TECHNICAL FIELD
The present invention relates an improved exhaust
purifying apparatus for purifying exhaust gas discharged from
an internal combustion engine.
BACKGROUND ART
Various types of exhaust purifying apparatuses for
internal combustion engines are known today, among which are
an "exhaust purifying apparatus for an internal combustion
engine" disclosed in Japanese Patent Laid-open Publication No.
HEI-3-85316 and an "exhaust purifying apparatus for a motor
bicycle or the like" disclosed in Japanese Patent Laid-open
Publication No. HEI-4-287821.
The exhaust purifying apparatus in the HEI-3-85316
publication is shown in Figs. 17 and 18, where an exhaust pipe
100 is coupled to an exhaust port of a small-size internal
combustion engine mounted on a motor bicycle or the like, and
a internal pipe 101 made of a porous sheet is disposed within
the exhaust pipe 100 and extending along the inner surface of
the pipe 100, with catalyst-bearing layers 102 attached to the
inner and outer surfaces of the porous internal pipe 101.
The exhaust purifying apparatus in the HEI-4-287821
publication is shown in Figs. 19 to 21, where an exhaust
muffler (corresponding to the exhaust pipe) 110 is coupled to
an exhaust port of a small-size internal combustion engine
mounted on a motor bicycle or the like, and a catalyst pipe 111
is provided in the central region of the exhaust muffler 110
with a catalyst-bearing member 112 received within the pipe
111. The catalyst-bearing member 112 comprises a honeycomb
having catalyst materials attached thereto.
As known in the art, in order to allow catalysts to perform
their exhaust purifying function to a sufficient degree, it is
generally necessary to activate the catalysts by heating them
to a high temperature. But, with a small-size internal
combustion engine, it is not easy to increase the exhaust gas
temperature sufficiently to activate the catalysts, and hence
some measure has to be taken to increase the catalyst
temperature as high as possible. To this end, one must take
into account the fact that the temperature of exhaust gas
flowing in the exhaust pipe is higher in the central region
(i.e., the central region as viewed in cross section) of the
pipe and lower in the peripheral region or near the inner wall
surface of the pipe remote from the central region.
However, because the catalyst-attached internal pipe 101
is disposed near and along the inner wall surface of the
exhaust pipe 100, the exhaust purifying apparatus shown in
Figs. 17 and 18 can not easily provide a sufficient purifying
capability.
On the other hand, the exhaust purifying apparatus shown in
Figs. 19 to 21 can easily perform a sufficient purifying
capability because the catalyst bearing member 112 is located
in the central region of the exhaust muffler 110 and the
relatively high exhaust temperature can keep the catalysts
hot. But, the honeycomb catalyst bearing member 112 in the
apparatus in Figs. 19 to 21 tends to cause a greater loss in the
exhaust gas pressure than the porous internal pipe 101 in the
apparatus of Figs. 17 and 18. An even greater pressure loss
would result in the central region of the muffler 110 where the
exhaust gas flows at a higher speed. The performance of the
internal combustion engine would be adversely influenced by
the pressure loss to a substantial degree; in particular, the
pressure loss could be a significant adverse factor for low-power
internal combustion engines such as those of motor
cycles. Further, the arrangement that the honeycomb catalyst
member 112 is received in the catalyst pipe 111 would require
a considerable manufacturing cost as compared to the
arrangement that the catalyst-attached internal pipe 101 is
just received in the exhaust pipe 100.
DISCLOSURE OF THE INVENTION
It is therefore an object of the present invention to
provide an exhaust purifying device for an internal combustion
engine which achieves a sufficient purifying function while
minimizing an adverse effect on the performance of the engine
and yet can be manufactured at low cost.
The present invention provides an exhaust purifying device
for an internal combustion engine which is characterized in
that a steel sheet member having inner and outer catalytic-metal-bearing
surfaces is disposed substantially in the
central region of an exhaust port extending from an exhaust
port of the internal combustion engine. Thus, the catalytic
metal is placed in the region of the exhaust pipe where the
temperature of the exhaust gas from the engine is relatively
high. The high-temperature exhaust gas effectively activates
the catalytic metal on the steel sheet member to thereby allow
the catalytic metal to perform its exhaust purifying function
to a sufficient degree. The steel sheet member is preferably
in the form of a hollow cylinder extending in the axial
direction of the exhaust port so that a pressure loss in the
exhaust gas flowing through the steel sheet member can be
reduced. Preferably, the cylinder is made of a porous steel
sheet and closed at its upstream end. In this case, the
exhaust gas is directed to pass through small openings formed
through the wall thickness of the cylinder, during which time
the exhaust gas contacts the catalytic metal on the inner and
outer catalytic-metal-bearing surfaces. Thus, the exhaust is
acted on by the catalytic metal in a greater area of the
surfaces and accordingly can provide an enhanced exhaust
purifying capability.
