as represented by the Administrator of the U.S. Environmental Protection Agency
    Inventors: James H. Abbott, Dennis C. Drehmel, Geddes H. Ramsey
  • Patent number: 5468384
    Abstract: The present invention relates to a module for filtering, separating, purifying gases or liquids, or for catalytic conversion, comprising:- a substantially cylindrical housing (13),- at least one rigid element (4) of which at least one end (5) is substantially cylindrical and whose axis is parallel to that of the housing (13),- at least one elastically deformable metal part in the form of a ring (6), fixed firstly to the housing (13) and connected secondly to said end (5) of said element (4), characterized in that the joint between said ring (6) and said end (5) of said element (4) is a hoop fitting.
    Type: Grant
    Filed: November 9, 1994
    Date of Patent: November 21, 1995
    Assignee: Societe Anonyme Dite Societe des Ceramiques Techniques
    Inventors: Daniel Garcera, Edouard Toujas, Jacques Gillot
  • Patent number: 5468455
    Abstract: A honeycomb body includes an axis along which a flow of fluid is to be conducted through the honeycomb body. At least two oppositely disposed end surfaces define the honeycomb body along the axis. An internal structure for conducting an electric current for heating is formed of at least one sheet-metal layer. Metal support configurations each support the internal structure at a respective one of the end surfaces. An electric insulation is disposed between the internal structure and the support configuration. A method for producing an electrically heatable honeycomb body includes producing at least one approximately rectangular sheet-metal layer having two opposed end edges being aligned approximately perpendicularly to an axis. Each end edge is encompassed with a folded joint having a ceramic layer resting on the at least one sheet-metal layer, to form support configurations. The sheet-metal layer and the folded joints are corrugated at obtuse angles preferably being approximately perpendicularly to the axis.
    Type: Grant
    Filed: June 21, 1994
    Date of Patent: November 21, 1995
    Assignee: Emitec Gesellschaft fuer Emissionstechnologie mbH
    Inventor: Rolf Bruck
  • Patent number: RE35134
    Abstract: A resistance adjusting type heater including a honeycomb structure having a large number of passages, at last two electrodes for energizing the honeycomb structure, and a resistance adjusting mechanism such as a slit provided between the electrodes to heat the gas flowing through the passages formed in the honeycomb structure. A catalytic converter includes a main monolith catalyst and the above-described heater placed adjacent to and upstream of the main monolith catalyst. A catalytic converter includes a honeycomb structure having a large number of passages, a catalyst carried on the honeycomb structure, at least two electrodes for energizing the honeycomb structure, and a resistance adjusting mechanism provided between the electrodes. A catalytic converter includes a main monolith catalyst, and a heater placed adjacent to and upstream of the main monolith catalyst.
    Type: Grant
    Filed: October 19, 1993
    Date of Patent: December 26, 1995
    Assignee: NGK Insulators, Ltd.
    Inventors: Hiroshige Mizuno, Fumio Abe, Takashi Harada