US5319929A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Catalytic converter system
Assignee: BASF Catalysts LLC
•
Filing: 1992-08-05
•
Granted: 1994-06-14
•
Expires: 2012-08-05
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, desirably, a separate unheated conventional catalytic converter in tandem relation. The system also provides means for providing electrical power greater than 500 watts for 2 seconds or more whereby the temperature of the catalyst is raised and maintained at least 650 F. An advantage of preferred embodiments 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 material operative prior to, during and after start-up. Power switching means are provided for heating an electrically heatable catalytic converter and are characterized by at least one actuatable solid state switch, preferably in combination with means for actuating said switches.
Inventors
- 👤 Richard C. Cornelison
- 👤 William A. Whittenberger
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 10:07
CPC Classifications
H; H03; H03K; H03K17/00; H03K17/12; H03K17/122; B; B01; B01D; B01D53/00; B01D53/34; B01D53/92; B01D53/94; B01D53/9445; B01D53/9454; 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; F01N2330/00; F01N2330/02; F01N2330/04; Y; Y02; Y02A; Y02A50/00; Y02A50/20; Y02T; Y02T10/00; Y02T10/10; Y02T10/12
Claims Analysis
Total Claims: 107
Claim 1
Independent Claim
76 words
An exhaust system for an internal combustion engine including an exhaust pipe, and comprising an electrically heatable catalytic converter in tandem relation with a separate conventional catalytic converter free of electrical heating means, and means for applying power of at least 500 watts for about 2 or more seconds to said electrically heatable catalytic converter, said means for applying power including at least one metal oxide semiconductor field effect transistor and means for actuating said transistor.
Claim 2
Dependent Claim
76 words
An exhaust system for an internal combustion engine including an exhaust pipe, and comprising an electrically heatable catalytic converter in tandem relation with a separate conventional catalytic converter free of electrical heating means, and means for applying power of at least 500 watts for about 2 or more seconds to said electrically heatable catalytic converter, said means for applying power including at least one metal oxide semiconductor field effect transistor and means for actuating said transistor.
Claim 3
Dependent Claim
101 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 applying power of at least 1500 watts for from 2 to 30 seconds to said electrically heatable catalytic converter; said means for applying electrical power including a plurality of metal oxide semiconductor field effect transistors (MOSFETS) connected in parallel and means for actuating said transistors in unison; whereby the temperature in said electrically heatable catalytic converter can be elevated to at least about 650F.
Claim 4
Dependent Claim
101 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 applying power of at least 1500 watts for from 2 to 30 seconds to said electrically heatable catalytic converter; said means for applying electrical power including a plurality of metal oxide semiconductor field effect transistors (MOSFETS) connected in parallel and means for actuating said transistors in unison; whereby the temperature in said electrically heatable catalytic converter can be elevated to at least about 650F.
Claim 5
Dependent Claim
136 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 including a voltage source of from 12 to 60 volts capable of providing power at the rate of 1500 to 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 0.005 ohm to 2.2 ohms; said means for providing electrical power including a plurality of metal oxide semiconductor field effect transistors connected in parallel and means for actuating said transistors in unison; whereby the temperature in said electrically heatable catalytic converter may be elevated to at least about 650 F.
Claim 6
Dependent Claim
136 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 including a voltage source of from 12 to 60 volts capable of providing power at the rate of 1500 to 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 0.005 ohm to 2.2 ohms; said means for providing electrical power including a plurality of metal oxide semiconductor field effect transistors connected in parallel and means for actuating said transistors in unison; whereby the temperature in said electrically heatable catalytic converter may be elevated to at least about 650 F.
Claim 7
Dependent Claim
72 words
An exhaust system for an internal combustion engine as defined in claim 2 further comprising means including a voltage source of from 12 to 60 volts capable of providing power of from about 500 to 12000 watts for from 2 to 60 seconds prior to and at start-up to said electrically heatable catalytic converter, and wherein said electrically heatable catalytic converter has a total resistance of from 0.005 ohm to 2.2 ohms.
Claim 8
Dependent Claim
33 words
An exhaust system as defined in claim 2 wherein said means for applying electrical power includes means for applying power to said electrically heatable catalytic converter prior to starting said internal combustion engine.
