Method for testing catalytic converter durability

Abstract

The present application relates in general to methods for testing the performance of an automotive catalytic converter under conditions simulating those which occur in motor vehicles over extended driving conditions.

We claim:  
     
         1 . A method for simulating catalytic converter aging using a non-engine based exhaust component rapid aging system (NEBECRAS), the method comprising: 
 supplying fuel to a combustor via a nozzle at an air to fuel ratio (AFR) and under conditions effective to produce an air and fuel mixing feedstream having a feedstream flowpath comprising an air shroud effective to prevent flame from attaching to the nozzle during combustion of the fuel and to prevent flame from remaining in constant contact with an inner wall of the combuster tube during combustion of the fuel;    substantially continuously and effectively stoichiometrically combusting the fuel in the feedstream to produce an exhaust product; and    exposing a catalytic converter to the exhaust product, producing an aged catalytic converter.    
     
     
         2 . The method of  claim 1  further comprising evaluating said aged catalytic converter.  
     
     
         3 . The method of  claim 1  wherein the feedstream flowpath comprises at least a first collapse, a first expansion, and a second collapse.  
     
     
         4 . The method of  claim 3  further comprising igniting said fuel at said expansion to produce a flame.  
     
     
         5 . The method of  claim 3  wherein said flowpath further comprises a second expansion and a third collapse.  
     
     
         6 . The method of  claim 4  wherein said flowpath further comprises a second expansion and a third collapse.  
     
     
         7 . The method of  claim 1  further comprising producing a first area on a fuel injection side of the nozzle having a pressure sufficiently low to draw fuel into the combustion tube.  
     
     
         8 . The method of  claim 7  further comprising producing a second area on a burner side of the nozzle having a pressure sufficiently high to prevent the flame from attaching to the nozzle, said pressure also being sufficiently high to shear fuel droplets as they enter said flame.  
     
     
         9 . The method of  claim 1  further comprising directing air against an inner wall of said combuster tube downstream of said nozzle at a location intersecting a spray of fuel from said nozzle.  
     
     
         10 . The method of  claim 8  further comprising directing air against an inner wall of said combuster tube downstream of said nozzle at a location intersecting a spray of fuel from said nozzle.  
     
     
         11 . The method of  claim 2  further comprising producing a first area on a fuel injection side of the nozzle having a pressure sufficiently low to draw fuel into the combustion tube.  
     
     
         12 . The method of  claim 11  further comprising producing a second area on a burner side of the nozzle having a pressure sufficiently high to prevent said flame from attaching to said nozzle, said pressure also being sufficiently high to shear fuel droplets as they enter said flame.  
     
     
         13 . The method of  claim 2  further comprising directing air against an inner wall of said combuster tube downstream of said nozzle at a location intersecting a spray of fuel from said nozzle.  
     
     
         14 . The method of  claim 12  further comprising directing air against an inner wall of said combuster tube downstream of said nozzle at a location intersecting a spray of fuel from said nozzle.  
     
     
         15 . The method of  claim 3  further comprising producing a first area on a fuel injection side of the nozzle having a pressure sufficiently low to draw fuel into the combustion tube.  
     
     
         16 . The method of  claim 15  further comprising producing a second area on a burner side of the nozzle having a pressure sufficiently high to prevent said flame from attaching to said nozzle, said pressure also being sufficiently high to shear fuel droplets as they enter said flame.  
     
     
         17 . The method of  claim 3  further comprising directing air against an inner wall of said combuster tube downstream of said nozzle at a location intersecting a spray of fuel from said nozzle.  
     
     
         18 . The method of  claim 16  further comprising directing air against an inner wall of said combuster tube downstream of said nozzle at a location intersecting a spray of fuel from said nozzle.  
     
     
         19 . The method of  claim 6  further comprising producing a first area on a fuel injection side of the nozzle having a pressure sufficiently low to draw fuel into the combustion tube.  
     
