CN101418710B - 嵌有加热器结构的电加热颗粒过滤器 - Google Patents

嵌有加热器结构的电加热颗粒过滤器 Download PDF

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CN101418710B
CN101418710B CN2008101497571A CN200810149757A CN101418710B CN 101418710 B CN101418710 B CN 101418710B CN 2008101497571 A CN2008101497571 A CN 2008101497571A CN 200810149757 A CN200810149757 A CN 200810149757A CN 101418710 B CN101418710 B CN 101418710B
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E·V·冈策
M·R·查普曼
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GM Global Technology Operations LLC
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/42—Auxiliary equipment or operation thereof
    • B01D46/4263—Means for active heating or cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
    • F01N13/0097—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series the purifying devices are arranged in a single housing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/023—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
    • F01N3/027—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using electric or magnetic heating means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/105—General auxiliary catalysts, e.g. upstream or downstream of the main catalyst
    • F01N3/106—Auxiliary oxidation catalysts
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    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • F01N3/2006—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating
    • F01N3/2013—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating using electric or magnetic heating means
    • F01N3/2026—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating using electric or magnetic heating means directly electrifying the catalyst substrate, i.e. heating the electrically conductive catalyst substrate by joule effect
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Abstract

本发明涉及嵌有加热器结构的电加热颗粒过滤器。具体地，提供了一种用于处理发动机产生的排气的排气系统。该系统主要包括颗粒过滤器，其对排气颗粒进行过滤捕集，其中，颗粒过滤器的上游端接收发动机排气，并且其中，颗粒过滤器的上游表面具有经机械加工的槽。电阻材料的格栅插入颗粒过滤器的上游外表面上的这些经机械加工的槽中，并且选择性地加热流经该格栅的排气从而引起颗粒过滤器内颗粒的燃烧。

