Insulator

Abstract

In a two-layer insulator, the number of components in the covering material provided within the insulator is reduced, thereby enabling weight reduction. [Solution] The insulator comprises an inner insulator positioned around the exhaust component, an outer insulator positioned around the inner insulator, and a covering member positioned in a first space between the inner insulator and the exhaust component, and in a second space between the outer insulator and the inner insulator. The inner insulator is provided with one or more through holes that connect the first space and the second space, and the covering member is inserted through the through holes and positioned to straddle the first space and the second space.

Description

Technical Field

[0001] The present disclosure relates to an insulator that covers an exhaust component.

Background Art

[0002] Patent Document 1 discloses an exhaust gas purification device in which a two-layer insulator is provided from a connection portion on the upstream side of a case that houses a catalyst for exhaust gas purification to the catalyst housing portion. And, Patent Document 1 describes that by providing a first heat insulating material between the two layers of the insulator and a second heat insulating material between the case and the insulator, radiation of heat and sound to the surroundings is suppressed.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the two-layer insulator described in Patent Document 1, heat insulating materials are provided between the catalyst case and the inner insulator, and between the inner insulator and the outer insulator, respectively.

[0005] Therefore, in order to configure the two-layer insulator, there is a problem that the number of component parts of covering members such as heat insulating materials provided in the insulator increases and the component weight of the insulator increases, compared with a one-layer insulator. Also, there is a problem that the amount of carbon dioxide emissions increases with the increase in component weight. And this problem occurs similarly not only in exhaust gas purification devices but also in insulators that cover the surroundings of exhaust components through which exhaust gas flows.

[0006] One aspect of this disclosure is to reduce the number of components in the covering member provided within the insulator, thereby enabling weight reduction in a two-layer insulator. [Means for solving the problem]

[0007] One aspect of the present disclosure is an insulator for covering at least a portion of an exhaust component. The insulator comprises an inner insulator disposed around the exhaust component, an outer insulator disposed around the inner insulator, and a covering member. The covering member is disposed in a first space between the inner insulator and the exhaust component, and in a second space between the outer insulator and the inner insulator.

[0008] Furthermore, the inner insulator is provided with one or more through holes that connect the first space and the second space. The covering member is inserted through the through holes of the inner insulator and positioned to straddle the first space and the second space.

[0009] Therefore, according to the insulator of this disclosure, the covering member placed in the first space and the covering member placed in the second space can be made of a single covering member, and the number of parts can be reduced compared to the insulator described in Patent Document 1. In addition, since the number of parts is reduced, the overall weight of the insulator can also be reduced.

[0010] In one aspect of this disclosure, at least a portion of the covering member is bonded to the inner insulator. This is also acceptable. In this way, displacement of the covering material inside the insulator due to vibrations of exhaust components can be suppressed, and the deterioration of the function of the covering material (for example, functions such as heat insulation and sound insulation) can be suppressed.

[0011] In one aspect of this disclosure, the covering member may be a wire mesh. This makes it easier to discharge liquids such as condensed water that accumulate inside the insulator to the outside. The wire mesh can also absorb vibrations of the insulator.

[0012] In one aspect of this disclosure, the exhaust component is a catalyst shell in which a catalyst for purifying exhaust gas is housed within a case, and the inner insulator and covering member may be arranged on the upstream side of the catalyst shell from which the exhaust gas flows.

[0013] In other words, in a catalytic converter shell, the upstream side where exhaust gas flows in tends to become hotter because of the high-temperature exhaust gas discharged from the engine. In contrast, by placing the two-layer insulator of this disclosure on the upstream side of the catalytic converter shell as described above, it is possible to insulate the heat from the exhaust gas and block exhaust noise on the upstream side of the catalytic converter shell. Therefore, by placing the insulator of this disclosure on the upstream side of the catalytic converter shell as described above, the function of the insulator can be performed more effectively. [Brief explanation of the drawing]

[0014] [Figure 1] This is a plan view showing the external appearance of the exhaust gas purification device according to the embodiment. [Figure 2] This is a perspective view showing the external appearance of the exhaust gas purification device according to the embodiment. [Figure 3] This is an exploded perspective view showing the configuration of the exhaust gas purification device according to the embodiment. [Figure 4] This is a VV cross-sectional view in Figure 1. [Figure 5] This is an explanatory diagram showing the state of attachment of the covering member to the inner insulator. [Figure 6] This is a cross-sectional view showing the assembled state of the covering member in a modified exhaust gas purification device, corresponding to Figure 4. [Modes for carrying out the invention]

[0015] Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the drawings. In this embodiment, the exhaust component of the present disclosure is described as an exhaust gas purification device that purifies exhaust gas discharged from the engine using an exhaust gas purification catalyst.