According to another aspect of the present invention, a
hollow cylinder is provided and supported substantially in the
central region of the exhaust pipe, and the hollow cylinder is
made of a steel sheet having inner and outer catalytic-metal-bearing
surfaces. Also, a partition plate is provided within
the exhaust pipe to block passage of the exhaust gas between
the cylinder and the exhaust pipe. The partition plate
functions to suppress the pulsating motion of the exhaust gas
caused by the engine, so as to provide a generally smooth
steady flow of the exhaust gas. Owing to the provision of such
a partition plate, the purifying capability of the exhaust
purifying apparatus does not significantly vary and hence can
be enhanced effectively. Further, because the steel cylinder
is supported via the partition plate suppressing the pulsating
motion of the exhaust gas, no separate support is required.
The steel cylinder is mounted in such a manner that the
cylinder is free to axially expand or contract relative to the
exhaust pipe, and this feature advantageously accommodates a
difference in amounts of axial thermal expansion between the
steel cylinder and exhaust pipe.
According to another aspect of the present invention, a
first catalytic-metal-bearing member is provided within the
exhaust pipe along an inner wall surface of said pipe and a
second catalytic-metal-bearing member is provided
substantially in the central region of the first catalytic-metal-bearing
member. Because the catalytic-metal-bearing
members are provided near the inner wall surface of and in the
central region of the exhaust pipe, the exhaust purifying
function can be further enhanced without adversely affecting
the performance of the internal combustion engine.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a side elevational view showing a motor cycle on
which is mounted an exhaust purifying apparatus for an internal
combustion engine according to a first embodiment of the
present invention,
Fig. 2 is a side view showing an embodiment of an exhaust
pipe employed in the apparatus of Fig. 1 and constructed in
accordance with the present invention,
Fig. 3 is a sectional view taken along the line A - A of
Fig. 2, showing an upstream exhaust purifier shown in Fig. 2,
Fig. 4 is a sectional view taken along the line B - B of
Fig. 3,
Fig. 5 is a perspective view showing an embodiment of a
downstream exhaust purifier shown in Fig. 2,
Fig. 6 is a sectional view taken along the line C - C of
Fig. 2,
Fig. 7 is a sectional view taken along the line D - D of
Fig. 6,
Fig. 8 is a sectional view taken along the line E - E of
Fig. 6,
Figs. 9A to 9E are views showing how a second catalytic-metal-bearing
member of the downstream exhaust purifier of
Fig. 5 is assembled,
Figs. 10A to 10D are views showing modifications of the
second catalytic-metal-bearing member,
Figs. 11A to 11H are views showing modifications of a
support structure for the second catalytic-metal-bearing
member,
Fig. 12 is a perspective view showing another embodiment of
the downstream exhaust purifier,
Fig. 13 is a sectional view taken along the line F - F of
Fig. 12,
Fig. 14 is a view showing a modification of the downstream
exhaust purifier of Fig. 12,
Fig. 15 is a sectional view taken along the line G - G of
Fig. 14,
Figs. 16A to 16E are views showing still another embodiment
of the exhaust purifier apparatus,
Fig. 17 is a cross-sectional view of an exhaust pipe in a
prior art exhaust purifying apparatus,
Fig. 18 is a side view, partly in vertical section, of the
exhaust pipe of Fig. 17,
Fig. 19 is a plan view of an exhaust muffler in another
prior art exhaust purifying apparatus,
Fig. 20 is a perspective view, partly in vertical section,
of the exhaust purifying apparatus of Fig. 19, and
Fig. 21 is a vertical sectional view of a catalyst pipe and
peripheral components in the exhaust purifying apparatus of
Fig. 19.
BEST MODE FOR CARRYING OUT THE INVENTION
Fig. 1 is a side elevational view showing a motor cycle 1
on which is mounted an exhaust purifying apparatus for an
internal combustion engine according to a first embodiment of
the present invention. As shown, the motor cycle 1 includes a
two-cycle internal combustion engine 3 provided near the
central part of a vehicle body 2, and an exhaust pipe 5
connected to an exhaust port 4 of the engine 3. The rear end
portion of the exhaust pipe 5 is coupled to a muffler 6.
Fig. 2 shows details of the exhaust pipe 5, which is formed
of a thin steel sheet and has a circular sectional shape. The
exhaust pipe 5 having an upstream end portion 5a connected by
flange coupling to the engine exhaust port 4 of Fig. 1 and
having a downstream end portion 5b connected by flange coupling
to the muffler 6 of Fig. 1 (the words "upstream" and
"downstream" are used herein in terms of the flow of exhaust
gas from the engine exhaust port 4). Upstream and downstream
exhaust purifiers 10 and 20 are provided within the exhaust
pipe 5; in other words, the former is a front-stage exhaust
purifier and the latter is a rear-stage exhaust purifier. The
portion of the exhaust pipe 5 in which the downstream exhaust
purifier 20 is disposed is greater in diameter than the other
portions of the pipe 5.
