Exhaust Catalyst High Density Section for Warm-Up
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Solution Overview
Problem
Existing exhaust gas purification catalysts for internal combustion engines have low purification performance during warm-up due to uneven exhaust gas flow rates and insufficient catalyst metal utilization, particularly in green vehicles with energy-saving mechanisms.
Innovation Solution
The catalyst metal density is increased in high exhaust gas flow rate areas of the catalyst layer, with a high density section formed at the leading end and optimized in terms of size and position to enhance warm-up performance, allowing for reduced catalyst metal usage while maintaining effective purification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the catalyst metal amount is reduced to lower costs, then the purification performance during warm-up deteriorates
Solution Approach 1:
The patent applies local quality by creating a high density section with concentrated catalyst metal in the leading end portion of the catalyst, while other portions have lower catalyst metal density. This non-uniform distribution optimizes the cold start performance where it is most needed (leading end) while reducing overall catalyst metal usage, thereby resolving the contradiction between reducing metal usage and maintaining purification performance during warm-up.
2Ease of manufacture
If the catalyst metal is distributed uniformly in the through-holes, then the manufacturing simplicity is maintained, but the catalyst metal utilization efficiency deteriorates during warm-up
Solution Approach 1:
The patent implements local quality by forming a high density section with concentrated catalyst metal in the leading end portion, creating a non-uniform distribution that optimizes cold start performance. This approach maintains reasonable manufacturing simplicity through wash coating while significantly improving catalyst metal utilization efficiency during the critical warm-up period.
3Reliability
If the catalyst layer thickness is increased to improve purification performance, then the catalyst metal usage amount increases
Solution Approach 1:
The patent applies local quality by concentrating catalyst metal in a high density section at the leading end portion rather than uniformly distributing it throughout the entire catalyst layer. This allows achieving effective purification performance during cold start with reduced overall catalyst metal usage, as the concentrated catalyst in the high density section handles the critical warm-up period efficiently.
Solution Approach 2:
The patent segments the catalyst layer into a high density section with concentrated catalyst metal and other portions with lower density. This segmentation allows the high density section to provide sufficient purification performance during warm-up while the reduced catalyst metal in other portions lowers overall usage, resolving the contradiction between performance and metal consumption.
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 configuration improves the warm-up performance of the catalyst, ensuring cleaner exhaust gas discharge and reducing catalyst metal usage, thereby enhancing purification efficiency and cost-effectiveness.
Implementation Method 1
a catalyst metal is supported, at high density, in a leading end section of the exhaust gas purification catalyst... the catalyst metal is effectively utilized, during warm-up of the internal combustion engine
Data Source
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AI summary
Provided is an exhaust gas purification catalyst in which the performance of a catalyst metal can be brought out properly, the purification catalyst boasting excellent purification performance during warm-up of an internal combustion engine. The exhaust gas purification catalyst 10 is provided with a substrate 1 and a catalyst layer. A leading end section 1a positioned upstream in the direction of exhaust gas flow (arrow) has a portion in which the flow rate of exhaust gas is relatively high and a portion in which the flow rate of exhaust gas is relatively low during warm-up of the internal combustion engine. The catalyst layer in the portion of relatively high flow rate of exhaust gas has a high density section 6 in which a noble metal is supported at relatively high density. The high density section 6 is formed to be shorter than the total length of the exhaust gas purification catalyst 10 from the leading end section 1a in the direction of exhaust gas flow.