DE102022004639A1 - Device for heating a catalytic converter in an exhaust system - Google Patents

Abstract

The present disclosure discloses an apparatus for heating a catalytic converter in an exhaust system. The device comprises a heating element arranged in an exhaust pipe upstream of the catalytic converter. The heating element is operable between a first position and a second position and includes one or more first devices configured to be in fluid communication with a source of secondary air to deliver secondary air toward the catalyst when the heating element is in the first position. Furthermore, the device comprises at least one actuator coupled to the heating element and a control unit communicatively coupled to the at least one actuator. The controller actuates the actuator in response to an operating condition to actuate the heating element between the first position and the second position. The controller controls the heater element to the first position to selectively heat exhaust gas and secondary air to heat the catalyst.

Description

The following description particularly describes the invention and the mode in which it is to be carried out.

The present disclosure generally relates to the field of motor vehicles. In particular, but not exclusively, the present disclosure relates to exhaust systems in vehicles. Further, embodiments of the present disclosure disclose an apparatus for heating a catalytic converter in an exhaust system.

With the increasing emission of noxious gases such as CO ₂ , NO _x , etc. into the atmosphere, the need for improved catalytic converters and exhaust aftertreatment systems in an engine has rapidly multiplied in recent years. The use of catalytic converters in vehicle exhaust systems has promoted the reaction of chemical pollutants emitted by internal combustion engines. This approach has proven very effective in reducing the level of pollution attributable to vehicles including, but not limited to, light commercial, passenger and commercial vehicles. The effectiveness of a catalytic converter depends on the operating temperature and several other parameters, such as: B. the chemical kinetics, the attack surface and so on. Over the years, the performance and effectiveness characteristics of a catalytic converter have been carefully studied to optimize peak or near-peak catalytic converter performance when the engine is at its normal operating temperature. At lower catalyst temperatures, particularly at temperatures well below those developed at normal engine operating temperatures, e.g. For example, during cold starts or engine warm-up, the ability of a catalytic converter to adequately promote exhaust reactions to control pollutants is significantly reduced.

Reduced catalyst temperatures are commonly encountered during warm-up of an engine after a cold start, i.e. at ambient temperatures of around 25°C to 28°C. Generally, catalyst warm-up occurs much faster than warm-up of the engine itself. However, warm-up of the catalyst may take longer last, e.g. B. about 100 seconds, which has a significant impact on the time it takes for a catalyst to reach its effective operating temperature, commonly referred to as the "light off temperature". During this time, little or no reduction reaction of the exhaust pollutants takes place, and during this catalyst warm-up period, a significant proportion of the pollutants are emitted by the vehicle under typical urban driving conditions. This can increase the emission of carbon and nitrogen containing gases into the atmosphere, which must be avoided at all costs. Several approaches have been proposed in the past to cause a catalyst to “light off” at a very early stage of an engine's cold start. One of the approaches is to provide a passive device or element, e.g. B. a heating element in thermal communication with the catalyst. The heater element heats the catalyst and activates the catalyst to synchronously perform its intended function during cold engine start-up.

The PCT publication WO2020260331A1 [hereinafter referred to as the “'331 publication”] discloses an exhaust aftertreatment device having such a heating element in which a heating conductor can be looped or doubled in certain areas to achieve increased heating capacity. The material of the heating conductor can also be adjusted so that in certain areas, e.g. B. by higher ohmic resistances, a higher heat output is achieved. The heating conductor can be formed as a heating disk, which is arranged downstream in the direction of flow of the exhaust gas. A gap is formed between the heated disk and the catalytic converter. The heating pane is connected to a voltage source via a marked electrical contact, so that the heating pane can be heated electrically. Another such heating arrangement is disclosed in PCT publication WO2017198292 [hereinafter referred to as the '292 publication]. The heater assembly of the '292 publication is adapted to inductively heat the exhaust gas in an exhaust passage by a first heater disposed outside the exhaust passage upstream of the selective catalytic reduction catalyst. The heaters discussed in the '331 and '292 publications result in a pressure drop in the exhaust gas and eventually an increasing back pressure in the exhaust gases during most of the engine operating time, which is undesirable. This is because the increased back pressure during engine operation increases CO ₂ emissions to the atmosphere, increasing the CO ₂ footprint.

US Patent No: US4404795A [hereinafter referred to as the '795 patent] proposes another approach to reducing particulate emissions contained in an exhaust gas. The apparatus of the '795 patent includes a secondary air supply housing provided in front of a collector [filter] disposed on the inlet side of a collector. The secondary air supply housing is designed to move linearly between a retracted position and an advanced position NEN position can be moved, being in contact with the front of the catch member by driving an actuator. The secondary air supply housing is connected to a secondary air supply pump via a check valve to prevent backflow of exhaust gas. An electrical heater is located at an opening of the secondary air supply housing, behind which a porous element is attached. The electric heating element is operated by a heater control. While the '795 patent discloses a linearly movable air supply housing, it uses a check valve to prevent back pressure.

