Particulate Filter Regeneration Using a Fuel-Operated Heater

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Solution Overview

Problem

Hybrid vehicles face challenges in purging particulate filters of carbonaceous soot due to their engines often operating at lower loads or being stopped, which limits opportunities for regeneration.

Innovation Solution

Activating a fuel-operated heater to heat the exhaust system when the engine is stopped, allowing heat from the heater to be applied to the particulate filter to purge soot without affecting vehicle drivability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the engine is operated at lower loads to purge the particulate filter, then the particulate filter regeneration is improved, but the vehicle drivability deteriorates

Engineering Contradiction:

Improveparticulate filter regenerationVSAvoidvehicle drivability

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The fuel operated heater is activated before the engine is stopped to preheat the exhaust system and particulate filter. This preliminary heating action enables the filter to reach regeneration temperature even when the engine is subsequently stopped, allowing filter purification without compromising drivability during engine operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The fuel operated heater serves as an intermediary device that provides the necessary heat for particulate filter regeneration without requiring the main engine to operate at suboptimal loads. The heater mediates between the need for filter regeneration and the need for maintaining engine efficiency and drivability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If the engine is stopped to reduce emissions and improve fuel economy, then the vehicle emissions are reduced and fuel economy is improved, but the opportunity to purge the particulate filter is lost

Engineering Contradiction:

Improvefuel economyVSAvoidparticulate filter regeneration

Core Design Contradiction:

Loss of energyVSProductivity

Solution Approach 1:

The system performs preliminary heating of the exhaust system and particulate filter using the fuel operated heater before the engine is stopped. This advance preparation ensures that the filter can begin its regeneration process even when the engine is subsequently shut off, allowing emission reduction through engine stopping while still achieving filter purification.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The fuel operated heater continues the useful thermal action needed for particulate filter regeneration even after the main engine is stopped. This maintains the regeneration process continuity, ensuring that filter purification can proceed during periods when the engine is off, thus preserving both fuel economy and filter maintenance.

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If the fuel operated heater is activated to heat the exhaust system for particulate filter regeneration, then the particulate filter regeneration is improved, but the energy consumption increases

Engineering Contradiction:

Improveparticulate filter regenerationVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The fuel operated heater is activated for a limited preliminary period before engine shutdown to raise the exhaust system and particulate filter temperature to the required regeneration level. This preliminary heating action reduces the total energy consumption compared to running the engine at high load for extended periods, as the heater only needs to provide enough heat to initiate regeneration before the engine is stopped.

Inventive Principle:

Principle #10Preliminary action

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

Enables effective regeneration of the particulate filter with reduced energy consumption and maintains vehicle drivability, even when the engine is stopped.

Implementation Method 1

activating a fuel operated heater that is configured to heat a passenger cabin of a vehicle

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 2

heat in exhaust of the fuel operated heater may be applied to purge a particulate filter

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

heat in exhaust of the fuel operated heater may be applied to purge a particulate filter

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12234757B1Methods and systems for regenerating a particulate filter

Publication Date: 2025.02.25 FORD GLOBAL TECH LLC

AI summary

Systems and methods for heating a vehicle via a fuel operated heater are presented. In one example, the fuel operated heater heats a catalyst in an exhaust system of an internal combustion engine to reduce engine emissions. In another example, the fuel operated heater heats a particulate filter to purge soot from the particulate filter.