EXHAUST FLUID TANK PROVIDED WITH AN EXHAUST SYSTEM

Abstract

A exhaust fluid tank includes a base having an inner base surface and an outer surface; a first end wall, a second end wall, a first side wall, and a second side wall, each extending from the base and each wall having an inner surface and an outer surface. A first heating element is disposed within the exhaust fluid tank.

Description

INTRODUCTION

[0001] The subject disclosure relates to an exhaust fluid tank provided with an exhaust system.

[0002] Some vehicles incorporate diesel engines that may be provided with an exhaust system that is configured to reduce the amount of regulated constituents that may be emitted by the vehicle. The exhaust system may make use of fluids that are mixed with the exhaust gases prior to release into the external operating environment of the vehicle. The fluids may be stored in a storage tank that may freeze when the vehicle is exposed to freezing temperatures.

[0003] Accordingly, it is desirable to provide an exhaust fluid system capable of inhibiting or thawing the fluid that may be stored in the storage tank.

SUMMARY

[0004] In one exemplary embodiment an exhaust system is provided. The exhaust system includes an exhaust pipe that extends from an internal combustion engine and an exhaust fluid system that is operatively connected to the exhaust pipe. The exhaust fluid system is configured to inject an exhaust fluid into the exhaust pipe. The exhaust fluid system includes an exhaust fluid tank and a heating system disposed within the exhaust fluid tank. The exhaust fluid tank has a base with an inner base surface and an outer base surface each extending between a first end wall, a second end wall, a first side wall, and a second side wall, each wall having an inner surface and an outer surface.

[0005] In addition to one or more of the features described herein, the heating system includes a first heating element that is disposed on the inner base surface.

[0006] In addition to one or more of the features described herein, the heating system includes a second heating element that is disposed on the inner surface of at least one of the first side wall and the second side wall.

[0007] In addition to one or more of the features described herein, the first heating element is spray deposited on the inner base surface and the second heating element is spray deposited on the inner surface of at least one of the first side wall and the second side wall.

[0008] In addition to one or more of the features described herein, the first heating element and the second heating element are electrically conductive coatings.

[0009] In addition to one or more of the features described herein, a thermally conductive coating is disposed on at least one of the first heating element and the second heating element.

[0010] In addition to one or more of the features described herein, a solid plate disposed on at least one of the first heating element and the second heating element.

[0011] In addition to one or more of the features described herein, the heating system includes a first heating element that is disposed between the inner base surface and the outer base surface.

[0012] In addition to one or more of the features described herein, the heating system includes a second heating element that is disposed between the inner surface and the outer surface of at least one of the first side wall and the second side wall.

[0013] In addition to one or more of the features described herein, the heating system includes a first heating element that extends between the first side wall and the second side wall.

[0014] In addition to one or more of the features described herein, the first heating element engages the inner base surface.

[0015] In addition to one or more of the features described herein, the heating system includes a second heating element that is spaced apart from the first heating element and extends between the first side wall and the second side wall.

[0016] In addition to one or more of the features described herein, the second heating element engages the inner base surface.

[0017] In addition to one or more of the features described herein, a third heating element is disposed on the outer base surface.

[0018] In addition to one or more of the features described herein, the internal combustion engine is a diesel engine.

[0019] In another exemplary embodiment an exhaust fluid tank is provided. The exhaust fluid tank includes a base having an inner base surface and an outer surface; a first end wall, a second end wall, a first side wall, and a second side wall, each extending from the base and each wall having an inner surface and an outer surface; and a first heating element that is disposed between the inner base surface and the outer base surface.

[0020] In addition to one or more of the features described herein, a second heating element is disposed between the inner surface and the outer surface of at least one of the first side wall and the second side wall.

[0021] In yet another exemplary embodiment an exhaust fluid tank is provided. The exhaust fluid tank includes a base having an inner base surface and an outer surface extending between a first end wall, a second end wall, a first side wall, and a second side wall, each extending from the base and each having an inner surface and an outer surface. The exhaust fluid tank further includes a first heating element that is disposed on the inner base surface.

