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 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
1Productivity
If catalytic converters operate at ambient temperature, then the device structure is simple and energy consumption is low, but the conversion efficiency of harmful emissions is very low
Solution Approach 1:
The patent applies preliminary action by incorporating heating elements within the catalytic converter structure that can be activated before the converter reaches its light-off temperature. These heating elements pre-heat the catalyst substrate and incoming exhaust gases, ensuring the converter is ready to operate at optimal temperature immediately when the engine starts, thereby eliminating the cold-start emissions problem without requiring the entire system to be heated to high temperatures continuously
Solution Approach 2:
The patent implements local quality by creating zones of different temperatures within the catalytic converter structure. Heating elements are strategically positioned to create localized high-temperature zones around the catalyst substrate where the conversion reactions occur, while other parts of the converter structure remain at lower temperatures. This allows efficient emissions conversion at the catalyst location without uniformly heating the entire device, thus resolving the contradiction between conversion efficiency and overall temperature
2Loss of time
If the catalytic converter is heated to light-off temperature quickly, then cold-start emissions are reduced, but energy consumption increases
Solution Approach 1:
The patent utilizes porous materials in the catalyst substrate structure, which provide high surface area for catalytic reactions while maintaining low thermal mass. The porous structure allows rapid heat transfer from the heating elements to the catalyst active sites, enabling quick achievement of light-off temperature.同时, the porous structure facilitates efficient heat distribution throughout the exhaust gas flow, reducing the total energy required for heating by maximizing the effectiveness of each unit of heat input
Solution Approach 2:
The patent applies self-service by designing the heating system to utilize waste heat from the exhaust gases themselves once the engine is running. After initial heating by the electric heating elements brings the converter to light-off temperature, the exothermic catalytic reactions and hot exhaust gases continue to maintain the required temperature, eliminating the need for continuous external heating and significantly reducing ongoing energy consumption
3Stability of the object's composition
If metal wires are uniformly distributed throughout the substrate body, then heating coverage is even, but heating efficiency decreases due to excessive inductance
Solution Approach 1:
The patent implements local quality by creating non-uniform distributions of metal wires or conductive particles within the catalyst substrate. Rather than uniform distribution, the conductive elements are concentrated in specific zones or patterns that optimize the electromagnetic field interaction and inductive heating efficiency. This localized concentration of conductive material creates stronger local heating zones that can be strategically positioned to achieve both uniform overall heating and high heating power, resolving the contradiction between even heating coverage and heating efficiency
Solution Approach 2:
The patent applies segmentation by dividing the catalyst substrate into multiple zones with different concentrations or types of conductive particles. This segmentation allows different regions of the substrate to be heated at different rates or intensities, optimizing the overall heating process. By segmenting the heating zones, the system can achieve uniform temperature distribution across the entire substrate while maintaining high local heating power where needed, thus resolving the contradiction between even heating and heating efficiency
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 heat transfer and uniform heating patterns.
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
The use of induction heating, where a substrate body with metal wires is heated by a varying electromagnetic field generated by an induction coil
Implementation Method 3
ensuring rapid heat transfer and uniform heating patterns
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. In this way the metal wires are heated, resulting in heating of the substrate body and heating of exhaust gas flowing in the cells. Individual lengths of wire or wire lengths that are joined together are configured as loop conductors.