Tank system with a main tank and a melting device having a melt tank

• US 7,912,360 B2
• Filed: 09/26/2006
• Issued: 03/22/2011
• Est. Priority Date: 09/26/2005
• Status: Expired due to Fees

• Current Assignee: DBK David + Baader GmbH
• Original Assignee: DBK David + Baader GmbH
• Inventors: Gschwind, Thomas
• Primary Examiner(s): Campbell; Thor S
• Application Number:
  US11/528,478
• Publication Number:
  US 20070157602A1
• Time in Patent Office: 1,638 Days
• Field of Search: 392/302, 392/456
• US Class Current: 392/456
• 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: B60K 15/00 Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks tanks in general B65D, F17C; supplying combustion engines with combustible mixtures or constituents F02M
• CPC Class Codes: B60K 2015/03348 for supplying additives to fuel
• CPC Class Codes: B60K 2015/03427 for heating fuel, e.g. to avoiding freezing
• CPC Class Codes: B60S 1/488 electrically
• CPC Class Codes: F01N 2610/02 the substance being ammonia or urea
• CPC Class Codes: F01N 2610/10 the substance being heated, e.g. by heating tank or supply line of the added substance
• CPC Class Codes: F01N 2610/14 Arrangements for the supply of substances, e.g. conduits
• CPC Class Codes: F01N 2610/1406 Storage means for substances, e.g. tanks or reservoirs
• CPC Class Codes: F01N 2610/1466 Means for venting air out of conduits or tanks
• CPC Class Codes: F01N 3/2066 Selective catalytic reduction [SCR]
• CPC Class Codes: F02M 21/10 for fuels with low melting point, e.g. apparatus having heating means
• CPC Class Codes: F02M 31/125 Fuel
• CPC Class Codes: F02M 37/0082 Devices inside the fuel tank other than fuel pumps or filters electrical pumps submerged in fuel tanks F02M37/10, jet pumps F02M37/025
• CPC Class Codes: F02N 19/04 by heating of fluids used in engines
• CPC Class Codes: F02N 19/10 by heating of engine coolants
• CPC Class Codes: Y02A 50/20 Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/30 Use of alternative fuels, e.g. biofuels

Abstract

A tank system can provide a predetermined cold start volume (V_KS) of an operating liquid required by a liquid consumer after a cold start. The tank system can provide a urea solution to an SCR catalytic converter. The tank system includes a main tank with a filling opening through which the interior of the main tank can be filled with operating liquid. To melt a predetermined volume of the frozen liquid in a fast, efficient and complete manner, a melting device is provided. The melting device includes a melt tank which encloses a melting space and which comprises an inlet opening through which the melting space can be filled with the operating liquid from the interior of the main tank. The melting device includes a cold start heater for melting frozen liquid in the melting space. The melting space is at least as large as the cold start volume (V_KS) and is smaller than the interior of the main tank.

Claims

1. A tank system for providing a selected cold start volume of an operating liquid required by a liquid consumer after a cold start, the tank system comprising a main tank containing an operating liquid comprising a urea solution, the main tank including a filling opening through which an interior of the main tank can be filled with operating liquid, a melting device comprising a melt tank and a discharge opening, the melt tank enclosing a melting space and comprising an inlet opening through which the melting space can be filled from the interior of the main tank with the operating liquid, and the melting device comprising a cold start heater for melting operating liquid frozen in the melting space, wherein the melting space is at least as large as the cold start volume and is smaller than the interior of the main tank.

2. The tank system of claim 1, wherein the cold start heater comprises at least one heating element and at least one heat distribution element, the at least one heating element having a predetermined limited, maximum heating power and configured to generate heat, the at least one heat distribution element conductively coupled to the at least one heating element, the at least one heating distribution element comprises defrosting surfaces projecting into the melt tank and extending away from the heating element such that heat is transferred from the defrosting surfaces into the liquid frozen in the melt tank, the defrosting surfaces span a melting liquid volume equal to or greater than the cold start volume, wherein the cold start volume is sufficient for the liquid consumer to operate within a defined cold start period.

3. The tank system of claim 1, wherein the melting device is disposed in the interior of the main tank.

4. The tank system of claim 1, wherein the melting device is disposed on the outside of the main tank.

5. The tank system of claim 1, wherein the melt tank is disposed on a bottom of the main tank.

6. The tank system of claim 1, wherein the melt tank is arranged on a tank jacket of the main tank.

7. The tank system of claim 1, wherein the melting device is spatially separated from the main tank, wherein the interior of the main tank is in fluid communication with the inlet opening of the melt tank via a connection line.

8. The tank system of claim 1, wherein the melt tank is formed open on one side.

9. The tank system of claim 1, wherein the melt tank has a ventilation valve.

10. The tank system of claim 1, wherein the main tank comprises a discharge opening.

11. The tank system of claim 1, wherein the melt tank and the main tank are integrally formed together.

12. The tank system of claim 1, wherein the melt tank and the main tank are separate components.

13. The tank system of claim 1, wherein the cold start heater is positioned in the melting space.

14. The tank system of claim 1, wherein the cold start heater is positioned on an outer wall of the melt tank.

15. The tank system of claim 1, further comprising a heating device for melting operating liquid frozen in the interior of the main tank.