Description

嵌有加热器结构的电加热颗粒过滤器
相关申请的交叉引用
[0001]本申请要求了2007年6月15日提交的美国临时申请No.60/934,986的优先权。上述申请的内容作为参考并入本文。
政府权利的声明
[0002]本发明是依据美国政府与能源部(DoE)的合约No.DE-FC-04-03AL67635提出的。美国政府对本发明具有一定权利。
技术领域
[0003]本发明涉及用于加热颗粒过滤器(或称微粒捕集器)的方法和系统。
背景技术
[0004]本节的陈述只是为了提供与本发明相关的背景信息，可能并不构成现有技术。
[0005]柴油机通常具有比汽油机更高的效率，因为柴油燃料的压缩比增大并且能量密度更高。柴油机的燃烧循环产生颗粒，通常是通过布置在废气流中的颗粒过滤器(PF)对柴油机排气中的颗粒进行过滤捕集。随着时间的过去，PF会变满并且必须清除所捕集的柴油机颗粒。再生过程中，柴油机颗粒在PF内燃烧。
[0006]传统的再生方法是在主燃烧事件之后向废气流中喷射燃料。该燃烧后喷射燃料在置于废气流中的一个或多个催化剂上燃烧。燃料在催化剂上的燃烧期间，所释放的热量提高了排气温度，该温度使PF内捕集的颗粒燃烧。然而，这种方法会导致比所预期的更高的温度剧增，这对排气系统部件(包括PF)有害。
发明内容
[0007]因此，本发明提供了一种用于处理发动机产生的排气的排气系统。该系统主要包括颗粒过滤器(PF)，其对排气颗粒进行过滤捕集，其中，PF的上游端接收发动机排气，并且其中，颗粒过滤器的上游表面具有经机械加工的槽。电阻材料的格栅被插入PF的上游外表面上的这些经机械加工的槽中，并且选择性地加热流经该格栅的排气从而引起PF内颗粒的燃烧。
[0008]另一方面，本发明提供了一种用于处理发动机产生的排气的排气系统。该系统主要包括：接收发动机排气的催化剂，其中，催化剂的下游端从催化剂中释放排气并且其中颗粒过滤器的下游外表面具有经机械加工的槽；以及，被插入催化剂的下游外表面的这些经机械加工的槽中并且选择性地加热流经该格栅的排气的电阻材料的格栅。
[0009]从本文的描述将明显看出本发明的更多适用领域。应当理解，详细描述和特定例子只是起到举例的作用，无意限制本发明的范围。
附图说明
[0010]本文所述附图只是为了起到举例的作用，而决不意图限制本发明的范围。
[0011]图1是示例性汽车的原理框图，该汽车具有根据本发明各方面的颗粒过滤器和颗粒过滤器再生系统。
[0012]图2是示例性壁流整体式颗粒过滤器的截面图，其具有嵌入的电阻格栅。
[0013]图3是图2所示颗粒过滤器的透视图，其具有经机械加工的槽。
[0014]图4包括示例性格栅的前方透视图，示出了电阻路径的各种模式。
[0015]图5是示例性催化剂和具有嵌入的电阻格栅的颗粒过滤器的侧面透视图。
[0016]图6包括催化剂的透视图，其具有经机械加工的槽。
具体实施方式
[0017]下列描述实际上只是示例性的并且没有意图限制本发明、应用或用途。应当理解，在所有附图中，用相同的附图标记表示相同或相应的零件和特征。本文所用的术语“模块”是指专用集成电路(ASIC)、电子电路、执行一种或多种软件或固件程序的处理器(共享的、专用的或成组的)和存储器、组合逻辑电路、和/或其它的提供所述功能的适当部件。
[0018]现在参照图1，示出了包括根据本发明各方面的柴油机系统11的示例性汽车10。应当理解，柴油机系统11实际上只是示例性的，并且本文所述颗粒过滤器再生系统可以在采用了颗粒过滤器的各种发动机系统中应用。这些发动机系统可以是但不限于直喷式汽油机系统和均质充气压燃式发动机系统。为了便于论述，将就柴油机系统论述本发明。
[0019]涡轮增压柴油机系统11包括燃烧空气和燃料混合物以产生驱动转矩的发动机12。空气经由空气滤清器14进入该系统。空气流经空气滤清器14并且被吸入涡轮增压器18中。涡轮增压器18对进入系统11的新鲜空气进行压缩。通常，空气压缩得越大，发动机12的输出就越大。然后，压缩空气在进入进气歧管22之前流经空气冷却器20。
[0020]进气歧管22内的空气被分入气缸26。尽管只示出四个气缸26，但应当理解本发明的系统和方法可以在具有多个气缸的发动机中应用，包括但不限于2、3、4、5、6、8、10和12个气缸。也应当理解，本发明的系统和方法可以在v型气缸结构中应用。由燃料喷射器28将燃料喷入气缸26。压缩空气的热量点燃了空气/燃料混合物。空气/燃料混合物的燃烧产生废气。废气从气缸26排入排气系统。
[0021]排气系统包括排气歧管30、柴油机氧化催化剂(催化剂)32和颗粒过滤器(PF)34。可选地，EGR阀(未示出)将一部分废气再循环回进气歧管22中。其余废气被引入涡轮增压器18中来驱动涡轮。该涡轮促进了从空气滤清器14出来的新鲜空气的压缩。废气从涡轮增压器18流出，流过催化剂32和PF34。催化剂32根据在后燃烧空燃比对废气进行氧化。PF34接收从催化剂32出来的废气并且对废气中存在的颗粒物质进行过滤捕集。
[0022]控制模块44根据各种检测信息和/或模型信息来控制发动机12和PF再生。更详细地说，控制模块44估算PF34的颗粒物质负载量。当估算的颗粒物质负载量达到阈值(如，5克/升的颗粒物质)并且废气流速处于预定范围内时，通过电源46来控制供给PF34的电流从而启动再生过程。根据PF34内的颗粒物质量来改变再生过程的持续时间。预料再生过程能持续1-6分钟。然而，只在再生过程的起始时期通电。更详细地说，电能对PF34的前方加热一段阈时期(如，1-2分钟)。对流经前端面的废气进行加热。利用由PF34的被加热面附近的颗粒物质的燃烧产生的热量或是流经PF34的被加热废气产生的热量来完成再生过程的剩余时期。
[0023]特别参照图2，PF34优选为整体式颗粒过滤器并且包括交替的封闭单元/孔道50和开口单元/孔道52。这些单元/孔道50、52通常是方形截面，沿轴向贯穿该部件。PF34的壁面58优选为由堇青石材料制成的多孔的蜂窝陶瓷壁面组成。应当理解，任何蜂窝陶瓷材料都在本发明范围内。相邻孔道是交替地堵住一端，如56所示。这就迫使柴油颗粒穿过多孔的载体壁面，其充当机械过滤器。颗粒物质沉积在封闭孔道50内，废气经过开口孔道52排出。颗粒物质59流入PF34并且被捕集在其中。
[0024]参照图3并继续参照图2，为了再生的目的，PF34的前方或上游外表面(也称作前端面)的一个或多个部分经过机械加工或者磨出槽62。如图3所示，机械加工出槽62以容纳具有电阻材料的格栅64。可以各种模式加工出槽62以配合格栅64的模式。如所预料地，格栅64的电阻材料可以单路径或多路径模式形成，如图4所示。通过将格栅64插入槽62中，格栅64贴在PF34的前端面上。当处于适当位置时，槽62有助于保持格栅64在PF34中的位置并且格栅64成层流状。
[0025]在各种实施例中，槽62的深度是这样的，当格栅64贴在PF34上时，在PF34与格栅64之间存在间隙66，如图2所示。间隙66使得在格栅64被加热时能进行热膨胀(下文将继续描述)。在各种实施例中，格栅64由能进行低热膨胀的电阻材料(如，具有42％的镍和58％的铁的INVAR42)组成。
[0026]参照图5和图6，在各种实施例中，当汽车10具有催化剂32时，催化剂32的后端或下游外表面(也称作后端面)的一个或多个部分经过机械加工或者磨出槽68。如图6所示，机械加工出槽68以容纳格栅64。如上所述，可以各种模式加工出槽68以配合格栅64的模式。通过将格栅64插入催化剂32的后端面的槽68中，格栅64可以嵌在催化剂32与PF34之间。当处于适当位置时，槽68有助于保持格栅64在PF34中的位置并且格栅64成层流状。
[0027]在各种实施例中，槽68的深度是这样的，当格栅64贴在PF34上时，在PF34与格栅64之间存在间隙(与图2中的66一样)。间隙使得在格栅64被加热时能进行热膨胀(下文将继续描述)。在各种实施例中，格栅64由能进行低热膨胀的电阻材料(如，具有42％的镍和58％的铁的INVAR(因瓦合金)42)组成。
[0028]在上述任一实施例中，向格栅64通电以加热格栅64。流过格栅64的排气带着格栅64产生的热能顺着PF34的孔道50、52往下一小段距离。将格栅64嵌入PF34或催化剂32中限制了辐射热损失。热能点燃了PF34的前端附近的颗粒物质。然后，颗粒燃烧所产生的热量被引导通过PF34从而引起PF34内其余颗粒的燃烧。
[0029]现在本领域技术人员能够从上文的描述知道，可以以多种形式实施本发明的宽泛教导。因此，尽管用特定例子描述了本发明，但是，本发明的实际范围不会因此受到限制，因为对本领域技术人员来说通过研究附图、说明书和下列权利要求可以很明显地得到其它变型。

