Abstract: In a method of making a gaseous emissions treatment component, a ‘green’ ceramic mix is extruded through a die to form an extrusion having cells extending along the extrusion, the cells being bounded by walls dividing adjacent cells from one another. In concert with the extruding, metal is fed through the die with the extruded mix. A length of the extrusion and associated metal is then cut off and fired to form the component.

Abstract: In a process for manufacturing a component for an emissions treatment unit, green ceramic product is extruded through a die to form an extrusion having a honeycomb substrate structure with an array of parallel, linear tubular cells extending along its length, the cells bounded by walls dividing adjacent cells from one another. A ceramic unit is obtained by cutting off, curing and firing a length of the extrusion a length of the extrusion. Following the firing, a mixture of a flowable, uncured curable material and a particulate metal component is injected from an end of the ceramic unit into selected ones of the cells so as to block the selected cells over at least a part of their lengths while maintaining all of the walls of the ceramic unit. The injected mixture is then cured to render it solid.

Abstract: As wire is wound around and onto the surface of a former to form a coil, perturbations such as waves are introduced into turns of the coil, each perturbation being formed in a length of the wire less than the full length of a respective turn and projecting along the former surface, the perturbation having an initial shape and size. The coil is taken from the former and fixed in form. A surrounding jacket is radially collapsed onto the wire coil to uniformly press the coil against an internal compressible body in the course of which the overall diameter of the coil is reduced. Resulting stresses in the wire generated during the collapse are relieved by alteration of the perturbations from their initial shape and size to a subsequent shape and size.

Abstract: Techniques are disclosed to aid fixing of an elongate wire within an elongate, linear cell of a honeycomb ceramic substrate unit for a gaseous emissions treatment assembly. In one method, the wire is formed with a resiliently flexible element, and inserted into the cell, the insertion act causing the resiliently flexible element to flex and to cause a part of the element to bear against a wall of the cell and so provide frictional retention of the wire in the cell. In another, method, an adhesive is used either on the outside of the wire or the inside of the cell. In another method, the wire is scored at spaced intervals along its length to provide relief spaces for linear expansion of the wire to reduce stress at its interface with cell walls.

Abstract: A gaseous emissions treatment component has a honeycomb substrate along and through which extend elongate cells for the passage of gaseous emissions through the substrate. The cells are bounded by walls dividing adjacent cells from one another. Metal elements occupy and extend along some of the cells. A metal element has an outer surface shape matching the inner surface of an immediately adjacent part of the cell within which the metal element is located.

Abstract: An assembly for treating gaseous emissions has a substrate along which extend cells for the passage of emissions gas. Lengths of conducting wire are located in a set of the cells and an induction heating coil is used to generate a varying electromagnetic field, so as to inductively heat the lengths of conducting wire. The substrate body has a front for entry of flowing emissions gas to be treated into the substrate body and a back for exit of treated gaseous emissions gas. The lengths of conducting wire have projections extending from the front and/or back of the substrate body so that when inductively heated, the wire parts in the substrate body heat the surrounding substrate and the wire projections heat the flowing emissions gas directly.

Abstract: An assembly for use in treating gaseous exhaust emissions has an inductive heater mounted next to a gaseous emissions treatment unit. and downstream substrate units or upstream and downstream sections of a single substrate. The upstream unit or section has linear passages extending the length of the first substrate body for the passage of emissions gas but with some of the passages blocked by metal inserts for use in inductive heating of the upstream unit. The concentration of metal inserts is high and the metal inserts are distributed to enable rapid intense inductive heating of the slice or section to achieve “light off” temperature rapidly in order to pass heat-supplemented gaseous emissions at light-off temperature to the downstream substrate or section as quickly as possible.

Abstract: A gaseous emissions treatment component is made by extruding a green ceramic mix through a die to form an extrusion having a honeycomb substrate with elongate cells extending its length and with the cells bounded by walls dividing adjacent cells from one another. Molten metal for use in induction heating of the component is placed in selected cells and is solidified by cooling.

Abstract: In a process for manufacturing a catalytic converter component, a ceramic unit is used that has been prepared by extruding green ceramic product through a die to form an extrusion having a honeycomb substrate structure in which tubular passages extend along the extrusion, the passages bounded by walls dividing adjacent passages from one another. The unit is obtained by cutting off a length of the extrusion and curing and firing it. The process further comprises flowing insulation material from one end of the unit into selected ones of the elongate passages, the insulating material then being cured. The passages are selected so that the cured insulation material forms an internal thermal insulating barrier between a core zone and a radially outer zone of the unit. Passages in the inner and outer zones are free of insulation material and the honeycomb structure walls include walls crossing the insulating barrier.

Abstract: An assembly for treating gaseous emissions has a substrate with cells for the passage of an emissions gas to be treated and inductive heating elements located in some of the cells. An electromagnetic field generator mounted near the substrate generates a varying electromagnetic field, so as to inductively heat the inductive heating elements and so heat the substrate. Some of the inductive heating elements have a first natural resonant frequency other inductive elements have a second natural resonant frequency different from the first resonant frequency. A power supply for the electromagnetic field generator is operated with a frequency closer to the first resonant frequency for a time and is operated with a frequency closer to the second resonant frequency period for a subsequent time period. By switching between the frequencies at different times, the heating profile can be moved in the substrate.

