US5052178A — Unitary hybrid exhaust system and method for redu…

Claim 1

Independent Claim 193 words

A system for removing particulate matter from exhaust gas of an internal combustion engine, said system comprising: a) a main flow passage and a by-pass flow passage for conducting said exhaust gas from an inlet portion to an outlet portion of said system; b) valve means for selectively directing said exhaust gas through one of said passages; c) filtering means for filtering said exhaust gas directed through said main flow passage; d) regeneration means positioned intermediate said valve means and said filtering means for selectively regenerating said filtering means by removing said particulate matter therefrom; e) an oxidation means positioned downstream of said filtering means in said main flow passage for further oxidizing said particulate matter; and f) a control means for controlling the flow of said exhaust gas, selectively activating said regeneration means upon sensing of a predetermined condition, and deactivating said regeneration means when the regenerating of said filtering means has been completed; wherein said system is a unitary system with said flow passages, said valve means, said filtering means, said regeneration means and said oxidation means are positions within a single housing including said inlet portion and said outlet portion.

Claim 2

Independent Claim 193 words

A system for removing particulate matter from exhaust gas of an internal combustion engine, said system comprising: a) a main flow passage and a by-pass flow passage for conducting said exhaust gas from an inlet portion to an outlet portion of said system; b) valve means for selectively directing said exhaust gas through one of said passages; c) filtering means for filtering said exhaust gas directed through said main flow passage; d) regeneration means positioned intermediate said valve means and said filtering means for selectively regenerating said filtering means by removing said particulate matter therefrom; e) an oxidation means positioned downstream of said filtering means in said main flow passage for further oxidizing said particulate matter; and f) a control means for controlling the flow of said exhaust gas, selectively activating said regeneration means upon sensing of a predetermined condition, and deactivating said regeneration means when the regenerating of said filtering means has been completed; wherein said system is a unitary system with said flow passages, said valve means, said filtering means, said regeneration means and said oxidation means are positions within a single housing including said inlet portion and said outlet portion.

Claim 3

Dependent Claim 24 words

The system as defined in claim 1, wherein said oxidation means is positioned in both said main flow passage and said by-pass flow passage.

Claim 4

Dependent Claim 24 words

The system as defined in claim 2, wherein said by-pass flow passage includes a muffler positioned intermediate said valve means and said oxidation means.

Claim 5

Dependent Claim 17 words

The system as defined in claim 1, wherein said oxidation means is a precious metal oxidation catalyst.

Claim 6

Dependent Claim 17 words

The system as defined in claim 1, wherein said filtering means is an uncatalyzed ceramic particulate trap.

Claim 7

Dependent Claim 21 words

The system as defined in claim 1, wherein said filtering means is a ceramic particulate trap including a base metal catalyst.

Claim 8

Dependent Claim 30 words

The system as defined in claim 1, wherein said regeneration means is a high, temperature diesel-fueled burner and includes an igniter for igniting said burner upon said sensed predetermined condition.

Claim 9

Dependent Claim 49 words

The system as defined in claim 7, wherein said system generally operates in a trapping mode with said exhaust gas flowing through said main flow passage and periodically in a regeneration mode with said exhaust gas flowing through said by-pass flow passage upon the sensing of said predetermined condition.

Claim 10

Dependent Claim 41 words

The system as defined in claim 8, further comprising as sensor means positioned adjacent said filtering means within said main flow passage for sensing said predetermined condition, said predetermined condition being sufficient build-up of said particulate matter within said filtering means.

Claim 11

Dependent Claim 43 words

The system as defined in claim 1, further comprising a temperature sensor for sensing the outlet temperature of the exhaust gas flowing through said filtering means such that said control means will deactivate said regeneration means upon the sensing of a predetermined temperature.

Claim 12

Dependent Claim 14 words

The system as defined in claim 7, wherein said igniter is a spark plug.

Claim 13

Dependent Claim 173 words

A unitary system for removing particulate matter from exhaust gas of an internal combustion engine comprising; a housing having an inlet portion and an outlet portion; a main flow passage and a by-pass flow passage extending from said inlet portion to said outlet portion for conducting said exhaust gas through said housing; valve means for directing said exhaust gas through one of said passages; filtering means positioned in said main flow passage for filtering said particulate matter from said exhaust gas; regeneration means positioned intermediate said valve means and said filtering means in said main flow passage for selectively regenerating said filtering means by removing said particulate matter therefrom; an oxidation means positioned downstream of said filtering means within both said main flow passage and said by-pass flow passage for further oxidizing said particulate matter; and a control means for controlling the flow of said exhaust gas, selectively activating said regeneration means upon sensing of a predetermined condition and for deactivating said regeneration means upon completion of the regeneration of said filtering means.

