Segmented Ceramic Supporting Pin for High-Voltage Honeycomb Insulation
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Solution Overview
Problem
Existing supporting pins for electrically heatable honeycomb bodies in exhaust gas treatment systems face challenges in maintaining reliable electrical insulation and mechanical stability, especially at higher voltages and in conditions with soot deposits or moisture, as they are difficult to insulate effectively and have limited distance between electrically conductive parts.
Innovation Solution
A supporting pin with a ceramic core, metalized end regions for brazing, and a long electrically non-conductive intermediate region to ensure insulation, along with features like a smooth surface to prevent soot deposition and structural enhancements for increased creepage distance, allowing for secure fastening and reliable electrical insulation even at higher voltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal core is used in the supporting pin, then mechanical strength is improved, but electrical insulation becomes difficult to achieve reliably
Solution Approach 1:
The supporting pin is segmented into distinct functional regions: metalized end regions for mechanical strength and brazing, and a ceramic intermediate region for electrical insulation. This segmentation allows each part to perform its specialized function without compromising the other.
Solution Approach 2:
The supporting pin uses composite construction combining metalized regions (for strength and brazing) with a ceramic intermediate region (for insulation). This composite structure resolves the contradiction by integrating materials with complementary properties in a single component.
2Reliability
If the distance between conductive parts is increased to improve insulation, then electrical insulation is improved, but the pin length increases
Solution Approach 1:
The ceramic intermediate region provides high electrical resistance per unit length, allowing sufficient insulation distance to be achieved in a compact form. The specific parameters of the ceramic material (dielectric strength, resistivity) are optimized to provide adequate insulation in a shortened distance compared to air or other insulators.
3Reliability
If a ceramic core is used instead of metal core, then electrical insulation is improved, but mechanical strength decreases
Solution Approach 1:
Different regions of the supporting pin have different material properties optimized for their specific functions: metalized end regions provide local mechanical strength and brazing capability, while the ceramic intermediate region provides local electrical insulation. Each location has the quality it needs without requiring the entire pin to have all properties.
4Reliability
If the intermediate region length is increased to improve insulation, then electrical insulation is improved, but device complexity increases
Solution Approach 1:
The supporting pin merges multiple functions into a single integrated component: the metalized end regions provide both mechanical strength and brazing surfaces, while the ceramic intermediate region provides electrical insulation. This merging eliminates the need for separate insulating elements or complex assembly structures, reducing overall device complexity despite the functional requirements.
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 ceramic core supporting pin provides reliable electrical insulation and mechanical stability, effectively supporting electrically heatable honeycomb bodies at higher voltages while preventing soot deposition and reducing the risk of electrical leakage, making it suitable for use in exhaust gas treatment systems.
Implementation Method 1
a core (8) made of electrically non-conductive ceramic material
Implementation Method 2
at least one end region, in the present case the first end region (5), has a metalized surface (4), so that a subsequent brazing into a metal honeycomb (14) is facilitated
Data Source
AI summary
A supporting pin for supporting an electrically heatable honeycomb body on a first honeycomb body includes a first end region, a second end region, an intermediate region, a core made of electrically non-conductive ceramic material and a metalized surface on at least one end region. The intermediate region is electrically non-conductive and has a length of at least 3 mm, preferably 5 to 15 mm. The supporting pin is particularly suitable for stabilizing electrically heatable honeycomb bodies in exhaust gas treatment systems for internal combustion engines, particularly for motor vehicles. When higher electrical voltages, such as 48 V, are used for electrically heatable honeycomb bodies, good electrical isolation is also assured in exhaust gas systems carrying soot particles with simultaneous safe support and suppression of vibrations.