Honeycomb Catalytic Converter Nested in Muffler Casing
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Solution Overview
Problem
Catalytic converters in exhaust systems experience significant pressure losses due to abrupt changes in flow cross-sections, which hampers efficient operation and compliance with emission and noise regulations.
Innovation Solution
A device with a catalytic converter formed by a honeycomb body within a casing tube, integrated into a silencer, where the casing tube has openings for exhaust gas flow between the catalytic converter and the muffler volume, maintaining consistent flow cross-sections and incorporating sound absorption or reflection to reduce noise and pressure losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If catalytic converters are integrated into the exhaust system with conventional piping, then exhaust gas treatment is achieved, but pressure losses increase due to abrupt changes in flow cross-section
Solution Approach 1:
The patent combines the catalytic converter and silencer into a single integrated device, eliminating the need for separate components and connecting piping. The catalytic converter is positioned directly within the silencer housing, creating a seamless flow path that removes abrupt cross-section changes and reduces pressure losses while maintaining exhaust gas treatment effectiveness.
Solution Approach 2:
The catalytic converter is nested within the silencer housing, with the honeycomb body positioned inside the silencer's internal chamber. This nesting arrangement allows the catalytic converter to be accommodated within the existing silencer volume without requiring additional external piping, thereby eliminating flow cross-section transitions and reducing pressure losses.
2Productivity
If catalytic converters with larger diameter are used, then exhaust gas treatment capacity is improved, but pressure losses increase due to abrupt cross-section changes
Solution Approach 1:
The catalytic converter with its honeycomb body is nested within the silencer housing, allowing the use of a larger-diameter catalytic converter without increasing the overall external diameter of the exhaust system. The silencer housing accommodates the catalytic converter internally, maintaining consistent flow cross-section throughout the system and preventing pressure losses while providing adequate treatment capacity.
Solution Approach 2:
The patent transitions from a linear arrangement of components to a three-dimensional nested configuration. The catalytic converter is positioned in the internal chamber of the silencer, utilizing the vertical and radial dimensions within the silencer housing rather than extending the external diameter. This dimensional reorganization allows larger treatment capacity without increasing external system diameter, avoiding pressure losses.
3Reliability
If separate catalytic converter and silencer components are used, then component functionality is maintained, but device complexity and installation space requirements increase
Solution Approach 1:
The patent merges the catalytic converter and silencer into a single integrated device, combining two separate functional components into one unit. The catalytic converter is positioned directly within the silencer housing, eliminating the need for separate components, connecting piping, and multiple installation points. This integration reduces system complexity while maintaining both exhaust gas treatment and noise reduction functionalities.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Minimizes pressure losses and achieves effective exhaust gas treatment while meeting emission and noise regulations by maintaining consistent flow cross-sections and utilizing sound absorption or reflection for noise reduction.
Implementation Method 1
the catalytic converter being formed by a honeycomb body which has a plurality of flow channels through which exhaust gas can flow
Implementation Method 2
the casing tube accommodating the honeycomb body having openings which allow overflow from the honeycomb body to the volume enclosed by the muffler
Implementation Method 3
incorporating sound absorption or reflection to reduce noise and pressure losses
Implementation Method 4
incorporating sound absorption or reflection to reduce noise and pressure losses
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a device for the aftertreatment of exhaust gases of an internal combustion engine, comprising at least one catalytic converter (8, 9, 31), through which exhaust gas can flow, and at least one muffler (1, 20), which is formed by a closed volume and through which exhaust gas can flow along an inflow section (3, 27) to an outflow section (4, 28). The catalytic converter (8, 9, 31) is made of a honeycomb body which has a plurality of flow channels through which exhaust gas can flow, wherein the honeycomb body is received in a casing tube (12, 13, 32), which surrounds the honeycomb body, and is bonded to the casing tube, and the catalytic converter (8, 9, 31) is arranged in the interior of the muffler (1, 20).