Honeycomb Body Electric Heating Wire Pin Assembly
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Solution Overview
Problem
Existing honeycomb body arrangements for exhaust gas aftertreatment systems face challenges with high-voltage electric heating elements, including increased corrosive loss and operational complexity, especially when using 48-volt systems, and require effective temperature management and assembly simplicity while minimizing pressure losses.
Innovation Solution
A honeycomb body arrangement with an electric heating device featuring an electrically insulated heating wire, supported by a pin arrangement at a specific distance from the honeycomb body, using a nickel-chromium wire core and a metal sheath with powdered mineral oxide insulation, allowing for efficient heat dissipation and reduced corrosive loss, and a pin arrangement for heat conduction and structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-voltage (48V) electric heating elements are used to achieve adequate ohmic resistance heating, then the heating efficiency is improved, but the corrosive loss of the heating conductor increases significantly
Solution Approach 1:
The patent introduces a ceramic insulator as an intermediary material between the heating conductor and the corrosive exhaust gas environment. This ceramic coating acts as a protective barrier that prevents direct contact between the high-voltage heating element and the corrosive atmosphere, thereby maintaining heating efficiency while dramatically reducing corrosive loss of the conductor material.
2Ease of manufacture
If the heating element is incorporated during the production process of the exhaust gas aftertreatment device, then the assembly simplicity is improved, but selective machining of metal layers is required which increases manufacturing complexity
Solution Approach 1:
The patent segments the heating element into separate modular components that can be independently manufactured and then assembled. This segmentation allows the heating element to be installed as a separate module rather than requiring integrated machining during honeycomb body production, thereby reducing manufacturing complexity while maintaining assembly simplicity.
3Temperature
If the heating element is positioned close to the honeycomb body for effective heating, then the temperature management efficiency is improved, but the pressure losses increase
Solution Approach 1:
The patent applies local quality by positioning the heating element specifically at the inlet region of the honeycomb body where the exhaust gas first enters. This localized heating approach efficiently raises the temperature of the incoming gas stream without requiring the heating element to be positioned throughout the entire flow path, thereby achieving effective temperature management while minimizing interference with gas flow and reducing pressure losses.
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 configuration enables selective temperature management, reduced corrosive loss, and stable operation under varying conditions, while maintaining low pressure losses and allowing for extended heating influence on both exhaust gas and catalytically active coatings, suitable for 48-volt systems and long-term durability.
Implementation Method 1
the heating wire (3) has an electrical resistance in a range of from 0.5 to 5 ohms
Implementation Method 2
The at least one heating wire (3) is surrounded by an insulator (9)
Data Source
AI summary
The invention relates to a honeycomb body with an electric heating device. The electric heating device includes at least one electrically insulating heating wire which is fixed by a pin assembly to a front side of a honeycomb body. The electrically insulated heating wire is positioned at a distance of at least five times and a maximum of fifteen times that of the wire diameter.