Exhaust-Gas Heater Connection Structure for High-Current Thermal Stability
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Solution Overview
Problem
Existing connection units for electrical supply lines to exhaust-gas heaters in internal combustion engine systems are not adequately resistant to thermal overload and do not efficiently handle large electrical currents, posing challenges in rapidly heating exhaust-gas treatment units.
Innovation Solution
A connection unit with a conductive connection element and a carrier element, featuring a radial projection for dual support and connection functions, supported by insulating materials and a preloading unit to manage thermal stresses, ensuring electrical insulation and secure attachment of supply lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the connection unit uses a simple structure, then the manufacturing cost and complexity are reduced, but the resistance to thermal overload and ability to handle large electrical currents deteriorates
Solution Approach 1:
The connection unit is divided into distinct functional segments: the connection element for electrical connection, the carrier element for mounting, and the support unit for insulation and positioning. This segmentation allows each component to be optimized for its specific function while maintaining overall structural simplicity.
Solution Approach 2:
The support unit acts as an intermediary component between the conductive connection element and the carrier element, providing electrical insulation and mechanical support. This intermediary structure enables the connection unit to handle large currents without direct contact between conductive parts, improving thermal and electrical reliability.
2Power
If the connection element has a large cross-section to handle large electrical currents, then the current carrying capacity is improved, but the space required and device size increase
Solution Approach 1:
The connection element transitions from a conventional two-dimensional flat contact surface to a three-dimensional cylindrical structure with radial projection. This dimensional change allows the current path to extend through the volume of the cylinder rather than just across a surface, increasing current handling capacity without proportionally increasing the footprint area.
Solution Approach 2:
The connection element with radial projection is nested within the support unit, which itself is mounted on the carrier element. This nested arrangement allows the connection unit to accommodate the necessary large cross-section for current handling while maintaining a compact overall structure that fits within the exhaust system constraints.
3Reliability
If the connection element is electrically insulated from the carrier element, then electrical safety is improved, but the complexity of insulation and mounting increases
Solution Approach 1:
The support unit combines multiple functions into a single component: it provides electrical insulation between the connection element and carrier element, mechanical support for the connection element, and positioning features for secure mounting. This merging of functions reduces the total number of separate components and simplifies the overall assembly process.
Solution Approach 2:
The support unit is designed as a multi-functional element that simultaneously serves as an insulator, mechanical support, and mounting interface. This universal component approach eliminates the need for separate insulation pieces and mounting brackets, reducing assembly complexity while maintaining electrical safety.
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 provides a simple, reliable, and thermally stable structure capable of handling large electrical currents while maintaining electrical insulation and preventing overheating, ensuring efficient heat transfer to exhaust-gas treatment units.
Implementation Method 1
a support unit for axially and radially supporting the connection element on the carrier element, the support unit including a first support element of electrically insulating material supported on the carrier element in a first axial direction and radially outwardly
Implementation Method 2
the supply-line connection region including an end portion of the connection-element body and a radial projection of the connection-element body adjoining the end portion
Data Source
AI summary
A connection unit connects an electrical supply line to an exhaust-gas heater of an exhaust system. The connection unit includes a connection element having an electrically conductive connection-element body. The connection element has an exhaust-gas heater connection region in a first axial end region and has a supply-line connection region in a second axial end region. The supply-line connection region includes an end portion of the connection-element body and a radial projection adjoining the end portion. A carrier element fixes the connection unit to an exhaust-system component. The carrier element has a carrier-element opening wherethrough the connection-element body passes. A support unit axially and radially supports the connection element on the carrier element.