U.S. patent application number 12/720363 was filed with the patent office on 2010-09-16 for combination liquid-cooled exhaust manifold assembly and catalytic converter assembly for a marine engine.
This patent application is currently assigned to INDMAR PRODUCTS COMPANY INC.. Invention is credited to Joerg Berger, Travis Stevens, Richard J. Waggoner.
Application Number | 20100229540 12/720363 |
Document ID | / |
Family ID | 42729566 |
Filed Date | 2010-09-16 |
United States Patent
Application |
20100229540 |
Kind Code |
A1 |
Waggoner; Richard J. ; et
al. |
September 16, 2010 |
Combination Liquid-Cooled Exhaust Manifold Assembly And Catalytic
Converter Assembly For A Marine Engine
Abstract
An exhaust system for a marine engine comprising liquid cooled
manifold and catalytic converter assemblies. Each assembly uses a
separate cooling system to cool either the exhaust manifold or a
shell inside which resides the catalytic converter. The housing or
shell containing the catalytic converter uses water to cool an
exterior surface of a water jacket to an acceptable temperature
conforming to federal regulations. The liquid-cooled manifold
assembly may use either water or glycol to cool a jacket
surrounding tubes extending from the engine block to the catalytic
converter assembly.
Inventors: |
Waggoner; Richard J.; (Punta
Gorda, FL) ; Berger; Joerg; (Ann Arbor, MI) ;
Stevens; Travis; (Jackson, MI) |
Correspondence
Address: |
WOOD, HERRON & EVANS, LLP
2700 CAREW TOWER, 441 VINE STREET
CINCINNATI
OH
45202
US
|
Assignee: |
INDMAR PRODUCTS COMPANY
INC.
Millington
TN
|
Family ID: |
42729566 |
Appl. No.: |
12/720363 |
Filed: |
March 9, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61209772 |
Mar 11, 2009 |
|
|
|
Current U.S.
Class: |
60/298 |
Current CPC
Class: |
Y02T 10/12 20130101;
F01N 2260/024 20130101; Y02T 10/20 20130101; F01N 3/046 20130101;
F01N 3/10 20130101 |
Class at
Publication: |
60/298 |
International
Class: |
F01N 3/10 20060101
F01N003/10; F01N 13/10 20100101 F01N013/10 |
Claims
1. An exhaust system for a marine engine, comprising: a combination
of a liquid-cooled exhaust manifold assembly and a liquid-cooled
catalytic converter assembly, which liquid-cooled exhaust manifold
assembly comprises a manifold jacket surrounding tubular exhaust
runners extending from cylinders of the marine engine to the
catalytic converter assembly, liquid being supplied to and from the
manifold jacket to cool the outside surface of the manifold jacket
to maintain the outside temperature of the manifold jacket below a
predetermined temperature, and liquid being supplied to and from a
fluid passage surrounding a catalytic converter housing to cool and
maintain the outside surface of the catalytic converter assembly
below a predetermined temperature.
2. The system of claim 1 wherein said manifold jacket is made of
sheet metal.
3. The system of claim 1 wherein said manifold jacket is shaped
like a clam shell.
4. The system of claim 1 wherein said manifold jacket is made from
multiple pieces welded together.
5. The system of claim 1 wherein each of the tubular exhaust
runners is approximately the same length.
6. The system of claim 1 wherein the liquid being supplied to and
from the housing to cool the outside surface of the manifold is
water.
7. The system of claim 1 wherein the liquid being supplied to and
from the housing to cool the outside surface of the manifold is
glycol.
8. An exhaust system for a marine engine, comprising: a
liquid-cooled catalytic converter assembly including a catalytic
converter fixed inside an inner shell and an outer shell
surrounding the inner shell, the inner and outer shells defining a
fluid passage therebetween, the outer shell being joined to the
inner shell proximate an inlet end of the catalytic converter
assembly, wherein the outer shell has a fluid inlet in fluid
communication with the fluid passage to introduce fluid into the
fluid passage to cool and maintain the outside surface of the
catalytic converter assembly below a predetermined temperature when
liquid passes through the fluid passage; and a liquid-cooled
exhaust manifold assembly comprising a plurality of tube stubs
welded to a mounting plate, a baffle, and a plurality of tubular
exhaust runners welded to the baffle and the mounting plate and
extending therebetween, said exhaust manifold assembly further
comprising a manifold jacket surrounding the tubular exhaust
runners and being welded to the baffle and the tube stubs, said
manifold jacket having an inlet for introducing fluid inside said
manifold jacket and an outlet for removing fluid from the manifold
jacket to cool the outside surface of the manifold jacket to
maintain the outside temperature of the manifold jacket below a
predetermined temperature.
