Systems and methods for providing heat to a catalyst of an after-treatment system

Abstract

Methods and system are provided to heat a catalyst of an after-treatment system for a vehicle. The after-treatment system comprises a heating module having a plurality of heating elements. Each of the plurality of heating elements is independently operable to provide thermal energy to the catalyst of the after-treatment system. One or more of the heating elements of the heating module are selectively operated to provide heat to the catalyst based on an operational parameter of the after-treatment system.

1 - 15 . (canceled) 
     
     
         16 . A method of controlling an after-treatment system for a vehicle, the after-treatment system comprising a heating module having a plurality of heating elements, wherein each of the plurality of heating elements is independently operable to provide thermal energy to a catalyst of the after-treatment system, the method comprising:
 determining how many of the plurality of heating elements to selectively operate based on an operational parameter of the after-treatment system; and   in response to the determination, selectively operating one or more of the heating elements of the heating module.   
     
     
         17 . The method of  claim 16 , further comprising:
 in response to the determination, selectively operating one or more of the heating elements of the heating module to limit battery throughput.   
     
     
         18 . The method of  claim 16 , further comprising:
 in response to the determination, selectively operating one or more of the heating elements of the heating module to provide heat to the catalyst until a threshold temperature of the catalyst is achieved.   
     
     
         19 . The method of  claim 18 , wherein the threshold temperature of the catalyst is achieved within a time threshold. 
     
     
         20 . The method of  claim 18 , further comprising:
 in response to determining that the threshold temperature has been achieved, deactivating one of the plurality of heating elements of the after-treatment system.   
     
     
         21 . The method of  claim 16 , wherein the operational parameter comprises at least one of:
 an engine temperature;   an exhaust gas flow-rate through the after-treatment system;   a maximum thermal energy output from the plurality of heating elements;   temperature of the catalyst;   battery throughput; or   an amount of particulate matter in the after-treatment system.   
     
     
         22 . The method of  claim 16 , further comprising determining one or more contextual factors, wherein the one or more contextual factors comprise at least one of:
 an ambient temperature;   a state of charge of a power source of the vehicle;   a time since a last engine start-up; or   a delta temperature between the temperature of the after-treatment system and the ambient temperature; and   wherein at least one of the plurality of heating elements of the heating module is selectively operated to provide heat to the catalyst based on one or more of the contextual factors.   
     
     
         23 . The method of  claim 18 , further comprising:
 starting an engine of the vehicle after the after-treatment system reaches the threshold temperature.   
     
     
         24 . The method of  claim 16 , further comprising:
 controlling at least one of the plurality of heating elements with at least one pulse-width modulation switch.   
     
     
         25 . An after-treatment system comprising:
 a heating module comprising a plurality of heating elements, wherein each of the plurality of heating elements is independently activatable to provide thermal energy to a catalyst of the after-treatment system; and   a control module to determine how many of the plurality of heating elements to selectively operate based on an operational parameter of the after-treatment system.   
     
     
         26 . The after-treatment system of  claim 25 , wherein the heating module comprises a metallic foam, the metallic foam comprising:
 a first section; and   a second section, wherein the first section and second section are physically joined and electrically isolated.   
     
     
         27 . The after-treatment system of  claim 26 , wherein each of the first and second seconds are electrically connected to a separate pulse-width modulation, PWM, switch. 
     
     
         28 . The after-treatment system of  claim 25 , wherein the first and second section have different physical characteristics, the characteristics being at least one of:
 different surface area;   different volume; or   different structure.   
     
     
         29 . A vehicle comprising the after-treatment system of  claim 25 . 
     
     
         30 . A non-transitory computer-readable medium having instructions encoded thereon for carrying out a method to control an after-treatment system of a vehicle, the after-treatment system comprising a heating module having a plurality of heating elements, wherein each of the plurality of heating elements is independently operable to provide thermal energy to a catalyst of the after-treatment system, the method comprising:
 determining how many of the plurality of heating elements to selectively operate based on an operational parameter of the after-treatment system.