Combined Heat Exchanger Catalyst Exhaust Gas System

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Solution Overview

Problem

Existing thermoelectric generators for motor vehicles are expensive and inefficient, and current exhaust systems struggle to recover energy from exhaust gases effectively while quickly bringing components to operating temperature for efficient pollutant conversion.

Innovation Solution

A combined heat exchanger and catalytic converter component in a common housing, where the heat exchanger and catalyst body have separate thermal masses, allowing for efficient heat transfer and rapid heating of the catalyst, with a thermoelectric generator converting thermal energy into electrical energy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If a thermoelectric generator is used to convert thermal energy from exhaust gas into electrical energy, then energy recovery is achieved, but the component size becomes large and production cost increases

Engineering Contradiction:

Improveenergy recovery efficiencyVSAvoidcomponent size

Core Design Contradiction:

Use of energy by moving objectVSVolume of moving object

Solution Approach 1:

The patent combines the heat exchanger and catalytic converter into a single integrated component with shared housing and common exhaust gas flow path. This merging reduces the overall component size while maintaining energy recovery functionality through the heat exchanger and pollutant conversion functionality through the catalyst.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated component performs multiple functions simultaneously: heat exchange for energy recovery, catalytic conversion for pollutant reduction, and exhaust gas flow management. This multi-functionality eliminates the need for separate components, reducing overall system volume while improving energy recovery efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If the catalyst body is heated quickly to operating temperature for efficient pollutant conversion, then light-off behavior is optimized, but energy is lost from the exhaust gas flow

Engineering Contradiction:

Improvepollutant conversion efficiencyVSAvoidthermal energy loss

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The heat exchanger is positioned to preheat the exhaust gas before it enters the catalyst body, using the thermal energy from the exhaust flow itself. This preliminary heating action brings the catalyst to operating temperature faster without significant external energy input, optimizing light-off behavior while minimizing thermal energy loss.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent converts the thermal energy that would otherwise be wasted during catalyst heating into a useful resource by using it to preheat the exhaust gas flow through the heat exchanger. This transforms potential energy loss into beneficial preheating that accelerates catalyst light-off while maintaining overall energy efficiency.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Loss of energy

If separate thermal masses are used for heat exchanger and catalyst body, then heat transfer efficiency is maximized, but device complexity increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidcomponent structure complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The integrated component is segmented into distinct functional zones: the heat exchanger section with its own thermal mass and flow paths, and the catalyst body section with its separate thermal mass. This segmentation allows independent thermal management of each function, maximizing heat transfer efficiency while maintaining a compact integrated structure through shared housing and exhaust gas flow path.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration maximizes energy recovery from exhaust gases, ensures rapid catalyst heating, and enhances pollutant conversion efficiency across all engine operating points, while maintaining a compact design.

Implementation Method 1

Thermoelectric materials are of a type that can effectively convert thermal energy into electrical energy (Seebeck effect)

Methodology Applied

Scientific EffectSeebeck effect: Seebeck Effect

Implementation Method 2

a heat exchanger around which the exhaust gas can flow, with a first thermal mass

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

the catalytically generated heat, so that a maximum of thermal energy is dissipated through the heat exchanger

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Data Source

PatentEP2324217B1Combination of a heat exchanger and catalyst as a component of an exhaust gas system

Publication Date: 2012.05.16 EMITEC GESELLSCHAFT FUR EMISSIONSTECHNOLOGIE MBH

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AI summary

Component (1) of an exhaust gas system (2) of an internal combustion engine (3), wherein the component (1) comprises at least a housing (4) with an inlet (5) and an outlet (6) for an exhaust gas (7), and at least one inflow (8) and one outflow (9) for a medium (10), wherein the component (1) further comprises a heat exchanger (11) around which the exhaust gas (7) can flow, said exchanger having a first thermal mass (12), and a catalyst body (13) through which the exhaust gas (7) can flow, said catalyst body having a second thermal mass (14).