Patent Grant
8628606
Field of the Invention
The invention relates to an exhaust gas treatment device for generating an electric potential and/or an electric field and/or plasma. The intended effect of the plasma is to at least agglomerate or electrically charge soot particles in a flow of exhaust gas, thus promoting deposition of the particles in a particle filter. Such an exhaust gas treatment device can be employed in a motor vehicle, for example. The invention also relates to a method for treating exhaust gas and a motor vehicle having the device.
In the case of motor vehicles with mobile internal combustion engines and, in particular, in the case of motor vehicles with a diesel drive, the exhaust gas from the internal combustion engine generally contains quantities of soot particles, and they must be discharged into the environment. That is stipulated by corresponding exhaust gas regulations, which specify limits for the number and mass of soot particles per unit of exhaust gas weight or exhaust gas volume and, in some cases, also for an entire motor vehicle. Soot particles are, in particular, unburned carbon and hydrocarbon compounds in the exhaust gas.
The fact that the provision of an electric field and/or a plasma causes agglomeration of small soot particles into larger soot particles and/or causes an electric charge in soot particles, is known. Electrically charged soot particles and/or relatively large soot particles are generally very easy to remove in a filter system. Due to their relatively high inertia, soot particle agglomerates are transported more sluggishly in a flow of exhaust gas and thus settle more easily at points where a flow of exhaust gas is deflected. Due to their charge, electrically charged soot particles are attracted to surfaces, accumulating on those surfaces and losing their charge. That, too, facilitates the removal of soot particles from the stream of exhaust gas during the operation of motor vehicles.
The systems already proposed for generating and/or (temporarily) maintaining an electric field and/or plasma are generally very complex technically and/or inadequate in terms of efficiency. It has likewise been possible to identify problems with the formation of a uniform electric field and/or an electric field matched selectively to the flow of exhaust gas. At any rate, none of the existing systems appears to be ready for series production as part of motor vehicle construction.
It is accordingly an object of the invention to provide an exhaust gas treatment device having two honeycomb bodies for generating an electric potential, a method for treating exhaust gas and a motor vehicle having the device, which overcome the hereinafore-mentioned disadvantages and at least partially solve the highlighted problems of the heretofore-known devices, methods and vehicles of this general type. In particular, it is intended to disclose a device for generating an electric field for a mobile exhaust gas treatment system which is an improvement over the prior art.
With the foregoing and other objects in view there is provided, in accordance with the invention, an exhaust gas treatment device, comprising a first at least partially electrically conductive honeycomb body having a first front side and a first rear side, a second at least partially electrically conductive honeycomb body having a second front side and a second rear side, the first honeycomb body and the second honeycomb body defining an intermediate space therebetween, a power supply configured to form an electric potential between the first honeycomb body and the second honeycomb body, and a multiplicity of electrodes fastened to the first honeycomb body, extending beyond the first rear side by a first length into the intermediate space and positioned at a first distance from the second front side of the second honeycomb body.
In an exhaust gas treatment device of this kind, an electric field can be generated between the electrodes (first pole) on the first honeycomb body and the second honeycomb body (second pole) with the aid of the power source. In this case, the electrodes act substantially as point-like or punctiform electrodes, as compared with a flat electrode formed by the second front side of the second honeycomb body. A configuration of this kind is particularly suitable for generating an electric field and/or for the formation of a plasma because, as a rule, electric charges emerge at the electrodes acting in a point-like or punctiform manner, due to the high concentration of the electric field in this area. The large number of electrodes significantly improves the formation of a selectively specified field in the intermediate space.
The first honeycomb body and/or the second honeycomb body preferably have metallic components which are electrically conductive. In addition to extruded honeycomb bodies, which are at least partially constructed by using such materials, honeycomb bodies which are constructed with at least one at least partially structured metal foil (if appropriate made of stacks including alternate smooth and corrugated metal foils) are used, in particular. The first honeycomb body and/or the second honeycomb body preferably have channels (running in a straight line and/or parallel) extending from the front side to the rear side. The channels are formed by perforated channel walls, if appropriate. The first honeycomb body and/or the second honeycomb body preferably have a channel density of between 50 cpsi and 1000 cpsi, preferably about 600 cpsi [channels per square inch]. This provides sufficient attachment points for the electrodes over the cross section, thus making it possible to set the two dimensional or three dimensional form of the electric field very precisely. At least some of the electrodes, preferably all of the electrodes, are constructed as (rectilinear) metallic pins with a diameter of between 0.5 mm and 3 mm, preferably 1 mm to 2 mm [millimeters].
