Electrically Heated Catalyst Insulation via Curved Introducing Portion
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Solution Overview
Problem
Existing electrically heated catalysts face insulation performance deterioration due to particulate matter (PM) adhesion, which can lead to electricity flowing through the case, compromising insulation and safety.
Innovation Solution
The design incorporates a heat generating element, a case, and a mat with a tubular portion, an inclined portion, and an introducing portion, where the inner tube is curved to direct exhaust gas flow uniformly and reduce turbulence, preventing PM adhesion and electricity flow between the inner tube and the case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a double tube structure with an inner tube is used to provide insulation, then insulation performance is improved to some extent, but particulate matter may still adhere depending on exhaust gas flow direction, deteriorating insulation performance and allowing electricity to flow through the case
Solution Approach 1:
The introducing portion is designed with a curved shape where the center of curvature is positioned outside the introducing portion. This curvature configuration optimizes exhaust gas flow distribution, reducing turbulence and preventing particulate matter from adhering to the inner tube and case, thereby maintaining insulation performance and preventing electricity leakage
Solution Approach 2:
The case is designed with different structural characteristics in different regions: the inlet portion has a smaller inner diameter, the tubular portion has a larger inner diameter, and the introducing portion has a specific curved shape. These localized structural variations optimize exhaust gas flow distribution throughout the catalyst, preventing PM adhesion in critical insulation areas while maintaining heating efficiency
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 effectively suppresses the flow of electricity through the case by minimizing PM adhesion and maintaining insulation performance, ensuring efficient heat distribution and safety.
Implementation Method 1
a heat generating element which generates heat by applying electricity
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Electricity is suppressed from flowing through a case (5) of an electrically heated catalyst (1). For this purpose, the case (5) for accommodating a heat generating element (3) includes a tubular portion (53) which is formed in parallel to a central axis, an inlet portion (51) which is provided on the upstream side from the tubular portion (53) and which has an inner diameter smaller than that of the tubular portion (53), an inclined portion (52) which connects the tubular portion (53) and the inlet portion (51), and an introducing portion (54) which extends from a connected portion between the inlet portion (51) and the inclined portion (52) toward inside of the case (5) and which is curved so that a center of curvature is positioned at the outside; and an inner tube (4) interposed by a mat (6) for supporting the heat generating element (3) includes a tubular portion (42) which is formed in parallel to a central axis, and an inclined portion (41) which is provided on the upstream side from the tubular portion (42), which has inner diameters that are decreased on the more upstream side, and which is curved.