Zigzag Heating Grid for Vehicle Exhaust Purification
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Solution Overview
Problem
Existing heating elements in vehicle exhaust gas purification devices are not durable, poorly suited for elliptical conduits, and lack uniform heating capabilities, leading to inefficiencies and potential damage from aggressive conditions.
Innovation Solution
A heating member with a conductive peripheral frame, central support, and a perforated heating grid formed of elongated elements arranged in a zigzag pattern, optimized for elliptical sections, providing uniform and rapid heating while minimizing size impact and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a heating element is mounted opposite the upstream face of a purification unit, then rapid heating of the purification unit is achieved, but the heating element is easily damaged by aggressive conditions in the exhaust system
Solution Approach 1:
The heating element is divided into multiple independent heating wires arranged in a grid pattern between a peripheral frame and a central support. This segmentation allows the heating function to be distributed across multiple elements, reducing the risk of complete failure and improving durability while maintaining rapid heating capability.
Solution Approach 2:
The heating wires are pre-tensioned and anchored to both the peripheral frame and central support, creating a resilient structure that can withstand thermal expansion and mechanical stress from aggressive exhaust conditions before damage occurs.
2Ease of manufacture
If a heating element is designed for circular cross-section ducts, then manufacturing is simplified, but it is poorly suited for elliptical cross-section ducts which are often required by vehicle exhaust system layout constraints
Solution Approach 1:
The heating element structure is designed with an elliptical configuration where the peripheral frame and central support are positioned to match elliptical duct cross-sections. The heating wires are arranged in a grid pattern that conforms to the elliptical geometry, allowing the same manufacturing process to produce elements adapted to both circular and elliptical ducts.
Solution Approach 2:
The heating element design with adjustable peripheral frame and central support positioning enables a single component type to serve multiple duct configurations (both circular and elliptical), making the heating element universally applicable to different exhaust system layouts without requiring custom manufacturing for each duct shape.
3Strength
If the heating grid uses thick strands for durability, then strength is improved, but the heating grid occupies more space and impacts exhaust line size
Solution Approach 1:
The heating element uses a composite structure combining a rigid peripheral frame and central support with tensioned heating wires. This composite design achieves high structural strength and durability while maintaining a compact form factor, as the wires provide strength without the bulk of solid material.
Solution Approach 2:
The heating wires function as thin, flexible elements that are tensioned between the frame and support, providing both structural integrity and heating capability. This thin-film approach minimizes the volume of the heating element while maintaining sufficient strength to withstand exhaust system conditions.
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 solution enhances durability, allows for easy integration into various exhaust gas purification devices, including those with elliptical sections, and ensures uniform heating, reducing the risk of damage and inefficiencies.
Implementation Method 1
a heating element for a vehicle exhaust gas purification device... comprising an electrically conductive peripheral frame... a central support disposed substantially at the geometric center, and a perforated heating grid... formed of a plurality of elongated heating elements
Data Source
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AI summary
The invention relates to a heating member (30) for a vehicle exhaust gas purifying device comprising an electrically conductive peripheral frame (42) having an inner edge (46), a central support (64) arranged substantially at the geometric centre (G) of the inner edge (46), and a perforated heating grid (72) formed of a plurality of elongate heating elements (74) each having first and second ends (75, 76) opposite one another, the first end (75) being linked to the peripheral frame (42) and the second end (76) being linked to the central support (64). Each elongate heating element (74) occupies a respective angular sector (77) of the heating grid (72) and is arranged in zigzag manner inside this angular sector (77) so as to form a succession of strands (82, 83) connected by nodes (88) and being linked by said nodes (88) to the elongate heating elements (74) occupying the neighbouring angular sectors (77).