Segmented Cooling Module Catalytic Coating for NMOG Emission Control
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Solution Overview
Problem
In compact vehicle installation spaces, achieving maximum NMOG emission credits is hindered by the reduced front face of heat exchangers, which limits the effectiveness of catalytic coatings like PremAir®, used for ozone conversion, due to the larger depth of components like charge air coolers.
Innovation Solution
A cooling module design featuring a first and second heat exchanger connected in a common frame, where the second heat exchanger is composed of smaller, thinner units that can be through-coated before assembly, allowing for a larger coated surface area and enhanced ozone conversion efficiency, with both heat exchangers having a catalytic coating that splits ozone molecules into oxygen molecules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a single deep heat exchanger is used to meet installation space constraints, then the installation space is optimized, but the catalytic coating surface area is reduced and cannot achieve maximum NMOG emission credits
Solution Approach 1:
The second heat exchanger is divided into multiple partial heat exchangers (first partial heat exchanger and second partial heat exchanger) arranged one behind the other in the flow direction. This segmentation allows each partial heat exchanger to be individually through-coated with catalytic coating, maximizing the total coated surface area while maintaining a compact overall depth that fits installation space constraints.
2Volume of moving object
If the front face of heat exchangers is reduced to fit compact installation spaces, then installation space is optimized, but the NMOG credit calculation is limited
Solution Approach 1:
Instead of increasing the front face area (two-dimensional solution), the patent extends the catalytic coating into the depth dimension by using multiple partial heat exchangers arranged sequentially. This allows the coated surface area to increase in the flow direction, maximizing NMOG credits without increasing the frontal installation space footprint.
3Reliability
If a through-coating is applied to a deep heat exchanger, then ozone conversion is improved, but the coating cannot be functionally effective due to depth limitations
Solution Approach 1:
By segmenting the deep heat exchanger into multiple shallower partial heat exchangers, each unit can receive effective through-coating with catalytic material. The segmented structure ensures that the coating penetrates fully through each partial heat exchanger thickness, achieving functional effectiveness that would be impossible in a single deep unit of equivalent total depth.
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 design achieves maximum NMOG emission credits and increases coating stability, ensuring compliance with stringent emission regulations even in tight installation spaces, while eliminating the need for additional sensors and enhancing coating efficiency.
Implementation Method 1
The first and the second heat exchanger have a catalytic coating. The second heat exchanger is composed of at least one first and one second partial (component) heat exchanger which are arranged one behind the other in the flow direction of the cooling air and which are operatively connected with one another.
Implementation Method 2
a cooling module composed of at least a first and a second heat exchanger, which are connected in a common frame or directly with one another, and wherein cooling air can flow through both heat exchangers
Data Source
AI summary
A cooling module, composed of at least one first and one second heat exchanger, are connected in a common frame or directly to one another, it being possible for cooling air to flow through both heat exchangers. The second heat exchanger has a greater structural depth than the first heat exchanger in the flow direction of the cooling air. The first heat exchanger and the second heat exchanger have a catalytic coating and the second heat exchanger is composed of at least one first and one second partial heat exchanger which are arranged one behind the other in the flow direction of the cooling air and which are operatively connected to one another. By means of the configuration according to the invention, the largest possible catalytically active coating surface area is attained.