Fig. 3 shows a detailed structure of the upstream exhaust
purifier 10 in a sectional view taken along the line A - A of
Fig. 2. The upstream exhaust purifier 10 includes an internal
pipe 11 having numerous small openings 11c formed through the
wall thickness thereof, which is disposed within the exhaust
pipe 5 and in the form of a hollow cylinder made of a thin,
porous steel sheet and extending along the inner wall surface
of the exhaust pipe 5. The internal pipe 11 has one or upstream
end portion 11a fixed by welding to the inner wall surface of
the exhaust pipe 5 and the other or downstream end portion 11b
supported by a support member 13 in such a manner that the
downstream end portion 11b is free to axially move (expand or
contract) relative to the exhaust pipe 5 so as to accommodate
a difference in amounts of axial thermal expansion between the
two pipes 5 and 11.
The inner wall surface of the internal pipe 11 has a layer
of catalytic metal, such as platinum or rhodium, which is
formed by, for example, applying a solution of the catalytic
metal onto the surface. A clearance 5c is formed between the
intermediate portion of the exhaust pipe 5 and the internal
pipe 11.
As shown in Fig. 4, the exhaust pipe 5 comprises a pair of
upper and lower hollow cylinder halves each having a
semicircular sectional shape, which are welded together into
a hollow cylinder with the internal pipe 11 received therein.
The support member 13 comprises a corrugated sheet that is
wound around the outer periphery of the internal pipe 11 with
its parallel ridges and grooves extending in the axial
direction of the exhaust pipe 5 (i.e., the ridges and grooves
alternating along the periphery of the pipe 11). Overlapping
surfaces of the thus-wound corrugated sheet are secured
together by spot-welding. By means of such a corrugated
structure, the support member 13 can resiliently deform
relative to the internal pipe 11 in the radial direction
thereof to allow the downstream end portion 11a of the internal
pipe 11 to axially slide along the support member 12, to
thereby accommodate a difference in amounts of axial thermal
expansion between the exhaust pipe 5 and internal pipe 11 due
to the temperature of the exhaust gas. Note that the above-mentioned
corrugated sheet is just illustrative and the
support member 13 may be implemented in any other suitable
manner, such as by a stainless steel wire knitted into a ring
disposed around the outer periphery of the internal pipe 11.
Protecting members 14 are in the form of a pair of hollow
cylinder halves (each having a substantially semicircular
sectional shape) are bolted to nuts 15 welded to the outer
periphery of the exhaust pipe 5, so as to together form a
substantially cylindrical cover for the exhaust pipe 5 that are
heated by the exhaust gas flowing therethrough.
Fig. 5 shows the downstream exhaust purifier 20 of Fig. 2,
which includes a first catalytic-metal-bearing member 18
provided within the exhaust pipe 5 near the inner wall surface
of the pipe 5. The first catalytic-metal-bearing member 18
comprises a pair of hollow cylinder halves 21 each having a
semicircular sectional shape so as to together form a hollow
cylinder within the exhaust pipe 5 as shown in Fig. 5. A second
catalytic-metal-bearing member 22, which is in the form of a
straight hollow cylinder smaller in diameter than the first
catalytic-metal-bearing member 18, is provided substantially
in a central region (i.e., central region as viewed in cross
section) of the bearing member (and hence substantially in a
central region of the exhaust pipe 5). It can be said that the
exhaust pipe 5 and first and second catalytic-metal-bearing
members 18 and 22 are mounted concentrically. The first and
second catalytic-metal-bearing members 18 and 22 both extend
in the axial direction of the exhaust pipe 5.
Each of the first and second catalytic-metal-bearing
members 18 and 22 is made of a thin, porous steel sheet to have
numerous small openings 21a, 22c formed through the wall
thickness thereof. A layer of catalytic metal, such as
platinum or rhodium, is formed on the wall surfaces of the
first and second catalytic-metal-bearing members 18 and 22 by,
for example, applying a solution of the catalytic metal onto
the surfaces. A clearance is formed between the exhaust pipe
5 and the hollow cylinder halves 21 of the first catalytic-metal-bearing
member 18.
As shown in Fig. 6, a support structure 23 is provided, at
one or upstream end portion (left end portion in the figure)
22a of the second catalytic-metal-bearing member 22, to
support the end portion 22a in such a manner that the end
portion 22a is free to axially move (expand or contract)
relative to the exhaust pipe 5. The support structure 23
includes a cushion member 24 wound around the upstream end
portion 22a of the second catalytic-metal-bearing member 22,
an annular holder 25 receiving and holding the cushion member
24 in place, and a bracket 26 that secures the annular holder
25 with the cushion member 24 to the exhaust pipe 5. Because
of the cushion member 24, the support structure 23 accommodates
a difference in amounts of axial thermal expansion between the
exhaust pipe 5 and the second catalytic-metal-bearing member
22 by allowing the upstream end portion 22a to axially move
relative to the exhaust pipe 5. Further, a cap 28 is provided
within the second catalytic-metal-bearing member 22 to close
the upstream end portion 22a of the member 22.
