MULTI-PASS CATALYTIC CONVERTER
20230055120 · 2023-02-23
Assignee
Inventors
- Michael Willcox (Redwood City, CA, US)
- Simon Jackson (Redwood City, CA, US)
- Brede Kolsrud (San Mateo, CA, US)
Cpc classification
F01N2260/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N13/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2470/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/2006
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2470/24
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/2803
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/2892
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T10/12
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
Abstract
A multi-pass catalytic converter can divide a catalyst block into several catalytic volumes and enable the exhaust gas to flow through each volume in two or more passes consecutively. As the exhaust gas in an early pass can emit sensible thermal energy and chemical reaction energy to preheat the remaining catalytic volumes via conductive heat transfer, it can shorten the catalyst light-off time for the later passes and the whole catalyst block. By recouping the previously lost dissipating heat from the early catalytic volume, the present disclosure can significantly reduce the catalyst light-off time and emission concentration. Furthermore, one or more mixing chambers can be utilized to thoroughly mix the exhaust gas.
Claims
1. A multi-pass catalytic converter for treating exhaust gas of an internal combustion engine, comprising: an elongated converter housing having an upstream terminal and a downstream terminal; a catalyst block disposed in the elongated converter housing, the catalyst block having a first diameter; and an inlet pipe being substantially in close contact with a surface of an inner catalytic volume of the catalyst block, the inlet pipe having a second diameter that is smaller than the first diameter, wherein the multi-pass catalytic converter is configured to: enable the exhaust gas to enter the catalyst block via the inlet pipe at the upstream terminal; enable, in a first pass, the exhaust gas to flow through and react with the inner catalytic volume of the catalyst block; and enable, in a second pass, the exhaust gas to revert, flow through, and react with an outer catalytic volume of the catalyst block, the outer catalytic volume being disposed between the inner catalytic volume and the elongated converter housing.
2. The multi-pass catalytic converter of claim 1, wherein, in the first pass, thermal sensible energy from the exhaust gas and chemical reaction energy from conversion reactions in the inner catalytic volume are utilized to increase the temperature of the outer catalytic volume.
3. The multi-pass catalytic converter of claim 2, wherein the outer catalytic volume emits heat to maintain an internal temperature of the inner catalytic volume.
4. The multi-pass catalytic converter of claim 1, wherein the multi-pass catalytic converter is configured to further mix the exhaust gas using one or more mixing chambers before and/or after the inner and outer catalytic volumes to improve the conversion efficiency of the catalytic converter.
5. The multi-pass catalytic converter of claim 1, wherein the inner catalytic volume is disposed along a center axis of the elongated converter housing, and wherein the outer catalytic volume is disposed between the inner catalytic volume of the catalyst block and the elongated converter housing.
6. The multi-pass catalytic converter of claim 1, wherein the multi-pass catalytic converter is further configured to: enable the exhaust gas to exit the elongated converter housing via an outlet pipe at the downstream terminal.
7. The multi-pass catalytic converter of claim 1, further comprising: a mixing chamber disposed at the downstream terminal of the elongated converter housing, the mixing chamber configured to revert and mix the exhaust gas after the first pass.
8. The multi-pass catalytic converter of claim 1, wherein the inner catalytic volume and the outer catalytic volume each has different material specifications.
9. The multi-pass catalytic convert of claim 1, wherein the first pass is in a first flow direction and the second pass is in a second flow direction that is opposite to the first flow direction.
10. A multi-pass catalytic converter for treating exhaust gas, comprising: an elongated converter housing having an upstream terminal and a downstream terminal; a catalyst block disposed in the elongated converter housing, the catalyst block comprising a first catalytic volume, a second catalytic volume, and a third catalytic volume; and an inlet pipe being substantially in close contact with a surface of the first catalytic volume, wherein the multi-pass catalytic converter is configured to: enable exhaust gas to enter the catalyst block via the inlet pipe at the upstream terminal; enable, in a first pass, the exhaust gas to flow through and react with the first catalytic volume; enable, in a second pass, the exhaust gas to revert, flow through, and react with the second catalytic volume; and enable, in a third pass, the exhaust gas to revert, flow through, and react with the third catalytic volume of the catalyst block.
11. The multi-pass catalytic converter of claim 10, wherein sensible thermal energy and chemical reaction energy released in the first catalytic volume are utilized to preheat at least one of the second catalytic volume and the third catalytic volume.