The present disclosure is directed to overcoming one or more of the above limitations or other such limitations in the prior art.

One or more deficiencies of a conventional exhaust aftertreatment unit in an exhaust system are overcome and additional advantages are provided by the apparatus claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In one non-limiting embodiment of the disclosure, an apparatus for heating a catalyst of an exhaust aftertreatment unit in an exhaust system is disclosed. The device comprises a heating element which is arranged upstream of the catalytic converter in an exhaust pipe of the exhaust system. The heating element is operable between a first position and a second position within the exhaust pipe, and the heating element is provided with one or more first devices configured to be in fluid communication with a source of secondary air to deliver secondary air toward the catalytic converter when the heating element is actuated to the first position. Furthermore, the device comprises at least one actuator coupled to the heating element and a control unit communicatively coupled to the at least one actuator. The controller is configured to actuate the at least one actuator in response to an operating condition to actuate the heating element between the first position and the second position. The controller is further configured to operate the heater in the first position to selectively heat exhaust and the secondary air to heat the catalyst.

In an embodiment of the disclosure, the first position of the heating element is arranged perpendicularly to a flow direction of the exhaust gas, and the second position of the heating element is arranged parallel to the flow direction of the exhaust gas.

In one embodiment of the disclosure, the device includes an injection plate attached to a distal end of the heating element, the injection plate being provided with one or more second features structured to be in fluid communication with the one or more first features of the heating element.

In one embodiment of the disclosure, the heating element is actuated between the first position and the second position by a pivoting actuator and/or a hinged actuator. Furthermore, the device comprises a plurality of heating elements connected to a pivotable shaft, each of the plurality of heating elements having the one or more first means for discharging the secondary air towards the catalytic converter. The pivotable shaft is provided with a duct for distributing the secondary air to the one or more first means defined in each of the plurality of heating elements.

In one embodiment of the disclosure, the operating condition is a cold start condition of an engine, and the first position of the heating element corresponds to the cold start condition of the engine.

In one embodiment of the disclosure, a free end of the latch arm that engages the opening includes a polymeric liner.

In a further non-limiting embodiment of the disclosure, an exhaust system for a vehicle is disclosed. The exhaust system has an exhaust pipe that is in fluid communication with an engine of the vehicle, and an exhaust aftertreatment unit that includes a catalyst is disposed in the exhaust pipe. The system includes a device for heating a catalyst in an exhaust aftertreatment unit. The device comprises a heating element which is arranged upstream of the catalytic converter in an exhaust pipe of the exhaust system. The heating element is operable between a first position and a second position within the exhaust pipe, and the heating element is provided with one or more first devices configured to be in fluid communication with a source of secondary air to deliver secondary air towards the catalytic converter, when the heating element is actuated to the first position. Furthermore, the device comprises at least one actuator coupled to the heating element and a control unit communicatively coupled to the at least one actuator. The controller is configured to actuate the at least one actuator in response to an operating condition to actuate the heating element between the first position and the second position. The controller is further configured to operate the heater in the first position to selectively heat exhaust and the secondary air to heat the catalyst.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

• 1 ein schematisches Blockdiagramm eines Abgassystems mit einer Nachbehandlungseinheit in einem Fahrzeug gemäß einer Ausführungsform der vorliegenden Offenbarung zeigt;
• 2 eine schematische Vorderansicht einer Vorrichtung zum Beheizen eines Katalysators in einem Abgassystem gemäß einigen Ausführungsformen der vorliegenden Offenbarung zeigt;
• 3 eine schematische Seitenansicht der Vorrichtung aus 2 mit einer Vielzahl von Heizelementen gemäß einigen Ausführungsformen der vorliegenden Offenbarung zeigt;
• 4 eine schematische Vorderansicht der Vorrichtung aus 2 mit einer Einspritzplatte zum Einführen von Sekundärluft gemäß einigen Ausführungsformen der vorliegenden Offenbarung zeigt;
• 5 und 6 schematische Vorderansichten der Vorrichtung zum Beheizen eines Katalysators in einem Abgassystem mit klappbarem Betätigungsmodus des Heizelements gemäß einigen Ausführungsformen der vorliegenden Offenbarung zeigen;
• 7 und 8 schematische Vorderansichten der Vorrichtung zum Beheizen eines Katalysators in einem Abgassystem mit rotierendem Betätigungsmodus des Heizelements gemäß einigen Ausführungsformen der vorliegenden Offenbarung zeigen;
• 9 eine schematische Seitenansicht der Vorrichtung aus 2 mit einer Vielzahl von Heizelementen, die winklig um einen zweiten Drehpunkt angeordnet sind, zeigt.

