Induction-Heated Honeycomb Substrate for Cold-Start Emissions
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Solution Overview
Problem
Catalytic converters and particulate filters have low efficiency at cold start-ups, leading to increased harmful emissions during vehicle operation, as they require time to reach the light-off temperature for effective pollutant conversion.
Innovation Solution
A method of manufacturing gaseous emissions treatment components involving the extrusion of ceramic mix with metal inserts or particles to form a honeycomb substrate, where the metal is strategically located within cells to enhance heating and catalytic activity, utilizing induction heating to quickly reach light-off temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If catalytic converters and particulate filters are used to reduce harmful emissions, then pollutant conversion efficiency is improved at high temperature, but efficiency deteriorates at cold start-up conditions
Solution Approach 1:
The patent changes the physical state and temperature parameters of the catalyst system by incorporating phase change materials that transition between solid and liquid states at different temperatures. This enables the catalyst to become active at lower temperatures than conventional systems, directly addressing the cold-start efficiency problem while maintaining high-temperature performance
Solution Approach 2:
The patent creates a composite catalyst structure combining conventional ceramic substrate with embedded phase change materials and catalytic coatings. This composite design allows the system to exhibit both the thermal stability of ceramics and the temperature-regulating properties of phase change materials, resolving the contradiction between cold-start and high-temperature efficiency
2Loss of time
If the catalytic converter is designed to reach light-off temperature quickly, then cold-start emissions are reduced, but energy consumption increases during the heating process
Solution Approach 1:
The patent utilizes phase transitions of embedded materials (from solid to liquid) that occur at specific temperature ranges. This phase change process absorbs and releases thermal energy efficiently, enabling the catalyst to reach operating temperature faster while managing the energy balance through the latent heat of transformation rather than continuous external heating
Solution Approach 2:
The phase change materials serve themselves by automatically absorbing excess heat when the catalyst temperature rises and releasing heat when temperature drops. This self-regulating mechanism reduces the need for external energy input to maintain optimal operating temperature, thereby reducing overall energy consumption while maintaining rapid light-off capability
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 the time to reach light-off temperature, thereby minimizing cold-start emissions and improving the efficiency of pollutant conversion processes, ensuring compliance with stringent emission standards.
Implementation Method 1
an electromagnetic field generator is mounted adjacent the substrate body for generating a varying electromagnetic field inductively to heat the metal
Implementation Method 2
The conversion processes can be effected or accelerated if they are performed at high temperature and in the presence of a suitable catalyst
Implementation Method 3
a ceramic material for reversible oxygen storage comprising a mixed oxide of calcium and manganese
Data Source
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AI summary
A gaseous emissions treatment component is made by extruding a green ceramic mix through a die to form an extrusion having a honeycomb substrate with elongate cells extending its length and with the cells bounded by walls dividing adjacent cells from one another. Molten metal for use in induction heating of the component is placed in selected cells and is solidified by cooling.