# US 11,498,045 B2 · Catalyst device

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- Number: US 11,498,045 B2
- Document ID: US11498045B2
- Status: Granted
- Kind: B2
- Application number: 17/467,456
- Filed: 2021-09-07
- Published: 2022-03-24
- Granted: 2022-11-15
- Earliest claimed: 2020-09-18
- Assignees: Toyota Jidosha Kabushiki Kaisha
- Applicants: Toyota Jidosha Kabushiki Kaisha
- Inventors: Toshinori Oki
- Web page: https://patentgrep.com/patent/US11498045B2

## CPC

- B01J 19/0053: {Details of the reactor}
- F01N 3/2026: {directly electrifying the catalyst substrate, i.e. heating the electrically conductive catalyst substrate by joule effect}
- B01D 53/9454: {characterised by a specific device}
- F01N 3/2006: {Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating (by electrically controlling the supply of combustible mixture or its constituents only F02D41/0235)}
- F01N 3/2853: {using mats or gaskets between catalyst body and housing}
- F01N 13/08: Other arrangements or adaptations of exhaust conduits {(pipes, joints or supports therefor in general F16L; collecting or removing exhaust gases of vehicle engines in workshops B08B15/00, on highways E01C1/005)}
- F01N 13/18: Construction facilitating manufacture, assembly, or disassembly
- B01J 2219/00135: Electric resistance heaters
- B01J 2219/0015: by thermal insulation means
- F01N 2240/16: an electric heater, i.e. a resistance heater
- F01N 2240/20: a flow director or deflector
- F01N 2260/20: for heat or sound protection, e.g. using a shield or specially shaped outer surface of exhaust device
- F01N 2260/26: for preventing enter of dirt into the device
- F01N 2470/24: Concentric tubes or tubes being concentric to housing, e.g. telescopically assembled
- Y02T 10/12: Improving ICE efficiencies
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16)
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A catalyst device includes a heating element that generates heat when energized, a case that accommodates a catalyst support (heating element), an inflow pipe that draws exhaust gas into the case, and a connecting pipe that connects the inflow pipe and the case to each other. The case includes an end portion, which protrudes further in an upstream direction than an end face of the catalyst support. The inflow pipe is disposed inside the case. The catalyst device includes a triple-walled pipe structure, in which the connecting pipe overlaps with the end portion of the case and the inflow pipe in a covering manner.

## Claims

### Claim 1

A catalyst device that is disposed in an exhaust passage, the catalyst device comprising:
a catalyst that purifies exhaust gas;
a heating element that generates heat when energized and is configured to heat the catalyst;
a case that is a pipe accommodating the catalyst and the heating element;
a mat that is an insulating body for fixing the heating element in the case;
a connecting pipe that is connected to an end portion of the case that is on an upstream side in a gas discharging direction, the gas discharging direction being a direction in which the exhaust gas flows in the exhaust passage; and
an inflow pipe that is connected to an upstream end of the connecting pipe and has a radius smaller than a radius of the case, wherein
the end portion on the upstream side of the case protrudes further in an upstream direction than an upstream end of the heating element and is an electrically insulating portion,
a portion in which the inflow pipe and the connecting pipe are connected to each other is a first connection portion,
a portion in which the connecting pipe and the case are connected to each other is a second connection portion,
the first connection portion includes:
a first joint portion in which the connecting pipe is joined to an outer circumferential surface of the inflow pipe; and
a double-walled pipe structure that is located downstream of the first joint portion and in which the connecting pipe covers an insertion end portion of the inflow pipe, and the connecting pipe and the inflow pipe overlap with each other such that the connecting pipe and the inflow pipe are separated from each other in a radial direction,
the second connection portion includes a second joint portion in which the connecting pipe is joined to an outer circumferential surface of the case,
the catalyst device further comprises a triple-walled pipe structure between the first connection portion and the second connection portion,
the case, the connecting pipe, and the inflow pipe overlap with one another in the triple-walled pipe structure such that
the inflow pipe is disposed inside the case,
the inflow pipe and the case are separated from each other in the radial direction, and
the case and the connecting pipe are separated from each other in the radial direction, and
an upstream end of the second joint portion is located downstream of a downstream end of the inflow pipe.

### Claim 2 (depends on 1)

The catalyst device according to claim 1, wherein
the end portion of the case is covered with an insulating layer in the insulating portion, and
the end portion of the case includes an upstream edge that is included in the triple-walled pipe structure.

### Claim 3 (depends on 1)

The catalyst device according to claim 1, wherein
the inflow pipe includes an increasing radius portion, and
in the increasing radius portion, a radius of an end portion of the inflow pipe that is inserted into the case increases in a downstream direction.

### Claim 4 (depends on 1)

The catalyst device according to claim 1, wherein
the connecting pipe includes an inclined portion, and
in the inclined portion, a radius of the connecting pipe in the first connection portion decreases in an upstream direction.

### Claim 5 (depends on 1)

The catalyst device according to claim 1, wherein
the case includes a decreasing radius portion, and
in the decreasing radius portion, a radius of the end portion of the case covering the inflow pipe decreases in an upstream direction.

### Claim 6 (depends on 1)

The catalyst device according to claim 1, wherein
the double-walled pipe structure is a first double-walled pipe structure, and
the second connection portion further includes a second double-walled pipe structure which is located between the upstream end of the second joint portion and the downstream end of the inflow pipe and in which the connecting pipe covers the case, and the connecting pipe and the case overlap with each other such that the connecting pipe and the case are separated from each other in the radial direction.