12. The multi-pass catalytic converter of claim 10, wherein the multi-pass catalytic converter is further configured to: enable the exhaust gas to exit the elongated converter housing via an outlet pipe.
13. The multi-pass catalytic convert of claim 10, wherein the first pass and the third pass are in a first flow direction, and the second pass is in a second flow direction that is opposite to the first flow direction.
14. The multi-pass catalytic converter of claim 10, further comprising: one or more mixing chambers before and/or after the first catalytic volume, the second catalytic volume and the third catalytic volume, the one or more mixing chambers configured to revert and mix the exhaust gas.
15. The multi-pass catalytic converter of claim 10, wherein the first catalytic volume is disposed along a center axis of the elongated converter housing, and the second catalytic volume is sandwiched between the first catalytic volume and the third catalytic volume.
16. A method of thermal management in a multi-pass catalytic converter, comprising: dividing a catalyst block into a plurality of catalytic volumes, the plurality of catalytic volumes comprises at least one early catalytic volume and at least one late catalytic volume; and enabling exhaust gas to flow through the at least one early catalytic volume and the at least one late catalytic volume respectively, wherein thermal energy released in the at least one early catalytic volume can preheat the at least one late catalytic volume to reduce its light-off time.
17. The method of thermal management of claim 16, wherein the thermal energy released by the exhaust gas comprises thermal sensible energy of the exhaust gas and the chemical reaction energy in the at least one early catalytic volume.
18. The method of thermal management of claim 16, further comprising: enabling the exhaust gas to be thoroughly mixed via one or more mixing chambers.
Description
DESCRIPTION OF DRAWINGS
[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
[0030]
DETAILED DESCRIPTION
[0031] Various embodiments of the present technology are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without departing from the spirit and scope of the present technology.
[0032]
[0033] As shown in
[0034]
[0035] As shown in
[0036]
[0037] According to some embodiments, a heat shield (not shown) can cover all or part of the elongated converter housing 302. The heat shield can prevent undesired thermal loss of the catalyst and protect nearby components from overheating.
[0038] As shown in
[0039] According to some embodiments, the inlet pipe 304 can be placed along a center axis of the catalyst block 301. Accordingly, an inner catalytic volume 306 of the catalyst block is disposed along the center axis of the catalyst block 301. The inner catalytic volume 306 can form a first pathway for the first pass of the exhaust gas, allowing the gas to flow from the upstream terminal to the downstream terminal.
[0040] During the first pass of the exhaust gas, the sensible thermal energy from the combustion can warm up the catalyst in the inner catalytic volume 306 gradually and active the catalytic converter as shown below, as examples:
CxHy+O2.fwdarw.CO2+H2O (1)
2CO+O2.fwdarw.CO2 (2)
[0041] Both reactions (1) and (2) are oxidation reactions that release chemical reaction energy. As a result, the exhaust gas can increase in temperature as the reactions proceed. As a result, the combined thermal energy and the newly-released chemical reaction energy can gradually increase the catalyst temperature of the inner catalytic volume 306.
[0042] Furthermore, thorough conductive heat transfer, the combined sensible and chemical reaction heat from the inner catalytic volume 306 can radiate thermal energy into areas next to it and increase those areas' temperature. As shown in
[0043] According to some embodiments, the catalyst core can adopt a ceramic monolith with a honeycomb structure. According to some embodiments, the catalyst core can be a metallic foil monolith. As the exhaust gas flow through the honeycomb structure of the catalyst support/core in the early pass, the unevenly distributed hydrocarbons, e.g., the early HC or the late HC during an exhaust stroke, can get blended evenly for the later passes, which improves the catalyst's efficiency.
[0044] According to some embodiments, a mixing chamber 308 can be disposed at the terminal side or downstream terminal of the inner catalytic volume 306. The optional mixing chamber 308 can take a geometry that is sized to encourage the blending of the exhausted gas. The size of the mixing chamber 308 can be smaller, equal, or larger than the volume needed to support one trapped-mass worth of exhaust. According to some embodiments, the size of the mixing chamber 308 can be larger than the cylinder displacement volume because the hot exhaust gas expands in volume.
[0045] According to some embodiments, the mixing chamber 308 can be shaped to enable a complete 180-degree turn or U-turn of the exhaust gas after the first pass. For example, as shown in
[0046] After the exhaust reverts within the mixing chamber 308, it can enter the preheated outer catalytic volumes 310 for more catalytic reactions in a second pass. The outer catalytic volumes 310, as shown in
[0047] According to embodiments, instead of first entering the catalyst block 301 via the center, the exhaust gas can enter the block via the outside diameter, or the outer catalytic volumes 310, in the first pass. After taking a U-turn close to the downstream terminal, the exhaust gas can return to the second pass via the inner catalytic volume 306.
