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EP0531367A1 - Catalytic converter - Google Patents

Catalytic converter

Info

Publication number
EP0531367A1
EP0531367A1 EP91909918A EP91909918A EP0531367A1 EP 0531367 A1 EP0531367 A1 EP 0531367A1 EP 91909918 A EP91909918 A EP 91909918A EP 91909918 A EP91909918 A EP 91909918A EP 0531367 A1 EP0531367 A1 EP 0531367A1
Authority
EP
European Patent Office
Prior art keywords
protective material
envelope
tags
pad
protective
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP91909918A
Other languages
German (de)
French (fr)
Inventor
John Edward Carson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Unifrax Emission Control Europe Ltd
Original Assignee
Fibre Techniques Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fibre Techniques Ltd filed Critical Fibre Techniques Ltd
Publication of EP0531367A1 publication Critical patent/EP0531367A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
    • F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
    • F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
    • F01N3/2864—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing the mats or gaskets comprising two or more insulation layers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2310/00—Selection of sound absorbing or insulating material
    • F01N2310/02—Mineral wool, e.g. glass wool, rock wool, asbestos or the like
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2350/00—Arrangements for fitting catalyst support or particle filter element in the housing
    • F01N2350/02—Fitting ceramic monoliths in a metallic housing
    • F01N2350/04—Fitting ceramic monoliths in a metallic housing with means compensating thermal expansion

Definitions

  • This invention concerns catalytic converters principally for motor vehicles.
  • Catalytic converters are used for treatment of exhaust gases from motor vehicle engines to render them substantially harmless before emission to atmosphere. Treatment is by passing the exhaust gases through a chamber enclosing as porous ceramic block whose pores are coated with a suitable catalyst.
  • the ceramic block is contained in a chamber formed from two half shells welded together at their edges, the chamber having an inlet and an outlet.
  • the block is wrapped in fibrous material in order to insulate it from colder temperatures outside the converter, to provide sound proofing and to cushion the ceramic block against expansion and contraction of the chamber.
  • a commonly used fibrous material is that sold under the trade name SAFFIL which is 95% alumina and provided as a low density mat.
  • SAFFIL 95% alumina and provided as a low density mat.
  • two pads of fibrous material are used, one being laid in the first half shell and the other on top of the converter block when it has been laid on the first pad of fibrous material. This method -is unsatisfactory in a number of respects. Firstly, the pads do not always meet at the ends leaving unprotected areas of catalytic converter block. Secondly, the fibrous material is pre-cut and its weight adjusted to be within tolerance, but the resultant pad thickness can vary considerably even by a factor of two. That variation in thickness presents problems when putting together a catalytic converter. Proposals have been made in U.K. Patent Applications Nos. 2171180A and 2205929A for methods of wrapping ceramic blocks to facilitate fitting of same catalytic converters.
  • An object of this invention is to provide a way of installing fibrous material about catalytic converter blocks so that the above-mentioned disadvantages are overcome or at least mitigated.
  • fibrous material pads for catalytic converter blocks be provided in a preferably sealed envelope.
  • said envelope preferably has its depth reduced in at least localised areas or positions by drawing together of opposing faces of the envelope.
