EXHAUST MUFFLER, TWO-STROKE ENGINE OR FOUR-STROKE ENGINE HAVING AN EXHAUST MUFFLER, AND CATALYTIC CONVERTER FOR AN EXHAUST MUFFLER
20220305440 · 2022-09-29
Inventors
- Niels Kunert (Ottenbach, DE)
- Dietmar Widmann (Leutenbach, DE)
- Martin Christoph Arenz (Stuttgart, DE)
- Michael Dietenberger (Waiblingen, DE)
- Johannes Alber (Stuttgart, DE)
- Jan-Eilert Kueper (Erdmannhausen, DE)
- Marcus Bonifer (Hanau, DE)
- Hans Hildenbrand (Hanau, DE)
Cpc classification
F01N3/2046
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N1/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/2885
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/017
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2260/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2590/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2330/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2230/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/002
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/2835
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2510/0682
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/2817
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N1/089
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2590/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2490/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2330/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01N13/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
An exhaust muffler has an exhaust inlet, an exhaust outlet, as well as a catalytic converter which, in the flow direction, is disposed between the exhaust inlet and the exhaust outlet. The catalytic converter has at least one throughflow body which includes at least one wire body. At least one first component region of the throughflow body is coated with a catalytically functioning coating. The throughflow body moreover has a second component region which in terms of volume has a smaller quantity of catalytically functioning coating than the first component region.
Claims
1. An exhaust gas muffler comprising: an exhaust gas inlet and an exhaust gas outlet; a catalytic converter arranged in flow direction between said exhaust gas inlet and said exhaust gas outlet; said catalytic converter including at least one throughflow body defined by at least one wire body; said throughflow body having a first end face arranged upstream with respect to said flow direction through said throughflow body and further having a second end face arranged downstream with respect to said flow direction through said throughflow body; said throughflow body having at least one first component region coated with a catalytically functioning coating of a first quantity; and, said throughflow body further having a second component region having a catalytically functioning coating of a second quantity smaller than said first quantity with respect to volume.
2. The exhaust muffler of claim 1, wherein the second component region does not have any catalytically functioning coating.
3. The exhaust muffler of claim 1, wherein said throughflow body is assembled from a plurality of dimensionally stable individual bodies; and, each one of said individual bodies, when viewed individually, has the same coating or no coating in all regions.
4. The exhaust muffler of claim 1, wherein at least 50% of said second end face is formed by said second component region.
5. The exhaust muffler of claim 1, wherein said second end face is formed completely by said second component region.
6. The exhaust muffler of claim 1, wherein said first component region, viewed in a cross section through said first component region perpendicular to said flow direction, extends across at least 30% of the area of said throughflow body.
7. The exhaust muffler of claim 1, wherein said first component region is formed by at least one first wire body; and, said second component region is formed by at least one second wire body.
8. The exhaust muffler of claim 7, wherein said second component region is formed by at least two second wire bodies; and, at least one of the second wire bodies has a depression for receiving said at least one first wire body.
9. The exhaust muffler of claim 1, wherein said throughflow body has a peripheral surface extending from said first end face to said second end face; and, said peripheral surface is formed to a degree of at least 50% by said second component region.
10. The exhaust muffler of claim 1, wherein said second component region completely surrounds said first component region.
11. The exhaust muffler of claim 1, wherein said first component region and said second component region each, in at least one cross section, extend over the entire cross-sectional area of the exhaust muffler measured perpendicularly to said flow direction.
12. The exhaust muffler of claim 1, wherein each of said first and second component regions has a consistent thickness (a, b, b.sub.1, b.sub.2) measured in said flow direction.
13. The exhaust muffler of claim 1, wherein at least 50% of the first end face is formed by said second component region.
14. The exhaust muffler of claim 1, wherein said first end face is formed completely by said first component region.
15. The exhaust muffler of claim 1, wherein said second component region defines said second end face.
16. The exhaust muffler of claim 1, wherein said first component region has a greatest thickness (a) measured in said flow direction and said second component region has a greatest thickness (b, b.sub.1, b.sub.2) measured in said flow direction; and, said greatest thickness (a) of said first component region is at most 30% of said greatest thickness (b, b.sub.1, b.sub.2) of said second component region.
17. The exhaust muffler of claim 1, wherein at least one wire body is formed of compression molded metal wire.
18. The exhaust muffler of claim 1, wherein said throughflow body is configured of at least two individual bodies of dissimilar structures.
