Catalytic converter substrate

Patent metadata

Field	Value
Publication number	US-9669359-B2
Application number	US-201514795362-A
Country	US
Kind code	B2
Filing date	Jul 9, 2015
Priority date	Jul 6, 2012
Publication date	Jun 6, 2017
Grant date	Jun 6, 2017

Abstract

The present teachings provide for a catalytic converter for modifying the composition of exhaust gas of an engine. The catalytic converter includes a housing, a substrate body, and a first layer of catalyst material. The housing can define an inlet for receiving the exhaust gas from the engine, a main chamber in fluid communication with the inlet, and an outlet in fluid communication with the main chamber for exhausting the modified exhaust gas. The substrate body can be disposed within the central chamber and can define a plurality of flow channels. The flow channels can provide fluid communication between the inlet and the outlet. The first layer of catalyst material can provide a first section of the flow channels with a first overall wall thickness that is greater than a second overall wall thickness of a second section of the flow channels.

First claim

What is claimed is:

1. A catalytic converter for modifying the composition of exhaust gas of an engine, the catalytic converter comprising:
a housing defining an inlet for receiving the exhaust gas from the engine, a main chamber in fluid communication with the inlet, and an outlet in fluid communication with the main chamber for exhausting the modified exhaust gas;
a substrate body disposed within the main chamber and defining a plurality of flow channels, the flow channels providing fluid communication between the inlet and the outlet; and
a first layer of catalyst material providing a first section of the flow channels with a first overall wall thickness that is greater than a second overall wall thickness of a second section of the flow channels;
a second layer of catalyst material providing the second section of the flow channels with the second overall wall thickness, the second layer is opposite to the first layer, and the second layer has a thickness that is less than the first layer;
wherein a first flow channel of the plurality of flow channels defined in part by the first layer and the second layer extends along a curved path, the first layer having the first overall wall thickness is radially outward of the second layer having the second overall wall thickness relative to an axis of the curved path.

2. The catalytic converter of claim 1 , wherein the axis is a central axis of the substrate body.

3. The catalytic converter of claim 1 , wherein each of the plurality of flow channels follows a respective helical path about an axis of the substrate body.

4. The catalytic converter of claim 1 , wherein the first layer lines the first section and the second layer lines the second section.

5. The catalytic converter of claim 4 , further comprising a third layer of catalyst material that lines a third section of the flow channels, the third layer having a third thickness that transitions from the first thickness proximate to the first layer to the second thickness proximate to the second layer.

6. The catalytic converter of claim 1 , wherein one of the first section or the first layer defines a key slot and the other of the first section or the first layer includes a key that is disposed within the key slot.

7. The catalytic converter of claim 1 , wherein the key widens with increased distance into the key slot.

8. A catalytic converter for modifying the composition of exhaust gas of an engine, the catalytic converter comprising:
a housing defining an inlet for receiving the exhaust gas from the engine, a main chamber in fluid communication with the inlet, and an outlet in fluid communication with the main chamber for exhausting the modified exhaust gas;
a substrate body disposed within the main chamber and defining a plurality of flow channels that provide fluid communication between the inlet and the outlet, a first channel of the plurality of flow channels following a path that curves about an axis;
a first layer of catalyst material lining a first portion of the first channel, the first layer having a first thickness; and
a second layer of catalyst material lining a second portion of the first channel, the second layer having a second thickness that is less than the first thickness, the first layer of the first channel is opposite to and radially outward of the second layer of the first channel relative to the axis, the first layer and the second layer together define a portion of the first channel.

9. The catalytic converter of claim 8 , wherein the axis is a central axis of the substrate body.

10. The catalytic converter of claim 8 , wherein the curved path curves helically about the axis.

11. The catalytic converter of claim 8 , wherein each of the plurality of flow channels follows a respective helical path about the axis.

12. The catalytic converter of claim 8 , further comprising a third layer of catalyst material lining a third portion of the first channel, the third layer having a third thickness that transitions from the first thickness proximate to the first layer to the second thickness proximate to the second layer.

13. The catalytic converter of claim 8 , wherein one of the first portion or the first layer defines a key slot and the other of the first portion or the first layer includes a key that is disposed within the key slot.

Assignees

• Denso Int America Inc

Inventors

• Szczepanski Edward

Classifications

• B01J35/04

  Operations & Transport · mapped topic

• F01N2510/0682

  having a discontinuous, uneven or partially overlapping coating of catalytic material, e.g. higher amount of material upstream than downstream or vice versa · CPC title

• F01N2330/38

  flow channels with means to enhance flow mixing,(e.g. protrusions or projections) · CPC title

• B01J37/0244

  Coatings comprising several layers · CPC title

• B01D53/9454 Primary

  characterised by a specific device · CPC title