This invention relates to reducing and trapping diesel particulates of a diesel engine for vehicles.

Federal and state governments have imposed increasingly strict regulations over the years governing the levels of hydrocarbon (HC), carbon monoxide (CO) and nitrogen oxide (NOx) pollutants that a motor vehicle may emit to the atmosphere.

In diesel engine systems, a diesel particulate filter (DPF), is provided to trap the particulate matter in the exhaust passage of the diesel engine. Conventionally, a dosing valve is mounted into the exhaust manifold of a diesel system to inject diesel fuel into the exhaust to reduce the particulate matter and thus reduce NOx emissions. Since the temperature of the exhaust manifold can reach 600 C, water cooling is required to ensure that the valve survives. Such a water cooling is known from the documents EP 1 211 396 A2 and EP 1 176 292 A1.

Thus, there is a need to eliminate water cooling of an exhaust dosing valve.

An object of the invention is to fulfill the need referred to above. In accordance with the principles of the present invention, this objective is achieved by providing dosing structure for supplying diesel fuel to an exhaust passage of a diesel system. The dosing structure includes an electrically operated control valve constructed and arranged to receive a supply of diesel fuel. A dosing valve is constructed and arranged to receive fuel from the control valve and to deliver the fuel to the exhaust passage. An extension tube is fluidly coupled between the control valve and the dosing valve to space the control valve from the dosing valve and to permit fuel to be delivered from the control valve, through the extension tube, and to the dosing valve.

In accordance with another aspect of the invention, a method is provided for supplying diesel fuel to an exhaust passage of a diesel system to reduce particulates in the exhaust passage. The method provides a dosing valve coupled to an exhaust passage of a diesel system. An electrically operated control valve is associated with the dosing valve to supply diesel fuel to the dosing valve. The method spaces the control valve from the dosing valve such that heat generated in the exhaust passage is less at the control valve than at the dosing valve. The control valve is operated to supply diesel fuel to the dosing valve with the dosing valve injecting diesel fuel into the exhaust passage.

Other objects, features and characteristics of the present invention, as well as the methods of operation and the functions of the related elements of the structure, the combination of parts and economics of manufacture will become more apparent upon consideration of the following detailed description and appended claims with reference to the accompanying drawings, all of which form a part of this specification.

The invention will be better understood from the following detailed description of the preferred embodiments thereof, taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts, in which:

• FIG. 1 is a schematic diagram of an exhaust gas purifying system including a diesel dosing structure in accordance with an embodiment of the present invention.
• FIG. 2 is a view of the diesel dosing structure of FIG. 1.
• FIG. 3 is an enlarged view of a dosing valve of the dosing structure of FIG. 2.
• FIG. 4 is a block diagram of a dosing system including the dosing structure.

Referring to FIG. 1 of the drawings, a multi-cylinder diesel engine, generally indicated at 10, for vehicles is provided with an exhaust passage 12 and intake passage 13. The intake passage 13 is distributes intake air to each cylinder. The exhaust passage 12 and the intake passage 13 are connected by an exhaust gas recirculation (EGR) passage 14 in the conventional manner.

The engine 10 is provided with a common rail fuel injection device, generally indicated at 16. The fuel injection device 16 is provided with a supply pump 18, common rail 20 and an injector 22 provided for every cylinder. Fuel pressurized by the supply pump 18 is distributed to each injector 22 via the common rail 20.

A variable capacity turbocharger 24 is provided in the exhaust passage 12 downstream of the EGR passage 14. Compressor 26, installed in the intake passage 13, can be considered to be part of the turbocharger 24. A turbine (not shown) of the turbocharger 24 transforms the energy of the flow of exhaust gas into rotational energy, and can drive the compressor 26 using this rotational energy.

A diesel particulate filter (DPF) 28 which traps particulate matter in the exhaust gas is installed in the exhaust passage 12 downstream of the turbine 24. Diesel fuel bums off the particulates trapped in the filter, thus regenerating particulate storage capacity.

As shown in FIG. 1, a dosing structure, generally indicated at 30, is provided in the exhaust passage 12 upstream of the filter 28. With reference to FIG. 2, the dosing structure 30 includes a control valve 31, a dosing valve 32 and an extension tube 48 there-between. The dosing valve 32 is preferably in the form of a poppet valve. As shown in FIG. 3, the poppet valve 32 has a valve member 34 that extends outwardly from a body 36 of the valve 31 when in the opened position, permitting fuel to flow into the exhaust line 12. End 38 is inserted (e.g., threaded) into the exhaust manifold 40 (see FIG. 2). The poppet valve 32 preferably has all metal construction (e.g., stainless steel), capable of withstanding the high temperature of the manifold 40. The poppet valve 32 is constructed and arranged to create a particular spray configuration into the exhaust passage.

The control valve 31 is preferably a gasoline, electrically operated fuel injector without a precision orifice. Since there is no need for special spray patterns from the injector, a simple pencil stream is sufficient. A suitable injector can be of the type disclosed in U.S. Patent No 6,685,112, the content of which is hereby incorporated by reference into this specification. The control valve 31 has a fuel inlet 42 and a fuel outlet 44. The inlet 42 receives diesel fuel from the tank 46 (FIG. 1). The fuel outlet 44 is connected with one end of the extension tube 48, with another end of the extension tube being connected with an inlet 50 of the dosing valve 32. The control valve 31 controls the flow rate to the dosing valve 32 and also shuts-off the flow. The extension tube 48 is of sufficient length to place the control valve 31 away from the heat of the manifold 40. The extension tube 48 can be a metal tube or can be a flexible tube such as a fiberglass braided Teflon hose, capable of withstanding 230 C. Utilization of the flexible extension tube allows for mounting the control valve 31 on a chassis and the dosing valve 32 on the exhaust. This configuration accommodates large amounts of displacement. In other applications, the control valve and the dosing valve are mounted on the engine, thus a metal extension tube can be used. All connections between the tube 48 and the valves 31 and 32 are preferably welded.

FIG. 3 show a block diagram of a dosing system, generally indicated at 53, employing the dosing structure 30. Electrical connections are shown in dashed lines. Thus, an Electronic Control Unit (ECU) 54 can periodically control a fuel pump 56 to deliver diesel fuel from tank 28 to the control valve 31. The ECU also controls the control valve 31 to send fuel through the extension tube 48 to the dosing valve 32 and into the exhaust line 12 to reduce particulates and possibly reduce NOx emissions. It can be appreciated that instead of the ECU 54 controlling the fuel injector 31, a separate controller can control the fuel injector 31.

The dosing structure 30 also reduces oil dilution. In addition, system cost is reduced since a smaller particulate trap can be used, the water cooled system is eliminated, O-rings and polymers are eliminated in high temperature locations, and the structure 30 uses exiting technologies.

The foregoing preferred embodiments have been shown and described for the purposes of illustrating the structural and functional principles of the present invention, as well as illustrating the methods of employing the preferred embodiments and are subject to change without departing from such principles. Therefore, this invention includes all modifications encompassed with the following claims.