US6546721B2 — Exhaust gas purification device

Claim 1

Independent Claim 208 words

An exhaust gas purification device of an engine having a combustion chamber comprising an exhaust passage and a particulate filter arranged in said exhaust passage for removing particulate in exhaust gas exhausted from said combustion chamber; said particulate filter being a particulate filter having a function of removing, by oxidation, particulate in the exhaust gas without emitting a luminous flame when an amount of discharged particulate discharged from the combustion chamber per unit time is smaller than an amount of particulate removable by oxidation per unit time without emitting a luminous flame on the particulate filter and of absorbing NO x in exhaust gas when an air-fuel ratio of the exhaust gas flowing into the particulate filter is lean and releasing the absorbed NO x when the air-fuel ratio of the exhaust gas flowing into the particulate filter becomes the stoichiometric air-fuel ratio or rich; the amount of said discharged particulate and the temperature of the particulate filter being maintained in most operating states within a simultaneous particulate and NO x treatment region in a temperature region wherein the amount of discharged particulate becomes smaller than an amount of particulate removable by oxidation and a NO x absorption rate becomes more than a certain value at all times.

Claim 2

Dependent Claim 208 words

An exhaust gas purification device of an engine having a combustion chamber comprising an exhaust passage and a particulate filter arranged in said exhaust passage for removing particulate in exhaust gas exhausted from said combustion chamber; said particulate filter being a particulate filter having a function of removing, by oxidation, particulate in the exhaust gas without emitting a luminous flame when an amount of discharged particulate discharged from the combustion chamber per unit time is smaller than an amount of particulate removable by oxidation per unit time without emitting a luminous flame on the particulate filter and of absorbing NO x in exhaust gas when an air-fuel ratio of the exhaust gas flowing into the particulate filter is lean and releasing the absorbed NO x when the air-fuel ratio of the exhaust gas flowing into the particulate filter becomes the stoichiometric air-fuel ratio or rich; the amount of said discharged particulate and the temperature of the particulate filter being maintained in most operating states within a simultaneous particulate and NO x treatment region in a temperature region wherein the amount of discharged particulate becomes smaller than an amount of particulate removable by oxidation and a NO x absorption rate becomes more than a certain value at all times.

Claim 3

Dependent Claim 23 words

An exhaust gas purification device as set forth in claim 1 , wherein a precious metal catalyst is carried on the particulate filter.

Claim 4

Dependent Claim 94 words

An exhaust gas purification device as set forth in claim 2 , wherein an active oxygen release agent which absorbs oxygen and holds the oxygen when excess oxygen is present in the surroundings and releases the held oxygen in the form of active oxygen when the concentration of oxygen in the surroundings falls is carried on the particulate filter and wherein active oxygen is released from the active oxygen release agent and the particulate adhered on the particulate filter is oxidized by the released active oxygen when the particulate adheres on the particulate filter.

Claim 5

Dependent Claim 140 words

An exhaust gas purification device as set forth in claim 2 , wherein an NO x absorbent for absorbing the NO x in the exhaust gas when the air-fuel ratio of the exhaust gas flowing into the particulate filter is lean and releasing the absorbed NO x when the air-fuel ratio of the exhaust gas flowing into the particulate filter becomes the stoichiometric air-fuel ratio or rich is carried on the particulate filter; the air-fuel ratio of the exhaust gas flowing into the particulate filter is usually maintained lean so that the NO x in the exhaust gas is absorbed in the NO x absorbent, and air-fuel ratio control means is provided for making the air-fuel ratio of the exhaust gas flowing into the particulate filter temporarily rich when NO x is to be released from the NO x absorbent.

