Emissions control during engine cold starts

Patent metadata

Field	Value
Publication number	US-11193438-B1
Application number	US-202117192207-A
Country	US
Kind code	B1
Filing date	Mar 4, 2021
Priority date	Mar 4, 2021
Publication date	Dec 7, 2021
Grant date	Dec 7, 2021

Abstract

Methods and systems are provided for an engine of a vehicle during a cold start. In one example, a method may include heating a catalyst of an exhaust aftertreatment device with a plurality of electric heaters during an unfueled engine operation. The engine may be operated as a pump to oscillate air across the exhaust aftertreatment device, thereby heating the air via the plurality of electric heaters which, in turn, heats the catalyst. A configuration of the catalyst may promote expedited light-off which may reduce emissions during the cold start.

First claim

The invention claimed is:

1. A method for an engine, comprising:
heating a catalyst of an exhaust aftertreatment device with a plurality of electric heaters during an unfueled engine operation by using the engine to oscillate air between a first direction and a second direction across the exhaust aftertreatment device.

2. The method of claim 1 , wherein heating the catalyst includes arranging each electric heater of the plurality of electric heaters between substrates of the catalyst and wherein air is heated by the plurality of electric heaters as the air oscillates and the heated air heats the substrates of the catalyst.

3. The method of claim 2 , wherein heating the catalyst further includes stacking the substrates in contact with the plurality of electric heaters along a direction of air flow through the exhaust aftertreatment device and heating the substrates by conduction of heat from the plurality of electric heaters to the substrates.

4. The method of claim 3 , wherein heating the catalyst during the unfueled engine operation includes opening each of an intake valve and exhaust valve of a cylinder and cranking the engine with the intake valve and the exhaust valve open and wherein the engine is cranked by an electric device.

5. The method of claim 4 , wherein cranking the engine while the intake valve and the exhaust valve are open includes flowing air in the first direction from an exhaust manifold to the cylinder during an intake stroke and an expansion stroke of the cylinder and flowing the air in the second direction from the cylinder to the exhaust manifold during an exhaust stroke and a compression stroke of the cylinder.

6. The method of claim 5 , wherein flowing the air in the first direction through the exhaust aftertreatment device includes sequentially heating a third substrate, a second substrate, and a first substrate of the substrates of the catalyst by the heated air.

7. The method of claim 6 , wherein flowing the air in the second direction through the exhaust aftertreatment device includes sequentially heating the second substrate, the third substrate, and a fourth substrate of the substrates of the catalyst by the heated air.

8. The method of claim 7 , wherein oscillating the air between the first direction and the second direction across the exhaust aftertreatment device includes heating the second substrate and the third substrate twice as much as the first substrate and the fourth substrate with each cylinder cycle.

9. A method for heating an exhaust aftertreatment device, comprising:
responsive to a request for a cold engine start;
opening an intake valve and an exhaust valve of a cylinder without fueling the cylinder;
rotating a crankshaft to oscillate a first flow of air between the cylinder and an exhaust system, the exhaust system including the exhaust aftertreatment device;
activating electric heaters coupled to the exhaust aftertreatment device and arranged sequentially between catalyst substrates of the exhaust aftertreatment device; and

responsive to a temperature of at least one substrate of the catalyst substrates reaching a threshold;
deactivating one or more of the electric heaters;
adjusting actuation of the intake valve and the exhaust valve; and
fueling the cylinder.

10. The method of claim 9 , wherein oscillating the first flow of air between the cylinder and the exhaust system includes passing the first flow of air across inner substrates of the catalyst substrates twice as much as outer substrates of the catalyst substrates and wherein the catalyst substrates are arranged along a direction of the first flow of air.

11. The method of claim 10 , wherein passing the first flow of air across the inner substrates includes passing the first flow of air through catalyst substrates configured with one or more of thin walls, at least one catalytic metal, and a wash coat to expedite heating and wherein passing the first flow of air across the outer substrates includes passing the first flow of air through catalyst substrates configured with larger volumes than the inner substrates to enable high flow rates therethrough for peak engine power output.

12. The method of claim 9 , wherein deactivating the one or more electric heaters responsive to the temperature of the at least one substrate of the catalyst substrates reaching the threshold includes deactivating at least one electric heater in contact with the at least one substrate and directing power from the deactivated at least one electric heater to active electric heaters to increase a heating rate at the active electric heaters.

13. The method of claim 9 , wherein adjusting the actuation of the intake valve and the exhaust valve includes adjusting a timing of intake valve opening and the exhaust valve opening to a nominal timing, the nominal timing being a valve timing optimized for engine operation when the cylinder is fueled and sparked, and wherein adjusting the actuation of the intake valve and the exhaust valve further includes adjusting the first flow of air to flow in a single direction from the cylinder to the exhaust aftertreatment device.

14. The method of claim 9 , further comprising rotating the crankshaft to oscillate a second flow of air between an intake manifold and the cylinder.

15. The method of claim 9 , wherein opening the intake valve and the exhaust valve responsive to the request for the cold engine start includes opening the intake valve and the exhaust valve concurrently when one or more of the temperature of the exhaust aftertreatment device is below the threshold and an engine temperature is below an optimal operating temperature.

16. An engine system, comprising:
an aftertreatment device arranged in an exhaust system of the engine system;
a plurality of heaters separating catalyst substrates of the aftertreatment device;
a cylinder fluidly coupled to the aftertreatment device by the exhaust system, the cylinder having an intake valve and an exhaust valve; and
a controller with computer readable instructions stored on non-transitory memory that, when executed, cause the controller to:
responsive to a request for a cold engine start;
open the intake valve and the exhaust valve of the cylinder without fueling the cylinder;
cycle the cylinder by rotating a crankshaft to oscillate air flow back and forth between the aftertreatment device and the cylinder;
heat the aftertreatment device by activating the plurality of heaters.

17. The engine system of claim 16 , wherein the catalyst substrates are arranged sequentially along a direction of gas flow in the aftertreatment device and wherein inner substrates of the catalyst substrates are configured with thin walls, a lower thermal mass than outer substrates of the catalyst substrates, and catalytic materials to expedite heating of the inner substrates.

18. The engine system of claim 17 , wherein the outer substrates of the catalyst substrates are configured with substrate volumes corresponding to a maximum exhaust gas flow rate from an engine of the engine system and a displacement of the engine.

19. The engine system of claim 16 , wherein the aftertreatment device includes three or more catalyst substrates and the plurality of heaters includes two or more heaters and wherein the two or more heaters are operable independent of one another.

20. The engine system of claim 16 , wherein the plurality of heaters is heated to at least 1200° C. and wherein air flowing through the plurality of heaters is heated to at least 800° C.

Assignees

• Ford Global Tech Llc

Inventors

• Zhang Xiaogang

Classifications

• F01N3/2026

  directly electrifying the catalyst substrate, i.e. heating the electrically conductive catalyst substrate by joule effect · CPC title

• F01N3/2013 Primary

  using electric or magnetic heating means · CPC title

• F02N2300/102

  Control of the starter motor speed; Control of the engine speed during cranking · CPC title

• F02D41/0255 Primary

  to accelerate the warming-up of the exhaust gas treating apparatus at engine start · CPC title

• F02D13/06

  Cutting-out cylinders · CPC title