9. The system of claim 8 wherein said manifold jacket is made from
sheet metal.
10. The system of claim 9 wherein said manifold jacket is shaped
like a clam shell.
11. The system of claim 8 wherein said manifold jacket is made from
multiple parts.
12. The system of claim 8 wherein said catalytic converter assembly
has bosses adapted to receive oxygen sensors.
13. The system of claim 8 wherein said exhaust manifold assembly
has four tubular exhaust runners.
14. The system of claim 8 wherein said tubular exhaust runners of
said exhaust manifold assembly are welded to stubs welded to said
mounting plate of said exhaust manifold assembly.
15. An exhaust system for a marine engine, comprising: a
liquid-cooled catalytic converter assembly including a catalytic
converter, an inner shell and an outer shell surrounding the inner
shell, the inner and outer shells defining a fluid passageway
therebetween, wherein the outer shell has a fluid inlet in fluid
communication with the fluid passage to introduce fluid into the
fluid passage to cool and maintain the outside surface of the
catalytic converter assembly below a predetermined temperature when
liquid passes through the fluid passage; and a liquid-cooled
exhaust manifold assembly comprising a mounting plate for securing
the exhaust system to the marine engine, a plurality of tube stubs
welded to the mounting plate, a baffle, and a plurality of exhaust
runners, each of said exhaust runners being welded to the mounting
plate at one end and to the baffle at the other end, said baffle
being welded to the catalytic converter assembly, said manifold
assembly further comprising a manifold jacket comprising upper and
lower half shells welded together and surrounding the exhaust
runners, said manifold jacket having an inlet for introducing fluid
inside a fluid cavity defined by said manifold jacket, said baffle
and said tube stubs and an outlet for removing fluid from the
manifold jacket to cool the outside surface of the manifold jacket
to maintain the outside temperature of the manifold jacket below a
predetermined temperature.
16. The system of claim 15 wherein said manifold jacket is made
from multiple pieces of sheet metal.
17. The system of claim 15 wherein said catalytic converter
assembly has bosses adapted to receive oxygen sensors.
18. The system of claim 15 wherein said exhaust manifold assembly
has four tubular exhaust runners.
19. The system of claim 15 wherein said exhaust runners of said
exhaust manifold assembly are tubular.
20. The system of claim 15 wherein each of the exhaust runners is
approximately the same length.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing of U.S.
provisional Patent Application. Ser. No. 61/209,772, filed Mar. 11,
2009 entitled "Combination Liquid-Cooled Exhaust and Catalytic
Converter For a Marine Engine" which is fully incorporated
herein.
FIELD OF THE INVENTION
[0002] The present invention relates to exhaust systems for
combustion engines and, more particularly, to the exhaust manifold
and catalytic converter of such exhaust systems.
BACKGROUND OF THE INVENTION
[0003] Exhaust systems for a combustion engine generally include a
manifold connected to the combustion engine at one end and bolted
to an exhaust pipe at the other end. The exhaust pipe extends a
distance from the manifold and generally has a catalytic converter
system bolted thereto. These catalytic converter systems generally
include a ceramic substrate having a catalyst coated thereon and a
metal housing surrounding the substrate. In general, the catalysts
require a minimum temperature to react with the emissions and
reduce them. Higher reaction temperatures enhance the removal of
harmful emissions from the exhaust gases. The core temperature of
conventional catalytic converters is typically 1,000 to 1,400
degrees Fahrenheit. In automobile applications, the exterior
surfaces of the catalytic converters are air cooled, rather than
water cooled, to a temperature of about 600 to 1,000 degrees
Fahrenheit. Such high temperature far exceeds the 200 degrees
Fahrenheit set by the United States Coast Guard for the exterior
temperature of the exhaust system of inboard or stern drive
engines.