A partition plate 27 is provided, at the downstream end
portion (right end portion in the figure) of the second
catalytic-metal-bearing member 22, to support that end and
block passage of the exhaust gas between the second catalytic-metal-bearing
member 22 and the exhaust pipe 5. The partition
plate 27, which is a dish-shaped end plate made of a thin steel
plate, has a flange along the entire outer periphery thereof
and is fixed in place by the flange being plug-welded to the
inner wall surface of the exhaust pipe 5. The other or
downstream end portion 22b is threaded through a central
through-hole 27b and fixed by welding to the entire edge of the
plate 27 defining the through-hole 27b.
As shown in Fig. 7 which is a sectional view taken along the
line D - D of Fig. 6, the cushion member 24 comprises a
corrugated sheet that is wound around the outer periphery of
the second catalytic-metal-bearing member 22 with its parallel
ridges and grooves extending in the axial direction of the
exhaust pipe 5 (i.e., the ridges and grooves alternating along
the outer periphery of the member 24). The thus-wound
corrugated sheet is fixed around the second catalytic-metal-bearing
member 22 by spot-welding its overlapping surfaces.
Owing to such a corrugated structure, the cushion member 24 can
resiliently deform relative to the member 22 in the radial
direction thereof, so as to accommodate a difference in amounts
of axial thermal expansion between the exhaust pipe 5 and
second catalytic-metal-bearing member 22.
As shown in Fig. 8 which is a sectional view taken along the
line E - E of Fig. 6, each of the hollow cylinder halves 21 of
the first catalytic-metal-bearing member 18 is spot-welded at
its opposite edges to the inner wall surface of the exhaust
pipe 5.
The following paragraphs describe how the above-mentioned
second catalytic-metal-bearing member 22 is assembled, with
reference to Figs. 6 and 9A - 9E.
First, the cap 28 is fit into the upstream end portion 22a
of the second catalytic-metal-bearing member 22 as shown in
Fig. 9A, and the outer peripheral edge of the cap 28 and the
inner wall surface of the member 22 are fixed together by spot
welding in order to close the upstream end portion 22a as shown
in Fig. 9B. Then, as shown in Fig. 9C, the downstream end
portion 22b of the second catalytic-metal-bearing member 22 is
threaded through the central through-hole 27b of the partition
plate 27 and welded to the edge defining the hole 27b.
After that, the annular holder 25 receiving the cushion
member 25 (Fig. 6) is threaded on the upstream end portion 22a
of the second catalytic-metal-bearing member 22 as shown in
Fig. 9D, and the second catalytic-metal-bearing member 22 is
assembled into a predetermined condition as shown in Fig. 9E.
The second catalytic-metal-bearing member 22 assembled as
shown in Fig. 9E is then positioned in the lower half of the
exhaust pipe 5 as shown in Fig. 6, and a part of the outer
surface of the annular holder 25 is welded to the bracket 26
previously fixed to the exhaust pipe 5. Finally, the upper
hollow cylinder half of the exhaust pipe 5 is placed edge to
edge on the lower hollow cylinder half, then the upper and
lower hollow cylinder halves are welded together, and then the
flange 27a of the partition plate 27 is plug-welded to the
inner wall surface of the exhaust pipe 5. This completes the
required assembly of the second catalytic-metal-bearing member
22.
Next, with reference to Figs. 2 and 6, a description will
be given as to how the upstream and downstream exhaust
purifiers 10 and 20 behave.
As shown in Fig. 2, the exhaust gas from the internal
combustion engine is introduced into the exhaust pipe 5 via its
upstream end portion 5a. As the introduced exhaust gas passes
through the upstream exhaust purifier 10, the exhaust gas
contacts the catalytic metal layers on the inner and outer
surfaces of the internal pipe 11 and is effectively purified
through its chemical reaction with the catalytic metal. The
exhaust gas thus purified by the upstream exhaust purifier 10
is then directed toward the downstream exhaust purifier 20.
As shown in Fig. 6, the exhaust gas initially purified by
the upstream exhaust purifier 10 is prevented from flowing into
the second catalytic-metal-bearing member 22 through its
upstream end portion 22a because the end portion 22a is closed
by the cap 28.
A portion of the exhaust pipe 5 in which the downstream
exhaust purifier 20 is disposed is greater in diameter than the
other portions of the pipe 5 as noted earlier, and this
greater-diameter portion is partitioned off by the partition
plate 27 so that an expanding chamber 29 is formed in the
greater-diameter portion upstream of the plate 27. The
expanding chamber 29 functions to suppress the pulsating
motion of the exhaust gas caused by the engine 3, so as to
provide a generally smooth steady flow of the exhaust gas.
