U.S. patent application number 11/284074 was filed with the patent office on 2007-05-24 for exhaust treatment device with condensate gate.
Invention is credited to David M. Thaler.
Application Number | 20070113547 11/284074 |
Document ID | / |
Family ID | 37561802 |
Filed Date | 2007-05-24 |
United States Patent
Application |
20070113547 |
Kind Code |
A1 |
Thaler; David M. |
May 24, 2007 |
Exhaust treatment device with condensate gate
Abstract
A method and apparatus for treating fluid are provided. The
fluid treatment device may include a housing having a fluid
treatment element therein. The device may further include at least
one of (i) an inlet channel coupled to the housing and configured
to direct fluid toward the fluid treatment element and (ii) an
outlet channel coupled to the housing and configured to direct
fluid away from the fluid treatment element. The at least one of
the inlet channel and the outlet channel may include a shell member
having an inner diameter and defining a fluid passage. The at least
one of the inlet channel and the outlet channel may further include
a gate member coupled to and arranged at least partially within the
shell member and extending longitudinally from a first gate member
portion having a diameter less than the inner diameter of the shell
member to a second gate member portion having a diameter greater
than the inner diameter of the shell member.
Inventors: |
Thaler; David M.;
(Mossville, IL) |
Correspondence
Address: |
CATERPILLAR INC.;100 N.E. ADAMS STREET
PATENT DEPT.
PEORIA
IL
616296490
US
|
Family ID: |
37561802 |
Appl. No.: |
11/284074 |
Filed: |
November 21, 2005 |
Current U.S.
Class: |
60/309 ;
60/310 |
Current CPC
Class: |
F01N 3/005 20130101;
Y02T 10/12 20130101 |
Class at
Publication: |
060/309 ;
060/310 |
International
Class: |
F01N 3/02 20060101
F01N003/02; F01N 3/04 20060101 F01N003/04; F01N 7/12 20060101
F01N007/12 |
Claims
1. An apparatus for treating fluid, comprising: a housing having a
fluid treatment element therein; at least one of (i) an inlet
channel coupled to the housing and configured to direct fluid
toward the fluid treatment element and (ii) an outlet channel
coupled to the housing and configured to direct fluid away from the
fluid treatment element; wherein at least one of the inlet channel
and the outlet channel includes: a shell member having an inner
diameter and defining a fluid passage; a gate member coupled to and
arranged at least partially within the shell member and extending
longitudinally from a first gate member portion having a diameter
less than the inner diameter of the shell member to a second gate
member portion having a diameter greater than the inner diameter of
the shell member.
2. The apparatus of claim 1, wherein at least a portion of the gate
member has a frustoconical form.
3. The apparatus of claim 2, wherein the frustoconical form of the
gate member extends from the first gate member portion to the
second gate member portion.
4. The apparatus of claim 1, wherein: the gate member extends from
the first gate member portion toward and into engagement with the
shell member; and a fluid volume is defined within the shell member
between the gate member and an internal wall of the shell
member.
5. The apparatus of claim 4, wherein: the gate member extends from
the first gate member portion toward and into sealing engagement
with shell member.
6. The apparatus of claim 5, wherein the gate member is welded to
the shell member.
7. The apparatus of claim 6, wherein the gate member is welded to
the shell member about an entire circumference of the gate
member.
8. The apparatus of claim 1, wherein: the shell member is a first
shell member; and the apparatus includes a second shell member
arranged at least partially about the first shell member.
9. The apparatus of claim 8, including insulating material arranged
between the first and second shell members.
10. The apparatus of claim 8, wherein the gate member is coupled to
the second shell member.
11. The apparatus of claim 8, wherein the gate member is coupled to
the first shell member and the second shell member.
12. The apparatus of claim 8, wherein: the first gate member
portion is arranged at least partially within the first shell
member; and the second gate member portion is arranged outside of
the first shell member.
13. The apparatus of claim 12, wherein the second gate member
portion is arranged inside the second shell member.
14. The apparatus of claim 12, wherein a frustoconical portion of
the gate member extends from the first gate member portion to the
second gate member portion.
