GB2559565A

GB2559565A - Vehicle exhaust system

Info

Publication number: GB2559565A
Application number: GB1702090.0A
Authority: GB
Inventors: Fletcher Simon
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2017-02-08
Filing date: 2017-02-08
Publication date: 2018-08-15
Anticipated expiration: 2037-02-08
Also published as: GB2559565B; GB201702090D0

Abstract

A catalytic converter system for a vehicle comprises a catalytic converter 24 including a housing 56 containing a substrate 58, and a heating device 54. At least a portion of the heating device is positioned internally of the housing and is located within the substrate, such that the heating device is arranged to heat the interior of the substrate. The heating device may comprise a resistive or conductive element, and the heating element may extend through an aperture 90 in the housing. The heating device may be removable, possibly by way of a mounting portion, and the heating device may be positioned at an upstream end of the catalytic converter. The catalytic converter may comprise a heating jacket that is heated by the same or a different heat supply to that of the heating device. There may be a plurality of heat devices arranged around the circumference of the housing, and there may be an engine control unit and heat control unit configured to adjust the temperature of the heating device in dependence on a sensor input. Also claimed is a catalytic substrate comprising an aperture, and a vehicle comprising such a catalytic converter system or catalytic substrate.

Description

(71) Applicant(s):

Jaguar Land Rover Limited (Incorporated in the United Kingdom)

Abbey Road, Whitley, Coventry, Warwickshire, CV3 4LF, United Kingdom (56) Documents Cited:

GB 1349426 A DE 102004046918 A1 US 5285640 A

F01N 3/20 (2006.01)

EP 1510672 A1 US 5562885 A (58) Field of Search:

INT CL F01N Other: WPI, EPODOC (72) Inventor(s):

Simon Fletcher (74) Agent and/or Address for Service:

Jaguar Land Rover

Patents Department W/1/073, Abbey Road, Whitley, COVENTRY, CV3 4LF, United Kingdom (54) Title of the Invention: Vehicle exhaust system

Abstract Title: Catalytic converter system with internal heating device (57) A catalytic converter system for a vehicle comprises a catalytic converter 24 including a housing 56 containing a substrate 58, and a heating device 54. At least a portion of the heating device is positioned internally of the housing and is located within the substrate, such that the heating device is arranged to heat the interior of the substrate.

The heating device may comprise a resistive or conductive element, and the heating element may extend through an aperture 90 in the housing. The heating device may be removable, possibly by way of a mounting portion, and the heating device may be positioned at an upstream end of the catalytic converter. The catalytic converter may comprise a heating jacket that is heated by the same or a different heat supply to that of the heating device. There may be a plurality of heat devices arranged around the circumference of the housing, and there may be an engine control unit and heat control unit configured to adjust the temperature of the heating device in dependence on a sensor input. Also claimed is a catalytic substrate comprising an aperture, and a vehicle comprising such a catalytic converter system or catalytic substrate.

At least one drawing originally filed was informal and the print reproduced here is taken from a later filed formal copy.

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VEHICLE EXHAUST SYSTEM

TECHNICAL FIELD

The present disclosure relates to a vehicle exhaust system and particularly, but not exclusively, to a catalytic converter system of a vehicle exhaust system. Aspects of the invention relate to a catalytic converter system and to a vehicle.

BACKGROUND

Vehicle exhaust systems are configured to control the flow and treatment of exhaust gases that are expelled from a vehicle engine, before the gases are released into the atmosphere. Vehicle exhaust systems typically comprise an exhaust manifold that is configured to collect exhaust gases from the engine and that directs the gases into downstream components of the exhaust system. In particular, the exhaust manifold may be connected to a turbocharger system, which, in turn, is connected to a hot end of the exhaust system.

It is well known that internal combustion engines can produce undesirable chemical species in their exhaust streams, and the use of catalysis technology has been found to be effective in reducing emissions of such species into the atmosphere. To this end, the hot end of the exhaust system typically comprises aftertreatment devices, such as a catalytic converter and associated piping. A catalytic converter typically includes a ceramic or metallic core having a honeycomb structure, and pores of the honeycomb structure are coated with powdered catalysts. The powdered catalysts can include precious metals such as platinum, palladium and rhodium, which increase the rate of reaction between oxygen from the atmosphere and carbon monoxide, oxides of nitrogen and hydrocarbons from the engine, converting the pollutants to relatively harmless compounds in the tail gas.

