Metal Honeycomb Catalytic Converter Structure With Angled Axial Sections
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Solution Overview
Problem
Existing catalytic converters with metallic honeycomb bodies face issues such as oblique flow channels that prevent the use of support pins, damage from small bending radii, increased heat capacity due to smooth metal foils, and higher production costs.
Innovation Solution
A catalytic converter design with a honeycomb body formed by winding metal foils, featuring axial sections with varying flow channel angles relative to the center axis, eliminating the need for smooth metal foils and reducing material stress, while allowing uninterrupted flow channels and simplified construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If structured metal foils with opposite alignments are stacked to form the honeycomb body, then the foils are prevented from slipping into one another, but the flow channels become oblique and do not run parallel to the center axis, preventing the use of support pins
Solution Approach 1:
The honeycomb body is divided into multiple axial sections along its axial extent, where each section can have flow channel sections running at different angles relative to the center axis. This segmentation allows different portions of the honeycomb body to have different flow channel orientations, enabling support pins to be used in sections where flow channels run parallel to the center axis while other sections maintain oblique flow channels for structural stability.
2Volume of moving object
If small bending radii are used in the metal foils, then the honeycomb body can be formed with compact structure, but the matrix of the honeycomb body is damaged as a result of the small bending radii
Solution Approach 1:
The invention changes the bending radius parameter of the metal foils to a larger value, avoiding the matrix damage that occurs with small bending radii. By using larger bending radii in the formation of the honeycomb body, the structural integrity and reliability of the metal foil matrix are maintained while still achieving a compact overall structure through the axial section configuration.
3Device complexity
If smooth metal foils are used between the structured metal foils, then the honeycomb body structure is simplified, but the heat capacity increases and heating time is extended
Solution Approach 1:
The invention extracts and removes the smooth metal foils from the honeycomb body structure, eliminating the unnecessary material that increases heat capacity and heating time. The structured metal foils alone are sufficient to form the honeycomb body with appropriate flow channels, and removing the smooth foil layer reduces the overall heat capacity while maintaining structural integrity.
4Stability of the object's composition
If smooth metal foils are used in the honeycomb body, then the structure is more stable, but the material requirement increases and production costs are higher
Solution Approach 1:
The invention removes the smooth metal foils from the honeycomb body construction, eliminating the additional material requirement and associated production costs. The structured metal foils alone provide sufficient structural stability when configured in axial sections, making the smooth foil layer redundant and its removal both cost-effective and functionally adequate.
Data Source
AI summary
A catalytic converter for aftertreatment of exhaust gases from an internal combustion engine, having a honeycomb body formed by wrapping from at least one metal foil, where the honeycomb body has a center axis that runs along its axial extent from a gas entry side of the honeycomb body up to a gas exit side of the honeycomb body, and the honeycomb body has a multitude of flow channels through which a flow can pass from a gas entry side of the honeycomb body to a gas exit side, wherein the honeycomb body is divided into individual axial sections along its axial extent along which the center axis runs, where the axial sections have flow channel sections that run along different angles relative to the center axis.