Claims (17)

1.一种用于处理发动机产生的排气的排气系统，包括：
颗粒过滤器，其对排气颗粒进行过滤捕集，其中，颗粒过滤器的上游端接收来自发动机的排气，
其特征在于，颗粒过滤器的上游表面具有经机械加工的槽；以及
电阻材料制成的格栅，其被插入到颗粒过滤器的上游外表面的经机械加工的槽中从而形成该上游外表面的无覆盖部分，并且选择性地加热流经该格栅的排气以使颗粒过滤器内的颗粒燃烧开始。
2.如权利要求1所述的系统，其中，经机械加工的槽按第一模式形成，其中，电阻材料的格栅按第二模式形成，且其中，第一模式与第二模式相匹配。
3.如权利要求2所述的系统，其中，第二模式是单路径模式。
4.如权利要求2所述的系统，其中，第二模式是多路径模式。
5.如权利要求1所述的系统，其中，经机械加工的槽的深度使得当格栅被插入经机械加工的槽中时在格栅与颗粒过滤器之间有间隙。
6.如权利要求1所述的系统，其中，电阻材料由低热膨胀材料组成，其中所述低热膨胀材料是从包括铁和镍的组中选择的。
7.如权利要求1所述的系统，还包括控制模块，其在颗粒过滤器再生循环的起始时期控制向格栅的通电。
8.如权利要求7所述的系统，其中，控制模块估算颗粒过滤器内的颗粒量，并且其中，当该颗粒量超出阈值量时控制通电。
9.一种用于处理发动机产生的排气的排气系统，包括：
接收发动机排气的催化剂，其中，催化剂的下游端从催化剂中释放排气，并且其中催化剂的下游外表面具有经机械加工的槽；以及
电阻材料制成的格栅，其被插入到催化剂的下游外表面的经机械加工的槽中从而形成该下游外表面的无覆盖部分，并且选择性地加热流经该格栅的排气。
10.如权利要求9所述的系统，还包括置于催化剂下游并且对排气颗粒进行过滤捕集的颗粒过滤器，并且其中，来自格栅的被加热排气使颗粒过滤器内颗粒的燃烧开始。
11.如权利要求9所述的系统，其中，经机械加工的槽按第一模式形成，其中，电阻材料的格栅按第二模式形成，并且其中，第一模式与第二模式相匹配。
12.如权利要求11所述的系统，其中，第二模式是单路径模式。
13.如权利要求11所述的系统，其中，第二模式是多路径模式。
14.如权利要求9所述的系统，其中，经机械加工的槽的深度使得当格栅被插入经机械加工的槽中时在格栅与催化剂之间有间隙。
15.如权利要求9所述的系统，其中，电阻材料由低热膨胀材料组成，其中所述低热膨胀材料是从包括铁和镍的组中选择的。
16.如权利要求10所述的系统，还包括控制模块，其在颗粒过滤器再生循环的起始时期控制向格栅的通电。
17.如权利要求16所述的系统，其中，控制模块估算颗粒过滤器内的颗粒量，并且其中，当该颗粒量超出阈值量时控制通电。
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