# US 8,783,414 B2 · Exhaust system

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- Number: US 8,783,414 B2
- Document ID: US8783414B2
- Status: Granted
- Kind: B2
- Application number: 13/185,615
- Filed: 2011-07-19
- Published: 2012-01-26
- Granted: 2014-07-22
- Earliest claimed: 2010-07-22
- Assignees: Eberspächer Exhaust Technology GmbH & Co. KG
- Applicants: Gerd Gaiser
- Inventors: Gerd Gaiser
- Web page: https://patentgrep.com/patent/US8783414B2

## CPC

- F01N 13/102: {having thermal insulation}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/32: {at least two} layers being foamed {and next to each other}
- B32B 2266/06: Open cell foam
- B32B 2266/08: Closed cell foam
- B32B 2597/00: Tubular articles, e.g. hoses, pipes
- B32B 2605/08: Cars
- 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 2310/06: Porous ceramics
- F01N 2330/22: Metal foam
- F01N 2510/02: for thermal insulation
- F01N 2510/04: for sound absorption
- 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)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

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.

## Claims

### Claim 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.

### Claim 2 (depends on 1)

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.

### Claim 3 (depends on 1)

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.

### Claim 4 (depends on 1)

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.

### Claim 5 (depends on 1)

The component according to claim 1, wherein the jacket further comprises at least one connecting element which is designed integrally with the jacket.

### Claim 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.

### Claim 7 (depends on 6)

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.

### Claim 8 (depends on 7)

The exhaust system according to claim 7, wherein the foam comprises at least one of metal and a mineral material.

### Claim 9 (depends on 6)

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.

### Claim 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.

### Claim 11 (depends on 4)

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.

### Claim 12 (depends on 11)

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.

### Claim 13 (depends on 1)

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.

### Claim 14 (depends on 1)

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.

### Claim 15 (depends on 14)

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.

### Claim 16 (depends on 8)

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.

### Claim 17 (depends on 8)

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.

### Claim 18 (depends on 17)

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.

### Claim 19 (depends on 10)

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.

### Claim 20 (depends on 19)

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.