19. The exhaust muffler of claim 1, wherein said throughflow body is configured by at least two wire bodies of dissimilar structures.
20. The exhaust muffler of claim 1, wherein said throughflow body comprises at least one metal lattice.
21. The exhaust muffler of claim 20, wherein said metal lattice forms said first component region.
22. The exhaust muffler of claim 1, wherein said first component region comprises a plurality of portions configured so as to be mutually separate; said second component region extends between said plurality of portions; and, said first component region includes a plurality of first component regions connected to one another by at least one heat conducting element.
23. The exhaust muffler of claim 1, wherein said second component region has a catalytically functioning coating of less than 1 mg/cm.sup.3.
24. The exhaust muffler of claim 1, wherein one of the following applies: a) said second component region is coated with a washcoat; and, b) said second component region is uncoated.
25. The exhaust muffler of claim 1, wherein said throughflow body is formed by at least one wound mat.
26. The exhaust muffler of claim 25, wherein said first component region, in a direction transverse to said flow direction through said throughflow body, is at least partially surrounded by said second component region.
27. The exhaust muffler of claim 25, wherein said first component region is formed by at least one first mat and said second component region is formed by at least one second mat.
28. The exhaust muffler of claim 27, wherein said at least one first mat and said at least one second mat have dissimilar thicknesses (d, e).
29. The exhaust muffler of claim 28, wherein said at least one first mat and said at least one second mat have dissimilar widths (f, g) measured in said flow direction.
30. The exhaust muffler of claim 1, wherein said catalytic converter has a catalytic converter housing wherein said throughflow body is disposed.
31. The exhaust muffler of claim 30, wherein said throughflow body is press-fitted into said catalytic converter housing.
32. A two-stroke engine or mixture-lubricated four-stroke engine comprising: an exhaust gas muffler; said exhaust gas muffler including: an exhaust gas inlet and an exhaust gas outlet; a catalytic converter arranged in flow direction between said exhaust gas inlet and said exhaust gas outlet; said catalytic converter including at least one throughflow body defined by at least one wire body; said throughflow body having a first end face arranged upstream with respect to said flow direction through said throughflow body and further having a second end face arranged downstream with respect to said flow direction through said throughflow body; said throughflow body having at least one first component region coated with a catalytically functioning coating of a first quantity; and, said throughflow body further having a second component region having a catalytically functioning coating of a second quantity smaller than said first quantity with respect to volume.
33. A catalytic converter for an exhaust muffler, the catalytic converter comprising: at least one throughflow body defined by at least one wire body; said throughflow body having a first end face arranged upstream with respect to said flow direction through said throughflow body and further having a second end face arranged downstream with respect to said flow direction through said throughflow body; said throughflow body having at least one first component region coated with a catalytically functioning coating of a first quantity; and, said throughflow body further having a second component region having a catalytically functioning coating of a second quantity smaller than said first quantity with respect to volume.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] The invention will now be described with reference to the drawings wherein:
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DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0072]
[0073] The two-stroke engine 8 has a cylinder 12 in which a piston 13 is mounted in a reciprocating manner. The piston 13 delimits a combustion chamber 14 configured in the cylinder 12. The piston 13 by way of a connecting rod 16 drives a crankshaft 17 which is mounted in the crankcase 15 so as to be rotatable about a rotational axis 18. The interior of the crankcase 15 in the region of the bottom dead center of the piston 13 is fluidically connected to the combustion chamber 14 by way of a plurality of transfer channels 19. A spark plug 20 protrudes into the combustion chamber 14. A discharge opening 21 leads out of the combustion chamber 3. The discharge opening 21 by way of a discharge channel 22 is connected to the exhaust inlet 24 of an exhaust muffler 23. An exhaust outlet 25 leads out of the exhaust muffler 23. The exhaust gases escape into the environment by way of the exhaust outlet 25.
[0074] During the operation of the two-stroke engine 8 combustion air and fuel are suctioned into the interior of the crankcase 15 during the upward stroke of the piston 13. During the subsequent downward stroke of the piston 13 the fuel/air mixture is compressed in the crankcase 15. The connection between the transfer channels 19 and the combustion chamber 14 is controlled by the piston 13. As soon as the transfer channels 19 open toward the combustion chamber 14, fuel/air mixture from the crankcase 15 flows into the combustion chamber 14. During the subsequent upward stroke of the piston 13 the fuel/air mixture is compressed in the combustion chamber 14 and in the region of the top dead center of the piston 13 ignited by the spark plug 20. The subsequent combustion accelerates the piston 13 in the direction toward the crankcase 15. The discharge opening 21 is controlled by the piston 13. As soon as the discharge opening 21 is opened by the piston 13, exhaust gases flow out of the combustion chamber 14, and fresh mixture flows into the combustion chamber 14 by way of the transfer channels 19.