[0048] According to some embodiments, the catalyst block 301 can be a homogenous catalyst that contains the same type and density of catalyst support or core, washcoat, and precious catalyst metals. According to some embodiments, the divided catalytic volumes, e.g., 306 and 310, can respectively adopt suitable specifications in catalyst support, washcoat and catalyst to maximize the preferred mixing and heating effects.
[0049] For example, the first air pathway and reaction channel, e.g., the inner catalytic volume 306, can adopt a more porous catalyst support, e.g., a permeable ceramic monolith, to facilitate the flow of the exhaust gas with less net backpressure. For example, the inner catalytic volume 305 in the first pass can be 200 CPSI (cell per square inch). In contrast, the outer catalytic volume or later catalytic volumes in the later passes can be 300 CPSI.
[0050] Similarly, different types and density of precious catalyst metals can be utilized in different catalytic volumes or chambers. For example, the later catalytic volumes can utilize higher density precious metal catalysts, e.g., Pt or Pd, than an early volume to obtain optimized catalyst efficiency.
[0051] According to some embodiments, the exhaust gas, after the duel-pass conversion, can exit the converter housing via an outlet pipe 312. The outlet pipe 312, as a part of the exhaust system, can connect to a muffler assembly (not shown).
[0052] According to some embodiments, a mixing chamber (not shown) can be disposed closed to the upstream terminal so that the exhaust gas can be mixed before entering the inner catalytic volume 306.
[0053] The present disclosure can apply to both a two-way catalyst and a three-way catalyst, or any after-treatment systems that utilize the catalytic reaction mechanisms. For example, in a three-way catalyst, a first pass of the exhaust gas can be through an Rd catalyst for NOx removal, and later passes can be through a Pd/Pt catalyst for CO and HC removal.
[0054]
[0055] According to some embodiments, a heat shield (not shown) can cover all or part of the elongated converter housing 402. The heat shield can prevent undesired thermal loss of the catalyst and protect nearby components from overheating.
[0056] According to some embodiments, the catalytic block 401 can be divided into three catalytic volumes: a first catalytic volume 406 (A1) with a first diameter D1, can be disposed along a center axis of the catalyst block 401; a second catalytic volume 410 (A2) with a second diameter D2, can be sandwiched between the first catalytic volume 401 (A1) and a third catalytic volume 414 (A3), which is associated with an outside diameter D3 of catalyst block 410.
[0057] According to some embodiments, flow areas are maintained, for example, such that:
D12=Amult_1*(D22−D12)=Amult2*(D32−D22) (3)
[0058] Where D1 is the diameter of A1, D2 is outside diameter (OD) of A2, and D3 is outside diameter (OD) of catalyst block 410, and Amult_1 and Amult_2 are area multipliers to allow higher/lower flow velocity between each section.
[0059] As shown in
[0060] According to some embodiments, one or more mixing chambers can facilitate the reversions of the exhaust gas. As shown in
[0061] After the reversion within the first mixing chamber 408, the exhaust gas can enter the preheated second catalytic volumes 410 for more catalytic reactions in a second pass. According to some embodiments, the exhaust gas, after the first pass, can be hotter than before. As the catalyst in the second catalytic volumes 410 and the reactants are hotter, the reaction rate within the second catalytic volumes 410 can be substantially higher. Similarly, the thermal energy emitted in the second catalytic volumes 410 can preheat the third catalytic volumes 414 before gas passage. On the other hand, this thermal energy can keep the first catalytic volume 406 warm in return.
[0062] As shown in
[0063] After the second reversion within the second mixing chamber 412, the exhaust gas can enter the preheated third catalytic volumes 414 for more catalytic reactions. After exiting the third catalytic volumes 414, the exhaust gas can exit the converter via an outlet pipe 416.
[0064] According to some embodiments, the catalyst block 401 can be a homogenous catalyst that contains the same type and density of materials. According to some embodiments, the divided catalytic volumes, e.g., 406, 410, and 414, can individually adopt its respective material specifications in catalyst support, washcoat, and catalyst to maximize the said mixing and heating effects.
[0065] For example, the first air pathway and reaction channel, e.g., the first catalytic volume 406, can adopt a porous catalyst support to reduce net backpressure. For example, the first catalytic volume 406 can be 200 CPSI (cell per square inch), whereas the second or third catalytic volume can be 300 CPSI.
