Generator set exhaust processing system and method
An exhaust processing device for implementation in a marine environment is disclosed. The exhaust processing device includes an inner tubular structure configured to receive exhaust gases from a generator set (genset) and communicate the exhaust gases therethrough. The exhaust processing device also includes an exhaust processing element mounted within the inner tubular structure to process the exhaust gases and an outer tubular structure mounted around the inner tubular structure to form an intermediate space therebetween. The exhaust processing device further includes at least one orifice through which to deliver a flow of water to the intermediate space to maintain the outer tubular structure at a temperature below a temperature of the exhaust processing element.
This application claims the benefit of U.S. Provisional Application 60/621,134 filed Oct. 22, 2004, entitled “Exhaust Processing Assembly for Marine Application”.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENTNot applicable.
FIELD OF THE INVENTIONThe present invention relates generally to generator sets and, more particularly, to an exhaust possessing system for generator sets employed within watercraft such as pleasure boats.
BACKGROUND OF THE INVENTIONWatercraft such as sport boats, cruisers, sailboats, yachts, fishing boats, jet boats, and the like, commonly employ on-board generator sets (often referred to as “gensets”) to generate electricity for use on the watercraft. The gensets typically include an alternator driven by a dedicated internal combustion engine. As with all internal combustion engines, the engines of gensets produce exhaust. This exhaust, if unprocessed, has various components that are undesirable for a number of reasons, such as potentially pollutive elements and undesirable smells.
Despite these undesirable characteristics of exhaust, relatively few watercraft employ any exhaust-processing devices in conjunction with onboard gensets to eliminate or reduce the undesirable exhaust components from the exhaust being expelled into the environment. In fact, with the exception of watercraft employing gensets having high-power ratings (e.g., above 25 hp), conventional watercraft are not mandated by current Environmental Protection Agency (EPA) requirements to employ any exhaust-processing devices.
Further, while some watercraft (particularly larger watercraft that employ high-power gensets) employ exhaust-processing devices, these devices are not readily applicable to smaller watercraft, particularly pleasurecraft because they add to the size and cost of the genset and present a relatively hot surface that cannot be adequately arranged within the confined spaces of smaller watercraft. That is, the exhaust emanating from gensets is typically at a high temperature and may reach temperatures of up to 1500 degrees F. Accordingly, the exhaust created by an individual genset can rapidly heat up an exhaust-processing device to present an external surface that is extremely hot, albeit, not as hot as the exhaust itself. In smaller watercraft, however, due to the relatively cramped quarters on the craft, it is difficult to arrange a genset and an associated exhaust-processing system so that people will not brush up against, or otherwise come into contact with, the heated surfaces of the system.
It would therefore be desirable to provide a system and method for processing exhaust produced by a genset disposed on a watercraft. It would be further desirable to provide a system and method for processing exhaust produced by a watercraft genset to reduce undesirable components of the exhaust before the exhaust is expelled from the watercraft. It would also be desirable to provide a system and method for protecting against contact with heated surfaces of an exhaust-processing system associated with a genset disposed in a small watercraft, where people might come into contact with the exhaust-processing device.
SUMMARY OF THE INVENTIONThe present invention overcomes the aforementioned drawbacks by providing a system and method for processing exhaust produced by a watercraft genset to reduce undesirable components of the exhaust before the exhaust is expelled from the watercraft. Furthermore, a system and method protects the exhaust-processing system from presenting external surfaces with undesirable temperatures.
In accordance with one embodiment, an exhaust processing device for implementation in a marine environment is disclosed. The exhaust processing device includes an inner tubular structure configured to receive exhaust gases from a generator set (genset) and communicate the exhaust gases therethrough. The exhaust processing device also includes an exhaust processing element mounted within the inner tubular structure to process the exhaust gases and an outer tubular structure mounted around the inner tubular structure to form an intermediate space therebetween. The exhaust processing device further includes at least one orifice through which to deliver a flow of water to the intermediate space to maintain the outer tubular structure at a temperature below a temperature of the exhaust processing element.
In accordance with another embodiment, a genset assembly for use in a watercraft is disclosed. The genset assembly includes a genset having an alternator and an engine with an exhaust manifold. The genset assembly also includes an exhaust processing device coupled to the exhaust manifold of the engine. The exhaust processing device further includes an inner conduit to receive exhaust from the exhaust manifold at an input end and allow the exhaust to pass therefrom to an output end and an exhaust processing element positioned within the inner conduit to reduce undesirable exhaust components. Additionally, the exhaust processing device includes an outer conduit positioned about the inner conduit to define an intermediate space therebetween, wherein upon operation of the genset, a temperature of the outer conduit is maintained to be lower than a temperature of the inner conduit by a flow of water through the at least one intermediate space.
