Method for Operating a Particulate Filter in a Vehicle, and Particulate Filter for an Internal Combustion Engine in a Vehicle

Abstract

A method operates a particulate filter through which exhaust gas can flow in a vehicle, in which ash is introduced into a filter body of the particulate filter, wherein at least one ash former or at least one ash component is arranged on at least one carrier material upstream of the filter body in the direction of flow of the exhaust gas.

Claims

1.-25. (canceled)

26. A method of operating a particulate filter of a vehicle, through which particulate filter exhaust gas can flow, the method comprising: arranging at least one ash former or at least one ash constituent part at least indirectly on at least one carrier material upstream of a filter body of the particulate filter in a flow direction of the exhaust gas; and introducing ash into the filter body of the particulate filter via the at least one ash former or the at least one ash constituent part.

27. The method according to claim 26, wherein a catalytically coated particulate filter is used as the particulate filter.

28. The method according to claim 26, wherein an organic material is used as the at least one carrier material.

29. The method according to claim 26, wherein an ash former or an ash constituent part is used as the at least one carrier material.

30. The method according to claim 29, wherein no further ash former or ash constituent part is used on, at or in the carrier material.

31. The method according to claim 29, wherein the carrier material is decomposed by way of the exhaust gas.

32. The method according to claim 26, wherein the carrier material is introduced in a positively locking, non-positive, adhesive, or loose manner in front of or on an end face of the particulate filter.

33. The method according to claim 26, wherein the at least one ash former or ash constituent part is connected in a positively locking, non-positive, or adhesive manner to the carrier material.

34. The method according to claim 26, wherein the at least one ash former or ash constituent part is arranged or enclosed loosely in the carrier material.

35. The method according to claim 26, wherein a spacing is produced by way of shaping of the carrier material or by way of spacer elements between the ash former or ash constituent part and the carrier material on one side, and the filter body on the other side.

36. The method according to claim 26, wherein at least one of the carrier material and the ash former or the ash constituent part has at least two layers or a shape which provides at least one cavity for introducing the ash former or the ash constituent part.

37. The method according to claim 26, wherein the ash former or the ash constituent part is printed onto the carrier material by way of at least one printed layer.

38. The method according claim 37, wherein a locally different distribution of the ash former or the ash constituent part on the carrier material is produced in the at least one printed layer.

39. The method according to claim 26, wherein the ash former or the ash constituent part is formed from at least two different materials, and a respective material, from which the ash former or the ash constituent part is formed, is applied in a locally different concentration onto, on, or in the carrier material.

40. The method according to claim 26, wherein the ash former, the ash constituent part, or the carrier material is pierced, needled or perforated.

41. The method according to claim 26, wherein metals, metal oxides or metal compounds are used as the ash former or the ash constituent part.

42. The method according to claim 26, wherein alkali metals, alkali metal oxides, alkali metal hydroxides, alkali metal carbonates or alkali metal compounds are used as the ash former or the ash constituent part.

43. The method according to claim 26, wherein alkali metals in compounds with silicon are used as the ash former or the ash constituent part.

44. The method according to claim 26, wherein alkaline earth metals, alkaline earth metal oxides, alkaline earth metal hydroxides, alkaline earth metal carbonates or alkaline earth metal compounds are used as the ash former or the ash constituent part.

45. The method according to claim 26, wherein magnesium, magnesium oxide, magnesium carbonate, magnesium hydroxide or magnesium compounds are used as the ash former or the ash constituent part.

46. The method according to claim 26, wherein calcium, calcium oxide, calcium carbonate, calcium hydroxide or calcium compounds are used as the ash former or the ash constituent part.

47. The method according to claim 26, wherein in manufacturing the vehicle equipped with the particulate filter, an internal combustion engine of the vehicle is operated such that conditions are set at least in a region of the ash former or the ash constituent part, which conditions are suitable for an input of ash into the filter body and/or for a decomposition of the carrier material.

48. The method according to claim 47, wherein a temperature and/or a mass flow of the exhaust gas of an internal combustion engine of the vehicle which is equipped with the particulate filter, which exhaust gas flows through the particulate filter, are set in such a way that the ash is deposited at least predominantly on at least one wall of the filter body.

