Non-overlapping Grid Exhaust Heating Device for Uniform Current Flow

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Solution Overview

Problem

Existing exhaust gas heating devices for combustion engines face challenges in simplifying production and ensuring uniform heating to prevent hotspots and weak areas, which can affect their performance and longevity.

Innovation Solution

A non-overlapping grid design with specific geometric features, such as junction zones and recesses, is used to simplify production and prevent hotspots, ensuring uniform current flow and reduced mechanical stress, made from conductive materials like FeCrAl or Inconel, and manufactured through cutting or 3D printing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional grid designs with overlapping strands are used, then production complexity increases, but manufacturing precision and reliability deteriorate due to hotspots and weak areas

Engineering Contradiction:

Improveproduction simplificationVSAvoidgrid performance consistency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The grid is segmented into distinct non-overlapping strands with clearly defined separation zones. Each strand is an independent heating element with uniform cross-section, eliminating the complexity of overlapping configurations while ensuring consistent current distribution and preventing hotspot formation at overlap regions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention introduces junction zones with specific geometric characteristics (width ≥ 2×strand width) that differ from the regular strand sections. These localized geometric modifications ensure uniform current density at connection points, preventing weak areas and maintaining reliability without affecting overall manufacturing simplicity.

Inventive Principle:

Principle #3Local quality

2Reliability

If grid strands are designed to overlap, then connectivity is improved, but manufacturing complexity and production difficulty increase

Engineering Contradiction:

Improvestrand connectivityVSAvoidgrid structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Instead of continuous overlapping strands, the grid uses discrete non-overlapping strands separated by clear gaps. Connectivity is achieved through defined junction zones rather than continuous overlap, simplifying the overall structure while maintaining electrical and mechanical continuity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The junction zones incorporate curved transitions with radii ≥ 0.5×strand width, replacing sharp angular connections. This curvature ensures uniform stress distribution and simplifies manufacturing processes like laser cutting or 3D printing, while maintaining structural integrity and electrical conductivity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Manufacturing precision

If angular points are present in the grid design, then geometric precision is achieved, but hotspots and mechanical stress concentrations occur

Engineering Contradiction:

Improvegeometric accuracyVSAvoidhotspots and stress concentrations

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

All angular points in the grid design are replaced with curved transitions having radii of curvature ≥ 0.5×strand width. This eliminates stress concentration points and prevents hotspot formation during operation, while the curvature can be precisely controlled through modern manufacturing methods like laser cutting or 3D printing, maintaining geometric accuracy.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The invention changes the geometric parameter at connection points from sharp angles to curved transitions with specific radius constraints. This parameter modification eliminates the harmful effects of angular points while the curvature radius is controlled within defined limits to ensure manufacturing precision and consistent performance.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If variable strand widths are used in junction zones, then current distribution is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecurrent distribution uniformityVSAvoidproduction simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention applies a specific parameter rule for junction zone width (≥ 2×strand width) rather than using variable widths throughout. This single parameter change ensures uniform current distribution at connection points while maintaining constant strand widths in regular sections, greatly simplifying manufacturing processes and quality control.

Inventive Principle:

Principle #35Parameter changes

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 enhances the mass production efficiency, improves the grid's performance and longevity by eliminating overlaps and angular points, ensuring consistent heating and reducing the risk of temperature extremes and mechanical stress.

Implementation Method 1

a grid and power supply device connected to the grid to pass electrical current in the grid

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS11225892B2Exhaust gas heating device, in particular for a combustion engine, comprising a grid wherein an electric current runs

Publication Date: 2022.01.18 FAURECIA SYST DECHAPPEMENT SAS

AI summary

A heating device comprises a grid and a power supply device connected to the grid to pass an electric current in the grid. The grid is formed by strands delimiting openings between the strands. The strands of the grid do not overlap.