Three-way catalyst packaging structure with supercharger function and packaging method

Abstract

The invention discloses a three-way catalyst packaging structure with a supercharger function and a packaging method. The three-way catalyst packaging structure comprises a supercharger assembly, a clamshell assembly, a barrel assembly and an air outlet assembly. An air outlet of the supercharger assembly is inserted into an air inlet of the clamshell assembly for full-length welding connection and fixation; inserting an air inlet of the cylinder assembly into an air outlet of the clamshell assembly for full-length welding connection and fixation; and inserting the air outlet of the cylinder assembly into the air inlet of the air outlet assembly for full-length welding connection and fixation. According to the three-way catalyst packaging structure, arrangement is more compact compared with flange connection and hoop connection, meanwhile, a reserved space for a tightening tool, a peripheral space reserved in a cabin and a tightening torque space can be omitted, a whole engine body is small, and arrangement of the cabin is facilitated. Compared with an existing structure, the weight is reduced, and the engine is lightened. And meanwhile, the problems of air leakage, abnormal sound and the like caused by sealing gasket aging, bolt loosening and the like are avoided. The structure greatly improves the space utilization rate, and is simple and high in practicability.

Description

Technical Field

[0001] This invention relates to the field of automotive exhaust aftertreatment technology, and in particular to a three-way catalytic converter encapsulation structure and encapsulation method with turbocharger function. Background Technology

[0002] With technological advancements, the automotive industry is placing increasingly higher demands on the design of exhaust aftertreatment systems, making the structural design and manufacturing of these systems paramount. The design of the aftertreatment packaging structure must not only meet structural performance requirements but also improve space utilization and weight reduction.

[0003] Currently, there are two main types of connection methods between the turbocharger assembly's turbine outlet and the three-way catalytic converter assembly: flange connection and clamp connection. Both methods require space for tightening tools, and the engine compartment needs sufficient peripheral space and tightening torque allowance. The flanges on both the turbocharger and three-way catalytic converter assemblies are relatively heavy, which is detrimental to product weight reduction. Therefore, using a three-way catalytic converter product solution with integrated turbocharger functionality can significantly reduce the cost of aftertreatment products and improve space utilization, which is of significant practical importance.

[0004] Currently, there are two main types of connection methods between the turbocharger assembly's turbine outlet and the three-way catalytic converter assembly.

[0005] 1. Flange connection: Flange connections typically use triangular or square flanges. The turbocharger flange is equipped with bolts, which are tightened with nuts after being connected to the three-way catalytic converter. A gasket is used to seal the turbocharger flange and the three-way catalytic converter.

[0006] 2. Clamp connection: The clamp connection uses a V-flange, clamp assembly and sealing ring. The sealing ring is set in the groove of the turbocharger assembly outlet V-flange. Unscrew the bolts on the clamp assembly, put the clamp assembly into the turbocharger assembly outlet V-flange, then align the three-way catalytic converter assembly inlet V-flange with the turbocharger assembly outlet V-flange, and then slightly fix it with the clamp assembly.

[0007] Both connection methods require space for tightening tools, and the engine compartment needs to have surrounding space and tightening torque space, resulting in low space utilization. The flanges and clamps on the turbocharger assembly and the three-way catalytic converter assembly are relatively heavy, which is not conducive to product weight reduction; if the connection method is used for too long, there are risks such as aging of the seals and loosening of bolts, which may lead to problems such as air leakage and abnormal noise. Summary of the Invention

[0008] The purpose of this invention is to provide a three-way catalytic converter packaging structure and packaging method with turbocharger function, addressing issues of engine compartment space utilization, product lightweighting, and cost control in the connection method between the turbocharger assembly and the three-way catalytic converter assembly.

[0009] To solve the above-mentioned technical problems, the present invention provides a three-way catalytic converter packaging structure with a turbocharger function, including a turbocharger assembly, a shell assembly, a cylindrical body assembly, and an exhaust assembly. The booster assembly is inserted into the clam shell assembly and welded in place. The cylindrical assembly is inserted into the clam shell assembly and welded in place. The cylinder assembly is inserted into the air outlet assembly and welded in place.

[0010] Preferably, the turbocharger assembly is formed by casting and bonding.

