Delphi Technologies, Inc.

Oxus America, Inc.

David Emil Nelson

Bob Xiaobin Li

Mark David Hemingway

Gregory Stephen Sims

Michael Ralph Foster

Joachim Kupe

Suresh Baskaran

Darrell R Herling

Delbert L Lessor

Robert X Li

Joseph V Mantese

Thomas Hubert Van Steenkiste

Alan Gerard Turek

David Alexander Goulette

Jeffrey B Hardesty

Carl Elmer Miller

Tom L Stuart

Mark Ray McClanahan

Thomas W Silvis

Gerald R Stabel

Blaine Roy Danley

Robert P Johnston

Joshua J Titus

Pertrice Auguste Wethey

Alfred R Webster

David Kwo-Shyong Chen

An oxygen generator includes a monolithic body having first and second channels extending longitudinally therein. An electrode is operatively disposed in the first channels and a counter-electrode is operatively disposed in the second channels. The second channels are formed in the monolithic body so each second channel is electrically isolated from, yet adjacent to a first channel, resulting in an alternating configuration of first and second channels. The first channels have fluid or oxygen flowing therethrough, while the second channels have the other of oxygen or fluid flowing therethrough. An output manifold, having an oxygen collection area separated from a fluid collection area, operatively engages with the monolithic body. The oxygen collection area receives substantially pure oxygen from one of the second or first channels, and the fluid collection area receives oxygen-depleted fluid from the other of the first or second channels.

Monolithic supported oxygen generator

A new kinetic spray process is disclosed that enables one to secure a plurality of ceramic elements together quickly without the need for glues or other adhesives. The process finds special utilization in the formation of non-thermal plasma reactors wherein the kinetic spray process can be used to simultaneously secure the ceramic elements together and to form electrical connections between like electrodes in the non-thermal plasma reactor.

Method for securing ceramic structures and forming electrical connections on the same

A filler metal including not more than about 0.1% C, not more than about 1.0% Si; not more than about 0.8% Mn; from about 10.5% to about 13.0% Cr; from about 0.65% to about 4.0% Ni; from about 10(% C) to about 1.5% Ti; not more than about 0.5% each of N, S, P, Mo, Nb, Cu, V, or Co; and balance essentially Fe, wherein a weld test pad of the filler metal contains a microstructure comprising martensite. A method of attaching together two components using a modified filler metal which forms a weld containing an amount of martensite sufficient to increase the volume of the weld thereby at least partially offsetting shrinkage of the weld upon cooling, and articles produced thereby.

Weld filler metal that reduces residual stress and distortion

A non-thermal plasma reactor is provided. The non-thermal plasma reactor includes a plasma-generating substrate, a housing and a mat. The plasma-generating substrate has one or more flow paths for an exhaust gas. The housing has an inlet and an outlet. The mat retains the plasma-generating substrate in the housing such that the one or more flow paths are in fluid communication with the inlet and the outlet. A voltage is supplied to the plasma-generating substrate to generate a plasma field. An electrically insulating layer is disposed between the plasma-generating substrate and the housing for preventing an arc of electricity from the plasma-generating substrate and/or the voltage to the housing.

Apparatus and method for mat protection of non-thermal plasma reactor

A method for preparing a non-thermal plasma reactor substrate includes disposing electrical vias on green stage first and second ceramic plates; filling the electrical vias with conductive material; and forming electrical contact via cover pads; disposing conductive material on the first ceramic plate to form an electrode plate having a main electrode portion and a terminal lead for electrically connecting the main electrode portion to the electrical vias; laminating the electrode plate and the second ceramic plate together, embedding the electrode therebetween; co-firing the plates to form a laminated co-fired embedded-conductor element; stacking a plurality of the laminated co-fired embedded-conductor elements to form a multi-cell stack, the filled electrical vias aligning in the stack to provide an electrical bus for connecting alternating elements in the stack; and disposing spacers with matching vias and via cover pads between adjacent pairs of elements to form exhaust gas passages.