The first honeycomb body is therefore a significant component of this exhaust gas treatment device, being decisive for the provision of the entire configuration for the formation of the electric field. This can accordingly be described independently of the overall configuration as follows: an at least partially electrically conductive honeycomb body having a first front side and a first rear side, wherein a multiplicity of electrodes, which are fastened to the first honeycomb body, extend over a first length beyond the first rear side.
The electrodes are preferably connected in an electrically conductive manner, e.g. brazed or welded, to the honeycomb body. The number of electrodes is preferably at least 10 or even at least 30.
With regard to the provision of the electrodes, it is preferred if the first length with which the electrodes project beyond the first rear side of the first honeycomb body is at least 2 mm [millimeters], preferably at least 3 mm. The first length should furthermore be at most 20 mm, preferably at most 15 mm, and particularly preferably at most 10 mm. It is preferred if all the electrodes meet the above requirements, although different first lengths can be provided, if appropriate, for at least some of the electrodes.
On one hand, this configuration of the first length (or of the protrusion) of the electrodes ensures that the electric field is formed only between the electrodes and the second honeycomb body and not between the second honeycomb body and the first honeycomb body. At the same time, sufficient compactness and mechanical stability of the exhaust gas treatment device is ensured. The exhaust gas treatment device according to the invention has the advantage that the position of the electrodes can be set in a particularly precise way and hence that a particularly accurately defined electric field and/or plasma can be operated in the intermediate space. The first length (or protrusion) of the electrodes can thus be adapted selectively to the flow of exhaust gas to be treated and/or to the spatial conditions, depending on the power supply.
As an alternative or supplement to the fastening of the multiplicity of electrodes and the first honeycomb body, it is proposed that a multiplicity of electrodes, which are fastened to the second honeycomb body, extend beyond the second front side with a second length into the intermediate space and are positioned at a second distance from the first rear side of the first honeycomb body. The magnitude of the second length and/or the magnitude of the second distance can differ from or be equal to the magnitude of the first length and the magnitude of the first distance, respectively.
In accordance with another advantageous feature of the exhaust gas treatment device of the invention, the first length of at least one electrode is made different from the first length of the other electrodes. In this way, a concentrated or expanded electric field toward the second front side of the second honeycomb body can be generated in the region of the at least one longer or shorter electrodes. This can be appropriate in the central region of the honeycomb bodies, for example, where there is an increased flow of exhaust gas and hence also more particles have to be deposited.
In addition to the first length, the electrodes can (as an alternative or supplementary measure) differ from one another at least with regard to one of the following properties:
In accordance with a further advantageous feature of the exhaust gas treatment device of the invention, at least the first rear side of the first honeycomb body or at least the second front side of the second honeycomb body has a non-planar shape. Through the use of a configuration of this kind, the flow distribution over the cross section can be influenced by the honeycomb bodies. The channels in the honeycomb bodies can have different lengths through one honeycomb body having a non-planar shape, for example. In this way, the construction of the honeycomb body and the prevailing flow of exhaust gas can also be matched to the electric field that can be generated.
It is furthermore possible for the first rear side of the first honeycomb body and/or the second front side of the second honeycomb body to have a shape which deviates from a planar surface (in other words a surface which is flat or lies in one plane). These differences in shape (or differences in the length of the intermediate space over the cross section) can be compensated for by variation of the first length of the electrodes. As a result, it is thus nevertheless possible for the first distance between the electrodes and the second honeycomb body to be set so as to be equal at any point even though the first rear side of the first honeycomb body is disposed at different distances from the second front side of the second honeycomb body.