     
         20 . The method of  claim 19  further comprising producing a second area on a burner side of the nozzle having a pressure sufficiently high to prevent said flame from attaching to said nozzle, said pressure also being sufficiently high to shear fuel droplets as they enter said flame.  
     
     
         21 . The method of  claim 6  further comprising directing air against an inner wall of said combuster tube downstream of said nozzle at a location intersecting a spray of fuel from said nozzle.  
     
     
         22 . The method of  claim 20  further comprising directing air against an inner wall of said combuster tube downstream of said nozzle at a location intersecting a spray of fuel from said nozzle.  
     
     
         23 . The method of  claim 2  wherein: 
 said flame comprises a hot region comprising maximum temperatures;  
 said nozzle provides sufficient fuel shearing and atomization to prevent said hot region from impacting said inner wall of said combustor.  
 
     
     
         24 . The method of  claim 4  wherein: 
 said flame comprises a hot region comprising maximum temperatures;  
 said nozzle provides sufficient fuel shearing and atomization to prevent said hot region from impacting said inner wall of said combustor.  
 
     
     
         25 . The method of  claim 6  wherein: 
 said flame comprises a hot region comprising maximum temperatures;  
 said nozzle provides sufficient fuel shearing and atomization to prevent said hot region from impacting said inner wall of said combustor.  
 
     
     
         26 . The method of  claim 19  wherein: 
 said flame comprises a hot region comprising maximum temperatures;  
 said nozzle provides sufficient fuel shearing and atomization to prevent said hot region from impacting said inner wall of said combustor.  
 
     
     
         27 . The method of  claim 20  wherein: 
 said flame comprises a hot region comprising maximum temperatures;  
 said nozzle provides sufficient fuel shearing and atomization to prevent said hot region from impacting said inner wall of said combustor.  
 
     
     
         28 . The method of  claim 21  wherein: 
 said flame comprises a hot region comprising maximum temperatures;  
 said nozzle provides sufficient fuel shearing and atomization to prevent said hot region from impacting said inner wall of said combustor.  
 
     
     
         29 . The method of  claim 22  wherein: 
 said flame comprises a hot region comprising maximum temperatures;  
 said nozzle provides sufficient fuel shearing and atomization to prevent said hot region from impacting said inner wall of said combustor.  
 
     
     
         30 . The method of  claim 1  further comprising providing substantially continuous automated fuel metering control.  
     
     
         31 . The method of  claim 6  further comprising providing substantially continuous automated fuel metering control.  
     
     
         32 . The method of  claim 19  further comprising providing substantially continuous automated fuel metering control.  
     
     
         33 . The method of  claim 22  further comprising providing substantially continuous automated fuel metering control.  
     
     
         34 . The method of  claim 29  further comprising providing substantially continuous automated fuel metering control.  
     
     
         35 . The method of  claim 30  further comprising providing substantially continuous automated safety control.  
     
     
         36 . The method of  claim 31  further comprising providing substantially continuous automated safety control.  
     
     
         37 . The method of  claim 32  further comprising providing substantially continuous automated safety control.  
     
     
         38 . The method of  claim 33  further comprising providing substantially continuous automated safety control.  
     
     
         39 . The method of  claim 34  further comprising providing substantially continuous automated safety control.  
     
     
         40 . The method of  claim 1  further comprising creating one or more thermal excursions during said combustion.  
     
     
         41 . The method of  claim 40  wherein said creating one or more thermal excursions in the catalyst comprises: 
 using an AFR effective to generate about 3 percent carbon monoxide; and  
 injecting secondary air to create about 3% oxygen in the exhaust before exposing said exhaust product to the catalytic converter.  
 
     
     
         42 . The method of  claim 6  further comprising creating one or more thermal excursions in the catalyst during said combustion.  
     
     
         43 . The method of  claim 42  wherein said creating one or more thermal excursions in the catalyst comprises: 
 using an AFR effective to generate about 3 percent carbon monoxide; and  
 injecting secondary air to create about 3% oxygen in the exhaust before exposing said exhaust product to the catalytic converter.  
 