The novel features and characteristics of the disclosure are set forth in the appended claims. However, the disclosure itself, as well as a manner of use, other objects and advantages thereof, are best understood by reference to the following detailed description of an embodiment when read in conjunction with the accompanying drawings. One or more embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which like reference numbers represent like elements, in which:

• 1 12 shows a schematic block diagram of an exhaust system with an aftertreatment unit in a vehicle according to an embodiment of the present disclosure;
• 2 12 shows a schematic front view of an apparatus for heating a catalyst in an exhaust system according to some embodiments of the present disclosure;
• 3 a schematic side view of the device 2 with a plurality of heating elements according to some embodiments of the present disclosure;
• 4 a schematic front view of the device 2 10 with an injection plate for introducing secondary air according to some embodiments of the present disclosure;
• 5 and 6 12 shows schematic front views of the apparatus for heating a catalyst in an exhaust system with foldable heater element actuation mode according to some embodiments of the present disclosure;
• 7 and 8th 12 shows schematic front views of the apparatus for heating a catalyst in an exhaust system with rotary actuation mode of the heater element according to some embodiments of the present disclosure;
• 9 a schematic side view of the device 2 with a plurality of heating elements angularly arranged about a second pivot point.

The figures show embodiments of the present disclosure for purposes of illustration only. Those skilled in the art will readily appreciate from the following description that alternative embodiments of the device presented herein may be used without departing from the principles of the disclosure described herein.

While the embodiments in the disclosure are subject to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the figures and are described below. However, it should be understood that the disclosure is not intended to be limited to the particular form disclosed, but on the contrary the disclosure is intended to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.

It should be noted that those skilled in the art are motivated by the present disclosure and can modify various features of an apparatus, assembly, system, device, or method without departing from the scope of the disclosure. Therefore, such modifications are considered part of the disclosure. Accordingly, the drawings only show those specific details that are important for understanding the embodiments of the present disclosure, so as not to obscure the disclosure with details that will be readily apparent to those skilled in the art having the benefit of the present description. Additionally, the device and exhaust system of the present disclosure may be employed in any type/branch of vehicles, including commercial vehicles, passenger vehicles, trucks, and the like. However, the vehicle as a whole is not shown in the drawings of the disclosure for the sake of simplicity.

As used in the disclosure, the terms "comprises...", "comprising" or other variations thereof are intended to cover non-exclusive inclusions such that an apparatus, assembly, system, device, or method includes a list of components that not only includes those components, but may also include other components not expressly listed or pertaining to such an apparatus, assembly, system, device, or method. In other words, one or more elements in the apparatus, assembly, system, device, or method continued with "comprises..." does not, without further limitation, include the presence of other elements or additional elements in the apparatus , the assembly, the system, the device or the process.

Embodiments of the present disclosure disclose an apparatus for heating a catalyst of an exhaust aftertreatment unit in an exhaust system. The catalyst in the exhaust after-treatment unit needs to be heated as part of the exhaust after-treatment process in which particulate matter and harmful gases such as carbon-based gases and nitrogen-based gases undergo chemical reactions such as a reduction reaction. In one embodiment, the reaction may comprise a selective catalytic reduction (SCR) reaction carried out in the presence of a reducing agent, such as e.g. B. ammonia, expires, but is not limited to. The apparatus of the present disclosure is designed to light-off the catalyst during cold engine starts without causing back pressure in the exhaust flow when engine operation reaches normality. The device comprises a heating element which is arranged upstream of the catalytic converter in an exhaust pipe of the exhaust system. The heating element can be adjustable between a first position and a second position within the exhaust pipe. Further, the heating element may be provided with one or more first devices configured to be in fluid communication with a source of secondary air for discharging secondary air toward the catalyst when the heating element is actuated to the first position. In one embodiment, the one or more first features may be openings, slots, etc. that can establish fluid communication between the exhaust pipe and the secondary air source.

The apparatus also includes at least one actuator coupled to the heating element and a controller communicatively coupled to the at least one actuator. The actuator may be a rotary actuator, or a linear actuator, or a combination of rotary and linear actuators, depending on the type of actuation required. Furthermore, the control unit can actuate the at least one actuator depending on an operating state of an engine in order to actuate the heating element between the first position and the second position. In one embodiment, the operating condition may be a cold start condition of an engine, wherein the first position of the heating element corresponds to the cold start condition of the engine. The operating condition may also include normal operation of the engine, where the heating element may be placed in the second position to reduce the effects of back pressure in the exhaust flow. When the control unit actuates the at least one actuator to place the heating element in the first position, the heating element can heat the exhaust gas and the secondary air for the purpose of heating the catalyst. In an embodiment of the disclosure, the first position of the heating element may be a direction in which the heating element is oriented normal to the flow direction of the exhaust gas. In another embodiment, the second position of the heating element corresponds to a parallel orientation of the heating element relative to the flow direction of the exhaust gas. In an embodiment of the disclosure, the heating element may be actuated between the first position and the second position by a pivoting actuator and/or a hinged actuator. Further, the device may include a plurality of heating elements connected to a pivotable shaft, each of the plurality of heating elements having the one or more first means for discharging the secondary air towards the catalytic converter. In some embodiments, the pivotable shaft may be ducted to distribute the secondary air to the one or more first devices defined in each of the plurality of heating elements.