This allows the exhaust gas to flow as indicated by black
arrows, and a portion of the exhaust gas flowing near and along
the inner wall surface of the exhaust pipe 5 comes into contact
with the catalytic metal layers on the inner and outer surfaces
of the first catalytic-metal-bearing member 18 to be purified
through its chemical reaction with the catalytic metal.
In the meantime, another portion of the exhaust gas flows
into the second catalytic-metal-bearing member 22 via the
numerous small openings 22c, flows through the member 22 and
then is discharged through the downstream end portion of the
exhaust pipe 5 into the atmosphere. As the exhaust gas flows
in the second catalytic-metal-bearing member 22, it comes into
contact with the catalytic metal layer surfaces on the member
22 to be purified through its chemical reaction with the
catalytic metal.
When passing through the numerous small openings 22c formed
in the second catalytic-metal-bearing member 22, the exhaust
gas contacts the catalytic metal layers on the outer and inner
wall surfaces of the member 22. Therefore, the exhaust gas can
contact a great area of the catalytic metal layers, and thus
the catalytic metal can perform its exhaust purifying function
to a sufficient degree.
As previously discussed in relation to the prior art
apparatuses, it is necessary to activate the catalyst metal by
heating in order to allow the catalyst metal to perform its
exhaust purifying function to a sufficient degree, and the
temperature of the exhaust gas flowing in the exhaust pipe is
higher in the central region of the pipe and lower near the
inner wall surface of the pipe. According to the embodiment of
the present invention, even a relatively hot portion of the
exhaust gas flowing in the central region of the exhaust pipe
5 is caused to flow in the downstream exhaust purifier 20 in
contact with the catalytic metal layer, the catalytic metal can
be sufficiently activated by being heated by the high-temperature
exhaust gas and thus perform its exhaust purifying
function to a sufficient degree. In addition, the second
catalytic-metal-bearing member 22, in the form of a hollow
cylinder having a porous wall, effectively reduces a pressure
loss of the exhaust gas flowing through the member 22, so that
the engine performance will not be significantly influenced by
the pressure loss.
In the above-mentioned manner, the exhaust gas from the
internal combustion engine 3 can be purified efficiently by
contacting the catalytic metal layers on the first and second
catalytic-metal-bearing members 18 and 22. Besides, because
the exhaust gas is allowed to flow in a generally smooth steady
current, the purifying capability of the downstream exhaust
purifier 20 does not significantly vary, which would result in
uniform and efficient exhaust purification.
Due to heat of the reaction, the second catalytic-metal-bearing
member 22 becomes much hotter than the exhaust pipe 5.
While the downstream end portion 22b is fixed to the exhaust
pipe 5 via the partition plate 27, the upstream end portion 22a
is movably mounted via the support structure 23 on the fixed
bracket 26 of the exhaust pipe 5. Thus, when a difference in
amounts of axial thermal expansion occurs between the exhaust
pipe 5 and the member 22, the upstream end portion 22a is
allowed to move relative to the bracket 26, in the upstream
direction as indicated by a white arrow, to thereby accommodate
the difference in axial expansion. Specifically, the
difference in axial expansion between the exhaust pipe 5 and
the second catalytic-metal-bearing member 22 is accommodated
by the resilient deformation of the cushion member 24.
The second catalytic-metal-bearing member 22 has been
described above as being closed at the upstream end portion 22a
by the straight vertical cap 28, but the closing structure of
the upstream end portion 22a may be modified in various ways as
shown in Figs. 10A to 10D.
In the modification of Fig. 10A, the upstream end portion
22a of the second catalytic-metal-bearing member 22 is closed
by a porous cap 31 that projects upstream in a dome-like shape.
The cap 31 may be made by pressing a porous sheet material. In
Fig. 10B, another modified cap 32 is formed by squeezing or
pressing the upstream end portion 22a flat.
In Fig. 10C, a modified cap 33 comprises a plurality of
porous blades that are attached spirally (i.e., in the shape of
a pinwheel) to the upstream end portion 22a of the second
catalytic-metal-bearing member 22. This spiral cap 33
functions to increase the flowing resistance of the exhaust
gas. Finally, in the modification of Fig. 10D, the upstream
end portion 22a of the second catalytic-metal-bearing member
22 is closed by a cap 34 made of a flat porous plate. In stead
of providing the flat porous cap 34, the upstream end portion
22a may itself be folded toward its center along the entire
peripheral edge thereof to form an integral cap.
Each of the caps 31, 32, 33 and 34 functions in the same way
as in the above-described first embodiment, and additionally,
the pressure loss resulting from the provision of the cap is
substantially reduced as compared to the first embodiment by
virtue of its porous nature.
While the second catalytic-metal-bearing member 22 has
been described above being supported at one end portion
supported movably relative to the exhaust pipe 5 and fixed at
the other end portion to the exhaust pipe 5, the mounting
mechanism of the member 22 may be modified in various ways as
shown in Figs. 11A to 11H. In each of these figures, the
exhaust gas flows rightward as indicated by black arrows and
the one or upstream end portion 22a of the second catalytic-metal-bearing
member 22 is allowed to move leftward as
indicated by a white arrow.
