Exhaust heat recovery unit

An exhaust heat recovery unit, includes: a heat exchanger that is provided inside an exhaust pipe through which exhaust gas flows, the heat exchange being formed from silicon carbide, and the heat exchanger performing heat exchange between the exhaust gas and a heat medium; and a retention member that is provided at the periphery of the heat exchanger, is formed of a ceramic sheet or an expandable graphite sheet, and is sandwiched between the exhaust pipe and the heat exchanger, thereby retaining the heat exchanger in the exhaust pipe.

CROSS-REFERENCE TO RELATED APPLICATION

This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2017-186509 filed on Sep. 27, 2017, which is incorporated by reference herein.

BACKGROUND

Technical Field

The present disclosure relates to an exhaust heat recovery unit.

Related Art

Japanese Patent Application Laid-open (JP-A) No. 2016-223717 discloses a heat exchanger where a metal band that uses a metal such as stainless steel (SUS) is interposed between a ceramic honeycomb structure and a case. By installing the heat exchanger of JP-A No. 2016-223717 in an automobile, exhaust gas and a heat medium such as a coolant can be made to flow in cells of the honeycomb structure and exchange heat.

Here, when the engine is stopped, normally the flow of the coolant (heat medium) inside the heat exchanger stops. Additionally, in a case where the engine has been stopped after high-load travel, there is the concern that, when the heat of the exhaust pipe that has reached a high temperature because of the exhaust gas at the time of the high-load travel is transmitted to the heat exchanger, the coolant (heat medium) that has stopped flowing will boil. Particularly in a configuration where, as in JP-A No. 2016-223717, a metal band is interposed between a ceramic honeycomb structure and a case, it is easy for heat to be transmitted from the case to the honeycomb structure, and it is easy for the coolant (heat medium) to boil.

SUMMARY

An aspect of the present disclosure is an exhaust heat recovery unit, that includes: a heat exchanger that is provided inside an exhaust pipe through which exhaust gas flows, the heat exchange being formed from silicon carbide, and the heat exchanger performing heat exchange between the exhaust gas and a heat medium; and a retention member that is provided at the periphery of the heat exchanger, is formed of a ceramic sheet or an expandable graphite sheet, and is sandwiched between the exhaust pipe and the heat exchanger, thereby retaining the heat exchanger in the exhaust pipe.

DETAILED DESCRIPTION

An example of an embodiment pertaining to the present disclosure will be described below on the basis of the drawings.

First, the configuration of an exhaust pipe structure10to which an exhaust heat recovery unit30pertaining to the present embodiment has been applied will be described.FIG. 1is a sectional view of the exhaust pipe structure10.

The exhaust pipe structure10is an exhaust pipe structure for a vehicle such as an automobile, and is a pipe structure for exhausting to the atmosphere (outside the vehicle) exhaust gas exhausted from the engine of the vehicle. Specifically, as shown inFIG. 1, the exhaust pipe structure10is equipped with an exhaust pipe20and the exhaust heat recovery unit30.

The exhaust pipe20is configured by a tubular pipe (seeFIG. 3), and the exhaust gas flows in one direction inside the exhaust pipe20. In the drawings, the gas flow direction, which is the direction in which the exhaust gas flows, is indicated by the direction of arrows A. The exhaust pipe20is formed in a tubular shape as a result of vertically divided members being joined to each other by welding, for example. Specifically, as shown inFIG. 3, the exhaust pipe20has an upper member24, which configures the upper portion of the exhaust pipe20, and a lower member26, which configures the lower portion of the exhaust pipe20. The exhaust pipe20is formed in a tubular shape as a result of flange portions24A and26A that project laterally from the upper member24and the lower member26, respectively, being joined to each other by welding, for example. The outer shape of the exhaust pipe20is configured to be a substantially rectangular shape. Specifically, the outer shape of the exhaust pipe20is configured to be a substantially rectangular shape whose corner portions are rounded.

As shown inFIG. 1, in the upper member24is formed an opening25into which a later-described inlet portion34and outlet portion35of the exhaust heat recovery unit30are inserted. It will be noted that the exhaust gas has a temperature in the range of 200° C. to 800° C., for example.

