Honeycomb Body Flange Brazing Integration
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Solution Overview
Problem
The existing processes for producing honeycomb bodies with a flange piece for measurement sensors require additional working steps and are costly, as they involve separate joining of the flange piece to the tubular casing.
Innovation Solution
A process that integrates the production of a honeycomb body with a flange piece for a measurement sensor by forming a hole in a tubular casing, fitting a flange piece, introducing a honeycomb structure, and joining all components in a single heat treatment process, such as brazing or welding, eliminating the need for additional steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the flange piece is joined to the tubular casing in a separate working step, then the joining can be performed with dedicated equipment, but the production time and cost increase
Solution Approach 1:
The patent combines the joining of the flange piece to the tubular casing with the joining of the honeycomb structure to the tubular casing into a single common heat treatment process. This merging of operations eliminates the need for separate joining steps, thereby reducing production time and cost while maintaining manufacturing quality through the use of appropriate brazing or welding procedures.
2Ease of manufacture
If multiple separate joining steps are used, then each joining can be optimized independently, but the device complexity and cost increase
Solution Approach 1:
The patent merges multiple joining operations into a single common heat treatment process, thereby simplifying the production process and reducing device complexity. By performing the joining of the flange piece and the honeycomb structure to the tubular casing simultaneously, the patent eliminates the need for multiple separate joining equipment and process controls.
3Reliability
If additional working steps are introduced for flange piece installation, then the measurement sensor can be securely mounted, but the production cost increases
Solution Approach 1:
The patent combines the flange piece installation with the honeycomb structure installation and joining operations into a single integrated process. The flange piece is inserted into the tubular casing through the same opening as the honeycomb structure, and both are joined simultaneously in a common heat treatment process, thereby ensuring secure sensor mounting while eliminating additional working steps and reducing production 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 approach reduces production costs and simplifies the process by joining the tubular casing, honeycomb structure, and flange piece in a single heat treatment, ensuring a secure and cost-effective integration of the measurement sensor.
Implementation Method 1
joining the tubular casing to the honeycomb structure and the flange piece by brazing or welding in a single, common, heat treatment process
Implementation Method 2
joining the tubular casing to the honeycomb structure and the flange piece by brazing or welding in a single, common, heat treatment process
Data Source
AI summary
A process for producing a honeycomb body includes a) producing a tubular casing from sheet metal; b) introducing a hole, delimited by a rim, into the sheet metal; c) fitting a flange piece for a measurement sensor to the hole rim; d) introducing a honeycomb structure into the tubular casing; and e) joining the tubular casing to the honeycomb structure and the flange piece by brazing or welding in a single, common, heat treatment process. Steps a), b) and c) are carried out in any desired order. A honeycomb body includes a honeycomb structure. A tubular casing surrounds the honeycomb structure, has a hole delimited by a rim, and has a necked region surrounding the hole. A flange piece for a measurement sensor is brazed to the hole rim. The process allows a flange piece to be connected to the tubular casing in an advantageous manner as part of an on-going heat treatment process, resulting in a simple and fast production and consequently a reduction of costs.