Crystallized Glass Joint Structure for Exhaust Insulation Stability
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Solution Overview
Problem
Existing insulating materials, particularly crystallizable or partially crystallized glasses, are not sufficiently resistant to environmental conditions in exhaust systems of internal combustion engines, leading to impaired electrical resistance and control behavior due to moisture condensation, and lack thermal stability and fatigue strength.
Innovation Solution
A joining connection design using crystallizable or partially crystallized glass with a structure that extends the creepage distance and includes a predominantly amorphous glass layer with minimal pores, optionally with high-temperature-stable ceramics, and a crystallite arrangement that interlocks to enhance mechanical stability and thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crystallizable or partially crystallized glass is used as insulating material, then electrical resistance is improved, but reliability deteriorates due to moisture condensation in exhaust systems
Solution Approach 1:
The patent extends the creepage distance by creating a three-dimensional path along the surface of the insulating component. The structure includes surface features such as ribs, grooves, or protrusions that force moisture to travel a longer, more complex path rather than a direct linear distance, thereby maintaining electrical resistance even when condensation is present
Solution Approach 2:
The patent combines crystallizable or partially crystallized glass with specific surface structures to create a composite insulating system. The glass material provides base electrical insulation properties while the added surface structures (ribs, grooves, protrusions) create additional physical barriers against moisture, achieving synergistic protection
2Reliability
If elastomeric material is used to extend creepage distance, then electrical insulation is improved, but thermal stability deteriorates in hot zone of exhaust systems
Solution Approach 1:
The patent changes the material parameter from elastomeric to crystallizable or partially crystallized glass, which has significantly higher thermal stability. This material substitution allows the insulating component to maintain its electrical insulation properties and structural integrity at the high temperatures found in exhaust systems while still providing extended creepage distance through surface structures
3Reliability
If insulating component surface is extended to increase creepage distance, then electrical resistance is improved, but mechanical stability deteriorates
Solution Approach 1:
The patent extends the creepage distance in the lateral dimension by adding surface structures such as ribs, grooves, and protrusions rather than increasing the overall length of the insulating component. This allows electrical insulation to be improved without significantly increasing the component's footprint or compromising its mechanical strength
Solution Approach 2:
The use of crystallizable or partially crystallized glass provides a composite structure that combines electrical insulation properties with high mechanical strength. The material's inherent properties maintain structural integrity while the added surface features extend the creepage path
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 design provides enhanced electrical insulation and mechanical stability, maintaining high resistance and stability up to 1000°C, with minimal porosity and a strong bond between components, suitable for high-temperature applications.
Implementation Method 1
the surface of the electrically insulating component 53, which extends between the joining partners, forms a structure S, in particular a protrusion or depression, by which in particular the direct path from the at least one joining partner to the at least one other joining partner along the surface is extended
Implementation Method 2
an at least predominantly amorphous glass layer can be arranged in the joining connections disclosed herein, which preferably comprises less than 10 pores per cm3
Implementation Method 3
a crystallisable or at least partially crystallized glass and its use
Implementation Method 4
maintaining high resistance and stability up to 1000°C
Implementation Method 5
these are often not sufficiently safe in such an environment to ensure unimpaired control behavior against the impairments described above
Data Source
Figure 1~1a
Figure 2~2c
Figure 3~4
AI summary
The invention relates to a join comprising an at least partially crystallized glass and the use thereof, a glass that can be crystallized, an at least partially crystallized glass, and use thereof.