Exhaust system
View Patent ↗A component of an exhaust system for a combustion engine, particularly of a motor vehicle, which at least in part regions includes a self-supporting jacket. The jacket includes a porous, open-pore or closed-pore cellularly constructed foam. The foam is of a self-supporting design. By using such a foam the insulation of the component can be improved.
1. An internal combustion engine exhaust system component comprising a self-supporting exhaust system component jacket comprising:
an outer layer comprised of a closed-pore foam or of a non-porous tube, the outer layer forming an exhaust system component jacket outer surface;
an inner layer inside of the outer layer and adjoining the outer layer, the inner layer comprising porous cellularly constructed open pore foam, wherein the foam of the inner layer is of a self-supporting design; and
a lining layer inside of the inner layer and adjoining the inner layer, the lining layer comprising an open-pore foam wherein the open-pore foam of the lining layer has a smaller pore size than the open-pore foam of the inner layer, the lining layer forming an exhaust system component jacket inner surface.
2. The component according to claim 1 , wherein at least the inner layer of foam is baked onto at least one of the outer layer and the liner layer, respectively.
3. The component according to claim 1 , wherein at least one of the inner layer and the lining layer, respectively, is integrally formed with or from the foam of the inner layer.
4. The component according to claim 1 , wherein the foam of at least one of the outer layer, the inner layer and the lining layer consists essentially of at least one of a metal and a mineral material.
5. The component according to claim 1 , wherein the jacket further comprises at least one connecting element which is designed integrally with the jacket.
6. An internal combustion engine exhaust system comprising:
an exhaust gas pipe; and
an exhaust component connected to the exhaust gas pipe, the exhaust component comprising a self-supporting exhaust system component jacket comprising a porous cellularly constructed foam, wherein the foam has self-supporting properties and the exhaust system component jacket comprises:
an outer layer comprising a closed-pore foam or of a non-porous tube, the outer layer forming an exhaust system component jacket outer surface;
an inner layer inside of the outer layer and adjoining the outer layer, the inner layer comprising porous cellularly constructed open pore foam; and
a lining layer inside of the inner layer and adjoining the inner layer, the lining layer comprising an open-pore foam wherein the open-pore foam of the lining layer has a smaller pore size than the open-pore foam of the inner layer, the lining layer forming an exhaust system component jacket inner surface.
7. The exhaust system according to claim 6 , wherein:
the foam is baked onto at least one of the outer layer and the linear layer, respectively; and
at least one of the linear layer and the outer layer, respectively, is integrally formed with or from the foam.
8. The exhaust system according to claim 7 , wherein the foam comprises at least one of metal and a mineral material.
9. The exhaust system according to claim 6 , wherein the material of the jacket in at least two regions has at least one of a different density and a different material and a different wall thickness as compared to a remainder of the multi-layered foam structure.
10. A method for producing a component of an internal combustion engine exhaust system, the method comprising the steps of:
providing a raw foam compound;
admixing a foaming agent in different concentrations to the raw foam compound in at least two jacket regions; and
baking of the raw foam compound with two jacket regions so that a component jacket has, in at least the two jacket regions, following the baking, at least one of a different density and a different material thickness to form a self-supporting jacket comprising:
an outer layer comprising a closed-pore foam or of a non-porous tube, the outer layer forming an exhaust system component jacket outer surface;
an inner layer inside of the outer layer and adjoining the outer layer, the inner layer comprising a porous cellularly constructed open pore foam; and
a lining layer inside of the inner layer and adjoining the inner layer, the lining layer comprising an open-pore foam wherein the open-pore foam of the lining layer has a smaller pore size than the open-pore foam of the inner layer, the lining layer forming an exhaust system component jacket inner surface.
11. The component according to claim 4 , wherein the outer layer, the foam of the inner layer and the foam of the lining layer comprise at least one of an aluminum alloy and a stainless steel alloy.
12. The component according to claim 11 , wherein the jacket inner surface is an inner hot exhaust gas passage surface in contact with an exhaust stream and the inner hot exhaust gas passage surface defines an inner hot exhaust gas passage.
13. The component according to claim 1 , wherein the outer layer comprises a stainless steel alloy foam, the lining layer comprises an aluminum alloy foam or a stainless steel alloy foam and the inner layer comprises an aluminum alloy foam.
14. The component according to claim 1 , wherein the jacket inner surface is an inner hot exhaust gas passage surface in contact with an exhaust stream and the inner hot exhaust gas passage surface defines an inner hot exhaust gas passage.
15. The component according to claim 14 , wherein the outer layer comprises a stainless steel alloy foam, the lining layer comprises an aluminum alloy foam or a stainless steel alloy foam and the inner layer comprises an aluminum alloy foam.
16. The exhaust system according to claim 8 , wherein the outer layer, the foam of the inner layer and the foam of the lining layer comprise at least one of an aluminum alloy a stainless steel alloy.
17. The exhaust system according to claim 8 , wherein the jacket inner surface is an inner hot exhaust gas passage surface in contact with an exhaust stream and the inner hot exhaust gas passage surface defines an inner hot exhaust gas passage.
18. The exhaust system according to claim 17 , wherein the outer layer comprises a stainless steel alloy foam, the lining layer comprises an aluminum alloy foam or a stainless steel alloy and the inner layer comprises an aluminum alloy foam.
19. The method according to claim 10 , wherein the jacket inner surface is an inner hot exhaust gas passage surface in contact with an exhaust stream and the inner hot exhaust gas passage surface defines an inner hot exhaust gas passage.
20. The method according to claim 19 , wherein the outer layer comprises a stainless steel alloy foam, the lining layer comprises an aluminum alloy foam or a stainless steel alloy foam and the inner layer comprises an aluminum alloy foam.