A catalytic converter for processing exhaust gases

Abstract

The claimed matter discloses a catalytic converter (302, 402, 404) for processing exhaust gases of an internal combustion engine (104). The catalytic converter (302, 402, 404) comprises the noble metals platinum, palladium, and rhodium. The content of rhodium used in the catalytic converter (302, 402, 404) is lesser than the individual contents of platinum and palladium.

Description

TITLE OF THE INVENTION:A CATALYTIC CONVERTER FOR PROCESSING EXHAUST GASESTECHNICAL FIELD

[0001] The claimed subject matter in general relates to catalytic converters for internal combustion engines. The claimed subject matter, in particular relates to optimization of catalytic converters used in the exhaust systems.BACKGROUND

[0002] The motor vehicles which use internal combustion engine for power generation, need to process the exhaust gases before releasing them into the atmosphere. Some of the harmful gases coming out of the exhaust port of the combustion engine are unburnt hydrocarbons (HC), carbon monoxide (CO), nitrogen oxide (NO2) and Nitric oxide. These harmful gases need to be processed to convert them into less harmful gases. One of the major components used in the exhaust gas treatment is a catalytic converter (CATCON).

[0003] The catalytic converter typically consists of a ceramic structure coated with a metal catalyst, usually platinum, rhodium and / or palladium. These are referred as noble metals. The structure exposes the maximum surface area of the catalyst to the exhaust gases.

[0004] When the exhaust gases come in contact with the surface of the catalytic converter, a chemical reaction takes place. In the catalytic converter, oxygen is used in oxidation and reduction reactions to convert harmful gases into less harmful substances.

[0005] The catalytic converters typically use noble metals like platinum, palladium and Rhodium. Rhodium is significantly more expensive than platinum andpalladium, making catalytic converters that rely heavily on rhodium costly to manufacture.

[0006] Lower displacement gasoline engines produce less NOx compared to Gasoline direct injection (GDI) or diesel engines. Using catalytic converters designed for higher NOx emissions results in unnecessary cost and complexity.

[0007] Meeting stringent emission control standards is essential for regulatory compliance, particularly for lower displacement engines which have different emission profiles.

[0008] The claimed subject matter proposes optimizing the composition of catalytic converter with regard to the noble metals used.SUMMARY

[0009] The claimed subject matter is defined in the independent claims. Further details are defined in the dependent claims.

[0010] The claimed subject matter relates to catalytic converters for processing the exhaust gases in internal combustion engines. The claimed subject matter discloses a catalytic converter for processing of exhaust gases and a method of manufacturing the catalytic converter.

[0011] The claimed subject matter discloses a specific composition of noble metals used in a catalytic converter. The noble metals used in the catalytic converter typically comprise platinum, palladium and rhodium.

[0012] The claimed subject matter proposes that the catalytic converter comprises a combination of platinum, palladium, and rhodium, with platinum and palladium contributing more to the overall noble metal content than rhodium.

[0013] In one embodiment the catalytic converter has a composition of the noble metals platinum, palladium, and rhodium in the proportions 2:2: 1 respectively.

[0014] In one embodiment the catalytic converter has a composition of the noble metals platinum, palladium, and rhodium in the proportions 25:30: 1 respectively.

[0015] In one embodiment the catalytic converter has a composition of the noble metals platinum, palladium, and rhodium in the proportions 10: 10: 1 respectively.

[0016] In one embodiment the catalytic converter has a composition of the noble metals platinum, palladium, and rhodium in the proportions 5:9: 1 respectively.

[0017] The claimed subject matter proposes a method of manufacturing the catalytic converter for processing the exhaust gases of an internal combustion engine. The method comprises manufacturing a catalytic converter comprising the metals platinum, palladium, and rhodium, wherein the content of rhodium is lesser than the individual contents of platinum and palladium. The content may refer to volume or weight of the noble metals.

[0018] The features discussed herein and advantages of the claimed subject matter will be better understood with reference to the detailed description, drawings and claims. This summary is provided to introduce the claimed subject matter in a simplified form. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The detailed description is described with reference to the accompanying figures. In the figures, similar reference numerals are used throughout the drawings to reference like features and components.Figure 1 illustrates a two wheeled motor vehicle.Figure 2 illustrates a system for processing exhaust gases in prior arts.Figure 3 illustrates a system for processing exhaust gases in one embodiment according to the claimed subject matter.Figure 4 illustrates a system for processing exhaust gases in another embodiment according to the claimed subject matter.Figure 5 illustrates a method of manufacturing a catalytic converter.DETAILED DESCRIPTION

[0020] The claimed subject matter now will be described with exemplary embodiments. However, the claimed subject matter may be embodied in many different forms and should not be construed as limited to the embodiments described herein. These embodiments are provided only as examples so that this disclosure is clear and concise.

