Catalytic Deflector Support via Undulating Holding Elements

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Solution Overview

Problem

Catalytic converters in motor vehicles face stress from high operating temperatures and vibrations, leading to material expansion and potential cracking of welded deflector components, which compromises their durability.

Innovation Solution

A deflector assembly within the catalytic converter's inlet cone is supported by a ring-shaped support means with undulating holding elements that contact both the support surface and the enclosure, eliminating the need for welding and allowing for expansion without cracking, using a combination of annular and radial undulations to secure the deflector in place.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the deflector is fixed by welding to the inlet cone, then the attachment stability is improved, but the risk of cracking due to thermal expansion and vibrations increases

Engineering Contradiction:

Improveattachment stabilityVSAvoidcracking resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The support means is divided into multiple separate arms (at least two) that extend from the deflector to the inlet cone, rather than using a single welded structure. This segmentation allows each arm to independently accommodate thermal expansion and reduces stress concentration, eliminating the cracking issue while maintaining attachment stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support means acts as an intermediary element between the deflector and the inlet cone, providing a flexible connection that absorbs thermal expansion stresses. This intermediary structure transfers loads while accommodating dimensional changes, preventing direct stress transmission that would cause cracking in welded joints.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If the deflector is supported close to the inlet cone, then the structural stability is improved, but the clearance required for thermal expansion increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidclearance distance

Core Design Contradiction:

Stability of the object's compositionVSLength of stationary object

Solution Approach 1:

The support means is designed with flexible arms that can dynamically adjust their position and orientation in response to thermal expansion. This dynamic capability allows the support structure to maintain stable deflector positioning while accommodating the necessary clearance for dimensional changes during operation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The support means employs thin, flexible arm structures that can bend and deform elastically to accommodate thermal expansion. These flexible arms provide the necessary clearance absorption while maintaining structural stability, allowing the deflector to remain securely positioned without requiring excessive clearance distance.

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If the support means is rigidly fixed to the enclosure, then the attachment stability is improved, but the ability to accommodate thermal expansion decreases

Engineering Contradiction:

Improveattachment stabilityVSAvoidthermal expansion accommodation

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The support means is designed to change its physical parameters (shape, position, orientation) in response to thermal expansion. The arms can flex, bend, and adjust their configuration, allowing the structure to adapt to dimensional changes while maintaining stable attachment. This parameter variability enables simultaneous achievement of stability and thermal accommodation.

Inventive Principle:

Principle #35Parameter changes

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

This solution enhances the deflector's resistance to thermal expansion and vibrations, reducing the risk of cracking and improving the attachment stability without the need for welding, thus extending the device's lifespan.

Implementation Method 1

said radial undulations being shaped to block said support means radially with respect to said enclosure

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

Due to the high temperatures mentioned above, these materials are subject to significant expansion which can lead to permanent deformations and cracks on the deflector fixed by welding to the inlet cone

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentEP3097282B1Catalytic aftertreatment device for motor vehicle and adapted deflector

Publication Date: 2020.04.15 RENAULT SA

Figure 1~2
Figure 3~4

AI summary

The invention concerns a post-treatment device comprising an enclosure (12) defining a tubular chamber inside which a deflector element is disposed, comprising: -at least one substantially ring-shaped support means extending parallel to the wall of the enclosure with a predefined clearance (J1), supporting the deflector elements substantially at the centre of the tubular chamber by means of at least two arms, the ends of which are attached to the support means and to the deflector element, -two holding elements (28, 30) positioned to either side of said support means (24) axially, between same and the enclosure (12), each having an open, substantially annular general shape with radial undulations, in contact alternately with an inner surface (12a) of the enclosure and a bearing surface (24a, 24b) facing the support means (24), said radial undulations being shaped to radially block the support means relative to the enclosure.