By virtue of the proximity of the catalytic converter to the vehicle engine, some residual heat is transferred from the engine to the exhaust gases, and from the engine to the catalytic converter, warming the catalytic converter and promoting the chemical reactions taking place therein. To increase the rate of reaction further, in recent years vehicle manufacturers have developed exhaust systems that allow for some additional electrical heating of the exhaust gases. However, it has been observed that such systems tend not to be particularly effective at increasing the temperature of the catalyst structure quickly. When the engine is started in cold conditions, in which the engine is below the normal engine operating temperature, this can lead to a delay in the catalysts reaching a catalyst working temperature, and increased fuel consumption.

There remains a need to provide a vehicle exhaust system having an improved catalyst heating arrangement. The present invention has been devised to mitigate or overcome at least some of the above-mentioned problems.

SUMMARY OF THE INVENTION

According to an aspect of the present invention there is provided a catalytic converter system for a vehicle, comprising: a catalytic converter including a housing containing a substrate; and, a heating device. At least a portion of the heating device is positioned internally of the housing and is located within the substrate, such that the heating device is arranged to heat the interior of the substrate.

Arranging the heating device to heat the interior of the substrate means that the heating device is configured to heat the complex interior surface defined by the internal honeycomb structure of the substrate. Such an arrangement beneficially allows for efficient heating of catalysts that are dispersed on the interior surface of the substrate, independent of an amount of fuel being burned, bringing the temperature of the catalysts to a corresponding catalyst working temperature more quickly compared with known prior art systems.

In an embodiment, the heating device includes a heating element. The heating element may extend through an aperture defined by the housing and thus extends into the housing and is surrounded by the substrate. The proximity between the heating element and the substrate allows for efficient heating of the substrate and the catalysts dispersed thereon. The heating element may be an electrically resistive heating element, or the heating element may be a heat-conductive element.

Advantageously, the heating device may be removable from the catalytic converter. Such an arrangement allows for the heating device to be separated from the catalytic converter for maintenance activity, such that an old or damaged heating device can be repaired or replaced without necessitating repair or replacement of other components of the catalytic converter system.

Optionally, the heating device has a mounting portion which is removably mounted onto the housing. In this case, the heating device may be configured to be removably fixed to the catalytic converter by way of a screw connection. This advantageously creates a secure connection between the heating device and the catalytic converter, while allowing for removal or replacement of the heating device without damage to the heating device or to surrounding components.

The heating device may be positioned at, or towards, an upstream end of the catalytic converter. Beneficially, this allows for exhaust gases to be heated on entry to the catalytic converter, such that heat from the heating device is transferred along the substrate towards a downstream end by the exhaust gases as they pass through the catalytic converter.

Advantageously, the catalytic converter system may further comprise a heater jacket. The heater jacket may be in the form of a heat-conductive heater jacket. The heater jacket facilitates distribution of heat around the substrate, for more even heating of the substrate and the catalysts dispersed thereon.

The heater jacket and heating device may be heated by the same heat supply. Optionally, the heating device is configured to heat the heater jacket, or alternatively, the heater jacket may be configured to heat the heating device. In an embodiment, the heater jacket and heating device may be heated by different heat supplies.

Optionally, the catalytic converter system comprises a plurality of heating devices. The plurality of heating devices may be spaced about a circumference of the housing. Advantageously, the energy output of each heating device may be controllable independently. In this way, each heating device may be heated to a different temperature and, in particular, to a temperature that is required for efficient heating of the catalyst in the vicinity of that heating device.

The catalytic converter system may comprise a heat control unit (HCU) and an engine control unit (ECU). In this instance, the ECU may have an input configured to receive sensor data and an output configured to transmit a signal to the HCU in dependence on the sensor data. Optionally, the HCU may be configured to command a temperature change of the heating device in dependence on the signal transmitted from the ECU. The HCU may therefore be configured to command a temperature change of the heating device in dependence on the sensor data.

