Catalytic Converter With Internal Flow Channels
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Solution Overview
Problem
Catalytic converters for internal combustion engines face challenges in achieving quick light-off temperatures for effective exhaust gas purification after cold-starting, as existing methods either rely on oxygen-rich mixtures or external heating, which may not ensure complete purification below the minimum operating temperature.
Innovation Solution
A catalytic converter design featuring a housing with a catalyst element that allows fluid to flow both around and through it, utilizing ribs on the catalyst surface and a regulating element to control fluid flow, enabling enhanced catalytic activity and temperature management through heating or cooling, thereby improving the catalytic effect and protecting the catalytic layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluid flows only around the catalyst element, then the structure is simple, but the catalytic effect is limited due to restricted active surface area and heat transfer
Solution Approach 1:
The catalyst element is designed as a hollow structure with walls containing numerous pores or channels. Fluid can flow through these pores in addition to flowing around the external surface, dramatically increasing the active surface area available for catalytic reactions while maintaining a compact overall structure
Solution Approach 2:
The invention transitions from two-dimensional surface catalysis (fluid flowing only around the catalyst) to three-dimensional volumetric catalysis (fluid flowing through the catalyst walls as well). This adds an internal dimension to the catalytic process, maximizing the utilization of catalyst material
2Temperature
If the catalyst element is solid without internal flow paths, then the structure is simple, but the heat transfer efficiency for warming up or cooling down is insufficient
Solution Approach 1:
The porous or channelled wall structure of the catalyst element creates extensive internal surface area and short diffusion paths, enabling highly efficient heat transfer between the flowing fluid and the catalyst material. This allows rapid warming up of the catalyst during cold start and effective cooling when needed
Solution Approach 2:
The invention utilizes fluid flow (gas or liquid) through the internal pores and channels of the catalyst element as a heat transfer medium. The fluid acts as a conveyor of thermal energy, efficiently transporting heat to or from the catalyst material depending on the operational requirements
3Reliability
If the catalyst element has high active surface area, then the catalytic effect is enhanced, but the pressure drop across the catalyst increases
Solution Approach 1:
The catalyst element features non-uniform pore size distribution and varying wall thickness in different regions. This local variation in structure allows optimization of catalytic activity in regions where fluid residence time is longer, while maintaining lower pressure drop in regions where flow velocity is higher, balancing both requirements
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 design enhances the catalytic effect by allowing fluid to flow on both sides of the catalyst element, increasing the active surface area and enabling efficient warming or cooling, which accelerates the purification process and protects the catalytic layer from overheating, ensuring effective exhaust gas treatment across various operating conditions.
Implementation Method 1
The catalyst element has ribs on a surface that faces the exhaust gas. The flow of fluid through the catalyst element can be selected depending on the available installation space and/or a maximum exhaust gas flow. The catalyst element is formed such that fluid can flow around and through the catalyst element, thereby the catalytic function of the catalyst element can be increased.
Implementation Method 2
The flow of hot fluid through the catalyst element internally increases the catalytic effect of the catalyst element... The flow of fluid through and around the catalyst element can be selected depending on the available installation space for the catalytic converter and/or a maximum exhaust gas flow. Therefore, the catalytic converter advantageously is designed for cooling and for warming up or heating.
Implementation Method 3
The engine-external measures have included the use of electrically heatable elements in the exhaust gas stream upstream of the corresponding component, warming up the exhaust gas stream as it flows through and transfer the heat to the component for bring the component to a temperature corresponding to the minimum operating temperature
Implementation Method 4
The catalytic converter advantageously is designed for cooling and for warming up or heating. The warming up serves generally for the exhaust gas, whereas the cooling serves for protecting the catalytic effect and any catalytic layer that is applied.
Data Source
AI summary
A catalytic converter for an internal combustion engine has a housing (2) and a catalyst element (12) formed in the housing (2). The housing (2) is formed such that exhaust gas of the internal combustion engine can flow through the housing (2). The catalyst element (12) is formed such that fluid can flow around and through it. Additionally, the catalyst element (12) has a plurality of ribs (15) on its surface (14) that faces the exhaust gas.