It is furthermore preferred if the at least one electrode has a tip which tapers conically. It is furthermore preferred if all of the electrodes have such a tip. A tip which tapers conically makes it possible to achieve a higher concentration in the electric field in the region of the tip, further promoting the formation of an electric field and/or plasma between the electrodes and the second honeycomb body. At the same time, the pins of which the electrodes are formed can have a certain thickness, which is greater than the cross section of the tip, thereby achieving a high mechanical stability of the electrodes and good fastening of the electrodes in the first honeycomb body.
It is moreover advantageous if the at least one electrode is offset toward the intermediate space. This means, in particular, that the diameter of the electrode changes abruptly at least once, in particular decreases in the direction of the intermediate space. In this way, reliable fastening to the first honeycomb body is ensured, even when there is wear on the electrode.
In accordance with an added advantageous feature of the exhaust gas treatment device of the invention, precisely with a view toward use in a motor vehicle, the first distance is between 5 mm and 100 mm. The range from 25 mm to 40 mm is very particularly preferred. It has been found that such first distances are particularly advantageous for the formation of an electric field and/or plasma.
In accordance with an additional feature of the invention, an insulator surrounding the intermediate space is provided. The first honeycomb body should generally be insulated electrically from the rest of the exhaust system and, in particular, also from a surrounding exhaust line to enable a voltage to be built up (only) between the electrodes and the second honeycomb body. An electric insulator surrounding the intermediate space is also advantageous for the purpose of ensuring that an electric field forms only between the electrodes and the second honeycomb body and not between the electrodes and the wall of the exhaust line. It is also possible to avoid an electric field between the wall and the electrodes if the distance from the electrodes to the wall is in each case greater than the distance from the electrodes to the second honeycomb body. In a particularly preferred embodiment, a ring of polymethyl methacrylate or a similar material is provided as an electric insulator between the two honeycomb bodies.
According to a development of the exhaust gas treatment device, the second honeycomb body is embodied as a ring. In particular, the second honeycomb body is disposed in a ring around the original central direction of flow of the exhaust gas, as a result of which the exhaust gas is at least partially deflected in order to flow through the second honeycomb body. The second honeycomb body can thus also be used, in particular, as an annular catalyst carrier body.
It is also possible to make the electric insulator, at least of one honeycomb body, from mica. Mica is, in particular, a clear transparent material (aluminosilicate) with a high dielectric resistance. Mica is resistant to a constant working temperature of at least 550° C. and has a melting point of about 1250° C. Moreover, mica is resistant to almost all media, e.g. alkalis, chemicals, gases, oils and acids. The mica insulator can, for example, be constructed as a supporting mat in such a way that it also simultaneously compensates for differences of expansion due to temperature differences between the first honeycomb body and/or the second honeycomb body, on one hand, and the exhaust line on the other. The electric insulator should have an electric strength with respect to electric voltages of at least 20 kV [20 kilovolts=20,000 volts], preferably of at least 30 kV [30 kilovolts=30,000 volts].
In accordance with yet another feature of the exhaust gas treatment device of the invention, the power supply is set up to generate an electric voltage of at most between 5 kV [5 kilovolts=5000 volts] and 30 kV [30 kilovolts=30,000 volts] between the first honeycomb body and the second honeycomb body. The power supply to the electrodes is generally accomplished (individually, jointly and/or in groups) through the electrically conductive first honeycomb body. What is being proposed herein is therefore, in particular, a high-voltage supply. At a distance of between 5 mm and 50 mm and a voltage of 5 kV [kilovolts], mean field strengths of above 1 million V/m [volts per meter] can be achieved in the intermediate space. In the region of the electrodes, there is an additional concentration of the electric field to significantly above this value, due to the point-like form of the electrodes. Such electric fields are particularly suitable for the formation of a plasma. The high field concentration in the region of the electrodes promotes the emergence of electrons from the electrodes.
