Exhaust Aftertreatment System with Electric Heating and Deflection
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Solution Overview
Problem
The cold start phase of gasoline engines poses challenges in meeting stringent emissions regulations due to high particle emissions, increased back pressure, and inefficient catalytic converter heating, leading to increased fuel consumption and performance issues.
Innovation Solution
An exhaust aftertreatment system with a configuration that includes a first three-way catalyst and a particle filter arranged in separate housings, with a deflection element to redirect the exhaust gas flow, and an electric heating element to quickly heat the catalytic converters and particle filter, optimizing their positioning and heating for efficient emissions reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the catalytic converter is heated quickly during cold start, then cold-start emissions are reduced, but additional heating components and energy consumption are required
Solution Approach 1:
The patent combines the heating function with the existing catalytic converter structure by integrating heating elements directly into the catalytic converter housing. This merging of functions allows the same component to serve both as the emission treatment device and the heating device, thereby reducing overall system complexity while effectively reducing cold-start emissions.
Solution Approach 2:
The heating element is activated before the catalytic converter reaches its light-off temperature to preheat the catalyst. This preliminary action ensures that the catalytic converter is ready to function efficiently as soon as the engine starts, reducing cold-start emissions without requiring a completely separate heating system.
2Stress or pressure
If the particulate filter is regenerated continuously, then exhaust backpressure is prevented from excessive levels, but fuel consumption increases
Solution Approach 1:
The patent implements periodic regeneration cycles rather than continuous regeneration. The control unit monitors soot loading and activates the heating element only when regeneration is needed, using brief high-temperature pulses to oxidize accumulated soot. This periodic approach maintains acceptable backpressure levels while minimizing the impact on fuel consumption compared to continuous regeneration.
Solution Approach 2:
The system uses the engine's own exhaust heat and oxygen to perform regeneration when conditions are favorable, without requiring additional fuel injection or external heating. The control unit leverages existing exhaust parameters to regenerate the filter, allowing the system to service itself using resources already available in the exhaust stream.
3Speed
If the exhaust aftertreatment components are positioned close to the engine, then heating efficiency is improved, but system integration and space constraints are increased
Solution Approach 1:
The patent positions the heating element, catalytic converter, and particulate filter in a nested or closely integrated arrangement near the engine exhaust outlet. The heating element is housed within or adjacent to the catalytic converter, which in turn is positioned close to the engine, creating a compact multi-functional assembly that maximizes heating efficiency while managing spatial constraints through careful geometric 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
This configuration enables rapid and efficient heating of exhaust aftertreatment components, reducing cold start emissions and facilitating particle filter regeneration, thereby improving fuel efficiency and compliance with emissions regulations.
Implementation Method 1
an electric heating element with which the internal combustion engine exhaust stream can be heated independently of the exhaust gas flow
Implementation Method 2
An exhaust gas flow from the internal combustion engine is deflected by at least 100° by a deflecting element between the first housing and the second housing
Implementation Method 3
a first three-way catalyst which can be heated independently of the exhaust gas flow of the internal combustion engine
Implementation Method 4
Thermal oxidation of the soot trapped in the GPF requires a sufficiently high temperature combined with the presence of oxygen in the exhaust system
Data Source
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AI summary
The invention relates to an exhaust aftertreatment system for an internal combustion engine (10) with an exhaust system (20) in which, in the direction of flow of an exhaust stream from the internal combustion engine (10), a first three-way catalyst (34) located close to the engine is arranged, and downstream of the first three-way catalyst (34) located close to the engine, a second three-way catalyst (40) located close to the engine and a particulate filter (42) are arranged. The first three-way catalyst (34) located close to the engine can be heated independently of the exhaust stream from the internal combustion engine by means of an electric heating element (30). It is provided that the first three-way catalyst (34) located close to the engine is arranged in a first housing (28) and the second three-way catalyst (40) located close to the engine is arranged in a second housing (38), wherein the central axis (M1) of the first housing (28) and the central axis (M2) of the second housing are arranged at an angle of -10° to 70° to each other.In this process, an exhaust gas flow from the combustion engine (10) is deflected by at least 100° by a deflecting element (36) between the first housing (28) and the second housing (38).