The exhaust heat recovery unit30has the function of exchanging heat between the exhaust gas flowing through the exhaust pipe20and a heat medium to thereby recover the heat of the exhaust gas and reutilize the heat. As the heat medium, for example, a coolant (long life coolant (LLC)) for cooling the engine is used. The heat medium has a temperature lower than the temperature of the exhaust gas. In the case of using a coolant as the heat medium, the temperature of the heat medium reaches about 130° C. at its highest, for example.

As shown inFIG. 1, the exhaust heat recovery unit30specifically has a heat exchanger32, an inlet portion34and an outlet portion35, a lead-in pipe36, a lead-out pipe37, O-rings38and39, and a retention member33.

The heat exchanger32is provided inside the exhaust pipe20and has the function of exchanging heat between the exhaust gas flowing through the inside of the exhaust pipe20and the heat medium. Specifically, the heat exchanger32has a heat exchanger body321and a flow passage forming portion323in which an inflow passage341and an outflow passage351are formed.

The flow passage forming portion323is integrally provided in the upper surface of the heat exchanger body321. The inflow passage341allows the heat medium from the inlet portion34to flow therethrough toward the near side of the page inFIG. 1(direction −D inFIG. 2) and the far side of the page inFIG. 1(direction +D inFIG. 2) at the upper surface of the heat exchanger body321. The outflow passage351allows the heat medium from the heat exchanger body321to flow therethrough toward the far side of the page inFIG. 1(direction −E inFIG. 2) and the near side of the page inFIG. 1(direction +E inFIG. 2) to the outlet portion35at the upper surface of the heat exchanger body321. It will be noted that when the engine of the vehicle is stopped, the heat medium does not flow into the inlet portion34, and the flow of the heat medium inside the heat exchanger body321stops.

As shown inFIG. 2, in the heat exchanger body321are formed plural gas flow passages32A that allow the exhaust gas to flow therethrough along the direction of arrows A from a side surface32F to a side surface32R (seeFIG. 1) of the heat exchanger body321. The gas flow passages32A have inflow openings42, into which the exhaust gas flows, and outflow openings, from which the exhaust gas flows out.

The gas flow passages32A are arranged two-dimensionally (grid-like) as seen from the direction of arrows A. The inflow openings42and the outflow openings of the gas flow passages32A are arranged two-dimensionally in the side surface32F and the side surface32R (seeFIG. 1), respectively. The side surface32F is a surface of the heat exchanger32that faces upstream in the gas flow direction. The side surface32R is a surface of the heat exchanger32that faces downstream in the gas flow direction.

Moreover, as shown inFIG. 1, inside the heat exchanger body321are formed plural medium flow passages32B that allow the heat medium to flow therethrough from the inflow passage341(the inlet portion34) toward the outflow passage351(the outlet portion35). The plural medium flow passages32B are disposed alternating with the plural gas flow passages32A and are partitioned from the gas flow passages32A by partition walls. Additionally, heat exchange takes place, via the partition walls, between the heat medium flowing through the medium flow passages32B and the exhaust gas flowing through the gas flow passages32A.

Furthermore, the heat exchanger32, including the heat exchanger body321and the flow passage forming portion323, is formed of silicon carbide. Silicon carbide is superhard, resistant to heat, and resistant to wear.

The inlet portion34is an open portion for leading the heat medium into the inside (the inflow passage341) of the heat exchanger32. The inlet portion34is formed of silicon carbide integrally with the flow passage forming portion323of the heat exchanger32. Specifically, as shown inFIG. 1, the inlet portion34extends upward from the upper end portion (the upper part of the inflow passage341) of the gas flow direction (direction A) downstream-side part of the flow passage forming portion323of the heat exchanger32. Moreover, the distal end portion of the inlet portion34projects outward in the radial direction of the exhaust pipe20through the opening25in the upper member24of the exhaust pipe20. A lead-in passage34A that communicates with the inflow passage341is formed in the inlet portion34.

