Granted Patent B2

US 7,919,052 · App. 11/878,903 · Granted Apr 5, 2011

Abstract

Claims (53)

1. A catalytic converter comprising:

a housing defining a conduit and having a support wall defining an opening in said conduit;

a removable catalyst element covering said opening for treating an exhaust gas passing through said conduit, a first side of said catalyst element abutting a surface of said support wall adjacent to the periphery of said opening;

a removable bar abutting a second, opposite side of said catalyst element;

an anchorage anchoring a first end of said bar to said wall; and

a bolt bolting a second end of said bar to said wall with a threaded engagement to press said catalyst element against said surface of said wall, thus clamping said catalyst element between said wall and said bar,

wherein said bolt and threaded engagement are configured such that when said threaded engagement is tightened, the clamping force applied by said bar to press said catalyst element against said wall is increased,

wherein said bar, wall, anchorage and bolt are formed from respective materials having different thermal expansion coefficients, said materials selected so that said clamping force increases with increasing temperature, and said clamping force is sufficiently strong at an elevated operating temperature that said catalyst element sealingly engages said wall, to prevent leakage of said gas through a gap between said surface of said wall and said catalyst element.

2. The catalytic converter of claim 1 , wherein said first end of said bar is removably anchored to said wall.

3. The catalytic converter of claim 2 , wherein said anchorage is mounted in said housing, and has an aperture releaseably receiving and engaging said first end of said bar thus anchoring said first end.

4. The catalytic converter of claim 3 , wherein said anchorage comprises an elongated arm extending from said wall, said arm having two joined plate members forming a generally L-shaped cross-section, one of said plate members facing said catalyst element and having said aperture.

5. The catalytic converter of claim 3 , wherein said first end of said bar has a pin, said pin slidably received in said aperture of said anchor support.

6. The catalytic converter of claim 5 , wherein said bar has two opposite edges, one of said edges abutting said catalyst element, said pin extending along a line between, and generally parallel, to said edges, said line being closer to one of said edges.

7. The catalytic converter of claim 1 , wherein said bar has a recessed portion between said ends, said recessed portion being spaced from said catalyst element to allow passage of said gas.

8. The catalytic converter of claim 7 , wherein said bar has a central portion protruding from said recessed portion towards said catalyst element for restricting expansion of a central portion of said catalyst element.

9. The catalytic converter of claim 1 , wherein said second end of said bar has a sleeve, said bolt extending through said sleeve.

10. The catalytic converter of claim 9 , comprising a nut and a support plate, said support plate forming said wall and having an aperture, said bolt extending through said aperture and being coupled to said nut such that said bolt and said nut clamp said plate and said bar therebetween.

11. The catalytic converter of claim 10 , comprising a washer-gasket unit placed between said nut and said support plate.

12. The catalytic converter of claim 1 , comprising a restriction bar mounted in said housing and across said opening of said wall, for restricting expansion of a central portion of said catalyst element.

13. The catalytic converter of claim 1 , wherein said catalyst element comprises a peripheral frame and a catalyst core mounted to said frame, said frame bearing the clamping force applied to said catalyst element by said bar and said wall.

14. The catalytic converter of claim 13 , wherein said frame is formed from a material selected from carbon steel and stainless steel.

15. The catalyst converter of claim 1 , wherein said wall and said bar have a first thermal expansion coefficient, and said bolt and said anchorage have a second thermal expansion coefficient smaller than said first thermal expansion coefficient.

16. The catalyst converter of claim 15 , wherein said first thermal expansion coefficient is about 9.6×10 −6 in/in. ° F., and said second thermal expansion coefficient is about 7.6×10 −6 in/in. ° F.

17. The catalytic converter of claim 15 , wherein each one of said wall and said bar is made of stainless steel, and each one of said bolt and said anchorage is made of carbon steel.

18. The catalytic converter of claim 1 , wherein said bar is a first bar, and said catalytic converter comprises a second bar having a first end anchored to said wall and a second end bolted to said wall thus clamping said catalyst element between said wall and said second bar.

19. The catalytic converter of claim 18 , wherein each one of said first bar and second bar has a longitudinal axis, said longitudinal axes being aligned with each other at an angle from 30 to 90 degrees.

