EGHR Device With Air Delivery for Exhaust Temperature Management
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Solution Overview
Problem
Existing exhaust systems face challenges in managing high exhaust temperatures, leading to material degradation and increased manufacturing complexity, while conventional cooling methods extend cold-start duration and require exotic materials or larger packaging.
Innovation Solution
An exhaust gas heat recovery (EGHR) device with a bypass positioned upstream of a catalyst and an air delivery system configured to manage exhaust gas temperatures by bypassing or flowing air upstream, allowing for temperature control and reduced reliance on exotic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If exotic materials are used to resist higher engine temperatures, then temperature resistance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The system dynamically changes the thermal parameters of the exhaust system by switching between cooling mode (bypass open, coolant flowing) and heating mode (bypass closed, coolant bypassed). This allows the use of standard materials rather than exotic high-temperature materials, reducing manufacturing complexity while maintaining temperature resistance through active thermal management.
Solution Approach 2:
The patent implements a dynamic thermal management system with a controllable bypass valve and coolant flow control that adapts the exhaust system's thermal state in real-time based on operating conditions. This dynamic approach replaces static high-temperature material solutions with an active control system, reducing manufacturing complexity and material costs.
2Temperature
If engine cooling is enhanced to reduce exhaust temperatures, then temperature control is improved, but packaging size and manufacturing complexity increase
Solution Approach 1:
The coolant system serves multiple functions: it cools the exhaust system during high-temperature operations, bypasses the EGHR device during cold-start conditions to maintain exhaust heat, and can be integrated with existing engine cooling infrastructure. This multi-functionality avoids the need for separate dedicated cooling systems, reducing packaging size while maintaining effective temperature control.
Solution Approach 2:
The patent merges the exhaust cooling function with the existing engine coolant system by integrating the EGHR device and bypass valve into the established coolant circulation path. This consolidation eliminates the need for separate cooling components, reducing overall packaging size and manufacturing complexity while maintaining effective temperature control.
3Temperature
If larger cooling systems are used to manage exhaust temperatures, then temperature management is improved, but cold-start duration increases
Solution Approach 1:
The system dynamically switches between cooling and heating modes using a controllable bypass valve. During cold-start, the bypass is closed to trap heat in the exhaust system and warm the catalyst. During normal operation, the bypass opens to allow coolant flow for temperature management. This dynamic control prevents heat loss during cold-start while maintaining temperature management capability, reducing cold-start duration without sacrificing thermal control.
Solution Approach 2:
The coolant flow through the EGHR device is controlled in periodic cycles based on exhaust temperature and catalyst temperature feedback. The system alternates between cooling phases (when temperatures are high) and bypass phases (when heating is needed), optimizing both temperature management and cold-start performance by timing coolant intervention to minimize heat loss during critical warm-up periods.
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 system effectively manages exhaust gas temperatures, reduces material degradation, and minimizes cold-start duration by utilizing the EGHR device and air delivery system, enhancing engine performance and reducing manufacturing complexity.
Implementation Method 1
an exhaust gas heat recovery (EGHR) device with a bypass arranged upstream of a catalyst... the EGHR may cool the exhaust gas during operating conditions where exhaust temperatures are increased
Implementation Method 2
an air delivery system configured to flow air upstream of the EGHR device... the air delivery system may increase exhaust gas temperatures when temperatures are cooler
Data Source
AI summary
Methods and systems are provided for an exhaust gas heat recovery (EGHR) device and an air delivery system. In one example, a system includes an exhaust gas heat recovery (EGHR) device with a bypass arranged upstream of a catalyst and an air delivery system configured to flow air upstream of the EGHR device.