Exhaust Catalyst with Overlapping Coatings for Rapid Heating
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Solution Overview
Problem
Existing exhaust gas catalytic converters require large amounts of catalysts to achieve optimal operating temperature quickly during regeneration, which is inefficient and costly, and they often have reduced performance due to partial coating of channels, leading to longer warm-up phases and unpredictable temperature profiles.
Innovation Solution
An exhaust gas catalytic converter with a monolith having sections coated with different catalytic coatings, where the coatings overlap in a central area, creating a high catalyst concentration for efficient heat release and catalytic activity, allowing for rapid heating during regeneration with relatively small amounts of catalysts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the monolith is coated with catalytic coatings only in defined sections to save material, then the amount of catalyst is reduced, but the catalyst performance and heating efficiency are reduced
Solution Approach 1:
The patent applies different catalytic coatings to different sections of the monolith channels based on local requirements. The first catalytic coating is applied to the inlet-side section where rapid heating is needed, while the second catalytic coating is applied to the outlet-side section for complete exhaust gas cleaning. This local differentiation allows material savings while maintaining high catalyst performance in each specific zone.
2Quantity of substance
If overlapping catalytic converter coatings are applied in partial areas to save material, then the catalyst material is reduced, but the catalytic efficiency is reduced
Solution Approach 1:
The patent segments the catalytic converter into distinct functional zones along the channel length. The first catalytic coating is applied to the inlet-side section and the second catalytic coating to the outlet-side section, with a clear spatial separation. This segmentation allows each coating to perform its specific function optimally without the efficiency loss associated with overlapping partial-area coatings.
3Loss of time
If large amounts of catalyst are used to achieve quick heating during regeneration, then the optimal operating temperature is reached quickly, but the cost and material usage increase
Solution Approach 1:
The patent changes the spatial distribution parameter of the catalytic coatings, concentrating the first catalytic coating in the inlet-side section where it is most needed for rapid heating. This parameter change in coating distribution allows quick heating performance with reduced overall catalyst quantity, avoiding the need to use large amounts of catalyst throughout the entire monolith.
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 enables a short and efficient heating-up phase with predictable temperature profiles, achieving optimal operating temperature quickly and efficiently, even at low initial temperatures, while minimizing catalyst usage and ensuring complete regeneration.
Implementation Method 1
the monolith has a first section provided with a first catalytic coating, has a second section provided with a second catalytic coating
Implementation Method 2
the temperature in the catalytic converter increases during the heating-up phase because the catalytic reaction is exothermic
Data Source
Figure 1a~1e
Figure 2a~2e
Figure 3a~3f
AI summary
The invention relates to an exhaust gas catalyst comprising a monolith with parallel channels, wherein the monolith has: a first section (2) provided with a first catalytic coating; a second section (5) provided with a second catalytic coating; and a first sub-region (6) in which the first and second sections (2, 5) overlap, wherein: the first section (2) tapers from the inlet side (8) to the outlet side (9); the second section (5) tapers from the outlet side (9) to the inlet side (8); and the center of the monolith is located in the first sub-region (6). The invention also relates to uses of the catalyst and methods for its production.