Induction Heating for Catalytic Converter Light-Off
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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 idling or low engine operation, as they require high temperatures to initiate effective pollutant conversion processes.
Innovation Solution
The implementation of induction heating using a varying electromagnetic field to rapidly heat metal inserts within the catalytic converter or particulate filter substrate, which in turn heats the ceramic substrate and exhaust gases, thereby accelerating the attainment of light-off temperature and enhancing catalytic reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If catalytic converters are used at cold start-up temperatures, then the device structure is simple and easy to manufacture, but the conversion efficiency of harmful emissions is low
Solution Approach 1:
The patent applies preliminary action by incorporating an induction heating system that activates before the catalytic converter reaches its light-off temperature. The heating element pre-heats the catalyst substrate to the required operating temperature (typically 300-400°C), ensuring the catalyst is ready to immediately convert emissions effectively from the start, rather than waiting for passive heating during cold operation.
2Productivity
If the catalytic converter is heated to light-off temperature quickly, then the conversion efficiency improves, but the energy consumption increases
Solution Approach 1:
The patent implements periodic action through a control system that activates the induction heating element only during cold start conditions or when emissions conversion efficiency is below optimal levels. The system monitors temperature and emissions parameters, cycling the heating element on and off as needed, rather than maintaining continuous heating, thus achieving rapid light-off when required while minimizing unnecessary energy consumption during normal operating conditions.
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 method significantly reduces the time to reach light-off temperature, enhancing the efficiency of pollutant conversion processes and minimizing emissions during cold start-ups, aligning with stringent emission reduction 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
heat the metal and so heat the substrate body
Implementation Method 3
heat the metal and so heat the substrate body... accelerating the attainment of light-off temperature
Data Source
Figure 1~3
Figure 4~6C
Figure 7~9B
AI summary
An assembly for use in treating gaseous exhaust emissions has an inductive heater mounted next to a gaseous emissions treatment unit. The upstream unit or section has linear passages extending the length of the first substrate body for the passage of emissions gas but with some of the passages blocked by metal inserts for use in inductive heating of the upstream unit. The concentration of metal inserts is high and the metal inserts are distributed to enable rapid intense inductive heating of the slice to achieve "light off' temperature rapidly in order to pass heat-supplemented gaseous emissions at light-off temperature to the downstream substrate or section as quickly as possible.