49. The method according to claim 26, wherein the particulate filter is used for filtering particulates out of the exhaust gas of an internal combustion engine of the vehicle which is equipped with the particulate filter, which internal combustion engine is operated as a gasoline engine.

50. A particulate filter for an internal combustion engine of a vehicle, comprising: a filter body for filtering particulates, which filter body can be flowed through by exhaust gas of the internal combustion engine; and at least one ash former or at least one ash constituent part arranged at least indirectly on at least one carrier material upstream of the filter body in a flow direction of the exhaust gas.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] FIG. 1 shows a diagrammatic sectional view of a particulate filter according to the invention in accordance with a first embodiment for a vehicle, in particular for an internal combustion engine of a vehicle, a method according to the invention in accordance with a first embodiment being illustrated using FIG. 1.

[0045] FIG. 2 shows a diagrammatic sectional view of the particulate filter according to the invention in accordance with a second embodiment, the method according to the invention in accordance with a second embodiment being illustrated using FIG. 2.

[0046] FIG. 3 shows a diagrammatic sectional view of the particulate filter according to the invention in accordance with a third embodiment, the method according to the invention in accordance with a third embodiment being illustrated using FIG. 3.

[0047] FIG. 4 shows a diagrammatic sectional view of the particulate filter according to the invention in accordance with a fourth embodiment, the method according to the invention in accordance with a fourth embodiment being illustrated using FIG. 4.

[0048] FIG. 5 shows a diagrammatic sectional view of the particulate filter according to the invention in accordance with a fifth embodiment, the method according to the invention in accordance with a fifth embodiment being illustrated using FIG. 5.

[0049] FIG. 6 shows a diagrammatic perspective view of a carrier material of the particulate filter according to the invention in accordance with a sixth embodiment.

[0050] FIG. 7 shows a diagrammatic exploded view of a carrier material of the particulate filter according to the invention in accordance with a seventh embodiment.

[0051] FIG. 8 shows a diagrammatic perspective view of a carrier material of the particulate filter according to the invention in accordance with an eighth embodiment.

[0052] FIG. 9 shows a diagrammatic perspective view of a carrier material of the particulate filter according to the invention in accordance with a ninth embodiment.

[0053] FIG. 10 shows a diagrammatic illustration of the vehicle which is configured as a motor vehicle and is equipped with the particulate filter and an internal combustion engine.

[0054] In the figures, identical or functionally identical elements are provided with identical designations.

DETAILED DESCRIPTION OF THE DRAWINGS

[0055] FIG. 1 shows a diagrammatic sectional view of a particulate filter 1 in accordance with a first embodiment of a vehicle which is configured as a motor vehicle. In particular, the vehicle is configured as a car and preferably here as a passenger car. The vehicle is shown diagrammatically in FIG. 10 and is denoted by 15 there. The vehicle 15 is equipped with the particulate filter 1 and with an internal combustion engine 14 which is preferably configured as a gasoline engine or is operated as a gasoline engine. As an alternative, the internal combustion engine 14 can be a diesel engine or else another internal combustion engine. The internal combustion engine 14 has at least one or more combustion chambers which are configured, for example, as cylinders. During combustion operation of the internal combustion engine 14, the respective combustion chamber is supplied at least with air and fuel, in particular liquid fuel, with the result that a fuel/air mixture is produced in the respective combustion chamber. The fuel/air mixture is burned, which results in the exhaust gas of the internal combustion engine 14. This means that, during combustion operation, exhaust gas which is provided by the internal combustion engine 14 is produced in the internal combustion engine 14, in particular in the respective combustion chamber. Here, an exhaust gas section 16 is provided, by means of which the exhaust gas is discharged from the respective combustion chamber. Therefore, the exhaust gas section 16 can be flowed through by the exhaust gas, or the exhaust gas section 16 is flowed through by the exhaust gas during combustion operation. Here, the particulate filter 1 is arranged in the exhaust gas section 16 and can be flowed through by the exhaust gas. By means of the particulate filter 1, particulates which are possibly contained in the exhaust gas, in particular soot particulates, are filtered at least partially from the exhaust gas, by the particulates from the exhaust gas which flows through the particulate filter 1 being deposited onto the particulate filter 1, in particular in its interior. As the service life increases, a quantity of particulates deposited in the particulate filter 1 increases, this quantity of particulates also being called loading of the particulate filter 1. In order to at least reduce the loading of the particulate filter 1, the particulate filter 1 is subjected to a regeneration. This regeneration is also called a filter regeneration.