[0075] The two-stroke engine 8 can also be a two-stroke engine operating with stratified scavenging whereby air which purges exhaust gases from the combustion chamber 14 prior to fresh fuel/air mixture flowing out of the crankcase 15 is pre-supplied into the transfer channels 19.
[0076] The rotating parts in the crankcase 15 are lubricated by the fuel/air mixture which is pre-compressed in the interior of the crankcase 15. To this end, two-stroke oil is added to the fuel. During combustion, the two-stroke oil leads to the formation of soot and, depending on the sequence of the combustion, can also migrate from the combustion chamber 14 into the exhaust muffler 23 without being combusted.
[0077] The exhaust muffler 23 can be of any customary configuration. The exhaust muffler 23 can preferably be made of a plurality of metal shells which are connected to one another on an encircling edge 51 (
[0078]
[0079] The catalytic converter 26 is disposed in the flow path between the two muffler chambers 47 and 48. The catalytic converter housing 27 in the embodiment has a multiplicity of inlet openings 29 by way of which exhaust gas enters the interior of the catalytic converter housing 27. The catalytic converter housing 27 has outlet openings 30 by way of which the exhaust gas exits the catalytic converter housing 27. In the embodiment, the exhaust gas from the muffler chamber 47 enters the catalytic converter housing 27 by way of the inlet openings 29, and exits to the second muffler chamber 48 by way of the outlet openings 30. Another arrangement of the catalytic converter 26 in the flow path may also be provided.
[0080] A throughflow body 31 is disposed in the catalytic converter housing 27. The throughflow body 31 has a peripheral surface 38 which is in contact with the catalytic converter housing 27. Advantageously, the entire peripheral surface 38 is in contact with the catalytic converter housing 27.
[0081] The entire exhaust gas advantageously flows through the throughflow body 31. The throughflow body 31 has a first component region 32 and a second component region 33. The component regions 32 and 33 differ in the quantity of catalytically functioning coating in terms of volume of the respective component region 32, 33. The first component region 32 in terms of volume has a larger quantity of catalytically functioning coating than the second component region 33. The thickness of the catalytically functioning coating in the first component region 32 is advantageously larger than in the second component region 33. In a variant of embodiment, the second component region 33 does not have any catalytically functioning coating. The second component region 33 can have a washcoat for enlarging the surface. It can also be provided that the second component region 33 does not have any coating, thus neither a washcoat nor a catalytically functioning coating.
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[0083] The inflow direction 65 is the direction by way of which the exhaust gas flows in through the respective inlet opening 29. The inflow direction 65 is directed so as to be perpendicular to the area of the respective inlet opening 29. Alternatively, it can also be provided that there are identical numbers of inlet openings 29 and of outlet openings 30 but the flow cross sections are dissimilar such that the total flow cross section of all outlet openings is smaller than the total flow cross section of all inlet openings. A dissimilar number of inlet openings and outlet openings in combination with dissimilar flow cross sections of the inlet openings and outlet openings may also be advantageous.
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[0085] The diameter of the wire of the wire bodies 34, 35 or, in the case of a non-round cross section, the largest extent of the wire in the cross section is advantageously from 0.1 mm to 2 mm, in particular from 0.2 mm to 1 mm, preferably from 0.3 mm to 1 mm. The largest extent of the wire in the cross section is particularly preferably at most 0.5 mm. A wire diameter of these orders of magnitude is preferable for the wire bodies.
[0086] Both end faces 36 and 37 in the embodiment are formed completely by the second component region 33. The throughflow body 31 has the peripheral surface 38. The peripheral surface 38 extends from the first end face 36 to the second end face 37. The peripheral surface 38 is advantageously in contact with the catalytic converter housing 27. The throughflow body 31 can preferably be held in the catalytic converter housing 27 by way of the press-fit of the peripheral surface 38 in relation to the catalytic converter housing 27. The peripheral surface 38 in the embodiment is formed completely by the second component region 33. The peripheral surface 38 in the embodiment to the extent of 50% is in each case formed by the two wire bodies 35. In a cross section through the first component region 32 perpendicular to the flow direction 40, the first component region 32 advantageously extends across at least 30%, in particular at least 50%, of the area of the throughflow body 31. The first component region 32, in at least one cross section through the first component region 32 perpendicular to the flow direction 40, advantageously extends across at most 806%, in particular at most 70%, of the area of the throughflow body 31 in this cross section.