Claim 9
Dependent Claim
48 words
An exhaust system in accordance with claim 5 wherein said means for applying electrical power 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 10
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 11
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 12
Dependent Claim
22 words
An exhaust system as defined in claim 3 wherein the electrically heatable catalytic converter is located upstream of said conventional catalytic converter.
Claim 13
Dependent Claim
45 words
An exhaust system as defined in claim 1 wherein said means for applying electrical power includes temperature responsive means for applying power to said electrically heatable catalytic converter also after starting the internal combustion engine to maintain the temperature to at least about 200 F.
Claim 14
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 15
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 16
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 17
Dependent Claim
18 words
An exhaust system as defined in claim 1 wherein the conventional catalytic converter includes a ceramic honeycomb monolith.
Claim 18
Dependent Claim
18 words
An exhaust system as defined in claim 2 wherein the conventional catalytic converter includes a ceramic honeycomb monolith.
Claim 19
Dependent Claim
18 words
An exhaust system as defined in claim 3 wherein the conventional catalytic converter includes a ceramic honeycomb monolith.
Claim 20
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 21
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 22
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 23
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 24
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 25
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 26
Dependent Claim
26 words
An exhaust system as defined in claim 22 wherein the thin metal honeycomb monolith is a thin high temperature resistive, corrosion resistant thin metal honeycomb monolith.
Claim 27
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 28
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 29
Dependent Claim
23 words
An exhaust system as defined in claim 3 wherein the electrically heatable catalytic converter includes a corrugated thin ferritic stainless steel honeycomb monolith.
Claim 30
Dependent Claim
21 words
An exhaust system as defined in claim 23 wherein the thin high temperature resistive, corrosion resistant metal is a nickel-containing metal.
Claim 31
Dependent Claim
16 words
An exhaust system as defined in claim 27 wherein the nickel-containing metal is a nickel/chromium/aluminum/iron alloy.
Claim 32
Dependent Claim
40 words
An exhaust system as defined in claim 1 wherein the electrically heatable catalytic converter includes a honeycomb monolith formed of corrugated thin, high temperature resistive, corrosion resistant metal having a coating comprising gamma alumina on at least one surface thereof.
Claim 33
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 comprising gamma alumina on at least one surface thereof.
Claim 34
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 comprising gamma alumina on at least one surface thereof.
Claim 35
Dependent Claim
37 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 comprising gamma alumina on at least one surface thereof.
Claim 36
Dependent Claim
30 words
An exhaust system as defined in claim 27 wherein the corrugated high temperature resistive, corrosion resistant thin metal includes a coating comprising gamma alumina on at least one surface thereof.
Claim 37
Dependent Claim
50 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 including gamma alumina on at least one surface thereof and a noble metal catalyst deposited on the surface of the alumina coating.
Claim 38
Dependent Claim
50 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 and a noble metal catalyst deposited on the surface of the alumina coating.
Claim 39
Dependent Claim
50 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 thereof and a noble metal catalyst deposited on the surface of the alumina coating.
Claim 40
Dependent Claim
53 words
An exhaust system as defined in claim 1 wherein the electrically heatable catalytic converter includes a honeycomb monolith formed of corrugated thin high temperature resistive, corrosion resistant metal 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 41
Dependent Claim
20 words
An exhaust system as defined in claim 37 wherein the high temperature resistive, corrosion resistant metal is a nickel-containing metal.
Claim 42
Dependent Claim
16 words
An exhaust system as defined in claim 38 wherein the nickel-containing metal is a nickel/chromium/aluminum/iron alloy.
Claim 43
Dependent Claim
31 words
An exhaust system as defined in claim 34 wherein the noble metal catalyst is selected from platinum, palladium, rhodium, ruthenium, and mixtures of two or more of said noble metal catalysts.
Claim 44
Dependent Claim
31 words
An exhaust system as defined in claim 35 wherein the noble metal catalyst is selected from platinum, palladium, rhodium, ruthenium, and mixtures of two or more of said noble metal catalysts.
Claim 45
Dependent Claim
31 words
An exhaust system as defined in claim 36 wherein the noble metal catalyst is selected from platinum, palladium, rhodium, ruthenium, and mixtures of two or more of said noble metal catalysts.
Claim 46
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 50 to 700 cells per square inch.
