U.S. patent number RE33,118 [Application Number 07/215,225] was granted by the patent office on 1989-11-28 for exhaust processor.
This patent grant is currently assigned to Arvin Industries, Inc.. Invention is credited to George E. Scheitlin, Mark A. Sickels, Robert T. Usleman.
United States Patent |
RE33,118 |
Scheitlin , et al. |
November 28, 1989 |
Exhaust processor
Abstract
An "in-line" exhaust processor includes a housing having an
inlet for introducing a combustion product from an engine and an
outlet for exhausting filtered or otherwise treated combustion
product from the housing. A first substrate is situated in a
forward or upstream position within the housing to filter
combustion product introduced into the housing through the inlet. A
second substrate is situated in an adjacent rearward or downstream
position within the housing to filter combustion product from at
least two sources in the manner explained below. Each substrate
includes a cellular structure having opposite inlet and outlet ends
and a longitudinal axis. The housing includes a first clam shell
portion and a complementary second clam shell portion joined to the
first clam shell portion to surround and hold the substrate pair in
series. The exhaust processor further includes a bypass channel for
diverting a selected portion of the combustion product introduced
into the housing through the housing inlet to the second
substrate.
Inventors: |
Scheitlin; George E. (Columbus,
IN), Sickels; Mark A. (Columbus, IN), Usleman; Robert
T. (Columbus, IN) |
Assignee: |
Arvin Industries, Inc.
(Columbus, IN)
|
Family
ID: |
26909837 |
Appl.
No.: |
07/215,225 |
Filed: |
July 5, 1988 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
Reissue of: |
639803 |
Aug 13, 1984 |
04625511 |
Dec 2, 1986 |
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Current U.S.
Class: |
60/299; 55/343;
55/466; 55/484; 60/311; 422/168; 422/170; 422/171; 422/176 |
Current CPC
Class: |
F01N
3/28 (20130101); F01N 13/011 (20140603); F01N
3/031 (20130101); F01N 13/009 (20140601); F01N
3/0211 (20130101); F01N 13/017 (20140601); F01N
13/0097 (20140603); F01N 13/1888 (20130101); F01N
2530/04 (20130101); F01N 2470/06 (20130101); F01N
2350/02 (20130101); Y02T 10/20 (20130101); Y02T
10/12 (20130101); F01N 2330/06 (20130101) |
Current International
Class: |
F01N
3/021 (20060101); F01N 3/28 (20060101); F01N
3/031 (20060101); F01N 7/02 (20060101); F01N
7/00 (20060101); F01N 7/18 (20060101); F01N
7/04 (20060101); F01N 003/24 (); F01N 003/02 () |
Field of
Search: |
;60/297,299,311
;422/168,170,171,176,180 ;55/343,466,484,DIG.30 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2417435 |
|
Oct 1975 |
|
DE |
|
1257056 |
|
Feb 1961 |
|
FR |
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Primary Examiner: Hart; Douglas
Attorney, Agent or Firm: Barnes & Thornburg
Claims
What is claimed is:
1. An exhaust processor assembly comprising
a housing including an interior wall, an inlet for introducing a
combustion product into the housing and an outlet for exhausting
combustion product from the housing,
first and second substrate means for treating combustion product
introduced into the housing through the inlet, the first substrate
means having an outer boundary, the interior wall of the housing
and the outer boundary of the first substrate means cooperating to
define a .Iadd.first .Iaddend.passageway therebetween, .Iadd.the
second substrate means having an outer boundary, the interior wall
of the housing and the outer boundary of the second substrate means
cooperating to define a second passageway therebetween,
.Iaddend.and .Iadd.first .Iaddend.bypass means for
.[.distibuting.]. .Iadd.distributing .Iaddend.distributing a
portion of the combustion product introduced into the housing
through the inlet to the second substrate means for treatment
therein through the .Iadd.first .Iaddend.passageway such that said
distributed portion bypasses the first substrate means without
flowing inside the outer boundary of the first substrate means to
reach the second substrate means.Iadd., and
second bypass means for distributing combustion product exhausted
from the first substrate means through the second passageway to the
housing outlet for exhaustion therethrough without flowing inside
the outer boundary of the second substrate means to reach the
housing outlet.Iaddend..
