Exhaust energy recovery for engines

• US 9,157,359 B2
• Filed: 09/28/2012
• Issued: 10/13/2015
• Est. Priority Date: 09/28/2012
• Status: Expired due to Fees

• Current Assignee: Empire Technology Development LLC (Allied Inventors Management, LLC)
• Original Assignee: Empire Technology Development LLC (Allied Inventors Management, LLC)
• Inventors: Bewlay, Stephen L.
• Primary Examiner(s): Denion, Thomas
• Assistant Examiner(s): TRAN, DIEM T
• Application Number:
  US13/976,440
• Publication Number:
  US 20140238005A1
• Time in Patent Office: 1,110 Days
• Field of Search: 602/98, 603/20
• US Class Current: 1/1
• CPC Class Codes: B60K 13/04 concerning exhaust collecting exhaust gases with central suction systems not forming part of vehicles, e.g. in workshops or tunnels B08B15/002, otherwise along carriageways E01C1/005; extensions for melting snow on roads E01H5/00, E01H6/00; exhaust or silencing apparatus for internal combustion engines per se F01N; pipes, joints or supports therefor F16L
• CPC Class Codes: F01N 13/1816 the pipe sections being joined together by flexible tubular elements only, e.g. using bellows or strip-wound pipes
• CPC Class Codes: F01N 2240/02 a heat exchanger
• CPC Class Codes: F01N 5/02 the devices using heat
• CPC Class Codes: F01N 5/025 the device being thermoelectric generators
• CPC Class Codes: F02G 5/02 Profiting from waste heat of exhaust gases
• CPC Class Codes: F28D 21/0003 the heat being recuperated from exhaust gases F28D21/0014 takes precedence
• CPC Class Codes: H10N 10/13 characterised by the heat-exchanging means at the junction
• CPC Class Codes: H10N 19/101 Multiple thermocouples connected in a cascade arrangement
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

Technologies are generally described for recovery of energy from engines. The described technology may be applied to systems, methods, and/or apparatuses. An example exhaust energy recovery apparatus (50) may include at least one thermal to electrical energy conversion element (60) having at least one side for thermal coupling along a substantial length (34, 35, 36) of an exhaust duct (30) for a combustion engine. The example apparatus (50) may also include a cover (52) located over at least a portion of the exhaust duct (30) adjacent to the at least one energy conversion element (60). A channel (53) may be formed between the cover (52) and an exterior portion of the exhaust duct (30), the channel having at least one inlet (54, 56) for admission of cooling fluid.

Claims

1. An exhaust energy recovery apparatus, comprising:

at least one thermal to electrical energy conversion element having at least one side for thermal coupling along a substantial length of an exhaust duct of an engine, wherein the exhaust duct includes a substantially tubular portion comprising a diverging tubular portion contiguous to a converging tubular portion, wherein the substantially tubular portion first diverges from an inlet end to enable hot exhaust gases entering the exhaust duct via the inlet end to expand in the diverging tubular portion, and then continuously converges toward an outlet end to enable the exhaust gases to enter the converging tubular portion for maintenance of consistent contact of the exhaust duct with the exhaust gases as the exhaust gases contract from progressive heat extraction in order to maximize the heat extraction; and

a cover located over at least a portion of the exhaust duct adjacent to the at least one thermal to electrical energy conversion element and forming a channel between the cover and an exterior portion of the exhaust duct, the channel having at least one inlet for admission of cooling fluid.

2. The apparatus of claim 1, wherein the at least one thermal to electrical energy conversion element has at least one side for thermal coupling along the exhaust duct between the engine and an exhaust muffler.

3. The apparatus of claim 1, further comprising at least one array of the at least one thermal to electrical energy conversion element.

4. The apparatus of claim 1, wherein the at least one thermal to electrical energy conversion element forms a thermoelectric generator, a thermo-ionic converter, or a pyro-electric converter.

5. The apparatus of claim 1, further comprising a plurality of thermal to electrical energy conversion elements including the at least one thermal to electrical energy conversion element, wherein the plurality of thermal to electrical energy conversion elements includes a first thermal to electrical energy conversion element located on the diverging tubular portion and a second thermal to electrical energy conversion element located on the converging tubular portion.

6. The apparatus of claim 1, wherein one or both of the diverging tubular portion diverges arithmetically and the converging tubular portion converges arithmetically.