[0021] Some of the terms used in this document may be used with different expressions and also interchangeably. Some examples are given below.

[0022] The expression ‘exhaust gases’ or ‘gases’ may be used to indicate processed exhaust gases or unprocessed exhaust gases or both. The expression ‘exhaust path’ may be used to indicate an exhaust pipe connected to the IC engine. The expressions ‘Internal combustion engine’, ‘IC engine’ and ‘engine’ may be used interchangeably. The expression vehicle may be used to mean a two wheeled motor vehicle, a three wheeled motor vehicle or a four wheeled motor vehicle or all of them. The claimed subject matter is applicable to all types of vehicles. The expressions ‘two wheeled motor vehicle’, ‘motor vehicle’ and ‘vehicle’ may be used interchangeably. The expressions ‘first’ and ‘second’, while referring to ‘first CATCON or ‘second CATCON’ are used only symbolically and have no other attribute. These expressions may also be used interchangeably. The expressions ‘exhaust system’ and ‘system’ may be used interchangeably. The expressions “noble metals” and “metals” may be used interchangeably. The expression “catalytic converter” may refer to first catalytic converter or second catalyticconverter or both. Similarly, the expression “CATCON” may refer to first CATCON or second CATCON or both.

[0023] Only the details / components required to describe the claimed subject matter in specific, are disclosed in this document. The details / components which are commonly known or understood by people skilled in the art may not be covered in this document.

[0024] Achieving the optimal balance between cost, efficiency, and reduction of harmful emissions requires precise formulations of noble metals within a catalytic converter, particularly for a lower displacement gasoline engine, since NOx emission is lower compared to the Gasoline Diesel Injection (GDI) or diesel engines. So, in lower displacement gasoline engines, the reduction of NOx to N2 is not required to a higher extent.

[0025] Lower displacement gasoline engines are commonly found in several types of vehicles. These engines typically have smaller capacities, often below 1.5 liters, and are designed for fuel efficiency and lower emissions. These vehicles are designed to be economical, environmentally friendly, and suitable for urban and suburban driving conditions. They often prioritize fuel efficiency and lower emissions over high performance, making them ideal candidates for lower displacement gasoline engines and the corresponding catalytic converters optimized for such engines.

[0026] Thereby, the claimed subject matter provides optimizing the catalytic converter through specific ratios of platinum, palladium and rhodium used in the catalytic converter.

[0027] Figure 1 illustrates a typical two wheeled motor vehicle 100 according to one embodiment.

[0028] The two wheeled motor vehicle 100 is supported by a frame assembly, not shown. The two wheeled motor vehicle 100 includes a front wheel steered by a handlebar and a rear wheel. A rider seat for a rider and a seat for a pillion rider are placed rearward to a fuel tank. The Internal Combustion, IC, engine 104 is typically disposed below the fuel tank on the front portion of the two wheeled vehicle 100.

[0029] The IC engine 104 typically comprises an inlet port, an exhaust port or exhaust pipe / path, a combustion chamber, a crank shaft, a cam shaft, various valves, sensors etc. These are not shown in figures. Combustion chamber is where the fuel and air mixture is ignited. During the combustion process fuel ignites, creating high pressure gases that drive the engine’s piston. The exhaust gases from the engine 104 pass through the exhaust system 102.

[0030] Figure 2 illustrates an exhaust system 102 for processing exhaust gases in prior arts. The system 102 comprises an exhaust pipe whose one end is connected to the exhaust port of the engine 104 and the other end is open to the atmosphere. A catalytic converter CATCON, not shown, is disposed in the exhaust pipe. Typically an oxygen sensor 204 is disposed in the exhaust pipe downstream of the CATCON. The exhaust gases entering the CATCON are normally referred as unprocessed exhaust gases and the exhaust gases coming out of the CATCON are referred as processed exhaust gases. The oxygen sensor 204 provides the information regarding the level of oxygen present in the processed exhaust gases. The level of oxygen is an indication of how efficiently the CATCON is functioning. As the chemical reaction in the CATCON uses part of the oxygen from the unprocessed exhaust gases, the level of oxygen in the processed exhaust gases indicates how efficiently the chemical reaction is happening, thereby indicating how efficiently the harmful exhaust gases are converted to less harmful substances. Typically, a controller (not shown) reads the data from the oxygen sensor 204 and may use the data to control some of the parameters of the engine 104.

