Structured Sheet Metal Honeycomb Body for Exhaust Purification
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Solution Overview
Problem
Existing honeycomb bodies for exhaust-gas purification systems face challenges in achieving a stable, cost-effective, and material-saving design with high purification efficiency, while also ensuring compactness and favorable acoustic properties.
Innovation Solution
A honeycomb body composed of a sheet metal material with elevations and edge contours, where the area percentage of elevations is at least 80%, providing a stiff and dimensionally stable structure that enhances bending resistance, thermal stability, and acoustic properties, and allows for efficient exhaust-gas purification through turbulent flow promotion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If smooth sheet metal material is used for the honeycomb structure, then manufacturing is simpler and material usage is lower, but bending resistance and structural stability are insufficient
Solution Approach 1:
The patent applies curvature to the sheet metal material by forming elevations (protrusions) on the surface of the honeycomb structure. This curvature increases the bending resistance and structural stability without requiring additional components, directly resolving the contradiction between strength and structural complexity.
2Ease of operation
If additional flow manipulation components are added to the honeycomb body, then exhaust gas flow manipulation is improved, but device complexity and production costs increase
Solution Approach 1:
The patent merges the flow manipulation function with the structural element itself. The elevations on the sheet metal material serve dual purposes: they provide structural stability and simultaneously manipulate exhaust gas flow by generating turbulence. This eliminates the need for separate flow manipulation components, resolving the contradiction between operational capability and device complexity.
Solution Approach 2:
The structured sheet metal material with elevations performs multiple functions: it provides structural support, manipulates flow, and promotes turbulence all in one component. This multi-functionality reduces the total number of parts needed while maintaining or improving performance.
3Stability of the object's composition
If more material is used to increase honeycomb body stability, then structural stability improves, but material usage and production costs increase
Solution Approach 1:
By forming elevations on the sheet metal material, the patent increases dimensional stability through geometric curvature rather than by adding more material. This allows achieving higher stability with the same or reduced material quantity, resolving the contradiction between stability and material 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
The structured sheet metal material results in a honeycomb body with improved bending resistance, thermal stability, and acoustic properties, ensuring high exhaust-gas purification efficiency while reducing material usage and production costs, and eliminating the need for additional flow manipulation components.
Implementation Method 1
The structured sheet metal material results in a honeycomb body with improved bending resistance, thermal stability, and acoustic properties, ensuring high exhaust-gas purification efficiency while reducing material usage and production costs, and eliminating the need for additional flow manipulation components
Data Source
AI summary
A honeycomb body includes at least one housing and a honeycomb structure for a waste-gas purification system having at least one sheet metal material. The sheet metal material has elevations in at least one section and an edge contour enclosing the elevations. A portion of the area of the elevations in the at least one section is at least 80%. A particle separator, a catalyst carrier body and a motor vehicle having the honeycomb body are also provided.