Porous Metal Structure with Variable-Pitch Plates for Catalyst Area
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Solution Overview
Problem
Conventional porous metal structures with flat and corrugated plates have limited catalyst coating and heat generation areas due to small contact surfaces, affecting the performance of catalytic converters and heaters.
Innovation Solution
A structure where corrugated plates are alternately stacked with differing pitches and heights to maximize contact area and increase catalyst coating and heat generation, with vertices of each plate coinciding for enhanced durability and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flat plate and corrugated plate are alternately stacked to form passage parts, then the structure is simple to manufacture, but the catalyst coating area and heat generation area are small, deteriorating performance
Solution Approach 1:
The patent applies corrugated plates with curved wave patterns instead of flat plates. The curvature increases the surface area of each plate while maintaining the alternating stacking structure. This allows the catalyst coating area and heat generation area to expand without complicating the manufacturing process, as the corrugated shape can be produced through standard forming techniques.
Solution Approach 2:
The patent introduces different pitch dimensions (first pitch L1 and second pitch L2) in the alternating corrugated plates. By varying the pitch in different dimensions and orientations, the structure maximizes surface area exposure while maintaining structural integrity. This dimensional variation allows for increased catalyst coating area without sacrificing manufacturing simplicity.
2Ease of manufacture
If a flat plate and corrugated plate are alternately stacked to form passage parts, then the structure is simple to manufacture, but the heat generation area and contact area with air are small, deteriorating heater performance
Solution Approach 1:
The corrugated plates with their wave-like curvature provide increased surface area for heat generation. When heating elements are applied to these corrugated surfaces, the effective heat generation area is maximized compared to flat plates, while the manufacturing process remains simple through standard corrugation forming.
Solution Approach 2:
By implementing different pitch values (L1 and L2) in alternating directions, the patent creates a multi-dimensional surface structure that increases contact area with passing air. This enhances heat transfer efficiency without requiring complex manufacturing, as the varying pitch can be achieved through sequential forming operations.
3Reliability
If vertices of corrugated plates coincide during assembly to allow surface contact fixation, then durability is improved, but the assembly precision requirement increases
Solution Approach 1:
The patent employs asymmetric pitch design where the first pitch L1 and second pitch L2 are deliberately made different. This asymmetry creates a unique interlocking pattern when vertices coincide, providing mechanical stability and durability. The asymmetric design ensures proper alignment during assembly, actually reducing the precision requirement compared to symmetric designs that would require perfect matching.
Solution Approach 2:
The corrugated plates are segmented into repeating units with defined vertices that serve as alignment features. By designing these segments to coincide at specific vertices during assembly, the structure achieves durable surface contact fixation. The segmentation into modular units with characteristic pitch dimensions simplifies the assembly process while ensuring proper positioning.
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 new structure enhances catalyst performance by increasing coating area and heat generation, while improving durability through surface contact and assembly stability.
Implementation Method 1
The first corrugated plates and the second corrugated plates may be manufactured as heating coils that generate heat when power is applied thereto
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention comprises: a case that is open at both ends; and first corrugated plates and second corrugated plates which are alternately stacked inside the case and form a passage through which air or gas passes. First upper vertices in contact with the lower surface of one of the second corrugated plates and first lower vertices in contact with the upper surface of one of the second corrugated plates are repeatedly formed in each of the first corrugated plates, and the distance between the first upper vertices and the second lower vertices forms a first pitch (L1). Second upper vertices in contact with the lower surface of one of the first corrugated plates and second lower vertices in contact with the upper surface of one of the first corrugated plates are repeatedly formed in each of the second corrugated plates, and the distance between the second upper vertices and the second lower vertices forms a second pitch (L2). The first pitch (L1) and the second pitch (L2) can be formed differently from each other to increase the surface area in contact with air or gas and improve performance.