Compact After-treatment Component for Engine Exhaust
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Solution Overview
Problem
Modern after-treatment systems for internal combustion engines are complex and bulky, leading to packaging issues and increased heat rejection, which complicates both assembly and service, while also reducing system effectiveness due to the need for temperature management.
Innovation Solution
A compact after-treatment component design featuring a vessel with an outer shell containing a diesel oxidation catalyst, catalyzed filter, and diffusers, which efficiently processes exhaust streams and reduces heat loss through a reverse-flow configuration and DEF injection for NOx reduction, thereby minimizing component count and heat rejection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex after-treatment systems are used to reduce emissions, then emission reduction effectiveness is improved, but system complexity and packaging space increase
Solution Approach 1:
The patent combines multiple after-treatment functions (diesel oxidation catalyst for HC/CO oxidation and catalyzed particulate filter for PM filtration) into a single integrated component housed in one vessel. This merging approach maintains emission reduction effectiveness while reducing system complexity and packaging requirements compared to using separate components for each function.
Solution Approach 2:
The single after-treatment component performs multiple functions simultaneously: oxidizing hydrocarbons and carbon monoxide via the diesel oxidation catalyst, filtering particulate matter through the catalyzed particulate filter, and managing exhaust flow through integrated diffusers. This multi-functionality reduces the number of separate components needed while maintaining comprehensive emission control.
2Reliability
If multiple components are used in after-treatment systems, then emission control functions are improved, but assembly and service complexity increase
Solution Approach 1:
By integrating the diesel oxidation catalyst, catalyzed particulate filter, and flow management components into a single assembled unit within one vessel, the patent reduces the number of separate assembly operations and service interventions needed. The integrated design allows for simpler installation and maintenance while preserving all necessary emission control functions.
3Reliability
If the number of components increases, then after-treatment functionality is improved, but heat rejection increases
Solution Approach 1:
The integrated design places the diesel oxidation catalyst and catalyzed particulate filter in close proximity within the same vessel, allowing thermal energy to be retained and utilized more effectively. The reduced surface area exposure compared to multiple separate components minimizes heat loss to the environment while maintaining all after-treatment functions.
4Volume of moving object
If compact packaging is achieved, then packaging issues are resolved, but component integration complexity increases
Solution Approach 1:
The patent arranges the diesel oxidation catalyst and catalyzed particulate filter in a nested or closely integrated configuration within the vessel, with components positioned to maximize space utilization. The diffusers and flow paths are designed to fit efficiently within the available volume, achieving compact packaging while managing integration complexity through careful spatial arrangement.
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
The solution provides a more compact, cost-effective, and less complex after-treatment system that effectively reduces emissions and minimizes heat rejection, improving packaging and operational efficiency.
Implementation Method 1
diesel oxidation catalyst configured for oxidizing hydrocarbons and carbon monoxide in the exhaust stream
Implementation Method 2
catalyzed filter in fluid communication with the intermediate diffuser and with the exit nozzle
Implementation Method 3
inlet diffuser disposed within the vessel... intermediate diffuser disposed within the vessel
Data Source
AI summary
An after-treatment component for receiving an exhaust stream from an internal combustion engine comprises a vessel having a first end, a second end, and an intermediate section. The vessel defines an inlet port and an outlet port. The inlet port is in fluid communication with an inlet diffuser disposed within the vessel. The inlet diffuser is in fluid communication with the inlet port and with a diesel oxidation catalyst disposed within the vessel. The diesel oxidation catalyst is in fluid communication with the inlet diffuser and with a transfer duct. The transfer duct is in fluid communication with the diesel oxidation catalyst and with an intermediate diffuser disposed within the vessel. The intermediate diffuser is in fluid communication with the transfer duct and with a catalyzed filter disposed within the vessel. The catalyzed filter is in fluid communication with the intermediate diffuser and with the outlet port.