Patent EP0456919A2 successfully refreshed from Google Patents.
EP0456919A2
Expired / Lapsed
EP
⏱️ 0.0 years remaining
Catalytic converter system
Assignee: WR Grace and Co Conn
•
Filing: 1990-12-22
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Granted: —
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Expires: 2010-12-22
Abstract
Abstract An exhaust system for an internal combustion engine adapted to correct the problem of pollution occurring at start-up and during at least initial engine running, and characterized by an electrically heatable catalytic converter and a separate conventional catalytic converter in tandem relation. The system also includes means for providing electrical power greater than 1500 watts in from 2 to 30 seconds whereby the temperature of the catalyst is raised to at least 650 F. A principal advantage is that there is provided a substantially improved means for augmenting conventional catalytic converter exhaust systems for modern requirements by inserting in the exhaust system an electrically heatable catalytic converter for conversion of pollutant materials during and, if necessary, shortly after start-up. Power switching means are provided for heating an electrically heatable catalytic converter and are characterized by a plurality of actuatable solid state switches preferably in combination with means for actuating them in unison.
Inventors
- 👤 Richard C. Cornelison
- 👤 William A. Whittenberger
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-10-31 10:33
CPC Classifications
B; B01; B01J; B01J35/00; B01J35/30; B01J35/33; F; F01; F01N; F01N3/00; F01N3/08; F01N3/10; F01N3/18; F01N3/20; F01N3/2006; F01N3/2013; F01N3/2026; F01N3/24; F01N3/28; F01N3/2803; F01N3/2807; F01N3/281; F01N3/2814; B01J35/50; B01J35/56; B01J35/57; F01N2330/00; F01N2330/02; F01N2330/04; Y; Y02; Y02T; Y02T10/00; Y02T10/10; Y02T10/12
Claims Analysis
Total Claims: 71
Claim 1
Independent Claim
78 words
An exhaust system for an internal combustion engine including an exhaust pipe, and characterized by an electrically heatable catalytic converter in tandem relation in said exhaust pipe with a separate conventional catalytic converter free of electrical heating means, and means for providing an electrical current greater than 500 amps for from 2 to 15 seconds to said electrically heatable catalytic converter whereby the temperature in said electrically heatable catalytic converter is raised to at least about 650 F.
Claim 2
Dependent Claim
78 words
An exhaust system for an internal combustion engine including an exhaust pipe, and characterized by an electrically heatable catalytic converter in tandem relation in said exhaust pipe with a separate conventional catalytic converter free of electrical heating means, and means for providing an electrical current greater than 500 amps for from 2 to 15 seconds to said electrically heatable catalytic converter whereby the temperature in said electrically heatable catalytic converter is raised to at least about 650 F.
Claim 3
Dependent Claim
74 words
An exhaust system for an internal combustion engine including an exhaust pipe, and characterized by an electrically heatable catalytic converter in tandem relation with a separate conventional catalytic converter free of electrical heating means, and means for providing electrical power of at least 1500 watts for from 2 to 30 seconds to said electrically heatable catalytic converter whereby the temperature in said electrically heatable catalytic converter is raised to at least about 650 F.
Claim 4
Dependent Claim
74 words
An exhaust system for an internal combustion engine including an exhaust pipe, and characterized by an electrically heatable catalytic converter in tandem relation with a separate conventional catalytic converter free of electrical heating means, and means for providing electrical power of at least 1500 watts for from 2 to 30 seconds to said electrically heatable catalytic converter whereby the temperature in said electrically heatable catalytic converter is raised to at least about 650 F.
Claim 5
Dependent Claim
112 words
An exhaust system for an internal combustion engine including an exhaust pipe, and characterized by an electrically heatable catalytic converter on tandem relation with a separate conventional catalytic converter free of electrical heating means, and means including a voltage source of from 12 to 60 volts capable of providing electrical power at the rate of from about 1500 to about 12000 watts for from 2 to 30 seconds prior to and at start-up to said electrically heatable catalytic converter, said electrically heatable catalytic converter having a total resistance of from .005 ohms to 2.2 ohms, whereby the temperature in said electrically heatable catalytic converter is raised to at least about 650 F.
