Apparatus and method for gaseous emissions treatment with induction heating of loop conductors

• US 10,207,222 B2
• Filed: 09/29/2016
• Issued: 02/19/2019
• Est. Priority Date: 09/18/2013
• Status: Active Grant

• Current Assignee: Advanced Technology Emission Solutions Inc
• Original Assignee: Advanced Technology Emission Solutions Inc
• Inventors: Crawford, Robin, Douglas, John
• Primary Examiner(s): Maines, Patrick
• Application Number:
  US15/279,857
• Publication Number:
  US 20170014763A1
• Time in Patent Office: 873 Days
• CPC Class Codes: B01D 2255/915 Catalyst supported on particulate filters
• CPC Class Codes: B01D 46/2418 Honeycomb filters used for filtering exhaust gases of an internal combustion engine F01N3/022; ceramic honeycomb structures per se C04B38/0006
• CPC Class Codes: B01D 46/4263 Means for active heating or cooling
• CPC Class Codes: B01D 53/94 by catalytic processes
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: F01N 2240/05 a magnetic, e.g. electromagnetic, device other than a valve
• CPC Class Codes: F01N 2510/00 Surface coverings
• CPC Class Codes: F01N 3/2013 using electric or magnetic heating means
• CPC Class Codes: F01N 3/2026 directly electrifying the catalyst substrate, i.e. heating the electrically conductive catalyst substrate by joule effect
• CPC Class Codes: F01N 3/26 Construction of thermal reactors
• CPC Class Codes: F01N 3/2828 Ceramic multi-channel monoliths, e.g. honeycombs
• CPC Class Codes: H05B 6/108 for heating a fluid
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

An assembly for treating gaseous emissions includes a substrate body having cells for the passages of emissions gas. Lengths of metal wire are located in selected ones of the cells and an induction heating coil is mounted adjacent the substrate body for generating a varying electromagnetic field. In this way the metal wires are heated, resulting in heating of the substrate body and heating of exhaust gas flowing in the cells. Individual lengths of wire or wire lengths that are joined together are configured as loop conductors.

Claims

1. An assembly for treating gaseous emissions comprising a substrate body having a plurality of parallel cells for the passage of emissions gas, a closed loop metal wire conductor with the ends of the wire being joined together to close the loop, located in a first set of the plurality of cells and having a first part thereof extending in a first direction along one of the set of cells and a second part thereof extending in a direction opposite to the first direction along another of the set of cells, and an induction heating coil mounted adjacent the substrate body for generating a varying electromagnetic field, thereby to inductively heat the first and second parts by inducing eddy currents therein and to heat the closed loop conductor by inducing current around the loop, the loop conductor permitting aggregation of induced currents and translation of heating thereby into a consistent wire temperature around the loop.

2. The assembly of claim 1, there being a length of metal wire in each of the first set of cells, the wire being hollow.

3. The assembly of claim 1, the substrate body having a front for entry of gaseous emissions to be treated and a back for exit of treated gaseous emissions, joins between the wire lengths being at the front and back ends.

4. The assembly of claim 1, the substrate body having a front for entry of gaseous emissions to be treated and a back for exit of treated gaseous emissions, the loop further including a portion in front of the front end for intercepting and inductively preheating gaseous emissions entering the substrate body.

5. The assembly as claimed in claim 4, wherein wire segments are located at the front of the substrate body but not at the back of the substrate body, the induction heating coil mounted adjacent the substrate body at the front of the assembly.

6. The assembly as claimed in claim 4, wherein wire segments in a first subset of the first set of cells are longer than wire segments in a second subset of the first set of cells.

7. The assembly as claimed in claim 4, the cells of the first set each containing a plurality of discrete wire lengths distributed along the length of the respective cell.

8. The assembly as claimed in claim 1, the location of the metal wire selected to obtain a generally uniform heating in at least a part of the substrate body.

9. The assembly as claimed in claim 1, there being a greater concentration of wire per unit volume of the substrate body towards the center of the substrate body than at the perimeter thereof.

10. The assembly as claimed in claim 9, wherein the cells of the first subset are closer to the center of the substrate body than the cells of the second subset.

11. The assembly as claimed in claim 1, the assembly having a front for entry of gaseous emissions to be treated and a back for exit of treated gaseous emissions, the substrate body having a relatively higher concentration of wire per unit volume of the substrate body near the front than near the back.

12. The assembly as claimed in claim 1, at least some of the lengths of wire being wire segments extending only partially along the lengths of the cells.

13. The assembly as claimed in claim 1, the substrate body having a front for entry of gaseous emissions to be treated and a back for exit of treated gaseous emissions, at least some of the wires projecting from the front of the substrate body.

14. The assembly as claimed in claim 1, the metallic composition of one wire being different from the metallic composition of at least one other wire.

15. The assembly as claimed in claim 1, the concentration of wire per unit volume of the substrate body selected to obtain a desired level of inductance heating near the center of the substrate body.

16. The assembly as claimed in claim 1, the substrate body made of a ceramic honeycomb material.

17. The assembly as claimed in claim 1, the metal being a ferromagnetic metal.

18. The assembly as claimed in claim 1, the wires having one of a hollow and an open cross-section configuration.

19. A method of treating gaseous emissions using an assembly having an induction heating coil mounted adjacent a substrate body, the substrate body having a plurality of parallel cells for the passage of emissions gas, a closed loop metal wire conductor with the ends of the wire being joined together to close the loop, located in a first set of the plurality of cells and having a first part thereof extending in a first direction along one of the set of cells and a second part thereof extending in a direction opposite to the first direction along another of the set of cells, the method comprising generating a varying electromagnetic field at the coil thereby to inductively heat the metal wire loop conductor and thereby to heat the substrate body.

20. The method as claimed in claim 19, further comprising generating the varying electromagnetic field when an engine which is the source of the emission gases is operating and when the substrate body is below a predetermined threshold temperature.

21. The method as claimed in claim 19, further comprising generating the varying electromagnetic field for an engine which is to be the source of the emission gases before start-up of the engine.

22. The method as claimed in claim 19, further comprising inductively preheating gaseous emissions before the gaseous emissions enter the substrate body.

23. The method as claimed in claim 19, further comprising the heat from the heated lengths of wire also being transferred to a catalyst coating the surface of the cells, the heated catalyst operable to accelerate pollution-reducing reactions of components in the gaseous emissions.