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 emissions during vehicle start-up and idling, as they require high temperatures to initiate pollutant conversion processes effectively.
Innovation Solution
The use of induction heating coils to generate a varying electromagnetic field, which heats metal wires or rods within the catalytic converter or particulate filter substrate, accelerating the heating of the ceramic substrate and exhaust gases, thereby enhancing the catalytic conversion of pollutants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If catalytic converters are used to treat exhaust gases, then harmful emissions are reduced through catalytic conversion, but the device has low efficiency when cold and cannot effectively reduce emissions during vehicle start-up and idling
Solution Approach 1:
The patent applies preliminary action by incorporating heating elements (electric heaters or induction heating coils) that preheat the catalytic converter substrate before the vehicle starts or during idle operation. This preliminary heating brings the catalyst to its light-off temperature faster, enabling it to become effective at reducing emissions sooner during cold start conditions
Solution Approach 2:
The patent changes the temperature parameter of the catalytic converter by introducing active heating mechanisms. Electric heaters increase the substrate temperature through resistive heating, while induction heating coils generate electromagnetic fields that induce eddy currents in metal wires embedded in the substrate, converting electrical energy to thermal energy to rapidly elevate the catalyst temperature to operational levels
2Reliability
If heating elements are added to preheat the catalytic converter, then cold-start emissions are reduced, but the device complexity increases
Solution Approach 1:
The patent merges the heating function with the existing catalytic converter structure by integrating heating elements directly into the substrate. Electric heaters are positioned within the substrate walls or around the perimeter, while induction heating coils wrap around the substrate or are embedded within it. This integration allows the heating and catalytic functions to work as a unified system, reducing overall device complexity compared to separate heating and conversion units
Solution Approach 2:
The patent replaces mechanical or chemical heating methods with electromagnetic induction heating. Instead of using combustion-based heaters or complex thermal management systems, induction heating coils generate electromagnetic fields that directly induce currents in metal wires within the substrate, providing efficient and controllable heating with simpler system architecture
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 achieves the light-off temperature, significantly reducing cold-start emissions by efficiently preheating the catalytic converter or particulate filter, thereby enhancing the conversion of harmful gases into less noxious forms.
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
Implementation Method 2
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 3
heats the metal wires or rods within the catalytic converter or particulate filter substrate, accelerating the heating of the ceramic substrate
Implementation Method 4
accelerating the heating of the ceramic substrate and exhaust gases
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. The metal wires are distributed non-uniformly through the substrate body to obtain a desired heating pattern.