[0031] There may be other components present in the exhaust system 102, for example, components for reducing noise in the exhaust pipes. However these are not described in this document.

[0032] Figure 3 illustrates a system 102 for processing exhaust gases in one embodiment according to the claimed subject matter.

[0033] The system 102 comprises the exhaust pipe as explained in previous paragraphs. A CATCON 302 is disposed in the exhaust pipe.

[0034] The CATCON 302 comprises noble metals, typically platinum, palladium and rhodium.

[0035] The claimed subject matter proposes that the CATCON 302 comprises a combination of platinum, palladium, and rhodium, with platinum and palladium contributing more to the overall noble metal content than rhodium. The content may refer to volume or weight of the noble metals.

[0036] In one embodiment the CATCON 302 has a composition of the metals platinum, palladium, and rhodium in the proportions 2:2: 1 respectively.

[0037] In one embodiment the CATCON 302 has a composition of the metals platinum, palladium, and rhodium in the proportions 25:30: 1 respectively.

[0038] In one embodiment the CATCON 302 has a composition of the metals platinum, palladium, and rhodium in the proportions 10: 10: 1 respectively.

[0039] In one embodiment the CATCON 302 has a composition of the metals platinum, palladium, and rhodium in the proportions 5:9: 1 respectively.

[0040] Figure 4 illustrates a system 102 for processing exhaust gases in another embodiment according to the claimed subject matter.

[0041] The system comprises the exhaust pipe as explained in previous paragraphs. At least one first CATCON 402 and at least one second CATCON 404 are disposed in series in the exhaust pipe. The at least one first CATCON 402 is disposed upstream of the at least one second CATCON 404 in the direction of the flow of the exhaust gases.

[0042] The CATCONs 402, 404 use noble metals like Ruthenium, Rhodium, Palladium and Platinum.

[0043] The claimed subject matter proposes that the at least one first CATCON 402 and / or the at least one second CATCON 404 or both comprise a combination of platinum, palladium, and rhodium, with platinum and palladium contributing more to the overall noble metal content than rhodium.

[0044] In one embodiment the at least one first CATCON 402 or the at least one second CATCON 404 or both CATCONs have a composition of the metals platinum, palladium, and rhodium in the proportions 2:2: 1 respectively.

[0045] In one embodiment the at least one first CATCON 402 or the at least one second CATCON 404 or both CATCONs have a composition of the metals platinum, palladium, and rhodium in the proportions 25:30: 1 respectively.

[0046] In one embodiment the at least one first CATCON 402 or the at least one second CATCON 404 or both CATCONs have a composition of the metals platinum, palladium, and rhodium in the proportions 10: 10: 1 respectively.

[0047] In one embodiment the at least one first CATCON 402 or the at least one second CATCON 404 or both CATCONs have a composition of the metals platinum, palladium, and rhodium in the proportions 5:9: 1 respectively.

[0048] Fig. 5 illustrates a method 500 of manufacturing a catalytic converter 302, 402, 404 for processing exhaust gases. Only the specific steps required for theclaimed subject matter are described. The steps which are commonly known are omitted.

[0049] The method step 502 discloses manufacturing at least one CATCON 302, 402, 404 comprising the metals platinum, palladium, and rhodium, wherein the content of rhodium is lesser than the individual contents of platinum and palladium.

[0050] The further method steps are disclosed in dependent claims.

[0051] The proposed solution has multiple technical advantages, for example, some are described below:

[0052] Optimizing Noble Metal Usage: By specifying that platinum and palladium will have a higher contribution than rhodium, the present claimed invention addresses the challenge of efficiently using expensive noble metals. Rhodium is typically more expensive than platinum and palladium, so reducing its proportion can lower costs without significantly compromising the performance of the catalytic converter.

[0053] Tailoring for Lower Displacement Engines: Lower displacement gasoline engines produce less NOx compared to GDI or diesel engines. The present claimed invention highlights that these engines do not require as high a degree of NOx reduction. This tailoring ensures that the catalytic converter's design is appropriate for the specific engine type, enhancing performance and efficiency.

