Induction-Heated Ceramic Substrate for Cold Start Emissions
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Solution Overview
Problem
Conventional emissions treatment systems, such as catalytic converters, particulate filters, and selective catalytic reduction systems, have low efficiency during the temperature range from ambient air start-up to light-off temperature, resulting in inadequate catalytic action and increased emissions during vehicle idling or city driving.
Innovation Solution
The process involves injecting a mastic-metal particle mixture into selected cells of a ceramic substrate, which is then cured to create a matrix that can be heated using induction heating, allowing for faster temperature increase and improved catalytic converter efficiency by incorporating metal particles with high magnetic permeability, such as stainless steel, to accelerate pollutant conversion processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional emissions treatment systems are used, then the structure is simple and manufacturing is easy, but the efficiency is low during cold start conditions
Solution Approach 1:
The patent applies composite materials by combining ceramic substrate with metal particles (such as stainless steel, iron, or nickel) dispersed within a mastic matrix. This composite structure enables induction heating capability while maintaining the catalytic function, resolving the contradiction between treatment efficiency and system complexity by integrating heating functionality directly into the substrate material itself.
Solution Approach 2:
The patent changes the physical and chemical parameters of the substrate by incorporating metal particles with specific magnetic properties (high magnetic permeability) into the mastic-ceramic matrix. This parameter change enables the substrate to respond to electromagnetic fields for rapid heating, improving cold start efficiency without requiring separate heating systems.
2Speed
If induction heating is implemented to rapidly increase temperature, then the catalytic action is improved, but the device complexity increases
Solution Approach 1:
The patent implements self-service by making the ceramic substrate itself capable of induction heating through embedded metal particles. The substrate serves its own heating needs without requiring external heating devices, achieving rapid temperature increase while minimizing system complexity by eliminating separate heating components.
Solution Approach 2:
The patent merges the heating function with the structural substrate by integrating metal particles directly into the ceramic-mastic matrix. This combination unifies the support structure and heating element into a single component, enabling rapid heating while reducing overall system complexity.
3Productivity
If metal particles are added to the mastic mixture, then induction heating capability is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by incorporating metal particles into the mastic mixture during the initial substrate manufacturing process, before the ceramic is formed and fired. This timing allows the metal particles to be uniformly distributed throughout the substrate structure, enabling subsequent induction heating while maintaining relatively simple manufacturing procedures.
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 enhances the efficiency of emissions treatment by rapidly heating the catalytic converter, thereby reducing cold start emissions and improving the conversion of noxious gases into less harmful forms, even at low temperatures, by utilizing the induction heating of metal particles within the mastic-metal particle mixture.
Implementation Method 1
heating using induction heating, allowing for faster temperature increase and improved catalytic converter efficiency by incorporating metal particles with high magnetic permeability
Implementation Method 2
incorporating metal particles with high magnetic permeability, such as stainless steel, to accelerate pollutant conversion processes
Implementation Method 3
carbon monoxide and nitric oxide. These gases are dangerous to health but can be converted to less noxious gases by oxidation respectively to carbon dioxide and nitrogen/oxygen. Other noxious gaseous emission products, including unburned hydrocarbons, can also be converted either by oxidation or reduction to less noxious forms
Implementation Method 4
carbon monoxide and nitric oxide. These gases are dangerous to health but can be converted to less noxious gases by oxidation respectively to carbon dioxide and nitrogen/oxygen. 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
In a process for manufacturing a component for an emissions treatment unit, green ceramic product is extruded through a die to form an extrusion having a honeycomb substrate structure with an array of parallel, linear tubular cells extending along its length, the cells bounded by walls dividing adjacent cells from one another. A ceramic unit is obtained by cutting off, curing and firing a length of the extrusion a length of the extrusion. Following the firing, a mixture of a flowable, uncured curable material and a particulate metal component is injected from an end of the ceramic unit into selected ones of the cells so as to block the selected cells over at least a part of their lengths while maintaining all of the walls of the ceramic unit. The injected mixture is then cured to render it solid.