2. An exhaust processor assembly comprising
a housing including an inlet for introducing a combustion product
into the housing and an outlet for exhausting combustion product
from the housing, first substrate means, situated in a forward
position within the housing, for treating combustion product
introduced into the housing through the inlet, the first substrate
means having an outer boundary defining .[.an.]. .Iadd.a first
.Iaddend.interior region,
second substrate means, situated in a rearward position within the
housing to lie adjacent to the first substrate means, for treating
combustion product introduced into the housing through the inlet,
.[.and.]. .Iadd.the second substrate means having an outer boundary
defining a second interior region,
first .Iaddend.bypass means, within the housing, for diverting a
.Iadd.first .Iaddend.portion of the combustion product introduced
into the housing through the inlet to the second substrate means
for treatment therein without flowing through the .Iadd.first
.Iaddend.interior region defined by the first substrate means to
reach the second substrate means such that said .Iadd.first
.Iaddend.diverted portion .[.bypass.]. .Iadd.bypasses .Iaddend.the
first substrate means .[.and the remaining undiverted portion
enters the interior region defined by the first substrate means.].,
.Iadd.and
second bypass means, within the housing, for diverting a second
portion of the combustion product introduced into the housing
through the inlet to the first substrate means for treatment
therein and to the outlet without flowing through the second
interior region defined by the second substrate means to reach the
outlet such that the second diverted portion bypasses the second
substrate, .Iaddend.
whereby said .Iadd.first .Iaddend.diverted portion of the
combustion product introduced into the housing is intercepted and
treated by only the second substrate means prior to being exhausted
from the housing through the housing outlet .Iadd.and said second
diverted portion of the combustion product introduced into the
housing is intercepted and treated by only the first substrate
means prior to being exhausted from the housing through the housing
outlet.Iaddend..
3. The processor of claim 2 wherein the housing further includes a
first clam shell portion and a complementary second clam shell
portion joined to the first clam shell portion to surround the
first and second substrate means.
4. The processor of claim 2 wherein
each of the first and second substrate means includes a structure
having opposite inlet and outlet ends and a longitudinal axis, and
the .Iadd.first and second .Iaddend.bypass means .[.includes.].
.Iadd.cooperate to provide .Iaddend.
frame means for positioning said pair of structures within the
housing in end-to-end relation such that the positioned cellular
structures are substantially coaxially aligned within the
housing.
5. The processor of claim 2 wherein the .Iadd.second
.Iaddend.bypass means includes channel means for conducting the
.[.undiverted.]. .Iadd.second diverted .Iaddend.portion of the
combustion product to the housing outlet for exhaustion
therefrom.
6. The processor of claim 4 wherein the frame means includes an
elongated partition member for dividing the interior of the housing
into first and second chambers, the elongated partition member
being rigidly fixed within the housing along the length thereof to
cause each chamber to be in communication with the housing inlet
and the housing outlet such that the first chamber defines one path
through the housing for conducting the .[.undiverted.].
.Iadd.second diverted .Iaddend.portion of the combustion product
and the second chamber defines another path through the housing for
conducting the .Iadd.first .Iaddend.diverted portion of the
combustion product.
7. The processor of claim 6, wherein the housing further includes a
first clam shell portion and a complementary second clam shell
portion, the second clam shell portion being joined to the first
clam shell portion to surround both of the structures, the first
clam shell portion and one side of the partition member cooperate
to define the first chamber, and the second clam shell portion and
the other side of the partition member cooperate to define the
second chamber.
8. .[.The processor of claim 4 wherein.]. .Iadd.An exhaust
processor assembly comprising
a housing including an inlet for introducing a combustion product
into the housing and an outlet for exhausting combustion product
from the housing,
first substrate means, situated in a forward position within the
housing, for treating combustion product introduced into the
housing through the inlet, the first substrate means having an
outer boundary defining an interior region,
second substrate means, situated in a rearward position within the
housing to lie adjacent to the first substrate means, for treating
combustion product introduced into the housing through the inlet,
and
bypass means, within the housing, for diverting a portion of the
combustion product introduced into the housing through the inlet to
the second substrate means for treatment therein without flowing
through the interior region defined by the first substrate means to
reach the second substrate means such that said diverted portion
bypasses the first substrate means and the remaining undiverted
portion enters the interior region defined by the first substrate
means, said diverted portion of the combustion product introduced
into the housing being intercepted and treated by only the second
substrate means prior to being exhausted from the housing through
the housing outlet,
each of the first and second substrate means including a cellular
structure having opposite inlet and outlet ends and a longitudinal
axis,
the bypass means including frame means for positioning said pair of
cellular structures within the housing in end-to-end relation such
that the positioned cellular structures are substantially coaxially
aligned within the housing, .Iaddend.the frame means .[.includes.].
