Electrically Heatable Catalyst with Intermediary Heating

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Solution Overview

Problem

Electrically heatable catalytic converters face challenges in achieving uniform heating and minimizing temperature gradients, leading to potential overheating and damage, especially during the catalytic converter cold phase when the internal combustion engine is not operating.

Innovation Solution

The solution involves an electrically heatable catalytic converter design with a first and second catalysis region arranged in series, an electric heating device positioned between them to facilitate uniform heat transfer, and a method where heated gas volumes are alternately moved between the regions using the internal combustion engine's rotation to enhance convective heat transport, reducing temperature gradients and ensuring efficient heating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If an electric heating device is used to heat the catalytic converter during cold phase, then the catalytic converter can be brought to operating temperature without internal combustion engine operation, but a pronounced temperature gradient arises across the catalytic converter leading to overheating and potential destruction

Engineering Contradiction:

Improvefuel consumptionVSAvoidtemperature gradient

Core Design Contradiction:

Use of energy by moving objectVSTemperature

Solution Approach 1:

The catalytic converter is divided into multiple catalysis regions (first and second catalysis regions) with the heating device positioned between them. This segmentation allows the heating device to transfer heat to multiple regions simultaneously, reducing the temperature gradient across the entire converter while maintaining efficient heating during cold phase operation

Inventive Principle:

Principle #1Segmentation

2Speed

If the electric heating device is positioned to heat the catalytic converter efficiently, then the heating speed increases, but the temperature gradient across the catalytic converter becomes more pronounced

Engineering Contradiction:

Improveheating speedVSAvoidtemperature gradient

Core Design Contradiction:

SpeedVSTemperature

Solution Approach 1:

The heating device is positioned as an intermediary element between the first and second catalysis regions. It serves as a heat transfer mediator that distributes thermal energy to both regions, enabling efficient heating while maintaining a more uniform temperature distribution across the catalytic converter structure

Inventive Principle:

Principle #24Intermediary (Mediator)

3Speed

If combustion measures are implemented to heat the catalytic converter, then the desired operating temperature is achieved quickly, but fuel consumption increases

Engineering Contradiction:

Improveheating speedVSAvoidfuel consumption

Core Design Contradiction:

SpeedVSUse of energy by moving object

Solution Approach 1:

The patent replaces the mechanical/chemical combustion-based heating system with an electric heating device. This substitution eliminates the need for additional fuel consumption while maintaining the ability to quickly bring the catalytic converter to operating temperature during cold phase conditions

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 allows for rapid and efficient heating of the catalytic converter to the desired operating temperature with minimized temperature peaks, even in the cold phase, reducing the risk of overheating and extending the lifespan of the converter.

Implementation Method 1

the heat energy of the heating device may be transferred uniformly to the first and second catalysis regions

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

convective heat transport between the heating device and the first and second catalysis regions

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

the catalytic converter has a dedicated electric heating device, which is electrically operated and brings the catalytic converter to the desired operating temperature

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 4

a gas volume which is heated by the heating device is moved, by a suitable method, both into the second catalysis region and into the first catalysis region

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11156140B2Electrically heatable catalyst and method for operating same

Publication Date: 2021.10.26 VITESCO TECH GERMANY GMBH

AI summary

An electrically heatable catalytic converter for the catalytic treatment of an exhaust gas in an exhaust-gas tract of an internal combustion engine is disclosed. The catalytic converter includes a first catalysis region for the catalytic treatment of the exhaust gas, and a second catalysis region is separate from the first catalysis region. The second catalysis region for the catalytic treatment of the exhaust gas is arranged downstream of the first catalysis region with a predetermined spacing to the first catalysis region. The catalytic converter includes an electric heating device through which the exhaust gas can flow. The electric heating device is arranged downstream of the first catalysis region and upstream of the second catalysis region and is designed to at least partially heat the first catalysis region and the second catalysis region.