The outlet portion35is an open portion for leading the heat medium out from the inside (the outflow passage351) of the heat exchanger32. The outlet portion35is formed of silicon carbide integrally with the flow passage forming portion323of the heat exchanger32. Specifically, as shown inFIG. 1, the outlet portion35extends upward from the upper end portion of the gas flow direction (direction A) upstream-side part of the flow passage forming portion323of the heat exchanger32. Moreover, the distal end portion of the outlet portion35projects outward in the radial direction of the exhaust pipe20through the opening25in the upper member24of the exhaust pipe20. A lead-out passage35A that communicates with the outflow passage351is formed in the outlet portion35.

As mentioned above, the distal end portions of the inlet portion34and the outlet portion35project outward of the exhaust pipe20, and the space on the inside (inner surface side) of the inlet portion34and the space on the inside (inner surface side) of the outlet portion35are isolated from the internal space of the exhaust pipe20. In the way described above, in the present embodiment, a pair of open portions formed in the heat exchanger32are configured by the inlet portion34and the outlet portion35.

Furthermore, in the present embodiment, as mentioned above, the heat exchanger32including the heat exchanger body321and the flow passage forming portion323, the inlet portion34, and the outlet portion35are integrally formed of silicon carbide. Specifically, the heat exchanger32, the inlet portion34, and the outlet portion35are formed, for example, by impregnating a porous body with metallic silicon.

The lead-in pipe36is a lead-in pipe that leads the heat medium from the outside of the exhaust pipe20via the inlet portion34into the heat exchanger32. The downstream end portion (lower end portion) of the lead-in pipe36is connected to the inlet portion34. Specifically, the downstream end portion of the lead-in pipe36is inserted into the inlet portion34.

The O-ring38is disposed on the inside of the inlet portion34between the inlet portion34and the lead-in pipe36. Specifically, the O-ring38is disposed between the outer surface of the lead-in pipe36and the inner surface of the inlet portion34and seals the space between the outer surface of the lead-in pipe36and the inner surface of the inlet portion34. More specifically, the O-ring38seals the space between the outer surface of the lead-in pipe36and the inner surface of the inlet portion34in a position on the radial direction outer side (upper side) of the exhaust pipe20.

In this way, the O-ring38is disposed on the inside of the inlet portion34, so the O-ring38contacts the heat medium that is lower in temperature than the exhaust gas but does not contact the exhaust gas flowing through the exhaust pipe20. That is, the O-ring38is disposed in a position in which it does not contact the exhaust gas flowing through the exhaust pipe20and in which it contacts the heat medium.

The O-ring38is configured in the shape of a ring with a circular cross section (see JIS B 0142) and, for example, is formed of an elastic resin material. The O-ring38is disposed between the outer surface of the lead-in pipe36and the inner surface of the inlet portion34in a state in which it is compressively (elastically) deformed in the radial direction.

The lead-out pipe37is a lead-out pipe that leads the heat medium out from the heat exchanger32via the outlet portion35to the outside of the exhaust pipe20. The upstream end portion (lower end portion) of the lead-out pipe37is connected to the outlet portion35. Specifically, the upstream end portion of the lead-out pipe37is inserted into the outlet portion35.

The O-ring39is disposed on the inside of the outlet portion35between the outlet portion35and the lead-out pipe37. Specifically, the O-ring39is disposed between the outer surface of the lead-out pipe37and the inner surface of the outlet portion35and seals the space between the outer surface of the lead-out pipe37and the inner surface of the outlet portion35. More specifically, the O-ring39seals the space between the outer surface of the lead-out pipe37and the inner surface of the outlet portion35in a position on the radial direction outer side (upper side) of the exhaust pipe20.

In this way, the O-ring39is disposed on the inside of the outlet portion35, so the O-ring39contacts the heat medium that is lower in temperature than the exhaust gas but does not contact the exhaust gas flowing through the exhaust pipe20. That is, the O-ring39is disposed in a position in which it does not contact the exhaust gas flowing through the exhaust pipe20and in which it contacts the heat medium.