Claim 47
Dependent Claim
29 words
An exhaust system as defined in claim 21 wherein the corrugated thin metal honeycomb monolith has a cell density of from about 100 to 700 cells per square inch.
Claim 48
Dependent Claim
29 words
An exhaust system as defined in claim 22 wherein the corrugated thin metal honeycomb monolith has a cell density of from about 100 to 700 cells per square inch.
Claim 49
Dependent Claim
105 words
An exhaust system as defined in claim 17 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 and secured to said strips.
Claim 50
Dependent Claim
106 words
An exhaust system as defined in claim 18 wherein the thin metal honeycomb monolith includes a centrally located stainless steel core formed of a plurality of stainless steel rods each having secured therto 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 51
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 from 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 52
Dependent Claim
24 words
An exhaust system as defined in claim 46 further characterized by an electrical terminal secured to and radially projecting from said conductor binder ring.
Claim 53
Dependent Claim
24 words
An exhaust system as defined in claim 47 further characterized by an electrical terminal secured to and radially projecting from said conductor binder ring.
Claim 54
Dependent Claim
24 words
An exhaust system as defined in claim 48 further characterized by an electrical terminal secured to and radially projecting from said conductor binder ring.
Claim 55
Dependent Claim
51 words
An exhaust system as defined in claim 46 further characterized by an electrical terminal secured to and radially projecting from said conductor binder ring, said system being further characterized by a housing having an opening for said electrical terminal, and an internally disposed insulating layer of ceramic fibers surrounding the core.
Claim 56
Dependent Claim
51 words
An exhaust system as defined in claim 47 further characterized by an electrical terminal secured to and radially projecting from said conductor binder ring, said system being further characterized by a housing having an opening for said electrical terminal, and an internally disposed insulating layer of ceramic fibers surrounding the core.
Claim 57
Dependent Claim
51 words
An exhaust system as defined in claim 48 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 electrical terminal, and an internally disposed insulating layer of ceramic fibers surrounding the core.
Claim 58
Dependent Claim
60 words
An exhaust system as defined in claim 46 further characterized by an electric terminal secured to and radially projecting from said conductor 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 59
Dependent Claim
60 words
An exhaust system as defined in claim 47 further characterized by an electric terminal secured to and radially projecting from said conductor 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 60
Dependent Claim
60 words
An exhaust system as defined in claim 48 further characterized by an electric terminal secured to and radially projecting from said conductor 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 61
Dependent Claim
46 words
An exhaust system as defined in claim 46 further characterized by an electric terminal secured to and radially projecting from said conductor 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 62
Dependent Claim
45 words
An exhaust system as defined in claim 47 further characterized by an electrical terminal secured to and projecting from said conductor 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 63
Dependent Claim
46 words
An exhaust system as defined in claim 48 further characterized by an electric terminal secured to an radially projecting from said conductor 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 64
Dependent Claim
50 words
An exhaust system as defined in claim 46 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 65
Dependent Claim
50 words
An exhaust system as defined in claim 48 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 66
Dependent Claim
50 words
An exhaust system as defined in claim 48 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 67
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 the 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 68
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 the 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 69
Dependent Claim
194 words
An exhaust system for an internal combustion engine including at least one 12 volt battery, an exhaust pipe, an electrically heatable catalytic converter, and power control means for providing a modulated electrical power of at least 500 watts for at least from 2 to 60 seconds to said electrically heatable catalytic converter, said power control means including at least one metal oxide semiconductor field effect transistor connected 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 2K of EPROM, at least 256 bytes of RAM, and analog and digital ports, said electrically heatable catalytic converter including a corrugated thin high temperature resistive, corrosion resistant metal foil monolith and having a cell density of from about 100 to about 700 cells per square inch, and a noble metal catalyst deposited in said cells.
Claim 70
Dependent Claim
194 words
An exhaust system for an internal combustion engine including at least one 12 volt battery, an exhaust pipe, an electrically heatable catalytic converter, and power control means for providing a modulated electrical power of at least 500 watts for at least from 2 to 60 seconds to said electrically heatable catalytic converter, said power control means including at least one metal oxide semiconductor field effect transistor connected 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 2K of EPROM, at least 256 bytes of RAM, and analog and digital ports, said electrically heatable catalytic converter including a corrugated thin high temperature resistive, corrosion resistant metal foil monolith and having a cell density of from about 100 to about 700 cells per square inch, and a noble metal catalyst deposited in said cells.
