Structured Metallic Honeycomb Body for Exhaust Gas Aftertreatment
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Solution Overview
Problem
Existing honeycomb bodies for exhaust gas aftertreatment in vehicles face challenges in achieving optimal contact between exhaust gas and catalytic coatings while minimizing pressure loss and production complexity, particularly under thermal and dynamic stresses.
Innovation Solution
A honeycomb body with a partially structured metallic layer featuring elevations and depressions angled up to 20° around a central axis, combined with metallic connecting strips for secure soldered or welded connections, promotes efficient gas deflection and flow while maintaining structural stability and reducing unwanted contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If deflection structures, guide vanes, or openings are provided in the channel walls to reduce laminar flow and increase contact between exhaust gas and catalytic coating, then the contact efficiency is improved, but the pressure loss across the honeycomb body increases
Solution Approach 1:
The patent changes the geometric parameters of the metallic layers by introducing structured surfaces with specific elevation and depression patterns. The angle α (5-20 degrees) of the structured surface relative to the plane perpendicular to the longitudinal axis is optimized to achieve the right balance between flow deflection (improving contact) and pressure loss minimization. This parameter optimization allows the system to achieve good contact efficiency without excessive pressure drop.
2Reliability
If metallic layers are structured with elevations and depressions to promote gas deflection and contact, then contact efficiency is improved, but the structural stability and durability under thermal and dynamic stresses may be compromised
Solution Approach 1:
The patent applies local quality by creating structured surfaces only in specific regions of the metallic layers, rather than uniformly across the entire structure. The structured portions with elevations and depressions are localized to areas where flow deflection is most beneficial, while other areas maintain simpler geometries that preserve structural integrity. This localized structuring allows the system to achieve good contact efficiency without compromising overall structural stability under thermal and dynamic loads.
3Reliability
If complex structured metallic layers are used to improve flow deflection and contact, then contact efficiency is improved, but the production complexity and cost increase
Solution Approach 1:
The patent optimizes the geometric parameters of the structured metallic layers, specifically the angle α (5-20 degrees) and the dimensions of elevations and depressions, to achieve effective flow deflection with relatively simple structures. These optimized parameters allow the structured layers to be manufactured using standard metal forming techniques without requiring complex multi-step processes, thereby maintaining production simplicity while achieving good contact efficiency.
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 enhances the contact between exhaust gas and catalytic material, reduces flow resistance, and improves durability, leading to improved performance and cost-effectiveness in exhaust gas treatment systems.
Implementation Method 1
at least one metal connecting strip (10) is provided between adjacent areas (11) of the at least one at least partially structured metal layer (6), which is shorter than the length (5) of the honeycomb body (1) and forms a soldered or welded connection to these adjacent areas (11)
Data Source
Figure 1
Figure 2~4
Figure 5~6
AI summary
The invention relates to a honeycomb body (1) for exhaust gas post-treatment having a first end face (2), a second end face (3), a central axis (4) and a length (5) that penetrates both end faces. This honeycomb body has at least an at least partially structured metallic layer (6), which is arranged about the central axis (4), wherein the structure (7) of the at least one metallic layer (6) has elevations (8) and depressions (9), which extend at least over part of the length (5) of the honeycomb body (1) and run obliquely to the central axis (4). At least one metallic connecting strip (10) is further provided between adjacent regions (11) of the at least one at least partially structured metallic layer (6) and is designed to be shorter than the length (5) of the honeycomb body (1) and forms a soldered connection (12) or welded connection (13) to said adjacent regions (11). A method for producing such a honeycomb body is also specified.