.Iadd.including .Iaddend.partition means for dividing the interior
of an axially forward portion of the housing into a first
passageway for conducting the undiverted combustion product and a
second passageway for conducting the diverted combustion product,
the partition means being rigidly fixed to the housing to cause one
mouth of each passageway to be in communication with the housing
inlet and the other mouth of each passageway to be in communication
with the inlet end of the structure of the second substrate means
such that the undiverted combustion product conducted through the
first passageway is sequentially introduced into the first and the
second substrate means for treatment therein and the diverted
combustion product conducted through the second passageway bypasses
the first substrate means and is introduced only into the second
substrate means for treatment therein.
9. The processor of claim 8 wherein the housing further includes a
first clam shell portion and a complementary second clam shell
portion, the second clam shell portion being joined to the first
clam shell portion to surround both of the substrate structures,
and the processor further comprises
means for supporting the structure of the second substrate means
between the first and second clam shell portions in proximity to
the outlet end of the housing.
10. The processor of claim 8 wherein the partition means includes a
shell half which includes a body section for receiving a portion of
a substrate structure therein and an inlet cone section for
conducting combustion product from the housing inlet to a substrate
structure received in the body section.
11. The processor of claim 10 wherein the shell half section is
formed to include a receptacle having an open mouth, and the shell
half is rigidly fixed to the housing to cause its mouth to open
toward the first clam shell portion and its inlet cone section to
be in communication with the housing inlet.
12. The processor of claim 9 further comprising
first means for mounting the structure of the first substrate means
to the shell half and to the first clam shell portion to be
suspended in the first passageway, and
second means for mounting the structure of the second substrate
means to the first and second clam shell portions to be in
communication with both of the first and second passageways.
13. The processor of claim 9 wherein the inlet cone section of the
shell half includes forward edge means for interrupting the flow of
combustion product introduced into the housing through the housing
inlet to segregate the undiverted and diverted portions of the
combustion product, the forward edge means and the first clam shell
portion cooperate to define the inlet mouth of the first passageway
through which the undiverted combustion product is conducted, and
the forward edge means and the second clam shell portion cooperate
to define the inlet mouth of the second passageway through which
the diverted combustion product is conducted.
14. .[.The processor of claim 4 wherein.]. .Iadd.An exhaust
processor assembly comprising
a housing including an inlet for introducing a combustion product
into the housing and an outlet for exhausting combustion product
from the housing,
first substrate means, situated in a forward position within the
housing, for treating combustion product introduced into the
housing through the inlet, the first substrate means having an
outer boundary defining an interior region,
second substrate means, situated in a rearward position within the
housing to lie adjacent to the first substrate means, for treating
combustion product introduced into the housing through the inlet,
and
bypass means, within the housing, for diverting a portion of the
combustion product introduced into the housing through the inlet to
the second substrate means for treatment therein without flowing
through the interior region defined by the first substrate means to
reach the second substrate means such that said diverted portion
bypasses the first substrate means and the remaining undiverted
portion enters the interior region defined by the first substrate
means, said diverted portion of the combustion product introduced
into the housing being intercepted and treated by only the second
substrate means prior to being exhausted from the housing through
the housing outlet,
each of the first and second substrate means including a cellular
structure having opposite inlet and outlet ends and a longitudinal
axis,
the bypass means including frame means for positioning said pair of
cellular structures within the housing in end-to-end relation such
that the positioned cellular structures are substantially coaxially
aligned within the housing, .Iaddend.the frame means .[.includes.].
.Iadd.including .Iaddend.a first shell half and a complementary
second shell half, each shell half including a body section for
receiving a portion of a structure therein and an inlet cone
section for conducting combustion product from the housing inlet to
a substrate structure received therein.
15. The processor of claim 14 wherein each body section is formed
to include an open mouth, the first shell half is rigidly fixed to
the housing to cause its mouth to open toward the first clam shell
portion, the second shell half is rigidly fixed to the housing to
cause its mouth to open toward its companion first clam shell
portion so that the two shell halves are held in confronting
relation.
16. The processor of claim 14 further comprising first means for
mounting the structure of the first substrate means to the rigidly
fixed shell halves to be suspended in the first passageway, and
second means for mounting the structure of the second substrate
means to the first and second clam shell portions to be in
communication with both of the first and second passageways.
17. The processor of claim 7, wherein
the first clam shell portion and said one side of the partition
member cooperate to define means for mounting the structure of the
first substrate means in the first chamber in proximity to the
housing inlet, and
the second clam shell portion and said other side of the partition
member cooperate to define means for mounting the structure of the
second substrate means in the second chamber in proximity to the
housing outlet.