15. The apparatus of claim 8, wherein a frustoconical portion of
the gate member engages the first shell member and the second shell
member.
16. The apparatus of claim 8, wherein a frustoconical portion of
the gate member extends from within the first shell member into
engagement with the second shell member.
17. The apparatus of claim 1, wherein: the gate member extends from
outside of the shell member into an opening in the shell member and
extends into the shell member a first distance from the opening;
and the shell member has an aperture therein configured for
permitting fluid egress from the shell member, the aperture being
arranged within the shell member within a second distance from the
opening, the second distance being less than or equal to the first
distance.
18. The apparatus of claim 1, wherein the fluid treatment element
is an exhaust treatment element for treating exhaust gas from an
engine.
19. The method of claim 18, wherein the exhaust treatment element
is a particulate filter.
20. The apparatus of claim 1, wherein the gate member is configured
for at least inhibiting a flow of condensed fluid within the
apparatus toward the fluid treatment device.
21. A method of assembling a fluid treatment apparatus, the method
comprising: inserting a gate member at least partially into a fluid
passage of a shell member having an inner diameter so that (i) a
first portion of the gate member having a diameter less than the
inner diameter of the shell member is arranged within the shell
member and (ii) a second portion of the gate member having a
diameter greater than the inner diameter of the shell member is
arranged outside the shell member; and coupling the shell member to
a housing having a fluid treatment element therein so that the
shell member is configured to direct a flow of fluid toward or away
from the fluid treatment element.
22. The method of claim 21, including coupling the gate member to
the shell member.
23. The method of claim 21, wherein: the shell member is a first
shell member; and the method includes arranging a second shell
member at least partially around the first shell member and at
least partially around the gate member.
24. The method of claim 23, including coupling the second portion
of the gate member to the second shell member.
25. The method of claim 24, including welding the gate member to at
least one of the first shell member and the second shell
member.
26. The method of claim 25, wherein the step of welding the gate
member to at least one of the first shell member and the second
shell member includes welding the gate member about an entire
circumference of the gate member.
27. The method of claim 23, wherein the step of arranging a second
shell member at least partially around the gate member includes
arranging the second shell member so that a frustoconical portion
of the gate member extending from within the first shell member to
a position outside of the first shell member extends within the
second shell member.
28. A method of assembling a fluid treatment apparatus, the method
comprising: arranging an annular gate member, having a generally
frustoconical portion, at least partially within a fluid passage of
a shell member; then coupling the shell member to a housing having
a fluid treatment element therein so that the shell member is
configured to direct a flow of fluid toward or away from the fluid
treatment element.
30. The method of claim 28, wherein the step of arranging an
annular gate member at least partially within a fluid passage of a
shell member includes coupling the gate member to the shell
member.
31. The method of claim 28, wherein: the shell member is a first
shell member; and the method includes arranging a second shell
member at least partially around the first shell member and at
least partially around the gate member.
32. The method of claim 31, including coupling the gate member to
the second shell member.
Description
TECHNICAL FIELD
[0001] This disclosure relates generally to a method and apparatus
for treating gases and, more particularly, to a method and
apparatus for treating exhaust gases from an engine.
BACKGROUND
[0002] A diesel particulate filter (DPF) is a fluid treatment
device that is commonly arranged within an exhaust gas stream of an
internal combustion engine to trap particulates present in the
exhaust gas. A DPF may include a cylindrical metal housing wrapped
around a cylindrical ceramic filter element. A resilient mat may be
compressed between the outer wall of the filter element and the
inner wall of the metal housing. Because the mat is resilient and
is compressed around the filter element by the housing wall, the
mat may help secure the filter element within the housing while
reducing vibratory effects between the housing and the filter.
[0003] A mat's effectiveness in securing a filter element within a
housing may partly depend on the mat's ability to exert pressure on
the filter element. The mat's exertion capacity may be decreased if
the mat deteriorates or if the mat is exposed to undesirable
conditions for a period of time. For example, if a mat is exposed
to excessive moisture for a prolonged period, the mat's capacity to
exert a holding pressure on a filter may be temporarily or
permanently relaxed. Thus, it may be helpful to prevent a mat's
overexposure to moisture within a DPF.