In one embodiment of the disclosure, the device may include an injection plate attached to a distal end of the heating element, wherein the injection plate may be provided with one or more second features structured to be in fluid communication with the one or more first facilities of the heating element are available. The one or more second devices may be fluidly coupled to the secondary air source such that the secondary air may be discharged through the one or more second devices and consequently through the one or more first devices into the exhaust flow.

The present disclosure also discloses an exhaust system for a vehicle with the device described above. The exhaust system includes an exhaust pipe that can be in fluid communication with an exhaust manifold of an engine of the vehicle. The exhaust system may also include an exhaust aftertreatment unit with a catalyst disposed within the exhaust pipe. The system includes the device for Heat up the catalyst as described in the previous paragraphs.

In the following sections, the present disclosure is presented with reference to 1 until 9 described. In the figures, the same element or elements having similar functions are denoted by the same reference numerals. Referring generally to the drawings, an exhaust system for a vehicle [not shown] is depicted and generally designated by the reference numeral (100). The exhaust system (100) may be represented as an operatively associated component in the interior of a vehicle [not shown]. It should be understood that the teachings of the present disclosure are not limited to any vehicle, and the vehicle is not illustrated in the figures for simplicity.

1 12 shows a schematic view of an exhaust system (100) in a vehicle [not shown] according to some embodiments of the disclosure. For purposes of illustration, an exhaust system (100) based on a diesel engine (10) will be considered. The engine (10) receives fresh air (charge) for combustion through a Fresh Air Inlet (FAI). The exhaust stream (ES) exiting the engine (10) may be directed to a downstream diesel oxidation catalyst (DOC) (20) to oxidize hydrocarbons and carbon monoxide present in the exhaust stream (ES). Hydrocarbon compounds can be oxidized to eventually break down into carbon dioxide and water, while carbon monoxide can be oxidized to carbon dioxide during the oxidation process. The oxidized exhaust gas can then go to a filter (30), such as. B. a diesel particulate filter (DPF), where particles such as soot can be removed from the exhaust gas. After the particle filtering in the filter (30), the exhaust gas can be fed to a downstream catalytic converter (40) which can perform a reduction reaction to convert various harmful components such as CO ₂ , NO _x , etc. into less harmful components. The catalyst (60) can be loaded with ingredients from an external source (U) to carry out the reactions. For example, if the catalyst (60) is an SCR catalyst, a reductant such as urea can be injected from source (U) so that NO _x can be converted to a less harmful compound such as ammonia (NH ₃ ) in the presence of urea. The reduced exhaust eventually exits the outlet (EO) for further processing or to the atmosphere. A range of sensors such as thermocouples (15), pressure sensor (25), NO _x sensors (35) and NH3 sensor (45) can be used to measure physical characteristics such as temperature, pressure, flow rate etc. of the exhaust gas, as well as quantitative aspects such as concentrations, Flow rates, etc. of various components in the exhaust gas are installed.

2 shows a schematic view of a device (200) for heating a catalyst (2) [in 1 shown as (60)] in the exhaust system (100). The exhaust system (100) comprises an exhaust pipe (1) which defines an exhaust path (1A), the section of which is connected to the device (200) and the catalyst (2) in 2 is shown. the inside 2 The catalytic converter (2) shown may be located downstream of the device (200) in the exhaust system (100) and is shown as a single unit (2) for purposes of illustration, although it may be of complex construction. The catalyst (2) can be arranged in the exhaust pipe (1) so that it can be exposed to the exhaust gas flow (EF) (hereinafter referred to as "exhaust gas flow"). In this way, the catalyst (2) can be in fluid and thermal communication with both the device (200) and the exhaust gas stream (EF). The heating of the catalytic converter (2) is required as part of an after-treatment process in which the harmful components such as carbon-containing gases and nitrogen-containing gases are subjected to chemical reactions such as a reduction reaction. Catalyst (2) heating, also known as “light off”, can be crucial to speeding up the rate of chemical reactions in the catalyst (2). The chemical reactions associated with the catalytic converter (2) can reduce the level of pollutants present in the exhaust stream (EF) before the exhaust stream (EF) is released to the atmosphere, thereby reducing the level of pollutants released to the atmosphere. Another requirement is that the catalytic converter (2) must be heated as soon as the engine (10) is started, particularly when the engine (10) is started in cold or ambient conditions [known as cold engine starting]. If the catalytic converter is not active during engine cold starts, CO ₂ emissions and other emissions to the atmosphere can increase significantly. The device (200) of the present disclosure is intended to heat the catalyst to a light-off temperature during cold start of the engine (10).