In the modification of Fig. 11A, the upstream end portion
22a projects upstream beyond the support structure 23 and is
closed by a flat cap 28. In the modification of Fig. 11B, the
upstream end of the support structure 23 is closed by a cap 36.
Between the upstream end portion 22a and the cap 36, there is
provided a clearance S1 having an axial length greater than an
expected maximum amount of axial thermal expansion of the
second catalytic-metal-bearing member 22. In this case, no cap
separate from the cap 36 needs to be attached to the upstream
end portion 22a of the catalytic-metal-bearing member 22. In
the modification of Fig. 11C, the annular holder member 25 of
the support structure 23 is greater in axial length than the
bracket 26 and projects upstream beyond the bracket 26.
Further, in Fig. 11D, the catalytic-metal-bearing member
22 is supported only at the downstream end portion 22b by a
supporting structure 37 in a so-called "cantilever" fashion.
The support structure 37 includes a cushion member 38 that
supports the downstream end portion 22b in such a manner that
the end portion 22a is free to axially move (expand and
contract) relative to the exhaust pipe 5, a holder member 39
receiving and holding the cushion member 38, and a partition
plate 27 fixing the holder member 39 to the exhaust pipe 5. A
clearance S2 is provided between the downstream end portion 22b
and a flange 39a of the holder member 39 so that movement of the
downstream end portion 22b relative to the exhaust pipe 5 is
limited within the bound of the clearance S2. In the
modification of Fig. 11E, cushion and holder members 38 and 39
are smaller in axial length than those of Fig. 11D.
In the modification of Fig. 11F, the catalytic-metal-bearing
member 22 is fixed at the upstream end portion 22a to
the exhaust pipe 5 via a bracket 41 and supported at the
downstream end 22b via a support structure 42 for axial
movement relative to the exhaust pipe 5. The support structure
42 includes a cushion member 43 that supports the downstream
end portion 22b in such a manner that the end portion 22b is
free to axially move (expand or contract) relative to the
exhaust pipe 5, a holder member 44 receiving and holding the
cushion member 43 in place, and a partition plate 27 fixing the
holder member 44 to the exhaust pipe 5. The downstream end
portion 22b projects downstream beyond the support structure
42.
Further, the modification of Fig. 11G is similar to that of
Fig. 11F, except that the upstream end portion 22a is closed by
a cap 45 having a locking projection to engage or disengage the
end portion by a user's snap action. The modification of Fig.
11H employs a pair of front and rear cushion members 48
different from the above-mentioned cushion members 24, 38, 43,
each of which comprises a stainless steel wire knitted into a
ring around the outer periphery of the downstream end portion
22b. Support structure 46 includes a seat 47 wound around the
downstream end portion 22b, the front and rear cushion members
48 disposed upstream and downstream of the seat 47,
respectively, for supporting the downstream end portion 22b in
such a manner that the end portion 22b is axially movable
relative to the exhaust pipe 5, a holder member 49 receiving
and holding the cushion members 48, and a partition plate 27
fixing the holder member 49 to the exhaust pipe 5.
The following paragraphs describe a second embodiment of
the downstream exhaust purifier with reference to Figs. 12 and
13.
In the downstream exhaust purifier 50 of Fig. 12, a first
catalytic-metal-bearing member 51 is provided near and along
the inner wall surface of the exhaust pipe, and a second
catalytic-metal-bearing member 52 is provided substantially in
a central region within the first catalytic-metal-bearing
member 51 (and hence in a central region of the exhaust pipe
5). The first and second catalytic-metal-bearing members 51
and 52 extend in the axial direction of the exhaust pipe 5.
The first catalytic-metal-bearing member 51 is a hollow
cylinder that is made of a porous steel sheet (having numerous
small openings 51c formed through the wall thickness thereof)
and has outwardly-widening conical portions 51a at the axially
opposite ends thereof, and at least one of the conical portions
51a is fixed by welding to the inner wall surface of the
exhaust pipe 5. The second catalytic-metal-bearing member 52
is a flat porous steel sheet (having numerous small openings
52c formed through the wall thickness thereof) and welded at at
least one of its longitudinal edges to the inner wall surface
of the first catalytic-metal-bearing member 51. On the wall
surfaces of the first and second catalytic-metal-bearing
members 51 and 52, a layer of catalytic metal, such as platinum
or rhodium, is formed by, for example, applying a solution of
the catalytic metal onto the surfaces. Fig. 13 is a sectional
view taken along the line F - F of Fig. 12, showing the flat
second catalytic-metal-bearing member 52 in an upright
position within the first catalytic-metal-bearing member 51.
The following paragraphs describe how the downstream
exhaust purifier 50 of Fig. 12 operates, with reference to Fig.
12.