Abstract: In various embodiments, an electromagnetic field generator generates one or more power signals applied to one or more coils to cause the induction heating of the pins of the emission control device, The pins can have a plurality of differing lengths, and the heating of the pins can cause a first region of the emission control device to heat faster than a second region of the emission control device.

Abstract: A gaseous emissions treatment system includes an emissions control substrate having a plurality of passages to facilitate a catalytic reaction in an exhaust gas from an internal combustion engine. A magnetic field generator responds to a control signal by generating a varying magnetic field to inductively heat the emission control substrate. A magnetic field concentrator is configured and positioned to increase the radiated varying magnetic field in a region on the same side of the magnetic field concentrator as the emissions control substrate. The magnetic field concentrator also acts as a shield to reduce the radiated varying magnetic field in a region on the distal side of the magnetic field concentrator from the emissions control substrate.

Abstract: Aspects of the subject disclosure may include, for example, an emission control system that includes an emission control device having a plurality of passages to facilitate emission control of an exhaust gas from a vehicle engine. A controller generates a control signal to initiate induction heating of the emission control device. An electromagnetic field generator responds to the control signal by generating a power signal applied to a coil to cause the induction heating of the emission control device, wherein a frequency of the power signal is adjusted to control a power transferred to the coil.

Abstract: Aspects of the subject disclosure may include, for example, an emission control system that includes an emission control device having a plurality of passages to facilitate emission control of an exhaust gas from a vehicle engine. A controller generates a control signal to control induction heating of the emission control device and determines a resonant frequency of a coil. An alternating current (AC) source responds to the control signal by generating a power signal applied to the coil to cause the induction heating of the emission control device, wherein a frequency of the power signal is selected based on the resonant frequency of the coil.

Abstract: Aspects of the subject disclosure may include, for example, an emission control system that includes an emission control device having a plurality of passages to facilitate emission control of an exhaust gas from a vehicle engine. A controller determines a resonant frequency of a coil and generates a control signal to control induction heating of the emission control device based on the resonant frequency of the coil. An alternating current (AC) source responds to the control signal by selectively generating a power signal to the coil to facilitate the induction heating of the emission control device via the coil.

Abstract: An emission control system includes an emission control device having a plurality of passages to facilitate emission control of an exhaust gas from a vehicle engine. An electromagnetic field generator responds to a control signal by generating an electromagnetic field via a coil to inductively to heat the emission control device, A controller, coupled to the electromagnetic field generator, generates a temperature signal indicating at least one temperature of the emission control device based on a change in impedance in the coil and generates the control signal based on the temperature signal and further based on a reference temperature to control the at least one temperature of the emission control device in accordance with the reference temperature.

Abstract: A method is disclosed for loading elongate wire lengths into elongate cells of a honeycomb ceramic substrate unit for a gaseous emissions treatment assembly, the cells each having a small cross-sectional area, the area shape matching the cross-sectional shape of the loaded wire lengths and marginally greater in area size than the wire lengths. A wire length is formed with a generally pointed end tip by pulling adjacent parts of a wire along the wire axis respectively in opposite directions from a desired wire breakage site. The tension and timing of the pulling operation are selected so that a desired tip profile is achieved. Initial alignment is done using machine vision. Subsequent adjustment is effected in dependence on feedback from sensors mounted close to the end of a wire insertion arm. Breakage and push insertion of wires is done using alternating gripping and moving of chucks or collets which have aperture shapes close in profile to the outer profile of the wire lengths.

Abstract: A gaseous emissions treatment assembly has a honeycomb ceramic substrate body with a plurality of cells for passage of exhaust gases. Respective lengths of metal wire are located in a number of the cells. An induction heating coil is mounted adjacent the substrate body for generating a varying electromagnetic field, thereby inductively to heat the lengths of wire and thereby to heat the substrate body.

Abstract: A gaseous emissions treatment system 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 one end of the substrate body for intercepting the flowing exhaust gas. A collector electrode for collecting electrons is mounted adjacent the other end of the substrate body for intercepting the flowing exhaust gas. An energizing and control circuit is used to apply a high voltage between the emitter and collector to stimulate the generation of free electrons while avoiding electrical breakdown of the flowing exhaust gas. Molecules and particles in the flowing exhaust gas are ionized and are subjected to electrohyrdrodynamically (EHD) induced forces.

Abstract: Aspects of the subject disclosure may include, for example, a emission control system that includes a emission control substrate having a plurality of passages to facilitate at least one catalytic reaction in an exhaust gas from an internal combustion engine. A magnetic field generator responds to a control signal by generating a magnetic field to inductively heat the emission control substrate. A magnetic shield is configured to direct at least a portion of the magnetic field to the emission control substrate. Other embodiments are disclosed.