Wastegate Valve Bypass Path for Catalytic Converter Heating

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Solution Overview

Problem

Internal combustion engine exhaust systems face challenges in rapidly heating catalytic converters to optimal operating temperatures during startup, especially in vehicles with larger engines and turbochargers, leading to increased emissions due to the thermal mass of intervening components.

Innovation Solution

A wastegate valve is introduced in the turbocharger bypass path, allowing gases to bypass the turbocharger and directly heat the catalytic converter monolith by redirecting them at a specific angle to maximize heat transfer, reducing momentum change and enthalpy loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a turbocharger is installed in the exhaust system to enhance engine performance, then engine power is improved, but the thermal mass of the turbocharger increases, causing a delay in heating the catalytic converter to optimal temperature during startup

Engineering Contradiction:

Improveengine powerVSAvoidcatalytic converter warm-up time

Core Design Contradiction:

PowerVSLoss of time

Solution Approach 1:

The exhaust flow is segmented into two separate paths: a first path through the turbocharger turbine for power generation, and a second bypass path directly to the catalytic converter for rapid heating. The wastegate valve controls the distribution of exhaust gas between these two paths, allowing the system to simultaneously achieve both engine power enhancement and rapid catalytic converter warm-up during startup conditions

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wastegate valve acts as an intermediary device that mediates the exhaust flow distribution between the turbocharger path and the bypass path. By controlling the wastegate valve opening, the system can direct a controlled portion of exhaust gas through the bypass path to rapidly heat the catalytic converter while maintaining sufficient flow through the turbocharger for engine performance

Inventive Principle:

Principle #24Intermediary (Mediator)

2Use of energy by moving object

If the engine size is reduced to limit fuel consumption and emissions, then fuel efficiency is improved, but the heat available to heat the catalytic converter is reduced

Engineering Contradiction:

Improvefuel efficiencyVSAvoidexhaust gas temperature

Core Design Contradiction:

Use of energy by moving objectVSTemperature

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system changes the flow distribution parameter by controlling the wastegate valve opening to direct a higher proportion of exhaust gas through the bypass path during startup conditions. This parameter change ensures sufficient heat delivery to the catalytic converter even when the overall exhaust temperature from a smaller engine is lower

Inventive Principle:

Principle #35Parameter changes

3Loss of time

If heating coils are installed within the catalytic converter to heat the monolith, then the catalytic converter reaches optimal temperature faster, but the system complexity and cost increase

Engineering Contradiction:

Improvecatalytic converter warm-up timeVSAvoidexhaust system complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The system uses the engine's own exhaust gas as the heating source for the catalytic converter, eliminating the need for external heating coils or auxiliary heating systems. By controlling the wastegate valve to direct exhaust flow through the bypass path, the hot exhaust gas self-heats the catalytic converter monolith, achieving rapid warm-up without adding system complexity or cost

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system converts what would normally be wasted exhaust flow (bypassing the turbocharger) into a beneficial heating source for the catalytic converter. The exhaust gas that would otherwise be unused for power generation is redirected through the bypass path to provide the necessary heat for rapid catalytic converter warm-up, turning a potential loss into a benefit

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 accelerates the heating of the catalytic converter to its optimal temperature during engine startup, reducing emissions and avoiding the need for additional heating coils, thus enhancing emissions control without increasing system complexity or cost.

Implementation Method 1

direct gases exiting the bypass path onto a leading face of a catalytic converter monolith for heating the monolith

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11560832B2Wastegate valve

Publication Date: 2023.01.24 JAGUAR LAND ROVER LTD

AI summary

A wastegate valve for a bypass path for a turbocharger in an internal combustion engine, the wastegate valve comprises a valve seat defining a plane which is non-orthogonal to the principal flow axis for gases flowing along the bypass path and a valve member pivotable from an open position to a closed position, wherein in the closed position the valve member is seated on the valve seat, and in a fully open position the valve member is positioned to direct gases exiting the bypass path onto a leading face of a catalytic converter monolith for heating the monolith.