     
     
         44 . The method of  claim 19  further comprising creating one or more thermal excursions in the catalyst during said combustion.  
     
     
         45 . The method of  claim 44  wherein said creating one or more thermal excursions in the catalyst comprises: 
 using an AFR effective to generate about 3 percent carbon monoxide; and  
 injecting secondary air to create about 3% oxygen in the exhaust before exposing said exhaust product to the catalytic converter.  
 
     
     
         46 . The method of  claim 22  further comprising creating one or more thermal excursions in the catalyst during said combustion.  
     
     
         47 . The method of  claim 46  wherein said creating one or more thermal excursions in the catalyst comprises: 
 using an AFR effective to generate about 3 percent carbon monoxide; and  
 injecting secondary air to create about 3% oxygen in the exhaust before exposing said exhaust product to the catalytic converter.  
 
     
     
         48 . The method of  claim 29  further comprising creating one or more thermal excursions in the catalyst during said combustion.  
     
     
         49 . The method of  claim 48  wherein said creating one or more thermal excursions in the catalyst comprises: 
 using an AFR effective to generate about 3 percent carbon monoxide; and  
 injecting secondary air to create about 3% oxygen in the exhaust before exposing said exhaust product to the catalytic converter.  
 
     
     
         50 . A method for simulating catalytic converter aging using a non-engine based exhaust component rapid aging system (NEBECRAS), the method comprising: 
 supplying fuel to a combustor via a nozzle at an air to fuel ratio (AFR) and under conditions effective to produce an air and fuel mixing feedstream having a feedstream flowpath comprising an air shroud effective to prevent flame from attaching to the nozzle during combustion of the fuel and to prevent flame from remaining in constant contact with an inner wall of the combuster tube during combustion of the fuel;    injecting lubricant into said feedstream flowpath;    substantially continuously and effectively stoichiometrically combusting components of the feedstream selected from the group consisting of the fuel, the lubricant, and combinations thereof to produce an exhaust product; and    exposing a catalytic converter to the exhaust product, producing an aged catalytic converter.    
     
     
         51 . The method of  claim 50  further comprising evaluating the aged catalytic converter.  
     
     
         52 . The method of  claim 50  wherein the feedstream flowpath comprises at least a first collapse, a first expansion, and a second collapse.  
     
     
         53 . The method of  claim 52  further comprising igniting said fuel at said expansion to produce a flame.  
     
     
         54 . The method of  claim 52  wherein said flowpath further comprises a second expansion and a third collapse.  
     
     
         55 . The method of  claim 53  wherein said flowpath further comprises a second expansion and a third collapse.  
     
     
         56 . The method of  claim 50  further comprising producing a first area on a fuel injection side of the nozzle having a pressure sufficiently low to draw fuel into the combustion tube.  
     
     
         57 . The method of  claim 56  further comprising producing a second area on a burner side of the nozzle having a pressure sufficiently high to prevent said flame from attaching to said nozzle, said pressure also being sufficiently high to shear fuel droplets as they enter said flame.  
     
     
         58 . The method of  claim 57  further comprising directing air against an inner wall of said combuster tube downstream of said nozzle at a location intersecting a spray of fuel from said nozzle.  
     
     
         59 . The method of  claim 53  further comprising producing a first area on a fuel injection side of the nozzle having a pressure sufficiently low to draw fuel into the combustion tube.  
     
     
         60 . The method of  claim 59  further comprising producing a second area on a burner side of the nozzle having a pressure sufficiently high to prevent said flame from attaching to said nozzle, said pressure also being sufficiently high to shear fuel droplets as they enter said flame.  
     
     
         61 . The method of  claim 60  further comprising directing air against an inner wall of said combuster tube downstream of said nozzle at a location intersecting a spray of fuel from said nozzle.  
     
     
         62 . The method of  claim 55  further comprising producing a first area on a fuel injection side of the nozzle having a pressure sufficiently low to draw fuel into the combustion tube.  
     
