Catalytic converter structures with induction heating

• US 9,488,085 B2
• Filed: 08/06/2014
• Issued: 11/08/2016
• 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 DAVID
• Application Number:
  US14/452,800
• Publication Number:
  US 20150075137A1
• Time in Patent Office: 825 Days
• Field of Search: 602/74, 602/83, 602/75, 602/99
• US Class Current: 1/1
• CPC Class Codes: F01N 2240/05 a magnetic, e.g. electromagnetic, device other than a valve
• CPC Class Codes: F01N 2330/06 Ceramic, e.g. monoliths
• CPC Class Codes: F01N 2510/00 Surface coverings
• CPC Class Codes: F01N 2900/0602 Electrical exhaust heater signals
• 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 3/2828 Ceramic multi-channel monoliths, e.g. honeycombs
• CPC Class Codes: F01N 3/2835 fibrous
• CPC Class Codes: F01N 9/00 Electrical control of exhaust gas treating apparatus monitoring or diagnostic devices for exhaust-gas treatment apparatus F01N11/00; conjoint electrical control of two or more combustion engine functions F02D43/00
• CPC Class Codes: H05B 6/108 for heating a fluid
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

A catalytic converter assembly has a substrate body with a plurality of cells for passage therethrough of exhaust gases. Metal is located at predetermined locations in the substrate body. An electromagnetic field generator is mounted adjacent the substrate for generating a varying electromagnetic field inductively to heat the metal and so heat the substrate.

Claims

1. A catalytic converter assembly comprising a substrate body of ceramic material having a plurality of passages therethrough, wherein metal is contained in a first set of the plurality of passages but not in a second set of the plurality of passages, the first set being less in number than the second set, wherein the metal contained in said first set of the plurality of passages comprises discrete metal bodies, wherein the discrete metal bodies are lengths of wire, wherein at least some of the lengths of wire are held in respective ones of the first set of the plurality of passages by an adhesive to bond the wire lengths to interior surfaces of said passages, and

and an induction heating coil mounted adjacent the substrate body for generating a varying electromagnetic field, thereby to inductively heat the metal, and thereby to heat the substrate body.

2. A catalytic converter assembly as claimed in claim 1, wherein the lengths of wire contained in said first set of the plurality of passages are made of a ferromagnetic metal.

3. A catalytic conversion process for use with an induction heating coil mounted adjacent a substrate body of ceramic material having a plurality of passages therethrough, wherein metal is contained in a first set of the plurality of passages but not in a second set of the plurality of passages, the first set being less in number than the second set, the process comprising generating a varying electromagnetic field at the coil, thereby inductively to heat the metal, and thereby to heat the substrate body, wherein the metal contained in the first set of passages comprises discrete metal bodies mounted in respective ones of said passages, the metal in each of said passages extending over a part of the cross sectional areas of said passages, wherein the discrete metal bodies are lengths of wire, and wherein at least some of the lengths of wire are held in respective ones of the first set of passages by an adhesive to bond said lengths of wire to interior surfaces of the respective ones of the first set of passages.

4. A catalytic conversion process as claimed in claim 3, further comprising generating the varying electromagnetic field when an engine which is the source of an exhaust gas flowing through the catalytic converter is operating and the catalytic converter is below a predetermined threshold temperature.

5. A catalytic conversion process as claimed in claim 3, further comprising generating the varying electromagnetic field before start-up of an engine to be the source of an exhaust gas flowing through the catalytic converter when the engine is at ambient air temperature.