[0016] [Embodiment] As shown in FIGS. 1 to 3, the exhaust gas purification device 1 includes an upstream connection portion 2 connected to an exhaust pipe of an engine for introducing exhaust gas discharged from the engine, and a downstream connection portion 4 for discharging the exhaust gas after purification by a catalyst toward an exhaust component on the downstream side such as a muffler. The exhaust gas purification device 1 also includes a catalyst shell 10 in which a catalyst is housed within a cylindrical case.

[0017] The upstream connection portion 2 and the downstream connection portion 4 can be respectively connected to the exhaust introduction portion 12 and the exhaust discharge portion 14 of the catalyst shell 10 to the exhaust pipes on the engine side and the muffler side. For this reason, the catalyst shell 10 can form an exhaust gas flow path as a part of the exhaust pipe of the engine, and the exhaust gas is purified by passing through the catalyst within the catalyst shell 10.

[0018] An insulator 20 that covers the catalyst shell 10 is provided around the catalyst shell 10. The insulator 20 is for heat insulation and sound insulation around the catalyst shell 10, and includes a main body side insulator 22 and an upstream side insulator 24.

[0019] As shown in FIG. 3, the main body side insulator 22 is configured to cover the periphery of the main body portion 16 in which the catalyst is housed in the catalyst shell 10. The main body portion 16 is disposed between the exhaust introduction portion 12 and the exhaust discharge portion 14 of the catalyst shell 10, and the main body side insulator 22 is divided into two in the vertical direction indicated by an arrow in FIG. 3 with the main body portion 16 interposed therebetween.

[0020] The two divided main body side insulators 22A and 22B have an arc-shaped cross-sectional shape in a direction perpendicular to the flow of the exhaust gas, and are fixed around the main body portion 16 by joining the flange portions 23 provided at both ends of the arc. The main body side insulators 22A and 22B are formed, for example, by press-forming a metal plate such as stainless steel or aluminum.

[0021] Furthermore, between the inner walls of the main body insulators 22A and 22B and the outer surface of the main body portion 16 of the catalyst shell 10, a plurality of covering members 32 are provided at intervals in line with the flow of exhaust gas in the main body portion 16. These covering members 32 are made of, for example, wire mesh and are joined to the inner walls of the main body insulators 22A and 22B by welding such as spot welding or adhesive bonding.

[0022] Therefore, the inner surface of the main body-side insulator 22 and the outer surface of the main body portion 16 are maintained at a substantially constant distance by the covering member 32. Consequently, the main body-side insulator 22 can reduce the heat and sound radiated from the catalyst shell 10 to the surroundings by the covering member 32 positioned in the space between it and the catalyst shell 10.

[0023] Next, the upstream insulator 24 is configured to cover the area around the exhaust gas inlet 12, which extends from the upstream connection portion 2 of the catalyst shell 10 to the main body portion 16. The upstream insulator 24 is a two-layer insulator comprising an outer insulator 26 and an inner insulator 28.

[0024] The outer insulator 26 is joined to the main body insulator 22 and, together with the main body insulator 22, is configured to cover the periphery of the catalyst shell 10. In contrast, the inner insulator 28 is positioned between the outer insulator 26 and the exhaust gas inlet 12 of the catalyst shell 10 and is configured to cover the periphery of the exhaust gas inlet 12 of the catalyst shell 10.

[0025] The outer insulator 26 and the inner insulator 28, like the main body insulator 22, are divided into two parts vertically in the direction indicated by the arrows in Figure 3, with the exhaust gas inlet 12 of the catalyst shell 10 in between.

[0026] Therefore, the outer insulators 26A and 26B and the inner insulators 28A and 28B, which are divided into two parts, have an arc-shaped cross-section, similar to the main body insulator 22, as shown in Figure 4. Figure 4 shows the upper half in the vertical direction indicated by the arrow in Figure 3 of the cross-section when the exhaust gas purification device 1 is cut in the middle of the exhaust gas flow path.

[0027] The outer insulators 26A and 26B and the inner insulators 28A and 28B have substantially the same shape as the outer shape of the exhaust inlet 12 of the catalytic converter shell 10. Furthermore, the inner circumference of the inner insulators 28A and 28B is larger than the outer circumference of the exhaust inlet 12 so that when the ends of the arc are joined together, a first space S1 for heat insulation and sound insulation is created between them and the outer surface of the exhaust inlet 12.

