Heating element for exhaust line

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Solution Overview

Problem

Existing heating elements for exhaust lines with multiple heating discs face challenges in mechanical support and electrical connection, affecting performance and durability.

Innovation Solution

A heating element design featuring a tubular housing with multiple heating discs and a connector that provides both mechanical support and electrical connection, utilizing wheel flanges and insulating rims to ensure proper alignment and insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple heating discs are arranged in series to improve heating performance and durability, then the heating element can maintain consistent heating and improve reliability, but the mechanical support and electrical connection complexity increases

Engineering Contradiction:

Improveheating element durabilityVSAvoidmechanical support and electrical connection complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines mechanical support and electrical connection functions into a single integrated connector structure. The wheel flange serves as both a mechanical support element that holds the heating discs in place and an electrical connector that provides electrical pathways between discs, eliminating the need for separate support and connection components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The wheel flange is designed as a multi-functional component that simultaneously performs mechanical support, electrical connection, and alignment functions. This universal component handles multiple tasks that would traditionally require separate dedicated parts, reducing overall system complexity while supporting multiple heating discs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If wheel flanges are used to provide mechanical support and electrical connection, then the alignment and electrical connectivity between heating discs is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvealignment precision between heating discsVSAvoidmanufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The wheel flange structure is segmented into distinct functional zones: the rim provides mechanical support and alignment, the hub provides electrical connection points, and the spokes provide structural integrity. This segmentation allows each part to be optimized independently while maintaining overall manufacturing feasibility through modular assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of trying to achieve precise alignment through complex positioning mechanisms, the patent inverts the approach by using the wheel flange's inherent geometric structure (rim, hub, spokes) to naturally guide and constrain the heating discs into correct positions during assembly, making precision alignment a result of the structure rather than a requirement of the assembly process.

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If insulating rims are added to prevent short circuits between heating discs, then the electrical insulation reliability is improved, but the device complexity increases

Engineering Contradiction:

Improveelectrical insulation reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulating rim is nested within the wheel flange structure, fitting into the space between the rim and hub. This nested placement allows the insulating component to be integrated into the existing structure without adding external protrusions or requiring additional mounting space, maintaining compactness while providing necessary electrical insulation.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 solution effectively supports multiple heating discs and ensures reliable electrical connections, enhancing the heating element's performance and durability by maintaining consistent heating and reducing the risk of short circuits.

Implementation Method 1

heating is achieved by applying an electric current between two end points of the metal heating disc, in order to heat it by Joule effect

Methodology Applied

Scientific EffectJoule effect: Joule Heating

Implementation Method 2

a connector supporting said at least two heating discs and providing an electrical connection between said at least two heating discs

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

the radial arm of the L forming a first bearing face capable of bearing axially against the periphery of a first disc of said at least two heating discs

Methodology Applied

Scientific EffectMechanical bearing: Ball Bearing

Data Source

PatentUS20250129733A1Heating element for exhaust line

Publication Date: 2025.04.24 FAURECIA SYST DECHAPPEMENT SAS

AI summary

A heating element for an exhaust line includes a substantially tubular housing that defines a passage section for the exhaust gases and at least two heating discs arranged across the passage section to force the exhaust gases to pass through the at least two heating discs. A connector supports the at least two heating discs and provides an electrical connection between the at least two heating discs.