Exhaust gas heating element

Abstract

An exhaust gas heating unit for an exhaust system of an internal combustion engine includes a jacket heating conductor element (12) with a jacket (16) and with an electrical heating conductor (14). The electrical heating conductor (14) extends in the jacket (16) and is surrounded by insulating material (18). A heat transfer surface formation (20) is arranged on an outer side of the jacket (16) and is in heat transfer contact with same.

Claims

1. An exhaust system for an internal combustion engine, the exhaust system comprising: an exhaust gas flow duct for a flow of exhaust gas in an exhaust gas flow direction; and at least one exhaust gas heating unit arranged in the exhaust gas flow duct, the exhaust gas heating unit comprising: a jacket heating conductor element comprising a jacket, an electrical heating conductor extending in the jacket, and insulating material surrounding the electrical heating conductor; and a heat transfer surface formation arranged on an outer side of the jacket and in heat transfer contact with the jacket, wherein the heat transfer surface formation comprises a heat transfer element extending along the jacket heating conductor element such as to helically surround the jacket heating conductor element in at least some areas, the jacket heating conductor element having two ends for electrically connecting the jacket heating conductor element to a voltage source outside the exhaust gas flow duct, the jacket heating conductor element being arranged with a spiral form, wherein the jacket heating conductor element helically surrounded by the heat transfer element is arranged in a double-spiral winding configuration in a plane that is essentially at right angles to the exhaust gas flow direction, such that the two ends of the jacket heating conductor element are positioned in the same length area of the exhaust gas flow duct in the exhaust gas flow direction.

2. An exhaust system in accordance with claim 1, further comprising an exhaust gas treatment unit comprising a catalytic converter unit or a particle filter unit, wherein the exhaust gas heating unit is arranged in an exhaust gas flow direction in the exhaust gas flow duct upstream in relation to the exhaust gas treatment unit.

3. An exhaust system in accordance with claim 2, wherein a heat transfer surface of the heat transfer surface formation is formed with catalytically active material in at least some areas, wherein the catalytically active material and the catalytic converter unit are associated with the same type of catalytic converter.

4. An exhaust system in accordance with claim 1, wherein a hydrocarbon release device is associated with at least one exhaust gas heating unit for releasing hydrocarbon into the exhaust gas stream upstream in relation to the exhaust gas heating element.

5. An exhaust system in accordance with claim 1, wherein: the jacket is made of a metallic material; or the heat transfer surface formation is connected to the jacket with a pressing on or shrinking on frictional engagement; or the heat transfer surface formation is connected to the jacket by a connection in substance; or any combination of the jacket is made of a metallic material and the heat transfer surface formation is connected to the jacket with a pressing on or shrinking on frictional engagement and the heat transfer surface formation is connected to the jacket by a connection in substance.

6. An exhaust system in accordance with claim 1, wherein helical portions of the heat transfer element are arranged along the at least some areas of the jacket heating conductor element in a shape of a screw.

7. An exhaust system in accordance with claim 1, wherein the jacket heating conductor element is configured to extend linearly in at least some areas.

8. An exhaust system in accordance with claim 1, wherein a heat transfer surface of the heat transfer surface formation is formed with catalytically active material in at least some areas.

9. An exhaust system in accordance with claim 8, wherein: the heat transfer element of the heat transfer surface formation is coated with catalytically active material; the heat transfer element is made of aluminum material.

10. An exhaust system in accordance with claim 8, wherein the catalytically active material comprises: platinum; or palladium; or rhodium; or any combination of platinum and palladium and rhodium.

11. An exhaust system in accordance with claim 8, wherein the catalytically active material comprises: iron zeolite material; or copper zeolite material; or vanadium oxide material; or any combination of iron zeolite material and copper zeolite material and vanadium oxide material.