Laminated co-fired sandwiched element for non-thermal plasma reactor

A non-thermal plasma reactor and method for preparing same for conversion of exhaust gas constituents is prepared from an extruded monolith comprising a plurality of conductive and exhaust channels separated by substantially planar dielectric barriers. Conductive material printed onto selected monolith channels form the conductive channels, which are connected along bus paths to form an alternating sequence of polarity, separated by exhaust channels. Conductive channels and channels not selected for exhaust flow are plugged to exclude exhaust gases and to prevent electrical leakage. During operation, exhaust gas flows through exhaust channels and is treated by the high voltage alternating current flowing through the conductive channels. The substantially planar dielectric barriers provide a uniform electrical response throughout the exhaust channels. In a preferred embodiment, the monolith comprises a perimeter boundary wall of increased wall thickness to provide electrical insulation between the conductive channels and the housing and to further provide robust crush resistance when inserting the element into a reactor housing. The one-piece monolith is specifically designed for fabrication via extrusion. A minimal number of in-line structural ligaments are preferably extruded as part of the monolith for providing optimal structural support while minimizing backpressure losses.

Plasma reactor design for treating auto emissions&#x2014;durable and low cost

A non-thermal plasma reactor is provided. The reactor includes a plasma-generating substrate, a housing, a voltage supplied to the plasma-generating substrate, and a retention material. The plasma-generating substrate has one or more flow paths for an exhaust gas. The plasma-generating substrate includes at least one weak area and at least one strong area. The housing has an inlet opening and an outlet opening. The voltage is supplied to the plasma-generating substrate for generating a plasma field. The retention material retains the plasma-generating substrate in the housing such that the one or more flow paths are in fluid communication with the inlet opening and the outlet opening. The retention material is configured to provide a higher retention force to the at least one strong area and a lower retention force to the at least one weak area.

Apparatus and method for retention of non-thermal plasma reactor

An edge-connected non-thermal plasma reactor includes an element having an edge-connected frame comprising a pair of dielectric edge connectors secured at opposite ends to a pair of outer dielectric plates. The dielectric edge connectors have a backplane and a plurality of tines protruding along one major surface of the backplane. The tines are spaced apart from one another at regular intervals so as to form pockets between adjacent tines. Alternating polarity electrode plates comprising a dielectric barrier plate having an electrode and terminal connection lead disposed on the dielectric barrier are arranged within the edge-connected frame so as to define the presence of a dielectric barrier next to a plasma cell, with the pockets engaging opposite ends of the electrode plates. Double and single dielectric edge-connected reactor elements are provided.

Edge-connected non-thermal plasma exhaust after-treatment device

A simplified, low cost method for preparing a non-thermal plasma reactor comprises forming cell building blocks of material having a high dielectric constant, printing a conductive print onto the cell walls, assembling the cells into a multi-cell stack, providing electrical connections for connecting said cells to a high voltage source, applying insulation to said multi-cell stack, and inserting the multi-cell stack into a non-thermal plasma reactor housing. The simplified design eliminates the need for spacers between individual cells, thus reducing the total number of components. The method employing formed shape building blocks provides flexibility and may be used in conjunction with conventional processing methods. The printing sequence is defined from the top of the multi-cell stack to the bottom, further minimizing the number of components. Use of a three-dimensional conductive print further simplifies preparation by eliminating the need for a secondary conductive print along the edge of the stack.

Design and method of manufacturing a plasma reactor for treating auto emissions-stacked shapes

