GDI Pollutant Abatement System with Localized Catalyst Distribution
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Solution Overview
Problem
Gasoline direct injection engines emit higher levels of fine particulate matter, posing environmental and regulatory challenges, as existing systems struggle to balance filtration efficiency with backpressure penalties and cost-effectiveness in meeting stringent emission standards.
Innovation Solution
A system comprising a close-coupled three-way catalyst (TWC) followed by a catalyzed gasoline particulate filter (GPF) with a specific precious metal distribution, where the TWC has a higher platinum group metal content than the GPF, optimized for efficient pollutant mitigation with reduced precious metal costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a wall-flow filter is used to reduce particle number emissions, then particle emissions are reduced below the target of 6x10^11 particles per kilometer, but backpressure increases
Solution Approach 1:
The patent applies different catalyst formulations to different zones of the filter substrate. The first region (upstream) contains a catalyst formulation optimized for particle oxidation, while the second region (downstream) contains a different formulation. This local differentiation allows the system to reduce particle emissions effectively while managing backpressure by optimizing catalytic activity in specific zones rather than uniformly across the entire filter.
2Productivity
If precious metal content in the particulate filter is increased to improve catalytic activity, then pollutant conversion efficiency increases, but system cost increases
Solution Approach 1:
The patent distributes precious metals non-uniformly across the filter substrate, concentrating them in the first upstream region where they are most needed for particle oxidation. The second downstream region contains less or different precious metal content. This localized distribution maintains high catalytic activity where required while reducing overall precious metal consumption and system cost.
Solution Approach 2:
The patent changes the parameters of catalyst formulation, including precious metal content, support material composition, and promoter additives, to optimize catalytic activity. By carefully selecting and adjusting these parameters, the system achieves high pollutant conversion efficiency without requiring excessive precious metal loading, thus balancing performance with cost-effectiveness.
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 system effectively reduces particulate matter and gaseous emissions while minimizing backpressure, meeting future legislative standards with lower precious metal costs, and improving NOx and CO tailpipe emissions.
Implementation Method 1
said catalyst promotes the oxidation of unburned hydrocarbons and carbon monoxide by oxygen
Implementation Method 2
the reduction of nitrogen oxides to nitrogen in the exhaust gas stream
Implementation Method 3
three-way catalytic converters. These are capable of converting the three essentially gaseous pollutants
Implementation Method 4
only wall-flow filters are effective in reducing the particle number emissions of these engines below the target
Data Source
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AI summary
The present invention is directed to a pollutant abatement system for vehicles propelled by a gasoline combustion engine, in particular a gasoline direct injection engine (GDI). In addition, this invention is concerned with a process of mitigating noxious compounds in the exhaust of such an engine efficiently by applying the inventive abatement system to fulfill future legislative exhaust regulations.