12. An exhaust system for an internal combustion engine, the exhaust system comprising: an exhaust gas flow duct for a flow of exhaust gas in an exhaust gas flow direction; and at least one exhaust gas heating unit arranged in the exhaust gas flow duct, the exhaust gas heating unit comprising: a jacket heating conductor element comprising a jacket, two electrical heating conductors extending in the jacket next to one another, and insulating material surrounding the electrical heating conductors; and a heat transfer surface formation arranged on an outer side of the jacket and in heat transfer contact with the jacket, wherein the heat transfer surface formation comprises a heat transfer element extending along the jacket heating conductor element such as to helically surround the jacket heating conductor element in at least some areas, the jacket heating conductor element having a first end for electrically connecting the two electrical heating conductors to a voltage source outside the exhaust gas flow duct, the jacket heating conductor element being arranged with a spiral form, wherein the jacket heating conductor element helically surrounded by the heat transfer element is arranged in a single-spiral winding configuration in a plane that is essentially at right angles to the exhaust gas flow direction, the jacket heating conductor element having a second end positioned in a central area of the single-spiral configuration, the two electrical heating conductors merging into one another at the second end of the jacket heating conductor element.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the drawings:

(2) FIG. 1 is a perspective view of a section of an exhaust gas heating unit comprising a high-temperature-resistant jacket heater;

(3) FIG. 2 is a side view of the exhaust gas heating unit according to FIG. 1;

(4) FIG. 3 is a schematic view of an exhaust system with an exhaust gas heating unit;

(5) FIG. 4 is a sectional view of an exhaust gas heating unit in an exhaust gas duct, viewed in the exhaust gas flow direction;

(6) FIG. 5 is a sectional view, corresponding to FIG. 4, of another alternative arrangement of the exhaust gas heating unit;

(7) FIG. 6 is a perspective view of another alternative arrangement of the exhaust gas heating unit;

(8) FIG. 7 is a sectional view, corresponding to FIG. 4, of an alternative arrangement of an exhaust gas heating unit;

(9) FIG. 8 is a perspective view of an alternative embodiment of an exhaust gas heating unit;

(10) FIG. 9 is a perspective cutaway view of a plurality of plate-shaped heat transfer elements of the exhaust gas heating unit according to FIG. 8;

(11) FIG. 10 is a perspective cutaway view, corresponding to FIG. 9, of heat transfer elements, each located opposite one another in pairs;

(12) FIG. 11 is a perspective cutaway view of a heat transfer element having an alternative configuration;

(13) FIG. 12 is a perspective view of a layering of plate-shaped heat transfer elements with spacing elements, having a wave-shaped structure, arranged between them;

(14) FIG. 13 is a perspective view of the heat transfer elements according to FIG. 12 in conjunction with a jacket heating conductor element;

(15) FIG. 14 is a detail view of a heat transfer element coated with catalytically active material;

(16) FIG. 15 is a schematic view of an exhaust system with an exhaust gas heating unit upstream in relation to a catalytic converter unit;

(17) FIG. 16 is a schematic view of an exhaust system with an exhaust gas heating unit arranged in an exhaust gas pipe upstream in relation to a catalytic converter unit; and

(18) FIG. 17 is a schematic view of an exhaust gas heating unit with a hydrocarbon release device associated with same.

DESCRIPTION OF PREFERRED EMBODIMENTS

(19) Referring to the drawings, FIGS. 1 and 2 show an exhaust gas heating unit 10 for an exhaust system of an internal combustion engine. The exhaust gas heating unit 10 comprises an especially high-temperature-resistant jacket heating conductor element 12 with a heating conductor 14 arranged in a core area of same. The heating conductor 14 may comprise one or more heating wires and is surrounded by an insulating material 18, for example, ceramic material, in an interior surrounded by a jacket 16.

