Induction Heating Wires in Honeycomb Substrate for Fast Light-Off
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Solution Overview
Problem
Catalytic converters and particulate filters have low efficiency when cold, leading to increased toxic emissions during vehicle start-up, as they require time to reach the light-off temperature for effective pollutant conversion.
Innovation Solution
A method for loading elongate wire lengths into a honeycomb ceramic substrate of a gaseous emissions treatment assembly, where the wires are formed with pointed tips and aligned to project into cells, facilitating quick induction heating through a varying electromagnetic field, thereby reducing the time to reach light-off temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional catalytic converters are used without induction heating, then the structure is simple and manufacturing is easy, but the time to reach light-off temperature is long and cold-start emissions are high
Solution Approach 1:
The patent applies preliminary action by inserting wires with pointed tips into the honeycomb substrate before final assembly, positioning them in advance to enable rapid induction heating when needed. This pre-positioning of heating elements allows the system to quickly reach light-off temperature without adding complex control mechanisms during operation.
Solution Approach 2:
The patent uses an intermediary approach by introducing wire elements as a mediating component between the electromagnetic field generator and the honeycomb substrate. These wires act as intermediate heat transfer media that convert electromagnetic energy to thermal energy, facilitating rapid heating of the substrate without direct electromagnetic coupling.
2Manufacturing precision
If wires are inserted into honeycomb cells without pointed tips, then manufacturing is simpler, but insertion precision and alignment are poor
Solution Approach 1:
The patent applies the spheroidality principle by forming wire tips with rounded or pointed curved geometries rather than sharp edges. This curvature allows the wire tips to smoothly engage with the honeycomb cell openings and follow the cell walls during insertion, improving alignment and positioning precision without requiring complex insertion mechanisms.
Solution Approach 2:
The patent uses asymmetry by creating wires with asymmetric tip geometries (pointed tips) that are different from the uniform cylindrical body. This asymmetric tip design provides directional insertion characteristics, allowing the wire to naturally align with and enter the honeycomb cells in the correct orientation, thereby improving insertion precision.
3Object-affected harmful factors
If cold catalytic converters are used during start-up, then energy consumption is lower, but toxic emissions are significantly increased
Solution Approach 1:
The patent applies parameter changes by using induction heating to rapidly change the temperature parameter of the catalytic converter from cold start conditions to light-off temperature. This controlled parameter change enables the catalyst to become active quickly, reducing harmful emissions during the critical cold-start period while managing energy consumption through targeted heating.
Solution Approach 2:
The patent uses periodic action through induction heating cycles that activate the catalytic converter only when needed (during cold-start conditions). The electromagnetic field is applied periodically or on-demand to heat the wires and substrate, rather than continuously, thereby reducing overall energy consumption while effectively addressing cold-start emissions.
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 enhances the efficiency of catalytic converters and particulate filters by rapidly heating them up during start-up, reducing cold-start emissions and improving pollutant conversion processes.
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
By energizing the field generator inductively to heat the wires, the time to 'light off'—the temperature at which the converter is hot enough to render exhaust emissions less toxic—is reduced
Data Source
AI summary
A method is disclosed for loading elongate wire lengths into elongate cells of a honeycomb ceramic substrate unit for a gaseous emissions treatment assembly, the cells each having a small cross-sectional area, the area shape matching the cross-sectional shape of the loaded wire lengths and marginally greater in area size than the wire lengths. A wire length is formed with a generally pointed end tip by pulling adjacent parts of a wire along the wire axis respectively in opposite directions from a desired wire breakage site. The tension and timing of the pulling operation are selected so that a desired tip profile is achieved. Initial alignment is done using machine vision. Subsequent adjustment is effected in dependence on feedback from sensors mounted close to the end of a wire insertion arm. Breakage and push insertion of wires is done using alternating gripping and moving of chucks or collets which have aperture shapes close in profile to the outer profile of the wire lengths.