The O-ring39is configured in the shape of a ring with a circular cross section (see JIS B 0142) and, for example, is formed of an elastic resin material. The O-ring39is disposed between the outer surface of the lead-out pipe37and the inner surface of the outlet portion35in a state in which it is compressively (elastically) deformed in the radial direction. In the way described above, in the present embodiment, a pair of seal members that seal the space between the inlet portion34and the lead-in pipe36and the space between the outlet portion35and the lead-out pipe37are configured by the O-rings38and39.

As shown inFIG. 2, the retention member33is disposed on the periphery of the heat exchanger32around a virtual line SL along the gas flow direction (direction A). Specifically, the retention member33is disposed in contact with side surfaces32M and32N, a bottom surface32T, and an upper surface32J of the heat exchanger32. That is, as shown inFIG. 3, the retention member33is disposed in a substantially rectangular tube shape so as to surround the virtual line SL. Specifically, the retention member33is disposed in a rectangular tube shape whose corner portions are rounded.

Furthermore, the retention member33is disposed on the entireties of the side surfaces32M and32N and the bottom surface32T of the heat exchanger32. At the upper surface32J of the heat exchanger32, the retention member33is formed in the shape of a frame surrounding the inlet portion34and the outlet portion35as seen in a plan view (seeFIG. 2).

Consequently, the retention member33is disposed on the periphery of the heat exchanger32around the virtual line SL along the gas flow direction (direction A), on the gas flow direction upstream side and downstream side of the inlet portion34and the outlet portion35.

Additionally, the retention member33is disposed in a state in which it is sandwiched between the inner peripheral surface of the exhaust pipe20and the side surfaces32M and32N, the bottom surface32T, and the upper surface32J of the heat exchanger32. Specifically, the retention member33is disposed in a compressively deformed state between the inner peripheral surface of the exhaust pipe20and the side surfaces32M and32N, the bottom surface32T, and the upper surface32J of the heat exchanger32.

In this way, the retention member33, by virtue of being sandwiched between the exhaust pipe20and the heat exchanger32, retains the heat exchanger32in the exhaust pipe20. That is, the retention member33has a retaining function of retaining the heat exchanger32in the exhaust pipe20.

Furthermore, because the retention member33is sandwiched between the exhaust pipe20and the heat exchanger32, the space between the heat exchanger32and the exhaust pipe20is sealed. That is, the retention member33functions as a gas seal that suppresses ingress of the exhaust gas into the space between the heat exchanger32and the exhaust pipe20.

Moreover, the retention member33is elastic and mitigates shock and vibration from the exhaust pipe20to the heat exchanger32. That is, the retention member33also functions as a buffer member that provides a buffer between the heat exchanger32and the exhaust pipe20.

The retention member33is formed of a ceramic sheet or an expandable graphite sheet. A ceramic sheet comprises ceramic fibers formed into a sheet. As the ceramic fibers, for example, silica-alumina fibers, alumina fibers, silica fibers, rock wool, and glass fibers can be used. An expandable graphite sheet comprises expandable graphite formed into a sheet. Examples thereof include GRAFOIL made by GrafTech. The thermal conductivity of a ceramic sheet is about 0.03 to 0.3 W/mk. The thermal conductivity of an expandable graphite sheet is about 1 to 10 W/mK. The thermal conductivity of the heat exchanger32formed mainly of silicon carbide is about 100 to 300 W/mK, and the thermal conductivities of a ceramic sheet and an expandable graphite sheet are lower than that of the heat exchanger32comprising silicon carbide.

Action and Effects of Present Embodiment

Next, the action and effects of the present embodiment will be described.

According to the exhaust heat recovery unit30pertaining to the present embodiment, the heat medium is led by the lead-in pipe36from the outside of the exhaust pipe20via the lead-in passage34A of the inlet portion34into the inflow passage341of the heat exchanger32(seeFIG. 1). The heat medium that has been led into the inflow passage341flows through the medium flow passages32B of the heat exchanger body321. Meanwhile, the exhaust gas inside the exhaust pipe20flows through the gas flow passages32A of the heat exchanger body321. Additionally, the heat medium flowing through the medium flow passages32B of the heat exchanger body321exchanges heat with the exhaust gas flowing through the gas flow passages32A. The heat medium that has exchanged heat with the exhaust gas flows through the outflow passage351of the heat exchanger32and the lead-out passage35A of the outlet portion35and is thereafter led out by the lead-out pipe37to the outside of the exhaust pipe20. Because of this, the heat of the exhaust gas flowing through the exhaust pipe20is recovered. This heat is reutilized outside the exhaust pipe20.