[0022] In addition to one or more of the features described herein, a second heating element is disposed on at least one of the inner surface of at least one of the first side wall and the second side wall.

[0023] In addition to one or more of the features described herein, the exhaust system is provided for after-treatment of diesel exhaust.

[0024] The above features and advantages, and other features and advantages of the disclosure are readily apparent from the following detailed description when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Other features, advantages and details appear, by way of example only, in the following detailed description, the detailed description referring to the drawings in which:

[0026] FIG. 1 is a schematic side view of an exhaust system;

[0027] FIG. 2 is a schematic section view of an exhaust fluid tank;

[0028] FIG. 3 is a partial sectional view of a heating system of the exhaust fluid tank;

[0029] FIG. 4 is a partial sectional view of a heating system of the exhaust fluid tank; and

[0030] FIG. 5 is a partial sectional view of a heating system of the exhaust fluid tank.

DETAILED DESCRIPTION

[0031] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses.

[0032] In accordance with an exemplary embodiment, an exhaust system 10 is shown in FIG. 1. The exhaust system 10 may be provided with a vehicle that incorporates an internal combustion engine 12, such as, a gasoline engine, a diesel engine, a flex fuel engine, a fuel cell, a hybrid engine, or the like. The exhaust system 10 is provided for the after-treatment of exhaust gases.

[0033] The exhaust system 10 includes an exhaust pipe 20 and an exhaust fluid system 22. The exhaust pipe 20 is operatively connected to the internal combustion engine 12 and extends from the internal combustion engine 12. The exhaust pipe 20 directs exhaust gases from the internal combustion engine 12 through exhaust treatment devices and noise attenuation devices. The exhaust pipe 20 defines an injection port 30 that fluidly connects the exhaust fluid system 22 to the exhaust pipe 20.

[0034] The exhaust fluid system 22 is operatively connected to the exhaust pipe 20 via the injection port 30. The exhaust fluid system 22 may be a diesel exhaust fluid system that is configured to inject an exhaust fluid 40 into the exhaust pipe 20 for after-treatment of diesel exhaust gases to reduce the concentration of certain exhaust constituents or compounds that may be present within the exhaust gases. The exhaust fluid system 22 includes an exhaust fluid tank 42, an exhaust fluid pump 44, and a heating system 46.

[0035] As shown in FIG. 1, the exhaust fluid tank 42 is positioned proximate the exhaust pipe 20 and is arranged to store the exhaust fluid 40. Referring to FIGS. 1, 2, and 3 the exhaust fluid tank 42 includes a base 50, a first side wall 52, a second side wall 54, a first end wall 56, a second end wall 58, and a cover 60.

[0036] The base 50 includes an inner base surface 70 and an outer base surface 72 that is disposed opposite the inner base surface 70. The first side wall 52 and the second side wall 54 are disposed opposite each other and extend from the base 50 towards the cover 60. The first end wall 56 and the second end wall 58 are disposed opposite each other and extend between the first side wall 52 and the second side wall 54. The first end wall 56 and the second end wall 58 extend from the base 50 towards the cover 60. The cover 60 is disposed opposite the base 50 and extends between the first side wall 52, the second side wall 54, the first end wall 56, and the second end wall 58. Each wall, i.e. the first side wall 52, the second side wall 54, the first end wall 56, and the second end wall 58, and the cover 60 include an inner surface (74a, 74b, 74c, 74d, 74e, respectively) and an outer surface (76a, 76b, 76c, 76d, 76e, respectively). The inner surfaces and the inner base surface 70 define an interior of the exhaust fluid tank 42 and the outer surfaces and the outer base surface 72 define an exterior of the exhaust fluid tank 42.