[0028] Furthermore, the outer insulators 26A and 26B have an inner circumference that is larger than the outer circumference of the inner insulators 28A and 28B, so that a second space S2 for heat insulation and sound insulation is created between them and the outer circumference of the inner insulators 28A and 28B.

[0029] The outer insulators 26A and 26B, like the main body insulators 22A and 22B, are formed into a cylindrical shape by joining the flange portions 27 provided on both ends of the arc of their cross-section, and are arranged around the inner insulators 28A and 28B. The inner insulators 28A and 28B are positioned inside the outer insulators 26A and 26B by sandwiching the flange portions 29 provided on both ends of the arc of their cross-section between the flange portions 27 of the outer insulators 26A and 26B.

[0030] The outer insulators 26A and 26B and the inner insulators 28A and 28B are constructed, like the main body insulators 22A and 22B, by press-forming a metal plate such as stainless steel or aluminum.

[0031] Next, a common covering member 34 is provided in the first space S1 between the catalyst shell 10 and the inner insulators 28A and 28B, and in the second space S2 between the inner insulators 28A and 28B and the outer insulators 26A and 26B.

[0032] In other words, as shown in Figure 5, in the inner insulators 28A and 28B, two through holes 36, 36 are provided in the outer circumferential direction at the opening on the main body portion 16 side of the catalyst shell 10. Also, the covering member 34, like the covering member 32, is made of wire mesh and is formed in the shape of a long, narrow string.

[0033] The covering member 34 is inserted through each of the two through holes 36, 36 on the outside of the inner insulators 28A, 28B. As a result, the covering member 34 is positioned to span the first space S1 and the second space S2 through the through holes 36.

[0034] The covering member 34 is positioned inside the inner insulators 28A and 28B, with both ends extending outward from the respective through holes 36. These ends are then joined at the joint 38 to the inner circumferential surfaces of the inner insulators 28A and 28B by welding, such as spot welding, or by adhesive bonding.

[0035] As described above, the exhaust gas purification device 1 of this embodiment is equipped with a two-layer insulator comprising an outer insulator 26 and an inner insulator 28 as an upstream insulator 24 covering the exhaust gas inlet 12 of the catalyst shell 10. The inner insulator 28 is provided with through holes 36, and a covering member 34 made of wire mesh is inserted through these through holes 36, thereby arranging a common covering member 34 in the first space S1 and the second space S2.

[0036] Therefore, according to the upstream insulator 24 of this embodiment, despite having a two-layer structure, the covering member 34 placed in the first space S1 and the second space S2 is common, and the number of parts of the covering member 34 can be reduced compared to the insulator described in Patent Document 1. Furthermore, since the number of parts of the covering member 34 can be reduced, the upstream insulator 24 can also be made lighter.

[0037] Furthermore, since the covering member 34 is joined to the inner insulator 28, displacement due to vibrations of the catalytic converter shell 10, which is an exhaust component, can be suppressed. Therefore, displacement of the covering member 34 can be suppressed, which can reduce the function of the covering member (for example, functions such as heat insulation and sound insulation). In addition, since the covering member 34 is made of wire mesh, it is possible to easily discharge liquids such as condensed water that accumulate inside the upstream insulator 24 to the outside.

[0038] [Differentiation] In the above embodiment, the inner insulators 28A and 28B are provided with two through holes 36, 36 in the outer circumferential direction, and the covering member 34 is described as being positioned outside the inner insulators 28A and 28B between the two through holes 36, 36.

[0039] In contrast, the covering member 34 may be inserted through each of the through holes 36 so as shown in Figure 6A, so as to be positioned inside the inner insulators 28A and 28B, between the two through holes 36, 36.

[0040] In this case, the covering member 34 may be positioned outside the inner insulators 28A and 28B, with both ends extending outward from the respective through holes 36, and both ends being joined to the outer circumferential surface of the inner insulators 28A and 28B at the joint portion 38.

[0041] Even in this manner, a common covering member 34 can be placed in the first space S1 between the catalyst shell 10 and the inner insulators 28A and 28B, and in the second space S2 between the inner insulators 28A and 28B and the outer insulators 26A and 26B.

[0042] Furthermore, as shown in Figures 6B to 6E, the inner insulators 28A and 28B may be provided with one through-hole 36 through which the covering member 34 is inserted, and the covering member 34 common to the first space S1 and the second space S2 may be inserted through the through-hole 36. In this case, the insertion direction and arrangement shape of the covering member 34 can be changed as appropriate.