[0004] Although catalytic converters have been required in cars for
many years, they have not been required in marine vessels with
inboard or stern drive engines. However, in 2009, catalytic
converters began being required by federal law in new marine
vessels with inboard or stern drive engines. This requirement is
challenging because it has been difficult to maintain a
sufficiently cooled exterior temperature for marine applications
while also maintaining a sufficiently high enough temperature in
the element or core of the catalytic converter. The United States
Coast Guard has a limit of 200 degrees Fahrenheit for the exterior
temperature of the exhaust system of inboard or stern drive
engines. The United States Environmental Protection Agency
("USEPA") has emissions standards which require use of a catalytic
converter in inboard or stern drive engines.
[0005] One known method of reducing the exterior temperature of the
housing in which resides a catalytic converter for a marine vessel
is to water cool the housing. This concept is disclosed in U.S.
Patent Publication No. US 2009/0175772, published Jul. 9, 2009.
[0006] However, there is a need to maintain all exposed surfaces
below the 200 degrees Fahrenheit limit by surrounding the exhaust
manifold with liquid to cool the tubes containing the exhaust prior
to these exhaust gases entering a liquid cooled catalytic
converter.
SUMMARY OF THE INVENTION
[0007] According to embodiments of the present invention, an
exhaust system for a marine engine comprises the combination of a
liquid-cooled exhaust manifold assembly and a liquid-cooled
catalytic converter assembly. The exhaust manifold comprises
individual tubular exhaust runners extending from each cylinder of
a marine engine to the catalytic converter assembly. These tubular
exhaust runners are the same length, but twisted, optimized in size
and shape, to give optimal engine performance. The catalytic
converter assembly, located downstream of the liquid-cooled exhaust
manifold assembly, functions to control engine exhaust emissions
exiting the liquid-cooled exhaust manifold assembly.
[0008] The exhaust manifold assembly further comprises a manifold
jacket surrounding the tubular exhaust runners. In one embodiment,
the manifold jacket is made of two pieces of sheet metal, the
manifold jackets being shaped like a clam shell. Liquid in the form
of water or glycol is circulated from a first pump through this
manifold jacket so as to always maintain the outside temperature of
the manifold jacket at less than 200.degree. F. whenever the engine
to which the manifold is connected is operated.
[0009] In one embodiment, the manifold jacket surrounding the
tubular runners of the manifold assembly is made from two shaped
sheet metal panels which are welded together and welded to stubs
welded to a mounting plate and a sheet metal baffle. Ports or
bosses on the manifold assembly are provided for the in-flow and
out-flow of water or glycol through the manifold assembly.
Similarly, an inlet port is provided for supplying cooling water to
fluid passage surrounding a catalytic converter housing to cool and
maintain the outside surface of the catalytic converter assembly
below a predetermined temperature. This water passage surrounding
the catalytic converter discharges the water into the exhaust gases
at the discharge end of the catalytic converter assembly.
[0010] Water from a second pump is also circulated through a fluid
passage surrounding the catalytic converter housing so that the
catalytic converter is always water-cooled and the outside
temperature of the converter assembly maintained at a temperature
of less than 200.degree. Fahrenheit when the engine is operated.
From the exhaust or downstream side of the catalytic converter
assembly, the water from the fluid passage flows around the
catalytic converter assembly inner shell and is mixed with exhaust
gases to be discharged with the exhaust gases after the gases have
passed through the catalytic converter.
[0011] According to another aspect of the present invention, the
exhaust system for a marine engine comprises: a liquid-cooled
catalytic converter assembly including a catalytic converter fixed
inside an inner shell and an outer shell surrounding the inner
shell, the inner and outer shells defining a fluid passage
therebetween. The outer shell is joined to the inner shell
proximate an inlet end of the catalytic converter assembly. The
outer shell has a fluid inlet in fluid communication with the fluid
passage to introduce fluid into the fluid passage to cool and
maintain the outside surface of the catalytic converter assembly
below a predetermined temperature when liquid passes through the
fluid passage.
