Catalyst Heating Module With Selective Elements for Battery Durability
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Solution Overview
Problem
Existing hybrid vehicle exhaust after-treatment systems face challenges in efficiently providing heat to catalysts, leading to increased battery energy throughput and reduced battery durability due to frequent power cycling of heating elements.
Innovation Solution
A heating module with independently operable heating elements is used to selectively provide thermal energy to the catalyst based on operational parameters and contextual factors, minimizing battery energy throughput by optimizing the number and activation of elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heating elements are frequently powered on and off to maintain catalyst temperature, then catalyst temperature control is achieved, but battery energy throughput increases and battery durability decreases
Solution Approach 1:
The heating module is divided into multiple independently controllable heating elements instead of using a single heating element. This segmentation allows selective operation of individual elements based on thermal requirements, reducing the frequency of power cycling and extending battery life while maintaining catalyst temperature control.
2Reliability
If multiple heating elements are selectively operated, then battery energy throughput is minimized and battery life is extended, but system complexity increases
Solution Approach 1:
The system dynamically selects which heating elements to operate based on real-time thermal requirements, exhaust flow conditions, and battery state. This dynamic operation optimizes battery energy throughput by activating only the necessary number of heating elements, while the control system manages the complexity through adaptive decision-making rather than fixed complex wiring.
3Speed
If all heating elements are operated simultaneously, then catalyst reaches threshold temperature quickly, but battery energy consumption increases
Solution Approach 1:
Instead of operating all heating elements simultaneously, the system activates only the necessary subset of heating elements required to achieve the catalyst temperature threshold. This partial action approach provides sufficient heating speed while minimizing battery energy consumption by avoiding unnecessary activation of excess heating elements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces battery degradation and extends battery life by minimizing energy throughput and internal resistance increases, while meeting emissions standards without the need for battery capacity upgrades.
Implementation Method 1
Each of the plurality of heating elements is independently operable to provide thermal energy to the catalyst
Data Source
AI summary
Methods and system are provided to heat a catalyst of an after-treatment system for a vehicle. The after-treatment system comprises a heating module having a plurality of heating elements. Each of the plurality of heating elements is independently operable to provide thermal energy to the catalyst of the after-treatment system. One or more of the heating elements of the heating module are selectively operated to provide heat to the catalyst based on an operational parameter of the after-treatment system.