  • Said drawing together of said envelope faces may be achieved in a variety of ways.
  • plastics tags such as of the type used for affixing labels to clothing and the like may be used, such tags comprising a thin flexible plastics rod with a T-bar at each end. Such tags are usually inserted by a specially designed machine.
  • the opposed faces of the envelope may be stitched or tacked together either by hand or preferably by machine.
  • Tags or stitches may be provided at discrete locations of the envelope, in an ordered pattern or randomly. Stitching or tacking may be provided in separate lines, possibly crossing over each other, or in one continuous line or indeed in any other desirable or convenient formation, particularly from production considerations. The positioning and spacing of tags or stitches may be dependent on the size of the pad of fibrous material.
  • the thickness of an envelope containing fibrous material may be controlled to within a desired range irrespective of the original thickness of the pad of fibrous material contained in the envelope.
  • the envelopes for use in the present invention are preferably made of plastics material and may be conveniently sealed by heat sealing along edges of overlapped sheets or of a folded sheet of suitable plastics material.
  • the plastics material itself should preferably be sufficiently strong to withstand the insertion of tags or stitches, for example without tearing.
  • the plastics material is preferably air permeable so that the pad of fibrous material can be flexed to follow the shape of a catalytic converter half shell and/or block and be compressed by said tags or stitching.
  • Non-woven textile material made from plastics fibres, such as polypropylene fibres, may be particularly suitable for producing envelopes for the invention.
  • Figure 1 shows a pad of fibrous material in an envelope
  • Figure 2 shows a pad of fibrous material in an envelope with a first stitch arrangement
  • Figure 3 shows a pad of fibrous material in an envelope with a second stitch arrangement
  • Figure 4 shows a pad of fibrous material in an envelope with a third stitch arrangement
  • Figure 5 shows, a pad of fibrous material in an envelope with a tag arrangement
  • FIG. 6 shows a pad of fibrous material in an envelope with a fourth stitch arrangement.
  • a pad of fibrous material typically SAFFIL
  • an envelope 10 of non-woven textile material made from polypropylene fibres The envelope is formed by heat sealing together edges of overlaid sheets of the textile material with the pad of SAFFIL therebetween or by heat sealing together edges of a sheet of the textile material folded about a pad of SAFFIL. The heat sealed join is indicated at 12.
  • enveloped pads will be used in a catalytic converter either side of a catalytic converter block for protection and sound proofing.
  • the enveloped pad of Figure 1 is shown treated to reduce its thickness, i.e. by drawing together the opposed larger faces of the envelope. That drawing together is achieved by means of stitching 16 through the envelope.
  • the stitching 16 is shown as a continuous line.
  • the pad of Figure 2 being thinner is easier to install in a catalytic converter and there is less likelihood of edges thereof being trapped between half shell edges to be welded together.
  • stitching 116 is in the form of straight lines in a crossover arrangement.
  • stitching 216 is in the form of discrete parallel lines.
  • tags 316 of the type comprising a rod and T-bar ends are used to draw the envelope faces towards each other to compress the pad of fibrous material therein.
  • the tags 316 are inserted using a special machine and are arranged in an orderly pattern.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Catalysts (AREA)

