Honeycomb Body Flexible Connecting Points Exhaust Gas
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Solution Overview
Problem
Honeycomb bodies in exhaust systems of internal combustion engines face durability issues due to extreme thermal and dynamic loadings, which current connecting techniques cannot adequately withstand, leading to reduced service life and poor thermoshock and vibration characteristics.
Innovation Solution
A honeycomb body with flexible connecting points formed by curved connecting lines and expansion joints between brazed sheet-metal foils, allowing for movement and distribution of load, and a brazed connection using high-temperature vacuum brazing, with a configuration that maximizes channel density and minimizes rigid connections to enhance durability and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional brazing techniques are used to connect sheet-metal foils in honeycomb bodies, then connection strength is achieved, but durability under extreme thermal and dynamic loadings deteriorates
Solution Approach 1:
The connecting line is segmented into discrete connecting points spaced at specific intervals (e.g., 5-50 mm apart), rather than continuous brazing. This segmentation allows the structure to flex and distribute thermal and dynamic stresses across multiple discrete connection zones, improving durability while maintaining connection strength at each point.
Solution Approach 2:
The invention changes the geometric parameters of the connecting structure by forming curved connecting lines with specific radii of curvature (e.g., 10-100 mm) and spacing connecting points at optimized intervals. These parameter changes enable the connecting line to flex under thermal expansion and dynamic loads, significantly improving reliability under extreme conditions while maintaining adequate connection strength.
2Stability of the object's composition
If rigid connecting techniques are used to ensure structural stability, then structural stability is improved, but flexibility to withstand thermal shock and vibration deteriorates
Solution Approach 1:
The connecting line is designed with curved geometry and spaced connecting points that allow dynamic movement and flexing in response to thermal expansion and vibration. The curved path (e.g., arc-shaped or sinusoidal) enables the connection to absorb dynamic loads while maintaining structural stability, transforming a static rigid connection into a dynamic adaptive structure.
Solution Approach 2:
The connecting line follows a curved path rather than a straight line, with specified radii of curvature (e.g., 10-100 mm). This curvature allows the connection to flex and accommodate thermal expansion and vibration, providing both structural stability and adaptability to extreme conditions simultaneously.
3Area of stationary object
If thin sheet-metal foils are used to increase surface area and reduce pressure loss, then geometric surface area and pressure loss characteristics are improved, but resistance to thermal and mechanical loading deteriorates
Solution Approach 1:
The invention embraces the use of thin sheet-metal foils (e.g., 10-50 μm) for the honeycomb structure while compensating for their reduced strength through the flexible connecting line design. The curved, segmented connecting points distribute and absorb thermal and mechanical stresses, allowing thin foils to maintain both high surface area and adequate resistance to loading.
Solution Approach 2:
By segmenting the connection into spaced discrete points rather than continuous brazing, the stress is distributed across multiple locations along the connecting line. This segmentation prevents stress concentration that would otherwise compromise thin sheet-metal foils under thermal and mechanical loading, enabling the use of thinner materials for improved surface area and reduced pressure loss.
4Strength
If connecting points are spaced closely to ensure structural integrity, then structural integrity is improved, but flexibility and ability to distribute thermal stress deteriorates
Solution Approach 1:
The invention optimizes the spacing parameter of connecting points (e.g., 5-50 mm intervals) and the curvature radius of the connecting line to achieve a balance between structural integrity and flexibility. This parameter optimization allows sufficient spacing to distribute thermal stresses while maintaining adequate structural strength through the curved geometry and brazing at each point.
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 solution significantly improves the service life and thermoshock characteristics of honeycomb bodies by allowing for flexible movement and load distribution, reducing the impact of thermal and dynamic stress, and enhancing vibration resistance.
Implementation Method 1
At least the top-side connecting points or the bottom-side connecting points define a curved connecting line and expansion joints formed between the connecting points of the curved connecting line
Implementation Method 2
a brazed connection using high-temperature vacuum brazing
Data Source
AI summary
A honeycomb body is formed of at least one at least partially structured sheet-metal foil and has a plurality of channels. The sheet-metal foil has a course or profile direction and includes top-side connecting points and bottom-side connecting points to itself or to at least one additional smooth sheet-metal foil or structured sheet-metal foil. At least the top-side connecting points or bottom-side connecting points form a curved connection line and expansion joints between the respective connection points of the curved connection line. An exhaust-gas treatment unit and a motor vehicle are also provided.