Exhaust Gas Heating Disc Holder with Arcuate Spokes
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Solution Overview
Problem
Existing exhaust gas treatment devices for motor vehicles face challenges in achieving rapid light-off temperatures for catalysts during cold starts, while also requiring high thermal resistance and efficient heating output at a low production cost.
Innovation Solution
The solution involves an exhaust gas treatment device with a heating disc in the exhaust gas flow direction, featuring a flat heating element and a holder with a spider network-like structure. The holder is radially larger than the heating element, providing high thermal resistance and efficient heat transfer, while the arched spokes compensate for thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a heating element is used to rapidly heat the catalyst during cold start, then the light-off temperature is reached quickly, but the production cost increases
Solution Approach 1:
The holder is segmented into multiple radial spokes that are interconnected to form a spiderweb-like structure. This segmentation allows the holder to achieve high thermal resistance and mechanical strength while using less material, reducing production cost. The segmented structure also allows for efficient heat distribution across the heating element surface.
Solution Approach 2:
The spokes of the holder are designed with an arcuate (curved) shape rather than straight lines. This curvature provides inherent thermomechanical strength to compensate for thermal expansion and contraction during heating cycles, eliminating the need for additional expensive expansion compensation mechanisms while maintaining structural integrity.
2Temperature
If the holder is made with high thermal resistance to maintain heating efficiency, then heat transfer is optimized, but the production cost increases
Solution Approach 1:
The holder is divided into multiple radial spokes that are interconnected. This segmented approach creates a structure with high thermal resistance that efficiently maintains heating temperature while using minimal material. The gaps between spokes reduce material usage and cost while the interconnected design maintains thermal efficiency.
Solution Approach 2:
The holder structure implements local quality by concentrating material only where thermally critical - at the spoke intersections and along the radial paths from the center. The areas between spokes remain open, reducing overall material usage and production cost while maintaining high thermal resistance where needed for heating efficiency.
3Strength
If the holder structure is made rigid to provide strong support, then mechanical strength is improved, but thermal expansion compensation becomes difficult
Solution Approach 1:
The spokes are designed with an arcuate shape instead of straight lines. This curvature provides inherent flexibility to accommodate thermal expansion and contraction while maintaining structural strength. The curved geometry allows the holder to expand and contract radially during heating cycles without compromising mechanical integrity or requiring additional expansion joints.
Solution Approach 2:
The holder structure changes its physical parameters (shape and dimensions) in response to temperature changes. The arcuate spokes are designed to expand and contract within specific parameter ranges, allowing the holder to adapt to thermal conditions while maintaining structural strength. This passive parameter adjustment eliminates the need for active thermal management systems.
4Stability of the object's composition
If the holder extends over the entire cross-sectional area to provide support, then structural stability is improved, but exhaust gas flow resistance increases
Solution Approach 1:
The holder is segmented into discrete radial spokes rather than forming a continuous solid structure. This segmentation provides structural stability through the distributed spoke framework while maintaining large open areas between spokes for exhaust gas flow. The segmented design achieves both structural integrity and minimal flow resistance with reduced material usage.
Solution Approach 2:
The radial spokes serve multiple functions simultaneously: they provide structural support, define the holder's radial extent, and create flow channels for exhaust gas. This multi-functionality allows the holder to achieve structural stability without requiring additional flow management components, reducing overall complexity and cost.
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 achieves rapid heat-up of catalysts during cold starts, maintains high thermal resistance, and ensures efficient heating output, while being cost-effective and easy to produce.
Implementation Method 1
The heating element is an electric resistance heater that heats up very quickly when an electric current is applied and then heats the catalyst via radiation and/or convection
Implementation Method 2
The heating element is an electric resistance heater that heats up very quickly when an electric current is applied and then heats the catalyst via radiation and/or convection
Implementation Method 3
the arcuate shape of the individual spokes provides the holder with exceptional thermomechanical strength. Consequently, expansions and contractions due to temperature variations are optimally compensated for by the arcuate shape
Implementation Method 4
The heating element is an electric resistance heater that heats up very quickly when an electric current is applied
Data Source
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AI summary
The present invention relates to an exhaust gas treatment device (1) for arrangement in the exhaust system of a motor vehicle, comprising a heating disc (3) which is associated with an exhaust gas aftertreatment component, in particular a catalyst (2). The heating disc (3) is formed by a planar heating element and a holder (6) coupled thereto, wherein the holder (6) extends over the cross-sectional area of the heating element and the holder (6) itself is disc-shaped, the inner surface of the heating disc (3) being formed by irregularly coupled arcuate spokes (9).