The device (200) as shown in 2 is shown comprises a heating element (3) which is arranged upstream of the catalytic converter (2) in the exhaust pipe (1). The heating element (3), as the name suggests, can generate heat in any known way. For example, the heating element (3) can be an electrical heating element that generates heat by electrical resistance (ohmic heating), induction (inductive heating) and the like. The heating element (3) can draw energy from a battery present in the vehicle to generate heat. As shown, the heating element (3) can be arranged in the exhaust pipe (1) in such a way that it can be adjusted between a first position (FP) and a second position (SP) within the exhaust pipe (1).

For example, the heating element (3) can be rotated about a pivot point (P) between the first position (FP) and the second position (SP). For actuation, the heating element (3) or the pivot point (P) can be coupled to at least one actuator (5). In one embodiment of the heating element (3) according to 2 the pivot point (P) can be coupled to a rotary actuator (5) so that the heating element (3) can be rotated through a desired angle between the first position (FP) and the second position (FP). In one embodiment, the first position (FP) of the heating element (3) means that the heating element (3) can be oriented perpendicularly to the exhaust gas flow (EF). The second position (SP) of the heating element (3), on the other hand, means that the heating element (3) can be rotated so that the heating element (3) is aligned parallel to the exhaust gas flow (EF). The rotation of the heating element (3) around the pivot point (P) is indicated by the arrows symbolized by (AD). In order to control the operation of the actuator (5) as required, the actuator (5) can be communicatively and operatively coupled to a control unit (6) assigned to the exhaust system (100). The control unit (6) can regulate the operation of the actuator (5) in response to an operating condition, such as a cold start condition or a normal operating condition of the engine (10). For example, during cold start of the engine (10), the control unit (6) cannot actuate the actuator (5), so the heating element (3) can remain in a default position (first position) (FP) normal to the exhaust gas flow (EF). Once the engine (10) starts running normally, the control unit (6) can send signals to the actuator (5) to bring the heating element (3) to the second position (SP). In this way, the control unit (6) enables the actuator (5) and the heating element (3) to be operated selectively as required.

Furthermore, the heating element (3), as in 2 shown, be provided with one or more first means (4) intended to establish fluid communication between a secondary air source (7) and the exhaust path (1A). The one or more first devices (4) can allow secondary air (SA) to exit from the secondary air source (SA) towards the catalytic converter (2) during operation. In one embodiment, the first means (4) can be openings, slots or holes that can allow secondary air (SA) to exit into the exhaust path (1A). Furthermore, the secondary air source (7) can be a compressor, a pump or any other device that can be designed to supply secondary air (SA) to the first means (4). The secondary air source (7) can optionally be connected to the control unit (6) in order to regulate the discharge of the secondary air (SA) into the first devices (4). The control unit (6) can also be connected to the heating element (3) in order to regulate the heating power of the heating element (3) as required.

The operational characteristics of the device (200) will now be described with reference to FIG 2 explained in detail. When the engine (10) is cold started, the heating element (3) can remain in the first position (FP), which for understanding can be called the standard position. In the first position (FP) of the heating element (3), the control unit (6) must not actuate the actuator (5), but can send signals to initiate the operation of the secondary air source (7) and the heating element (3). The heating element (3) generates heat that can be transferred to the exhaust stream (EF) by any of the heat transfer modes. On the other hand, the secondary air source (7) can inject secondary air (SA) into each of the first devices (4), whereby the secondary air (SA) enters and mixes with the exhaust gas flow (EF). Since the secondary air (SA) flows through the first devices (4) and the heating element (3) is thereby heated, the secondary air (SA) is also heated. This achieves better mixing of the secondary air (SA) with the exhaust gas flow (EF) as it exits each of the first devices (4). The mixture, which is at relatively high temperatures, moves to and heats the catalyst (2) to initiate and accelerate the operation of the catalyst (2). In one embodiment, the secondary air (SA) may undergo a reaction with the catalyst (2), which may be exothermic, which aids in heating the catalyst (2). As soon as the catalytic converter (2) has heated up and the engine (10) starts to run normally [ie the cold start phase of the engine (10) is completed], the control unit (6) can receive signals which correspond to the normal operating condition of the engine (10). . Based on these signals, the control unit (6) can send signals to the actuator (5) to actuate the heating element (3) about the pivot point (P) to the second position (SP) [e.g. B. to rotate). As shown, the second position (SP) may correspond to an orientation of the heating element (3) that is parallel to the exhaust flow (EF). The second position (SP) of the heating element (3) can prevent the pressure drop of the exhaust gas flow (EF) as well as the susceptibility of the exhaust gas flow (EF) to a back pressure during the flow (EF). In this way, the device (200) of the present disclosure improves the exhaust gas flow characteristics, apart from helping the catalyst (2) light-off during cold engine starts. In one embodiment, the control unit (6) can optionally interrupt or reduce the injection of secondary air (SA) from the secondary air source (7) and the heating of the heating element (3) when the heating element (3) is brought into the second position (SP). . As soon as a cold start is desired in the next cycle, the control unit (6) can actuate the actuator (5) in such a way that the actuator (5) moves the heating element (3) from the second position (SP) back to the first position (FP) in can move in the direction indicated by (AD). In this way, the control unit (6) can selectively align the heating element (3) relative to the exhaust gas flow (EF) in order to light up the catalytic converter (2) when required (cold start) and the heating element (3) relative to the exhaust gas flow (EF). disorientate to reduce the pressure drop and back pressure of the exhaust gas (EF) stream. In an embodiment as shown in 3 As shown, a plurality of heating elements (3) connected to a common pivot shaft (P) can be used. As in 3 As shown, the plurality of heating elements (3) may be arranged in parallel with each other, each heating element (3) having a number of first means (4) [not shown] for injecting the secondary air (SA). In the first position (FP) all heating elements (3) are perpendicular to the exhaust gas flow (EF), while in the second position (SP) all heating elements (3) remain parallel to the exhaust gas flow (EF). In one embodiment of the disclosure, the actuator (5) may be an electric actuator powered by a battery in the vehicle, or it may be a hydraulic actuator or a pneumatic actuator using fluid power. In the case of a rotary actuation of the heating element (3) as shown in 2 and 3 is shown, the actuator (5) can be, for example, an electric motor or a hydraulic/pneumatic motor.