(20) A heat transfer surface formation 20 is arranged on an outer surface 28 of the jacket 16, which is made of a metallic material, for example, a steel material. In the exemplary embodiment shown, the heat transfer surface formation 20 comprises a heat transfer element 22, which encloses the jacket heating conductor element 12 in a helical manner and is connected to the outer surface 28 thereof. The heat transfer element 22, which has a helical configuration, provides heat transfer surfaces 24, 26, around which exhaust gas can flow and at which the heat absorbed by the jacket 16 can be transferred to the exhaust gas, on both sides, which are oriented essentially in the direction of longitudinal extension of the jacket heating conductor element 12. Of course, a transfer of heat to the exhaust gas flowing around the jacket 16 also takes place in the area of the outer surface 28 of the jacket 16.

(21) The heat transfer element 22, which extends in a helical manner, is connected preferably by connection in substance, for example, by soldering or welding, to the outer surface 28 of the jacket 16. This may also be supported or, as an alternative, be provided by the heat transfer element 22 being pressed onto or shrunk onto the jacket 16.

(22) A very large overall area is provided for the heat transfer surface by a single component with the structure of the heat transfer element 22, which structure has a helical configuration. It should be pointed out that a similar configuration may also be achieved if a plurality of heat transfer elements, which have a ring-washer-like configuration, are arranged at the outer circumferential surface 28 of the jacket 16, for example, at an essentially uniformly spaced location to one another. A plurality of individual heat transfer elements, every one of which has to be fixed to the outer surface 28 of the jacket 16, are to be provided in this case, however.

(23) FIG. 3 shows in a schematic diagram the configuration of an exhaust system 30 for an internal combustion engine 32. The exhaust system 30 comprises an exhaust gas duct 36 in a one-part or multipart exhaust gas pipe 34. An exhaust gas heating unit 10, which may have, for example, the configuration described above with reference to FIGS. 1 and 2, is arranged upstream in relation to an exhaust gas treatment unit 38, for example, in relation to a catalytic converter unit 40. In the exemplary embodiment shown, the exhaust gas heating unit 10 or the jacket heating conductor element 12 thereof is arranged upstream of the exhaust gas treatment unit extending essentially elongated or linearly in the exhaust gas flow direction in the exhaust gas duct 36. At both longitudinal ends of the exhaust gas heating unit 10, this exhaust gas heating unit 10 is in contact with electrical lines 42, 44, via which the exhaust gas heating unit 10 is connected to the voltage source 46.

(24) The exhaust gas heating unit 10 can be energized by applying an electric voltage, especially in a start phase of the internal combustion engine 32, in which the exhaust system 30, especially also the catalytic converter unit 14, is cold and thus a catalytic reaction cannot be triggered therein, so that the jacket heating conductor element 12 and also the heat transfer surface formation 20 are heated. The exhaust gas coming into contact with the heat transfer surfaces 24, 26 or with the outer surface 28 absorbs heat and transports this heat to the catalytic converter unit 40, so that it is guaranteed that the catalytic converter unit 40 is heated faster and the temperature at which the catalytic reaction can start is thus reached more rapidly in case of a still comparatively low exhaust gas temperature or as a support for the thermal energy already being transported in the exhaust gases.

(25) FIGS. 4 through 7 show different arrangements in space of such an exhaust gas heating unit 10 in the exhaust gas duct 36. Thus, for example, FIG. 4 shows a configuration of the jacket heating conductor element 12 with the heat transfer surface formation 20 provided at the outer circumferential surface 28 thereof, which configuration is wound essentially in a plane that is at right angles to the exhaust gas flow direction A, especially wound like a double helix.

(26) The two ends 48, 50 of the jacket heating conductor element 12, which ends are exposed to the electrical contacting outside of the exhaust gas pipe, are in the same length area of the exhaust gas pipe 34 and can thus be connected electrically to the voltage source 46 in a simple manner.

(27) FIG. 5 shows a configuration, in which the jacket heating conductor element 12 is again wound in a single helix in a plane that is essentially at right angles to the exhaust gas flow direction A. The heating conductor 14, which is arranged in the jacket heating conductor element 12, has in this configuration two heating wires, which run next to one another and merge into one another at the end 50 of the jacket heating conductor element 12, which end 50 is positioned in the central area, so that both heating wires can be contacted at the end 48 of the jacket heating conductor element 12, which end 48 is outside of the exhaust gas pipe 34.

