Induction Heating Pins with Protrusions for Exhaust Gas Preheating
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Solution Overview
Problem
Existing exhaust gas treatment systems, such as catalytic converters, face inefficiencies in heat distribution and reaction initiation due to limited heating profiles along the substrate, leading to slower 'light-off' temperatures and increased power consumption.
Innovation Solution
The use of induction heating pins with protrusions, particularly spiral configurations, that extend from the substrate front end to induce turbulence in the gas flow, enhancing thermal transfer and preheating before the gas enters the substrate channels, thereby accelerating catalytic reactions and reducing power usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal pins are fully contained within substrate cells for induction heating, then heating is limited to positions along the substrate length, but this results in a less-than-ideal heating profile and slower light-off temperature achievement
Solution Approach 1:
The invention extracts the metal pin from the confined substrate cell and extends it outward to protrude from the substrate front face. This extraction allows the pin to interact directly with the incoming exhaust gas flow before it enters the substrate channels, creating a more effective heating profile that accelerates light-off temperature achievement while maintaining efficient heat distribution along the substrate length.
2Reliability
If induction heating is applied to achieve catalytic reactions, then power consumption increases, but extending heating duration delays shutdown and increases energy usage
Solution Approach 1:
The invention performs preliminary heating action by positioning the metal pin to protrude from the substrate front face, where it directly preheats the incoming exhaust gas before it enters the substrate channels. This preliminary action ensures that catalytic reactions initiate more quickly and effectively, allowing the induction heating system to be shut off earlier while still achieving reliable catalytic conversion, thereby reducing overall power consumption.
3Use of energy by stationary object
If gas flow enters substrate channels directly, then flow remains laminar, but this limits thermal transfer efficiency to the airflow
Solution Approach 1:
The invention introduces the metal pin as an intermediary element between the induction heating source and the exhaust gas flow. The pin protrudes from the substrate front face and acts as a mediator that directly contacts and heats the incoming gas, creating turbulence that enhances thermal transfer efficiency. This intermediary structure enables more effective energy transfer from the heating source to the gas flow before it enters the substrate channels.
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 increases the preheating effect, accelerates catalytic reactions, and allows for earlier shutdown of the induction heating system, improving efficiency and reducing power consumption by converting the gas flow from laminar to turbulent, ensuring quicker 'light-off' temperatures and enhanced heat distribution across the substrate.
Implementation Method 1
induction heated protruding pin technology causes the gas flow to be changed from a laminar state to a turbulent state and provides increased thermal transfer to the airflow before it enters the ceramic substrate channels
Implementation Method 2
U.S. patent Ser. No. 10/918,994 (Induction heating apparatus and methods)
Implementation Method 3
the turbulence-inducing part integral with the linear supporting part and extending away from the substrate
Data Source
AI summary
An assembly for induction heating an exhaust gas flow includes a substrate and linear cells for the flow of the gas through the substrate from a front end of the substrate body to a back end. Metal members such as pins or wires have linear supporting parts projecting from a front end of the substrate into front-end parts of the cells. The metal members have turbulence-inducing part to generate turbulence in the exhaust gas flowing into the cells and through the substrate. The turbulence-inducing parts are integral with respective linear supporting parts and extend away from the substrate. Configurations of an induction heating coil and a magnetic flux concentrator are adapted for the particular location and form of the pins.