Conductive Mesh Diesel Particulate Filter
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Solution Overview
Problem
Current emissions control systems for internal combustion engines require multiple devices to remove particulate matter, gaseous pollutants, and heat exhaust gases, increasing complexity and cost, while backup generator sets and diesel-electric vehicles need to dissipate excess electrical energy to prevent engine damage and overheating.
Innovation Solution
A novel apparatus that combines a filter, heater, and load bank in a single cartridge with a porous, electrically conductive mesh, allowing exhaust gases to flow through and trap particulate matter, while being electrically heated to dissipate energy and maintain engine load, thereby reducing system complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If multiple separate emission control devices are used to remove PM, gaseous pollutants, and heat exhaust gases, then the required emission reduction targets are achieved, but the system complexity and cost increase
Solution Approach 1:
The patent combines multiple separate emission control devices (particulate filter, gaseous pollutant removal device, and exhaust heater) into a single integrated device. The filter element contains both filtration media for PM removal and heating elements for thermal treatment, while also incorporating catalysts for gaseous pollutant conversion, thereby achieving multiple emission control functions in one unit and reducing system complexity
Solution Approach 2:
The integrated emission control device performs multiple functions simultaneously: it filters particulate matter through the filter element, heats exhaust gases using embedded heating elements, and removes gaseous pollutants via catalysts. This multi-functional design eliminates the need for separate devices for each emission control function, directly addressing the contradiction between emission reduction effectiveness and system complexity
2Reliability
If backup generator sets operate at low loads to provide standby power, then the emergency power supply function is maintained, but the engine suffers harm due to insufficient load
Solution Approach 1:
The patent converts the harmful effect of excess electrical energy (which would otherwise cause overheating damage to electric motors during no-load and braking conditions) into a beneficial load for the diesel engine. The load bank dissipates this excess energy as heat, providing a useful thermal load that prevents engine damage while maintaining the standby power function
3Reliability
If artificial load banks are connected to dissipate excess electrical energy, then the electric motors are protected from overheating, but additional equipment and system complexity are required
Solution Approach 1:
The patent merges the load bank function with the emission control device by integrating the heating elements into the filter structure. The same heating elements that warm exhaust gases for emission control also serve as the load bank to dissipate excess electrical energy, thereby protecting electric motors from overheating without requiring separate load bank equipment
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 apparatus effectively removes particulate matter, heats exhaust gases, and dissipates electrical energy, reducing the need for multiple devices, improving efficiency, and preventing engine damage by maintaining a minimum load and temperature, thus complying with environmental regulations and extending engine life.
Implementation Method 1
a porous, electrically conductive mesh is placed in the cartridge housing such that exhaust gas can flow in through the perforations in the cylindrical outer wall (315), through the conductive mesh, and out through the perforations in the cylindrical inner wall, said conductive mesh trapping the particulate matter carried by the exhaust gas
Implementation Method 2
At least two electrical terminals are in permanent electrical contact with the conductive mesh. An electrical power supply completes one or more electrical circuits through the conductive mesh
Data Source
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AI summary
An apparatus (200) for dissipating energy into the exhaust gas of an internal combustion engine (100) includes a container for confining a flow path for exhaust gas from an internal combustion engine (100) where the container has an inlet and an outlet. A porous, electrically conductive mesh (400) is placed in the container such that exhaust gas can flow through the conductive mesh (400). At least two electrical terminals (420) are in permanent electrical contact with the conductive mesh (40)). An electrical power supply (510) completes an electrical circuit through the conductive mesh (400) with the power supply having two or more electrical outputs electrically connected to an equal number of electrical terminals (420) on the conductive mesh (400). The apparatus (200) provides a filter, heater, electrical load and silencer.