Claim 14

Dependent Claim 173 words

A unitary system for removing particulate matter from exhaust gas of an internal combustion engine comprising; a housing having an inlet portion and an outlet portion; a main flow passage and a by-pass flow passage extending from said inlet portion to said outlet portion for conducting said exhaust gas through said housing; valve means for directing said exhaust gas through one of said passages; filtering means positioned in said main flow passage for filtering said particulate matter from said exhaust gas; regeneration means positioned intermediate said valve means and said filtering means in said main flow passage for selectively regenerating said filtering means by removing said particulate matter therefrom; an oxidation means positioned downstream of said filtering means within both said main flow passage and said by-pass flow passage for further oxidizing said particulate matter; and a control means for controlling the flow of said exhaust gas, selectively activating said regeneration means upon sensing of a predetermined condition and for deactivating said regeneration means upon completion of the regeneration of said filtering means.

Claim 15

Dependent Claim 25 words

The unitary system as defined in claim 12, wherein said by-pass flow passage includes a muffler positioned intermediate said valve means and said oxidation means.

Claim 16

Dependent Claim 18 words

The unitary system as defined in claim 12, wherein said filtering means is an uncatalyzed ceramic particulate trap.

Claim 17

Dependent Claim 31 words

The unitary system as defined in claim 12, wherein said regeneration means is a high temperature diesel-fueled burner and includes an igniter for igniting said burner upon said sensed predetermined condition.

Claim 18

Dependent Claim 50 words

The unitary system as defined in claim 15, wherein said system generally operates in a trapping mode with said exhaust gas flowing through said main flow passage and periodically in a regeneration mode with said exhaust gas flowing through said by-pass flow passage upon the sensing of said predetermined condition.

Claim 19

Dependent Claim 42 words

The unitary system as defined in claim 16, further comprising a sensor means positioned adjacent said filtering means within said main flow passage for sensing said predetermined condition, said predetermined condition being sufficient build-up of said particulate matter within said filtering means.

Claim 20

Dependent Claim 43 words

The system as defined in claim 12, further comprising a temperature sensor for sensing the outlet temperature of the exhaust gas flowing through said filtering means such that said control means will deactivate said regeneration means upon the sensing of a predetermined temperature.

Claim 21

Independent Claim 148 words

A method of removing particulate matter from the exhaust gas of an internal combustion engine comprising the steps of: a) providing a main flow passage and a by-pass flow passage within a unitary housing for conducting said exhaust gas from an inlet portion to an outlet portion of said unitary housing; b) providing a regeneration means, a filtering means and an oxidation means within said main flow passage of said unitary housing; c) conducting said exhaust gas initially through said filtering means to filter said particulate matter, and then through said oxidation means to further oxidize said particulate matter; d) periodically directing said exhaust gas through said by-pass flow passage and through said oxidation means; e) regenerating said filtering means while said exhaust gas is directed through said by-pass flow passage; and f) redirecting said exhaust gas through said main flow passage upon completion of said regenerating step.

Claim 22

Independent Claim 148 words

A method of removing particulate matter from the exhaust gas of an internal combustion engine comprising the steps of: a) providing a main flow passage and a by-pass flow passage within a unitary housing for conducting said exhaust gas from an inlet portion to an outlet portion of said unitary housing; b) providing a regeneration means, a filtering means and an oxidation means within said main flow passage of said unitary housing; c) conducting said exhaust gas initially through said filtering means to filter said particulate matter, and then through said oxidation means to further oxidize said particulate matter; d) periodically directing said exhaust gas through said by-pass flow passage and through said oxidation means; e) regenerating said filtering means while said exhaust gas is directed through said by-pass flow passage; and f) redirecting said exhaust gas through said main flow passage upon completion of said regenerating step.

Claim 23

Dependent Claim 36 words

The method as defined in claim 19, wherein the step of regenerating said filtering means includes directing a heated gas from said regeneration means through said filter means and said oxidation means during said regenerating step.

Claim 24

Dependent Claim 34 words

The method as defined in claim 19, wherein said step of periodically directing said exhaust gas through said by-pass flow passage is carried out upon sensing of a predetermined condition within said filtering means.

Claim 25

Dependent Claim 23 words

The method as defined in claim 21, wherein said predetermined condition is a sufficient build-up of said particulate matter within said filtering means.

Claim 26

Dependent Claim 39 words

The method as defined in claim 19, further comprising the step of sensing the outlet temperature of said exhaust gas flowing though said filtering means, and deactivating said regeneration means in response to the sensing of a predetermined temperature.

Claim 27

Dependent Claim 26 words

The method as defined in claim 20, wherein said regeneration means includes an igniter for igniting said regeneration means upon the sensing of said predetermined condition.