[0004] During operation of an internal combustion engine attached
to a DPF, hot exhaust gases from the engine cause components within
the DPF to heat up. When the engine is shut down, the DPF
components cool, and condensation may occur on surfaces of the DPF
components. This condensation, if allowed to pool around a mat, may
adversely affect the mat's characteristics, as referenced
above.
[0005] Various devices have been proposed for reducing a mat's
exposure to moisture within a DPF. For example, in one such device,
a cylindrical particulate filter is wrapped with a mat, and a sheet
of metal is wrapped around the filter and mat to form a cylindrical
metal housing. The cylindrical housing has a first outer diameter
along most of its length. A longitudinal end of the cylindrical
housing has a slightly decreased outer diameter with respect to the
first outer diameter. The cylindrical housing is then tightly
wrapped with a second, relatively longer piece of metal to form a
second, longer cylindrical housing. A condensate catch volume is
defined inside the second housing between the inner wall of the
second housing and the outer wall of the first housing at the
region of the first housing having a slightly decreased diameter.
The DPF is then arranged in a vertical orientation so that the
condensate catch volume faces upward. During operation, exhaust gas
from an internal combustion engine is directed into a lower
longitudinal end of the DPF and is exhausted from an upper
longitudinal end of the DPF. When the engine is shut down,
components within the DPF cool, and condensation is formed on the
interior wall of the second housing. When the condensation drips
down this wall, it is directed toward and held within the
condensate catch volume rather than directly into the first housing
(where the mat is arranged).
[0006] Exhaust treatment devices may be improved, for example by
providing alternative, robust devices and methods for preventing or
reducing moisture exposure within the devices.
[0007] The present invention is directed to overcome or improve one
or more disadvantages associated with prior apparatus and methods
for treating gases.
SUMMARY OF THE INVENTION
[0008] In one aspect of the present invention, a fluid treatment
device is disclosed. The fluid treatment device may include a
housing having a fluid treatment element therein. The device may
further include at least one of (i) an inlet channel coupled to the
housing and configured to direct fluid toward the fluid treatment
element and (ii) an outlet channel coupled to the housing and
configured to direct fluid away from the fluid treatment element.
The at least one of the inlet channel and the outlet channel may
include a shell member having an inner diameter and defining a
fluid passage. The at least one of the inlet channel and the outlet
channel may further include a gate member coupled to and arranged
at least partially within the shell member and extending
longitudinally from a first gate member portion having a diameter
less than the inner diameter of the shell member to a second gate
member portion having a diameter greater than the inner diameter of
the shell member.
[0009] In another aspect of the present invention, a method of
assembling a fluid treatment apparatus is disclosed. The method may
include inserting a gate member at least partially into a fluid
passage of a shell member having an inner diameter so that (i) a
first portion of the gate member having a diameter less than the
inner diameter of the shell member is arranged within the shell
member and (ii) a second portion of the gate member having a
diameter greater than the inner diameter of the shell member is
arranged outside the shell member. The method may further include
coupling the shell member to a housing having a fluid treatment
element therein so that the shell member is configured to direct a
flow of fluid toward or away from the fluid treatment element.
[0010] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory only and are not restrictive of the invention, as
claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate exemplary
embodiments or features of the invention and, together with the
description, serve to explain principles of the invention. In the
drawings,
[0012] FIG. 1 is a front cross-sectional view of a fluid treatment
device;
[0013] FIG. 2 is a partial front cross-sectional view of the fluid
treatment device of FIG. 1; and
[0014] FIG. 3 is a partial front cross-sectional view of the fluid
treatment device of FIG. 1.
[0015] Although the drawings depict exemplary embodiments or
features of the present invention, the drawings are not necessarily
to scale, and certain features may be exaggerated in order to
better illustrate and explain the present invention. The
exemplifications set out herein illustrate exemplary embodiments or
features of the invention and such exemplifications are not to be
construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION
[0016] Reference will now be made in detail to embodiments or
features of the invention, examples of which are illustrated in the
accompanying drawings. Generally, the same or corresponding
reference numbers will be used throughout the drawings to refer to
the same or corresponding parts.