[0037] Referring to FIG. 1, the exhaust fluid pump 44 extends at least partially through the cover 60 of the exhaust fluid tank 42. The exhaust fluid pump 44 is fluidly connected to the exhaust fluid tank 42 by a first fluid conduit 80 that extends into the exhaust fluid tank 42 and is fluidly connected to the exhaust pipe 20 by a second fluid conduit 82. The first fluid conduit 80 extends into the interior of the exhaust fluid tank 42 and is connected to an inlet of the exhaust fluid pump 44. The second fluid conduit 82 extends from an outlet of the exhaust fluid pump 44 to the injection port 30.

[0038] The exhaust fluid 40 may freeze while ambient air temperatures are below freezing. The heating system 46 is provided to thaw or inhibit freezing of the exhaust fluid 40 within the exhaust fluid tank 42. Referring to FIGS. 1 and 2, the heating system 46 may include a first heating element 90, a second heating element 92, and a third heating element 94. The first heating element 90, the second heating element 92, and the third heating element 94 are electrically connected to a power source and provide heating while electrically powered.

[0039] Referring to FIGS. 2-5, the first heating element 90 and the second heating element 92 are disposed within the exhaust fluid tank 42. The first heating element 90 engages the inner base surface 70. The second heating element 92 engages the inner surface 74a of the first side wall 52 and/or the inner surface 74b of the second side wall 54.

[0040] Referring to FIG. 3, the first heating element 90 and the second heating element 92 may be conductive coatings that are applied to the inner base surface 70 and the inner surface 74a of the first side wall 52 and/or the inner surface 74b of the second side wall 54, respectively. The conductive coating may be spray deposited on the inner base surface 70 and at least one of the inner surface 74a of the first side wall 52 and/or the inner surface 74b of the second side wall 54. The conductive coating is a thermally conductive coating that may include a conductive material, a resistive material, and a thermal dielectric material.

[0041] The conductive material is deposited on or sprayed on a substrate, a dielectric material that is disposed on the on the inner base surface 70 and the inner surface 74a of the first side wall 52 and/or the inner surface 74b of the second side wall 54, or directly on the inner base surface 70 and the inner surface 74a of the first side wall 52 and/or the inner surface 74b of the second side wall 54. The conductive material is a material that is thermally or electrically conductive.

[0042] The resistive material is deposited on or sprayed on the conductive material. The resistive material is material that is selected to convert electrical energy to thermal energy. In at least one embodiment, the conductive material and the resistive material are mixed together and applied to a substrate or directly on the inner base surface 70 and the inner surface 74a of the first side wall 52 and/or the inner surface 74b of the second side wall 54.

[0043] The thermal dielectric material may be deposited on or sprayed on the resistive material. The thermal dielectric material may be a composition that may aid in the heat transfer of the heat generated by the resistive material into the exhaust fluid 40. In at least one embodiment, a sealant may be applied over the conductive coating to protect the conductive coating.

[0044] In at least one embodiment, a solid plate may be disposed on or bonded to at least one of the first heating element 90 and the second heating element 92. The solid plate is a metallic thermally conductive plate that transfers heat generated by at least one of the first heating element 90 and/or the second heating element 92 to the exhaust fluid 40. A sealant or adhesive may be applied between the solid plate and an inner surface of the diesel exhaust fluid tank 42 to operatively connect the solid plate to the interior of the diesel exhaust fluid tank 42. In further embodiments, the first heating element 90 and the second heating element 92 may be embedded within the solid plate and the solid plate is disposed on the inner base surface 70 and the inner surface 74a of the first side wall 52 and/or the inner surface 74b of the second side wall 54.

[0045] Referring to FIGS. 2 and 4, the first heating element 90 and the second heating element 92 may be induction heaters, bus wires, a heating grid, thermally conductive elements, or resistive heating elements that are disposed within the base 50 and/or the first and second side walls 52, 54 of the exhaust fluid tank 42.

