Honeycomb Body Axial Stability via Interlocking Structured Layers
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Solution Overview
Problem
Existing honeycomb bodies for exhaust gas aftertreatment units deform over time due to thermal loads and gas flow, leading to instability and the need for costly joining methods like soldering or welding to prevent layer displacement.
Innovation Solution
A honeycomb body design featuring alternating layers with structured and smooth layers, where the structured layers have wave crests and troughs forming channel-like structures that prevent relative movement between layers, eliminating the need for additional joining methods by ensuring a precise fit and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal joining processes such as soldering or welding are used to connect layers, then the durability and stability of the honeycomb body is improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The structured layers are designed with self-interlocking features (protrusions and recesses) that automatically prevent relative axial displacement between layers during thermal expansion and contraction, eliminating the need for external joining processes like soldering or welding while maintaining structural stability
Solution Approach 2:
The honeycomb body is divided into multiple structured layers with alternating orientations, where each layer independently contributes to preventing displacement in specific directions, creating a distributed stabilization system that replaces centralized joining processes
2Duration of action of stationary object
If multiple joining connections are made to prevent layer displacement, then the durability is improved, but the manufacturing time and production cost increase
Solution Approach 1:
The self-interlocking structured layers provide automatic stabilization during thermal cycles and gas flow pulsations without requiring multiple joining operations, significantly reducing manufacturing time while ensuring long-term durability through the inherent mechanical interlocking design
Data Source
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AI summary
The invention relates to a honeycomb body for exhaust gas aftertreatment, having a multiplicity of layers (1, 2, 9, 10, 11, 20) stacked on one another, wherein flow channels are formed between the layers (1, 2, 9, 10, 11, 20), which extend along the axial extent (7) of the honeycomb body and can be flowed through in the axial direction (7), wherein the honeycomb body has first structured layers (1, 2, 21), wherein the structure is formed by successive wave peaks (3) and wave valleys (4), wherein protuberances (5, 6) in the direction of the wave peaks (3) belonging to the respective layer (1, 2, 21) are formed from adjacently arranged wave valleys (4) of a first structured layer (1, 2, 21), wherein, by means of the adjacently arranged protuberances (5, 6) of a first structured layer (1, 2, 21), a channel-like structure extending in the circumferential direction (8, 23) is formed in the first structured layer (1, 2, 21), into which structure a second layer (9, 10, 11, 20) is inserted in such a way that the second layer (9, 10, 20) is fixed in the axial direction (7) with respect to the first structured layer (1, 2, 21).