Products of combustion in the form of exhaust gases may be directed through an exhaust system where the exhaust gases may be treated before being discharged to the environment or other suitable location. A variety of exhaust system configurations, and chemical and/or physical processing techniques may be used to remove and sequester products of combustion from the exhaust gases before discharging the remaining components.
According to an aspect of the present disclosure, an exhaust system ionizes exhaust gases to remove products of combustion from an exhaust stream. The exhaust system includes an electrically conductive shell defining an exhaust pathway. The shell has a tapered portion that tapers inward to define a narrowing region of the exhaust pathway. The exhaust system further includes an ionization assembly and an electrical subsystem that applies an electrical potential difference between the shell and at least a portion of the ionization assembly located within the exhaust pathway.
The ionization assembly includes a support arm located within the exhaust pathway that extends into and along the narrowing region of the exhaust pathway. The ionization assembly further includes a plurality of electrically conductive discs mounted on and supported by the support arm. At least some of the discs are located within the narrowing region of the exhaust pathway, and are spaced apart from each other along a longitudinal axis of the exhaust pathway. The discs decrease in size relative to each other along the longitudinal axis with tapering of the shell. Components of the ionization assembly, such as the support arm and the discs are electrically insulated from the shell by an electrically insulating support structure.
A voltage source of the electrical subsystem includes a high electrical potential terminal in electrical communication with the shell, and a low electrical potential terminal in electrical communication with the discs to apply an electrical potential difference between the shell and the discs. Particles within exhaust gases traveling along the exhaust pathway are ionized and become negatively charged by the low electrical potential applied to the discs. These negatively charged particles are attracted by the high electrical potential of the shell. A filter element located along an inner surface of the tapered portion of the shell that surrounds the narrowing region of the exhaust pathway captures larger ionized particles, such as particulate matter or other products of combustion contained in the exhaust gases.
This Summary describes aspects of the present disclosure in a simplified form. This Summary is not intended to identify key features or essential features of claimed subject matter, nor is this Summary intended to limit the scope of the claimed subject matter.
Shell 110 includes a tapered portion 128 that tapers inward toward longitudinal axis 114 in a first direction 116 along longitudinal axis 114. Tapered portion 128 defines a narrowing region 118 of exhaust pathway 112 that narrows in the first direction 116 along longitudinal axis 114. In this example, first direction 116 corresponds to a flow direction of exhaust gases along exhaust pathway 112 in which longitudinal axis 114 of shell 110 is oriented parallel to the X-coordinate axis.
Exhaust system 100 includes an ionization assembly 140. Ionization assembly 140 includes a support arm 142 located within exhaust pathway 112. Support arm 142 extends into and along at least a portion of narrowing region 118 of exhaust pathway 112. Support arm 142 may be supported relative to shell 110 and electrically insulated from shell 110 by an electrically insulating support structure 144. Support structure 144 serves as an electrical insulator that electrically insulates discs 146 and/or support arm 142 from shell 110. In this example, support arm 142 projects from support structure 144 in the first direction 116 along longitudinal axis 114 and is collinear with the longitudinal axis. In other examples, support arm 142 may be parallel to and offset from the longitudinal axis. Also in other examples, support arm 142 may extend in an opposite or counter direction from the direct depicted in
Ionization assembly 140 includes a plurality of electrically conductive discs 146 mounted on and supported by support arm 142. In this example, ionization assembly 140 includes six discs, indicated individually by reference numerals 150-160. In other examples, an ionization assembly may include a single electrically conductive disc or 2, 3, 4, 5, 7, 8, 9, 10 or more electrically conductive discs. At least some or all of discs 146 may be located within narrowing region 118 of exhaust pathway 112. In other embodiments, narrowing region 118 may instead be a non-narrowing region, and expanding region, cylindrical, etc.
Discs 146 are spaced apart from each other along longitudinal axis 114 and along the support arm 142. In at least some examples, some or all of discs 146 may have different sizes and/or shapes relative to some or all of the other discs. In this example, discs 146 have a circular shape when viewed along longitudinal axis 114, and decrease in size (e.g., in diameter or width as measured in a plane that is orthogonal to longitudinal axis 114) relative to each other in first direction 116 along longitudinal axis 114 and along support arm 142. For example, disc 150 is larger than disc 152, disc 152 is larger than disc 154, disc 154 is larger than disc 156, disc 156 is larger than disc 158, and disc 158 is larger than 160. In other examples, at least some or all of discs 146 may have the same size and/or shape relative to each other. Also in other examples, at least some or all of discs 146 may have a non-circular shape when viewed along longitudinal axis 114, including a non-circular oval shape, polygonal shape, or other suitable shape.