The exhaust gas from the internal combustion engine flows
as denoted by arrows. More specifically, a portion of the
exhaust gas flowing near and along the inner wall surface of
the exhaust pipe 5 is caused to pass through the numerous small
openings 51c formed in the wall of the catalytic-metal-bearing
member 51, and another portion of the exhaust gas flowing in a
generally central region of the exhaust pipe 5 is caused to
pass through the numerous small openings 52a formed in the
second second catalytic-metal-bearing member 52. Thus, the
exhaust gas contacts the catalytic metal layers on the inner
and outer surfaces of the first and second catalytic-metal-bearing
members 51 and 52 and is effectively purified through
its chemical reaction with the catalytic metal.
When passing through the numerous small openings 52a formed
in the second catalytic-metal-bearing member 52, the exhaust
gas contacts the catalytic metal layers on the outer and inner
wall surfaces of the member 52. Therefore, the exhaust gas is
brought into contact with a great area of the catalytic metal
layers, and the catalytic metal can perform its exhaust
purifying function to a sufficient degree.
Further, because the second catalytic-metal-bearing member
52 contacts the relatively hot portion of the exhaust gas
flowing though the central region in the exhaust pipe 5, the
catalytic metal can be heated to be sufficiently activated and
therefore can perform its exhaust purifying function to a
sufficient degree. In addition, because the second catalytic-metal-bearing
member 52 is just in the form of a flat plate, a
pressure loss of the exhaust gas flowing in the member 52 can
be reduced even further than in the above-described first
embodiment of the downstream exhaust purifier.
The downstream exhaust purifier 50 of Fig. 12 may be
modified in such a manner as shown in Figs. 14 and 15. Namely,
in the modification, the first catalytic-metal-bearing member
51 is in the form of a hollow cylinder having a generally C-shape
in section with a part (bottom part in the example of
Fig. 14) cut away along the entire length thereof. As shown in
Fig. 15, the first catalytic-metal-bearing member 51 in the
form of the partly-cut-away hollow cylinder has a pair of
flanges 51b integrally formed with the opposed longitudinal
edges, which are in contact with the inner wall surface of the
exhaust pipe 5. In this example, one longitudinal edge portion
extends, through the opening between the opposed longitudinal
edges of the second catalytic-metal-bearing member 52, into
contact with the wall surface of the exhaust pipe 5.
Figs. 16A to 16E schematically shows several other
embodiments of the exhaust purifying apparatus.
The exhaust purifying apparatus 61 shown in Fig. 16A, which
comprises a pair of upstream (front-stage) and downstream
(rear-stage) exhaust purifiers disposed within an exhaust pipe
5, is characterized by the provision of a control valve (e.g.,
butterfly valve) 62 between the upstream and downstream
exhaust purifiers. The upstream exhaust purifier is
constructed in the same manner as the upstream exhaust purifier
10 of Fig. 3, and the downstream exhaust purifier is
constructed in the same manner as the downstream exhaust
purifier 50 of Fig. 12.
The exhaust purifying apparatus 63 shown in Fig. 16B
comprises three exhaust purifiers disposed in succession
within an exhaust pipe 5. The upstream (front-stage) exhaust
purifier is constructed in the same manner as the upstream
exhaust purifier 10 of Fig. 3, the central (intermediate-stage)
exhaust purifier is constructed in the same manner as
the downstream exhaust purifier 50 of Fig. 12, and the
downstream (rear-stage) exhaust purifier is an exhaust
discharging conduit 64 partly extending out of the exhaust pipe
5. The exhaust discharging conduit 64 is made of a porous
steel sheet, and a layer of catalytic metal, such as platinum
or rhodium, is formed on the inner and outer wall surfaces of
the conduit 64 by, for example, applying a solution of the
catalytic metal onto the surfaces.
The exhaust purifying apparatus 65 shown in Fig. 16C
comprises a catalytic-metal-bearing member 66 that is disposed
in a central region and extends in the axial direction of an
exhaust pipe 5. The catalytic-metal-bearing member 66 is made
of a flat, porous steel sheet, and a layer of catalytic metal,
such as platinum or rhodium, is formed on the opposite wall
surfaces of the member 66 by, for example, applying a solution
of the catalytic metal onto the surfaces. The exhaust
purifying apparatus 67 shown in Fig. 16D is a modification of
the exhaust purifying apparatus 65 of Fig. 16C, which is
characterized in that the catalytic-metal-bearing member 66 is
made of a corrugated porous steel sheet rather than the flat,
porous steel sheet of Fig. 16C.
The exhaust purifying apparatus 68 shown in Fig. 16E
comprises a catalytic-metal-bearing member 69 in the form of
a hollow semicylinder, which extends in the axial direction of
an exhaust pipe 5 and is closed at opposite ends. The
semicylindrical catalytic-metal-bearing member 69 has a hollow
space 69a, opening toward the inner wall surface of the exhaust
pipe 5, between the opposed longitudinal edges thereof. The
catalytic-metal-bearing member 69 is made of a porous steel
sheet, and a layer of catalytic metal, such as platinum or
rhodium, is formed on the inner and outer wall surfaces of the
member 69 by, for example, applying a solution of the catalytic
metal onto the surfaces.