[0043] In other words, as shown in Figure 6B, the covering member 34 may be inserted through the through hole 36 so that it is positioned from the first space S1 on the left side of the through hole 36 to the second space S2 on the right side. Alternatively, as shown in Figure 6C, the covering member 34 may be inserted through the through hole 36 so that it is positioned from the first space S1 on the right side of the through hole 36 to the second space S2 on the left side.

[0044] Furthermore, as shown in Figure 6D, the covering member 34 may be inserted through the through hole 36 so as to be positioned in the first space S1 and the second space S2 to the left of the through hole 36. Alternatively, as shown in Figure 6E, the covering member 34 may be inserted through the through hole 36 so as to be positioned in the first space S1 and the second space S2 to the right of the through hole 36.

[0045] In this way, even with only one through-hole 36, a common covering member 34 can be placed in both the first space S1 and the second space S2. The number of through holes 36 provided in the inner insulators 28A and 28B can be changed as appropriate. For example, three or more through holes 36 may be provided in the circumferential direction to weave the covering member 34 into.

[0046] Furthermore, the covering members 34 may be arranged in multiples at intervals along the flow of exhaust gas in the catalyst shell 10, similar to the covering members 32 of the main body side insulators 22A and 22B. In this case, one or more through holes 36 may be provided for each position where a covering member 34 is placed, allowing the covering member 34 to pass through.

[0047] [Other embodiments] In the above embodiment, the case in which the insulator of the present disclosure is applied to the exhaust gas purification device 1 was described. However, any insulator used to cover an exhaust component through which exhaust gas flows can be applied in the same manner to obtain the same effects. Furthermore, although the above embodiment described the insulator as being formed in a cylindrical shape, the insulator only needs to be able to cover a part of the exhaust component for purposes such as heat insulation, and may, for example, be a member with a substantially semicircular cross-section.

[0048] Furthermore, multiple functions of one component in the above embodiment may be realized by multiple components, or one function of one component may be realized by multiple components. Also, multiple functions of multiple components may be realized by one component, or one function realized by multiple components may be realized by one component. Furthermore, some parts of the configuration of the above embodiment may be omitted. Furthermore, at least some parts of the configuration of the above embodiment may be added to or replaced with the configuration of other above embodiments.

[0049] [Technical concepts disclosed in this specification] [Item 1] An insulator for covering at least a portion of an exhaust component, An inner insulator arranged around the aforementioned exhaust component, An outer insulator is positioned around the inner insulator, The system comprises a covering member disposed in a first space between the inner insulator and the exhaust component, and a second space between the outer insulator and the inner insulator. The inner insulator is provided with one or more through holes that connect the first space and the second space, The covering member is inserted through the through hole of the inner insulator and is positioned to span the first space and the second space.

[0050] [Item 2] The insulator described in item 1, An insulator in which at least a portion of the covering member is joined to the inner insulator.

[0051] [Item 3] An insulator as described in item 1 or item 2, The covering member is a wire mesh insulator.

[0052] [Item 4] An insulator described in any one of items 1 to 3, The aforementioned exhaust component is a catalyst shell in which a catalyst for purifying exhaust gas is housed within a case. The inner insulator is an insulator positioned on the upstream side of the catalyst shell from which exhaust gas flows. [Explanation of symbols]

[0053] 10...Catalyst shell, 24...Upstream insulator, 26, 26A, 26B...Outer insulator, 28, 28A, 28B...Inner insulator, 34...Covering member, 36...Through hole, S1...First space, S2...Second space.

Claims

1. An insulator for covering at least a portion of an exhaust component, An inner insulator arranged around the aforementioned exhaust component, An outer insulator is positioned around the inner insulator, The system comprises a covering member disposed in a first space between the inner insulator and the exhaust component, and a second space between the outer insulator and the inner insulator. The inner insulator is provided with one or more through holes that connect the first space and the second space, The covering member is inserted through the through hole of the inner insulator and is positioned to span the first space and the second space.

2. An insulator according to claim 1, An insulator in which at least a portion of the covering member is joined to the inner insulator.

3. An insulator according to claim 1 or claim 2, The covering member is a wire mesh insulator.

4. An insulator according to claim 1 or claim 2, The aforementioned exhaust component is a catalyst shell in which a catalyst for purifying exhaust gas is housed within a case. The inner insulator is an insulator positioned on the upstream side of the catalyst shell from which exhaust gas flows.

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