Regenerative Brake System for Catalytic Converter Heating

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Solution Overview

Problem

Hybrid vehicles face challenges in maintaining the catalytic converter at optimal operating temperatures due to intermittent engine use, leading to inefficient emission control and reduced battery life from excessive energy recharging and discharging.

Innovation Solution

A regenerative brake system that directly supplies electric current to an electrically heated catalytic converter, bypassing the vehicle battery, with the fraction of current determined by converter temperature, battery state, and other variables to optimize heating and reduce battery stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If the regenerative brake system recharges the vehicle battery with produced electrical energy, then the battery is recharged, but round trip energy losses occur and battery life is shortened due to excessive amp hour throughput

Engineering Contradiction:

Improvebattery rechargingVSAvoidround trip energy losses

Core Design Contradiction:

Use of energy by moving objectVSLoss of energy

Solution Approach 1:

The patent extracts the electrical energy produced by the regenerative brake system directly from the normal battery recharging path and redirects it to heat the catalytic converter. This extraction eliminates the round trip energy losses associated with charging and discharging the battery, while still achieving the desired heating function.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a controller as an intermediary that manages the distribution of electrical energy from the regenerative brake system. The controller acts as a mediator to route energy directly to the catalytic converter heater based on temperature sensors, bypassing the battery and optimizing energy utilization.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the internal combustion engine is used intermittently in hybrid vehicles, then the electric motor can power the vehicle, but the catalytic converter cools off between usage periods and operates below light-off temperature

Engineering Contradiction:

Improveintermittent engine useVSAvoidcatalytic converter temperature

Core Design Contradiction:

Adaptability or versatilityVSTemperature

Solution Approach 1:

The patent applies preliminary action by heating the catalytic converter using electrical energy from the regenerative brake system before the internal combustion engine is needed. Temperature sensors monitor the converter state, and the controller activates heating in advance to ensure the converter reaches light-off temperature when the engine starts, eliminating cold-start emissions.

Inventive Principle:

Principle #10Preliminary action

3Temperature

If electrically heated catalytic converters are connected to the vehicle battery to pre-heat, then the catalytic converter reaches light-off temperature, but excessive recharging and dispensing of energy from the battery reduces battery life

Engineering Contradiction:

Improvecatalytic converter temperatureVSAvoidbattery life

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent converts the normally wasted kinetic energy during braking into useful thermal energy for heating the catalytic converter. By capturing and redirecting this energy that would otherwise be lost, the system achieves converter heating without burdening the battery, effectively turning a waste stream into a beneficial resource.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 maintains the catalytic converter at optimal temperatures, reduces energy losses, and prolongs battery life by avoiding round trip energy losses and unnecessary charge throughput, while preparing the converter for internal combustion engine use, thus improving emission control and compliance with environmental regulations.

Implementation Method 1

The motor controller in turn sends an appropriate command to a motor/generator that switches the motor/generator from a motor mode applying energy to the wheels, i.e. propulsion mode to a generator mode, i.e. regenerative brake mode that converts kinetic energy from the wheels into electric current

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

At least a fraction of the electric current is sent to an electric heater that is incorporated with the catalytic converter to heat the catalytic converter

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS8919100B2Method of using a regenerative brake system for heating a motor vehicle catalytic converter and powering other electrical accessories

Publication Date: 2014.12.30 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A method for a motor vehicle includes using a regenerative brake system that produces electric current as a result of application of said regenerative brakes and sending at least a fraction of the electric current directly to an electrical accessory of the vehicle and bypassing the battery. One electrical accessory may be an electrically heated catalytic converter.