Catalytic converter structures with electrohydrodynamic heat and mass transfer

• US 9,617,888 B2
• Filed: 08/06/2014
• Issued: 04/11/2017
• 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:
  US14/452,812
• Publication Number:
  US 20150075138A1
• Time in Patent Office: 979 Days
• Field of Search: 60275, 60274, 60299, 42218601, 42218603, 42218604, 95283
• 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 ceramic substrate body with a plurality of cells for passage therethrough of exhaust gases. An emitter electrode for emitting free electrodes is mounted adjacent the substrate body for intercepting exhaust gas flowing at an upstream location of the catalytic converter. A collector electrode for collecting electrons is mounted adjacent the substrate body to intercept exhaust gas flowing at a downstream location of the catalytic converter. An energizing circuit is used to apply a high voltage between the emitter and collector to stimulate the generation of free electrons.

Claims

1. A catalytic converter component comprising a honeycomb substrate body having a plurality of passages therein for the passage therethrough of exhaust gas, an emitter electrode at an upstream location in the flowing exhaust gas and a collector electrode at a downstream location in the flowing exhaust gas for collecting electrons in the flowing exhaust gas, and an energizing circuit to generate free electrons at the emitter electrode and to receive the free electrons at the collector electrode at least one of the electrodes being a metal mesh at an end of the substrate body, the mesh having apertures, the mesh apertures having areas greater than the cross-sectional areas of the passages, wherein

the at least one of the electrodes further includes metal in at least some of the plurality of passages, the metal electrically and physically connected to the mesh.

2. A catalytic converter component as claimed in claim 1, the substrate body made of ceramic material.

3. A catalytic converter component as claimed in claim 1, the metal contained in at least some of the plurality of passages comprises metal particles in a binder, at least some of the particles in a passage electrically connected to one another to establish electrical continuity along the passage, the metal particles in a binder in the at least some of the plurality of passages blocking the respective passages.

4. A catalytic converter component as claimed in claim 1, the metal contained in at least some of the plurality of passages comprising metal bodies mounted in respective ones of said at least some of the plurality of passages.

5. A catalytic converter component as claimed in claim 4, wherein the metal bodies are lengths of wire, the lengths of wire electrically connected to one another.

6. A catalytic converter component as claimed in claim 1, the collector electrode being a metal sphere.

7. A process for treating exhaust gases in a catalytic converter comprising generating free electrons by applying a voltage between an emitter electrode located in an exhaust gas flow upstream of a honeycomb catalytic converter substrate and a collector electrode located in the exhaust gas flow downstream of the catalytic converter substrate, the free electrons flowing from the emitter to the collector, the passage of such electrons through the flowing exhaust gas being such as to introduce or increase turbulence in the flowing exhaust gas, wherein,

the substrate body is made of ceramic material and at least one of the electrodes is a metal mesh at one end of the substrate body,

the mesh has apertures, the mesh apertures have areas greater than the cross-sectional areas of the passages, and

the at least one of the electrodes further includes metal in at least some of the plurality of passages, the metal electrically and physically connected to the mesh.

8. A process as claimed in claim 7, wherein the applied voltage is in the range 25 to 50 kilovolts and the collector electrode is grounded.

9. A process as claimed in claim 7, the metal contained in said at least some of the plurality of passages comprises metal particles in a binder, at least some of the particles in each passage electrically connected to establish electrical continuity along the passage, the metal particles in a binder in the at least some of the plurality of passages blocking the respective passages.

10. A process as claimed in claim 7, the metal contained in at least some of the plurality of passages comprising metal bodies mounted in respective ones of said at least some of the plurality of passages.

11. A process as claimed in claim 10, wherein the metal bodies are lengths of wire, the lengths of wire electrically connected to one another.

12. A catalytic conversion process as claimed in claim 7, further comprising generating said free electron flow when an engine which is the source of the exhaust gas is operating and when the catalytic converter is below a predetermined threshold temperature.