According to another aspect of the invention, there is provided a catalytic substrate comprising an aperture extending into the body of the catalytic substrate, the catalytic substrate being configured for use within the catalytic converter system in accordance with a previous aspect of the invention.

According to another aspect of the invention, there is provided a vehicle comprising a catalytic converter system or a catalytic substrate in accordance with a previous aspect of the invention.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a schematic plan view of a vehicle having a vehicle exhaust system and a catalytic converter system of an embodiment of the invention;

Figure 2 is a perspective view of the vehicle exhaust system of Figure 1;

Figure 3 is a section view through a housing of a catalytic converter of the catalytic converter system of Figure 1;

Figure 4 is a schematic view of a heating device of the catalytic converter system of Figure 1;

Figure 5 is a schematic view of the heating device of Figure 4 in an ‘in use’ position in the catalytic converter as shown in Figure 3;

Figure 6 is a schematic view of two of the heating devices of Figure 4 in an ‘in use’ position in the catalytic converter as shown in Figure 3;

Figure 7 is a schematic view of the catalytic converter system of Figure 1;

Figure 8 is a section view through a housing and internal heater jacket of a catalytic converter of another embodiment of the invention, showing the heating device of Figure 4 in an ‘in use’ position in the catalytic converter; and

Figure 9 is a section view through a housing and internal heater jacket of a catalytic converter of another embodiment of the invention, showing a heater rod in an ‘in use’ position in the catalytic converter.

DETAILED DESCRIPTION

Figure 1 is a schematic view of a vehicle 10, comprising an engine 12 that is connected to a vehicle exhaust system 14. Although shown in schematic form in Figure 1, the exhaust system 14 is shown in a more realistic view in Figure 2. The exhaust system 14 comprises a plurality of components arranged so as to define a channel for exhaust gases flowing therethrough. In particular, as is conventional, the exhaust system 14 includes an exhaust gas manifold 16 that is fluidly connected to a turbocharger 18. The turbocharger 18 is itself connected to an inlet 20 of a hot end 22 of the exhaust system 14, comprising a catalytic converter 24 and a chamber 26 for selective catalytic reduction (SCR), and the hot end 22 is arranged so as to transition into a cold end 28 of the exhaust system 14 downstream. The cold end 28 itself comprises two ‘silencers’ 30 or mufflers with corresponding tail pipes 32.

When the vehicle 10 is in use, exhaust gases are produced in the engine 12. These exhaust gases are expelled from the engine 12 and are collected in the exhaust gas manifold 16, before passing through the downstream components of the vehicle exhaust system 14 and being released through the tail pipes 32 into the atmosphere. To guard against the release of undesirable chemical species, the vehicle exhaust system 14 is configured to treat the exhaust gases prior to their discharge into the atmosphere.

To this end, referring to Figures 1 and 7, the vehicle 10 comprises a catalytic converter system 34, comprising the catalytic converter 24 of the exhaust system 14, an Engine Control Unit (ECU) 36 having an input 38 and an output 40, a Heat Control Unit (HCU) 42 having an input 44 and an output 46, a plurality of sensors 48, 50, 52 and at least one heat source, provided by suitable heating devices 54. As shown most clearly in Figure 3, the catalytic converter 24 includes a sealed outer case 56, or housing, a substrate 58, at least one catalyst 60 and a mounting mat 62. The outer case 56 itself defines an interior volume within which the mounting mat 62 and substrate 58 are provided. The mounting mat 62 is formed from ceramic fibres and is positioned intermediate the outer case 56 and the substrate 58, such that the outer case 56, the mounting mat 62 and the substrate 58 are arranged in concentric relation.

The outer case 56 may be manufactured from steel and is hollow and generally cylindrical in shape (shown in Figure 7), encapsulating the substrate 58, which fills a major portion of the interior space. A central portion of the outer case 56 forms a main body 64, which tapers symmetrically at upstream and downstream ends of the outer case 56 to form substantially identical cylindrical forward and rearward connecting ends 66, 68, each having a smaller diameter than the main body 64.