7. The apparatus of claim 1, wherein the cover includes an outer wall having circumferential corrugations providing increased surface area.

8. The apparatus of claim 1, wherein the at least one thermal to electrical energy conversion element is thermally coupled to the exhaust duct by fixing to the exterior portion of the exhaust duct by a thermally conductive fixing agent and thermally coupled to flow of the cooling fluid by a heat exchange structure.

9. The apparatus of claim 8, wherein the heat exchange structure includes fins or plates disposed in the cooling fluid flow.

10. An exhaust energy recovery apparatus, comprising:

at least one thermal to electrical energy conversion element having at least one side for thermal coupling along a substantial length of an exhaust duct of an engine, wherein the exhaust duct has a substantially polygonal cross-sectional shape including a plurality of flat exterior surface portions, at least one of which is arranged for coupling to the at least one thermal to electrical energy conversion element, and includes a substantially tubular portion which diverges from an inlet end and converges toward an outlet end; and

a cover comprising an undulating wall located over at least a portion of the exhaust duct adjacent to the at least one thermal to electrical energy conversion element supported by one or more spacer members adapted to provide thermal insulation between the portion of the exhaust duct and the cover and forming a channel between the cover and an exterior portion of the exhaust duct, the channel having at least one inlet for admission of cooling fluid.

11. The apparatus of claim 10, wherein the channel has a substantially annular cross-sectional shape disposed circumferentially about the exhaust duct.

12. The apparatus of claim 10, wherein the cover is evenly spaced from the exhaust duct and is constructed from at least two longitudinal sections fixed together at axial seam portions.

13. The apparatus of claim 10, wherein the at least one thermal to electrical energy conversion element includes an electrical output coupled to a power regulator for supplying power to engine ancillaries.

14. The apparatus of claim 10, wherein the cover protects the at least one thermal to electrical energy conversion element and the at least one inlet of the channel includes a filter for excluding loose debris from the channel.

15. The apparatus of claim 14, wherein the at least one inlet includes an open end of the channel over which the filter is located.

16. The apparatus of claim 10, wherein the cover includes at least one access port for access to components of the exhaust duct.

17. The apparatus of claim 16, wherein the access port is provided for access to an engine condition sensor bay, a catalytic convertor, exhaust muffler,. or similar exhaust duct component.

18. The apparatus of claim 16, further comprising an openable door for covering the access port.

19. A method to recover energy from an engine, the method comprising:

providing at least one thermal to electrical energy conversion element having at least one side for thermal coupling along a substantial length of an exhaust duct of the engine, wherein the exhaust duct has a substantially polygonal cross-sectional shape including a plurality of flat exterior surface portions, at least one of which is arranged for coupling to the at least one thermal to electrical energy conversion element, and includes a substantially tubular portion comprising a diverging tubular portion contiguous to a converging tubular portion, wherein the substantially tubular portion first diverges from an inlet end to enable hot exhaust gases entering the exhaust duct via the inlet end to expand in the diverging tubular portion, and then continuously converges toward an outlet end to enable the exhaust gases to enter the converging tubular portion for maintenance of consistent contact of the exhaust duct with the exhaust gases as the exhaust gases contract from progressive heat extraction in order to maximize the heat extraction;

channeling a flow of cooling fluid along an exterior of the exhaust duct and over another side of the thermal to electrical energy conversion element; and

recovering electrical energy produced by the at least one thermal to electrical energy conversion element at an electrical output of the at least one thermal to electrical energy conversion element.

20. The method of claim 19, wherein channeling includes locating a cover having at least one inlet over a portion of the exhaust duct adjacent to the at least one thermal to electrical energy conversion element.

21. The method of claim 19, wherein recovering includes production of electrical energy by a thermoelectric effect, by a thermo-ionic effect, or by a pyro-electric effect.

22. The method of claim 19, wherein providing includes fixing the at least one thermal to electrical energy conversion element to an exterior surface of the exhaust duct.

23. The method of claim 22, wherein fixing includes fixing the at least one thermal to electrical energy conversion element between the engine and an exhaust muffler.

24. The method of claim 19, wherein channeling includes protecting the at least one thermal to electrical energy conversion element from impact by loose debris.

25. The method of claim 24, wherein protecting the at least one thermal to electrical energy conversion element includes filtering the fluid admitted into a cover.