Radial counterflow muffler for NO reduction and pollutant collection

• US 8,961,667 B2
• Filed: 02/01/2012
• Issued: 02/24/2015
• Est. Priority Date: 02/01/2011
• Status: Active Grant

• Current Assignee: Vorsana, Inc.
• Original Assignee: McCutchen Co.
• Inventors: McCutchen, David J., McCutchen, Wilmot H.
• Primary Examiner(s): Wilkins, III, Harry D
• Application Number:
  US13/364,247
• Publication Number:
  US 20120193221A1
• Time in Patent Office: 1,119 Days
• Field of Search: None
• US Class Current: 96/386
• CPC Class Codes: B01D 2257/404 Nitrogen oxides other than dinitrogen oxide
• CPC Class Codes: B01D 53/326 in electrochemical cells
• CPC Class Codes: C25B 11/034 Rotary electrodes
• CPC Class Codes: C25B 9/30 Cells comprising movable electrodes, e.g. rotary electrodes; Assemblies of constructional parts thereof
• CPC Class Codes: F01N 1/083 using transversal baffles defining a tortuous path for the gases or successively throttling gas flow
• CPC Class Codes: F01N 1/18 having rotary movement
• CPC Class Codes: F01N 2240/34 an electrolyser
• CPC Class Codes: F01N 3/01 by means of electric or electrostatic separators
• CPC Class Codes: F01N 3/0892 Electric or magnetic treatment, e.g. dissociation of noxious components electric filters F01N3/01; regeneration of exhaust filters F01N3/023; heating catalytic converters F01N3/2006
• CPC Class Codes: F01N 5/04 the devices using kinetic energy
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

A scrubbing muffler for internal combustion engines comprises coaxial counter-rotating disk pairs stacked in a cascade. Acoustic pulses are attenuated by doing work and dissipated by the circuitous path through the dynamic cascade. A motor and/or Venturi effect from slipstream over a vehicle assists exhaust and reduces backpressure for greater fuel economy. Exhaust gas fed at the axis is sheared between the disks of the first stage of the cascade as it passes radially outward into a shrouding tank disposed about the cascade. Vortex rebound at the tank wall advects flow radially inward back through the workspace between the first stage disks to axial extraction as feed for the second stage of the cascade. N2 and H2O, along with CO and NO, can pass radially inward to successive stages. Soot and CO₂ stay in the tank. NO and CO are reduced at a Faraday disk cathode.

Claims

1. A muffler for attenuating acoustic pulses in a flow of exhaust gas from an internal combustion engine while simultaneously collecting soot, the muffler comprising:

a plurality of disk pairs, each disk pair comprising a pair of self-propelled, rotatable coaxial disks, each disk pair positioned within a housing in a cascade configuration, the centers of each disk pair aligned with each other, and the plurality of disks structured to rotate about an axis of rotation defined along the aligned centers of the disks, each disk pair defining a radial workspace between them, the radial workspace having an axial feed port at the center of one of the disks and an axial extraction port at the center of the other disk;

a baffle disposed between each disk pair, the respective baffles disposed between respective axial feed ports and axial extraction ports of each disk pair, the baffles and the disks structured to feed gas from each respective axial feed port, radially out from the axial feed port under the respective baffle and radially into the respective axial extraction port over the respective baffle, the gas exiting the workspace through each respective axial extraction port;

vanes disposed on each disk and structured to drive each disk to rotate when the flow of gas across each disk engages the vanes;

a housing disposed around the periphery of the plurality of workspaces such that soot advected out of the workspace impinges the housing;

a soot collector for collecting the soot that impinges the housing; and

a soot hopper for storing the soot.

2. The muffler of claim 1, further comprising electrolytic means for NO reduction.

3. The muffler of claim 1, wherein the edge of each the rotating disks is a cathode.

4. The muffler of claim 1, further comprising a motor structured to, in addition to the flow of gas across the disks, drive rotation of at least one of the disks.

5. The muffler of claim 4, wherein the motor is switchable between a power output state and a power generation state.

6. The muffler of claim 1, wherein the muffler is mounted to a vehicle having an internal combustion engine, and wherein motion of the vehicle generates a slipstream over a muffler outlet, the slipstream increasing gas advection through the muffler outlet.

7. The muffler of claim 6, further comprising a motor structured to, in addition to the flow of gas across the disks, drive rotation of at least one of the plurality of disk pairs.

8. The muffler of claim 1, wherein the advection of gas comprises a slip stream of a vehicle.

9. The muffler of claim 8, further comprising a motor connected to at least one of the plurality of disk pairs and the motor is structured to be switchable between a power output state and a power generation state.

10. The muffler of claim 1, wherein the plurality of disk pairs is disposed within a housing, the housing having vanes on its external periphery and the housing structured to induce counter-rotation of at least one of the plurality of disk pairs.

11. The muffler of claim 1, further comprising an electrostatic precipitator structured to attract soot to the soot collector.

12. The muffler of claim 1, wherein the disks are made of a flexible energy-absorbing material.

13. The muffler of claim 1, wherein the vanes have a radial configuration.

14. The muffler of claim 1, wherein at least one of the plurality of disk pairs are counter-rotatable.

15. The muffler of claim 1, wherein each of the plurality of disk pairs are co-rotatable.

16. The muffler of claim 1, wherein a motor is structured to drive the baffles in counter-rotation with respect to the rotation of the disks.

17. A muffler for attenuating acoustic pulses in a flow of exhaust gas from an internal combustion engine while simultaneously collecting soot, the muffler comprising:

a plurality of disk pairs, each disk pair comprising a pair of self-propelled, rotatable coaxial disks, each disk pair positioned within a housing in a cascade configuration, the centers of each disk pair aligned with each other, and the plurality of disks structured to rotate about an axis of rotation defined along the aligned centers of the disks, each disk pair defining a radial workspace between them, the radial workspace having an axial feed port at the center of one of the disks and an axial extraction port at the center of the other disk;

a baffle disposed between each disk pair, the respective baffles disposed between respective axial feed ports and axial extraction ports of each disk pair, the baffles and the disks structured to feed gas from each respective axial feed port, radially out from the axial feed port under the respective baffle and radially into the respective axial extraction port over the respective baffle, the gas exiting the workspace through each respective axial extraction port;

a motor connected to the baffles of each of the disk pairs, the motor structured to drive the baffles to rotate about the axis of rotation of the disks

vanes disposed on each disk and structured to drive each disk to rotate when a flow of gas across each disk engages the vanes;

the housing disposed around the periphery of the plurality of workspaces such that soot advected out of the plurality of workspaces impinges the housing;

a soot collector for collecting the soot that impinges the housing; and

a soot hopper for storing the soot.

18. The muffler of claim 17, wherein the muffler is mounted to a vehicle having an internal combustion engine, and wherein motion of the vehicle generates a slipstream over a muffler outlet, the slipstream increasing gas advection through the muffler outlet.

19. The muffler of claim 17, further comprising a motor structured to, in addition to the flow of gas across the disks, drive rotation of at least one of the plurality of disk pairs.

20. The muffler of claim 19, wherein the motor is structured to be switchable between a power output state and a power generation state.