Exhaust system 100 includes an electrical subsystem 170. Electrical subsystem 170 includes a voltage source 172 having a high (e.g., positive charge relative to a ground reference) electrical potential terminal 174 in electrical communication with shell 110, and a low (e.g., negative charge relative to a ground reference) electrical potential terminal 176 in electrical communication with discs 146. In this example, a high electrical potential is applied to shell 110 by voltage source 172 via a first electrical pathway 178 that is in communication with high electrical potential terminal 174, and a low electrical potential is applied by voltage source 172 via a second electrical pathway 179 to discs 146 via low electrical potential terminal 176 to create an electrical potential difference between shell 110 and discs 146. In some examples, support arm 142 may take the form of an electrically conductive support arm that is also in electrical communication with low electrical potential terminal 176 (e.g., via electrical pathway 179) and with each of discs 146, so that a low electrical potential is applied to both support arm 142 and discs 146. As an example, support arm 142, as an electrically conductive support arm, may form part of electrical pathway 179 that electrically couples discs 146 to low electrical potential terminal 176.
Voltage source 172 is depicted schematically in
During operation of exhaust system 100, exhaust gases traveling along exhaust pathway 112 in the first direction 116 enter shell 110 via inlet portion 120. Particles within the exhaust gases are ionized and become negatively charged by the low electrical potential applied to discs 146. These negatively charged particles are attracted by the high electrical potential of shell 110. Narrowing region 118 may further compress exhaust gases traveling along exhaust path 112 within the vicinity of discs 146 to further improve ionization of exhaust gases at surfaces of the discs and/or support arm 142, which in turn increases the removal of exhaust components from the exhaust gases.
In at least some examples, exhaust system 100 may include a filter element 190 located along an inner surface of tapered portion 128 of the shell 110 that surrounds narrowing region 118 of exhaust pathway 112. Filter element 190 captures ionized particles that are attracted to the high electrical potential of the shell, such as particulate matter or other combustion products contained within the exhaust gases. Remaining exhaust gases are discharged from shell 110 via outlet portion 134.
Non-limiting use-environments for exhaust system 100 include within vehicle exhaust systems, building exhaust systems, building HVAC systems, building emergency/fire exhaust systems, and exhaust systems for electrical power generation to name a few examples. As a prophetic example, exhaust system 100 may eliminate approximately 80% of products of combustion from the exhaust gases without adding undue flow obstruction or backpressure to the exhaust pathway. Another potential benefit of the ionization of exhaust gases provided by exhaust system 100 includes the reduction of odors contained in the exhaust gases, for example, by the production of ozone via the ionization process.
In this example, filter element 190 covers interior surfaces of the tapered portion of the shell and tapers with the tapered portion of the shell. For example, filter element 190 tapers inward toward longitudinal axis 114 in the first direction 116 along longitudinal axis 114, and forms a generally conical structure. Filter element 190 may have a circular shape when viewed in section along longitudinal axis 114. In other examples, filter element 190 may have a non-circular shape when viewed in section (e.g., to conform with a shell having a non-circular shape), such as a non-circular oval shape, polygonal shape, or other suitable shape. Another view of filter element 190 is depicted in
In this example, inlet shell component 210 includes an inlet portion 120, an inlet-side tapered portion 122 that tapers outward away from longitudinal axis 114 in the first direction 116 (shown in
Support arm 142 may be secured to insulating support structure 144 at opening 428 via an intermediate fastener 426. Opening 428 passes through the hub of insulating support structure 144, enabling a fastener 432 located on an upstream side of support structure 144 to engage with intermediate fastener 426 through opening 428. A cover 434 may be inserted into opening 428 over fastener 432 on the upstream side of insulating support structure 144 to provide a more aerodynamic upstream surface.