[0056] The particulate filter 1 comprises a housing 2, in which a filter body 3 is arranged, through which the exhaust gas can flow. The filter body 3 is, for example, a structural element which is configured separately from the housing 2, and is arranged in the housing 2 here. The filter body 3 has a multiplicity of ducts and/or throughflow openings (cannot be seen in greater detail in the figures) which are flowed through by the exhaust gas during combustion operation. A flow direction of the exhaust gas through the particulate filter 1 is illustrated in FIG. 1 by way of an arrow 6, the exhaust gas flowing along or in the flow direction through the particulate filter 1.

[0057] In order for it then to be possible for a particularly high filtration rate or filtration efficiency of the particulate filter 1 to be realized at a particularly early time, a method for operating the particulate filter 1 is carried out. In the case of the method, ash is introduced into the filter body 3 in a targeted manner. In order for it to be possible here for the ash to be introduced into the filter body in a particularly simple and therefore inexpensive way, at least one ash element 8 is arranged at least indirectly, in particular directly, on at least one carrier material 9 upstream of the filter body 3 in the flow direction of the exhaust gas. Here, the ash element 8 and the carrier element 9 are arranged in the housing 2 and in the process upstream of the filter body 3, at least the ash element 8, for example, being spaced apart from the filter body 3, in particular at least in the flow direction of the exhaust gas. Within the context of the abovementioned method, it is therefore provided that the at least one ash element 8 is arranged at least indirectly on the at least one carrier material 9 upstream of the filter body 3 in relation to the flow direction of the exhaust gas which flows through the particulate filter 1.

[0058] The at least one ash element 8 can be, for example, at least one ash former, from which the ash which is to be introduced into the filter body 3 is formed, in particular, in such a way that the ash former is burned by way of the exhaust gas, in particular by way of the temperature thereof. As a result, combustion residues are produced from the ash former, the combustion residues of the ash former being the ash. This ash is then introduced into the filter body 3, in particular by virtue of the fact that the exhaust gas entrains the combustion residues, that is to say the ash, and therefore transports them into the filter body 3. Furthermore, it is conceivable that the at least one ash element 8 is at least one ash constituent part. The ash constituent part is per se ash and therefore forms per se at least part of the ash which is to be introduced or is introduced into the filter body 3. In other words, the ash constituent part forms at least part of the ash, without the ash constituent part being burned. The ash element 8 and the carrier material 9 are in each case solid components. This means that the ash element 8 and the carrier material 9 have a solid physical state while they are positioned or arranged upstream of the filter body 3 in the flow direction of the exhaust gas which flows through the particulate filter 1. In the case of the first embodiment, the components, that is to say the ash element 8 and the carrier material 9, are connected to one another, for example, or are held on one another. In particular, it is conceivable that the ash element 8 is arranged on and/or in the carrier material 9, in particular in a cavity of the carrier material 9.

[0059] The ash element 8 and the carrier material 9 form, for example, a structural unit which is arranged, for example, overall in the solid physical state in the housing 2 and in the process upstream of the filter body 3. In the case of the first embodiment, the structural unit and therefore the ash element 8 and the carrier material 9 are arranged upstream on an inlet-side (in relation to the flow direction) end side 7 of the filter body 3, the structural unit being arranged or supported, in particular via the carrier material 9, for example at least indirectly, in particular directly, on the end side 7 of the filter body 3. The structural unit can be formed, for example, by way of a wad or by way of a plurality of wads, it being possible for the respective wad to be formed from metal paper. This means that the respective wad has, for example, paper as the carrier material 9 and metal as the ash element 8, in particular when the ash element 8 is configured as an ash former. The metal is therefore arranged on or at the paper and is balled with the latter and shaped to form the respective wad.

[0060] In the case of the first embodiment, the ash element 8 and the carrier material 9 are components which are configured separately from one another and are connected to one another, the ash element 8 being arranged and held in the process on the carrier material. In particular, the ash element 8 is arranged and held on the carrier material 9, in particular on a surface of the carrier material 9. The carrier material 9 is, for example, a material which is different than an ash former and an ash constituent part.