Claim 6

Dependent Claim 210 words

An exhaust gas purification device as set forth in claim 2 , wherein an active oxygen release agent/NO x absorbent having the function of an active oxygen release agent which absorbs oxygen and holds the oxygen when excess oxygen is present in the surroundings and releases the held oxygen in the form of active oxygen when the concentration of oxygen in the surroundings falls and the function of a NO x absorbent absorbing the NO x in the exhaust gas when the air-fuel ratio of the exhaust gas flowing into the particulate filter is lean and releasing the absorbed NO x when the air-fuel ratio of the exhaust gas flowing into the particulate filter becomes the stoichiometric air-fuel ratio or rich is carried on the particulate filter; the air-fuel ratio of the exhaust gas flowing into the particulate filter is usually maintained lean so that the particulate adhered on the particulate filter is oxidized and the NO x in the exhaust gas is absorbed in the active oxygen release agent/NO x absorbent, and air-fuel ratio control means is provided for making the air-fuel ratio of the exhaust gas flowing into the particulate filter temporarily rich when NO x is to be released from the active oxygen release agent/NO x absorbent.

Claim 7

Dependent Claim 41 words

An exhaust gas purification device as set forth in claim 5 , wherein the active oxygen release agent/NO x absorbent is comprised of at least one of an alkali metal, an alkali earth metal, a rare earth, and a transition metal.

Claim 8

Dependent Claim 31 words

An exhaust gas purification device as set forth in claim 6 , wherein the alkali metal and alkali earth metal are comprised of metals higher in tendency toward ionization than calcium.

Claim 9

Dependent Claim 61 words

An exhaust gas purification device as set forth in claim 6 , further comprising temperature raising means for raising the temperature of the particulate filter to a SO x release temperature while maintaining the air-fuel ratio of the exhaust gas flowing into the particulate filter lean when SO x is to be released from the active oxygen release agent/NO x absorbent.

Claim 10

Dependent Claim 48 words

An exhaust gas purification device as set forth in claim 8 , wherein the temperature raising means makes the temperature of the particulate filter rise by causing a delay of the injection timing of main fuel or causing injection of auxiliary fuel in addition to the main fuel.

Claim 11

Dependent Claim 51 words

An exhaust gas purification device as set forth in claim 5 , wherein the air-fuel ratio control means alternately switches the air-fuel ratio of the exhaust gas flowing into the particulate filter between lean and rich when causing the release of SO x from the active oxygen release agent/NO x absorbent.

Claim 12

Dependent Claim 47 words

An exhaust gas purification device as set forth in claim 1 , wherein a mean air-fuel ratio in the combustion chamber is made rich or fuel is injected into the exhaust passage when making the air-fuel ratio of the exhaust gas flowing into the particulate filter rich.

Claim 13

Dependent Claim 117 words

An exhaust gas purification device as set fort in claim 11 , wherein the engine is an engine where the amount of generation of soot gradually increases and peaks when an amount of inert gas in the combustion chamber increases and where almost no soot is generated any longer when the amount of inert gas in the combustion chamber further increases and wherein when the amount of inert gas in the combustion chamber is larger than the amount of inert gas where the amount of generation of soot peaks and the air-fuel ratio of the exhaust gas flowing into the particulate filter should be made rich, the mean air-fuel ratio in the combustion chamber is made rich.

Claim 14

Dependent Claim 30 words

An exhaust gas purification device as set forth in claim 1 , wherein an amount of particulate removable by oxidation is a function of a temperature of the particulate filter.

Claim 15

Dependent Claim 49 words

An exhaust gas purification device as set forth in claim 13 , wherein the amount of particulate removable by oxidation is a function of at least one of concentration of oxygen and concentration of NO x in the exhaust gas in addition to the temperature of the particulate filter.

Claim 16

Dependent Claim 92 words

An exhaust gas purification device as set forth in claim 1 , further comprising control means for controlling at least one of an amount of discharged particulate, an amount of particulate removable by oxidation, and a temperature of the particulate filter so that the amount of discharged particulate and the temperature of the particulate filter become within a simultaneous particulate and NO x treatment region when at least one of the amount of discharged particulate and temperature of the particulate filter become out of the simultaneous particulate and NO x treatment region.

Claim 17

Dependent Claim 39 words

An exhaust gas purification device as set forth in claim 15 , wherein said control means controls the temperature of the particulate filter by controlling at least one of an amount of fuel injection and a fuel injection timing.

Claim 18

Dependent Claim 75 words

An exhaust gas purification device as set forth in claim 15 , wherein said engine is an engine where an amount of generation of soot gradually increases and peaks when an amount of exhaust gas recirculation increases and where almost no soot is generated any longer when the amount of exhaust gas recirculation further increases and wherein the control means controls the temperature of the particulate filter by controlling the amount of exhaust gas recirculation.