(28) FIG. 6 shows a configuration, in which the jacket heating conductor element 12 is arranged with two spiral-like winding configurations following one another. The two ends 48, 50 to be contacted electrically can thus be guided through the exhaust gas pipe 34, for example, at a spaced location in the exhaust gas flow direction A, which spaced location corresponds approximately also to the spaced location of the two spiral-like winding areas, each lying essentially in one plane.

(29) FIG. 7 shows a configuration, in which the exhaust gas heating unit 10 is arranged in an exhaust gas pipe 34 or in an exhaust-gas-carrying housing with a flattened, approximately rectangular cross section. The jacket heating conductor element 12 is wound in this case arranged in a meandering manner and has meandering sections 52 that run approximately parallel to one another, extend each essentially linearly and are connected by respective curved areas 54 of the jacket heating conductor element 12. The shape of the exhaust gas heating unit 10 can in this way be easily adapted to the circumferential contour of the exhaust gas pipe 34 or housing receiving this exhaust gas heating unit 10, and the fact that the heat transfer surface formation 20 is arranged at the outer surface 28 of the jacket heating conductor element 12 either in a helical manner or configured with a plurality of ring washers and can thus be easily adapted to the curved or bent configuration of the jacket heating conductor element 12 contributes to this as well.

(30) FIG. 8 shows an alternative embodiment of the exhaust gas heating unit 10, in which the jacket heating conductor element 12 is in contact with a plurality of plate-shaped heat transfer elements 56 of the heat transfer surface formation 20, which heat transfer elements 56 are arranged essentially parallel to one another. As suggested in FIG. 8, such an embodiment may also be easily adapted to many different circumferential contours of the exhaust gas pipe 34 or housing receiving the exhaust gas heating unit 10.

(31) For an efficient transfer of heat between the jacket heating conductor element 12 and the heat transfer elements 56, the jacket heating conductor element 12 is configured as wound in a meandering manner and has the meandering sections 52, which were already described with reference to FIG. 7, and curved areas 54 connecting these meandering sections 52. As illustrated in FIG. 9, jacket heating conductor element receptacles 58 are formed in the plate-shaped heat transfer elements 56 in association especially with the meandering sections 52. These receptacles 58 are open toward a heat transfer element circumferential edge area 60 and have an essentially semicircular configuration, which is adapted to a, for example, circular outer circumferential contour of the jacket 16. The jacket heating conductor element 12 can be fitted, for example, by press fit into these jacket heating conductor element receptacles 58 or/and can be connected to the individual heat transfer elements 56 by connection in substance, for example, by soldering or welding.

(32) To increase the stability of the exhaust gas heating unit 10 thus configured, the plate-shaped heat transfer elements 56 may be connected to one another and also to the exhaust gas pipe 34 receiving these heat transfer elements 56 or to a housing receiving these heat transfer elements 56 by holders, not shown in the figures.

(33) FIG. 10 shows a configuration, in which two such plate-shaped heat transfer elements 56 are each arranged located opposite one another and thus form a pair of heat transfer elements 62. In this case, the jacket heating conductor element receptacles 58, which are formed in the heat transfer elements 56 of a pair of heat transfer elements 62, are located opposite one another, so that the two heat transfer elements 56 of a respective pair of heat transfer elements 62 together essentially fully extend around the jacket 16 of the jacket heating conductor element 12 approximately in the same length area.

(34) The entire surface available for the transfer of heat is increased due to the paired association of the heat transfer elements 56 with one another. Since the heat transfer elements 56 of a respective pair of heat transfer elements 62 are essentially not offset to one another in the direction of longitudinal extension of the jacket heating conductor element 12, the flow resistance for the exhaust gas flowing around an exhaust gas heating element 10 configured in this manner is kept low. It should be pointed out that especially if a more intense swirling shall be generated in the exhaust gas stream, the heat transfer elements 56 of a respective pair of heat transfer elements 62 may also be arranged offset to one another in the direction of longitudinal extension of the heating conductor element 12 moved past these heat transfer elements 56.