[0012] The liquid-cooled exhaust manifold assembly comprises a
plurality of tube stubs welded to a mounting plate, a baffle and a
plurality of tubular exhaust runners secured to the baffle and the
mounting plate and extending therebetween. The exhaust manifold
assembly further comprises a manifold jacket surrounding the
tubular exhaust runners, the manifold jacket having an inlet for
introducing fluid inside the manifold jacket and an outlet for
removing fluid from the manifold jacket to cool the outside surface
of the manifold jacket to maintain the outside temperature of the
manifold jacket below a predetermined temperature.
[0013] According to another aspect of the present invention, the
exhaust system for a marine engine comprises a liquid-cooled
exhaust manifold assembly and a liquid-cooled catalytic converter
assembly downstream of the manifold assembly. The catalytic
converter assembly includes a catalytic converter, an inner shell
and an outer shell surrounding the inner shell. The inner and outer
shells define a fluid passageway therebetween. The outer shell has
a fluid inlet in fluid communication with the fluid passage to
introduce fluid into the fluid passage to cool and maintain the
outside surface of the catalytic converter assembly below a
predetermined temperature when liquid passes through the fluid
passage.
[0014] The liquid-cooled exhaust manifold assembly comprises a
mounting plate for securing the exhaust system to the marine
engine, a plurality of tube stubs welded to the mounting plate, a
baffle and a plurality of exhaust runners. Each of the exhaust
runners is welded to the mounting plate at one end and to the
baffle at the other end. The baffle is welded to the catalytic
converter assembly. The manifold assembly further comprises a
manifold jacket comprising upper and lower half shells welded
together and surrounding the exhaust runners. The manifold jacket
has an inlet for introducing fluid inside a fluid cavity defined by
the manifold jacket, baffle and tube stubs, and an outlet for
removing fluid from the manifold jacket to cool the outside surface
of the manifold jacket to maintain the outside temperature of the
manifold jacket below a predetermined temperature.
[0015] Thus the exhaust system of the present invention has two
separate cooling systems, each one functioning to cool the exterior
temperature of a part of the exhaust system. These and other
objects and advantages will be more readily apparent from the
following drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of an exhaust system in
accordance with the present invention;
[0017] FIG. 2 is a perspective view of the exhaust system of FIG.
1, a portion being cutaway;
[0018] FIG. 3 is a disassembled view of the liquid-cooled exhaust
manifold assembly of FIG. 1;
[0019] FIG. 3A is a partially disassembled view of a portion of the
exhaust system of FIG. 1;
[0020] FIG. 4 is a cross sectional view of a portion of the exhaust
system of FIG. 1;
[0021] FIG. 5 is a view taken along the line 5-5 of FIG. 4;
[0022] FIG. 6 is schematic illustration of the flow of fluids in
accordance with one embodiment of the invention;
[0023] FIG. 6A is a schematic illustration of the flow of fluids in
accordance with another embodiment;
[0024] FIG. 7 is a view taken along the line 7-7 of FIG. 1; and
[0025] FIG. 8 is a bottom perspective view of the exhaust system of
FIG. 1.
[0026] It should be understood that the appended drawings are not
necessarily to scale, presenting a somewhat simplified
representation of various features illustrative of the basic
principles of embodiments of the invention. The specific design
features of embodiments of the invention as disclosed herein,
including, for example, specific dimensions, orientations,
locations and shapes of various illustrated components, as well as
specific sequences of operations (e.g., including concurrent and/or
sequential operations), will be determined in part by the
particular intended application and use environment. Certain
features of the illustrated embodiments may have been enlarged or
distorted relative to others to facilitate visualization and clear
understanding.
DETAILED DESCRIPTION OF THE DRAWINGS
[0027] Referring to the drawings, and particularly to FIG. 1, there
is illustrated a diagrammatic illustration of an exhaust system 10
for a marine engine 12 (shown in phantom in FIG. 1). Arrows 14 are
shown in FIG. 1 illustrating exhaust gases exiting the cylinders of
the marine engine 12 and entering the exhaust system 10. Although
the drawings illustrate the engine 12 having four cylinders, those
skilled in the art will appreciate that the present invention may
be used with two cylinder marine engines or any other like
engine.