Abstract

Matière protectrice pour bloc convertisseur catalytique comprenant un tampon de matière fibreuse dans une enveloppe (10); la profondeur de cette dernière est réduite au moins dans des zones ou des positions localisées par rapprochement de faces opposées de l'enveloppe, par exemple par couture (16).A protective material for a catalytic converter block comprising a pad of fibrous material in a casing (10); the depth of the latter is reduced at least in areas or localized positions by bringing opposite faces of the casing together, for example by sewing (16).

Description

Title: Catalytic Converters
DESCRIPTION
This invention concerns catalytic converters principally for motor vehicles. Catalytic converters are used for treatment of exhaust gases from motor vehicle engines to render them substantially harmless before emission to atmosphere. Treatment is by passing the exhaust gases through a chamber enclosing as porous ceramic block whose pores are coated with a suitable catalyst.
The ceramic block is contained in a chamber formed from two half shells welded together at their edges, the chamber having an inlet and an outlet. The block is wrapped in fibrous material in order to insulate it from colder temperatures outside the converter, to provide sound proofing and to cushion the ceramic block against expansion and contraction of the chamber.
A commonly used fibrous material is that sold under the trade name SAFFIL which is 95% alumina and provided as a low density mat. Currently two pads of fibrous material are used, one being laid in the first half shell and the other on top of the converter block when it has been laid on the first pad of fibrous material. This method -is unsatisfactory in a number of respects. Firstly, the pads do not always meet at the ends leaving unprotected areas of catalytic converter block. Secondly, the fibrous material is pre-cut and its weight adjusted to be within tolerance, but the resultant pad thickness can vary considerably even by a factor of two. That variation in thickness presents problems when putting together a catalytic converter. Proposals have been made in U.K. Patent Applications Nos. 2171180A and 2205929A for methods of wrapping ceramic blocks to facilitate fitting of same catalytic converters.
These methods have proved to be acceptable in most areas but the presence of several layers of plastics material around and between layers of the fibrous material is seen as a possible source of contamination of the fibrous material that could impair its effectiveness.
An object of this invention is to provide a way of installing fibrous material about catalytic converter blocks so that the above-mentioned disadvantages are overcome or at least mitigated.
According to the invention it is proposed that fibrous material pads for catalytic converter blocks be provided in a preferably sealed envelope.
It is further proposed that said envelope preferably has its depth reduced in at least localised areas or positions by drawing together of opposing faces of the envelope. Said drawing together of said envelope faces may be achieved in a variety of ways. For example, plastics tags such as of the type used for affixing labels to clothing and the like may be used, such tags comprising a thin flexible plastics rod with a T-bar at each end. Such tags are usually inserted by a specially designed machine. Alternatively, the opposed faces of the envelope may be stitched or tacked together either by hand or preferably by machine.
Tags or stitches may be provided at discrete locations of the envelope, in an ordered pattern or randomly. Stitching or tacking may be provided in separate lines, possibly crossing over each other, or in one continuous line or indeed in any other desirable or convenient formation, particularly from production considerations. The positioning and spacing of tags or stitches may be dependent on the size of the pad of fibrous material.
By selecting the positioning of tags, stitching or tacking and the tension thereof, the thickness of an envelope containing fibrous material may be controlled to within a desired range irrespective of the original thickness of the pad of fibrous material contained in the envelope. The envelopes for use in the present invention are preferably made of plastics material and may be conveniently sealed by heat sealing along edges of overlapped sheets or of a folded sheet of suitable plastics material. The plastics material itself should preferably be sufficiently strong to withstand the insertion of tags or stitches, for example without tearing. In addition, the plastics material is preferably air permeable so that the pad of fibrous material can be flexed to follow the shape of a catalytic converter half shell and/or block and be compressed by said tags or stitching. Non-woven textile material made from plastics fibres, such as polypropylene fibres, may be particularly suitable for producing envelopes for the invention.
The invention will now be further described, by way of example only, with reference to the accompanying drawings, in which:-
Figure 1 shows a pad of fibrous material in an envelope;
Figure 2 shows a pad of fibrous material in an envelope with a first stitch arrangement;
Figure 3 shows a pad of fibrous material in an envelope with a second stitch arrangement; Figure 4 shows a pad of fibrous material in an envelope with a third stitch arrangement; Figure 5 shows, a pad of fibrous material in an envelope with a tag arrangement; and
Figure 6 shows a pad of fibrous material in an envelope with a fourth stitch arrangement. Referring to Figure 1 of the accompanying drawings, a pad of fibrous material, typically SAFFIL, is enclosed in an envelope 10 of non-woven textile material made from polypropylene fibres. The envelope is formed by heat sealing together edges of overlaid sheets of the textile material with the pad of SAFFIL therebetween or by heat sealing together edges of a sheet of the textile material folded about a pad of SAFFIL. The heat sealed join is indicated at 12.
Thus such enveloped pads will be used in a catalytic converter either side of a catalytic converter block for protection and sound proofing.
Turning to Figure 2 of the accompanying drawings, the enveloped pad of Figure 1 is shown treated to reduce its thickness, i.e. by drawing together the opposed larger faces of the envelope. That drawing together is achieved by means of stitching 16 through the envelope. The stitching 16 is shown as a continuous line.
The pad of Figure 2 being thinner is easier to install in a catalytic converter and there is less likelihood of edges thereof being trapped between half shell edges to be welded together.
In Figure 3 of the accompanying drawings stitching 116 is in the form of straight lines in a crossover arrangement. In Figure 4 stitching 216 is in the form of discrete parallel lines.
In Figure 5 plastics tags 316 of the type comprising a rod and T-bar ends (often used in affixing labels to clothing) are used to draw the envelope faces towards each other to compress the pad of fibrous material therein. The tags 316 are inserted using a special machine and are arranged in an orderly pattern.
Finally in Figure 6 discrete stitches 416 are used arranged randomly.