[0011] Preferably, the pre-catalyst is loaded along the length of the cylindrical structure at the outlet of the turbocharger assembly, and a shock-absorbing pad is arranged in the gap between the two; that is, the inner diameter of the cylindrical structure is equal to the diameter of the catalyst plus twice the thickness of the shock-absorbing pad.

[0012] Preferably, a certain distance is left between the pre-catalyst and the end face of the turbocharger assembly.

[0013] Preferably, the air outlet of the booster assembly is fully welded and fixed to the air inlet of the clam shell assembly; the air inlet of the cylinder assembly is fully welded and fixed to the air outlet of the clam shell assembly; and the air outlet of the cylinder assembly is fully welded and fixed to the air inlet of the air outlet assembly.

[0014] Preferably, the air outlet of the booster assembly and the air inlet of the clamshell assembly are parallel to each other; the air inlet of the cylinder assembly and the air outlet of the clamshell assembly are parallel to each other; and the air outlet of the cylinder assembly and the air inlet of the air outlet assembly are parallel to each other.

[0015] Preferably, the air outlet end face of the turbocharger assembly is parallel to the air inlet end face of the clam shell assembly, the air inlet end face of the cylinder assembly is parallel to the air outlet end face of the clam shell assembly, and the air outlet end face of the cylinder assembly is parallel to the air inlet end face of the air outlet assembly.

[0016] Preferably, the outer peripheral wall of the air outlet of the booster assembly is fitted with the inner peripheral wall of the air inlet of the clam shell assembly; the outer peripheral wall of the air inlet of the cylindrical assembly is fitted with the inner peripheral wall of the air outlet of the clam shell assembly; and the outer peripheral wall of the air outlet of the cylindrical assembly is fitted with the inner peripheral wall of the air inlet of the air outlet assembly.

[0017] The present invention also provides a method for packaging a three-way catalytic converter with a turbocharger function, comprising the following steps: Step 1: The turbocharger assembly is machined and formed using a casting and bonding machine; Step 2: Install the pre-catalyst and damping pads inside the cylindrical structure at the outlet of the turbocharger assembly; Step 3: Insert the air outlet of the turbocharger assembly into the air inlet of the shell assembly and weld the connection securely. Step 4: Insert the air inlet of the cylinder assembly into the air outlet of the clamshell assembly and weld the connection securely. Step 5: Insert the air outlet of the cylinder assembly into the air inlet of the air outlet assembly and weld the connection securely.

[0018] Compared with the prior art, the beneficial effects of the present invention are: 1. The turbocharger in the three-way catalytic converter encapsulation structure of the present invention is formed by casting and machining, so that the turbocharger can carry a pre-catalyst. Its arrangement is more compact than flange connection and clamp connection. At the same time, it can eliminate the space reserved for tightening tools, the surrounding space left in the engine compartment, and the tightening torque space, making the engine body smaller and facilitating engine compartment layout. 2. The three-way catalytic converter packaging structure of the present invention eliminates the flange, clamp, and gasket on the original turbocharger assembly and three-way catalytic converter assembly, and its weight is reduced compared with the existing structure, making the engine lighter; 3. The three-way catalytic converter packaging structure of the present invention eliminates the connection structure between the turbocharger assembly and the three-way catalytic converter assembly, avoiding problems such as air leakage and abnormal noise caused by aging of the sealing gasket and loosening of bolts. Attached Figure Description

[0019] Figure 1 This is an overall schematic diagram of the three-way catalytic converter packaging structure with turbocharger function provided by the present invention; Figure 2 This is a cross-sectional view of the three-way catalytic converter packaging structure with turbocharger function provided by the present invention; Figure 3 This is a partial cross-sectional view of the turbocharger assembly provided by the present invention.

[0020] In the diagram: 1. Intensifier assembly; 2. Clamshell assembly; 3. Cylinder assembly; 4. Air outlet assembly. Detailed Implementation

[0021] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The advantages and features of the present invention will become clearer from the following description and claims. It should be noted that the drawings are all in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the present invention.

[0022] In the description of this invention, it should be understood that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0023] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0024] In addition, the features, operations, and characteristics described in the specification can be combined in any suitable manner to form various embodiments. Similarly, the steps or actions described in the method can be rearranged in a manner that is readily apparent to those skilled in the art. Therefore, the various orders in the specification and drawings are merely for the purpose of clearly describing a particular embodiment and are not necessarily required orders, unless otherwise stated that a particular order must be followed. Example

[0025] This invention provides a three-way catalytic converter packaging structure with turbocharger function. Please refer to [link / reference]. Figure 1-3 It includes a booster assembly 1, a clamshell assembly 2, a cylinder assembly 3, and an exhaust assembly 4.