(35) FIG. 11 shows a heat transfer element 56, in which respective jacket heating conductor element receptacles 58 are formed in heat transfer element circumferential edge areas 60, 64, which are located opposite one another. It thus becomes possible to arrange at least one jacket heating conductor element 12 each on both sides, for example, on a side oriented upstream and on a side oriented downstream of the heat transfer elements 56 and to connect it permanently to same.

(36) FIG. 12 shows a configuration, in which a spacing element 66 each, which is configured with a wave-shaped structure, is arranged between the heat transfer elements 56 that are arranged essentially parallel to one another. A stable overall structure is obtained, in which the spacing elements 66 can be connected, for example, by soldering or welding or bonding at wave crest areas 68 to the heat transfer elements 56 arranged adjacent thereto. These spacing elements 66, which are preferably made of a metallic material as well, enlarge the overall surface provided for the transfer of heat and essentially fully cover the heat transfer elements 56 each arranged on both sides thereof. To provide a configuration that can be embodied in a simple manner, a respective spacing element 66 can be restored from the corresponding circumferential edge areas of the adjacent heat transfer elements 56 where jacket heating conductor element receptacles 58 are provided in the heat transfer elements.

(37) The spacing elements 66 may be configured such that exhaust gas can flow through them in order to avoid the formation of flow shadow areas or areas that are difficult to flow over. For example, these spacing elements 66 may be made of wire mesh or perforated sheet metal or expanded metal and thus have a plurality of openings, which make it possible for exhaust gas to pass through.

(38) Such a connected structure of the heat transfer surface elements 56 may also be supported at an exhaust gas pipe or at a housing carrying these heat transfer surface elements 56 by means of a holding element, not shown, so that vibrations also occurring during the vehicle operation cannot lead to the development of a change in position of an exhaust gas heating unit thus configured in an exhaust gas pipe or in a housing.

(39) FIG. 14 shows a detail of a heat transfer element 70, which has a plate-shaped configuration, for example, which is coated with catalytically active material 72 in at least some areas on its outer surface, around which exhaust gas can flow. For a stable bonding of such catalytically active material, it is advantageous for such a heat transfer element 70 to be made of aluminum or an aluminum alloy with a high aluminum content. During the application of such catalytically active material 72, the metallic surface with a large inner surface is at first usually coated with a porous, ceramic oxide coating, which is called washcoat. The catalytically active material is then applied to this coating, for example, in a so-called impregnation process.

(40) By applying catalytically active material 72 to one or more heat transfer elements 70, it becomes possible to bring the heat transfer elements 70 or the catalytically active coating 72 very rapidly to a temperature, at which the catalytic reaction can take place during the flowing around of the exhaust gas, by energizing one or more jacket heating conductor elements connected therewith. This makes it possible to provide a catalytic action in the exhaust system even in the start phase of an internal combustion engine almost without any time delay and thus also to markedly lower the emission of harmful substances immediately after starting an internal combustion engine.

(41) Such a coating with catalytically active material may be provided regardless of the configuration of the heat transfer surface formation. In particular, one or more of the heat transfer elements may be coated on at least one side, but preferably fully with catalytically active material in case of each of the configurations shown in FIGS. 1-13.

(42) The catalytically active material 72 is selected as a function of which type the catalytic converter action provided shall be. If, for example, the exhaust gas heating unit 10 shall be active as a three-way catalytic converter, the catalytically active material may contain platinum, palladium, rhodium or mixtures thereof. The temperature resistance of structural promoters improving the catalytically active material 72 may also be provided in this coating. If the action of a diesel oxidation catalytic converter shall be achieved, it is advantageous to use platinum and palladium as the principal components of the catalytically active material 72. Mixed oxides may also be used. If the action of an SCR catalytic converter shall be achieved, it is advantageous for the catalytically active material to be made of iron zeolite material, copper zeolite material or vanadium oxide material, e.g., vanadium pentoxide.