[0061] The structural unit and therefore the ash element 8 and the carrier material 9 can be arranged very simply in an inlet region 11 of the housing 2, the structural unit being arranged in the present case downstream of a section of the inlet region 11, which section widens in a funnel-shaped manner. In particular, the structural unit is arranged in a further section of the inlet region 11, it being possible, for example, for the further section to have the shape of a straight circular cylinder at least on the inner circumferential side. For example, in particular in a state in which the ash element 8 is arranged on the carrier material 9 and therefore forms the structural unit, the ash element 8 and the carrier material 9 can be introduced via a front-side access opening of the particulate filter 1 into the housing 2, in particular into the inlet region 11, in particular can be stuffed into the housing 2 or into the inlet region 11. Even if a plurality of structural units such as wads are arranged in the inlet region 11 for example, the filter body 3 can nevertheless be flowed around or through satisfactorily by exhaust gas. At least one aid can be attached to the structural unit, in particular to the ash element 8 and/or to the carrier material 9, which aid ensures advantageous adhering of the structural unit to the end side 7 of the filter body 3. This is the case, in particular, when the structural unit is of substantially flat configuration and bears substantially flatly against the end side 7.

[0062] Metals, metal oxides or metal compounds can be used as the ash element 8, in particular as the ash former or ash constituent part. In particular, the ash element 8 can comprise a slurry which can comprise metal and/or oxides, in particular metal oxides. A metal slurry of this type can be arranged with very low effort upstream of the filter body 3 and can be applied, for example, to the end side 7. Furthermore, it is conceivable to apply a metal suspension of the ash element 8 to the carrier material 9, which metal suspension can be formed, for example, on paper and/or plastic. For example, by way of setting of operation of the internal combustion engine 14, conditions can be set which bring it about that the ash which is provided by the ash element 8 is deposited at least predominantly in or onto the filter body 3, in particular on the walls of the filter body 3. This can be achieved by a suitable and sufficiently high temperature and a suitable mass flow of the exhaust gas being set in the particulate filter 1 and in the process at least in the region of the structural unit by way of corresponding operation of the internal combustion engine 14 which is arranged upstream of the particulate filter 1. For example, in the case of the throughflow of the filter body 3, the particulates which are contained in the exhaust gas are retained by means of the filter body 3.

[0063] The introduction of the ash into the filter body 3 is preferably carried out in the case of a first use of the internal combustion engine 14. In the case of this first use, the internal combustion engine 14 is operated in its combustion operation. By way of corresponding operation of the internal combustion engine 14, it is preferably ensured during production of the vehicle 15 that conditions which are suitable for an input of the ash into the filter body 3 prevail in the inlet region 11 and therefore at least in the region of the structural unit. As a result of the conditions, for example, the ash element 8 is released from the carrier material 9 and/or the ash element 8 is burned, in particular, when the ash element 8 is configured as an ash former, and/or the ash element 8 is decomposed or dispersed, as a result of which the ash can be distributed in a fine manner, for example. Furthermore, it is conceivable that the carrier material 9 is decomposed or dispersed by way of the conditions, in particular when a further ash former or at least one further ash constituent part is used as the carrier material 9. If, for example, the abovementioned further ash former is used as the carrier material 9, it can be provided that the further ash former is burned by way of the conditions, as a result of which the ash which is to be introduced into the filter body 3 is formed.

[0064] FIG. 2 shows a second embodiment. In the case of the second embodiment, the carrier material 9 which is solid, in particular, or is present in the solid physical state is configured as one or the ash element 8. Furthermore, it is conceivable that the ash element 8 is added to the carrier material 9.

[0065] FIG. 3 shows a third embodiment. In the case of the third embodiment, the ash element 8 and the carrier material 9 are configured as components which are configured separately from one another, the ash element 8 being received or enclosed in the carrier material 9, in particular over the full circumference. The ash element 8 can be configured or present, in particular, as granular material. The carrier material 9 which can be configured as a carrier forms at least one cavity 4, in which the ash element 8 is received, in particular completely. For example, at least one opening of the carrier material 9 is configured, for example, by way of heat, in particular of the exhaust gas, it being possible for the ash element 8 or the ash to flow, for example, via this opening out of the cavity 4 and to then pass into the particulate filter.