Opening 450 joins opening 428 that passes through hub 510. Fastener 432 having external threads may be inserted into opening 428 on the upstream side of support structure 144 where it engages internal threads of intermediate fastener 426 to retain intermediate fastener within opening 428 on the downstream side of the support structure. Cap 434 may be inserted behind fastener 432 to cover opening 428. When fastener 432 is threaded onto intermediate fastener 426, the fasteners may collectively provide a clamping force upon a narrowed region 714 of opening 428 of the support structure. Intermediate fastener 426 further includes internal threads 711 that accommodate external threads of support arm 142. In at least some examples, intermediate fastener 426 includes an opening 716 that aligns with opening 450 when threads 712 are engaged with threads of fastener 432. Opening 716 may accommodate one or more wires, cables, electrical connectors, or other suitable electrical pathways that pass through opening 450 from outside of the ionization assembly.
In this example, disc 900 has a circular shape bounded by outer edge 912. Disc 900 has an opening 916 located at a centroid of its circular shaped face 910 to accommodate a support arm, such as previously described support arm 142. In some examples, a diameter of opening 916 may vary among or between each disc of an ionization assembly that contains a plurality of electrically conductive discs. In this example, a support arm for supporting the plurality of discs may vary in size (e.g., diameter) and/or shape along its length to define a particular location along its length where each disc resides. For example, referring also to
Also in this example, disc 900 tapers toward outer edge 912 as indicated by tapered region 914 to provide a sharp outer edge or corner that may improve ionization of exhaust gas components flowing over or past the disc.
The various components described as being electrically conductive may be formed from any suitable material that provides substantial electrical conductivity, including materials that are or include electrically conductive metals such as copper, steel, aluminum, and iron, to name a few non-limiting examples. Components described as being electrically insulating, such as support structure 144 of ionization assembly 140, may be formed from any suitable material that does not provide substantial electrical conductivity. Where the electrically insulating material is located within the exhaust pathway that may contain exhaust gases of relatively high temperatures or is otherwise used in high temperature environments (such as support structure 144 located within the exhaust pathway) suitable electrically insulating materials may include ceramic, heat-tolerant polymers, or other heat tolerant electrical insulators.
The drawings accompanying this disclosure include schematic representations of example geometries and configurations. These drawings are not necessarily to scale. A non-limiting example of physical measurements for components of exhaust system 100 is provided below. These physical measurements in combination with each other describe a non-limiting example of the relative sizes and shapes of exhaust system components. These relative sizes and shapes may vary (e.g., by 10%, by 20%, or more) from the specific physical measurements described herein while still providing suitable or adequate removal of exhaust gas components.
In a non-limiting example, each of discs 146 have a thickness of 1 cm and are spaced 20 cm apart from each other on support structure 142. Disc 150 has a diameter of 75.7 cm and an opening at its centroid of 9 cm. Disc 152 has a diameter of 66.2 cm and an opening at its centroid of 8 cm. Disc 154 has a diameter of 56.7 cm and an opening at its centroid of 7 cm. Disc 156 has a diameter of 47.2 cm and an opening at its centroid of 6 cm. Disc 158 has a diameter of 37.7 cm and an opening at its centroid of 5 cm. Disc 150 has a diameter of 28.2 cm and an opening at its centroid of 4 cm. Outlet shell component 212 has a total length, as measured along longitudinal axis 114 of 270 cm. Tapered portion 128 has a length of approximately 182.3 cm, and tapers from a diameter of 111.6 cm to 42 cm with walls having a taper angle of 11 degrees relative to longitudinal axis 114. Inlet shell component 210 has a total length of 155 cm as measured along longitudinal axis 114 and varies in diameter from 68.4 cm to 110 cm. Support structure 144 has a thickness of 40 cm as measured along the longitudinal axis 114, with arms 460, 462, and 464 radially projecting from hub 510 at approximately 120 degrees relative to each other. Filter element 190 has a total length of 178.3 cm as measured along the longitudinal axis, and tapers from a diameter of 109-110 cm to 41 cm with walls having a taper angle of 11 degrees relative to longitudinal axis 114.
The various examples disclosed herein include features that may be used individually or in any combination. Claimed subject matter is not limited to the combination of features disclosed by an individual example, since features that are present in two or more of the disclosed examples may be used together in other combinations. Accordingly, it should be understood that the disclosed examples are illustrative and not restrictive. Variations to the disclosed examples that fall within the metes and bounds of the claims or equivalence of such metes and bounds are intended to be embraced by the claims.