(43) This catalytic effect can be used in an especially efficient manner if, as is illustrated in FIG. 15, such an exhaust gas heating unit 10 made of catalytically active material is arranged, for example, in a catalytic converter housing 74 upstream in relation to the catalytic converter unit 40 arranged therein. It should be pointed out that in typical construction the catalytic converter unit 40 may have a monolith 76, which is made, for example, of catalytically active material or is coated with same, which monolith 76 can be held in the catalytic converter housing 74 by a fiber mat 78 surrounding this catalytic converter unit 40.

(44) Provisions are preferably made in case of such a configuration for the catalytically active material 72 provided on the exhaust gas heating unit 10 and the catalytic converter unit 40 to provide the same type of a catalytic reaction. Thus, in a start phase, i.e., immediately after starting the internal combustion engine 32, which is illustrated, for example, in FIG. 3, by electrical energization, the exhaust gas heating unit 10 with the catalytically active material 72 provided on it can very rapidly be brought to the temperature necessary for carrying out the catalytic reaction and thus be active as catalytic converter, even before the catalytic converter unit 40 has reached the temperature needed for this. The catalytic converter unit 40 is heated, on the one hand, by the exhaust gas emitted from the internal combustion engine 32 also in the start phase and by the exhaust gas flowing around the exhaust gas heating unit 10, on the other hand, and is thus likewise rapidly brought to a sufficiently high temperature in order to carry out the catalytic reaction in this exhaust gas heating unit 10 as well. If this temperature is reached, the energization of the jacket heating conductor element 12 of the exhaust gas heating unit 10 can be ended. This can be either recognized by providing a temperature signal, or a defined time can be provided, throughout which the exhaust gas heating unit 10 is energized in the start phase of the internal combustion engine 32.

(45) FIG. 16 shows an embodiment, in which the exhaust gas heating unit 10 is not accommodated in the catalytic converter housing 74 upstream in relation to the catalytic converter unit 40, but rather in the exhaust gas pipe 34 adjoining the upstream end thereof. Such an arrangement may be advantageous, for example, if the exhaust gas heating unit 10 shall have the elongated configuration shown in FIGS. 1 and 2.

(46) FIG. 17 shows an exhaust system 30, in which a hydrocarbon release device 80 is provided in association with the exhaust gas heating unit 10 that is likewise made, for example, of catalytically active material 72. Like an injector, this hydrocarbon release device 80 may inject hydrocarbon into the exhaust gas stream, i.e., for example, the fuel also used for operation of the internal combustion engine 32, in the direction towards the exhaust gas heating unit 10. The hydrocarbon reacts on the hot surface of the exhaust gas heating unit 10, so that the reaction of the hydrocarbon releases reaction heat, which can additionally be transferred to the exhaust gas flowing in the direction of the catalytic converter unit 40, which then follows downstream. Such an embodiment is especially advantageous if the catalytic converter unit 40 is configured as an SCR catalytic converter, at which a selective catalytic reduction is carried out by reaction of the reducing agent, i.e., for example, a urea-water solution, injected by a reducing agent release device, not shown. A particle filter used as an exhaust gas treatment unit 38 may also be regenerated by the injection of hydrocarbon independently of the operation of the internal combustion engine 12.

(47) In another embodiment, hydrocarbon transported in the exhaust gas stream may also be provided by this hydrocarbon being emitted from the internal combustion engine 32 deliberately. For this purpose, it can be ensured, for example, by corresponding setting of the ignition angle or by late fuel injection, that only a part of the fuel ignites during the combustion taking place in the internal combustion engine 32, while a part of the fuel is emitted unburned and is available for reaction at the exhaust gas heating unit 10 or/and at the exhaust gas treatment unit 38.

(48) While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.