4 shows a schematic view of in 2 The device (200) shown has an injection plate (8) attached to the heating element (3) for injecting secondary air (SA). The functioning of 4 is more or less similar to the in 2 embodiment described, except for the presence of the injection plate (8) fixed to the heating element (3). The injection plate (3) as shown can serve as an extension of the heating element (3) which can be attached to the heating element (3) by any of the known fastening means. The injection plate (3) may have second features (8A) which may be openings, slots, holes, perforations etc. in fluid communication with the first features (4) in the heating element (3). The second means (8A) can be aligned with the first means (4) to establish fluid communication between the secondary air source (7) and the exhaust gas path (1A) to inject the secondary air (SA) into the exhaust gas stream (EF). In an embodiment of the disclosure, the pivot shaft (P) may be provided with auxiliary devices (8A) such as openings, holes, perforations, etc., so that the secondary air source (7) can inject the secondary air (SA) into the pivot shaft (P). The pivot shaft (P) can then distribute the secondary air (SA) to each of the first means (4) defined in the heating element (3) to direct the secondary air (SA) into the exhaust stream (EF).

5 until 6 show schematic views of the device (500 or 600) with different operating modes for operating the heating element (503 or 603). While 2 until 4 show a heating element (3) which can be rotatably actuated to orient and disorientate relative to the exhaust gas flow (EF). 5 until 6 a linear mode of actuation where the heating elements can be folded/collapsed through the use of linear actuators. As in each of the 5 until 6 As shown, pistons (510, 610) may be coupled to a linear actuator (5), such as an electric, hydraulic or pneumatic linear actuator, to effect reciprocation (PA) of the piston (510, 610). The pistons (510, 610) can reciprocate within housings (505, 605), such as cylinders, which can partially or fully enclose the length of the pistons (510, 610). The housings (505, 605) may in turn be connected to heating elements (503, 603) which have a foldable/collapsible configuration. When the heating element (3) is to be used to heat the catalytic converter (2), the control unit (6) cannot actuate the actuator (5), so that the heating element (503, 603) is in the first position (shown as 503a, 603a ) can remain. The heater element can generate heat and secondary air (SA) can be injected in this position to heat up the catalytic converter (2) during cold starts. If heating of the catalytic converter is not desired or if the engine is running under normal conditions, the actuator (5) can be activated by the control unit (6) to operate the piston (510, 610) in direction (PA) and the heating element (503, 603) to fold or collapse. A partially folded or collapsed state is represented by (503b, 603b). The actuation of the piston (510, 610) can be continued until the heating element (503, 603) is fully folded/collapsed as represented by (503c, 603c).

7 until 8th show schematic views of the device (700, 800) with Heizele ments (703, 803) in the divided state, which can be operated by rotary operation. The heating elements (703, 803) may each be coupled to pivot shafts (P) that allow rotary actuation between first and second positions. The first position is indicated by (703a, 703b) and corresponds to the cold start condition of the engine. When not needed, the heating elements (703, 803) can be rotated through an intermediate position (703b, 803b) to the second position (703c, 803c) which is parallel to the exhaust flow (EF).

9 shows a schematic view of the device (900) with a plurality of heating elements (903) arranged at an angle and connected to a common second pivot point (P2). Each heating element (903) can have channels or slots [not shown] through which the secondary air (SA) can be blown. The channels or slots help to disperse the incoming secondary air (SA) and thereby facilitate the exit of the secondary air (SA) into the exhaust flow (EF) [shown in any of the above figures] through the first means (4).