Here, in the embodiment, the retention member33sandwiched between the heat exchanger32and the exhaust pipe20is formed of a ceramic sheet or an expandable graphite sheet whose thermal conductivity is lower than that of silicon carbide.

For example, in the case of a configuration (comparative example 1) where the heat exchanger32is retained in the exhaust pipe20by a metal member interposed between the heat exchanger32and the exhaust pipe20, or in the case of a configuration (comparative example 2) where a heat exchanger32made of metal is retained in the exhaust pipe20by welding, for example, it is easy for heat to be transmitted from the exhaust pipe20to the heat exchanger32. This is because the configurations of comparative example 1 and comparative example 2 thermally are not much different from a state in which the heat exchanger32and the exhaust pipe20directly contact each other.

Particularly in a case where the engine has been stopped after high-load travel, there is the concern that, when the heat of the exhaust pipe20that has reached a high temperature because of the exhaust gas at the time of high-load travel is transmitted to the heat exchanger32, the heat medium that stopped flowing when the engine stopped will boil.

In contrast, in the present embodiment, as described above, a ceramic sheet or an expandable graphite sheet whose thermal conductivity is lower than that of the silicon carbide forming the heat exchanger32is used as the retention member33, so compared to comparative example 1 and comparative example 2, it is difficult for the heat of the exhaust gas to be transmitted from the exhaust pipe20to the heat exchanger32. Because of this, boiling of the heat medium caused by heat from the exhaust pipe20being transmitted to the heat exchanger32can be suppressed.

Consequently, even in a state in which the exhaust pipe20has reached a high temperature because of the exhaust gas at the time of high-load travel and the heat medium is not flowing inside the heat exchanger32, boiling of the heat medium caused by heat from the exhaust pipe20being transmitted to the heat exchanger32can be suppressed.

Furthermore, in the present embodiment, the retention member33is disposed on the periphery of the heat exchanger32around the virtual line SL along the flow direction of the exhaust gas. For this reason, the retention member33keeps the exhaust gas from flowing between the heat exchanger32and the exhaust pipe20, and the exhaust gas can be guided to the inflow openings42. Because of this, the amount of exhaust gas guided to the heat exchanger32increases and the heat exchange efficiency is improved.

Moreover, in the present embodiment, the retention member33is disposed on the periphery of the heat exchanger32around the virtual line SL along the flow direction of the exhaust gas, on the exhaust gas flow direction upstream side and downstream side of the inlet portion34and the outlet portion35.

For this reason, the exhaust gas can be kept from flowing in toward the inlet portion34and the outlet portion35from the exhaust gas flow direction upstream side and downstream side of the inlet portion34and the outlet portion35.

Example Modifications

In the present embodiment, a coolant is used as the heat medium, but the heat medium is not limited to this. As the heat medium, an automatic transmission fluid (ATF) or a continuously variable transmission (CTV) fluid may be used, and fluids such as liquids and gases used in heat exchange can be widely applied.

Furthermore, in the embodiment, the retention member33is disposed in a substantially rectangular shape so as to surround the virtual line SL, but the retention member33is not limited to this. For example, the retention member33may also have a configuration where it is disposed in a substantially circular shape about the virtual line SL. That is, the retention member33may be disposed in any shape so long as the configuration where the retention member33is disposed on the periphery of the heat exchanger32around the virtual line SL is a configuration where the retention member33is disposed so as to surround the virtual line SL.

The present disclosure is not limited to the above embodiment and can be modified, changed, and improved in various ways in a range that does not depart from the spirit thereof.

It is an object of the present disclosure to obtain an exhaust heat recovery unit that can suppress boiling of the heat medium caused by heat from the exhaust pipe being transmitted to the heat exchanger.