It is furthermore proposed that the power supply be connected to at least the first honeycomb body or the second honeycomb body at least in sections through the use of a coaxial cable. A shield for the coaxial cable can thus serve as a positive conductor for connecting the power supply to the first honeycomb body or the second honeycomb body, and an internal conductor of the coaxial cable can serve as a negative conductor for connecting the power source to the second honeycomb body or the first honeycomb body. Irrespective of the coaxial cable, the degree of protection of the connection should also comply with protection class IP68, and should thus be protected in a dust-tight manner and against continuous submersion.
In accordance with yet another advantageous feature of the invention, the first honeycomb body has at least one at least partially structured metal foil, and the second honeycomb body has at least one filter material. A partially structured metal foil can also be provided in the second honeycomb body. As a rule, an at least partially structured metal foil is electrically conductive and can thus assure the power supply to the electrodes. The at least partially structured metal foil can be coiled, wound and/or stacked to form the honeycomb body. The filter material of the second honeycomb body allows effective deposition of the agglomerated and/or electrically charged soot particles in the second honeycomb body. Preferred candidates for consideration as a filter material in this case are a metallic woven fabric and/or nonwoven formed by a multiplicity of wire filaments (welded or brazed together). The second honeycomb body can then be embodied, in particular, in the manner of an open particle separator, in which the channels are in part delimited by a metal foil with deflections and openings, on one hand, and by the filter material, on the other hand, wherein the channels do not have any closure from the second front side to the second rear side but instead have a plurality of deflections or openings, through the use of which the exhaust gas together with the particles is directed toward the filter material (or into an adjacent channel).
With the objects of the invention in view, there is also provided a method for treating exhaust gas containing soot particles. The method comprises providing an exhaust gas treatment device according to the invention, and at least temporarily applying an electric field between the first honeycomb body and the second honeycomb body, causing at least some of the soot particles flowing through the exhaust gas treatment device to be at least ionized or agglomerated and deposited on the second honeycomb body.
A preferred option in this context is for the exhaust gas initially to pass through the first honeycomb body and, if appropriate, to be brought into contact with a first catalyst as it does so, then to flow through the intermediate space, in which the electric field is formed, as a result of which ionization and/or agglomeration of the soot particles is initiated there, and finally to impinge upon the second honeycomb body, where the soot particles are preferably deposited. The cleaned exhaust gas then leaves the exhaust gas treatment device after emerging from the second rear side.
It is furthermore preferred if the power supply is operated in such a way that a current between the first honeycomb body and the second honeycomb body is regulated to 0.005 mA [milliamperes] to 0.5 mA, preferably to 0.01 mA to 0.1 mA. During the operation of the exhaust gas treatment device, a current arises through charge transfer to the soot particles. Regulation of the current to the proposed range of values allows sufficient charging of the soot particles but also prevents the occurrence of sparking.
The method according to the invention is furthermore advantageous if the electric field is activated and deactivated at a repetition rate of between 2 and 30,000 Hz [1/second], preferably between 2 and 2000 Hz, and particularly preferably between 50 and 2000 Hz. Such a repetition rate allows particularly effective generation of an electric field, as a result of which soot particles are at least ionized or agglomerate.
The method is also advantageous if the repetition rate is controlled in accordance with the exhaust gas temperature. If the internal combustion engine is already delivering exhaust gas at a temperature suitable, for example, for catalytic conversion, the repetition rate and/or the magnitude of the potential difference can be reduced.
It is also preferred if the electric field is activated with a rising ramp. This means, for example, in particular during the operation of the power supply at a repetition rate, that the voltage or current is increased to the operating level in a time equal to no more than half the reciprocal of the repetition rate. It has been found that a higher final voltage can be achieved in this way, without the occurrence of sparking.
In accordance with another mode of the method of the invention, a first set of the electrodes is operated differently from a second set of the electrodes. Thus, for example, the electrodes can be operated with separate circuits, i.e. can be activated and deactivated with different voltages and/or operating times. The electric field can thus be regulated in accordance with the actual flow of exhaust gas through the use of predetermined, calculated and/or measured parameters.