Claim 28

Dependent Claim 178 words

A unitary system for removing particulate matter from exhaust gas of an internal combustion engine comprising; a housing having an inlet portion and an outlet portion; a main flow passage and a by-pass flow passage each extending from said inlet portion to said outlet portion within said housing for conducting said exhaust gas through said housing; valve means for directing said exhaust gas through one of said passages; filtering means positioned in said main flow passage for filtering said particulate matter from said exhaust gas; a sound attenuation means positioned within said housing for attenuating sound generated by combustion gases; regeneration means positioned intermediate said valve means and said filtering means in said main flow passage for selectively regenerating said filtering means by removing said particulate matter therefrom; and a control means for selectively positioning said valve means to direct the flow of said exhaust gas through one of said main flow passage and said by-pass flow passage while prohibiting the flow of exhaust gas through the other of said main flow passage and said by-pass flow passage.

Claim 29

Dependent Claim 178 words

A unitary system for removing particulate matter from exhaust gas of an internal combustion engine comprising; a housing having an inlet portion and an outlet portion; a main flow passage and a by-pass flow passage each extending from said inlet portion to said outlet portion within said housing for conducting said exhaust gas through said housing; valve means for directing said exhaust gas through one of said passages; filtering means positioned in said main flow passage for filtering said particulate matter from said exhaust gas; a sound attenuation means positioned within said housing for attenuating sound generated by combustion gases; regeneration means positioned intermediate said valve means and said filtering means in said main flow passage for selectively regenerating said filtering means by removing said particulate matter therefrom; and a control means for selectively positioning said valve means to direct the flow of said exhaust gas through one of said main flow passage and said by-pass flow passage while prohibiting the flow of exhaust gas through the other of said main flow passage and said by-pass flow passage.

Claim 30

Dependent Claim 21 words

The unitary system as defined in claim 25, wherein said control means operates said valve in response to a predetermined condition.

Claim 31

Dependent Claim 50 words

The unitary system as defined in claim 26, wherein said system generally operates in a trapping mode with said exhaust gas flowing through said main flow passage and periodically in a regeneration mode with said exhaust gas flowing through said by-pass flow passage upon the sensing of said predetermined condition.

Claim 32

Dependent Claim 42 words

The unitary system as defined in claim 27, further comprising a sensor means positioned adjacent said filtering means within said main flow passage for sensing and predetermined condition, said predetermined condition being sufficient build-up for said particulate matter within said filtering means.

Claim 33

Dependent Claim 18 words

The unitary system as defined in claim 25, wherein said filtering means is an uncatalyzed ceramic particulate trap.

Claim 34

Independent Claim 176 words

A system for removing particulate matter from exhaust gas of an internal combustion engine, said system comprising: a) a main flow passage and a by-pass flow passage for conducting said exhaust gas from an inlet portion to an outlet portion of said system; b) valve means for selectively directing said exhaust gas through one of said passages; c) filtering means for filtering said exhaust gas directed through said main flow passage; d) regeneration means positioned intermediate said valve means and said filtering means for selectively regenerating said filtering means by removing said particulate matter therefrom; e) an oxidation means positioned downstream of said filtering means in both said main flow passage and said by-pass flow passage for further oxidizing said particulate matter; f) a muffler positioned within said by-pass flow passage and intermediate said valve means and said oxidation means; and g) a control means for controlling the flow of said exhaust gas, selectively activating said regeneration means upon sensing of a predetermined condition, and deactivating said regeneration means when the regeneration process has been completed.

Claim 35

Independent Claim 176 words

A system for removing particulate matter from exhaust gas of an internal combustion engine, said system comprising: a) a main flow passage and a by-pass flow passage for conducting said exhaust gas from an inlet portion to an outlet portion of said system; b) valve means for selectively directing said exhaust gas through one of said passages; c) filtering means for filtering said exhaust gas directed through said main flow passage; d) regeneration means positioned intermediate said valve means and said filtering means for selectively regenerating said filtering means by removing said particulate matter therefrom; e) an oxidation means positioned downstream of said filtering means in both said main flow passage and said by-pass flow passage for further oxidizing said particulate matter; f) a muffler positioned within said by-pass flow passage and intermediate said valve means and said oxidation means; and g) a control means for controlling the flow of said exhaust gas, selectively activating said regeneration means upon sensing of a predetermined condition, and deactivating said regeneration means when the regeneration process has been completed.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1994-09-30	1995-04-01	1995-10-01	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1998-09-30	1999-04-01	1999-10-01	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2002-09-30	2003-04-01	2003-10-01	$7700.00	Window Closed / Lapsed

Unitary hybrid exhaust system and method for reducing particulate emmissions from internal combustion engines

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