18. An exhaust processor assembly comprising
a housing including an interior wall, an inlet for introducing a
combustion product into the housing and an outlet for exhausting
combustion product from the housing,
a plurality of substrate means for treating combustion product
introduced into the housing through the inlet, one of the substrate
means having an outer boundary and being positioned within the
housing in close proximity to the housing inlet, the interior wall
of the housing and the outer boundary of said one of the substrate
means cooperating to define a passageway therebetween,
.[.and.].
.Iadd.first .Iaddend.bypass means for distributing a portion of the
combustion product introduced into the housing through the inlet to
a substrate means for treatment therein through the passageway such
that said distributed portion bypasses said one of the substrate
means positioned in close proximity to the housing inlet without
flowing inside the outer boundary of said one of the substrate
means to reach another of the substrate means.Iadd., and
second bypass means for distributing the combustion product
exhausted from said one of the substrate means to the housing
outlet without flowing inside an outer boundary of another of the
substrate means to reach the housing outlet.Iaddend..
19. The processor of claim 18 wherein the housing further includes
a first clam shell portion and a complementary second clam shell
portion joined to the first clam shell portion to surround the
plurality of substrate means.
20. The processor of claim 18 wherein
each of the plurality of substrate means includes a structure
having opposite inlet and outlet ends and a longitudinal axis, and
the .Iadd.first and second .Iaddend.bypass means .[.includes.].
.Iadd.cooperate to provide .Iaddend.frame means for positioning
said plurality of structures within the housing in end-to-end
relation such that the positioned cellular structures are
substantially coaxially aligned within the housing.
21. The processor of claim 1, wherein the housing further includes
a first clam shell portion and a complementary second clam shell
portion joined to the first clam shell portion to surround the
first and second substrate means.
22. The processor of claim 21, wherein the bypass means includes an
elongated partition member mounted in the housing to divide the
interior of the housing into longitudinally extending first and
second chambers in communication with the housing inlet and outlet,
the elongated partition member being configured to position the
first and second substrate means within the housing in
substantially coaxial end-to-end relation.
23. The processor of claim 22, wherein the first clam shell portion
includes a first flange, the second clam shell portion includes a
second flange, the elongated partition member includes a third
flange, and the first, second, and third flanges cooperate to
define a single splitline extending along the length of the
processor between the housing inlet and outlet.
24. The processor of claim 1, wherein the housing further includes
a first clam shell portion and a complementary second clam shell
portion, the second clam shell portion being joined to the first
clam shell portion to surround both of the structures, the first
clam shell portion and one side of the partition member cooperate
to define the first chamber, and the second clam shell portion and
the other side of the partition member cooperate to define the
second chamber.
25. The processor of claim 24, wherein
the first .[.claim.]. .Iadd.clam .Iaddend.shell portion and said
one side of the partition member cooperate to define means for
mounting the structure of the first substrate means in the first
chamber in proximity to the housing inlet, and
the second clam shell portion and said other side of the partition
member cooperate to define means for mounting the structure of the
second substrate means in the second chamber in proximity to the
housing oulet.
26. The processor of claim 2, wherein the bypass means includes an
elongated partition member mounted in the housing to divide the
interior of the housing into longitudinally extending first and
second chambers in communication with the housing inlet and outlet,
the elongated partition member being configured to position the
first and second substrate means within the housing in
substantially coaxial end-to-end relation.
27. The processor of claim 26, wherein the first clam shell portion
includes a first flange, the second clam shell portion includes a
second flange, the elongated partition member includes a third
flange, and the first, second, and third flanges cooperate to
define a single splitline extending along the length of the
processor between the housing inlet and outlet.
28. An exhaust processor assembly comprising
a housing including an inlet for introducing a combustion product
into the housing and an outlet for exhausting combustion product
from the housing,
an elongated partition member rigidly fixed within the housing to
divide the interior of the housing into only two longitudinally
extending chambers, each longitudinally extending chamber being in
communication with the housing inlet and outlet, a first of the
chambers defining a first delivery path for conducting a portion of
the combustion product through the housing, a second of the
chambers being arranged in side-by-side relation to the first
chamber to define a separate second delivery path for conducting a
remaining portion of the combustion product through the
housing,
first substrate means for treating said portion of combustion
product, the first substrate means being positioned in the first
chamber, and
second substrate means for treating said remaining portion of
combustion product, the second substrate means being positioned in
the second chamber so that said remaining portion of combustion
product is conducted to the second substrate means without flowing
through the first longitudinally extending chamber.