20. The catalytic converter of claim 18 , wherein a central portion of each one of said first and second bars has a notch, said notches facing each other and being sized to allow said second bar to be positioned across said first bar.

21. The catalytic converter of claim 1 , comprising a plurality of catalyst elements.

22. The catalytic converter of claim 1 , wherein said support wall is an inlet wall and said opening of said support wall is an inlet opening, said housing has an outlet wall defining an outlet opening, and another catalyst element covering said outlet opening is clamped between said outlet wall and a pressure bar bolted to said outlet wall.

23. The catalytic converter of claim 1 , comprising a flow distributor mounted in said housing upstream of said opening of said wall for distributing said gas over said opening, said flow distributor comprising a cone-shaped tube.

24. The catalytic converter of claim 23 , wherein said flow distributor comprises a plurality of nested, cone-shaped tubes.

25. A catalytic converter comprising:

a housing defining a conduit and having support means for defining an opening in said conduit;

a removable catalyst element covering said opening for treating an exhaust gas passing through said conduit, a first side of said catalyst element abutting a surface of said support means adjacent to the periphery of said opening;

pressure means for abutting a second, opposite side of said catalyst element;

anchorage means for anchoring a first end of said pressure means to said housing; and

bolt means for bolting a second end of said pressure means to said support means, with a threaded engagement means to press said catalyst element against said surface of said support means, thus clamping said catalyst element between said support means and said pressure means,

wherein said bolt meanings and threaded engagement means are configured such that when said threaded engagement means is tightened, the clamping force applied by said pressure means to press said catalyst element against said support means is increased,

wherein said pressure means, support means, anchorage means and bolt means are formed from respective materials having different thermal expansion coefficients, said materials selected so that said clamping force increases with increasing temperature, and said clamping force is sufficiently strong at an elevated operating temperature that said catalyst element sealingly engages said support means, to prevent leakage of said gas through a gap between said surface of said support means and said catalyst element.

26. A method of securing a catalyst element in a catalytic converter, comprising:

providing a housing defining a conduit and having a support wall defining an opening in said conduit;

covering said opening with a removable catalyst element for treating an exhaust gas passing through said conduit, a first side of said catalyst element abutting a surface of said wall adjacent to the periphery of said opening; and

abutting a second, opposite side of said catalyst element with a pressure bar by anchoring a first end of said bar to said wall with an anchorage and bolting a second end of said bar to said wall with a bolt and a threaded engagement to press said catalyst element against said surface of said wall, thus clamping said catalyst element between said wall and said bar,

wherein said bolt and threaded engagement are configured such that when said threaded engagement is tightened, the clamping force applied by said bar to press said catalyst element against said wall is increased,

wherein said bar, wall, anchorage and bolt are formed from respective materials having different thermal expansion coefficients, said materials selected so that said clamping force increases with increasing temperature, and said clamping force is sufficiently strong at an elevated operating temperature that said catalyst element sealingly engages said wall, to prevent leakage of said gas through a gap between said surface of said wall and said catalyst element.

27. A catalytic converter comprising:

a housing defining a generally longitudinally oriented conduit extending between an inlet and an outlet, said housing having a generally transversely oriented support wall mounted in said conduit between said inlet and said outlet, said support wall having an opening permitting an exhaust gas to pass through said conduit;

a removable catalyst element covering said opening in said support wall for treating said exhaust gas passing through said conduit; said catalyst element having a front side facing said support wall and a rear opposite side; and

at least one member abutting and extending across said rear side of said catalyst element, said member having a first end pivotally connected to said housing and a second opposite end of said member connected with a bolt to said support wall wherein in use, said catalyst element is held in compression between said support wall and said member.

28. A catalytic converter as claimed in claim 27 , wherein said bolt is adjustable to vary the compression of said catalyst element as it is held between said support wall and said member.

29. A catalytic converter as claimed in claim 27 , wherein said second end of said member is adapted to releasably engage said housing.

30. A catalytic converter as claimed in claim 29 , wherein said second end of said member has a pin receivable in an aperture in said housing.

31. A catalytic converter as claimed in claim 30 wherein said housing comprises a longitudinally extending arm member and wherein said aperture is in said arm member.

Assignments (11)