Resistive Heating Support Structure for Exhaust Emission Components
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Solution Overview
Problem
Conventional emission treatment component support structures for exhaust systems are complex and costly due to the need for additional heater elements to enhance the performance of emission treatment components, which are typically catalytic converters, particle filters, and NOx traps, as these components require higher temperatures for efficiency but incorporating heaters increases system complexity and size.
Innovation Solution
An emission treatment component support structure comprising an insulating layer with integrated resistive metal elements that can be heated by applying an electrical current, either through the vehicle's power system or a standalone power supply, allowing for uniform heat distribution to improve component efficiency without the need for additional heater elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heater element is included to heat the emission treatment component, then the performance of the emission treatment component is improved, but the device complexity and cost increase
Solution Approach 1:
The patent combines the heater element with the support structure by integrating resistive heating material into the support mat that already supports the emission treatment component. This merging eliminates the need for separate heater assemblies and reduces overall system complexity while maintaining the heating function.
Solution Approach 2:
The support structure serves dual functions: it mechanically supports the emission treatment component and simultaneously provides heating through integrated resistive material. This multi-functionality reduces the number of separate components needed in the exhaust system.
2Temperature
If a heater element is included to heat the emission treatment component, then the performance of the emission treatment component is improved, but the package size increases
Solution Approach 1:
By merging the heating function into the existing support structure, the patent eliminates the need for additional space-dedicating heater assemblies. The support mat itself becomes the heating element, maintaining compact packaging.
3Temperature
If a heater element is included to heat the emission treatment component, then the performance of the emission treatment component is improved, but the cost increases
Solution Approach 1:
The patent merges the heater element with the support structure, allowing both functions to be manufactured together in a single process. This integration reduces assembly steps and labor costs compared to installing separate heater assemblies.
Solution Approach 2:
The patent changes the material composition of the support structure by incorporating resistive heating material, transforming it from a passive support component to an active heating device. This material parameter change enables heating functionality without adding separate mechanical components.
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 support structure enhances the performance of emission treatment components by applying heat uniformly, reducing complexity and cost while maintaining a similar package size to standard systems, and allowing for efficient operation without the need for additional heating components.
Implementation Method 1
one or more resistive metal elements provided at least partially within and/or at least partially covering a surface of the insulating layer
Data Source
AI summary
An emission treatment component support structure for an exhaust system, the support structure comprising: an insulating layer configured to support a substrate of the emission treatment component within a housing; and one or more resistive metal elements provided at least partially within the insulating layer.