Induction Heated Catalytic Converter Substrate
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Solution Overview
Problem
Catalytic converters and particulate filters have low efficiency when cold, as they require high temperatures to effectively convert harmful emissions, leading to increased pollutant emissions during vehicle start-up and idling periods.
Innovation Solution
The use of induction heating coils to generate a varying electromagnetic field, which heats metal wires or rods within the catalytic converter or particulate filter substrate, accelerating the heating process by inducing eddy currents and transferring heat to the ceramic substrate and exhaust gases, thereby enhancing catalytic reaction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional catalytic converters are used during cold start-up, then the structure is simple and cost-effective, but the catalytic efficiency is low due to insufficient temperature
Solution Approach 1:
The patent applies preliminary action by incorporating an induction heating coil that activates before the catalytic converter reaches operating temperature. This coil generates an electromagnetic field that induces eddy currents in metal wires embedded in the substrate, pre-heating the converter to the required light-off temperature (approximately 300°C) before exhaust gases arrive, thereby ensuring immediate catalytic efficiency during cold start-up
Solution Approach 2:
The patent uses an intermediary mechanism by introducing metal wires (such as stainless steel or nickel alloys) as a mediator between the induction heating coil and the ceramic substrate. These wires act as heat transfer intermediaries, converting electromagnetic energy from the coil into thermal energy through eddy currents, and then conducting this heat to the substrate and catalyst layers, enabling rapid temperature rise without directly heating the entire converter structure
2Temperature
If induction heating is applied to the entire substrate uniformly, then heating coverage is complete, but heat distribution is inefficient due to electromagnetic field flux density variations
Solution Approach 1:
The patent applies local quality by distributing metal wires non-uniformly throughout the substrate based on electromagnetic flux density patterns. Areas with higher flux density receive fewer or no metal wires to avoid excessive heat generation, while areas with lower flux density receive more wires to ensure adequate heating. This localized differentiation of wire density optimizes heat distribution across the substrate, ensuring uniform temperature rise while minimizing electromagnetic energy loss and preventing hot spots
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 method quickly attains the light-off temperature, significantly reducing cold-start emissions and improving the efficiency of catalytic converters and particulate filters by preheating the substrate and exhaust gases, thus enhancing pollutant conversion processes.
Implementation Method 1
an induction heating coil mounted adjacent the substrate body for generating a varying electromagnetic field, thereby inductively to heat the lengths of wire and thereby to heat the substrate body
Implementation Method 2
heats metal wires or rods within the catalytic converter or particulate filter substrate, accelerating the heating process by inducing eddy currents
Data Source
AI summary
An assembly for treating gaseous emissions includes a substrate body having cells for the passages of emissions gas. Lengths of metal wire are located in selected ones of the cells and an induction heating coil is mounted adjacent the substrate body for generating a varying electromagnetic field for inductive heating of the assembly including gaseous emissions passing along the cells. Within the cells, parts of the cell walls and parts of the wire surfaces are exposed to the passage of the gaseous emissions and both the cell wall parts and the wire surface parts have pollution treating catalyst at their surfaces.