29. The processor of claim 28, wherein the housing further includes
a first clam shell portion and a complementary second clam shell
portion joined to the first clam shell portion to surround the
first and second substrate means.
30. The processor of claim 29, wherein the first clam shell portion
and one side of the partition member cooperate to define the first
chamber, and the second clam shell portion and the other side of
the partition member cooperate to define the second chamber.
Description
This invention relates to exhaust processors usable to filter
particulate matter from a contaminated fluid. More particularly,
this invention relates to an "in-line" exhaust processor assembly
including a processor housing and a pair of substrates mounted in
series within the housing for solid particle filtration.
Conventional exhaust processors include a housing in communication
with an exhaust manifold of an engine and a single monolithic
substrate disposed therein to filter out noxious pollutants from
the engine exhaust gases. However, in many cases a single substrate
cannot provide a sufficient amount of filtering capacity.
Typically, when more than one filter is needed, two substrates are
mounted within a housing in a "side-by-side" or "spaced-apart
parallel" relation. Hereinafter, such a conventional processor will
be referred to as a "parallel processor."
Many types of parallel processors are known. One type includes a
single inlet pipe that is coupled to two filters mounted in
parallel by means of a "Y design" three way joint. A separate sheet
metal housing having its own inlet and outlet ports is provided to
house each of said filters. Another type includes a web-shaped
common inlet cone that is coupled directly to two filters mounted
in parallel. Each filter is provided with its own sheet metal
housing. However, the web-shaped inlet cone is of sufficient size
to contemporaneously engage the inlet ends of each of the parallel
filters.
Manufacturers and users of exhaust processors such as catalytic
converters and diesel particulate traps will appreciate the
hardships and inconveniences generally associated with the design
and installation of all types of conventional parallel processors.
One problem relates to inadequate conservation of heat energy. For
example, parallel exhaust processors comprising a pair of diesel
particulate traps typically cause large quantities of heat energy
to be wasted during "regeneration" of the traps. The filter
elements or traps must periodically be cleaned to restore
functionality thereto. Heat is applied to each trap to burn and
oxidize the trapped carbon particles. In a diesel particulate trap
of parallel construction, the heat energy required to "clean" each
filter element must be conducted to the inlet face of each filter
element by a pipe system. Thus, a complex, space-consuming, dual,
heat delivery network of pipes and fixtures must be provided for
each parallel "trap" processor. A large amount of the heat energy
generated during such a regeneration burn is lost as waste exhaust
heat that is discharged to the atmosphere. Another problem is that
parallel processors are oftentimes not conveniently usable in
confined spaces due to their large, unwieldy size and great
bulk.
It is known to provide a processor housing having two substrates
mounted in an "in-line" or "series" configuration rather than the
parallel configuration described above in an attempt to avoid the
shortcomings associated with conventional parallel processors.
However, known "in line" processors have proven to be
unsatisfactory substitutes for conventional parallel processors.
One type of conventional in-line processor is provided with a
single, long, narrow substrate. It will be appreciated that it is
best to construct a substrate using a ceramic material and that it
is desirable, for purposes of strength, to keep the outside
diameter to length ratio of a ceramic substrate as near ot 1.0 as
possible. A long narrow substrate is inherently characterized by an
unacceptably high ratio and is quite fragile.
Another type of conventional in-line processor is provided with two
shorter filters mounted in series within a single passageway in
which all of the contaminated exhaust gas introduced into the
housing is required to pass. It will be understood that one or both
of these substrates can be prematurely clogged with particulate
matter unless the "filter efficiency" of each of these in-line
substrate filters is carefully "matched". Design and maintenance of
this second type of conventional in-line processor is undesirably
complicated by the need to install a less efficient filter in the
forward or upstream position within the housing and a filter
characterized by a higher efficiency in the rearward or downstream
position within the housing. Selection of properly "matched"
filters is an expensive and time-consuming procedure.
According to the present invention, an improved exhaust processor
of "in-line" construction is provided. The novel exhaust processor
includes a housing having an inlet for introducing a combustion
product from an engine and an outlet for exhausting filtered or
otherwise treated combustion product from the housing. A first
substrate is situated in a forward or upstream position within the
housing to filter combustion product introduced into the housing
through the inlet. A second substrate is situated in an adjacent
rearward or downstream position within the housing to filter
combustion product from at least two sources in the manner
explained below. Each substrate includes a cellular structure
having opposite inlet and outlet ends and a longitudinal axis. One
advantage of the novel processor is that both cellular structures
are of short length to minimize fragileness. Another advantage is
that both cellular structures are characterized by substantially
equivalent filter efficiencies to reduce design complexity and
cost. The pair of cellular structures are positioned within the
housing in end-to-end relation to be substantially coaxially
aligned therein.