[0026] Compared to common structures, the turbocharger assembly 1 in this embodiment integrates a catalyst. Its shape eliminates the outlet flange from existing structures, enlarging the original outlet. The enlarged structure is designed as a cylinder based on the diameter of the pre-catalyst, used to house the pre-catalyst and shock-absorbing pads. The inner diameter of the cylinder is equal to the catalyst diameter plus twice the thickness of the shock-absorbing pads. The length is designed based on the length of the pre-catalyst, generally requiring a distance of at least 2mm between the end face of the pre-catalyst and the end face of the turbocharger to prevent collision between the pre-catalyst and the turbocharger.

[0027] In this embodiment, the clamshell assembly 2 connects the front and rear stages. The inlet of the clamshell assembly 2 connects to the turbocharger assembly 1, and the outlet connects to the rear stage cylinder assembly 3. The interface structure is typically designed as a straight circular section, ensuring that the inner diameter of the inlet matches the outer diameter of the cylinder containing the catalyst in the turbocharger assembly, with a 0.2mm gap on each side, ensuring the straight section length is greater than 8mm. The turbocharger assembly 1 is inserted into the clamshell assembly 2 with an insertion distance of 6mm, and is fixed and sealed by full welding. The inner diameter of the outlet matches the outer diameter of the cylinder of the cylinder assembly 3, with a 0.2mm gap on each side, ensuring the straight section length is greater than 8mm. The cylinder assembly 3 is inserted into the clamshell assembly 2 with an insertion distance of 6mm, and is fixed and sealed by full welding. The shape of the clamshell assembly can be customized to include features such as clearance structures and sensor connectors.

[0028] In this embodiment, the cylinder assembly 3 is used to load the downstream catalyst, and the structure can be omitted as needed; the exhaust assembly 4 is used to cooperate with the subsequent exhaust pipe and muffler. All components are welded to ensure a firm connection, and a subsequent airtightness test is conducted to ensure that there is no air leakage at the connection.

[0029] Specifically, the air outlet of the booster assembly 1 is fully welded and fixed to the air inlet of the clam shell assembly 2; the air inlet of the cylinder assembly 3 is fully welded and fixed to the air outlet of the clam shell assembly 2; and the air outlet of the cylinder assembly 3 is fully welded and fixed to the air inlet of the air outlet assembly 4.

[0030] Furthermore, the air outlet of the booster assembly 1 and the air inlet of the clamshell assembly 2 are parallel to each other; the air inlet of the cylindrical assembly 3 and the air outlet of the clamshell assembly 2 are parallel to each other; the air outlet of the cylindrical assembly 3 and the air inlet of the exhaust assembly 4 are parallel to each other. The end face of the air outlet of the booster assembly 1 is parallel to the end face of the air inlet of the clamshell assembly 2, the end face of the air inlet of the cylindrical assembly 3 is parallel to the end face of the air outlet of the clamshell assembly 2, and the end face of the air outlet of the cylindrical assembly 3 is parallel to the end face of the air inlet of the exhaust assembly 4. The outer peripheral wall of the air outlet of the booster assembly 1 is in contact with the inner peripheral wall of the air inlet of the clamshell assembly 2; the outer peripheral wall of the air inlet of the cylindrical assembly 3 is in contact with the inner peripheral wall of the air outlet of the clamshell assembly 2; and the outer peripheral wall of the air outlet of the cylindrical assembly 3 is in contact with the inner peripheral wall of the air inlet of the exhaust assembly 4.

[0031] The present invention also provides a method for packaging a three-way catalytic converter with a turbocharger function, comprising the following steps: Step 1: The turbocharger assembly 1 is machined using a casting bonding machine; Step 2: Load the pre-catalyst and damping pads into the cylindrical structure at the outlet of turbocharger assembly 1; Step 3: Insert the air outlet of the turbocharger assembly 1 into the air inlet of the shell assembly 2 and weld them together to secure them. Step 4: Insert the air inlet of the cylinder assembly 3 into the air outlet of the clam shell assembly 2 and weld them together to secure them. Step 5: Insert the air outlet of cylinder assembly 3 into the air inlet of air outlet assembly 4 and weld them together to secure them.