Claim 19

Dependent Claim 54 words

An exhaust gas purification device as set forth in claim 15 , wherein a hydrocarbon feed device is arranged in the exhaust passage upstream of the particulate filter and wherein the temperature of the particulate filter is controlled by controlling the amount of hydrocarbons fed from the hydrocarbon feed device into the exhaust passage.

Claim 20

Dependent Claim 48 words

An exhaust gas purification device as set forth in claim 15 , wherein an exhaust control valve is arranged in the exhaust passage downstream of the particulate filter and wherein the opening degree of the exhaust control valve is controlled to control the temperature of the particulate filter.

Claim 21

Dependent Claim 54 words

An exhaust gas purification device as set forth in claim 15 , further comprising an exhaust turbocharger provided with a waist gate valve for controlling an amount of exhaust gas bypassing an exhaust turbine and wherein the opening degree of the waist gate valve is controlled to control the temperature of the particulate filter.

Claim 22

Dependent Claim 59 words

An exhaust gas purification device as set forth in claim 15 , wherein the control means reduces the amount of discharged particulate when the amount of discharged particulate is to be controlled when at least one of the amount of discharged particulate and temperature of the particulate filter is out of the simultaneous particulate and NO x treatment region.

Claim 23

Dependent Claim 44 words

An exhaust gas purification device as set forth in claim 21 , wherein the control means reduces the amount of discharged particulate by controlling at least one of an amount of fuel injection, fuel injection timing, fuel injection pressure, and injection of auxiliary fuel.

Claim 24

Dependent Claim 38 words

An exhaust gas purification device as set forth in claim 21 , wherein supercharging means is provided for supercharging an intake air and wherein said control means reduces the amount of discharged particulate by increasing the supercharging pressure.

Claim 25

Dependent Claim 45 words

An exhaust gas purification device as set forth in claim 21 , wherein exhaust gas recirculation device is provided for recirculating exhaust gas in an intake passage and wherein said control means reduces the amount of discharged particulate by reducing an exhaust gas recirculation rate.

Claim 26

Dependent Claim 36 words

An exhaust gas purification device as set forth in claim 15 , wherein said control means controls a concentration of oxygen in the exhaust gas so as to control the amount of particulate removable by oxidation.

Claim 27

Dependent Claim 48 words

An exhaust gas purification device as set forth in claim 25 , wherein exhaust gas recirculation device is provided for recirculating exhaust gas in an intake passage and wherein said control means controls the exhaust gas recirculation rate to control the concentration of oxygen in the exhaust gas.

Claim 28

Dependent Claim 59 words

An exhaust gas purification device as set forth in claim 25 , wherein secondary air feed device is provided for feeding secondary air inside the exhaust passage upstream of the particulate filter and wherein said control means feeds secondary air inside the exhaust passage upstream of the particulate filter to control the concentration of oxygen in the exhaust gas.

Claim 29

Dependent Claim 123 words

An exhaust gas purification device as set forth in claim 1 , wherein said engine is an engine where an amount of generation of soot gradually increases and peaks when an amount of inert gas in the combustion chamber increases and where almost no soot is generated any longer when the amount of inert gas in the combustion chamber further increases and wherein first combustion where the amount of inert gas in the combustion chamber is larger than the amount of inert gas where the amount of generation of soot peaks and second combustion where the amount of inert gas in the combustion chamber is smaller than the amount of inert gas where the amount of generation of soot peaks are selectively performed.

Claim 30

Dependent Claim 79 words

An exhaust gas purification device as set forth in claim 28 , wherein exhaust gas recirculation device is provided for recirculating exhaust gas discharged from the combustion chamber through an engine intake passage, the inert gas is comprised of exhaust gas recirculation gas, the exhaust gas recirculation rate when first combustion is being performed is at least about 55 percent, and the exhaust gas recirculation rate when second combustion is being performed is not more than about 50 percent.

Claim 31

Dependent Claim 56 words

An exhaust gas purification device as set forth in claim 28 , wherein an operating region of the engine is divided into a low load side first operating region and a high load side second operating region, first combustion is performed in the first operating region, and second combustion is performed in the second operating region.