The housing is desirably of "clam shell" construction although it
is within the scope of the present invention to employ a "stuffed
can" construction. The housing preferably includes a first clam
shell portion and a complementary second clam shell portion joined
to the first clam shell portion to surround and hold the substrate
pair in series.
The exhaust processor further includes novel bypass means for
diverting or distributing a selected portion of the combustion
product introduced into the housing through the housing inlet to
the second substrate. Importantly, the bypass means is situated
wholly within the housing. Installation of the novel bypass means
within an exhaust processor of in-line construction serves to
allocate combustion product among the two substrates in
substantially equal quantities. This feature .[.advantageous1y.].
.Iadd.advantageously .Iaddend.permits installation of two
substrates having substantially equivalent "filter efficiencies"
since each deployed substrate is exposed to roughly the same volume
of contaminated fluid or combustion product.
Provision of such an allocation function in an "in line" exhaust
processor is a novel departure from conventional practices. The
"diverted" portion of the untreated combustion product is routed
directly to the second or downstream substrate and thus entirely
bypasses the first or upstream substrate. In addition, the
remaining "undiverted" combustion product is routed directly to the
first substrate.
According to one preferred embodiment of the invention, the bypass
means includes an elongated partition member that is installed
along the length of the housing to divide the housing interior into
independant first and .[.secon.]. .Iadd.second .Iaddend.chambers.
Each chamber is exposed to the housing inlet and outlet to permit
combustion product to be conducted therethrough. The first
substrate is desirably mounted in an upstream position in the first
chamber in proximity to the housing inlet and the second substrate
is desirably mounted in an downstream position in the second
chamber in proximity to the housing outlet. The first chamber
serves to define one longitudinal path through the processor
housing for conducting only the undiverted combustion product to
the first substrate for treatment therein and for subsequent
exhaustion through the housing outlet. The second chamber serves to
define another longitudinal path through the housing for conducting
only the diverted combustion product to the second substrate for
treatment therein and for subsequent exhaustion through the housing
outlet.
According to another embodiment of the present invention, the
bypass means includes an elongated partition member or internal
shell that is installed in an upstream position extending along
only about one-half of the housing to divide the axially forward
portion of the housing interior into separate first and second
passageways. The first substrate is desirably mounted in the first
passageway in proximity to the housing inlet. Thus, the first
passageway defines one path for conducting undiverted combustion
product to the first substrate for treatment therein and for
subsequent exhaustion to the second substrate for treatment therein
prior to exhaustion from the housing. In addition, the second
passageway defines another path for conducting diverted combustion
product directly to the second substrate for treatment therein
prior to exhaustion from the housing.
One feature of each of the embodiments of the present invention is
the provision in an "in-line" exhaust processor of bypass means for
diverting a selected quantity of untreated combustion product to
the second substrate for treatment therein. This novel structure
causes the flow of combustion product introduced into the processor
to be split into substantially equivalent portions. In effect,
one-half of the initially untreated combustion product is allocated
and conducted to the first substrate for filtration therein, and
the other one-half of the untreated combustion product is allocated
and conducted to the second substrate for filtration therein. The
present invention advantageously permits installation of two
conventionally sized substrates having substantially equivalent
filter efficiencies within a compact exhaust processor assembly of
"in-line" construction.
In this specification and in the claims, the words "an exhaust
processor" are intended to refer to various types of catalytic
converters and processors, diesel particulate filters, and other
particulate traps in connection with which the invention may be
used.
The invention can best be understood by referring to the following
description and accompanying drawings which illustrate preferred
embodiments exemplifying the best mode of carrying out the
invention as presently perceived.