Claim 6
Dependent Claim
112 words
An exhaust system for an internal combustion engine including an exhaust pipe, and characterized by an electrically heatable catalytic converter on tandem relation with a separate conventional catalytic converter free of electrical heating means, and means including a voltage source of from 12 to 60 volts capable of providing electrical power at the rate of from about 1500 to about 12000 watts for from 2 to 30 seconds prior to and at start-up to said electrically heatable catalytic converter, said electrically heatable catalytic converter having a total resistance of from .005 ohms to 2.2 ohms, whereby the temperature in said electrically heatable catalytic converter is raised to at least about 650 F.
Claim 7
Dependent Claim
34 words
An exhaust system in accordance with claim 1 wherein said means for applying an electrical current includes means for applying current to said electrically heatable catalytic converter prior to starting said internal combustion engine.
Claim 8
Dependent Claim
48 words
An exhaust system in accordance with claim 4 wherein said means for applying electrical current includes temperature responsive means for applying current to said electrically heatable catalytic converter also after starting said internal combustion engine to maintain the temperature of the catalyst to at least about 650 F.
Claim 9
Dependent Claim
22 words
An exhaust system as defined in claim 1 wherein the electrically heatable catalytic converter is located upstream of said conventional catalytic converter.
Claim 10
Dependent Claim
22 words
An exhaust system as defined in claim 2 wherein the electrically heatable catalytic converter is located upstream of said conventional catalytic converter.
Claim 11
Dependent Claim
22 words
An exhaust system as defined in claim 3 wherein the elctrically heatable catalytic converter is located upstream of said conventional catalytic converter.
Claim 12
Dependent Claim
22 words
An exhaust system as defined in claim 1 wherein the electrically heatable catalytic converter is located downstream of said conventional catalytic converter.
Claim 13
Dependent Claim
22 words
An exhaust system as defined in claim 2 wherein the electrically heatable catalytic converter is located downstream of said conventional catalytic converter.
Claim 14
Dependent Claim
22 words
An exhaust system as defined in claim 3 wherein the electrically heatable catalytic converter is located downstream of said conventional catalytic converter.
Claim 15
Dependent Claim
18 words
An exhaust system as defined in claim 1 wherein the conventional catalytic converter includes a ceramic honeycomb monolith.
Claim 16
Dependent Claim
18 words
An exhaust system as defined in claim 2 wherein the conventional catalytic converter includes a ceramic honeycomb monolith.
Claim 17
Dependent Claim
18 words
An exhaust system as defined in claim 3 wherein the conventional catalytic converter includes a ceramic honeycomb monolith.
Claim 18
Dependent Claim
20 words
An exhaust system as defined in claim 1 wherein the conventional catalytic converter includes a corrugated thin metal honeycomb monolith.
Claim 19
Dependent Claim
20 words
An exhaust system as defined in claim 2 wherein the conventional catalytic converter includes a corrugated thin metal honeycomb monolith.
Claim 20
Dependent Claim
20 words
An exhaust system as defined in claim 3 wherein the conventional catalytic converter includes a corrugated thin metal honeycomb monolith.
Claim 21
Dependent Claim
21 words
An exhaust system as defined in claim 1 wherein the electrically heatable catalytic converter includes a corrugated thin metal honeycomb monolith.
Claim 22
Dependent Claim
21 words
An exhaust system as defined in claim 2 wherein the electrically heatable catalytic converter includes a corrugated thin metal honeycomb monolith.
Claim 23
Dependent Claim
21 words
An exhaust system as defined in claim 3 wherein the electrically heatable catalytic converter includes a corrugated thin metal honeycomb monolith.
