Induction Heating Movable Heat Profile 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 and low-temperature operations, as they require time to reach the light-off temperature for effective pollutant conversion.
Innovation Solution
The use of induction heating with a movable heat profile is implemented by varying the electromagnetic field frequency to quickly heat the substrate and catalysts in catalytic converters, allowing for efficient heat transfer and rapid initiation of catalytic reactions, even at low temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If catalytic converters operate at ambient temperature during cold start-up, then the device can function without heating, but the efficiency of pollutant conversion is low because the temperature is below light-off temperature
Solution Approach 1:
The induction heating coil activates before the catalytic converter reaches light-off temperature to preheat the substrate and catalyst. This preliminary heating action ensures that the converter reaches optimal operating temperature faster, improving pollutant conversion efficiency during cold start-up conditions
Solution Approach 2:
The system changes the temperature parameter by applying electromagnetic induction heating to raise the substrate and catalyst temperature from ambient conditions to light-off temperature. This parameter change enables the catalytic reactions to proceed efficiently by achieving the necessary thermal conditions
2Loss of time
If induction heating is applied to heat the substrate and catalyst, then the time to reach light-off temperature is reduced, but the device complexity increases due to the electromagnetic field generator and coil components
Solution Approach 1:
The patent replaces conventional thermal heating mechanisms with electromagnetic induction heating. The induction heating coil generates an electromagnetic field that directly induces eddy currents in the substrate and catalyst, converting electromagnetic energy to thermal energy without mechanical contact, thereby reducing the time to reach light-off temperature
Solution Approach 2:
The metal elements distributed within the substrate cells act as intermediaries to absorb electromagnetic energy from the induction coil and convert it to heat. These metal elements facilitate efficient energy transfer from the electromagnetic field to the substrate and catalyst, reducing overall system complexity while achieving rapid heating
3Power
If metal elements are distributed non-uniformly in the substrate to create a desired heating pattern, then the heating efficiency is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by distributing metal elements non-uniformly within the substrate cells based on specific heating requirements. Different regions of the substrate receive different densities of metal elements to create localized heating zones, optimizing heat distribution to where it is most needed for catalytic activation
Solution Approach 2:
The substrate is divided into multiple cells with metal elements strategically placed in selected cells rather than uniformly throughout. This segmentation allows for controlled heating patterns where metal elements are positioned in specific cells to create desired thermal gradients and heating profiles
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, enhancing the efficiency of pollutant conversion and reducing emissions during start-ups and idling conditions, thereby improving the overall performance of catalytic converters and particulate filters.
Implementation Method 1
an electromagnetic field generator is mounted adjacent the substrate body for generating a varying electromagnetic field inductively to heat the metal and so heat the substrate body
Implementation Method 2
generating a varying electromagnetic field inductively to heat the metal
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
Implementation Method 4
The conversion processes can be effected or accelerated if they are performed at high temperature and in the presence of a suitable catalyst
Data Source
Figure 1~3
Figure 4~29
Figure 5~7
AI summary
An assembly for treating gaseous emissions has a substrate (10) with cells (12) for the passage of an emissions gas to be treated and inductive heating elements (22) located in some of the cells (12). An electromagnetic field generator mounted near the substrate (10) generates a varying electromagnetic field, so as to inductively heat the inductive heating elements (22) and so heat the substrate (10). Some of the inductive heating elements (22) have a first natural resonant frequency other inductive elements (22) have a second natural resonant frequency different from the first resonant frequency. A power supply for the electromagnetic field generator is operated with a frequency closer to the first resonant frequency for a time and is operated with a frequency closer to the second resonant frequency period for a subsequent time period. By switching between the frequencies at different times, the heating profile can be moved in the substrate (10).