The substrate 58 may be manufactured from any suitable material, such as a ceramic or steel, and takes the form of a honeycomb structure having a plurality of pores 70. It should be appreciated that the substrate 58 could comprise a multi-channelled structure taking any number of alternative forms, and that the invention is not limited to a substrate 58 taking the form of a honeycomb structure. Typically, the substrate 58 is a catalytic substrate 58 and the pores 70 may be coated with a suitable catalyst 60, such as platinum, palladium and/or rhodium, which increases the conversion rate of carbon monoxide, oxides of nitrogen and hydrocarbons in the exhaust gases to harmless compounds for dispelling into the atmosphere through the tail pipes 32 (shown in Figure 1) of the vehicle 10. It is to be understood that the catalysts 60 identified are merely examples, and that any suitable addition or alternative may be used. The mounting mat 62 intermediate the outer case 56 and substrate 58 is positioned so as to accommodate the different thermal coefficients of expansion of the outer case 56 and substrate 58.

Referring to Figure 4, each heating device 54 comprises a head 72, a main body 74 and an elongated member 76. The head 72 comprises a terminal 78 for electrical connection to other components of the catalytic converter system 34, and the main body 74 includes a central electrode 80 and an outer shell 82. The elongated member 76 extends away from the main body 74, and is provided with a mounting portion 84 and a heating element 86, which is heated by way of electrical resistance when a current is applied at the terminal 78. The mounting portion 84 comprises a male screw thread 88, for mounting the heating device 54 to the catalytic converter 24. It should be appreciated that the heating devices 54 could provide heat in any number of ways, including by way of electrical resistance, plasma discharge, laser energy, infra-red heating or any other suitable means.

Figure 5 shows an arrangement in which the catalytic converter system 34 comprises a single heating device 54. As depicted, the outer case 56 comprises an aperture 90 through which the elongated member 76 of the heating device 54 extends, such that the heating element 86 is located within the substrate 58 of the catalytic converter 24. Expressed another way, a portion of the heating device is embedded within the substrate 58. In this way, the heating device 54 is positioned to heat an adjacent interior surface of the substrate 58 and the catalysts 60 dispersed thereon. While there may be a gap between the heating device 54 and the substrate 58, the proximity between the heating element 86 and the catalysts 60 advantageously allows for efficient heating of the catalyst coating 60, with minimal losses to the surrounding components. In this way, radiant heat energy is applied directly, that is, in close proximity, to the interior surface of the catalytic substrate. It should be appreciated that the heating device 54 could alternatively be in direct physical contact with the substrate 58.

In contrast, known systems for heating the substrate rely on external heat sources heating the catalytic substrate from the outside in, or rely on exhaust gases, which take time to come up to temperature and which then vary greatly in temperature in dependence on an instantaneous amount of fuel burned. Both approaches are deficient in raising the temperature of the catalytic converter rapidly. However, since the heating device 54 of the embodiments of the invention heats the system internally, it is therefore much more effective in increasing the temperature of the catalysts 60 and increasing the rate of reaction between compounds in the exhaust gases and oxygen from the atmosphere. Ultimately, exhaust emissions are reduced.

In order to assemble the catalytic converter 24 and heating device 54, a hole is first drilled in the catalytic converter 24 to form the aperture 90, which extends through the entire thickness of the outer case 56 and the mounting mat 62, and into the substrate 58. In a subsequent operation, a female screw thread 92 is formed on the outer case 56 that corresponds to the male screw thread 88 of the heating device 54. The female screw thread 92 could alternatively be formed simultaneously with the aperture 90, in a single step. It should be appreciated that the male and female screw threads 88, 92 could alternatively be reversed, such that the male screw thread 88 is formed on the outer case 56 and the female screw thread 92 is formed on the heating device 54.