[0032] The three-way catalytic converter encapsulation structure of this invention offers a more compact arrangement compared to flange and clamp connections. It also eliminates the need for reserved space for tightening tools, peripheral space in the engine compartment, and tightening torque space, resulting in a smaller overall engine size and easier engine compartment layout. Compared to existing structures, it reduces weight, contributing to engine lightweighting. Furthermore, it avoids problems such as air leakage and abnormal noise caused by aging gaskets and loose bolts. Its structure significantly improves space utilization, is simple, and highly practical.

[0033] The above description is merely a description of preferred embodiments of the present invention and is not intended to limit the scope of the present invention in any way. Any changes or modifications made by those skilled in the art based on the above disclosure shall fall within the protection scope of the claims.

Claims

1. A three-way catalyst package structure with a supercharger function, characterized by, It comprises a supercharger assembly (1), a shell assembly (2), a cylinder assembly (3) and an air outlet assembly (4). The supercharger assembly (1) is inserted into the shell assembly (2) and fixed by welding. The cylinder assembly (3) is inserted into the shell assembly (2) and fixed by welding. The cylinder assembly (3) is inserted into the air outlet assembly (4) and fixed by welding.

2. The three-way catalyst package with a supercharger function according to claim 1, wherein The supercharger assembly (1) is formed by casting and machining.

3. The three-way catalyst package with a supercharger function according to claim 2, wherein The pre-stage catalyst is loaded in the length direction in the cylindrical structure of the air outlet of the supercharger assembly (1), and the shock pad is arranged in the gap between them; that is, the inner diameter of the cylindrical structure is equal to the diameter of the catalyst plus twice the thickness of the shock pad.

4. The three-way catalyst package with a supercharger function according to claim 3, wherein A certain gap is left between the pre-stage catalyst and the end face of the supercharger assembly (1).

5. The three-way catalyst package with a supercharger function according to claim 1, wherein The air outlet of the supercharger assembly (1) is inserted into the air inlet of the shell assembly (2) and is fixed by full welding; the air inlet of the cylinder assembly (3) is inserted into the air outlet of the shell assembly (2) and is fixed by full welding; the air outlet of the cylinder assembly (3) is inserted into the air inlet of the air outlet assembly (4) and is fixed by full welding.

6. The three-way catalyst package with a supercharger function according to claim 5, wherein The axis of the air outlet of the supercharger assembly (1) and the air inlet of the shell assembly (2) are parallel; the axis of the air inlet of the cylinder assembly (3) and the air outlet of the shell assembly (2) are parallel; the axis of the air outlet of the cylinder assembly (3) and the air inlet of the air outlet assembly (4) are parallel.

7. The three-way catalyst package with a supercharger function according to claim 5, wherein The end face of the air outlet of the supercharger assembly (1) is parallel to the end face of the air inlet of the shell assembly (2); the end face of the air inlet of the cylinder assembly (3) is parallel to the end face of the air outlet of the shell assembly (2); the end face of the air outlet of the cylinder assembly (3) is parallel to the end face of the air inlet of the air outlet assembly (4).

8. The three-way catalyst package with a supercharger function according to claim 5, wherein The outer peripheral wall of the air outlet of the supercharger assembly (1) is attached to the inner peripheral wall of the air inlet of the shell assembly (2); the outer peripheral wall of the air inlet of the cylinder assembly (3) is attached to the inner peripheral wall of the air outlet of the shell assembly (2); the outer peripheral wall of the air outlet of the cylinder assembly (3) is attached to the inner peripheral wall of the air inlet of the air outlet assembly (4).

9. The packaging method of a three-way catalyst with a supercharger function according to any one of claims 1 to 8, characterized by, It comprises the following steps: Step one: the supercharger assembly (1) is formed by casting and machining; Step two: the pre-stage catalyst and the shock pad are loaded in the cylindrical structure of the air outlet of the supercharger assembly (1); Step three: the air outlet of the supercharger assembly (1) is inserted into the air inlet of the shell assembly (2) and is fixed by full welding; Step four: the air inlet of the cylinder assembly (3) is inserted into the air outlet of the shell assembly (2) and is fixed by full welding; Step five: the air outlet of the cylinder assembly (3) is inserted into the air inlet of the air outlet assembly (4) and is fixed by full welding.

Images