Claim 24
Dependent Claim
23 words
An exhaust system as defined in claim 1 wherein the electrically heatable catalytic converter includes a corrugated thin ferritic stainless steel honeycomb monolith.
Claim 25
Dependent Claim
23 words
An exhaust system as defined in claim 2 wherein the electrically heatable catalytic converter includes a corrugated thin ferritic stainless steel honeycomb monolith.
Claim 26
Dependent Claim
23 words
An exhaust system as defined in claim 3 wherein the electrically heatable catalytic converter includes a corrugated thin fderritic stainless steel honeycomb monolith.
Claim 27
Dependent Claim
37 words
An exhaust system as defined in claim 1 wherein the electrically heatable catalytic converter includes a honeycomb monolith formed of corrugated thin ferritic stainless steel having a coating of gamma alumina on at least one surface thereof.
Claim 28
Dependent Claim
37 words
An exhaust system as defined in claim 2 wherein the electrically heatable catalytic converter includes a honeycomb monolith formed of corrugated thin ferritic stainless steel having a coating of gamma alumina on at least one surface thereof.
Claim 29
Dependent Claim
38 words
An exhaust system as defined in claim 3 wherein the electrically heatable catalytic converter includes a honeycomb monolith formed of corrugated thin ferritic stainless steel having a coating of gamma alumina on at least one surface surface thereof.
Claim 30
Dependent Claim
49 words
An exhaust system as defined in claim 1 wherein the electrically heatable catalytic converter includes a honeycomb monolith formed of thin ferritic stainless steel having a coating of gamma alumina on at least one surface thereof and a noble metal catalyst deposited on the surface of the alumina coating.
Claim 31
Dependent Claim
49 words
An exhaust system as defined in claim 2 wherein the electrically heatable catalytic converter includes a honeycomb monolith formed of thin ferritic stainless steel having a coating of gamma alumina on at least one surface thereof and a noble metal catalyst deposited on the surface of the alumina coating.
Claim 32
Dependent Claim
49 words
An exhaust system as defined in claim 3 wherein the electrically heatable catalytic converter includes a honeycomb monolith formed of thin ferritic stainless steel having a coating of gamma alumina on at least one surface thereof and a noble metal catalyst deposited on the surface of the alumina coating.
Claim 33
Dependent Claim
31 words
An exhaust system as defined in claim 27 wherein the noble metal catalyst is selected from platinum, palladium, rhodium, ruthenium and mixtures of two or more of said noble metal catalysts.
Claim 34
Dependent Claim
31 words
An exhaust system as defined in claim 28 wherein the noble metal catalyst is selected from platinum, palladium, rhodium, ruthenium and mixtures of two or more of said noble metal catalysts.
Claim 35
Dependent Claim
31 words
An exhaust system as defined in claim 29 wherein the noble metal catalyst is selected from platinum, palladium, rhodium, ruthenium and mixtures of two or more of said noble metal catalysts.
Claim 36
Dependent Claim
30 words
An exhaust system as defined in claim 18 wherein the corrugated thin metal honeycomb monolith has a cell density of from about 100 to about 700 cells per square inch.
Claim 37
Dependent Claim
29 words
An exhaust system as defined in claim 19 wherein the corrugated thin metal honeycomb monolith has a cell density of from about 100 to 700 cells per square inch.
Claim 38
Dependent Claim
29 words
An exhaust system as defined in claim 20 wherein the corrugated thin metal honeycomb monolith has a cell density of from about 100 to 700 cells per square inch.
Claim 39
Dependent Claim
106 words
An exhaust system as defined in claim 19 wherein the thin metal honeycomb monolith includes a centrally located stainless steel core formed of a plurality of stainless steel rods each having secured thereto a pair of strips of corrugated thin metal foil and wound in a spiral about said rods to define a monolith core and each of said strips of corrugated thin metal foil having at its distal extremity a transversely extending metal bar secured thereto and when spirally wound, occupying a position on the outer periphery of said core; and a conductive binder ring wrapped about said monolith core and secured to said strips.
