Selective Soldering for Thermal Expansion in Particle Separator Supports
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Solution Overview
Problem
The existing supporting bodies for particle separators and catalytic converters face issues with thermal expansion, leading to solder joint failures and potential damage due to rigid structures, as they are not adequately designed to accommodate temperature-related expansions.
Innovation Solution
The solution involves strategically arranging soldered areas in the supporting body to distribute stress perpendicular to the main plane of the sheet metal foils, allowing for limited yielding in the circumferential direction, thereby accommodating thermal expansions without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If all contact points between sheet metal foils are soldered to create a rigid structure, then structural stability is improved, but thermal expansion causes solder joint failure and matrix damage
Solution Approach 1:
The patent applies local quality by transitioning from uniform soldering of all contact points to selective soldering of specific contact points only. The soldering is performed locally at predetermined locations where mechanical fastening elements are positioned, rather than across the entire matrix structure. This localized approach provides structural stability at critical points while leaving other areas flexible to accommodate thermal expansion, thereby preventing solder joint failure.
Solution Approach 2:
The patent segments the soldering process by dividing the matrix into multiple regions with different fastening densities. Instead of treating the entire matrix uniformly, the invention applies mechanical fastening elements at specific segmented locations along the channels. This segmentation allows different parts of the matrix to have different degrees of rigidity, enabling thermal expansion in non-critical areas while maintaining structural integrity at key support points.
2Strength
If sheet metal foils are tightly fitted in the pipe section to eliminate spaces, then mechanical stability is improved, but thermal expansion stresses cannot be accommodated
Solution Approach 1:
The patent applies local quality by creating zones of different mechanical properties within the matrix- pipe assembly. Mechanical fastening elements are positioned at specific locations to create localized rigid zones that provide mechanical stability, while leaving intermediate zones more flexible. This spatial variation in mechanical properties allows the structure to accommodate thermal expansion stresses without compromising overall mechanical stability.
Solution Approach 2:
The patent introduces dynamics by allowing the matrix structure to have variable rigidity along its length. The mechanical fastening elements create fixed points, but the spaces between these points allow for dynamic thermal expansion and contraction. This dynamic design enables the structure to adapt to temperature changes while maintaining mechanical stability at the fastening locations.
3Ease of manufacture
If mechanical fastening elements are positioned at regular intervals, then manufacturing simplicity is improved, but stress distribution during thermal expansion is suboptimal
Solution Approach 1:
The patent applies asymmetry by positioning mechanical fastening elements at irregular intervals rather than at regular spacings. The distances between consecutive fastening elements vary along the channels, creating an asymmetric pattern that optimizes stress distribution during thermal expansion. This asymmetric positioning prevents stress concentration at regular intervals while maintaining ease of manufacture through standardized fastening component usage.
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 ensures the supporting body remains stable and flexible, preventing damage from temperature fluctuations and maintaining structural integrity during operation.
Implementation Method 1
the solder balls melt and solder the two sheet metal foils together
Implementation Method 2
The individual sheet metal foils are fixed to one another and the entire matrix is fixed to the pipe section by soldering
Implementation Method 3
the sheet metal foils and thus the entire matrix are subjected to strong thermal expansion due to the high temperature fluctuations between the operating state and non-operating state
Data Source
Figure 1a~1b
Figure 1c
Figure 2a
AI summary
By means of the inventive, mostly strip-shaped, design and corresponding positioning of two-dimensional solder areas (5) on the end face (2a) of the e.g. cylindrical matrix (2) and analogous soldering spaces (105) extending from there into the depth direction (10), such selective soldering of only a comparatively few linear soldering zones (101) between the sheet foils (4a, b) is achieved, such that the finished support body has a high elasticity against temperature-induced expansions and is nevertheless sufficiently stable even under the operating conditions, which vary considerably, especially thermally.