FIG. 1 is a view of a longitudinal cross section of an in-line
exhaust processor incorporating one of the preferred embodiments of
the present invention with portions broken away;
FIG. 2 is an exploded view of the embodiment of FIG. 1 showing the
clam shell housing and a partition member;
FIG. 3 is a view of a "downstream" transverse cross section of the
embodiment shown in FIG. 1, taken along lines 3--3 of FIG. 1;
FIG. 4 is a view of an "upstream" transverse cross section of the
embodiment shown in FIG. 1, taken along lines 4--4 of FIG. 1;
FIG. 5 is a view of a longitudinal cross section of an in-line
exhaust processor incorporating another of the preferred
embodiments of the present invention with portions broken away;
FIG. 6 is an exploded view of the embodiment of FIG. 5 showing the
clam shell housing and a single interior shell;
FIG. 7 is a view of a "downstream" transverse cross section of the
embodiment shown in FIG. 5 taken along lines 7--7 of FIG. 5;
FIG. 8 is a view of an "upstream" transverse cross section of the
embodiment shown in FIG. 5, taken along lines 8--8 of FIG. 5;
FIG. 9 is a view of a longitudinal cross section of an in-line
exhaust processor incorporating another of the preferred
embodiments of the present invention with portions broken away;
FIG. 10 is an exploded view of the of the embodiment of FIG. 9
showing the clam shell housing and a pair of interior shells in
confronting relation;
FIG. 11 is a view of a "downstream" transverse cross section of the
embodiment shown in FIG. 9, taken along lines 11--11 of FIG. 9;
and
FIG. 12 is a view of an "upstream" transverse cross section of the
embodiment shown in FIG. 9, taken along lines 12--12 of FIG. 9.
An exhaust processor assembly 10 of the present invention includes
a housing 12 of the clam shell type including an upper half shell
14 and a lower half shell 16. Shell halves 14, 16 are
conventionally steel stampings. In final assembly, halves 14, 16
are welded or otherwise joined along shell flanges 18.
The housing 12 further includes a housing inlet 20 to receive a
combustion product 21 of an engine (not shown) into a cavity 22
formed by the marriage of the upper and lower half shells 14, 16.
Also, a housing outlet 24 is provided to exhaust combustion product
from the housing 12.
First and second substrates 26 and 28, respectively, are disposed
within the cavity 22 of the housing 12 in a manner to be described.
Each substrate is a cylindrically-shaped monolithic cellular
structure of conventional diameter and length. The substrate could
be a structure having a large number of thin-walled passages 29
extending radially and longitudinally between the ends 20, 24 of
the cellular structure. It will be understood that cellular
structure could alternatively be of the type used in a diesel
particulate trap without departing from the scope of the present
invention. Further, the "filter efficiency" of each of substrates
26, 28 is substantially equivalent, in contradistinction to
conventional in-line exhaust processors which inherently must use
two substrates having different "filter efficiencies". One
significant advantage of the present invention is that a pair of
substrates conventional size and of similar efficiency are usable
in a compact in-line exhaust processor.
In the embodiment of FIGS. 1-4, the exhaust processor 10 includes a
partition 30. The elongated partition 30 performs at least three
different functions in the present invention. The partition 30
provides means for positioning the substrates 26, 28 within the
housing 12 in coaxial alignment and also means for conducting a
portion of the combustion product 21 toward and away from each of
the substrates 26, 28. The partition 30 is a three dimensional,
thin-walled, sheet metal stamping and is constructed to include an
inlet cone section 32, a first body section 34, a transition
section 36, a second body section 38, and an outlet cone section
40. The partition 30 is installed in the interior cavity 22 of
housing 12 by means of peripheral flanges 42 as shown.
The inlet cone section 32 is positioned in close proximity to the
housing inlet 20 to interrupt the incoming flow of combustion
product 21. The inlet cone section 32 operates to split the flow of
combustion product 21 and deflect a portion 21a, 21b of the flow
toward either of the two substrates 26, 28. The partition 30
includes a contoured upper surface 44 and a contoured lower surface
46, and is formed to include two oppositely opening hollow
receptacles 48a, 48b.
A first receptacle 48a is defined by the contoured lower surface 46
of integral elements 32, 34, and 36. The receptacle 48a opens
toward the inwardly-facing surface 50 of lower clam shell half 16
to receive the first substrate 26 therebetween. A second receptacle
48b is defined by the contoured upper surface 44 of integral
elements 36, 38, and 40. The receptacle 48b opens toward the
inwardly-facing surface 52 of upper clam shell half 14 to receive
the second substrate 28 therebetween. Each substrate 26, 28 is
supported in its proper position in its respective chamber by any
conventional means such as mat 53.
