Multi-Stage Honeycomb Body Heating Circuit Design
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Solution Overview
Problem
Existing electrically heatable honeycomb bodies for catalytic exhaust gas purification in internal combustion engines lack the ability to achieve targeted and uniform heating across different flow sections, as they typically have a single heating circuit with fixed heat output, which is insufficient for optimal catalytic activity at varying temperatures.
Innovation Solution
The honeycomb body features multiple independent heating circuits formed by twisted and insulated stacks of electrically conductive layers, allowing for separate control of heating outputs and uniform temperature distribution across the flow section, achieved through distinct layer thicknesses and structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a single heating circuit with fixed heat output is used, then the structure is simple, but uniform temperature distribution across different flow sections cannot be achieved
Solution Approach 1:
The heating circuit is divided into multiple independent heating zones along the flow direction, with each zone having its own heating element and control. This segmentation allows different sections to be heated to different temperatures independently, achieving uniform temperature distribution across the catalyst bed while maintaining manageable system complexity through modular design.
Solution Approach 2:
Different heating outputs are applied to different flow sections based on local requirements. The heating elements are designed with varying power outputs matched to the specific thermal needs of each catalyst section, ensuring optimal temperature distribution throughout the converter while avoiding overheating in some areas and underheating in others.
2Adaptability or versatility
If multiple heating circuits with independent control are implemented, then targeted heating of specific areas with different heat outputs is enabled, but the structural complexity increases
Solution Approach 1:
The catalyst bed is divided into multiple heating zones with independent control, allowing targeted heating of specific areas. Each zone can be activated or adjusted independently based on operational requirements, providing high adaptability while the modular segmented structure keeps the overall system manageable.
Solution Approach 2:
The heating system incorporates dynamic control capabilities where each heating circuit can be independently adjusted in real-time based on temperature sensors and operational conditions. This dynamic adaptability allows the system to respond to changing engine operating conditions while maintaining a relatively simple underlying structure through standardized heating element design.
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 design enables efficient and uniform heating of exhaust gases, ensuring optimal catalytic activity by allowing independent control of heating circuits, thereby maintaining or achieving catalytic converter efficiency across varying engine operational temperatures.
Implementation Method 1
at least a first stack of layers (4) made of an electrically conductive material and a second stack of layers (5) made of an electrically conductive material... the first stack of layers (4) forms a first current path (8) for conducting an electric current for a first heating circuit (10) and the second stack of layers (5) forms a second current path (9) for conducting an electric current for a second heating circuit (11)
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to an electrically heatable honeycomb body (1) having channels (2), comprising at least one heating disk (3) having at least one first layer stack (4) made of an electrically conductive material and one second layer stack (5) made of an electrically conductive material, wherein the first layer stack (4) and the second layer stack (5) are interleaved with each other and electrically insulated from each other, wherein the first layer stack (4) forms a first current path (8) for conducting an electrical current for a first heating circuit (10) and the second layer stack (5) forms a second current path (9) for conducting an electrical current for a second heating circuit (11). According to the invention the first heating circuit (10) of the heating disk (3) is also operated at a power of 300 W to 500 W and the second heating circuit (11) of the heating disk is operated at 500 W to 700 W. Thus the exhaust gas of an internal combustion engine can be evenly heated by several independent heating circuits in a common heating disk even with different heating capacities using a simple design.