Heating Element With Low Resistivity Joining Portion
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Solution Overview
Problem
Existing heat generating elements, such as honeycomb structural bodies used for catalyst carriers, face challenges in adjusting their shape to suit various applications and ensuring efficient heat generation.
Innovation Solution
A heat generating element comprising multiple honeycomb structure units with partition walls forming cells for fluid flow, where the units are joined through a first joining portion with a volume resistivity of 1 Ω·cm or less, and optionally a second joining portion with a higher volume resistivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If honeycomb structure units are joined together to form a heat generating element, then the shape can be adjusted to suit different applications, but the heat generation characteristics may be compromised due to high resistance at joining portions
Solution Approach 1:
A joining portion with low volume resistivity (1 Ω·cm or less) is introduced as an intermediary between honeycomb structure units with higher volume resistivity (2 Ω·cm or more). This intermediary conducting layer ensures efficient electrical connection and heat generation while allowing modular assembly of different shapes.
Solution Approach 2:
The joining portion is designed with locally optimized low resistivity properties specifically at the connection points between honeycomb units, while the main body units maintain their structural integrity and higher resistivity characteristics. This localized quality differentiation resolves the contradiction between shape flexibility and heat generation efficiency.
2Power
If a joining portion with low volume resistivity is used to ensure good electrical connection, then heat generation efficiency is improved, but the joining portion may become a weak point for current concentration and overheating
Solution Approach 1:
The volume resistivity of the joining portion is precisely controlled to be 1 Ω·cm or less, creating an optimal electrical parameter that ensures low resistance connection while distributing current effectively. This parameter optimization prevents both excessive resistance (reducing power) and current concentration (causing overheating).
Solution Approach 2:
The joining portion acts as an intermediary conducting element that mediates between the higher resistivity honeycomb units and the electrical current flow, ensuring uniform current distribution and preventing localized overheating while maintaining efficient heat generation.
3Shape
If multiple honeycomb structure units are joined together, then the desired shape and size can be achieved, but the manufacturing complexity increases
Solution Approach 1:
The heat generating element is segmented into multiple standardized honeycomb structure units that can be independently manufactured and then assembled with joining portions. This segmentation allows flexible configuration of different shapes and sizes while maintaining relatively simple manufacturing processes for each modular unit.
Solution Approach 2:
The honeycomb structure units are designed as universal modular components that can be assembled in various configurations to create different shapes and sizes. The standardized joining portions provide multi-functional connections that simplify the overall manufacturing process despite the modular complexity.
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 proposed heat generating element achieves excellent heat generation characteristics and allows for easy adjustment of its shape, enhancing its applicability across different applications.
Implementation Method 1
the first joining portion has a volume resistivity that is lower than a volume resistivity of the honeycomb structure unit, and wherein the volume resistivity of the first joining portion is 1 Ω·cm or less
Implementation Method 2
configured to generate heat by energization
Data Source
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AI summary
Provided is a heat generating element, which has excellent heat generation characteristics, and has a shape that can be easily adjusted. A heat generating element according to an embodiment of the present invention includes a plurality of honeycomb structure units, each of which includes partition walls, and is configured to generate heat by energization, the partition walls defining and forming a plurality of cells that extend from a first end surface to a second end surface, and serve as fluid flow passages. The plurality of honeycomb structure units include a first honeycomb structure unit and a second honeycomb structure unit. The first honeycomb structure unit and the second honeycomb structure unit are joined to each other through intermediation of a first joining portion. The first joining portion has a volume resistivity that is lower than a volume resistivity of the honeycomb structure unit. The volume resistivity of the first joining portion is 1 Ω·cm or less.