The partition member 30 is installed in housing 12 to divide the
housing 12 along its entire length into a first chamber 54
containing the first substrate 26, and a second chamber 56
containing the second substrate 28. Each chamber 54, 56 is in
continuous communication with both the housing inlet 20 and outlet
24 to provide two separate longitudinal paths through the housing
12. The first chamber 54 is defined by the inwardly facing surface
50 of lower shell half 16 and the contoured lower side wall 46 of
the partition 30. The second chamber 56 is defined by the inwardly
facing surface 52 of upper shell half 14 and the contoured upper
side wall 44 of the partition 30.
When positioned as shown in FIG. 1, the inlet cone section 32 of
the partition 30 operates to split the flow of combustion product
21 admitted into the housing 12 so that about one-half of the flow
21a is delfected into the first chamber 54 and conducted toward the
first substrate 26, and the other one-half of the flow 21b is
deflected into the second chamber 56 and conducted toward the
second substrate 28. In particular, the "diverted" portion 21b of
the combustion product 21 is filtered only by the second substrate
28 and wholly bypasses the first substrate 26. A filtered
combustion product portion 21b is then discharged from the second
chamber 56 through housing outlet 24. The remaining "undiverted"
portion 21a is filtered by the first substrate 26, and then
discharged from the first chamber 54 through housing outlet 24. The
outlet cone section 40 is positioned in close proximity to the
housing outlet 24 to shunt the filtered discharge of the first and
second substrates 26, 28 toward the single housing outlet 24.
In the embodiment of the invention illustrated in FIGS. 5-8, those
elements numbered identically with the embodiment of FIGS. 1-4
perform the same or similar functions. In the embodiment of FIGS.
5-8, the partition 30 is replaced by internal shell half 58 which
is of reduced size and includes only inlet cone section 32 and
first body section 34. Inlet cone section 32 operates in the manner
described above to divert approximately one half of the incoming
combustion product 21 to the second substrate 28 so as to wholly
bypass the first substrate 26. Internal shell half 58 includes
peripheral flanges 60 so as to be rigidly fixable between shell
halves 14 and 16.
The first and second substrates 26, 28 are positioned within
housing 12 in end-to-end, substantially coaxial relation in this
embodiment by placing the first substrate 26 in a first passageway
62 between the internal shell half 58 and the lower shell half 16,
and by placing the second substrate 28 between shell halves 14 and
16 as shown best in FIG. 5. The substrates 26, 28 are again mounted
in their proper positions using any conventional technique.
In the embodiment of FIGS. 5-8, the second substrate 28 is exposed
to the filtered combustion product 21a exhausted from the first
substrate 26, in addition to the untreated combustion product 21b
which is conducted to the second substrate 28 through a second
passageway 64. This second passageway 64 is defined by
inwardly-facing surface 52 and the outwardly-facing surface 66 of
internal shell half 58 and causes combustion product portion 21b to
wholly bypass the first substrate 26.
In operation of the embodiment of FIGS. 5-8, about one-half of the
combustion product 21a is filtered by the first substrate 26 while
the entire flow of combustion product 21a, 21b is intercepted and
filtered by the second substrate 28. One advantage of this feature
is that provision of the bypass means guarantees that the in-line
exhaust processor of the present invention can continue to use two
substantially similar substrates of the same filter efficiency.
Another advantage of this feature is that it aids in conserving
heat during incineration of trapped solid particles within the
substrate. During regeneration of a particulate trap, heat energy
waste will be significantly minimized since heat applied to the
first substrate 26 will pass through said substrate 26 to aid in
the regeneration of the axially adjacent second substrate 28
whereas in conventional processors the heat energy applied to the
first substrate 26 is merely discharged to the atmosphere.
In the embodiment of the invention illustrated in FIGS. 9-12, those
elements numbered identically with the embodiment of FIGS. 1-8
perform the same or similar functions. In the embodiment of FIGS.
9-12 a companion internal shell half 68 is installed in the housing
12 in confronting relation to the internal shell half 58. Thus
installed, second passageway 64 is divided into upper and lower
components 70, 72 and is shaped to resemble an oblong annular ring
as best shown in FIGS. 11 and 12, rather than the arcuate crescent
section(s) of the embodiments of FIGS. 1-8 shown in FIGS. 3, 4, 7,
and 8.
Thus, a dual bypass passage 70, 72 is provided around the first
substrate 26. One effect of such a feature is that the lower bypass
passage 70 and the upper bypass passage 72 each operate to conduct
about one-quarter of the combustion product 21 introduced into the
housing 12 through the housing inlet 20.
Although the invention has been described in detail with reference
to certain preferred embodiments and specific examples, variations
and modifications exist within the scope and spirit of the
invention as described and defined in the following claims.
* * * * *