Claim 71
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 at least 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 material in said exhaust, 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 having a cell density of from 100 to 700 cells per square inch, and a noble metal catalyst deposited in said cells.
Claim 72
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 at least 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 material in said exhaust, 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 having a cell density of from 100 to 700 cells per square inch, and a noble metal catalyst deposited in said cells.
Claim 73
Independent Claim
115 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 thin high temperature resistive, corrosion resistant metal foil having a thin coating of a refractory metal oxide and a noble metal catalyst deposited thereon, comprising directly heating said foil with electric power from at least one 12 volt battery, at a power level in excess of 500 watts from a voltage source, modulating said power over a duty cycle of from 0% to 100% and switching said power through an actuatable solid state switch together with means for actuating said actuatable solid state switch.
Claim 74
Independent Claim
115 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 thin high temperature resistive, corrosion resistant metal foil having a thin coating of a refractory metal oxide and a noble metal catalyst deposited thereon, comprising directly heating said foil with electric power from at least one 12 volt battery, at a power level in excess of 500 watts from a voltage source, modulating said power over a duty cycle of from 0% to 100% and switching said power through an actuatable solid state switch together with means for actuating said actuatable solid state switch.
Claim 75
Independent Claim
124 words
A method for accelerating the response of an exhaust gas pollutant conversion catalyst in the exhaust from an internal combustion engine, and wherein the catalyst consists essentially of a corrugated stainless steel foil having a thin coating of refractory metal oxide and a noble metal catalyst deposited thereon, comprising directly heating said stainless steel foil with an 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 76
Independent Claim
124 words
A method for accelerating the response of an exhaust gas pollutant conversion catalyst in the exhaust from an internal combustion engine, and wherein the catalyst consists essentially of a corrugated stainless steel foil having a thin coating of refractory metal oxide and a noble metal catalyst deposited thereon, comprising directly heating said stainless steel foil with an 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 77
Dependent Claim
20 words
A method in accordance with claim 68 wherein the actuatable solid state switches are metal oxide semiconductor field effect transistors.
Claim 78
Dependent Claim
19 words
A method in accordance with claim 68 wherein the voltage source includes at least one 12 volt automobile battery.
Claim 79
Dependent Claim
23 words
A method in accordance with claim 68 wherein the voltage source provides an EMF in the range of from 12 to 60 volts.
Claim 80
Dependent Claim
39 words
A method in accordance with claim 68 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 81
Independent Claim
128 words
A system for accelerating the response of an exhaust gas pollution conversion catalyst comprising, an internal combustion engine exhaust line, an 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 82
Independent Claim
128 words
A system for accelerating the response of an exhaust gas pollution conversion catalyst comprising, an internal combustion engine exhaust line, an 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 83
Dependent Claim
18 words
A system in accordance with claim 73 wherein the voltage source is an automotive vehicle wet cell battery.
Claim 84
Dependent Claim
35 words
A system in accordance with claim 73 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 85
Dependent Claim
24 words
A system in accordance with claim 75 which is further characterized by gate driver means for actuating said actuatable solid state switches in unison.
Claim 86
Dependent Claim
36 words
A system in accordance with claim 73 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 87
Dependent Claim
20 words
A system in accordance with claim 73 wherein the actuatable solid state switches are metal oxide semiconductor field effect transistors.
Claim 88
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 89
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 90
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 91
Dependent Claim
128 words
An exhaust system for an internal combustion engine including at least one 12 volt battery, an exhaust pipe, an electrically heatable catalytic converter, and power control means for providing a modulated electrical power of at least 500 watts for at least 2 seconds to said electrically heatable catalytic converter, said power control means including at least one metal oxide semiconductor field effect transistor connected 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 from said at least one transistor 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.
Claim 92
Dependent Claim
128 words
An exhaust system for an internal combustion engine including at least one 12 volt battery, an exhaust pipe, an electrically heatable catalytic converter, and power control means for providing a modulated electrical power of at least 500 watts for at least 2 seconds to said electrically heatable catalytic converter, said power control means including at least one metal oxide semiconductor field effect transistor connected 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 from said at least one transistor 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.
