Title: Catalytic converters having non-linear flow channels

Abstract

Disclosed is a honeycomb catalyst substrate core having geometrically non-linear flow channels. In an embodiment, the honeycomb catalyst substrate core includes helical flow channels. In another embodiment, the honeycomb catalyst substrate core includes sinusoidal flow channels. In yet another embodiment, the honeycomb catalyst substrate core includes helical plus sinusoidal flow channels. The honeycomb catalyst substrate core comprises a plurality of parallel non-linear flow channels formed along a longitudinal axis of symmetry of the catalyst substrate core, each non-linear flow channel configured such that eddies occurs during engine exhaust gas flow. Also disclosed is a method for manufacturing a ceramic honeycomb having non-linear flow channels, comprising the steps extrusion soft ceramic material through a die whilst the die moves through six degrees of freedom along its axis of symmetry. Disclosure includes a method for manufacturing a ceramic honeycomb having non-linear flow channels using three-dimensional printing.

Inventors:

Masoudi, Mansour

Issue Date:

2020-10-27

Research Org.:

US Dept. of Energy, Washington, DC (United States)

Sponsoring Org.:

USDOE

OSTI Identifier:

1771555

Patent Number(s):

10815856

Application Number:

15/677,019

Assignee:

Masoudi, Mansour, Mill Creek, WA (United States)

Patent Classifications (CPCs):

F - MECHANICAL ENGINEERING F01 - MACHINES OR ENGINES IN GENERAL F01N - GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

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F - MECHANICAL ENGINEERING F01 - MACHINES OR ENGINES IN GENERAL F01N - GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL

F01N3/2828 - {Ceramic multi-channel monoliths, e.g. honeycombs}
F01N3/2842 - {specially adapted for monolithic supports, e.g. of honeycomb type

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J37/0217 - {Pretreatment of the substrate before coating}
B01J35/04 - Foraminous structures, sieves, grids, honeycombs

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B2111/0081 - {as catalysts or catalyst carriers}

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J37/0215 - {Coating}
B01J37/0225 - {of metal substrates}

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B38/0077 - {Materials with a non-porous skin}
C04B35/00 - Shaped ceramic products characterised by their composition {

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J37/08 - Heat treatment {

F - MECHANICAL ENGINEERING F01 - MACHINES OR ENGINES IN GENERAL F01N - GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL

F01N2330/34 - with flow channels of polygonal cross section
F01N3/281 - {Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates}

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B38/0096 - {Pores with coated inner walls}

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J37/0009 - {Use of binding agents

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B38/0006 - {Honeycomb structures

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DOE Contract Number:  

SC0015946

Resource Type:

Patent

Resource Relation:

Patent File Date: 08/15/2017

Country of Publication:

United States

Language:

English