In accordance with yet another embodiment, an exhaust processing device for implementation in a marine environment is disclosed. The exhaust processing device includes an inner passage to receive exhaust gases from a genset and communicate the exhaust gases to an output port. The exhaust processing device further includes an exhaust processing element mounted within the inner passage to reduce undesirable components in the exhaust and an outer wall of the exhaust processing device surrounding the inner passage. Additionally, the exhaust processing device includes an insulating passage arranged between the exhaust processing element and the outer wall to receive a flow of water therethrough. Furthermore, the exhaust processing device includes an insulating chamber arranged between the exhaust processing element and the outer wall and having a static insulating medium disposed therein, wherein the insulating passage and the insulating chamber work in concert to maintain a temperature of the outer wall that is substantially reduced from the operating temperature of the exhaust processing element.
Various other features and advantages of the present invention will be made apparent from the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to
Referring additionally to
Referring now to
At a first end 34 of the exhaust processing device 24, the device 24 is configured to interface the exhaust manifold 26 of the generator set 18, as shown in
Referring again to
In either case, the orifices 37 provide a passage for water to be communicated from the exhaust manifold 26 through the mounting face 36 and into the intermediate annular space 31 of the exhaust processing device 24. Upon entering the intermediate annular space 31, the water flows down the length of the exhaust processing device 24, from the first end 34 to a second, outlet end 40.
Still referring to
The catalyst 50 can be any of a variety of catalytic conversion elements known in the art such as a Platinum/Rhodium catalytic conversion element or other element used to reduce vehicle emissions and the like. The catalyst 50 can perform any of a number of exhaust processing/cleaning functions such as, for example, reduction in environmental pollutants or undesirable gases commonly found in exhaust (e.g., carbon monoxide). Although the present embodiment employs a catalytic conversion element as the catalyst 50, alternate forms of exhaust processing elements known in the art could also be utilized.
In operation, exhaust enters the inner tubular structure 30 at a high temperature (e.g., up to 1500° F.). As such, the catalyst 50 is specifically designed to operate optimally at these high temperatures. Accordingly, an outer surface 52 of the exhaust processing device 24 formed by the first tubular structure 28 is heated by the operating temperature of the catalyst 50. In this regard, to protect the outer surface 52 form reaching these high temperatures, water flows through the intermediate annular space 31 to perform the dual functionality of cooling and insulating. Accordingly, the first, outer tubular structure 28 creates a water jacket around the catalyst 50 by forming the intermediate annular space 31 as a passage through which water flows to maintain a temperature of the outer surface 52, preferably, such that the outer surface 52 would be comfortable to the touch.
Additionally, it is contemplated that the water may be forced, under pressure, through the orifices 37 and into the intermediate annular space 31. In this regard, it is contemplated that the water is pressurized, for example to 3 to 5 pounds per square inch (psi), within the intermediate annular space 31.
As previously addressed, the catalyst 50 is specifically designed to operate optimally at the high temperatures associated with the exhaust that it is processing. Accordingly, to protect the catalyst 50 from being cooled by the water flowing through the intermediate annular space 31, an additional annular space 54 may be formed between the intermediate large-diameter section 48 of the inner tubular structure 30 and the catalyst 50 to provide insulation. Accordingly, the additional annular space 54 forms an insulating chamber that can be filled with a static insulating medium. For example, the additional annular space 54 may be filled with air. Accordingly, the additional annular space 54 also makes it possible to accommodate some expansion/contraction of the catalyst 50 without the placement of significant stress upon the inner tubular structure 30. On the other hand, the additional annular space 54 may be filled with fiberglass or similar insulating substances to provide additional protection against cooling the catalyst 50 as well as to protect the outer surface 52 from the operating temperature of the catalyst 50.
Therefore, as described above, the intermediate annular space 31 forms an insulating passage through which a liquid coolant flows to act as a dynamic insulator between the catalyst 50 and the outer surface 52 of the outer tubular structure 28. Additionally, the additional annular space 54 forms an insulating chamber that can be filled with a static insulating medium to further insulate the catalyst 50 from the outer surface 52 of the outer tubular structure 28, and vice versa. Accordingly, the insulating passage and the insulating chamber work in concert to maintain a temperature of the outer surface 52 that is substantially reduced from the operating temperature of the catalyst 50.