In order to prevent the deposition of soot particles, it is also possible for an additional honeycomb body to be disposed upstream of the exhaust gas treatment device according to the invention. That honeycomb body evens out and/or even laminarizes a flow of exhaust gas flowing through to ensure that no flow vortices with dead zones—which promote deposition of soot particles—occur as it flows through the downstream exhaust gas treatment device according to the invention.
With the objects of the invention in view, there is concomitantly provided a motor vehicle, comprising an internal combustion engine and an exhaust gas treatment device according to the invention connected to the internal combustion engine for treating exhaust gases from the internal combustion engine.
The advantages and special embodiments described in connection with the exhaust gas treatment device according to the invention and the special methods of operation and advantages explained in connection with the method according to the invention can be applied to each other in an analogous and technologically appropriate manner within the scope of the invention.
Other features which are considered as characteristic for the invention are set forth in the appended claims, noting that the features presented individually in the claims can be combined in any technologically meaningful way and can be supplemented by explanatory material from the description, giving rise to additional variant embodiments of the invention.
Although the invention is illustrated and described herein as embodied in an exhaust gas treatment device having two honeycomb bodies for generating an electric potential, a method for treating exhaust gas and a motor vehicle having the device, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
Referring now to the figures of the drawings in detail and first, particularly, to
In the variant embodiments shown in
An intermediate space 15, in which an electric field and/or plasma can be generated during operation, is provided in each case between the first honeycomb body 12 and the second honeycomb body 13. The first rear side 26 of the first honeycomb body 12 and the second front side 25 of the second honeycomb body 13, lying opposite one another, are spaced apart by a second distance 22. The electrodes 6 project from the first honeycomb body 12 over a first length 8, as a result of which there is a first distance 16 between the electrodes 6 and the second front side 25 of the second honeycomb body. Moreover, the electrodes 6 have tips 10, which are preferably conical in order to achieve more intense concentration of an electric field at the tips 10 during operation.
The first honeycomb body 12 and the second honeycomb body 13 are insulated from one another by an electric insulator 14. Moreover, there is a power supply 18, through which an electric voltage can be generated between the first honeycomb body 12 (more specifically the numerous electrodes) and the second honeycomb body 13 (more specifically the second front side or face thereof).
There are various possible embodiments for enabling the first honeycomb body 12 and the second honeycomb body 13 to be insulated relative to one another. As
However, according to the embodiment of
According to the embodiment of
An electric insulator 14 can be freed from deposits at regular intervals during the operation of the exhaust gas treatment device 11 by applying a short and powerful current pulse to the electric insulator 14, leading to heating and ultimately to burn off of the soot particles. It is also possible for a number of such current pulses to be triggered. It is possible, for example, to trigger such a sequence of current pulses regularly before starting or when starting to put an exhaust gas treatment device according to the invention into operation.
A current pulse of this kind can be triggered by a short voltage peak, which is applied across the insulator 14 and/or between the first honeycomb body 12 and the second honeycomb body 13. Such a voltage peak can be significantly above the normal operating voltage, that is to say, for example, significantly above 30 kV [30 kilovolts=30,000 volts] and, in particular, significantly above 50 kV [50 kilovolts=50,000 volts]. At such high voltages, electrical conductivity is produced in the deposited soot on the electric insulator, leading to the formation of a current pulse. It is important that the voltage peak or the current pulse should be very short in duration, ensuring that only deposits of soot particles are burnt off, while the insulator 14 is not damaged.
According to the embodiment of
The electrodes can have various constructions. In
The invention provides an exhaust gas treatment device which is very compact and is therefore suitable for use in motor vehicle construction. It furthermore allows accurate setting of the electric field for bringing about efficient cleaning of the exhaust gases. In particular, the problems stated at the outset are thereby overcome.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2009 041 092 | Sep 2009 | DE | national |
This is a continuation, under 35 U.S.C. §120, of co-pending International Application No. PCT/EP2010/062464, filed Aug. 26, 2010, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German Patent Application DE 10 2009 041 092.9, filed Sep. 14, 2009; the prior applications are herewith incorporated by reference in their entirety.
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| Number | Date | Country | |
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| Parent | PCT/EP2010/062464 | Aug 2010 | US |
| Child | 13419636 | US |