Claims

1. Protective material for a catalytic converter block comprising a pad of fibrous material in an envelope, wherein said envelope has its depth reduced in at least localised areas or positions by drawing together of opposing faces of said envelope.
2. Protective material as claimed in claim 1 , wherein said opposing envelope faces are drawn together by means of tags therethrough.
3. Protective material as claimed in claim 2, wherein said tags comprise a thin rod with a T-bar at each end.
4. Protective material as claimed in claim 1, wherein said opposing envelope faces are drawn together by means of stitching.
5. Protective material as claimed in claim 2, 3 or 4 , wherein said tags or said stitches are provided at discrete locations of the envelope.
6. Protective material as claimed in claim 5, wherein said tags or said stitches are arranged randomly.
7. Protective material as claimed in claim 5, wherein said tags or said stitches are arranged in an orderly pattern.
8. Protective material as claimed in claim 4, wherein said stitching is provided in separate lines.
9. Protective material as claimed in claim 8, wherein said lines cross over each other.
10. Protective material as claimed in claim 4, wherein said stitching is provided in a continuous line.
11. Protective material as claimed in any one of claims 1 to 10, wherein the envelope is of plastics material.
12. Protective material as claimed in claim 11, wherein the envelope is sealed.
13. Protective material as claimed in claim 12, wherein the envelope is formed by heat sealing together overlapping edges of plastics sheet material.
14. Protective material as claimed in any one of claims 1 to 13, wherein the envelope is of air permeable material.
15. Protective material as claimed in claim 14, wherein the air permeable material is a non-woven textile material.
16. Protective material as claimed in claim 15, wherein the non-woven textile material of plastics fibres.
17. Protective material as claimed in claim 16, wherein said plastics fibres are of polypropylene.
18. Protective material as claimed in any one of claims 1 to 17, wherein the fibrous pad is of alumina.
19. Protective material for a catalytic converter block substantially as hereinbefore described with reference to and as illustrated in any one of Figures 2 to 6 of the accompanying drawings.
EP91909918A 1990-05-26 1991-05-16 Catalytic converter Withdrawn EP0531367A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB909011858A GB9011858D0 (en) 1990-05-26 1990-05-26 Catalytic converters
GB9011858 1990-05-26

Publications (1)

Publication Number Publication Date
EP0531367A1 true EP0531367A1 (en) 1993-03-17

Family

ID=10676648

Family Applications (1)

Application Number Title Priority Date Filing Date
EP91909918A Withdrawn EP0531367A1 (en) 1990-05-26 1991-05-16 Catalytic converter

Country Status (5)

Country Link
EP (1) EP0531367A1 (en)
JP (1) JPH05509372A (en)
GB (1) GB9011858D0 (en)
WO (1) WO1991019082A1 (en)
ZA (1) ZA913990B (en)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB9723148D0 (en) 1997-11-04 1998-01-07 Eurotex Thermal Engineering Li Sound muffling material and method of making thereof
JP2002532650A (en) 1998-12-16 2002-10-02 アスグラヴォー・ゲゼルシャフト・ミト・ベシュレンクテル・ハフツング・シュトッフェ・ツム・デメン・ウント・フェアシュテルケン Support mat for supporting exhaust gas catalyst
FR2925579A1 (en) * 2007-12-21 2009-06-26 Faurecia Sys Echappement Exhaust element e.g. catalyst, for e.g. petrol engine of motor vehicle, has web comprising layers containing respective fibers, where part of fibers in one of layers cooperates with material of another layer and forms assembling unit
JP2010101308A (en) * 2008-09-25 2010-05-06 Ibiden Co Ltd Mat product, method of manufacturing the mat product, exhaust gas treating apparatus, and muffler apparatus
WO2011047001A1 (en) * 2009-10-13 2011-04-21 3M Innovative Properties Company Non-woven mat and pollution control device with the same

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2520914A (en) * 1946-02-01 1950-09-05 Johns Manville Insulating material
JPS5817335B2 (en) * 1975-04-10 1983-04-06 トヨタ自動車株式会社 Method for manufacturing integrated catalyst component for exhaust gas purification
US4460645A (en) * 1979-02-21 1984-07-17 University College Cardiff Insulation
GB8504239D0 (en) * 1985-02-19 1985-03-20 W F J Refractories Ltd Use of fibrous materials
US4929429A (en) * 1988-02-11 1990-05-29 Minnesota Mining And Manufacturing Company Catalytic converter

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO9119082A1 *

Also Published As

Publication number Publication date
WO1991019082A1 (en) 1991-12-12
JPH05509372A (en) 1993-12-22
ZA913990B (en) 1992-05-27
GB9011858D0 (en) 1990-07-18

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