Additionally, as shown in
Furthermore, the catalyst 50 is preferably removable and replaceable. For example, in the embodiment shown in
Referring now to
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As shown in
Also, it is contemplated that one or more sensor devices 66 may be mounted on the exhaust processing device 24. The sensor devices 66 may be configured to provide information that is displayed via indicators (not shown) coupled to the sensor device 66. Accordingly, the indicators may be positioned on the exterior of the exhaust processing device 24 or communicate information to other devices such as a display near the steering column or the genset 18 (e.g., wirelessly or by way of various connection devices existing between the mounting face 36 and the exhaust manifold 26). For example, one or more temperature sensors could be mounted on the exhaust processing device 24 to indicate the temperatures at various locations on the device (e.g., at the catalyst 50 or along the outer surface 52 of the tubular structure 28). Also, for example, a pressure sensor could be located within the intermediate annular space 31 that would indicate a blockage of the flow of water through that space. Such pressure information could be of value in preventing excessive strain on an impeller of the pump 61.
Therefore, the above-described invention provides a system and method for integrating conventional catalytic conversion elements (or other exhaust processing elements) such as those employed on automobiles with gensets used on small watercraft for the purpose of processing exhaust gases discharged from the gensets. In this regard, the present invention includes a cooling chamber surrounding an inner exhaust-processing chamber to allow coolant to flow about the exhaust processing chamber and prevent heat from the catalytic conversion process to excessively raise the temperature of an outer surface of the overall device. Additionally, the present invention, in at least some embodiments, provides a system and method for the coolant that is directed through the cooling chamber to be drawn from the genset itself. Accordingly, the coolant is water that is obtained from the body of water within which the watercraft is operating and then returned to that body of water after use.
While the foregoing illustrates and describes various embodiments of this invention, it is to be understood that the invention is not limited to the precise construction herein disclosed. The invention can be embodied in other specific forms without departing from the spirit of the invention. For example, the present invention is intended to be applicable to a wide variety of water vehicles and other (e.g., non-vehicular) devices that employ gensets in proximity to a water source. The present invention is also intended to be used with exhaust processing systems that employ a variety of different types of catalysts, catalytic conversion devices, or other exhaust processing elements.
Also, for example, the water provided to the exhaust processing device need not be provided via the exhaust manifold of a genset as discussed above, but rather could be provided via a separate supply line or other mechanism. Also, in certain embodiments, more than one catalyst could be used and the tubular sections 28, 30 could vary from tubes having circular cross-sections to other tubular structures or other conduits having other shapes (e.g., oval or rectangular cross-sections).
Therefore, one aspect of the invention includes an exhaust processing device for implementation in a marine environment. The exhaust processing device includes an inner tubular structure configured to receive exhaust gases from a generator set (genset) and communicate the exhaust gases therethrough. The exhaust processing device also includes an exhaust processing element mounted within the inner tubular structure to process the exhaust gases and an outer tubular structure mounted around the inner tubular structure to form an intermediate space therebetween. The exhaust processing device further includes at least one orifice through which to deliver a flow of water to the intermediate space to maintain the outer tubular structure at a temperature below a temperature of the exhaust processing element.
According to another aspect of the invention, a genset assembly for use in a watercraft includes a genset having an alternator and an engine with an exhaust manifold. The genset assembly also includes an exhaust processing device coupled to the exhaust manifold of the engine. The exhaust processing device further includes an inner conduit to receive exhaust from the exhaust manifold at an input end and allow the exhaust to pass therefrom to an output end and an exhaust processing element positioned within the inner conduit to reduce undesirable exhaust components. Additionally, the exhaust processing device includes an outer conduit positioned about the inner conduit to define an intermediate space therebetween, wherein upon operation of the genset, a temperature of the outer conduit is maintained to be lower than a temperature of the inner conduit by a flow of water through the at least one intermediate space.
According to still another aspect of the invention, an exhaust processing device for implementation in a marine environment includes an inner passage to receive exhaust gases from a genset and communicate the exhaust gases to an output port. The exhaust processing device further includes an exhaust processing element mounted within the inner passage to reduce undesirable components in the exhaust and an outer wall of the exhaust processing device surrounding the inner passage. Additionally, the exhaust processing device includes an insulating passage arranged between the exhaust processing element and the outer wall to receive a flow of water therethrough. Furthermore, the exhaust processing device includes an insulating chamber arranged between the exhaust processing element and the outer wall and having a static insulating medium disposed therein, wherein the insulating passage and the insulating chamber work in concert to maintain a temperature of the outer wall that is substantially reduced from the operating temperature of the exhaust processing element.
The present invention has been described in terms of the preferred embodiment, and it should be appreciated that many equivalents, alternatives, variations, and modifications, aside from those expressly stated, are possible and within the scope of the invention. Therefore, the invention should not be limited to a particular described embodiment. Accordingly, reference should be made to the following claims, rather than to the foregoing specification, as indicating the scope of the invention.