[0028] The exhaust system 10 comprises a combination of two basic
components: a liquid-cooled exhaust manifold assembly 16 and a
liquid-cooled catalytic converter assembly 18 located downstream of
the exhaust manifold assembly 16. In order to assemble the exhaust
system 10, the two components, the liquid-cooled exhaust manifold
assembly 16 and a liquid-cooled catalytic converter assembly 18,
are welded together.
[0029] Referring to FIGS. 3 and 3A, the components of the
liquid-cooled exhaust manifold assembly 16 will be described. The
liquid-cooled exhaust manifold assembly 16 comprises a mounting
plate 20 made of steel having mounting holes 22 therethrough for
mounting the liquid-cooled exhaust manifold assembly 16 to the
engine block 12 with fasteners (not shown). See FIG. 3A. The
mounting plate 20 also has a plurality of spaced exhaust holes 24
therethrough which allow the exhaust gases to pass through the
mounting plate 20 and into the catalytic converter assembly 18 via
tubular exhaust runners 26.
[0030] As shown in FIGS. 3A and 7, a plurality of tube stubs 28
(one per each exhaust hole 24 of mounting plate 20) are secured via
welds 124 to mounting plate 20, secured to the lower half shell 36
of the manifold jacket 32 with welds 122 and extend upwardly from
the mounting plate 20. Each tube stub 28 has a hollow interior into
which one of the tubular exhaust runners 26 fits. The tube stubs 28
provide welding surfaces to which the lower half shell 36 of the
manifold jacket 32 of the exhaust manifold assembly 16 is welded,
as described below.
[0031] As shown in FIGS. 3A and 7, each of the tubular exhaust
runners 26 is welded at one end to one of the tube stubs 28 at weld
124. The other end of each of the hollow tubular exhaust runners 26
is welded to a baffle 30. Each of the tubular exhaust runners 26 is
the same length to optimize engine performance. During operation of
the marine engine 12, exhaust gases pass through the interior of
the tubular exhaust runners 26 into the catalytic converter
assembly 18. See FIG. 4.
[0032] As best shown in FIG. 3, exhaust manifold assembly 16
further comprises a manifold jacket 32 comprising an upper half
shell 34 and a lower half shell 36, shown separated in FIGS. 3 and
3A. The manifold jacket 32 is made of sheet metal and is shaped
like a clam shell. Each of the pieces 34, 36 of the manifold jacket
32 is shaped like half a clam shell.
[0033] As shown in the drawings, a first boss 38 having a passage
40 therethrough is welded to the outer surface of lower half shell
36 around an opening 42 (see FIGS. 3 and 3A) through the lower half
shell 36 to create a fluid inlet 44. Similarly, a second boss 46
having a passage 48 therethrough is welded to the outer surface of
lower half shell 36 around an opening 50 (see FIGS. 3 and 3A)
through the lower half shell 36 to create a fluid outlet 52.
[0034] As shown in FIG. 3, upper half shell 34 has an opening 120
around which is welded a boss 126 having a passage 128. As shown in
FIG. 2, boss 126 is adapted to receive a bleed valve 75 to remove
excess air when the fluid cavity 54 described below is filled with
fluid.
[0035] As shown in FIGS. 7 and 8, the upper and lower half shells
34, 36 are welded together with a continuous weld 56, the upper
half shell 34 fitting over a portion of the lower half shell 36 in
a "shoebox" manner. As shown in FIG. 7, the lower half shell 36 is
welded to the tube stubs 28 at welds 122 and the upper half shell
34 is welded to the lower half shell 36 at weld 56.
