Exhaust Gas Heating Conductor With Flow Openings for Low Back Pressure
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Solution Overview
Problem
Existing heating conductors for exhaust gas heating arrangements in internal combustion engines have limitations in efficiently transferring heat to exhaust gases due to high back pressure and restricted flow conditions, which hinder optimal heat transfer and efficiency.
Innovation Solution
The heating conductor features a meandering or spirally wound structure with throughflow openings that allow exhaust gas to flow freely, reducing back pressure and increasing the heat transfer surface area, while the flow openings' geometry influences current flow paths to adapt to specific flow conditions, enhancing heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heating conductor is designed without flow-through openings, then it provides continuous heating surface area, but it generates high back pressure that restricts exhaust gas flow
Solution Approach 1:
The heating conductor is designed with flow-through openings that create a porous structure, allowing exhaust gas to pass through the conductor itself. This resolves the contradiction by providing continuous heating surface area while maintaining low back pressure, as the openings enable gas flow through the heating element rather than forcing flow around it.
Solution Approach 2:
The heating conductor transitions from a two-dimensional flat structure to a three-dimensional structure with flow-through openings. This dimensional change allows the conductor to provide heating surface area while simultaneously creating flow paths through its thickness, resolving the conflict between heat transfer efficiency and back pressure.
2Ease of manufacture
If the heating conductor has a simple straight structure, then it allows easy manufacturing, but it provides limited heat transfer surface area
Solution Approach 1:
The heating conductor is segmented into multiple heating sections separated by flow-through openings. This segmentation allows the conductor to be cut from a flat metal blank in a simple manufacturing process while creating multiple distinct heating zones that collectively provide large heat transfer surface area.
Solution Approach 2:
The heating conductor utilizes three-dimensional spatial arrangement with flow-through openings, allowing it to achieve large heat transfer surface area through its structure rather than requiring extended length. The openings create vertical dimension utilization that increases effective heating surface without complicating manufacturing.
3Temperature
If flow openings are added to the heating conductor, then back pressure is reduced and heat transfer surface area increases, but the structural complexity increases
Solution Approach 1:
The heating conductor is segmented into heating sections by flow-through openings, creating a modular structure that naturally provides both heat transfer surface area and flow paths. This segmentation approach achieves complex thermal-flow functionality through a relatively simple repetitive pattern that can be manufactured by cutting from a flat blank.
Solution Approach 2:
The flow-through openings serve multiple functions simultaneously: they reduce back pressure by providing flow paths, increase heat transfer surface area by creating additional heating zones, and can be designed to influence current distribution. This multi-functionality reduces the need for separate components, offsetting the structural complexity with functional integration.
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 design significantly reduces back pressure, increases heat transfer efficiency by allowing exhaust gas to flow around a larger surface area, and adapts heat transfer behavior to flow conditions, resulting in improved thermal interaction with the exhaust gas.
Implementation Method 1
the heating conductor itself is more effectively exposed to exhaust gas flow, depending also on the geometry of these flow-through openings, thus enabling increased heat transfer to the exhaust gas flowing around the heating conductor
Implementation Method 2
heat transfer to the exhaust gas flowing around the heating conductor
Implementation Method 3
Since, during heating operation, the heating conductor is traversed by electric current and, in the area of a respective flow opening, current flow paths with an electrical resistance dependent on their cross-sectional geometry are formed on both sides of such a flow opening
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A heating conductor for an exhaust gas heating arrangement for an exhaust system for an internal combustion engine comprises a plurality of heating conductor sections (22, 84), wherein at least one, preferably several, flow openings (124) through which exhaust gas can flow are provided in at least one heating conductor section (82, 84), preferably in several or each heating conductor section (82, 84).