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[0088] As is shown in
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[0090] The second component region 33 forms the peripheral surface 38 of the throughflow body 31. The peripheral surface 38 is formed completely by the second component region 33. As is also shown in
[0091] The first end face 36 and the second end face 37 are in each case formed by the first component region 32 as well as by the second component region 33. At least 30%, in particular at least 50%, of the first end face 36 here is advantageously formed by the second component region 33. In an embodiment, it can also be provided that the first component region 32 has a length which is measured in the flow direction 40 and is smaller than the length c of the second component region 33. In this case, the first end face 36 and/or the second end face 37 can be formed completely by the second component region 33.
[0092] The throughflow body 31 can be produced in that the cylindrical first component region 32 is press-fitted into the hollow-cylindrical second component region 33. Alternatively, it can also be provided that the completed and coated first component region 32 is surrounded by a wire body which is uncoated or coated only with a washcoat and which forms the second component region 33. For example, the wire body that forms the second component region 33 can be wound around the first component region 32. The second component region 33 here can be configured with larger dimensions so that the second component region 33 protrudes beyond the first component region 32 and can thus form the first and/or the second end face 36, 37.
[0093] In an alternative embodiment, the throughflow body 31 can be wound. This is schematically illustrated in
[0094] The throughflow body 31 can be formed by at least one mat 62, 63 which is wound. The throughflow body 31 formed by winding is advantageously compression molded after being wound.
[0095] The mats 62 and 63 can have the same thickness. In the embodiment the mat 62 has a thickness d. The mat 63 has a thickness e. The thicknesses d and e are dissimilar in the embodiment. The thickness d in the embodiment is smaller than the thickness e. It can also be provided that the thickness d is greater than the thickness e.
[0096] The at least one first mat 62 has a catalytically functioning coating. Additionally, the at least one first mat 62 can have a washcoat below the catalytically functioning coating. The at least one second mat 63 does not have any catalytically functioning coating, or in terms of volume a smaller quantity of catalytically functioning coating than the at least one first mat 62. The catalytically functioning coating of the second mat 63 can preferably be less than 1 mg/cm.sup.3. The at least one second mat 63 can have a washcoat or no coating for enlarging the surface.
[0097] A first mat 62 and a second mat 63 in the non-wound state are illustrated in
[0098] As a result, the at least one second mat 63 overlaps the at least one first mat 62 on at least one end face 36, 37 of the throughflow body 31. As a result, the at least one second mat 63 can form at least one end face 36 and/or 37 of the throughflow body 31, as is schematically illustrated in
[0099] It can also be provided that the widths g and f are of identical size, and the mats 62 and 63 are wound so as to have an offset in the flow direction 40, thus parallel to the widths f and g. The disposal of such a mat 62′ is illustrated by a dashed line in
[0100] Alternatively, it can also be provided that both mats 62 and 63 have identical widths g and f and are wound without any offset such that both component regions 32 and 33, thus both mats 62 and 63, in the case of a completed throughflow body 31 protrude at both end faces 36 and 37, as is illustrated in the throughflow body 31 in
[0101] In an embodiment, the first component region 32 and the second component region 33 are compact regions. The smallest area that completely encases the first component region 32 advantageously does not include any portions of the second component region 33. Alternatively, it can be provided that the component regions are disposed in an alternating manner in one or a plurality of cross sections, wherein each component region is intersected at least twice in at least one cross section. Exemplary embodiments of this type are shown in
[0102] Provided in the embodiment as per
[0103] In the embodiment as per
[0104] 10, the mats 62 and 63 can have the same width f, g or dissimilar widths f and g and/or be wound so as to have a mutual offset in the flow direction 40.
[0105] The dashed line 66 in
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[0107] The first mat 62 has a thickness d, and the second mat 63 has a thickness e. The thicknesses d and e can be of an identical size. In an advantageous alternative variant of embodiment the thicknesses d and e are of dissimilar sizes.