[0036] As shown in FIG. 2, fluid cavity 54 is defined by the upper
and lower half shells 34, 36 welded together, the baffle 30 welded
to one end of the tubular exhaust runners 26 and the mounting plate
20 secured to the other ends of the tubular exhaust runners 26. As
shown in FIG. 2, exhaust from the marine engine 12 passes through
the tubular exhaust runners 26 into the catalytic converter
assembly 18. This exhaust is cooled by either glycol or water
passing through the fluid cavity 54, the fluid entering fluid
cavity 54 via fluid inlet 44 and exiting fluid cavity 54 via fluid
outlet 52, as shown in FIGS. 6 and 6A.
[0037] According to one aspect of the invention shown in FIG. 6,
glycol from a fluid source 66 is pumped via a first pump 60 via
conduit or pipe 62 to the fluid inlet 44, through the fluid cavity
54 of the exhaust manifold assembly 16, out the fluid cavity 54 via
fluid outlet 52 and passes via conduit or pipe 64 back to the fluid
source 66. This is considered a closed loop system and used
primarily for use in salt water to prevent corrosion of the tubular
exhaust runners 26.
[0038] According to another aspect of the invention shown in FIG.
6A, water from a fluid source 68 is pumped via a first pump 70 via
conduit or pipe 72 to the fluid inlet 44, through the fluid cavity
54 of the exhaust manifold assembly 16, out the fluid cavity 54 via
fluid outlet 52 and passes via conduit or pipe 74 back to the fluid
source, which is commonly the water of a water body on which the
boat is used. This is considered an open system and used primarily
for use in fresh water without affecting the tubular exhaust
runners 26 which are exposed to the fluid of the fluid cavity 54 in
both embodiments.
[0039] FIGS. 4 and 5 illustrate the liquid-cooled catalytic
converter assembly 18 which comprises a catalytic converter 76 held
in place via a compressible mat 78 inside an inner shell or housing
80. An outer shell 82 surrounds the inner shell 80 and is welded to
the inner shell 80 at location 84 proximate an inlet 86 to the
liquid-cooled catalytic converter assembly 18 and at locations 88
proximate bosses 90. Bosses 90 are adapted to receive oxygen
sensors 92 which help determine whether catalytic converter 76 is
functioning properly. A fluid passage 94 is defined between the
inner and outer shells 80, 82. As shown in FIGS. 4 and 5, the inner
shell 80 is not concentric with the outer shell 82 proximate an
outlet 96 of the liquid-cooled catalytic converter assembly 18.
Therefore, as shown in FIG. 5, the fluid passage 94 is
crescent-shaped in cross-section proximate the outlet 96 of the
catalytic converter assembly 18.
[0040] A boss 98 having a passage 100 therethrough is welded to the
outer shell 82 around an opening 102 (see FIG. 4) through the outer
shell 82 to create a fluid inlet 104. Water or some other fluid is
pumped from fluid pump 106 through the fluid inlet 104 into the
fluid passage 94. The fluid is illustrated by the arrows 108 in
FIG. 4, while the exhaust is illustrated by arrows 110. After the
fluid exits the fluid passage 94, it is mixed with the exhaust
gases and both together exit the outlet of the liquid-cooled
catalytic converter assembly 18. As illustrated in FIGS. 6 and 6A,
fluid such as water from a fluid source 112 is pumped via a pump
114 via conduit or line 116 into the fluid inlet 104 of the
liquid-cooled catalytic converter assembly 18. The fluid is then
passed through the fluid passage 94 and exits the liquid-cooled
catalytic converter assembly 18, as indicated by the arrows
118.
[0041] While the present invention has been illustrated by a
description of the various embodiments, and while these embodiments
have been described in considerable detail, it is not the intention
to restrict or in any way limit the scope of the appended claims to
such detail. Additional advantages and modifications will readily
appear to those skilled in the art. Thus, the invention in its
broader aspects is therefore not limited to the specific details,
representative apparatus and method, and illustrative examples
shown and described. In particular, a person having ordinary skill
in the art will appreciate that any of the blocks of the above
flowcharts may be deleted, augmented, made to be simultaneous with
another, combined, or be otherwise altered in accordance with the
principles of the embodiments of the invention. Accordingly,
departures may be made from such details without departing from the
spirit or scope of applicant's general inventive concept.
[0042] Although we have described various embodiments of the
invention, we do not intend to be limited except by the scope of
the following claims.
* * * * *