[0046] The first heating element 90 may be disposed or embedded within the base 50 such that the first heating element 90 is disposed between the inner base surface 70 and the outer base surface 72. The first heating element 90 may be molded into the base 50 of the exhaust fluid tank 42. The second heating element 92 may be disposed or embedded within a wall of the exhaust fluid tank 42 such that the second heating element 92 is disposed between the inner surface 74 and the outer surface 76 of at least one of the first side wall 52 (i.e. 74a, 76a), the second side wall 54 (i.e. 74b, 76b), and the cover 60 (i.e. 74e, 76e). The second heating element 92 may be molded into at least one of the first side wall 52 and the second side wall 54.

[0047] Referring to FIG. 1, the third heating element 94 may be incorporated with the exhaust fluid pump 44. The third heating element 94 may be provided with or run along the first fluid conduit 80 to provide heating to the first fluid conduit 80 and/or exhaust fluid 40 that is disposed proximate the first fluid conduit 80.

[0048] Referring to FIGS. 1 and 2, the third heating element 94 may be disposed on an exterior surface of the exhaust fluid tank 42. For example, the third heating element 94 may be provided with a blanket that is disposed about at least a portion of the exhaust fluid tank 42. In such a configuration, the third heating element 94 may disposed on or engage the outer base surface 72.

[0049] The third heating element 94 may provide primary heating of the exhaust fluid 40 within the exhaust fluid tank 42. The first heating element 90 and the second heating element 92 may provide secondary heating of the exhaust fluid 40 within the exhaust fluid tank 42.

[0050] Referring to FIG. 5, the first heating element 90 and the second heating element 92 may be configured as inserts or plate heaters that are inserted into the exhaust fluid tank 42. The first heating element 90 and the second heating element 92 are each inserted into the interior of the exhaust fluid tank 42 and are spaced apart from each other. The first heating element 90 and the second heating element 92 each extend between the base 50, the first side wall 52, and the second side wall 54. The first heating element 90 and the second heating element 92 each engage the inner base surface 70 and the inner surface 74a of the first side wall 52 and/or the inner surface 74b of the second side wall 54.

[0051] Coordination of operation of the heating system 46 may be dictated or controlled by a control module 100 that is in communication with the heating system 46, as shown in FIG. 1. The control module 100 may be a controller that is in communication with an overall vehicle controller or may be integrated with the overall vehicle controller.

[0052] The control module 100 may include a microprocessor or central processing unit (CPU) in communication with various types of computer readable storage devices or media. Computer readable storage devices or media may include volatile and nonvolatile storage in read-only memory (ROM), random-access memory (RAM), and keep-alive memory (KAM), for example. KAM is a persistent or non-volatile memory that may be used to store various operating variables while the CPU is powered down. Computer-readable storage devices or media may be implemented using any of a number of known memory devices such as PROMs (programmable read-only memory), EPROMs (electrically PROM), EEPROMs (electrically erasable PROM), flash memory, or any other electric, magnetic, optical, or combination memory devices capable of storing data, some of which represent executable instructions, used by the control module 100 in controlling or coordinating operation of the heating system 46.

[0053] The control module 100 is in communication with the first heating element 90, the second heating element 92, and the third heating element 94 of the heating system 46 as well as in communication with a fluid temperature sensor 102 and/or an ambient temperature sensor 104.

[0054] The control module 100 may receive a signal indicative of a temperature of the exhaust fluid 40 from the fluid temperature sensor 102 and may receive a signal indicative of an ambient air temperature from the ambient temperature sensor 104.

[0055] The control module 100 commands the heating system 46 to operate, responsive to at least one of the signals indicating a fluid temperature being less than a fluid temperature threshold or an ambient temperature being less than ambient temperature threshold.

[0056] The control module 100 may command the heating system 46 to operate the third heating element 94 by providing electrical power to the third heating element 94. Should the temperature of the exhaust fluid 40 not rise above the fluid temperature threshold, the control module 100 may command the heating system 46 to operate at least one of the first heating element 90 and the second heating element 92 by providing electrical power to at least one of the first heating element 90 and the second heating element 92. If the temperature of the exhaust fluid 40 becomes greater than the fluid temperature threshold, the control module 100 may command the heating system 46 to cease operation by ceasing the provision of electrical power to the first heating element 90, the second heating element 92, and the third heating element 94.

