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, as they require high temperatures to effectively convert harmful emissions, leading to increased pollutant production during vehicle start-up and idling periods.
Innovation Solution
The use of induction heating, where a substrate body with metal wires is heated by a varying electromagnetic field generated by an induction coil, with optimized wire distribution patterns to enhance heating efficiency and speed up the catalytic conversion process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If catalytic converters are used to reduce harmful emissions, then emission conversion is improved, but efficiency is low when cold leading to increased pollutant production during start-up
Solution Approach 1:
The patent applies preliminary action by heating the catalytic converter substrate before the vehicle starts moving or during idle periods. The induction heating system activates the catalyst beforehand, ensuring it reaches operational temperature (light-off temperature) before cold-start emissions occur, thereby eliminating harmful emissions from the outset rather than allowing them to accumulate during warm-up
Solution Approach 2:
The patent changes the temperature parameter of the catalytic converter substrate using induction heating. By rapidly increasing the substrate temperature from ambient conditions to the required light-off temperature (typically 250-300°C for three-way catalysts), the system transforms the catalyst from an inactive state to an active state, resolving the contradiction between cold operation and efficient emission conversion
2Speed
If induction heating is used to heat the substrate body, then heating speed is improved, but energy consumption increases
Solution Approach 1:
The patent applies local quality by using induction heating coils positioned specifically around the substrate body to generate localized electromagnetic fields. This targeted approach heats only the catalytic converter substrate and immediate surrounding areas rather than the entire exhaust system, achieving rapid heating while minimizing overall energy consumption by concentrating thermal energy where it is most needed
Solution Approach 2:
The patent replaces traditional mechanical heating methods (such as fuel injection into the exhaust stream or contact with hot engine components) with electromagnetic induction heating. This substitution enables more efficient and controlled heat generation through electromagnetic fields directly inducing currents in the substrate, achieving faster heating rates with reduced energy losses compared to conventional thermal transfer methods
3Stability of the object's composition
If metal wires are distributed non-uniformly in the substrate body, then heating uniformity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the substrate body into distinct zones with different wire densities or configurations. Rather than attempting uniform wire distribution throughout, the system segments the heating regions to match the thermal requirements of different substrate areas, achieving overall heating uniformity through coordinated localized heating zones that compensate for inherent thermal gradients
Solution Approach 2:
The patent employs asymmetry in the metal wire distribution pattern within the substrate body. By intentionally creating non-uniform wire arrangements that are asymmetric relative to the substrate geometry, the system compensates for asymmetric heat loss patterns and thermal conduction pathways, achieving uniform temperature distribution across the substrate while the asymmetric wire pattern becomes a designed feature rather than a manufacturing defect
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 quickly attains the light-off temperature, significantly reducing cold-start emissions and improving the efficiency of catalytic converters and particulate filters by ensuring rapid heating of the substrate and exhaust gases.
Implementation Method 1
an induction 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
generating a varying electromagnetic field, thereby inductively to heat the lengths of wire
Data Source
AI summary
An assembly for treating gaseous emissions includes a substrate body having a front and a rear and cells for the passage of emissions gas. Inductance heating metal is located in the substrate body and an induction heating coil is mounted adjacent the substrate body for generating a varying electromagnetic field for inductively heating the metal and thereby heating the substrate body. A greater concentration of the metal is located near the front of the substrate body than near the rear.