16. The tank system of claim 1, wherein the melt tank is dimensioned such that the melting space has a volume that is at least as large as the cold start volume which is sufficient for an SCR catalytic converter to operate within defined cold start period.

30. A method of using the tank system of claim 1, the method comprising melting a liquid held in the tank system, wherein the liquid is suitable for use with an SCR catalytic converter, windscreen, or headlamp cleaning system.

31. The method of claim 30, wherein the liquid comprises an aqueous urea solution.

32. The method of claim 31, wherein the aqueous urea solution comprises 30% to 35% of urea.

33. The method of claim 30, wherein the liquid is a cleaning solution for windscreen and/or headlamp cleaning systems.

17. A kit for a tank system for providing a predetermined cold start volume of an operating liquid to a liquid consuming device after a cold start, the kit comprising a main tank module with a filling opening through which an interior of the main tank module is filled with operating liquid comprising a urea solution, a melting module that is connectable to the main tank module, the melting module comprising a melt tank module enclosing a melting space and an inlet opening through which operating liquid from the interior flows to fill the melting space can be filled with operating liquid from at least one of the interior of the main tank module and a discharge opening, and a cold start heating module for melting operating liquid frozen in the melting space, the cold start module configured to be coupled to the melt tank module, the melting space is at least as large as a cold start volume and is smaller than the interior of the main tank module.

18. The kit according to claim 17, wherein the cold start module is the cold start heater comprises at least one heating element and at least one heat distribution element, the at least one heating element having a predetermined limited, maximum heating power and configured to generate heat, the at least one heat distribution element conductively coupled to the heating element, the heating distribution element comprises defrosting surfaces projecting into the tank and extending away from the heating element such that heat is transferred from the defrosting surfaces into liquid frozen in the tank, the defrosting surfaces span a melting liquid volume equal to or greater than the cold start volume, wherein the cold start volume is sufficient for the liquid consuming device to operate within a defined cold start period.

19. The kit for the tank system of claim 18, wherein the melt tank module includes a receiving opening, the cold start heating module is configured to pass through the receiving opening into the melt tank module.

20. The kit of claim 19, further comprising locking means for sealing the receiving opening of the melt tank module.

21. The kit of claim 17, wherein the melt tank module defines a melt tank portion, in which a melting liquid volume of the cold start heating module is positioned, a volume of the melt tank portion is equal to or greater than the melting liquid volume.

22. The kit of claim 21, wherein the melt tank module comprises a discharge opening in the melt tank portion configured to couple to a fluid line coupled to the liquid consuming device or into which a discharge device can be inserted such that the discharge device expands through the discharge opening and into the melting liquid volume.

23. The kit of claim 17, wherein the melt tank module is configured to be repeatedly detachable from the main tank module.

35. The kit of claim 17, wherein the melt tank module defines the melting space that is at least as large as the cold start volume which is sufficient for an SCR catalytic converter to operate within a cold start period.

24. A kit for a cold start system for melting liquid in a tank of a motor vehicle, the liquid comprising a urea solution suitable for an SCR catalytic converter, the kit comprising a tank module having a receiving opening and a cold start heating module, at least a portion of the cold start heating module configured to be inserted into the tank module through the receiving opening and configured to be repeatedly coupled to and detached from the tank, wherein the cold start heating module is a cold start heater, the cold start heater comprises at least one heating element and at least one heat distribution element, the at least one heating element having a predetermined limited, maximum heating power and configured to generate heat, the at least one heat distribution element conductively coupled to the heating element, the heating distribution element comprises defrosting surfaces projecting into the tank and extending away from the heating element such that heat is transferred from the defrosting surfaces into liquid frozen in the tank, the defrosting surfaces span a melting liquid volume equal to or greater than a cold start volume, wherein the cold start volume of the melted liquid comprising the urea solution is sufficient for a liquid consuming device to operate within a defined cold start period.

25. The kit of claim 24, further comprising a locking means for sealing the receiving opening of the melting tank module.

26. The kit of claim 24, wherein the tank module defines a melting tank portion, the melting liquid volume of the cold start heating module is substantially equal to a volume of the melting tank portion.

27. The kit of claim 26, wherein the melting tank module comprises a discharge opening in the melting tank portion configured to couple to a fluid line or into which a discharge device can be inserted such that the discharge device extends through the discharge opening into the melting liquid volume.

28. The kit of claim 24, wherein the tank module is formed as an add-on module which is fluidly connected to the fluid tank.

29. The kit of claim 24, further comprising an additional tank module configured to be repeatedly coupled to and detached from the main tank module.

34. The kit of claim 24, wherein the defrosting surfaces span the melting liquid volume that is equal to or greater than the cold start volume which is sufficient for an SCR catalytic converter to operate within the defined cold start period.