Phase Change Material in Catalyst Honeycomb for Temperature Control
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Solution Overview
Problem
Current catalytic converters face inefficiencies due to temperature-related issues, such as high pollutant emissions during cold starts and catalyst degradation, and require complex designs to maintain optimal operating temperatures, which increase manufacturing costs and complexity.
Innovation Solution
Incorporating phase change materials within the catalytic converter's honeycomb structure to regulate temperature between engine shut-down and start-up, and during operation, using materials with specific melting points to absorb and release heat, thereby reducing cold start problems and preventing overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If complex designs with vacuum sealed chambers and shrouds are used to maintain catalyst temperature, then temperature maintenance capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the phase change material from complex vacuum sealed chambers and shrouds, placing it directly into the honeycomb structure cells. This eliminates the need for additional containment components while maintaining the temperature regulation function, directly resolving the contradiction between temperature maintenance capability and device complexity
Solution Approach 2:
The phase change material is nested directly within the honeycomb catalyst structure cells, integrating the temperature regulation function into the existing catalyst architecture. This nested integration eliminates separate containment systems while preserving thermal control, addressing both temperature maintenance and complexity reduction
2Temperature
If phase change materials are placed in vacuum sealed chambers, then temperature regulation is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The invention removes the phase change material from complex vacuum sealed chambers and places it directly into the honeycomb cells. This extraction eliminates the need for specialized containment manufacturing while preserving the temperature regulation function, directly improving ease of manufacture
Solution Approach 2:
The patent merges the phase change material placement with the existing honeycomb structure, utilizing the same manufacturing process and components. This consolidation eliminates separate vacuum chamber manufacturing steps, reducing both manufacturing complexity and cost while maintaining temperature regulation
3Temperature
If additional components are added to maintain catalyst temperature, then temperature control capability is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines the temperature control function with the existing honeycomb catalyst structure by placing phase change material directly in the cells. This merging eliminates the need for additional separate components, reducing manufacturing cost while maintaining temperature control capability
Solution Approach 2:
The honeycomb structure serves multiple functions: it provides the catalyst support and simultaneously houses the phase change material for temperature control. This multi-functionality eliminates the need for additional dedicated temperature control components, reducing manufacturing cost while maintaining control 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 solution allows for efficient temperature maintenance of the catalyst, reducing cold start emissions and preventing overheating, while simplifying the design and manufacturing process, thus addressing the complexity and cost issues of existing systems.
Implementation Method 1
A phase change material is contained in at least some of those cells where catalyst is not present such that the phase change materials are adjacent the cells containing the catalyst in the honeycomb body
Implementation Method 2
using materials with specific melting points to absorb and release heat
Data Source
AI summary
A vehicle exhaust system is provided and comprises a catalyst positioned in an exhaust passage of a vehicle. The catalyst is in the form of a washcoat supported on a substrate. The system includes a phase change material located adjacent to the catalyst to maintain the temperature of the catalyst between engine shut-down and subsequent start-up as well as to regulate the temperature during engine operation. In some embodiments, the phase change material comprises particles of a metal or metal alloy encapsulated in a ceramic material. The metal or metal alloy is adapted to have a phase change that occurs within a temperature range wherein the catalyst is active.