Integrated Particulate Filter Heat Exchanger for Exhaust Energy Recovery
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Solution Overview
Problem
Conventional energy recovery systems for internal combustion engines face challenges such as increased space, weight, and backpressure due to separate heat exchangers and particulate filters, which hinder efficient energy utilization and protect the particulate filter from excessive heat.
Innovation Solution
An integrated system where a particulate filter with a heat exchanging area transfers heat to a secondary fluid line, allowing for continuous energy recovery and reducing backpressure, using a closed or open thermodynamic cycle to convert heat into usable energy, and optionally incorporating a thermoelectric generator or endothermic reformer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a separate heat exchanger is added to the exhaust gas line to recover energy, then energy recovery capability is improved, but system space, weight, and cost increase
Solution Approach 1:
The patent combines the particulate filter and heat exchanger into a single integrated component. The filter housing serves as the heat exchanger body, with fluid channels formed within the filter structure itself. This merging eliminates the need for separate heat exchanger units, reducing system weight, space, and complexity while maintaining both filtration and heat recovery functions.
Solution Approach 2:
The particulate filter is designed to perform multiple functions simultaneously: it filters exhaust gases from the engine while also serving as a heat exchanger to transfer thermal energy from exhaust gases to a working fluid. This multi-functionality allows a single component to replace what would traditionally require separate units, addressing the weight and space constraints.
2Loss of energy
If a separate heat exchanger is installed in the exhaust line, then energy recovery is enabled, but backpressure in the exhaust line increases
Solution Approach 1:
By integrating the heat exchanger functionality into the particulate filter structure, the patent avoids adding separate heat exchanger components to the exhaust flow path. The exhaust gases flow through the filter media and housing, which already contains internal fluid channels for heat transfer, thereby recovering energy without introducing additional backpressure restrictions.
3Loss of energy
If a separate heat exchanger is added to recover energy, then heat recovery capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent integrates the heat exchanger functionality into the particulate filter structure, eliminating the need for separate heat exchanger components. The filter housing contains internal fluid channels that serve as heat transfer pathways, reducing the number of parts, assembly steps, and system complexity while maintaining effective heat recovery capability.
4Loss of energy
If exhaust gases flow through a separate heat exchanger, then heat recovery is achieved, but the filter and additional after-treatment devices are exposed to excessive heat
Solution Approach 1:
The patent uses a working fluid circulating through channels in the filter housing as an intermediary to transfer heat from the exhaust gases. This fluid acts as a heat transfer medium that absorbs thermal energy from the exhaust stream while protecting the filter structure and downstream components from excessive heat exposure, enabling safe and effective heat recovery.
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 integrated system enhances energy recovery efficiency, protects the particulate filter by managing heat, and reduces system bulk and cost, while maintaining engine efficiency by utilizing the thermal energy in exhaust gases for mechanical, electrical, or chemical energy production.
Implementation Method 1
the filtering part and heat exchanging part being arranged to transfer heat by conduction from the exhaust gases to said fluid
Implementation Method 2
the secondary line can be a closed loop forming a Rankine thermodynamic cycle
Implementation Method 3
a turbine located downstream from said particulate filter, capable of expanding the gas going out of said particulate filter
Implementation Method 4
a condenser located downstream from said turbine, capable of condensing the expanded gas into a liquid
Data Source
Figure 1~3
Figure 4~5
AI summary
The energy recovery system (12) comprises: an exhaust line (1) which is capable of collecting exhaust gas from an exhaust manifold of the engine and which is equipped with a particulate filter (2); a secondary line (13) which is thermally linked with, but distinct from, the exhaust line (1), and which carries a fluid. The particulate filter has a filtering part in which exhaust gases can flow and a heat exchanging part in which said fluid can flow, the filtering part and heat exchanging part being arranged to transfer heat by conduction from the exhaust gases to said fluid. The secondary line is connected to energy recovery means capable of recovering energy from said heat.