[0017] Referring now to FIG. 1, a fluid treatment device 10 for
treating fluid is shown. More particularly, FIG. 1 shows a diesel
particular filter (DPF) 10 for treating exhaust gas from an engine.
It should be appreciated that while a DPF is shown in the drawings
and described herein for explanatory purposes, other types of fluid
treatment devices 10 may be used in accordance with this
disclosure. For example, various devices having fluid treatment
elements, such as substrates, may be used.
[0018] The DPF 10 may include an element housing 14, a fluid
treatment element 18 arranged within the housing 14, a mat 22
arranged between the housing 14 and the fluid treatment element 18,
and inlet and outlet channels, such as inlet and outlet portions
34, 42, configured to permit fluid flow toward and away from the
fluid treatment element 18, respectively.
[0019] The housing 14 may form a metallic shell for the DPF 10 for
receiving a stream of engine exhaust gas from an exhaust pipe 38
via the exhaust inlet portion 34. The gas is directed from the
inlet portion 34 through the fluid treatment element 18, and out of
the DPF 10 via the exhaust outlet portion 42.
[0020] The housing 14 may be formed into a generally cylindrical
shape and may be made from a suitable metallic material, such as
steel, for handling hot exhaust gases.
[0021] The fluid treatment element 18 may be an exhaust treatment
element 18, such as a cylindrical ceramic substrate for treating
exhaust gas from an engine. For example, as discussed earlier, a
ceramic substrate 18 may be used to remove particulates from a
stream of engine exhaust gas.
[0022] A mat 22 may be arranged between the housing 14 and the
fluid treatment element 18. For example, the mat 22 may be formed
from a resilient material and may be compressed to a predetermined
amount between an inner surface of the housing 14 and an outer
surface of the fluid treatment element 18. The mat 22 may take the
form of a single piece of material covering a substantial portion
of the outer surface of the fluid treatment 18 (as shown in FIG.
1). However, it should be appreciated that, alternatively, the mat
may take other forms, such as one or more relatively smaller strips
of material, each covering a relatively small portion of the outer
surface of the fluid treatment element 18. The mat 22 may be formed
from an intumescent material, a non-intumescent material, or a
combination material having intumescent and non-intumescent
properties, and may also function as a heat and/or vibration
insulator between the fluid treatment element 18 and the housing
14. In one embodiment, the mat 22 may be formed at least in part
from alumina-silicate cloth.
[0023] Referring now to FIG. 2, the inlet portion 34 may form a
fluid passage 46. The inlet portion 34 may include first and second
shell members 54, 58, and insulating material 62 arranged between
the first and second shell members 54, 58.
[0024] In one embodiment, the first shell member 54 may be formed
from a sheet of metal arranged to form a generally cylindrical
cavity 59 having an inner diameter D1. An additional piece of
material 60 (e.g., steel) may be sealingly attached to one end of
the shell member 54. An opening 60a may be formed in the piece of
material 60 to permit insertion of the exhaust pipe 38 into the
cavity 59.
[0025] The second shell member 58 may similarly be formed from a
sheet of metal arranged to form a generally cylindrical cavity 63
having an inner diameter D2. The second shell member 58 may be
arranged around the first shell member such that an internal cavity
66 is formed between the first and second shell members 54, 58. An
additional piece of material 65 (e.g., steel) may be sealingly
attached to one end of the second shell member 58. An opening 65a
may be formed in the piece of material 65 to permit insertion of
the exhaust pipe 38 into the cavity 59. As referenced above,
insulating material 62 may be held within the cavity 66 and within
a cavity 67 formed between the two pieces of material 60, 65.
Spacing elements 69, such as clips 69, may be arranged between the
first and second shell members 54, 58 and between the pieces of
material 60, 65 to maintained desired spaced relationships
therebetween.
