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 harmful emissions during vehicle start-up due to the slow attainment of light-off temperature, which is crucial for effective pollutant conversion.
Innovation Solution
The use of an induction heating system that generates a varying electromagnetic field to heat conducting wires within the substrate body, which in turn heats the ceramic substrate and exhaust gases, thereby accelerating the catalytic conversion processes by rapidly achieving the light-off temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional passive heating is used without induction heating, then the structure is simpler and energy consumption is lower, but the time to reach light-off temperature is longer and cold-start emissions are higher
Solution Approach 1:
The induction heating system performs preliminary heating action on the substrate body before the catalytic converter reaches operating temperature. The electromagnetic field is applied in advance to rapidly heat the substrate to light-off temperature, preventing the harmful effect of cold-start emissions before they occur.
Solution Approach 2:
The patent replaces the conventional passive thermal conduction heating mechanism with an active electromagnetic induction heating system. The induction heating coil generates a varying electromagnetic field that directly induces eddy currents in the substrate body, converting electromagnetic energy to thermal energy more efficiently and rapidly than conventional heating methods.
2Object-generated harmful factors
If induction heating is used to rapidly heat the substrate, then cold-start emissions are reduced, but energy consumption increases
Solution Approach 1:
The induction heating system operates periodically rather than continuously. The controller activates the induction heating coil only during cold-start conditions when the substrate temperature is below light-off temperature, and deactivates it once the target temperature is reached. This periodic operation reduces overall energy consumption while still achieving the benefit of reduced cold-start emissions.
Solution Approach 2:
The system incorporates temperature sensing and control feedback to monitor the substrate temperature and regulate the induction heating operation. When the substrate reaches light-off temperature, the feedback signal automatically shuts off or reduces the induction heating power, preventing excessive energy consumption while ensuring emissions are controlled.
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 approach significantly reduces cold-start emissions by quickly attaining the necessary temperature for effective catalytic action, enhancing the efficiency of gaseous emissions treatment and reducing the period required to reach light-off temperature.
Implementation Method 1
an induction heating coil for generating a varying electromagnetic field, thereby to inductively heat the lengths of conducting wire
Implementation Method 2
the heated lengths of conducting wire within the cells of the first set operating to heat the substrate body
Implementation Method 3
heat the emissions gas passing through cells of the second set
Data Source
AI summary
An assembly for treating gaseous emissions has a substrate along which extend cells for the passage of emissions gas. Lengths of conducting wire are located in a set of the cells and an induction heating coil is used to generate a varying electromagnetic field, so as to inductively heat the lengths of conducting wire. The substrate body has a front for entry of flowing emissions gas to be treated into the substrate body and a back for exit of treated gaseous emissions gas. The lengths of conducting wire have projections extending from the front and/or back of the substrate body so that when inductively heated, the wire parts in the substrate body heat the surrounding substrate and the wire projections heat the flowing emissions gas directly.