Honeycomb Body Connection-Free Area Design
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Solution Overview
Problem
Honeycomb bodies in exhaust gas systems of internal combustion engines face durability issues due to extreme thermal and dynamic stresses, with existing soldering patterns failing to withstand these conditions effectively, particularly in terms of flexibility and reproducibility.
Innovation Solution
A honeycomb body design with a structured metallic layer forming connection points that are spaced to create a connection-free area around each point, using a high-temperature vacuum soldering process to connect sheet metal foils with varying profiles, ensuring a flexible structure that can withstand thermal and dynamic loads by distributing connection points uniformly across the cross-section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If connection points are densely distributed to fix the honeycomb structure, then structural stability is improved, but flexibility and durability under thermal stress deteriorate
Solution Approach 1:
The connection points are segmented into discrete, spaced-apart locations rather than continuous connections. The distance between connection points is at least 5mm, creating isolated connection zones that allow the metallic layers to flex independently between connection points while maintaining overall structural stability.
Solution Approach 2:
Different regions of the honeycomb structure have different connection densities. Connection points are strategically positioned at locations requiring structural support while leaving other regions connection-free to accommodate thermal expansion and flexing. The connection-free areas between points provide local flexibility while connection points provide local stability.
2Strength
If soldering material is applied extensively to connect metallic layers, then connection strength is improved, but manufacturing precision and reproducibility deteriorate
Solution Approach 1:
The metallic layers are pre-positioned and aligned before soldering, with connection points predetermined at specific locations. The soldering material is then applied only at these pre-defined locations, ensuring consistent positioning and reducing variability in the soldering pattern across different manufactured units.
Solution Approach 2:
The patent replaces extensive mechanical soldering with a reduced set of precisely positioned solder connections. By using connection points instead of continuous or extensive soldering, the manufacturing process becomes more controlled and reproducible, with solder applied at specific predetermined locations rather than over large areas.
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 design significantly enhances the service life and thermal shock behavior of the honeycomb structure, allowing it to maintain flexibility and durability under extreme conditions, while avoiding rigid connections and diffusion issues.
Implementation Method 1
a soldering material is positioned in specific zones of such a honeycomb body in order to connect the metallic components to one another
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a honeycombed body (1) comprising at least one housing (2) and a honeycombed structure (3) having a plurality of channels (4). Said honeycombed structure (3) is made of at least one at least partially structured metallic layer (5) that forms connecting points (6) fixing the honeycombed structure (3). At the most 20 % of the inner contact points (7) in a cross-section (8) of the honeycombed structure (3) form a connection point (6), and the connection points (6) are at a distance from each other such that a connection-free area (9), that is respectively the same size, is formed surrounding said points.