[0026] A gate member 50 may be configured at least partially within
the fluid passage 46 of the inlet portion 34 for at least
inhibiting flow of condensed fluid within the fluid treatment
device 10. In the embodiment of FIGS. 1 and 2, the gate member 50
is a generally frustoconical member arranged partially within the
first shell member 54. The gate member 50 extends longitudinally
from a first gate member portion 50a having an outer diameter D3
less than the inner diameter D1 of the first shell member 54 to a
second gate member portion 50b with an outer diameter D4 greater
than the inner diameter D1 of the first shell member 54. The first
gate member portion 50a is arranged within the fluid passage 46 of
the first shell member 54, while the second gate member portion 50b
is arranged outside the fluid passage 46 of the first shell member
54 and inside the second shell member 58.
[0027] The gate member 50 may extend from the first gate member
portion 50a into sealing engagement with the first shell member 54,
for example at an exterior surface location 70 on gate member 50
between the first and second gate member portions 50a, 50b. In one
embodiment, the gate member 50 is welded to the first shell member
54 at location 70 (FIG. 2) about all or substantially all of the
circumference of gate member 50. Thus, a fluid volume 74 may be
defined within the first shell member 54 between an outer surface
of the gate member 50 and an inner surface of the first shell
member 54. It should be appreciated that the gate member 50 may
alternatively be welded to the first shell member 54 at various
locations about the circumference of the gate member 50.
[0028] The gate member 50 may also be coupled to the second shell
member 58. For example, the gate member 50 and the second shell
member 58 may be welded together, for example at or proximate an
end location 78 (FIG. 2) of gate member 50, either about all or
substantially all of the entire circumference of the gate member 50
or at various locations thereon.
[0029] In the embodiment of FIG. 2, the gate member 50 extends from
outside of the first shell member 54 into an opening 82 of the
first shell member 54 and extends into the first shell member 54 a
distance D5 from the opening 82.
[0030] The gate member 50 may be configured to extend into the
fluid passage 46 a predetermined radial distance D7 away from the
first shell member 54. For example, the outer diameter D4 of the
gate member portion 50a may be smaller than the inner diameter D1
of the first shell member 54 by a value of twice the distance
D7.
[0031] As illustrated in FIG. 3, the outlet portion 38 may be
configured generally the same as the inlet portion 34.
[0032] The first and second shell members 54', 58' of the outlet
portion 38 may each have an aperture 86' therein configured for
permitting fluid (e.g., condensation) egress from within the first
shell member 54' and the outlet portion 38. A tube 90' may be
inserted through the apertures 86' for transmitting the fluid out
of the outlet portion 38. In the embodiment of FIG. 3, the aperture
86' in the first shell member 54' is arranged within the first
shell member 54' at least partially within a distance D6' from the
opening 82'. The distance D6' may, in one embodiment, be less than
or equal to the distance D5' so that if the fluid treatment device
10 is arranged in a vertical orientation and the outlet portion 38
is arranged atop the housing 14, if condensate becomes held within
the fluid volume 74', the condensate may drain from the outlet
section 38 via the tube 90'.
INDUSTRIAL APPLICABILITY
[0033] In an assembly operation, the fluid treatment element 18 may
be wrapped with the mat 22 and the housing 14. The fluid inlet
portion 34 for carrying fluid toward the fluid treatment element 18
and the fluid outlet portion 38 for carrying fluid away from the
fluid treatment element 18 may each be assembled by inserting the
frustoconical gate member 50 partially into the fluid passage 46
formed by the first shell member 54. The first gate member portion
50a may be arranged within the first shell member 54, and the
second gate member portion 50b may be arranged outside the first
shell member 54.
[0034] The gate member 50 may then be coupled to the first shell
member 54, for example via a welding process as referenced above.
The welding process may form a weld around the outer surface of
gate member 50 and the end, or an outer surface of, the first shell
member 54.
