Induction Heated Catalytic Converter Cold Start Emissions
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Solution Overview
Problem
Catalytic converters have low efficiency at cold start-ups, as they require time to reach the light-off temperature for effective pollutant conversion, leading to increased emissions during this period.
Innovation Solution
Induction heating is applied using a metal coil and metal inserts within the catalytic converter's cells to generate a varying electromagnetic field, inducing eddy currents and hysteresis in the metal elements, which quickly heats the ceramic substrate and exhaust gases, enhancing the catalyst's temperature and reaction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If catalytic converters are used for pollutant conversion, then harmful emissions are reduced, but efficiency is low during cold start-ups due to insufficient temperature
Solution Approach 1:
The patent applies preliminary heating action by incorporating heating elements (such as electric heaters or exhaust gas recirculation systems) that activate before the catalytic converter reaches light-off temperature. This preliminary action raises the substrate temperature in advance, enabling the catalyst to become active sooner and reduce cold start emissions more effectively.
Solution Approach 2:
The patent changes the temperature parameter by implementing active heating mechanisms that increase the substrate temperature from ambient levels to the required light-off temperature (typically 250-300°C or higher) during cold start conditions. This parameter change transforms the catalyst from an inactive state to an active state, resolving the efficiency problem during cold starts.
2Productivity
If the catalytic converter operates at high temperature for efficient pollutant conversion, then conversion efficiency improves, but time to reach light-off temperature increases during cold start-ups
Solution Approach 1:
The patent implements preliminary heating action using integrated heating elements that activate immediately upon engine start-up. These heaters begin raising the substrate temperature before the exhaust gas flow would naturally heat the converter, thereby reducing the time delay to reach light-off temperature while maintaining the required temperature for efficient conversion.
Solution Approach 2:
The patent replaces the natural thermal convection mechanism (relying solely on exhaust gas flow to heat the converter) with an active electrical heating system. This substitution provides more direct and controllable heating, reducing the time to reach operational temperature while ensuring the catalyst achieves the necessary temperature for efficient pollutant conversion.
3Object-affected harmful factors
If heating elements are added to accelerate light-off temperature attainment, then cold start emissions are reduced, but device complexity increases
Solution Approach 1:
The patent applies multi-functionality by designing heating elements that serve dual purposes: they heat the substrate to achieve light-off temperature and simultaneously act as structural supports or anchors within the converter housing. This integration reduces the need for separate components, thereby limiting the increase in device complexity while still achieving reduced cold start emissions.
Solution Approach 2:
The patent merges the heating function with existing structural elements of the catalytic converter. For example, thermal mass blocks are integrated into the converter housing to serve both as heat storage elements and as structural components. This merging approach adds the necessary heating capability while minimizing the increase in overall device complexity.
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 accelerates the attainment of light-off temperature, significantly reducing harmful emissions during cold start-ups and improving the overall efficiency of pollutant conversion processes.
Implementation Method 1
inducing eddy currents and hysteresis in the metal elements, which quickly heats the ceramic substrate and exhaust gases
Implementation Method 2
inducing eddy currents and hysteresis in the metal elements, which quickly heats the ceramic substrate and exhaust gases
Implementation Method 3
Induction heating is applied using a metal coil and metal inserts within the catalytic converter's cells to generate a varying electromagnetic field
Implementation Method 4
These gases are dangerous to health but can be converted to less noxious gases by oxidation respectively to carbon dioxide and nitrogen/oxygen
Implementation Method 5
Other noxious gaseous emission products, including unburned hydrocarbons, can also be converted either by oxidation or reduction to less noxious forms
Data Source
AI summary
A gaseous emissions treatment component has a honeycomb substrate along and through which extend elongate cells for the passage of gaseous emissions through the substrate. The cells are bounded by walls dividing adjacent cells from one another. Metal elements occupy and extend along some of the cells. A metal element has an outer surface shape matching the inner surface of an immediately adjacent part of the cell within which the metal element is located.