Claims
1. An exhaust processing device for implementation in a marine environment, the exhaust processing device comprising:
- an inner tubular structure configured to receive exhaust gases from a generator set (genset) and communicate the exhaust gases therethrough;
- an exhaust processing element mounted within the inner tubular structure to process the exhaust gases;
- an outer tubular structure mounted around the inner tubular structure to form an intermediate space therebetween; and
- at least one orifice through which to deliver a flow of water to the intermediate space to maintain the outer tubular structure at a temperature below a temperature of the exhaust processing element.
2. The exhaust processing device of claim 1 further comprising a buffer chamber separating at least one of the catalyst and the inner tubular structure and the inner tubular structure and the outer tubular structure.
3. The exhaust processing device of claim 2 wherein the buffer chamber is filled with at least one of air and a solid insulation.
4. The exhaust processing device of claim 3 wherein the solid insulation includes fiberglass.
5. The exhaust processing device of claim 1 wherein the exhaust processing element is a catalyst and wherein each of the inner and outer tubular structures are cylindrical.
6. The exhaust processing device of claim 1 wherein the inner tubular structure and the outer tubular structure are configured to extend coaxially from an output port of the genset toward an output end where the exhaust and water are expelled from the exhaust processing device.
7. The exhaust processing device of claim 6 wherein the outer tubular structure extends to the output end and the inner tubular structure terminates at an inner downstream end that is short of the output end.
8. The exhaust processing device of claim 7 wherein a flapper valve is positioned proximate the inner downstream end of the inner tubular structure to prevent backflow of the water into the inner tubular structure.
9. The exhaust processing device of claim 1 further comprising a mounting face arranged at an upstream end of the inner tubular structure and the outer tubular structure to engage the genset, and wherein the mounting face includes a primary orifice to connect the inner tubular structure to an exhaust port of the genset and the at least one orifice through which to deliver a flow of water from the genset.
10. The exhaust processing device of claim 1 wherein the water is pressurized as it flows between the inner tubular structure and the outer tubular structure.
11. A genset assembly for use in a watercraft, the genset assembly comprising:
- a genset having an alternator and an engine with an exhaust manifold;
- an exhaust processing device coupled to the exhaust manifold of the engine;
- wherein the exhaust processing device includes: an inner conduit to receive exhaust from the exhaust manifold at an input end and allow the exhaust to pass therefrom to an output end; an exhaust processing element positioned within the inner conduit to reduce undesirable exhaust components; an outer conduit positioned about the inner conduit to define an intermediate space therebetween; and wherein upon operation of the genset, a temperature of the outer conduit is maintained to be lower than a temperature of the inner conduit by a flow of water through the at least one intermediate space.
12. The generator set assembly of claim 11 wherein the water is provided from the genset to the intermediate space by way of at least one orifice in a mounting face of the exhaust processing device.
13. The generator set assembly of claim 11 further comprising a secondary intermediate space formed between the outer conduit and the inner conduit to insulate the outer conduit from the temperature of the inner conduit.
14. The generator set assembly of claim 13 wherein the secondary intermediate space is filled with at least one of a gas insulator and a solid insulator.
15. The generator set assembly of claim 14 wherein the solid insulator includes fiberglass.
16. An exhaust processing device for implementation in a marine environment, the exhaust processing device comprising:
- an inner passage to receive exhaust gases from a genset and communicate the exhaust gases to an output port;
- an exhaust processing element mounted within the inner passage to reduce undesirable components in the exhaust;
- an outer wall of the exhaust processing device surrounding the inner passage;
- an insulating passage arranged between the exhaust processing element and the outer wall to receive a flow of water therethrough;
- an insulating chamber arranged between the exhaust processing element and the outer wall and having a static insulating medium disposed therein; and
- wherein the insulating passage and the insulating chamber work in concert to maintain a temperature of the outer wall that is substantially reduced from the operating temperature of the exhaust processing element.
17. The exhaust processing device of claim 16 wherein the static insulating medium includes at least one of air and fiberglass.
18. The exhaust processing device of claim 16 further comprising at least one orifice in communication with the insulating passage to receive the flow of water from the genset.
19. The exhaust processing device of claim 16 wherein the exhaust processing element includes a catalytic converter.
20. The exhaust processing device of claim 16 wherein the inner passage includes at least one expanded portion configured to receive the exhaust processing element.
Type: Application
Filed: Oct 11, 2005
Publication Date: May 4, 2006
Inventors: Brian Zwieg (Sheboygan, WI), Richard Koehl (Sheboygan Falls, WI)
Application Number: 11/247,627
International Classification: B63H 21/34 (20060101); B63H 21/32 (20060101); B63H 21/38 (20060101); F01N 3/28 (20060101); F01N 7/00 (20060101); F01N 3/04 (20060101);