In an embodiment of the disclosure, the control unit (6) (such as an ECU) can be a central control unit or a dedicated control unit connected to the exhaust system (100) of the engine (10). The controller may be implemented by any computing system used to implement the features of the present disclosure. The control unit can consist of a processing unit. The processing unit may include at least one data processor for executing program components for executing user or system generated requests. The processing unit can be a specialized processing unit, such as e.g. B. Integrated system (bus) controllers, memory management control units, floating point units, graphics processing units, digital signal processing units, etc. The processing unit may comprise a microprocessor, such as AMD Athlon, Duron or Opteron, ARM's application, embedded or secure processors, IBM PowerPC, Intel's Core , Itanium, Xeon, Celeron, or other series of processors, etc. The processing unit may be implemented using a mainframe, distributed processor, multi-core, parallel, grid, or other architectures. In some embodiments, embedded technologies such as application-specific integrated circuits (ASICs), digital signal processors (DSPs), field programmable gate arrays (FPGAs), etc. may be used.

In some embodiments, the CU may communicate with one or more memory devices (e.g., RAM, ROM, etc.) via a memory interface. The storage interface can be connected to storage devices including, without limitation, storage drives, removable disk drives, etc. that support connection protocols such as Serial Advanced Technology Attachment (SATA), Integrated Drive Electronics (IDE), IEEE-1394, Universal Serial Bus (USB), Fiber Channel , Small Computing System Interface (SCSI), etc. The storage drives may further include a drum, magnetic disk drive, magneto-optical drive, optical drive, redundant array of independent disks (RAID), solid-state storage devices, solid-state drives, and so forth.

The device (200) of the present disclosure has a number of inherent advantages. An advantage is that the heating element (3) can only be used when needed and can be disoriented when not in use. This is beneficial in reducing the effects of the pressure drop and potential back pressure experienced by the exhaust and thereby improving the effectiveness and efficiency of the aftertreatment unit in the exhaust system. Another advantage is that the integration of the secondary air injection with the heating element improves the uniformity index related to mixing, eliminating the need for an additional heating element to heat the secondary air during operation. Another advantage is the flexibility to use different types and quantities of actuators depending on the design and space constraints in the exhaust systems.

It is understood that those skilled in the art can develop a device and exhaust system with a similar configuration without departing from the scope of the present disclosure. Such modifications and variations can be made without departing from the scope of the present disclosure. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents.

Equivalents:

With respect to use of substantially all plural and/or singular terms herein, those skilled in the art may translate from plural to singular and/or singular to plural as appropriate to the context and/or application. The different sins gular/plural permutations may be explicitly mentioned here for clarity.

Those skilled in the art will understand that the terms used herein, and particularly in the appended claims (e.g., in the body of the appended claims), should generally be construed as "open-ended" terms (e.g., the term "including" should be read as " including but not limited to", the term "with" should be interpreted as "at least", the term "includes" should be interpreted as "includes but is not limited to", etc.). It will further be understood by those skilled in the art that when a certain number of incorporated claims are intended, such intent is expressly stated in the claim and that in the absence of such mention, no such intent is present. For example, as an aid to understanding, the following appended claims may contain use of the introductory phrases "at least one" and "one or more" to introduce claim recitals. However, the use of such expressions should not be construed to mean that the introduction of a claim list by the indefinite article "a" or "an" limits a particular claim containing such introduced claim list to inventions containing only such list, themselves if the same claim contains the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g. "a" and/or "an" should typically be construed to mean mean “at least one” or “one or more”); the same applies to the use of certain articles to introduce claims enumeration. Furthermore, even where a particular number of a preambled claim is expressly mentioned, those skilled in the art will recognize that such mention should typically be interpreted to mean at least the number mentioned (e.g., the mere mention of "two mentions ' without other modifiers typically at least two mentions or two or more mentions). Furthermore, in those cases where a convention analogous to "at least one of A, B, and C, etc." is used, such construction is generally meant in the sense in which those skilled in the art would understand the convention (e.g. “a system) with at least one of A, B and C” would include systems containing A alone, B alone, C alone, A and B together, A and C together, B and C together and/or A, B and C together, etc., including but not limited to). In those cases where a convention analogous to "at least one of A, B, or C, etc." is used, such construction is generally meant in the sense in which those skilled in the art would understand the convention (e.g., " a system with at least one of “A, B or C” includes systems containing A alone, B alone, C alone, A and B together, A and C together, B and C together and/or A, B and C together etc. include, but is not limited to). It will also be understood by those skilled in the art that virtually any disjunctive word and/or sentence containing two or more alternative terms, whether in the specification, claims or drawings, is to be construed as implying the possibility of one of the terms to include either or both of the terms. For example, the phrase "A or B" is understood to include the possibilities of "A" or "B" or "A and B." While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are intended for purposes of illustration and not limitation, with the true scope being indicated by the following claims.