Claim 32

Dependent Claim 51 words

An exhaust gas purification device as set forth in claim 1 , wherein further provision is made of flow direction switching means able to alternately switch a direction of flow of exhaust gas flowing through the particulate filter between a first direction and a second direction opposite to the first direction.

Claim 33

Dependent Claim 45 words

An exhaust gas purification device as set forth in claim 31 , wherein said flow direction switching means alternately switches the direction of flow of the exhaust gas flowing through the particulate filter between the first direction and the second direction by a predetermined timing.

Claim 34

Dependent Claim 171 words

An exhaust gas purification device as set forth in claim 31 , wherein said flow direction switching means is comprised of a switching valve device arranged in the exhaust passage, the particulate filter is provided with exhaust gas outflow and inflow ends at its two ends; a first passage extending up to one of the exhaust gas outflow and inflow ends of the particulate filter, a second passage extending from the particulate filter up to the other of the exhaust gas outflow and inflow ends, and an exhaust bypass passage communicating with the outside air are branched from said switching valve device; and said switching valve device can switch the direction of flow of the exhaust gas among a first direction passing through the first passage, particulate filter, and second passage toward the exhaust bypass passage, a second direction passing through the second passage, particulate filter, and first passage toward exhaust bypass passage, and a third direction not passing through the particulate filter, but directly heading toward the exhaust bypass passage.

Claim 35

Dependent Claim 79 words

An exhaust gas purification device as set forth in claim 33 , wherein said switching valve device switches the direction of flow of the exhaust gas to one of the first direction or second direction passing through the particulate filter and the third direction where the exhaust gas does not pass through the particulate filter so that the temperature of the particulate filter becomes a temperature range where the NO x absorption rate becomes more than a certain value.

Claim 36

Dependent Claim 54 words

An exhaust gas purification device as set forth in claim 34 , wherein said switching valve device switches the direction of flow of the exhaust gas to the third direction when the temperature of the particulate filter is outside the temperature range where the NO x absorption rate becomes more than a certain value.

Claim 37

Dependent Claim 105 words

An exhaust gas purification device as set forth in claim 33 , wherein the first passage and the second passage are formed so that the temperature of the exhaust gas flowing from the second passage to the particulate filter becomes lower than the temperature of the exhaust gas flowing from the first passage to the particulate filter and wherein the switching valve device switches the flow of direction of the exhaust gas to one of the first direction or second direction so that the temperature of the particulate filter becomes a temperature range where the NO x absorption rate becomes more than a certain value.

Claim 38

Dependent Claim 108 words

An exhaust gas purification device as set forth in claim 33 , wherein the switching valve device switches the direction of flow of the exhaust gas to the third direction when the temperature of the particulate filter may become lower than the temperature range where the NO x absorption rate becomes more than a certain value when stopping the feed of fuel and makes the direction of flow the exhaust gas the first direction or second direction when the temperature of the particulate filter is higher than the temperature range where the NO x absorption rate becomes more than a certain value when stopping the feed of fuel.

Claim 39

Dependent Claim 163 words

An exhaust gas purification device as set forth in claim 31 , wherein an active oxygen release agent/NO x absorbent having the function of an active oxygen release agent which absorbs oxygen and holds the oxygen when excess oxygen is present in the surroundings and releases the held oxygen in the form of active oxygen when the concentration of oxygen in the surroundings falls and the function of a NO x absorbent absorbing the NO x in the exhaust gas when the air-fuel ratio of the exhaust gas flowing into the particulate filter is lean and releasing the absorbed NO x when the air-fuel ratio of the exhaust gas flowing into the particulate filter becomes the stoichiometric air-fuel ratio or rich is carried inside the particulate filter and wherein the particulate trapped in the particulate filter is moved by the direction of flow of the exhaust gas being switched to the first direction or the second direction by the flow direction switching means.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2006-04-14	2006-10-14	2007-04-15	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2010-04-14	2010-10-14	2011-04-15	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2014-04-14	2014-10-14	2015-04-15	$7700.00	Window Closed / Lapsed

Exhaust gas purification device

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