[0066] Similarly, different types and density of precious catalyst metals can be utilized in different catalytic volumes or regions. For example, the later catalytic volumes can utilize higher density precious metal catalysts, e.g., Pt or Pd, than an early catalytic volume as the conversion efficiency is higher in the later passes.
[0067] According to some embodiments, the multi-pass catalytic converter can be more than three passes. e.g., four or more passes, as long as it maintains the benefits without excessive side effects, e. g., overheating of the catalyst or weak pressure of the exhaust gas. Furthermore, the multi-pass catalytic converter can adopt an incomplete half pass, e.g., or two and a half pass, if needed.
[0068] In addition, the present disclosure can apply to both a two-way catalyst and a three-way catalyst, or any after-treatment systems of similar mechanisms.
[0069]
[0070] At step 502, the dual-pass catalytic converter can enable the exhaust gas to enter the catalyst block via an inlet pipe. According to some embodiments, the inlet pipe can be substantially in close contact with a surface of the inner catalytic volume so that the exhaust gas can flow through the catalyst block via an air path defined by the shape and size of the inlet pipe.
[0071] According to some embodiments, the inlet pipe can be disposed along a center axis of the catalyst block. Accordingly, an inner catalytic volume of the catalyst block is disposed along the center axis of the catalyst block. The inner catalytic volume can form a first pathway for the first pass of the exhaust gas, allowing the gas to flow from an upstream terminal to a downstream terminal of the converter.
[0072] At step 504, the dual-pass catalytic converter is configured to enable, in a first pass, the exhaust gas to flow through and react with the inner catalytic volume. According to some embodiments, the combined sensible thermal energy and the chemical reaction energy released in the first pass can preheat the outer catalytic volume so that its light-off time can be reduced.
[0073] According to some embodiments, the dual-pass catalytic convert can further comprise a mixing chamber at the terminal side of the inner catalytic volume. The mixing chamber can facilitate a 180-degree turn or U-turn of the exhaust gas after the first pass. According to some embodiments, the mixing chamber can have an additional catalyst coating to maximize catalytic conversion.
[0074] At step 506, the dual-pass catalytic converter can enable, in a second pass, the exhaust gas to revert, flow through, and react with the outer catalytic volume. According to some embodiments, the outer catalytic volume can be disposed between the inner catalytic volume and the inner wall of the elongated converter housing. According to some embodiments, after being heated up in the first pass, the exhaust gas entering the second pass can be hotter before. As the catalyst in the outer catalytic volume has been preheated, and the exhaust gas is hotter, the reaction temperature and rate of the outer catalytic volume can be substantially higher. This can result in improved efficiency of the catalyst block. Furthermore, due to the bi-directional conductive heat dissipation, the heat accumulated in the second pass can keep the inner catalytic volume warm in return.
[0075] According to embodiments, instead of first entering the catalyst block at the center, the exhaust gas can enter the block via the outer catalytic volume in the first pass. After taking a U-turn close to the downstream terminal, the exhaust gas can return to the second pass via the inner catalytic volume.
[0076] At step 508, the dual-pass catalytic converter can enable the exhaust gas to exit the converter housing and enter, for example, a muffler assembly.
[0077]
[0078] At step 604, the method further comprises enabling exhaust gas to first flow through the at least one early catalytic volume and consecutively flow through the at least one late catalytic volume. During the early pass, through conductive heat transfer, the thermal energy in the at least one early catalytic volume can increase the temperature of the at least one late catalytic volume. As a result, the at least one late catalytic volume can get preheated or even reach its catalyst light-off temperature before the gas passage.
[0079] Furthermore, according to some embodiments, one or more mixing chambers can be adapted to facilitate the one or more reversion of the exhaust gas. The shape and size of the mixing chamber are configured to maximize the reversion of the exhaust gas without excessive pressure loss.
[0080] At step 606, the method further comprises enabling the exhaust gas to exit the converter housing via an outlet pipe connecting to a muffler assembly.
[0081]
[0082] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. For example, other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Accordingly, other implementations are within the scope of the following claims.
[0083] Although a variety of examples and other information was used to explain aspects within the scope of the appended claims, no limitation of the claims should be implied based on particular features or arrangements in such examples, as one of ordinary skill would be able to use these examples to derive a wide variety of implementations. The described features and steps are disclosed as examples of components of systems and methods within the scope of the appended claims.