Claim 40
Dependent Claim
24 words
An exhaust system as defined in claim 19 further characterized by an electric terminal secured to and radially projecting from said conductor binder ring.
Claim 41
Dependent Claim
51 words
An exhaust system as defined in claim 19 further characterized by an electric terminal secured to and radially projecting from said conductor binder ring, said system being further characterized by a housing having an opening for said electric terminal, and an internally disposed insulating layer of ceramic fibers surrounding the core.
Claim 42
Dependent Claim
59 words
An exhaust system as defined in claim 19 further characterized by an electrical terminal secured to and radially projecting from said binder ring and being further characterized by a housing having an opening for said electric terminal and wherein said housing includes an end cap adaptor at each end thereof, said adaptors being dimensioned to accept said exhaust pipe.
Claim 43
Dependent Claim
45 words
An exhaust system as defined in claim 19 further characterized by an electrical terminal secured to and radially projecting from said binder ring and said housing having an opening for said electric terminal and further including means for electrically insulating said terminal from said housing.
Claim 44
Dependent Claim
51 words
An exhaust system as defined in claim 19 further including at least one battery and means for connecting said centrally located stainless steel rods to the negative pole of said at least one battery , and means for connecting said terminal to the positive pole of said at least one battery.
Claim 45
Dependent Claim
34 words
An exhaust system as defined in claim 22 including field effect transistor switch means for applying electrical power to said terminal to complete an electrical circuit and heat the corrugated thin metal honeycomb monolith.
Claim 46
Dependent Claim
50 words
An exhaust system as defined in claim 37 including field effect transistor switch means for applying electrical power to said terminal to complete an electrical circuit and heat the corrugated thin metal honeycomb monolith and wherein said switch means includes a plurality of MOSFET field effect transistors connected in parallel.
Claim 47
Dependent Claim
115 words
An electrically heatable catalytic converter comprising a housing, and an electrically heatable catalytic core including a plurality of centrally located stainless steel rods each having secured thereto a pair of strips of corrugated thin metal foil wound in a spiral about said centrally located bars and each one of said pair of strips of corrugated thin metal foil having a transversely extending metal strip secured to the distal extremity thereof; a conductive binder ring surrounding said core and attached to said transversely extending metal strips, a terminal radially projecting from said binder ring and extending through said housing, means for insulating said terminal from said housing, and insulating means between said housing and said core.
Claim 48
Dependent Claim
115 words
An electrically heatable catalytic converter comprising a housing, and an electrically heatable catalytic core including a plurality of centrally located stainless steel rods each having secured thereto a pair of strips of corrugated thin metal foil wound in a spiral about said centrally located bars and each one of said pair of strips of corrugated thin metal foil having a transversely extending metal strip secured to the distal extremity thereof; a conductive binder ring surrounding said core and attached to said transversely extending metal strips, a terminal radially projecting from said binder ring and extending through said housing, means for insulating said terminal from said housing, and insulating means between said housing and said core.
Claim 49
Dependent Claim
203 words
An exhaust system for an internal combustion engine including at least one 12 volt battery, an exhaust pipe, an electrically heatable catalytic converter in tandem relation with a separate catalytic converter free of electrical heating means, and power control means for providing a modulated electrical power of at least 1500 watts for from 2 to 30 seconds to said electrically heatable catalytic converter, said power control means including a plurality of metal oxide semiconductor field effect transistors connected in parallel to said battery, means for sensing the temperature of said electrically heatable catalytic converter, means responsive to said temperature sensing means for controlling the application of electrical power to said electrically heatable catalytic converter whereby the temperature is rapidly raised to and maintained at a temperature in excess of the light-off temperature of pollutant materials in said exhaust, and said controlling means including a microcomputer chip including a CPU, at least about 2K of EPROM, at least about 256 bytes of RAM, and analog and digital ports, said electrically heatable catalytic converter including a corrugated thin ferritic stainless steel monolith and having a cell density of from 100 to 700 cells per square inch, and a noble metal catalyst deposited in said cells.
