Compact Exhaust Heating Module Radial Flow Deflection
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Solution Overview
Problem
Existing heating modules for exhaust gas purification systems are not compact enough and inefficient in heating oxidation catalytic converters, leading to suboptimal regeneration of particle filters and other exhaust gas cleaning units.
Innovation Solution
A compact heating module design featuring a secondary branch with overflow pipe sections that allow for radial deflection of the exhaust gas flow, minimizing back pressure and enabling effective mixing with the main branch, along with an electrothermal heating element and HC injector configuration to achieve efficient temperature distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional heating module design is used, then the oxidation catalytic converter can be heated, but the module is not compact enough and the heating efficiency is suboptimal
Solution Approach 1:
The secondary branch is positioned concentrically within the main branch, with the oxidation catalytic converter nested inside the heating module structure. This nesting arrangement allows the heating components and catalytic converter to occupy the same spatial envelope, significantly reducing the overall module volume while maintaining effective heating capability
Solution Approach 2:
The patent transitions from a conventional linear or radial branch configuration to a concentric cylindrical arrangement where the secondary branch occupies the internal volume of the main branch. This dimensional reorganization maximizes space utilization and achieves compactness without compromising heating efficiency
2Temperature
If the exhaust gas flow is directed through the secondary branch, then the oxidation catalytic converter is heated, but back pressure increases
Solution Approach 1:
The deflection chambers are positioned specifically at the inlet and outlet regions of the secondary branch, creating localized flow management zones. These chambers provide smooth radial deflection paths only where needed, while the central section maintains a straight flow path, thereby minimizing overall flow resistance and back pressure
Solution Approach 2:
The deflection chambers employ curved, rounded flow paths instead of sharp angles or abrupt transitions. This smooth curvature allows the exhaust gas to transition radially between the main and secondary branches without creating turbulence or pressure losses, effectively reducing back pressure while maintaining heating efficiency
3Volume of moving object
If the secondary branch is positioned concentrically within the main branch, then the module becomes compact, but the flow path configuration becomes complex
Solution Approach 1:
The heating module is divided into distinct functional segments: the main branch for primary exhaust flow, the concentric secondary branch for heating, and deflection chambers at inlet/outlet regions for flow transition. This segmentation allows each component to have a simple, optimized geometry while the assembly achieves compactness, reducing overall design complexity
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 design allows for efficient heating of oxidation catalytic converters, reducing the length of the heating module, minimizing back pressure, and ensuring uniform temperature distribution, thereby enhancing the regeneration process of particle filters and other exhaust gas cleaning units.
Implementation Method 1
an oxidation catalytic converter connected downstream of the HC injector in the flow direction of the exhaust gas for supplying thermal energy to an exhaust gas purification unit
Implementation Method 2
the soot that has accumulated on the filter is burned off (oxidized)
Implementation Method 3
an electrothermal heating element connected upstream of it. This is operated when this oxidation catalytic converter has to be heated to its light-off temperature
Implementation Method 4
the secondary branch has a deflection chamber on the inlet side and on the outlet side in each case extending from the main branch in the radial direction
Implementation Method 5
the exhaust gas flow is divided into a main line and a secondary line for the purpose of actively bringing about the regeneration of a particle filter
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A heating module (1) for an exhaust-gas purification system connected to the outlet of an internal combustion engine comprises a catalytic burner, with an HC injector (14) and with an oxidation catalytic converter (12) positioned downstream of the HC injector (14) in the flow direction of the exhaust gas, for supplying thermal energy to an exhaust-gas purification unit of the exhaust-gas purification system. It is provided here that the heating module (1) has a main section (2), a secondary section (3) which comprises the catalytic burner (12, 14), and a device (4, 5) for controlling the exhaust-gas mass flow flowing through the secondary section (3). In a first embodiment, the main section (2) has, in the inlet region of the heating module (1), an overflow pipe portion (6) which has overflow openings (7), between which overflow diverting chambers (8) is situated, parallel to the main section (2) of the heating module (1), the secondary section portion (11) with the oxidation catalytic converter (12). In another embodiment, it is provided that the secondary section (3) has, at the inlet side and outlet side, in each case one diverting chamber (8) which extends in the radial direction from the main section (2), between which diverting chambers (8) is situated, parallel to the main section (2) of the heating module (1), the secondary section portion (11) with the oxidation catalytic converter (12).