[0057] The control module 100 may command the heating system 46 to operate at least one of the first heating element 90 and the second heating element 92, responsive to at least one of the signals indicating a fluid temperature being less than a fluid temperature threshold or an ambient temperature being less than ambient temperature threshold. The control module 100 may command that electrical power be provided to at least one of the first heating element 90 and the second heating element 92 at least until the temperature of the exhaust fluid 40 becomes greater than the fluid temperature threshold. In at least one embodiment, electrical power may be provided to at least one of the first heating element 90 and the second heating element 92 continuously.

[0058] While the above disclosure has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from its scope. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiments disclosed, but will include all embodiments falling within the scope thereof.

Claims

1. An exhaust system, comprising: an exhaust pipe extending from an internal combustion engine; and an exhaust fluid system operatively connected to the exhaust pipe and configured to inject a exhaust fluid into the exhaust pipe, the exhaust fluid system, comprising: an exhaust fluid tank having a base with an inner base surface and an outer base surface each extending between a first end wall, a second end wall, a first side wall, and a second side wall, each wall having an inner surface and an outer surface, and a heating system disposed within the exhaust fluid tank.

2. The exhaust system of claim 1, wherein the heating system includes a first heating element that is disposed on the inner base surface.

3. The exhaust system of claim 2, wherein the heating system includes a second heating element that is disposed on the inner surface of at least one of the first side wall and the second side wall.

4. The exhaust system of claim 3, wherein the first heating element is spray deposited on the inner base surface and the second heating element is spray deposited on the inner surface of at least one of the first side wall and the second side wall.

5. The exhaust system of claim 3, wherein the first heating element and the second heating element are electrically conductive coatings.

6. The exhaust system of claim 3, further comprising a thermally conductive coating that is disposed on at least one of the first heating element and the second heating element.

7. The exhaust system of claim 3, further comprising a solid plate disposed on at least one of the first heating element and the second heating element.

8. The exhaust system of claim 1, wherein the heating system includes a first heating element that is disposed between the inner base surface and the outer base surface.

9. The exhaust system of claim 8, wherein the heating system includes a second heating element that is disposed between the inner surface and the outer surface of at least one of the first side wall and the second side wall.

10. The exhaust system of claim 1, wherein the heating system includes a first heating element that extends between the first side wall and the second side wall.

11. The exhaust system of claim 10, wherein the first heating element engages the inner base surface.

12. The exhaust system of claim 10, wherein the heating system includes a second heating element that is spaced apart from the first heating element and extends between the first side wall and the second side wall.

13. The exhaust system of claim 12, wherein the second heating element engages the inner base surface.

14. The exhaust system of claim 3, further comprising: a third heating element that is disposed on the outer base surface.

15. The exhaust system of claim 1, wherein the internal combustion engine is a diesel engine.

16. An exhaust fluid tank provided with an exhaust system, comprising: a base having an inner base surface and an outer surface; a first end wall, a second end wall, a first side wall, and a second side wall, each extending from the base and each wall having an inner surface and an outer surface; and a first heating element that is disposed between the inner base surface and the outer base surface.

17. The exhaust fluid tank of claim 16, further comprising: a second heating element that is disposed between the inner surface and the outer surface of at least one of the first side wall and the second side wall.

18. A exhaust fluid tank provided with an exhaust system, comprising: a base having an inner base surface and an outer surface extending between a first end wall, a second end wall, a first side wall, and a second side wall, each extending from the base and each having an inner surface and an outer surface; and a first heating element that is disposed on the inner base surface.

19. The exhaust fluid tank of claim 18, further comprising: a second heating element that is disposed on at least one of the inner surface of at least one of the first side wall and the second side wall.

20. The exhaust fluid tank of claim 18, wherein the exhaust system is provided for after-treatment of diesel exhaust.