[0066] FIG. 4 shows a fourth embodiment. In the case of the fourth embodiment, the ash element 8 is held on the carrier material 9, it being possible for the ash element 8 and the carrier material 9 to be configured as components which are configured separately from one another and are connected to one another. Here, at least one or more spacer elements 10 is/are provided. The spacer element 10 is supported, for example, at least indirectly, in particular directly, on the filter body 3 and in the process on the end side 7 which is also called an end face. By means of the spacer element 10, the ash element 8 is spaced apart from the filter body 3, in particular from the end side 7, in particular at least in the flow direction of the exhaust gas. For example, via the spacer element 10, the carrier material 9 is supported at least indirectly, in particular directly, on the filter body 3, in particular on the end side 7. The end side 7 runs, for example, in a plane which extends at least substantially perpendicularly with respect to the flow direction of the exhaust gas. In the present case, for example, the respective spacer element 10 is formed by way of the carrier material 9. The ash element 8 is preferably spaced apart completely from the filter body 3, with the result that the ash element 8 does not make contact with the filter body 3. For example, the ash element 8 is configured in one piece. As an alternative or in addition, precisely one ash element is preferably provided in the form of the ash element 8.

[0067] FIG. 5 shows a fifth embodiment. The fifth embodiment is, for example, a combination of the first, third and fourth embodiment. The structural unit and/or the carrier material 9 and/or the ash element 8 can be connected, for example, in a positively locking and/or non-positive and/or integrally joined manner to the filter body 3, in particular to the end side 7.

[0068] FIG. 6 shows the carrier material 9 in accordance with a sixth embodiment, in the case of which the carrier material 9 can be one or the ash element 8, or else the ash element 8 is added to the carrier material 9. In the case of the sixth embodiment, connecting elements 5 are provided which are formed, for example, by way of the carrier material 9 and/or the ash element 8. By means of the connecting elements 5, the carrier material 9 or the ash element 8 is connected, for example, in a positively locking and/or non-positive manner to the filter body 3. Furthermore, the connecting elements 5 can serve as spacer elements for spacing the ash element 8 apart from the filter body 3, in particular from the end side 7.

[0069] The particulate filter 1, in particular the filter body 3, has, for example, a catalytically active coating. In particular, at least one part region of the filter body 3 is provided with the catalytically active coating. The catalytically active coating acts, for example, as an oxidation catalytic converter, with the result that the particulate filter 1 is configured as a catalytically active particulate filter.

[0070] FIG. 7 shows a seventh embodiment. Here, a carrier material 9 does not have an ash element, that is to say does not have an ash former or an ash constituent part. The carrier material 9 has, for example, a carrier and one or the ash element 8, the carrier material 9 with the ash element 8 and the carrier material 9 being configured as structural elements which are configured separately from one another and are connected to one another. To this end, the first connecting parts 12 are provided which are formed, for example, by way of the carrier material 9. Moreover, the second connecting parts 13 are provided which are formed, for example, by way of the carrier material 9, in particular its carrier, and/or by way of the ash element 8. By means of the connecting parts 12 and 13, the carrier material 9 and the carrier material 9 with the ash element 8 are connected to one another. This connection via the connecting parts 12 and 13 can be, for example, non-positive and/or positively locking and/or integrally joined. In particular, the connection of the connecting parts 12 and 13 can be adhesive.

[0071] FIG. 8 shows an eighth embodiment, in the case of which the carrier material 9 is one or the ash element 8, or else the ash element 8 is added to the carrier material 9.

[0072] Finally, FIG. 9 shows a ninth embodiment. Here, the carrier material 9 is free from an ash element, with the result that the carrier material 9 does not have an ash former or an ash constituent part. Here, the ash element 8 is arranged or held partially on the carrier material 9. A carrier material 9, however, is an ash element or comprises an ash element, the carrier materials 9 and 9 being connected to one another. Here, the ash element 8 is partially also arranged or held on the carrier material 9.

LIST OF DESIGNATIONS

[0073] 1 Particulate filter [0074] 2 Housing [0075] 3 Filter body [0076] 4 Cavity [0077] 5 Connecting element [0078] 6 Arrow [0079] 7 End side [0080] 8 Ash element [0081] 9, 9, 9 Carrier material [0082] 11 Inlet region [0083] 12 Connecting part [0084] 13 Connecting part [0085] 14 Internal combustion engine [0086] 15 Vehicle [0087] 16 Exhaust gas section