Dimensionally Accurate Honeycomb Body Molding

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Solution Overview

Problem

Honeycomb bodies with metallic structures face challenges in achieving dimensional accuracy, particularly when inserted into non-cylindrical housings, leading to deformation and non-uniform connections due to uneven pressure distribution and heat treatment effects.

Innovation Solution

A method involving a molding with inwardly-directed contact faces that reproduces the desired outer contour of the housing, providing support and stability during the insertion and heat treatment of the honeycomb structure, and allowing for flexible adjustment and easy removal, while preventing excessive contact pressure and potential sintered connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the honeycomb structure is inserted into a non-cylindrical housing without a molding, then the insertion process is simpler, but the housing deforms due to uneven pressure distribution during heat treatment

Engineering Contradiction:

Improveinsertion process simplicityVSAvoidhousing dimensional accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

A molding is introduced as an intermediary element between the honeycomb structure and the housing. The molding supports the housing outer regions during insertion and heat treatment, distributing forces evenly and preventing deformation while maintaining manufacturing simplicity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The molding is positioned in contact with the housing outer regions before the insertion and heat treatment processes begin. This preliminary support prevents deformation from occurring in the first place, rather than correcting it afterward

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If the honeycomb structure is inserted into a non-cylindrical housing without a molding, then the device complexity is reduced, but the connection uniformity deteriorates due to non-uniform pressure distribution

Engineering Contradiction:

Improveproduction process complexityVSAvoidconnection uniformity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The molding acts as a mediator that ensures uniform pressure distribution during heat treatment. It transfers forces evenly across the housing, guaranteeing reliable and uniform connection between the honeycomb structure and housing without significantly increasing process complexity

Inventive Principle:

Principle #24Intermediary (Mediator)

3Weight of moving object

If the housing is thin-walled to reduce weight, then the weight is reduced, but the housing becomes more prone to deformation under pressure from the honeycomb structure

Engineering Contradiction:

Improvehousing weightVSAvoidhousing shape stability

Core Design Contradiction:

Weight of moving objectVSStability of the object's composition

Solution Approach 1:

The molding serves as a protective intermediary that supports thin-walled housings during critical operations. It distributes pressure evenly and prevents deformation of the thin walls, allowing weight reduction without sacrificing structural stability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The molding provides beforehand cushioning support to the thin-walled housing during insertion and heat treatment. This prior protection prevents deformation before it can occur, enabling the use of lighter thin-walled constructions

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

Ensures the production of dimensionally accurate honeycomb bodies with stable connections, even in non-circular housings, by maintaining the desired shape and configuration, reducing deformation and ensuring reliable assembly and disassembly.

Implementation Method 1

contacting outer regions of the housing with a molding, at least during step b) or step c); and reproducing a desired outer contour of the housing with contact faces of the molding

Methodology Applied

Scientific EffectPhysical support and constraint:

Implementation Method 2

carrying out a heat treatment operation on the honeycomb structure having the housing

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS8281488B2Method for producing a dimensionally accurate honeycomb body

Publication Date: 2012.10.09 VITESCO TECHNOLOGIES GMBH

AI summary

A method for producing a honeycomb body having a honeycomb structure disposed in a housing, includes at least forming a honeycomb structure, inserting the honeycomb structure into a housing, carrying out a heat treatment operation on the honeycomb structure having the housing, contacting outer regions with a molding, at least during the inserting step or the heat treatment step, and reproducing a desired outer contour of the housing with contact faces of the molding. A molding and an exhaust gas treatment unit produced with a thin housing in a dimensionally accurate manner, are also provided.