Heater Element With Gradient Functional Layer For Regeneration
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Solution Overview
Problem
The existing heater elements with functional material-containing layers in vehicle compartment purification systems face challenges in effectively regenerating functional materials near the inlet side due to insufficient temperature rise, leading to low regeneration efficiency and reduced cost performance.
Innovation Solution
A heater element with a honeycomb structure and a functional material-containing layer where the layer's thickness increases from the inlet to the outlet end surface, ensuring that the functional material can be effectively regenerated by maintaining higher thickness in regions where temperature rise is easier, thus improving regeneration efficiency and cost performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a functional material-containing layer is provided on the surface of partition walls in a heater element, then the heating area is increased and heating efficiency is improved, but the temperature rise near the inlet side is insufficient, leading to low regeneration efficiency of functional materials
Solution Approach 1:
The patent applies local quality by making the functional material-containing layer have different thicknesses at different positions along the flow path. Specifically, the layer thickness increases from the inlet side to the outlet side, with the inlet side having a smaller thickness (5-20 μm) and the outlet side having a larger thickness (20-50 μm). This gradient structure ensures that functional materials are exposed to appropriate temperatures for effective regeneration while maintaining high heating efficiency throughout the element.
2Productivity
If the functional material layer thickness is increased to improve regeneration efficiency, then more functional material can be heated, but the temperature distribution becomes uneven and inlet side materials remain underheated
Solution Approach 1:
The patent applies parameter changes by varying the thickness parameter of the functional material-containing layer along the flow direction. The thickness transitions from 5-20 μm at the inlet to 20-50 μm at the outlet, creating an optimal temperature-exposure condition for functional materials at each position. This parameter variation ensures uniform temperature distribution effects while maximizing overall regeneration efficiency.
3Productivity
If the heater element processes large amounts of air for effective component capture, then purification performance is improved, but energy loss increases and cruising range is reduced
Solution Approach 1:
The patent applies discarding and recovering by using the heater element to not only heat air for ventilation but also to regenerate functional materials that capture harmful components. The functional materials adsorb components like water vapor and CO2 during normal operation, then are heated by the same heater element to release these components externally, regenerating the materials for continued use. This recovers the purification function without requiring separate high-energy ventilation operations.
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 enhances the regeneration efficiency of functional materials and improves the cost performance of the heater element by ensuring that the functional material can be effectively utilized, reducing the proportion of material that is difficult to regenerate due to insufficient temperature rise.
Implementation Method 1
the partition walls have PTC characteristics
Implementation Method 2
captures components to be removed such as water vapor and CO2 in the air of a vehicle compartment with a functional material such as an adsorbent
Implementation Method 3
a method of desorbing the substance adsorbed on the functional material to discharge the substance
Data Source
AI summary
A heater element including a honeycomb structure and a functional material-containing layer, wherein the honeycomb structure has an outer peripheral wall and partition walls provided inside the outer peripheral wall, the partition walls partitioning a plurality of cells that form flow paths extending from an inlet end surface to an outlet end surface, and at least the partition walls are made of a material having PTC characteristics, and wherein the functional material-containing layer is provided on a surface of the partition walls, and a thickness of the functional material-containing layer increases from the inlet end surface toward the outlet end surface.