Induction Heated Catalytic Converter Substrate for Cold Start Emissions
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Solution Overview
Problem
Catalytic converters and particulate filters have low efficiency when cold, leading to increased pollutant emissions during vehicle start-up and idling, as they require high temperatures to initiate catalytic conversion processes effectively.
Innovation Solution
The use of an induction heating system with a substrate body having metal wires configured as loop conductors and an induction heating coil to generate a varying electromagnetic field, which heats the metal wires and subsequently the substrate body, accelerating the heating of exhaust gases and catalysts to enhance pollutant conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If catalytic converters operate at ambient temperature during cold start-up, then the vehicle can be started immediately, but the catalytic conversion efficiency is extremely low and harmful emissions are not reduced
Solution Approach 1:
The patent applies preliminary action by heating the catalytic converter substrate before the engine starts or immediately after start-up. The induction heating coil generates electromagnetic fields that induce eddy currents in metal wires embedded in the substrate, rapidly heating it to light-off temperature (approximately 300°C) before significant emissions occur. This preliminary heating ensures the catalyst is active and ready to convert harmful emissions immediately.
Solution Approach 2:
The patent replaces the conventional mechanical/chemical heating method (relying on exhaust heat accumulation) with an electromagnetic induction heating system. Instead of waiting for the mechanical combustion process to generate sufficient heat, an electromagnetic field generator creates a varying electromagnetic field that directly induces thermal energy in the metal wires within the substrate, achieving rapid temperature rise without mechanical delay.
2Productivity
If the catalytic converter is heated rapidly to light-off temperature, then emission conversion efficiency improves, but additional energy consumption and system complexity increase
Solution Approach 1:
The patent applies multi-functionality by designing the metal wires to serve dual purposes: they act as both structural reinforcement elements within the ceramic substrate and as heating elements for rapid temperature rise. The same metal wires that provide mechanical strength to the substrate also serve as the inductive heating elements when exposed to the electromagnetic field, eliminating the need for separate heating components and reducing overall system complexity.
Solution Approach 2:
The patent applies self-service by using the substrate's own metal wire components as the heating elements. Rather than requiring external heating devices, the substrate contains embedded metal wires that automatically generate heat when exposed to the electromagnetic field from the induction coil. The substrate essentially heats itself through the induced eddy currents in its own structural wires, reducing the need for additional active heating components.
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 rapidly increases the temperature of catalytic converters and particulate filters, improving their efficiency during cold start-ups and idling conditions, thereby reducing harmful emissions by accelerating catalytic 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
Implementation Method 2
the varying electromagnetic field induces eddy currents in the loop conductor thereby to heat the loop conductor
Implementation Method 3
heat the lengths of wire and thereby to heat the substrate body
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
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. In this way the metal wires are heated, resulting in heating of the substrate body and heating of exhaust gas flowing in the cells. The metal wires are distributed non-uniformly through the substrate body to obtain a desired heating pattern.