A first aspect of the present disclosure is an exhaust heat recovery unit that includes: a heat exchanger that is provided inside an exhaust pipe through which exhaust gas flows, the heat exchange being formed from silicon carbide, and the heat exchanger performing heat exchange between the exhaust gas and a heat medium; and a retention member that is provided at the periphery of the heat exchanger, is formed of a ceramic sheet or an expandable graphite sheet, and is sandwiched between the exhaust pipe and the heat exchanger, thereby retaining the heat exchanger in the exhaust pipe.

A ceramic sheet comprises ceramic fibers formed into a sheet. As the ceramic fibers, for example, silica-alumina fibers, alumina fibers, silica fibers, rock wool, and glass fibers can be used. An expandable graphite sheet comprises expandable graphite formed into a sheet. Examples thereof include GRAFOIL made by GrafTech.

According to the exhaust heat recovery unit of the first aspect, in the heat exchanger, heat exchange takes place between the exhaust gas flowing through the exhaust pipe and the heat medium. Furthermore, the retention member provided on the periphery of the heat exchanger is sandwiched between the exhaust pipe and the heat exchanger and thereby retains the heat exchanger in the exhaust pipe.

Here, in the configuration of the first aspect, a ceramic sheet or an expandable graphite sheet whose thermal conductivity is lower than that of silicon carbide forming the heat exchanger is used as the retention member. For this reason, it is difficult for the heat of the exhaust gas to be transmitted from the exhaust pipe to the heat exchanger. Because of this, boiling of the heat medium caused by heat from the exhaust pipe being transmitted to the heat exchanger can be suppressed.

A second aspect is the exhaust heat recovery unit of the first aspect, wherein: the heat exchanger has inflow openings at a surface of the heat exchanger that faces upstream in a flow direction of the exhaust gas, and the heat exchanger performs heat exchange between exhaust gas flowing in through the inflow openings and the heat medium, and the retention member is disposed at the periphery of the heat exchanger around a virtual line along the flow direction of the exhaust gas.

According to the exhaust heat recovery unit of the second aspect, the heat exchanger has the inflow openings formed in the surface of the heat exchanger that faces upstream in the flow direction of the exhaust gas, and the heat exchanger exchanges heat between the exhaust gas flowing in from the inflow openings and the heat medium.

Here, in the configuration of the second aspect, the retention member is disposed on the periphery of the heat exchanger around the virtual line along the flow direction of the exhaust gas. For this reason, the retention member keeps the exhaust gas from flowing between the heat exchanger and the exhaust pipe, and the exhaust gas can be guided to the inflow openings. Because of this, the amount of exhaust gas guided to the heat exchanger increases and the heat exchange efficiency is improved.

It will be noted that the configuration where the retention member is disposed on the periphery of the heat exchanger around the virtual line is not limited to a configuration where the retention member is disposed in a circular shape about the virtual line and, for example, may also be a configuration where the retention member is disposed in a rectangular shape so as to surround the virtual line. It suffices for the configuration to be one where the retention member is disposed so as to surround the virtual line.

A third aspect is the heat exchanger of the second aspect, further includes: an inlet portion that is provided at the heat exchanger and that leads the heat medium into the heat exchanger; and an outlet portion that is provided at the heat exchanger and that leads the heat medium out from the heat exchanger, wherein the retention member is disposed at the periphery of the heat exchanger around a virtual line along the flow direction of the exhaust gas, at the exhaust gas flow direction upstream side and downstream side of the inlet portion and of the outlet portion.

According to the exhaust heat recovery unit of the third aspect, the heat medium is led into the heat exchanger through the inlet portion formed in the heat exchanger. Furthermore, the heat medium is led out from the heat exchanger through the outlet portion formed in the heat exchanger.

In the configuration of the third aspect, the retention member is disposed on the periphery of the heat exchanger around the virtual line along the flow direction of the exhaust gas on the exhaust gas flow direction upstream side and downstream side of the inlet portion and the outlet portion.

For this reason, the exhaust gas can be kept from flowing in toward the inlet portion and the outlet portion from the exhaust gas flow direction upstream side and downstream side of the inlet portion and the outlet portion.

The present disclosure can suppress boiling of the heat medium caused by heat from the exhaust pipe being transmitted to the heat exchanger.