A non-thermal plasma reactor for conversion of exhaust gas constituents is characterized by a reactor element prepared from a curved, swept-shaped substrate specifically designed for fabrication via extrusion. The as-extruded curved substrate comprises a thick outer wall surrounding a plurality of channels separated by dielectric barriers. Selected channels are coated with a conductive material to form conductor channels. The prepared reactor element preferably comprises multiple concentric exhaust channels, multiple concentric conductor channels having alternating polarity, each connected to its respective polarity via bus paths, in-line structural support ligaments for providing optimal structural support while preventing exhaust leakage, and thick outer walls providing high crush resistance and allowing robust mounting into the reactor housing. The nested, concentric arrangement and curved shape substrate advantageously enhances the reactor's ability to adapt to fit various vehicle sizes. High durability is afforded by the thick outer walls, and preferably, the inclusion of integral structural support ligaments. Fabrication of the extruded curved substrate is from material such as, but not limited to, dense cordierite, alumina, titania, mullite, plastic, and other high dielectric constant materials, or combinations thereof. Improved wall thickness is achieved over prior ceramic plate designs, thus providing the advantage of a more uniform electrical response. Improved resistance to voltage leakage is achieved by containing the channel conductors within dielectric channels (except at ends) and providing a dielectric coating at each end to prevent voltage leaks there.

Plasma reactor for treating auto emissions&#x2014;durable and low cost&#x2014;curved shapes

A non-thermal plasma reactor element includes a structural carrier; a thin electrode layer disposed upon the structural carrier; and a thin high k barrier layer disposed upon the electrode layer. Double, single and null dielectric carrier elements are provided. The structural support function for the element is substantially provided by the structural carrier while the dielectric barrier function is substantially provided by the high k barrier layer. This enables optimum utilization of conventional extrusion materials having low-cost, fabricability, mechanical and thermal properties (such as cordierite, mullite, and alumina) as structural carriers. Electrode layers and high k barrier layers are tailored to have dimensions as thin as possible for the particular NTP reactor application. In a preferred embodiment, a minimal number of structural ligaments are provided, thereby maximizing conversion efficiency while maintaining structural and electrical performance.

Structural carrier non-thermal plasma reactor

A low-loss electrode-printed structural dielectric barrier for a non-thermal plasma reactor and non-thermal plasma multi-cell stacks having low-loss electrodes. The low-loss electrode-printed structural dielectric barriers include a structural dielectric barrier having a first side and a second opposite side; a low-loss electrode pattern disposed on the second side of the structural dielectric barrier; the low-loss electrode pattern comprising first and second major electrode sections that are offset from any ribs, supports, ligaments, spacers, tines, or other structure that serves as a structural dielectric connection between dielectric barriers in a multi-cell stack, a connector disposed between and electrically connecting the first and second major electrode sections and offset relative to a centerline perpendicular to the rib orientation, and a bus path connector electrically connected to one of the major electrode sections and offset relative to the centerline.

Non-thermal plasma reactor substrate design-E-shape with low loss electrode pattern

Scaleable inter-digitized tine non-thermal plasma reactor

A non-thermal plasma (NTP) reactor structural conductor element includes a base conductor support and a high dielectric constant (&ldquo;high k&rdquo;) barrier layer supported by and substantially surrounding the base conductor support to form a structural conductor NTP reactor element. The structural conductor element may comprise a variety of shapes such as plates, sheets, half-box, I shapes, C shapes, or comb shapes, among others. In one embodiment, the dielectric barrier layer includes a coating applied to the base conductor support. In another embodiment, the dielectric barrier layer includes a high k film laminated to the base conductor support. In yet another embodiment, the base conductor support integrally forms the dielectric barrier layer via conversion of surfaces of the base conductor using electrochemical, thermal or chemical means to form the dielectric barrier layer.

Non-thermal plasma reactor and method-structural conductor

Single dielectric barrier extruded element non-thermal plasma reactors include first and second opposing dielectric barrier layers forming an exhaust channel therebetween, the first barrier layer provided with a first polarity conductor on an interior surface thereof and the second barrier layer provided with a second polarity conductor on the exhaust channel exterior surface. The second barrier layer provides the single dielectric barrier layer. The second polarity conductor serves as a conductor on the channel interior surface of the adjacent exhaust channel in repetitive fashion. The reactors are free of dedicated conductive passages. An electrode coating pattern having conductive coating extending fully to the side walls to connect with side bus connections eliminates the need for internal bus paths. Single dielectric barrier planar and swept-shaped reactor elements have minimal or partially extending internal support ligaments providing enhanced conversion efficiency.

Growing community of inventors

Waterford, MI, United States of America

David Emil Nelson