In a next step, a heating device 54 is inserted through the aperture 90 and into the passage of the catalytic converter 24. The male screw thread 88 of the heating device 54 is screwed into the corresponding female screw thread 92 of the aperture 90, such that the heating device 54 is removably fixed in position relative to the catalytic converter 24. The dimensions of the aperture 90 substantially correspond to the dimensions of the elongated member 76 of the heating device 54, such that the elongated member 76 is proximal to or in contact with the internal surface of the substrate 58, mounting mat 62 and outer case 56, and the main body 74 of the heating device 54 sits flush against an outer surface of the outer case 56.

Referring to Figure 6, the depicted embodiment comprises a plurality of apertures 90 that are machined at spaced intervals around the catalytic converter 24, the position of each aperture 90 corresponding to the desired position of a heating device 54 for heating the catalysts 60. Upon insertion of the heating devices 54 into the respective apertures 90 of the catalytic converter 24, the heating devices 54 are arranged in spaced relation about the outer case 56 of the catalytic converter system 34. The heating devices 54 may each be positioned at the same axial position along a longitudinal axis L (shown in Figure 7) of the catalytic converter 24, and spaced apart at intervals around the circumference of the catalytic converter 24. In an example, the heating devices 54 are positioned at, or towards, an upstream end of the catalytic converter 24, to heat the exhaust gases as they enter the catalytic converter 24.

The heating devices 54 may alternatively, or additionally, be spaced apart at intervals along the longitudinal axis L of the catalytic converter 24. Providing a ‘spread’ of heating devices spaced about the substrate means that the substrate is heated more evenly, thereby imparting more heat energy into the substrate and raising its temperature more quickly. It is envisaged that the heating devices 54 may be positioned at any location around the catalytic converter 24, and that space constraints in packaging the catalytic converter 24 in the vehicle 10 may somewhat dictate the location of the heating devices 54.

Advantageously, when embedded in the substrate 58, the heating devices 54 do not physically constrain the substrate 58, such that some relative movement is still possible between the outer case 56 and the substrate 58. Therefore, the heating devices 54 accommodate different thermal expansion coefficients between the metallic outer case 56 and ceramic substrate 58.

Referring to Figure 7, the ECU 36 of the catalytic converter system 34 is configured to determine an amount of heating that is required from the heating devices 54 and, in response, to command the HCU 42 to effect a temperature change of the heating devices 54. To this end, the plurality of sensors 48, 50, 52 include exhaust gas sensors 48, 50 and on-engine sensors 52 (shown in Figure 1), for monitoring a number of vehicle parameters. In particular, an exhaust gas sensor 48, 50 is positioned at each of the forward and rearward cylindrical connecting ends 66, 68 of the outer case 56 of the catalytic converter 24, for measuring data relating to parameters of the exhaust gas passing therethrough. For example, the exhaust gas sensors 48, 50 may be used to ascertain a concentration of particular chemical species within the exhaust gas stream, and/or the temperature of the exhaust gases. Each on-engine sensor 52 is similarly configured to measure data relating to parameters of the vehicle engine 12, such as engine operating temperature. Such parameters are indicative of a rate of catalysis in the catalytic converter 24 that is required to aid the conversion of chemical species in the exhaust gases to harmless compounds for release into the atmosphere.

During use, the input 38 of the ECU 36 receives sensor data transmitted from each of the exhaust gas sensors 48, 50 and on-engine sensors 52, and the output 40 of the ECU 36 is configured to subsequently send signals to the HCU 42 in dependence on the sensor data. In particular, the ECU 36 interprets the sensor data to determine an amount of heating that is required at each of the heating devices 54 in order to achieve a desired pattern of thermal variation across the catalytic converter 24. The desired pattern of thermal variation is that which will increase the temperature of the catalysts 60 to a corresponding catalyst working temperature. The ECU 36 subsequently transmits a signal to the input 44 of the HCU 42, configuring the output 46 of the HCU 42 to supply an appropriate electrical current, or electrical signal, to the heating devices 54. The HCU 42 is electrically connected to each heating device 54 separately, such that the electrical signal supplied to each heating device 54 can be controlled independently from the other heating devices 54.

