Comb Tooth Electrode Design for Heating Support
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Solution Overview
Problem
Existing electrically heating catalyst systems face a trade-off between improving impact resistance and increasing the amount of current passing through metal electrodes, as the joining strength between the honeycomb structure and electrodes decreases with wider tooth widths, which are necessary for higher current conduction.
Innovation Solution
The system incorporates a honeycomb structure with electrode layers and thermally sprayed fixed layers, featuring comb tooth-shaped connection portions with alternating first and second portions of varying widths, where the thermally sprayed fixed layers cover the second portions to enhance joining strength while allowing increased current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the width of each comb tooth portion is increased to increase the amount of current passing through the metal electrodes, then the current conduction capability is improved, but the joining strength between the honeycomb structure and the metal electrodes decreases
Solution Approach 1:
The tooth portion is divided into multiple segments along the width direction, with each segment having a different width. This segmentation allows different portions of the tooth to serve different functions: narrower segments provide strong thermal spray adhesion for joining strength, while wider segments provide sufficient cross-sectional area for current conduction.
Solution Approach 2:
Different width portions are assigned to different functional requirements: the first width portion (narrower) is optimized for joining strength where thermal spray fixed layers are applied, while the second width portion (wider) is optimized for current conduction. This local differentiation resolves the contradiction by optimizing each region for its specific function.
2Strength
If the width of each comb tooth portion is decreased to improve the joining strength between the honeycomb structure and the metal electrodes, then the impact resistance performance is improved, but the amount of current that passes through the metal electrodes decreases
Solution Approach 1:
The tooth portion is divided into multiple segments along the width direction, with each segment having a different width. This segmentation allows different portions of the tooth to serve different functions: narrower segments provide strong thermal spray adhesion for joining strength, while wider segments provide sufficient cross-sectional area for current conduction.
Solution Approach 2:
Different width portions are assigned to different functional requirements: the first width portion (narrower) is optimized for joining strength where thermal spray fixed layers are applied, while the second width portion (wider) is optimized for current conduction. This local differentiation resolves the contradiction by optimizing each region for its specific function.
3Reliability
If the tooth width is narrowed to enhance shock resistance, then the impact resistance is improved, but the electrical conductivity of the electrode structure decreases
Solution Approach 1:
The tooth portion is divided into multiple segments along the width direction, with each segment having a different width. This segmentation allows different portions of the tooth to serve different functions: narrower segments provide strong thermal spray adhesion for joining strength, while wider segments provide sufficient cross-sectional area for current conduction.
Solution Approach 2:
Different width portions are assigned to different functional requirements: the first width portion (narrower) is optimized for joining strength where thermal spray fixed layers are applied, while the second width portion (wider) is optimized for current conduction. This local differentiation resolves the contradiction by optimizing each region for its specific function.
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 configuration allows for an increased amount of current to pass through the metal electrodes while maintaining the necessary joining strength between the honeycomb structure and electrodes, optimizing both shock resistance and current conduction.
Implementation Method 1
a plurality of thermally sprayed fixed layers for fixing the pair of metal electrodes to the honeycomb structure
Implementation Method 2
heating the honeycomb structure itself by electrical conduction to increase a temperature of a catalyst supported on the honeycomb structure
Implementation Method 3
heating the honeycomb structure itself by electrical conduction
Data Source
AI summary
An electrically heating support includes: a honeycomb structure 1 including a honeycomb structure portion 10 having an outer peripheral wall 100; and electrode layers 11 provided on a surface of the outer peripheral wall 100; metal electrodes 2; and a plurality of thermally sprayed fixed layers 3, wherein each of the pair of metal electrodes 2 includes: a base portion 20; and a comb tooth-shaped connection portion 21 having a plurality of teeth portions 23, wherein each of the tooth portions 23 includes at least one first portion 23a and at least one second portion 23b narrower than the first portion 23a, and wherein at least one of the thermally sprayed fixed layers 3 is provided on an outer peripheral surface of the honeycomb structure 1 and the at least one second portion 23b so that the connection portion 21 is fixed to the honeycomb structure 1.