Hybrid Catalyst Warming via Power Module Heat and Insulation
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Solution Overview
Problem
Catalysts in three-way catalyst converters for hybrid vehicles are ineffective at low temperatures, leading to inadequate purification of exhaust gases containing CO, HC, and NOx, as they require higher temperatures to function optimally, and existing solutions do not effectively utilize the heat generated by power modules for warming the catalysts.
Innovation Solution
A catalyst temperature increasing apparatus that uses electric equipment resistant to high temperatures, such as power modules and inverter devices, to generate heat and transfer it to the catalyst converters, ensuring effective warming without degrading the equipment, and includes a heat insulating member to prevent excessive heat transfer to less resistant components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the catalyst temperature is increased to improve purification function, then the catalyst can effectively purify exhaust gases, but the risk of overheating adjacent electric equipment increases
Solution Approach 1:
A heat insulating member is introduced as an intermediary between the catalyst converter and the power module. This heat insulating member blocks excessive heat transfer from the catalyst to the power module, protecting the electric equipment from thermal damage while allowing the catalyst to operate at its required high temperature for effective purification
Solution Approach 2:
The patent segments the thermal management system by creating distinct thermal zones: the catalyst converter operates in a high-temperature zone for purification, while the power module is protected in a low-temperature zone by the heat insulating member. This segmentation allows each component to operate in its optimal thermal environment
2Object-affected harmful factors
If a heat insulating member is added to protect electric equipment, then thermal protection is improved, but device complexity increases
Solution Approach 1:
The heat insulating member serves multiple functions simultaneously: it acts as a thermal barrier to protect the power module, provides structural support between components, and may serve as a mounting surface. This multi-functionality reduces the need for additional separate protective components, thereby limiting the increase in device complexity
3Use of energy by moving object
If power modules are used to heat catalyst converters, then energy utilization is improved, but the power module temperature increases
Solution Approach 1:
The heat insulating member acts as a thermal mediator that allows controlled heat transfer from the power module to the catalyst converter. It enables the power module to function as a heater for the catalyst while preventing the power module itself from overheating by blocking excessive temperature rise
4Volume of moving object
If the catalyst converter is positioned close to the power module for space efficiency, then vehicle space utilization is improved, but thermal protection of the power module becomes more difficult
Solution Approach 1:
The heat insulating member is positioned between the catalyst converter and the power module, enabling close proximity placement of these components for space efficiency. The heat insulating member serves as a thermal barrier that allows the components to be located near each other without exposing the power module to damaging temperatures
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 solution allows for efficient warming of catalyst converters using waste heat from power modules, ensuring effective purification of exhaust gases at low temperatures without damaging the equipment, and includes a heat management system to prevent overheating of less resistant components.
Implementation Method 1
electric equipment... generating heat by electrification
Implementation Method 2
heat insulating member to prevent excessive heat transfer to less resistant components
Data Source
AI summary
An ECU executes a program including: detecting a catalyst temperature T upon start of an engine; outputting an instruction signal to drive a power module, which is disposed in contact with an outer surface of a catalyst and is high in heat resistance, with a low efficiency upon determination that the catalyst temperature need be increased; and outputting a valve opening instruction signal to a switch valve in a cooling system in such a manner as not to allow a coolant to flow in a coolant pipeline interposed between the power module and an electric part low in heat resistance.