Claim 93
Dependent Claim
127 words
An exhaust system for an internal combustion engine including at least one 12 volt battery, an exhaust pipe, an electrically heatable catalytic converter, 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 from said transistors to said electrically heatable catalytic converter whereby the temperature is rapidly raised and maintained at a temperature in excess of the light-off temperature of pollutant materials in said exhaust.
Claim 94
Dependent Claim
127 words
An exhaust system for an internal combustion engine including at least one 12 volt battery, an exhaust pipe, an electrically heatable catalytic converter, 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 from said transistors to said electrically heatable catalytic converter whereby the temperature is rapidly raised and maintained at a temperature in excess of the light-off temperature of pollutant materials in said exhaust.
Claim 95
Dependent Claim
22 words
An exhaust system as defined in claim 82 wherein the electrically heatable catalytic converter includes a polycellular corrugated thin metal foil monolith.
Claim 96
Dependent Claim
22 words
An exhaust system as defined in claim 83 wherein the electrically heatable catalytic converter includes a polycellular corrugated thin metal foil monolith.
Claim 97
Dependent Claim
26 words
An exhaust system as defined in claim 82 further characterized by an auxiliary battery power source in series with said at least one 12 volt battery.
Claim 98
Dependent Claim
26 words
An exhaust system as defined in claim 83 further characterized by an auxiliary battery power source in series with said at least one 12 volt battery.
Claim 99
Dependent Claim
43 words
An exhaust system as defined in claim 82 wherein said controlling means includes a microcomputer chip containing a CPU, at least 2K of EPROM, at least about 256 bytes of RAM, and analog and digital ports, and connected to said field effect transistors.
Claim 100
Dependent Claim
43 words
An exhaust system as defined in claim 83 wherein said controlling means includes a microcomputer chip containing a CPU, at least 2K of EPROM, at least about 256 bytes of RAM, and analog and digital ports, and connected to said field effect transistors.
Claim 101
Dependent Claim
159 words
An exhaust system for an internal combustion engine including a battery rated at from 12 to 60 volts, an exhaust pipe, an electrically heatable catalytic converter, and power control means for providing modulated electric power of at least 500 watts for at least 2 seconds to said electrically heatable catalytic converter, said power control means comprising a plurality of actuatable 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 from said actuatable metal oxide semiconductor field effect transistors to said electrically heatable catalytic converter, means for actuating said actuatable metal oxide semiconductor field effect transistors, whereby the temperature of said electrically heatable catalytic converter is rapidly raised and maintained at a temperature in excess of the light off temperature of pollutant material in the exhaust emanating from said internal combustion engine.
Claim 102
Dependent Claim
159 words
An exhaust system for an internal combustion engine including a battery rated at from 12 to 60 volts, an exhaust pipe, an electrically heatable catalytic converter, and power control means for providing modulated electric power of at least 500 watts for at least 2 seconds to said electrically heatable catalytic converter, said power control means comprising a plurality of actuatable 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 from said actuatable metal oxide semiconductor field effect transistors to said electrically heatable catalytic converter, means for actuating said actuatable metal oxide semiconductor field effect transistors, whereby the temperature of said electrically heatable catalytic converter is rapidly raised and maintained at a temperature in excess of the light off temperature of pollutant material in the exhaust emanating from said internal combustion engine.
Claim 103
Dependent Claim
77 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 application of electrical power from said transistors to said electrically heatable catalytic converter.
Claim 104
Dependent Claim
77 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 application of electrical power from said transistors to said electrically heatable catalytic converter.
Claim 105
Dependent Claim
22 words
A power control in accordance with claim 91 wherein the electrically heatable catalytic converter includes a polycellular corrugated thin metal foil monolith.
Claim 106
Dependent Claim
25 words
A power control in accordance with claim 91 further characterized by an auxiliary battery power source in series with said first mentioned battery power source.
Claim 107
Dependent Claim
43 words
A power control in accordance with claim 91 wherein the controlling means includes a microcomputer chip containing a CPU, at least about 2K of EPROM, at least 256 bytes of RAM, and analog and digital ports, and connected to said field effect transistors.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1997-06-13 | 1997-12-13 | 1998-06-14 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2001-06-13 | 2001-12-13 | 2002-06-14 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2005-06-13 | 2005-12-13 | 2006-06-14 | $7700.00 | Window Closed / Lapsed |