[0054] Specified Noble Metal Ratios: By providing specific ratios for the noble metals (e.g., 2:2: 1, 25:30: 1, 10: 10: 1, 5:9: 1), the present claimed invention addresses the need for precise formulations to optimize the catalytic converter’s performance. These ratios likely represent different formulations tested to find the most effective balance between cost, efficiency, and emissions reduction.

[0055] Cost-Effectiveness: The specified ratios and emphasis on higher contributions of platinum and palladium help in creating cost-effective solutions for catalytic converters. Since rhodium is more expensive, minimizing its use while still maintaining catalytic efficiency can reduce the overall cost of manufacturing.

[0056] Emission Control: The claimed subject matter solves the problem of emission control for lower displacement engines by providing an optimal combination of noble metals that efficiently reduce emissions to meet regulatory standards. This is crucial for compliance with environmental regulations without incurring unnecessary costs.

[0057] Overall the claimed subject matter offers a strategic approach to using noble metals in catalytic converters, balancing performance, cost, and regulatory compliance for lower displacement gasoline engines.Reference numerals and their description:100 Vehicle102 Exhaust system104 Engine204 Oxygen sensor302, 402, 404 Catalytic converter

Claims

We claim:

1. A catalytic converter (302, 402, 404) for processing exhaust gases of an internal combustion engine (104), the catalytic converter (302, 402, 404) comprising the noble metals platinum, palladium, and rhodium, wherein the content of rhodium being lesser than the individual contents of platinum and palladium.

2. The catalytic converter (302, 402, 404) for processing exhaust gases of an internal combustion engine (104) as claimed in claim 1, wherein the catalytic converter (302, 402, 404) having a composition of the noble metals platinum, palladium, and rhodium in the proportions 2:2: 1 respectively.

3. The catalytic converter (302, 402, 404) for processing exhaust gases of an internal combustion engine (104) as claimed in claim 1, wherein the catalytic converter (302, 402, 404) having a composition of the noble metals platinum, palladium, and rhodium in the proportions 25:30: 1 respectively.

4. The catalytic converter (302, 402, 404) for processing exhaust gases of an internal combustion engine (104) as claimed in claim 1, wherein the catalytic converter (302, 402, 404) having a composition of the noble metals platinum, palladium, and rhodium in the proportions 10: 10: 1 respectively.

5. The catalytic converter (302, 402, 404) for processing exhaust gases of an internal combustion engine (104) as claimed in claim 1, wherein the catalytic converter (302, 402, 404) having a composition of the noble metals platinum, palladium, and rhodium in the proportions 5:9: 1 respectively.

6. A method (500) of manufacturing a catalytic converter (302, 402, 404) for processing exhaust gases of an internal combustion engine (104), the method comprising the step:- manufacturing (502) the catalytic converter (302, 402, 404) comprising the noble metals platinum, palladium, and rhodium, wherein the content of rhodium is lesser than the individual contents of platinum and palladium.

7. The method of manufacturing a catalytic converter (302, 402, 404) for processing exhaust gases of an internal combustion engine (104) as claimed in claim 6 wherein the manufacturing comprises manufacturing the catalytic converter (302, 402, 404) which has a composition of the metals platinum, palladium, and rhodium in the proportions 2:2: 1 respectively.

8. The method of manufacturing a catalytic converter (302, 402, 404) for processing exhaust gases of an internal combustion engine (104) as claimed in claim 6 wherein the manufacturing comprises manufacturing the catalytic converter (302, 402, 404) which has a composition of the metals platinum, palladium, and rhodium in the proportions 25:30: 1 respectively.

9. The method of manufacturing a catalytic converter (302, 402, 404) for processing exhaust gases of an internal combustion engine (104) as claimed in claim 6 wherein the manufacturing comprises manufacturing the catalytic converter (302, 402, 404) which has a composition of the metals platinum, palladium, and rhodium in the proportions 10: 10: 1 respectively.

10. The method of manufacturing a catalytic converter (302, 402, 404) for processing exhaust gases of an internal combustion engine (104) as claimed in claim 6 wherein the manufacturing comprises manufacturing the catalytic converter (302, 402, 404) which has a composition of the metals platinum, palladium, and rhodium in the proportions 5:9: 1 respectively.

11. An exhaust system (102) for processing exhaust gases of an internal combustion engine (104), the exhaust system (102) comprising:- an exhaust pipe; and- at least one catalytic converter (302, 402, 404) being disposed in the exhaust pipe, wherein the at least one catalytic converter (302, 402, 404) comprises the noble metals platinum, palladium, and rhodium, wherein the content of rhodium is lesser than the individual contents of platinum and palladium.

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