Wave-like Holding Element for Exhaust Gas Heater Conductor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing exhaust gas heaters for internal combustion engines face challenges in stably fixing the heating conductor to the carrier, especially under thermal and dynamic loads, while maintaining a high heating output and avoiding excessive local stress.
Innovation Solution
A disc-like carrier with a spirally wound heating conductor is secured using wave-like holding elements with alternating antinode areas, where the first antinode areas form holding sections and the second antinode areas create fastening sections that engage with the carrier, providing a stable attachment through material connections like welding, and multiple fastening sections interact with radially arranged openings for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heating conductor is fixed to a carrier using conventional holding elements, then the heating conductor can be attached to the carrier, but the attachment is insufficient under strong thermal and dynamic loads
Solution Approach 1:
The holding element is designed with a wave-like structure that allows dynamic deformation under thermal and dynamic loads. The wave structure can flex and absorb stress while maintaining the attachment, preventing failure under extreme conditions.
Solution Approach 2:
The holding element is divided into multiple functional sections: holding sections with first antinode areas that grip the heating conductor, and fastening sections with second antinode areas that attach to the carrier. This segmentation allows each section to optimize its function independently.
2Reliability
If a wave-like holding element with alternating antinode areas is used, then stable attachment under thermal and dynamic loads is achieved, but the device complexity increases
Solution Approach 1:
The wave-like holding element serves multiple functions simultaneously: it holds the heating conductor, attaches to the carrier, absorbs thermal expansion, and resists dynamic loads. This multi-functionality is achieved through the alternating antnode areas that provide both holding and fastening capabilities.
Solution Approach 2:
The holding element utilizes changes in physical parameters along its length, specifically the alternating antnode areas with different flexibility characteristics. The first antnode areas are optimized for gripping the heating conductor while the second antnode areas are optimized for attaching to the carrier, creating a gradient of mechanical properties.
3Reliability
If multiple fastening sections engage with radially arranged openings in the carrier, then stability and stress distribution are improved, but the manufacturing complexity increases
Solution Approach 1:
The holding element is pre-formed with the wave-like structure and alternating antnode areas during manufacturing. This preliminary formation of the complex geometry allows for simpler final assembly, as the holding element can be directly attached to the carrier without requiring complex post-processing or assembly steps.
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 ensures a stable and thermally resistant fixation of the heating conductor, capable of withstanding strong thermal and dynamic loads, while allowing for a high heating output and distributing stress evenly across the carrier.
Implementation Method 1
a heating conductor (22) with a heating area (26) arranged on a first axial side (24) of the carrier (14)
Implementation Method 2
the at least one holding element (40) is formed in a wave-like manner with alternating successive first and second antinode areas (42, 44), the first antinode areas (42) forming holding sections (46) and the second antinode areas (44) forming fastening sections (50)
Implementation Method 3
at least one holding element (40) with at least one fastening section (50) is fixed to the carrier (14) on a second axial side (32) of the carrier by material connection, preferably welding
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An exhaust gas heater for an exhaust system of an internal combustion engine comprises a disk-shaped support (14) with an outer circumferential region (16) arranged radially outside with respect to a heater longitudinal axis (L) and a central region (20) arranged radially inside, a heating conductor (22) with a heating area (26) arranged on a first axial side (24) of the support (14), at least one retaining element (40) for holding the heating conductor (22) on the support (14), wherein the retaining element (40) comprises at least one retaining section (46) encompassing the heating conductor (22) in its heating area (26) and at least one fastening section (50) engaging in a fastening opening (48) in the support (14) and fixed to the support (14).