Catalyst Substrate with Induction-Heated Metal Particles
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Solution Overview
Problem
The challenge lies in inserting larger metal wires into substrate cells to reduce shaking during installation in vehicles, while maintaining efficient manufacturing and catalyst performance in exhaust gas purification systems.
Innovation Solution
A catalyst substrate with a ceramic base body and metal particles or fragments are used, where the metal particles are introduced into specific cells for induction heating, and the substrate is designed with a combination of cordierite and sealing portions to manage temperature and prevent catalyst deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the diameter of metal wire is increased to reduce shaking influence, then the stability of the substrate is improved, but the ease of insertion into substrate cells deteriorates
Solution Approach 1:
The patent changes the physical state of the metal from wire form to particle form, fundamentally altering the parameters of the metal component. This transformation allows the metal to be easily introduced into substrate cells while maintaining sufficient mass to provide stabilization function, thus resolving the contradiction between stability and ease of insertion
Solution Approach 2:
The patent uses metal particles that can be easily introduced and fixed into the substrate cells. These particles serve as a disposable or easily replaceable component that provides the necessary stabilization function without requiring complex insertion processes, thereby improving ease of manufacture while maintaining stability
2Productivity
If the temperature of the catalyst substrate is increased to enhance exhaust gas purification, then the efficiency of oxidation and reduction reactions is improved, but the risk of catalyst deterioration increases
Solution Approach 1:
The patent utilizes the phase transition properties of the cordierite substrate, which can withstand high temperatures without structural degradation. The substrate's ability to maintain structural integrity during thermal cycling allows the catalyst to operate at higher temperatures for improved productivity while protecting against deterioration through the substrate's thermal stability
Solution Approach 2:
The patent employs a composite structure consisting of cordierite substrate with embedded metal particles. This composite material combines the high-temperature stability of cordierite with the catalytic activity of metal particles, enabling efficient exhaust gas purification at elevated temperatures while the cordierite matrix protects the catalyst from deterioration
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 effectively increases the temperature of the catalyst substrate, enhancing the oxidation and reduction of harmful exhaust gases, while minimizing the influence of shaking and ensuring long-term catalyst functionality.
Implementation Method 1
the substrate is heated based on induction heating
Implementation Method 2
An electromagnetic field generator is mounted adjacent the substrate for generating a varying electromagnetic field inductively to heat the metal and so heat the substrate
Implementation Method 3
An electromagnetic field generator is mounted adjacent the substrate for generating a varying electromagnetic field inductively
Data Source
Figure 1~2
Figure 3
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AI summary
A catalyst substrate may include: a ceramic base body (90) including first and second ends (91, 92), the second end (92) being opposite to the first end (91), and the ceramic base body (90) being provided with a plurality of cells (93) each extending between the first and second ends (91, 92); and a plurality of metal particles or metal fragments (82) introduced into one or more internal spaces of one or more selected cells (93H) in the plurality of cells (93). Each of the plurality of metal particles or metal fragments (82) has a size equal to or less than an opening width of the cell. The plurality of metal particles or metal fragments (82) is configured to generate heat in accordance with varying magnetic field.