Reference List

100

exhaust system

10

engine

20

oxidation catalyst

30

Filters/DPF

40, 2

catalyst

15, 25, 35, 45

sensors

FAI

fresh air intake

IT, EF

exhaust flow, exhaust flow

u

External source

EO

exhaust outlet

200 to 900

apparatus

1

exhaust pipe

1A

exhaust path

3, 503, 603, 703, 803, 903

heating element

4

First facilities

5

actuator(s)

6

control unit

7

secondary air source

8th

injection plate

8A

auxiliary facilities

SA

secondary air

FP, 503a, 603a, 703a, 803a

First position

SP, 503c, 603c, 703c, 803c

second position

503b, 603b, 703b, 803b

intermediate positions

P

Pivot/pivot shaft

p2

Secondary Pivot/Swivel Shaft

AD

operating direction

504, 604

limbs

505, 605

housing/cylinder

510, 610

Pistons

PA

actuation of the piston

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• WO 2020260331 A1 [0005]
• WO 2017198292 [0005]
• US4404795A [0006]

Claims (10)

Device (200) for heating a catalytic converter (2) of an exhaust gas aftertreatment unit in an exhaust system (100), the device (100) comprising the following: a heating element (3) arranged upstream of the catalytic converter (2) in an exhaust pipe (1) of the exhaust system (100), the heating element (3) between a first position (FP) and a second position (SP) within the exhaust pipe (1) is operable, wherein the heating element (3) is defined with one or more first devices (4) configured to be in fluid communication with a secondary air source (7) to supply secondary air (SA) towards the catalytic converter (2) to emit when the heating element (3) is actuated to the first position (FP); at least one actuator (5) coupled to the heating element (3); and a control unit (6) communicatively connected to the at least one actuator (5), the control unit (6) being configured to actuate the at least one actuator (5) in response to an operating condition of an engine (10), to operate the heating element (3) between the first position (FP) and the second position (SP), wherein the control unit (6) is further configured to operate the heating element (3) in the first position (FP) to to selectively heat the exhaust gas (EF) and the secondary air (SA) to heat the catalytic converter (2). Device (200) according to claim 1 , wherein the first position (FP) of the heating element (3) is arranged perpendicular to a flow direction of the exhaust gas (EF) and the second position (SP) of the heating element (3) is arranged parallel to the flow direction of the exhaust gas (EF). Device (200) according to claim 1 comprising an injection plate (8) attached to a distal end of the heating element (3), the injection plate (8) being formed with one or more second means (8A) structured to be in fluid communication with of the one or more first devices (4) of the heating element (3). Device (200) according to claim 1 wherein the heating element (3) is actuated between the first position (FP) and the second position (SP) by a pivoting actuator and/or a hinged actuator. Device (200) according to claim 1 comprising a plurality of heating elements (3) coupled to a pivotable shaft (P), each of said plurality of heating elements (3) comprising said one or more first means (4) for directing said secondary air (SA). of the catalyst (2) to deliver. Device (200) according to claim 5 wherein the pivotable shaft (P) is provided with a duct for distributing the secondary air (SA) to the one or more first means (4) defined in each of the plurality of heating elements (3). Device (200) according to claim 1 , wherein the operating condition is a cold start condition of the engine (10), wherein the first position (FP) of the heating element (3) corresponds to the cold start condition of the engine (10). Exhaust system (100) for a vehicle, comprising: an exhaust pipe (1) in fluid communication with an engine (10) of the vehicle; an exhaust aftertreatment unit with a catalyst (2) which is arranged in the exhaust pipe (1); and a device (200) for heating a catalytic converter (2) in the exhaust gas aftertreatment unit, comprising: a heating element (3) arranged upstream of the catalytic converter (2) in an exhaust pipe (1) of the exhaust system (100), the heating element (3) between a first position (FP) and a second position (SP) within the exhaust pipe (1) is operable, wherein the heating element (3) is defined with one or more first devices (4) configured to be in fluid communication with a secondary air source (7) to deliver secondary air (SA) toward the catalytic converter (2) when the heating element (3) is actuated to the first position (FP); at least one actuator (5) coupled to the heating element (3); and a control unit (6) communicatively coupled to the at least one actuator (5), the control unit (6) being configured to actuate the at least one actuator (5) in response to an operating condition to heat the heating element (3 ) between the first position (FP) and the second position (SP), wherein the control unit (6) is further configured to operate the heating element (3) in the first position (FP) to selectively heat exhaust gas (EF) and the secondary air (SA) to heat the catalyst (2). Exhaust system (100) after claim 1 , wherein the first position (FP) of the heating element (3) is arranged perpendicularly to a flow direction of the exhaust gas (EF) and the second position (SP) of the heating element (3) is arranged parallel to the flow direction of the exhaust gas (EF), and wherein the the first position (FP) of the heating element (3) corresponds to a cold start condition of the engine, and the second position (SP) of the heating element (3) corresponds to a normal operating condition of the engine. Exhaust system (100) after claim 1 comprising a plurality of heating elements (3) coupled to a pivotable shaft (P), each of the plurality of heating elements (3) comprising one or more first means (4) for directing air towards the catalytic converter (2) to deliver.

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