Note that any of the catalytic-metal-bearing members 66 and
69 shown in Figs. 16C, 16D and 16E may be employed in the
plural-stage exhaust purifiers of Figs. 16A and 16B provided
within the exhaust pipe 5.
In the above-described first, second and third embodiments
and their modifications, the "steel sheet" bearing catalytic
metal is disposed in the central region of the exhaust pipe 5
or first catalytic-metal-bearing element 21, 51. More
specifically, in the first embodiment of Figs. 1 to 9 and its
modifications of Figs. 11A to 11H, the "steel sheet" bearing
catalytic metal is embodied as the second catalytic-metal-bearing
member 22 in the form of a hollow cylinder made of a
porous steel sheet; in the embodiment of Figs. 12 and 13 and
its modifications of Figs. 14 and 15, and in the examples of
the embodiment of Figs. 16A and 16B, the "steel sheet" bearing
catalytic metal is embodied as the second catalytic-metal-bearing
member 52 in the form of a flat porous steel plate; and
in the other examples of the third embodiment of Figs. 16C, 16D
and 16E, the "steel sheet" bearing catalytic metal is embodied
as the catalytic-metal-bearing members 66 and 69 in the form of
a flat or corrugated porous plate, or porous semicylinder.
The "steel sheet" bearing catalytic metal should be
understood as not being limited to the construction described
above in relation to various embodiments and modifications and
also as not being limited to the porous sheet. Also, the small
openings in the porous sheet or plate may be of any desired
shape, size and quantity.
INDUSTRIAL APPLICABILITY
As has been described so far, the exhaust purifying device
for an internal combustion engine according to the present
invention is characterized in that a steel sheet member having
inner and outer catalytic-metal-bearing surfaces is disposed
substantially in the central of an exhaust port extending from
an exhaust port of the internal combustion engine. Thus, the
catalytic metal is placed in the central region of the exhaust
pipe where the temperature of the exhaust gas from the engine
remains relatively high. The high-temperature exhaust gas
effectively activates the catalytic metal on the steel sheet
member, and this achieves the benefit that a sufficient exhaust
purifying function of the catalytic metal can be acquired at
low cost.
In one implementation, the steel sheet member is in the
form of a hollow cylinder extending in the axial direction of
the exhaust port, so that a pressure loss in the exhaust
flowing through the steel sheet member can be reduced
significantly to avoid adverse effects on the performance of
the internal combustion engine.
Further, the cylinder is made of a porous steel sheet and
closed at its upstream end. In this case, the exhaust gas is
directed to pass through small openings formed through the wall
thickness of the cylinder, during which time the exhaust gas
contacts the catalytic metal on the inner and outer catalytic-metal-bearing
surfaces. Thus, the exhaust is acted on by the
catalytic metal in a greater area Of the catalytic-metal-bearing
surfaces and hence can provide an further enhanced
exhaust purifying capability.
In another implementation, a hollow cylinder is provided
and supported substantially in the central region of the
exhaust pipe substantially along a center axis of said pipe,
and the hollow cylinder is made of a steel sheet having inner
and outer catalytic-metal-bearing surfaces. Also, a partition
plate is provided within the exhaust pipe to block passage of
the exhaust gas between the cylinder and the exhaust pipe.
Thus, the catalytic metal is placed in the central region of
the exhaust pipe where the temperature of the exhaust gas from
the engine remains relatively high, so that the high-temperature
exhaust gas effectively activates the catalytic
metal on the steel sheet member. This achieves the benefit
that a sufficient exhaust purifying function of the catalytic
metal can be acquired at low cost. In addition, the partition
plate functions to restrict the pulsating motion of the exhaust
gas caused by the engine, so as to provide a generally smooth
steady flow of the exhaust gas. Owing to the provision of such
a partition plate, the purifying capability of the exhaust
purifying apparatus does not significantly vary and can
achieve sufficient exhaust purification. Further, because the
steel cylinder is supported via the partition plate
restricting the pulsating motion of the exhaust gas, no
separate support is required, which simplifies the supporting
mechanism for the cylinder.
Besides, the steel cylinder is mounted in such a manner
that the cylinder is free to axially expand and contract
relative to the exhaust pipe, and this feature easily
accommodates a difference in axial thermal expansion between
the steel cylinder and exhaust pipe.
In still another implementation, a first catalytic-metal-bearing
member is provided within the exhaust pipe along an
inner wall surface of said pipe and a second catalytic-metal-bearing
member is provided substantially in the central of the
first catalytic-metal-bearing member. Thus, the catalytic-metal-bearing
members are provided near the inner wall surface
of and in the central region of the exhaust pipe, and the
exhaust purifying function can be further enhanced without
adversely affecting the performance of the internal combustion
engine and yet at low cost.