As an example, in the event that a high concentration of carbon monoxide is detected in the exhaust gas stream, the ECU 36 may be configured to instruct the HCU 42 to transmit an electrical signal to each heating device 54, increasing the temperature of the heating elements 86 (shown in Figure 4) of the heating devices 54 and thereby increasing the rate of reaction in the catalytic converter 24.

The vehicle exhaust system 14 presents a hostile environment for components of the catalytic converter system 34, and the catalytic converter 24, heating devices 54 and sensors 48, 50, 52 are subjected to large temperature fluctuations and vibrations. Such conditions can inevitably lead to wear and deformation of the components, and the delicate heating elements 86 and electrical components of the heating devices 54 are particularly vulnerable.

In the event that a heating device 54 of the catalytic converter system 34 does become worn or damaged, the described arrangement advantageously enables individual heating devices 54 to be removed from the catalytic converter system 34 without damage to adjacent components. Specifically, maintenance personnel are able to unscrew the damaged heating device 54 for repair or disposal, and to screw in a replacement heating device 54. Such an arrangement means that only the heater devices 54 themselves need replacing, without necessitating repair or replacement of any other components of the catalytic converter system 34, such as the expensive precious metals of the catalysts 60. Replacement of the heating devices 54 is therefore relatively inexpensive and straightforward.

Many of the identified advantages are also apparent in a number of alternative arrangements. Referring to Figure 8, an alternative catalytic converter 24’ is shown in which both internal and external heating of a substrate 58’ of the catalytic converter 24’ is enabled, allowing for more even heating of the substrate 58’ and catalysts 60’ deposited thereon. The catalytic converter 24’ comprises an outer case 56’ that encapsulates the substrate 58’, and each of the outer case 56’ and substrate 58’ are formed from a metallic material, such as steel, eliminating the need for a mounting mat to be positioned between the two. Instead, an internal heater jacket 94 is located intermediate the outer case 56’ and the substrate 58’, such that the outer case 56’, the heater jacket 94 and the substrate 58’ are arranged in concentric relation. The heater jacket 94 extends around substantially the entire circumference of the substrate 58’, and along substantially the entire length of the substrate 58’ along a longitudinal axis of the substrate 58’. Alternatively, the heater jacket 94 may extend around an arc of the circumference and/or along a portion of the length of the substrate 58’.

As previously described, an aperture 90’ extends through the entire thickness of the outer case 56’ and the heater jacket 94, and into the substrate 58’. A subsequent or simultaneous operation is conducted on the outer case 56’ to form a female screw thread 92’ corresponding to a male screw thread 88’ of a heating device 54’. In the same way as previously described, the heating device 54’ is then inserted and screwed into each aperture 90’ of the catalytic converter 24’.

Upon transmission of an electrical signal from the HCU 42 to each of the one or more heating devices 54’, the temperature of the heating devices 54’ is increased by way of electrical resistance. Some heat is transferred from the heating devices 54’ and to the heater jacket 94, which serves to distribute the heat more evenly around the circumference of the substrate 58’, for more even heating of the catalysts 60’. In this way, the heater jacket 94 and heating device 54’ are heated by the same heat supply. In other embodiments, it is envisaged that the heater jacket may be electrically heated, and may therefore be supplied with its own electrical supply or may have an electrical supply that is shared or integrated with the heating device 54.

A similar arrangement is shown in Figure 9, in which the heating device takes the form of a heater rod 54”. The heater rod 54” has a heating element in the form of a heatconductive element 86”, which is heated by a separate heat supply 96. The heater rod 54” is manufactured with a male screw thread 88”. Threaded apertures 90” are manufactured in an outer case 56” and heater jacket 94” of a catalytic converter 24”, as previously described, and the heater rods 54” are inserted and screwed into the corresponding apertures 90”. The ECU 36 transmits signals to the HCU 42 in dependence on sensor data, configuring the HCU 42 to transmit signals to the heat supply 96, causing a heating coil 98 of the heat supply 96 to increase in temperature. The heater rod 54” provides a path for heat to be transferred from the heat supply 96 to the heater jacket 94”, and the heater jacket 94” distributes the heat around the circumference of the substrate 58” for more even heating of the substrate 58”. It is envisaged that the heater jacket 94” could alternatively be arranged to heat the heater rod 54”. In this case, the heater rod 54” extends from the heater jacket 94” and into the substrate 58”.

