Flexible Flat Raw Matrix Wound Catalyst Support
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Solution Overview
Problem
Existing catalytic converters for internal combustion engines are complex to produce and have limitations in achieving high catalytic activity and efficient heat conduction, leading to delayed activation and reduced efficiency.
Innovation Solution
A flexible, flat raw matrix is wound spirally to form a catalyst support with recesses, dividing it into sections to reduce thermal mass and enhance heat conduction, allowing for quicker activation and improved catalytic performance by optimizing temperature distribution and pressure equalization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a traditional honeycomb catalyst support is used, then structural strength and stability are improved, but thermal mass is high leading to delayed activation and reduced heat conduction efficiency
Solution Approach 1:
The catalyst support is divided into multiple sections (first section with inflow opening, second section with outflow opening) separated by a transverse web. This segmentation reduces thermal mass in the inlet area while maintaining overall structural integrity, enabling faster heating and quicker activation of the catalytic converter.
2Reliability
If a complex multi-section catalyst support structure is used, then catalytic activity is improved, but manufacturing complexity increases
Solution Approach 1:
The catalyst support is formed from a flexible flat raw matrix that is wound spirally around a mandrel to create the three-dimensional honeycomb structure. This approach simplifies manufacturing compared to traditional complex multi-section structures, while the wound configuration maintains catalytic activity through optimized flow paths and surface area.
3Volume of moving object
If a compact catalyst support design is used, then space efficiency is improved, but pressure gradients increase reducing flow efficiency
Solution Approach 1:
The flexible flat raw matrix is wound in a spiral configuration around a mandrel, creating a structure where flow paths are optimized to minimize pressure gradients. The winding pattern ensures relatively uniform pressure distribution throughout the catalyst support, improving exhaust gas flow efficiency while maintaining compact volume.
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
The catalyst support achieves rapid heat-up and increased efficiency, ensuring the catalytic converter reaches operating temperature quickly and maintains high performance by reducing thermal mass and managing pressure gradients, thus enhancing exhaust gas purification.
Implementation Method 1
a flexible, flat raw matrix (50, 150) is wound up in a spiral shape to form a catalyst carrier (20)
Implementation Method 2
divide the catalyst support (20) into at least two sections (21, 22) arranged one behind the other in the direction of flow (a), thereby dividing the thermal mass and enhancing heat conduction
Data Source
Figure 1~2
Figure 3
AI summary
A flexible, planar raw matrix (50) that can be wound to form a catalyst support (20) is proposed. The planar raw matrix (50) has at least two recesses (53) arranged side by side in a transverse direction (b) of the raw matrix (50) and, when wound to form a catalyst support (20), overlapping in the transverse direction (b). Furthermore, a catalyst (1) comprising a catalyst support (20) wound from the flexible planar raw matrix (50) and a manufacturing process for such a catalyst (1) are proposed.