Catalyst Flow Body Recesses for Thermal Reliability
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Solution Overview
Problem
Catalytic converter flow bodies face reliability and durability issues due to high thermal and mechanical loads, limiting their operational range and effectiveness in exhaust systems.
Innovation Solution
A method for producing a robust catalytic converter flow body involves creating a base body with flow channels, introducing recesses in partition walls to connect adjacent channels, and using channel seals for fluid-tight sealing, allowing for advantageous flow guidance and heat transfer, while being made from materials like cordierite and processed through extrusion and firing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flow body designs are used, then manufacturing is simpler, but reliability and durability deteriorate under high thermal and mechanical loads
Solution Approach 1:
The flow body is divided into multiple flow channels separated by partition walls, with recesses created in these partition walls to enable selective fluid communication between adjacent channels. This segmentation allows independent control of flow paths while maintaining structural integrity under thermal and mechanical loads.
Solution Approach 2:
Recesses are selectively created in specific partition walls at specific locations to establish desired flow connections between adjacent channels. The channel closures are then selectively placed in these recesses to control fluid communication locally, creating advantageous flow guidance patterns throughout the flow body.
2Reliability
If flow channels are sealed completely, then fluid leakage is prevented, but heat transfer between adjacent channels deteriorates
Solution Approach 1:
The partition walls are segmented with recesses that create localized openings between adjacent flow channels. Channel closures are then selectively placed in these recesses to seal specific locations while leaving other recesses open, enabling controlled heat transfer between channels at selected positions while maintaining overall sealing integrity.
Solution Approach 2:
Different regions of the partition walls have different properties: some areas have channel closures for sealing, while other areas have open recesses for heat transfer. This local differentiation allows simultaneous achievement of both sealing reliability and heat transfer efficiency in different locations within the same flow body.
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 method results in a catalytic converter flow body that is robust, usable across a wide operating range, and effective in heat transfer, enhancing the efficiency of pollutant conversion and reducing emissions.
Implementation Method 1
the base body is dried using a freeze-drying process
Implementation Method 2
the base body is manufactured using an extrusion process
Implementation Method 3
A catalyst flow element can be used, for example, to convert pollutants into substances that are less harmful to health and/or the environment
Data Source
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AI summary
In order to provide a method for manufacturing a catalyst flow body, by means of which robust catalyst flow bodies usable in a wide operating range can be produced, it is proposed that the following process steps be carried out in the process: the provision of a base body which comprises a plurality of flow channels; the introduction of recesses into partitions of the base body which separate the flow channels from one another, so that at least two adjacent flow channels in a common end region of the at least two adjacent flow channels within the base body are fluidly connected to each other; and the arrangement of channel closures in the common end region to fluidly seal the common end region while maintaining the fluidly effective connection between the at least two adjacent flow channels in the common end region.