Claim 50
Dependent Claim
203 words
An exhaust system for an internal combustion engine including at least one 12 volt battery, an exhaust pipe, an electrically heatable catalytic converter in tandem relation with a separate catalytic converter free of electrical heating means, and power control means for providing a modulated electrical power of at least 1500 watts for from 2 to 30 seconds to said electrically heatable catalytic converter, said power control means including a plurality of metal oxide semiconductor field effect transistors connected in parallel to said battery, means for sensing the temperature of said electrically heatable catalytic converter, means responsive to said temperature sensing means for controlling the application of electrical power to said electrically heatable catalytic converter whereby the temperature is rapidly raised to and maintained at a temperature in excess of the light-off temperature of pollutant materials in said exhaust, and said controlling means including a microcomputer chip including a CPU, at least about 2K of EPROM, at least about 256 bytes of RAM, and analog and digital ports, said electrically heatable catalytic converter including a corrugated thin ferritic stainless steel monolith and having a cell density of from 100 to 700 cells per square inch, and a noble metal catalyst deposited in said cells.
Claim 51
Independent Claim
126 words
A method for accelerating the response of an exhaust gas pollutant conversion catalyst in the exhaust line from an internal combustion engine, and wherein the catalyst consists essentially of a corrugated stainless steel foil having a thin coating of a refractory metal oxide and a noble metal catalyst deposited thereon, comprising directly heating said stainless steel foil with and electric current in excess of 150 amps from a voltage source, modulating said current over a duty cycle of from 0% to 100% and switching said current through a plurality of actuatable solid state switches connected in parallel together with means for actuating said switches in unison, whereby the temperature of the catalyst is raised to at least about 650 F. in from 2 to 30 seconds.
Claim 52
Independent Claim
126 words
A method for accelerating the response of an exhaust gas pollutant conversion catalyst in the exhaust line from an internal combustion engine, and wherein the catalyst consists essentially of a corrugated stainless steel foil having a thin coating of a refractory metal oxide and a noble metal catalyst deposited thereon, comprising directly heating said stainless steel foil with and electric current in excess of 150 amps from a voltage source, modulating said current over a duty cycle of from 0% to 100% and switching said current through a plurality of actuatable solid state switches connected in parallel together with means for actuating said switches in unison, whereby the temperature of the catalyst is raised to at least about 650 F. in from 2 to 30 seconds.
Claim 53
Dependent Claim
20 words
A method in accordance with claim 46 wherein the actuatable solid state switches are metal oxide semiconductor field effect transistors.
Claim 54
Dependent Claim
19 words
A method in accordance with claim 46 wherein the voltage source comprises at least one 12 volt automobile battery.
Claim 55
Dependent Claim
23 words
A method in accordance with claim 46 wherein the voltage source provides an EMF in the range of from 12 to 60 volts.
Claim 56
Dependent Claim
39 words
A method in accordance with claim 46 wherein the voltage source is connected in parallel to the source side of the transistors and the electrically heatable catalytic converter is connected in parallel to the drain side of said transistors.
Claim 57
Independent Claim
137 words
A system for accelerating the response of an exhaust gas pollutant conversion catalyst comprising, an internal combustion engine exhaust line, an electrically heatable catalytic converter in said exhaust line, said electrically heatable catalytic converter including an electrically heatable corrugated thin metal foil monolith having a thin coating of refractory metal oxide on the foil surfaces thereof, and a noble metal catalyst deposited thereon, an electric heating circuit including a voltage source capable of providing a current of at least about 150 amps for up to 30 seconds prior to engine start-up, means connected to said voltage source for modulating said electric current according to a duty cycle ranging from 0% to 100%, means for switching said electric current through a plurality of actuatable solid state switches connected in parallel and means for actuating said switches in unison.