     
         63 . The method of  claim 62  further comprising producing a second area on a burner side of the nozzle having a pressure sufficiently high to prevent said flame from attaching to said nozzle, said pressure also being sufficiently high to shear fuel droplets as they enter said flame.  
     
     
         64 . The method of  claim 63  further comprising directing air against an inner wall of said combuster tube downstream of said nozzle at a location intersecting a spray of fuel from said nozzle.  
     
     
         65 . The method of  claim 50  wherein: 
 said flame comprises a hot region comprising maximum temperatures;  
 said nozzle provides sufficient fuel shearing and atomization to prevent said hot region from impacting said inner wall of said combustor.  
 
     
     
         66 . The method of  claim 53  wherein: 
 said flame comprises a hot region comprising maximum temperatures;  
 said nozzle provides sufficient fuel shearing and atomization to prevent said hot region from impacting said inner wall of said combustor.  
 
     
     
         67 . The method of  claim 55  wherein: 
 said flame comprises a hot region comprising maximum temperatures;  
 said nozzle provides sufficient fuel shearing and atomization to prevent said hot region from impacting said inner wall of said combustor.  
 
     
     
         68 . The method of  claim 62  wherein: 
 said flame comprises a hot region comprising maximum temperatures;  
 said nozzle provides sufficient fuel shearing and atomization to prevent said hot region from impacting said inner wall of said combustor.  
 
     
     
         69 . The method of  claim 63  wherein: 
 said flame comprises a hot region comprising maximum temperatures;  
 said nozzle provides sufficient fuel shearing and atomization to prevent said hot region from impacting said inner wall of said combustor.  
 
     
     
         70 . The method of  claim 64  wherein: 
 said flame comprises a hot region comprising maximum temperatures;  
 said nozzle provides sufficient fuel shearing and atomization to prevent said hot region from impacting said inner wall of said combustor.  
 
     
     
         71 . The method of  claim 50  further comprising providing substantially continuous automated fuel metering control.  
     
     
         72 . The method of  claim 64  further comprising providing substantially continuous automated fuel metering control.  
     
     
         73 . The method of  claim 70  further comprising providing substantially continuous automated fuel metering control.  
     
     
         74 . The method of  claim 50  further comprising providing substantially continuous automated safety monitoring control.  
     
     
         75 . The method of  claim 71  further comprising providing substantially continuous automated safety monitoring control.  
     
     
         76 . The method of  claim 72  further comprising providing substantially continuous automated safety monitoring control.  
     
     
         77 . The method of  claim 73  further comprising providing substantially continuous automated safety monitoring control.  
     
     
         78 . The method of  claim 50  further comprising creating one or more thermal excursions during said combustion.  
     
     
         79 . The method of  claim 50  further comprising creating one or more thermal excursions in the catalyst during said combustion.  
     
     
         80 . The method of  claim 79  wherein said creating one or more thermal excursions in the catalyst comprises: 
 using an AFR effective to generate about 3 percent carbon monoxide; and  
 injecting secondary air to create about 3% oxygen in the exhaust before exposing said exhaust product to the catalytic converter.  
 
     
     
         81 . The method of  claim 70  further comprising creating one or more thermal excursions in the catalyst during said combustion.  
     
     
         82 . The method of  claim 81  wherein said creating one or more thermal excursions in the catalyst comprises: 
 using an AFR effective to generate about 3 percent carbon monoxide; and  
 injecting secondary air to create about 3% oxygen in the exhaust before exposing said exhaust product to the catalytic converter.  
 
     
     
         83 . The method of  claim 77  further comprising creating one or more thermal excursions in the catalyst during said combustion.  
     
     
         84 . The method of  claim 83  wherein said creating one or more thermal excursions in the catalyst comprises: 
 using an AFR effective to generate about 3 percent carbon monoxide; and  
 injecting secondary air to create about 3% oxygen in the exhaust before exposing said exhaust product to the catalytic converter.