Many modifications may be made to the above examples without departing from the scope of the present invention as defined in the accompanying claims. For example, while the aforementioned embodiments include a screw connection between the heating device 54, 54’, 54” and the catalytic converter 24, 24’, 24”, the skilled person would appreciate that the connection may alternatively be by way of a push-fit or clip connection, or by any other suitable means.

Further, in relation to those arrangements comprising heater jackets 94, 94” described herein, it should be understood that the heater jacket 94, 94” and heating device 54’,

54” may be heated by different heat supplies. It would also be appreciated by the skilled person that the catalytic converter 24’ of Figure 8 and/or the catalytic converter 24” of Figure 9 may be configured such that the heating device 54’, 54” alternatively only extends as far as the heater jacket 94, 94”. An example is also envisaged in which the heater jacket 94” does not form part of the arrangement of Figure 9, such that the heater rod 54” extends through the outer case 56” and directly into the substrate 58” to heat the substrate 58”.

Claims

1. A catalytic converter system for a vehicle, comprising:

a catalytic converter including a housing containing a substrate; and a heating device, wherein at least a portion of the heating device is positioned internally of the housing and located within the substrate, such that the heating device is arranged to heat the interior of the substrate.

2. The catalytic converter system according to Claim 1, wherein the heating device includes a heating element.

3. The catalytic converter system according to Claim 2, wherein the heating element extends through an aperture defined by the housing and thus extends into the housing and is surrounded by the substrate.

4. The catalytic converter system according to Claim 2 or Claim 3, wherein the heating element is an electrically resistive heating element.

5. The catalytic converter system according to Claim 2 or Claim 3, wherein the heating element is a heat-conductive element.

6. The catalytic converter system of any preceding claim, wherein the heating device is removable from the catalytic converter.

7. The catalytic converter system of Claim 6, wherein the heating device has a mounting portion which is removably mounted onto the housing.

8. The catalytic converter system of Claim 7, wherein the heating device is configured to be removably fixed to the catalytic converter by way of a screw connection.

9. The catalytic converter system of any preceding claim, wherein the heating device is positioned at, or towards, an upstream end of the catalytic converter.

10. The catalytic converter system according to any preceding claim, further comprising a heater jacket.

11. The catalytic converter system according to Claim 10, wherein the heater jacket and heating device are heated by the same heat supply.

12. The catalytic converter system according to Claim 10 or Claim 11, wherein the heating device is configured to heat the heater jacket.

13. The catalytic converter system according to Claim 10 or Claim 11, wherein the heater jacket is configured to heat the heating device.

14. The catalytic converter system according to any one of Claims 10 to 13, wherein the heater jacket and heating device are heated by different heat supplies.

15. The catalytic converter system according to any preceding claim, comprising a plurality of heating devices.

16. The catalytic converter system according to Claim 15, wherein the plurality of heating devices are spaced about a circumference of the housing.

17. The catalytic converter system according to Claim 15 or Claim 16, wherein the energy output of each heating device is controllable independently.

18. The catalytic converter system according to any preceding claim, further comprising a heat control unit (HCU) and an engine control unit (ECU).

19. The catalytic converter system according to Claim 18, wherein the ECU has an input configured to receive sensor data and an output configured to transmit a signal to the HCU in dependence on the sensor data.

20. The catalytic converter system according to Claim 19, wherein the HCU is configured to command a temperature change of the heating device in dependence on the signal transmitted from the ECU.

21. A catalytic substrate comprising an aperture extending into the body of the catalytic substrate, the catalytic substrate being configured for use within the catalytic converter system according to any preceding claim.

22. A vehicle comprising a catalytic converter system according to any one of Claims 1 to 20 or a catalytic substrate according to Claim 21.

Intellectual

Property

Office

Application No: GB1702090.0 Examiner: Sarah Tatum