Claim 58
Independent Claim
137 words
A system for accelerating the response of an exhaust gas pollutant conversion catalyst comprising, an internal combustion engine exhaust line, an electrically heatable catalytic converter in said exhaust line, said electrically heatable catalytic converter including an electrically heatable corrugated thin metal foil monolith having a thin coating of refractory metal oxide on the foil surfaces thereof, and a noble metal catalyst deposited thereon, an electric heating circuit including a voltage source capable of providing a current of at least about 150 amps for up to 30 seconds prior to engine start-up, means connected to said voltage source for modulating said electric current according to a duty cycle ranging from 0% to 100%, means for switching said electric current through a plurality of actuatable solid state switches connected in parallel and means for actuating said switches in unison.
Claim 59
Dependent Claim
18 words
A system in accordance with claim 51 wherein the voltage source is an automotive vehicle wet cell battery.
Claim 60
Dependent Claim
35 words
A system in accordance with claim 51 wherein the voltage source is a direct current voltage source, and said voltage source is connected in parallel to the source sides of said actuatable solid state switches.
Claim 61
Dependent Claim
24 words
A system in accordance with claim 53 which is further characterized by gate driver means for actuating said actuatable solid state switches in unison.
Claim 62
Dependent Claim
36 words
A system in accordance with claim 51 which is further characterized by an auxiliary battery in series with said voltage source and connected to gate driver means for actuating said actuatable solid state switches in unison.
Claim 63
Dependent Claim
20 words
A system in accordance with claim 51 wherein the actuatable solid state switches are metal oxide semiconductor field effect transistors.
Claim 64
Dependent Claim
23 words
An exhaust system as defined in claim 1 wherein the electrically heatable catalytic converter is in juxtaposed relation with the conventional catalytic converter.
Claim 65
Dependent Claim
23 words
An exhaust system as defined in claim 2 wherein the electrically heatable catalytic converter is in juxtaposed relation with the conventional catalytic converter.
Claim 66
Dependent Claim
23 words
An exhaust system as defined in claim 3 wherein the electrically heatable catalytic converter is in juxtaposed relation with the conventional catalytic converter.
Claim 67
Dependent Claim
100 words
Power control means for an electrically heatable catalytic converter for treating exhaust from an internal combustion engine comprising a battery power source, a plurality of MOSFET (metal oxide semiconductor field effect transistor) transistors connected in parallel and to said battery power source, means for sensing the temperature of said electrically heatable catalytic converter, and means responsive to said temperature sensing means for controlling the the application of electrical power from said transistors to said electrically heatable catalytic converter whereby more than 500 amps for a period of from 2 to 15 seconds are applied to said electrically heatable catalytic converter.
Claim 68
Dependent Claim
100 words
Power control means for an electrically heatable catalytic converter for treating exhaust from an internal combustion engine comprising a battery power source, a plurality of MOSFET (metal oxide semiconductor field effect transistor) transistors connected in parallel and to said battery power source, means for sensing the temperature of said electrically heatable catalytic converter, and means responsive to said temperature sensing means for controlling the the application of electrical power from said transistors to said electrically heatable catalytic converter whereby more than 500 amps for a period of from 2 to 15 seconds are applied to said electrically heatable catalytic converter.
Claim 69
Dependent Claim
22 words
A power control in accordance with claim 59 wherein the electrically heatable catalytic converter includes a polycellular corrugated thin metal foil monolith.
Claim 70
Dependent Claim
25 words
A power control in accordance with claim 59 further characterized by an auxillary battery power source in series with said first mentioned battery power source.
Claim 71
Dependent Claim
44 words
A power control in accordance with claim 59 wherein the controlling means includes a microcomputer chip containing a CPU, at least about 2K of EPROM, at least about 256 bytes of RAM, and analog and digital ports, and connected to said field effect transistors.
References Cited (Backward Citations)
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