Bare heating elements for heating fluid flows
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heaters used to reduce NOx and particulate emissions in diesel engines often compromise engine performance and increase complexity and cost, as they require high temperatures for efficient operation.
Innovation Solution
A resistive heating element with a predefined shape, such as an airfoil or polygonal geometry, is directly exposed to the fluid flow, providing structural strength, efficient heat distribution, and reduced back pressure, while being integrated with dielectric members and electrical protection systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If traditional heaters are used to reduce NOx emissions, then emission reduction efficiency is improved, but engine performance deteriorates and system complexity increases
Solution Approach 1:
The patent combines the heating function with the structural support function into a single integrated component. The lattice structure serves both as the heating element carrier and as the mechanical support structure, eliminating the need for separate structural components and reducing overall system complexity while maintaining emission reduction efficiency
Solution Approach 2:
The heating element is designed to perform multiple functions simultaneously: it provides thermal energy for NOx reduction, maintains structural integrity under engine conditions, and facilitates fluid flow through its open lattice geometry. This multi-functionality reduces the number of separate components needed in the system
2Object-generated harmful factors
If heaters are added to achieve high temperatures for SCR catalysts, then NOx reduction efficiency is improved, but cost increases
Solution Approach 1:
The patent changes the geometric parameters of the heating element by using a lattice structure with specific cell sizes, wall thicknesses, and patterns. These parameter optimizations enable efficient heat transfer at lower material costs while achieving the required temperature levels for SCR catalyst operation, thereby reducing overall system cost
3Temperature
If heating elements are placed in exhaust flow, then heat transfer to fluid is improved, but back pressure increases
Solution Approach 1:
The heating element employs a lattice structure that functions as a porous medium, allowing exhaust gases to pass through multiple pathways rather than being blocked by a solid barrier. This porous geometry maintains open flow paths that minimize pressure drop while providing sufficient surface area for effective heat transfer to the exhaust stream
4Temperature
If heating elements are exposed directly to exhaust flow, then heat transfer efficiency is improved, but structural strength deteriorates
Solution Approach 1:
The heating element is constructed as a composite structure combining a corrosion-resistant alloy material with a optimized lattice geometry. The material composition provides resistance to high-temperature oxidation and sulfuric acid corrosion in the exhaust environment, while the lattice structure maintains mechanical strength through its geometric configuration, achieving both direct flow exposure and structural durability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively heats diesel exhaust gas while maintaining robustness, reducing back pressure, and minimizing cost and complexity, thereby enhancing emission reduction efficiency without negatively impacting engine performance.
Implementation Method 1
a heater for use in heating a fluid flow through a passageway... uses a resistive heating element
Data Source
AI summary
A heater for use in heating a fluid flow through a passageway is provided that includes a continuous resistive heating element having a predefined shape that is directly exposed to the fluid flow. The predefined shape includes a cross-sectional geometry that provides a required heat distribution, structural strength, and reduced back pressure within the passageway. The predefined shape may include airfoils, while the cross-sectional geometry provides a required heat distribution, structural strength, and reduced back pressure within the passageway.