[0035] After insulating material 62 and clips 69 are placed around
the outer surface of the first shell member 54, the second shell
member 58 may be arranged about the first shell member 54 and the
gate member 50. The gate member 50 then may be coupled to the
second shell member 58, for example via a welding process as
referenced above. The welding process may form a weld around the
end of, or around an inner surface of, gate member 50 and the end
of, or an inner surface of, second shell member 58. As shown in
FIG. 2, the second shell member 58 may be arranged about the first
shell member 54 and the gate member 50 such that a frustoconical
portion of the gate member 50 extending from within the first shell
member 54 to a position outside of the first shell member 54
extends within the second shell member 58. As shown in FIG. 2, the
second shell member 58 may extend beyond the longitudinal end of
gate member portion 50b, for example a predetermined distance D8.
This extension of the second shell member 58 beyond the edge of
gate member portion 50b may facilitate a welding process during
which the gate member 50 is coupled to the second shell member 58.
It should be appreciated that the distance D8 may be minimized or
reduced to substantially zero in order to place the filter-side end
of the gate member 50 as close as possible to the joint between the
inlet/outlet portion 34/38 and the housing 14, filter 18, and mat
22 to better protect the mat 22 from condensate formed on most
surface area in the inlet/outlet portion 34/38.
[0036] The inlet and outlet portions 34, 38 of the device 10 may be
coupled to the housing 14, for example via a clamping operation
during which each of the inlet and outlet portions 34, 38 is placed
adjacent the housing 14 and a clamping element 94 is arranged about
each of the portions 34, 38 to hold each of the portions 34, 38
together with the housing 14. In the embodiment of FIG. 1, portions
34, 38 and housing 14 each contain mating flanges 98, 102, around
which a clamping element 94 may be arranged. It should be
appreciated that one or more seals or gaskets may be arranged
between the clamped components for sealing the junctions
therebetween.
[0037] It should further be appreciated that the inlet and outlet
portions 34, 38 may be arranged so that a larger diameter portion
50b of the gate member 50 may be arranged toward the filter element
18, while a smaller diameter portion 50a of the gate member 50 may
be arranged relatively away from the filter element 18.
[0038] During operation of the fluid treatment device 10, hot
engine exhaust may be transmitted through the device 10 (for
example via exhaust pipes 38, 38'), and the components thereof may
be heated. When the engine is shut off, the components of the
device 10 may cool, and condensate may form on them. The gate
member 50 may operate to prevent or at least inhibit the condensate
50 from flowing toward the mat 18 within the housing 14. For
example, if the device 10 is arranged in a horizontal configuration
(as shown in FIGS. 1-3), condensate may gather in the fluid volume
74 and may pool between the gate member 50 and the piece of
material 60 at the rear of the cavity 59, rather than flowing from
the inlet portion 54 into the housing 14 and toward the mat 22.
[0039] If the device 10 is arranged in a vertical configuration,
condensate may still flow into and gather in the fluid volume 74,
74' rather than flowing from the inlet or outlet portion 54, 58
(whichever is placed atop the filter element 18) into the housing
14 and toward the mat 22.
[0040] It should be appreciated that the orientation and form of
the gate members 50 may facilitate holding condensate away from the
filter element 18 and mat 22 during start up of an engine until the
system heats up enough to evaporate the condensate. Moreover, the
forms (e.g., the frustoconical aspects thereof) of the gate members
50 disclosed herein may facilitate relatively smooth exhaust flow
transitions into and out of the filter element housing 14 during
operation of the device 10.
[0041] It should further be appreciated that since a gate member 50
may be attached to an inlet portion 34 or an outlet portion 38,
each of which may be detachable from the element housing 14, each
gate member 50 may be detached from the main housing 14 and
adjusted, replaced, or maintained without having to work directly
on the fluid treatment housing 14.
[0042] From the foregoing it will be appreciated that, although
specific embodiments of the invention have been described herein
for purposes of illustration, various modifications may be made
without deviating from the spirit or scope of the invention. Other
embodiments of the invention will be apparent to those skilled in
the art from consideration of the specification and figures and
practice of the invention disclosed herein. It is intended that the
specification and disclosed examples be considered as exemplary
only, with a true scope and spirit of the invention being indicated
by the following claims and their equivalents. Accordingly, the
invention is not limited except as by the appended claims.
* * * * *