Exhaust Gas Heater Connection Layout for Tight Vehicle Packaging
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Solution Overview
Problem
Existing exhaust gas heating devices for catalytic purification systems in vehicles are cumbersome due to the radial configuration of connection elements, making it difficult to connect to an electrical power source in restricted environments.
Innovation Solution
The introduction of a third connection element that allows for radial and axial independence of the second connection element, enabling it to bypass the heating element and connect to the second electrode, reducing space requirements and facilitating electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the first and second connection elements are arranged radially at 180° to each other, then the heating element can be connected to the power source, but the device becomes cumbersome and difficult to connect in restricted vehicle environments
Solution Approach 1:
The patent introduces a third connection element that adds a new spatial dimension to the connection arrangement. Instead of keeping all connection elements in the same radial plane, the third element extends in a different direction, allowing connections to be made in three-dimensional space rather than being constrained to a single radial line. This dimensional change enables compact routing of electrical connections within the housing.
Solution Approach 2:
The third connection element is arranged within the space radially delimited between the heating element and the peripheral wall of the housing. The electrical connection components are nested within the existing housing structure, utilizing the available internal space efficiently. This nesting approach allows multiple connection elements to coexist in a compact configuration without requiring additional external space.
2Volume of moving object
If the connection elements are arranged in a compact configuration, then the space required is reduced, but the connection paths become more constrained
Solution Approach 1:
The patent employs flexible connection elements including a connection mat and connection cable that can adapt their shape and routing to fit the available space. The connection cable with core and insulation sheath can bend and extend in different directions as needed, providing dynamic adaptability within the constrained space. This flexibility allows the electrical connections to be routed through the housing structure without requiring fixed, rigid pathways.
Solution Approach 2:
The connection mat covered with an insulating layer provides a flexible planar connection surface that can be conformally arranged within the housing. This flexible film structure allows electrical connections to be made across irregular surfaces and adapts to the available space between the heating element and housing wall, maintaining electrical connectivity while accommodating compact geometric constraints.
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 reduces the space needed for the heating device and simplifies the connection to an electrical power source, improving the usability and efficiency of the exhaust gas heating system.
Implementation Method 1
a heating element arranged in the housing and intended to heat the exhaust gas flowing through the housing
Implementation Method 2
the heating element comprises a metallic foam adapted to heat by joule effect when supplied with electricity by the electrical power source
Data Source
AI summary
An exhaust gas heating device includes a housing and a heating element arranged in the housing for heating exhaust gases flowing through the housing. The heating element comprises a first and a second connecting region. A power source for supplying electricity to the heating element, comprises a first connecting element, connected to the first connecting region of the heating element, and intended to supply the heating element (18) with electricity, and a second connecting element. The electrical power source comprises a third connecting element that comprises an electrical connector, electrically connecting the second connecting element to the second connecting region of the heating element.