Exhaust component with a helical heater

Patent metadata

Field	Value
Publication number	US-11105239-B2
Application number	US-201916454336-A
Country	US
Kind code	B2
Filing date	Jun 27, 2019
Priority date	Jun 27, 2019
Publication date	Aug 31, 2021
Grant date	Aug 31, 2021

Abstract

An exhaust component assembly includes a housing defining an internal passage for engine exhaust gas, at least one exhaust gas aftertreatment component within the internal passage, and at least one heater to heat the engine exhaust gas. The heater comprises a helical-shaped element with a surface that spirals about an axis for a predetermined length.

First claim

What is claimed is:

1. An exhaust component assembly, comprising:
a main housing defining an internal passage for engine exhaust gas;
a return housing in parallel with the main housing;
at least one exhaust gas aftertreatment component within the internal passage of the main housing; and
at least one heater positioned within the return housing to heat the engine exhaust gas, wherein the heater comprises a helical-shaped element with a surface that spirals about an axis for a predetermined length, and wherein exhaust gas exiting the at least one heater is first directed into the at least one exhaust gas aftertreatment component prior to entering a second exhaust gas aftertreatment component
a first connector having a first end connected to an outlet from the main housing and a second end connected to an inlet to the return housing, the outlet being downstream of the at least one exhaust gas aftertreatment component,
a second connector having a first end connected to an outlet from the return housing and a second end connected to an inlet to the main housing, the inlet being upstream of the at least one exhaust gas aftertreatment component,
a fan located within the return housing downstream of the at least one heater, and wherein heated exhaust gas exiting the helical-shaped element directly enters the fan and is then directed into the second connector.

2. The exhaust component assembly according to claim 1 wherein the helical-shaped element has an outermost dimension defined by an outer edge of the surface, and wherein the predetermined length is greater than the outermost dimension.

3. The exhaust component assembly according to claim 1 wherein the at least one heater further includes a center body portion extending along the axis, and wherein the surface spirals about the center body portion.

4. The exhaust component assembly according to claim 3 including electrodes connected to opposing ends of the center body portion, wherein the electrodes are connected to a power source and control module.

5. The exhaust component assembly according to claim 1 including a fan located within the return housing downstream of the helical-shaped element, and wherein the fan is driven by a motor.

6. The exhaust component assembly according to claim 1 including at least one valve positioned downstream of the at least one exhaust gas aftertreatment component and moveable at least between a first position and a second position, wherein the first position directs exhaust gas into the return housing, and wherein the second position allows exhaust gas to enter the second exhaust gas aftertreatment component that is positioned within the main housing downstream of the at least one exhaust gas aftertreatment component.

7. The exhaust component assembly according to claim 6 wherein the at least one valve comprises a first valve and including a second valve positioned upstream of the at least one exhaust gas aftertreatment component, wherein the second valve is moveable between an open position to allow heated exhaust gas to exit the return housing and enter an upstream end of the main housing and a closed position to prevent exhaust gas from exiting the return housing.

8. The exhaust component assembly according to claim 7 wherein the at least one exhaust gas aftertreatment component comprises a first catalyst and the second exhaust gas aftertreatment component comprises a second catalyst that is spaced from the first catalyst within the main housing by a gap within which the first valve is positioned.

9. The exhaust component assembly according to claim 8 wherein the first catalyst comprises a light off catalyst and the second catalyst comprises a main catalyst.

10. The exhaust component assembly according to claim 1 including an inlet pipe configured to direct exhaust gases from an engine into the upstream end of the main housing, and wherein heated exhaust gas exiting an outlet from the return housing combines with the exhaust gases from the engine to enter the upstream end of the main housing.

11. An exhaust component assembly, comprising:
a housing defining an internal passage for engine exhaust gas;
at least one exhaust gas aftertreatment component within the internal passage; and
at least one heater to heat the engine exhaust gas, wherein the heater comprises a helical-shaped element with a surface that spirals about an axis for a predetermined length, and wherein the surface includes a plurality of openings, and/or comprises a mesh or porous material.

12. An exhaust component assembly, comprising:
a housing defining an internal passage for engine exhaust gas, wherein the housing comprises a main housing and including a return housing in parallel with the main housing;
at least one exhaust gas aftertreatment component within the internal passage;
at least one heater to heat the engine exhaust gas, wherein the heater comprises a helical-shaped element with a surface that spirals about an axis for a predetermined length, wherein the at least one heater is positioned within the return housing, and wherein exhaust gas exiting a downstream end of the at least one exhaust gas aftertreatment component is directed into the return housing, passes through the helical-shaped element, and is directed into an upstream end of the at least one exhaust gas aftertreatment component; and
a secondary heater positioned upstream of the at least one exhaust aftertreatment component and downstream of an outlet from the return housing.

13. The exhaust component assembly according to claim 12 wherein the secondary heater comprises a grid element.

14. An exhaust component assembly, comprising:
a first housing defining an internal passage for engine exhaust gas;
at least one exhaust gas aftertreatment component positioned within the internal passage;
a second housing arranged parallel to the first housing;
a first connector having a first end connected to an outlet from the first housing and a second end connected to an inlet to the second housing;
a second connector having a first end connected to an outlet from the second housing and a second end connected to an inlet to the first housing; and
at least one heater positioned within the second housing, and wherein the at least one heater comprises a helical-shaped element with a surface that spirals about an axis for a predetermined length, and wherein heated exhaust gas exiting the at least one heater is first directed into the at least one exhaust gas aftertreatment component prior to entering a second exhaust gas aftertreatment component
a fan located within the second housing downstream of the helical-shaped element, and wherein heated exhaust gas exiting the helical-shaped element directly enters the fan and is then directed into the second connector.

15. The exhaust component assembly according to claim 14 wherein the helical-shaped element has an outermost dimension defined by an outer edge of the surface, and wherein the predetermined length is greater than the outermost dimension.

16. The exhaust component assembly according to claim 14 including
a first valve downstream of the at least one exhaust gas aftertreatment component and moveable at least between a first position and a second position, wherein the first position directs exhaust gas into the second housing and blocks flow into the second exhaust gas aftertreatment component that is positioned within the first housing downstream of the at least one exhaust gas aftertreatment component, and wherein the second position allows exhaust gas to enter the second exhaust gas aftertreatment component, and

Assignees

• Faurecia Emissions Control Technologies Usa Llc

Inventors

• Mccarrick Daniel
• Rohart Thomas

Classifications

• F01N3/2013 Primary

  using electric or magnetic heating means · CPC title

• F01N2240/16

  an electric heater, i.e. a resistance heater · CPC title

• F01N13/009

  having two or more separate purifying devices arranged in series · CPC title

• Y02T10/12

  Improving ICE efficiencies · CPC title

• F01N3/26

  Construction of thermal reactors · CPC title