[0108] The mats 62 and 63 can have dissimilar widths f, g and/or be disposed having a mutual offset in the flow direction 40 also in the embodiment as per
[0109] The illustrations in
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[0112] Both wire bodies 34 and 35 each have a consistent thickness a, b. Both wire bodies 34 and 35 in each case form part of the peripheral surface 38. At least 50%, in particular at least 80%, of the peripheral surface 38 is advantageously formed by the second throughflow body 35.
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[0116] The throughflow body 31 is disposed in the catalytic converter housing 27. The first wire bodies 34 are advantageously connected to the housing 27 by way of heat conducting elements 42. As a result, the heat created by the first wire bodies 34 can at least be partially dissipated into the catalytic converter housing 27, and excessive heating of the first wire bodies 34 is avoided.
[0117] It is provided in
[0118] The four-stroke engine 52 has the combustion chamber 14 which is configured in the cylinder 12 and is delimited by the piston 13. The crankshaft 17 which by the piston 13 is driven so as to rotate about the rotational axis 18 is disposed in the crankcase 15. The intake channel 11 opens into the combustion chamber 14 at a controllable inlet opening 53. An inlet valve 54 which can be actuated for example by way of a control cam or a rocker, in particular as a function of the rotary position of the crankshaft 17, is disposed at the inlet opening 53. A schematically illustrated outlet channel 60, which is likewise controlled by a valve not illustrated, leads out of the combustion chamber 14. The outlet channel 60 opens out at the exhaust inlet 24 of the exhaust muffler 23 (
[0119] In all variants of embodiment the second component region 33 can have no coating, a washcoat or a washcoat and a catalytically functioning coating. The quantity of catalytically functioning coating of the second component region 33 can accordingly be zero or more than zero. The quantity of catalytically functioning coating of the second component region 33 in terms of the volume is smaller than the quantity of catalytically functioning coating of the first component region 32.
[0120] In all exemplary embodiments the volume of the first component region 32 is advantageously 5% to 90%, in particular 5% to 80%, preferably 10% to 20%, of the total volume of the throughflow body 31. The volume of the first component region 32 is particularly advantageously at most 50%, in particular at most 30%, of the total volume of the throughflow body 31. The volume of the second component region 33 is advantageously 10% to 95%, in particular 20% to 95%, preferably 80% to 90%, of the total volume of the throughflow body 31. The volume of the second component region 32 is particularly advantageously at least 50%, in particular at least 70%, of the total volume of the throughflow body 31.
[0121] The embodiments illustrated can be combined with one another in an arbitrary manner so as to form further variants of embodiment according to the disclosure. The catalytic converter housing 27 for all exemplary embodiments can be configured in a manner corresponding to that described in the context of the first embodiment. In all variants of embodiment one wire body or a plurality of wire bodies can be formed by metal meshes or compression molded metal wire. In all exemplary embodiments, one individual body or a plurality of individual bodies can be formed by a metal lattice or a metal body of another structure. It can be provided that the throughflow body 31 is constructed exclusively from wire bodies. Alternatively, it can also be provided that the throughflow body 31, besides one or a plurality of wire bodies, has further individual bodies, in particular of metal, which are not formed from wire. The throughflow body 31 can preferably be constructed from a small number of individual, dimensionally stable individual bodies. The dimensionally stable individual bodies are advantageously press-fitted to one another and thus form a dimensionally stable throughflow body 31. The throughflow body 31 is advantageously formed by at most ten, in particular at most five, individual bodies. The throughflow body 31 particularly preferably has two to four individual bodies. Each individual body preferably forms only part of a single component region of the throughflow body 31. Accordingly, in the context of production accuracy, each individual body of the throughflow body 31 has a uniform catalytically functioning coating. The layer thickness of the catalytically functioning coating is uniform in the context of the production accuracy. Each individual body, in particular each wire body, of the throughflow body 31 is accordingly produced in a uniform manner. Each individual body of the throughflow body 31 is uniformly coated or not coated. This results in a simple production. In an embodiment, the throughflow body 31 is formed by a small number of dimensionally stable wire bodies.
[0122] In the exemplary embodiments the catalytic converter has an approximately rectangular shape or a cylindrical shape. However, another shape of the catalytic converter may also be advantageous. A spherical catalytic converter is in particular considered to be advantageous.
[0123] It is understood that the foregoing description is that of the preferred embodiments of the invention and that various changes and modifications may be made thereto without departing from the spirit and scope of the invention as defined in the appended claims.