Radial-Wall Honeycomb Heater for Uniform Catalyst Activation
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Solution Overview
Problem
Existing electrically heated catalyst systems suffer from non-uniform heating profiles and inefficient energy usage due to varying degrees of heat distribution, which degrade performance and reduce efficiency, particularly during cold-start conditions in vehicles.
Innovation Solution
A honeycomb structure with radial and angular walls is designed to maintain uniform cell density and hydraulic diameter, using varying radial wall thickness, length, and angular offsets to ensure consistent heat generation across the catalyst, supplemented by a method of applying electric potential to induce resistive heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional electrical heater is used to heat a catalyst, then the catalyst can be activated, but non-uniform heating profiles occur leading to inefficient energy usage
Solution Approach 1:
The heater is segmented into multiple independent heating zones along its length, with each zone having independently controllable heating elements. This allows different sections of the catalyst to be heated to different temperatures and at different rates, achieving uniform overall heating while optimizing energy distribution across zones
Solution Approach 2:
Different sections of the heater are designed with locally optimized properties including varying heating element densities, insulation thicknesses, and power ratings. The heating elements are positioned to create a temperature profile that compensates for heat loss patterns, ensuring uniform catalyst activation throughout the entire length while minimizing total energy consumption
2Speed
If heating power is increased to improve catalyst activation speed, then cold-start performance improves, but energy consumption increases
Solution Approach 1:
The heater incorporates pre-heating elements and insulation structures that are activated before the main heating phase. Thermal insulation layers are pre-positioned to minimize heat loss during the initial heating phase, allowing rapid catalyst activation without requiring excessive power input
Solution Approach 2:
The heating system operates in periodic cycles with alternating high-power and low-power phases. During high-power phases, heating elements operate at maximum capacity to rapidly increase catalyst temperature. During low-power phases, the system maintains temperature with minimal power input, creating an efficient periodic heating pattern that achieves fast activation while reducing overall energy consumption
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
The solution achieves a uniform heat profile and improved energy efficiency by maintaining consistent heat generation and catalyst activation, enhancing emissions reduction even during cold-start conditions.
Implementation Method 1
a flow of current through the intersecting walls located between the first electrode and the second electrode that generates resistive heating in the intersecting walls
Data Source
AI summary
An electrical heater and a method of heating a catalyst. The heater includes a honeycomb body that includes a honeycomb structure. The honeycomb structure includes a central axis extending longitudinally and a plurality of interconnected walls. The interconnected walls include a plurality of radial walls extending along a radius of the honeycomb body between the central axis and an outermost periphery of the honeycomb body and a plurality of angular walls arranged concentrically with respect to the central axis and spanning between the radial walls. The honeycomb structure includes a plurality of cells defined by the interconnected walls. The heater comprises a first electrode disposed at the central axis and a second electrode disposed radially outwardly of the central axis and in electrical communication with the first electrode via one or more of the intersecting walls that are located between the first electrode and second electrode.