Exhaust gas heater

Patent metadata

Field	Value
Publication number	US-12376194-B2
Application number	US-202318163663-A
Country	US
Kind code	B2
Filing date	Feb 2, 2023
Priority date	Feb 2, 2022
Publication date	Jul 29, 2025
Grant date	Jul 29, 2025

Abstract

An exhaust gas heater for an exhaust gas system of an internal combustion engine includes a carrier arrangement through which exhaust gas can flow in the direction of an exhaust gas heater longitudinal axis. The exhaust gas heater includes at least one heating conductor supported on the carrier arrangement. The at least one heating conductor is made with bent flat material for the provision of a heating conductor profile which is meandering at least in regions thereof. The heating conductor flat end faces are opposite one another and the heating conductor broad sides are opposite one another.

First claim

The invention claimed is:

1. An exhaust gas heater for an exhaust gas system of an internal combustion engine, the exhaust gas heater defining a longitudinal axis and comprising:
a carrier arrangement for accommodating an exhaust gas can flow therethrough in the direction of said longitudinal axis;
at least one heating conductor supported on said carrier arrangement;
said carrier arrangement including a carrier housing having a housing base arranged on a first axial side of said at least one heating conductor and extending transversely to the exhaust gas heater longitudinal axis, said housing base having a multiplicity of exhaust gas throughflow openings formed therein, said carrier arrangement further including a multiplicity of carrier elements on said housing base for supporting said at least one heating conductor;
said at least one heating conductor being made of bent flat material defining a heating conductor profile;
said heating conductor profile being meandering at least in regions thereof;
said at least one heating conductor having flat end faces lying opposite from each other and having heating conductor broad sides lying opposite each other;
said at least one heating conductor defining at least one heating conductor meandering field and having a plurality of mutually parallel meandering sections longitudinally extending in a direction of a meandering section longitudinal direction (M);
each two mutually adjacent meandering sections having respective meandering section end regions and being connected to each other at one of said meandering section end regions thereof via a corresponding meandering section connecting section transverse to said meandering section longitudinal direction (M) and, between said meandering section end regions thereof and in at least a portion thereof, being configured with a multiplicity of consecutive wave crests in the meandering section longitudinal direction (M) for providing an undulating structure of said mutually adjacent meandering sections meandering sections;
at least one of said carrier elements including a carrier pin fixed on said housing base, a carrier sleeve supported on said carrier pin and electrically insulating material interposed therebetween; and
said carrier sleeve being fixed to one of said mutually adjacent meandering sections at one of said wave crests by material connection.

2. The exhaust gas heater of claim 1 , wherein said at least one heating conductor is arranged to extend in the direction of said longitudinal axis with said heating conductor broad sides and with said flat end faces arranged to extend orthogonally to said longitudinal axis.

3. The exhaust gas heater of claim 1 , wherein said at least one heating conductor includes at least first and second heating conductor meandering fields;
said first heating conductor meandering field provides a first connector region for connecting said at least one heating conductor to a voltage source; and,
said second heating conductor meandering field provides a second connector region for connecting said at least one heating conductor to said voltage source.

4. The exhaust gas heater of claim 3 , wherein said first and second heating conductor meandering fields are provided by separate heating conductor material pieces.

5. The exhaust gas heater of claim 4 , wherein at least said first and second heating conductor meandering fields provided by separate heating conductor material pieces are formed to have the same shape as one another.

6. The exhaust gas heater of claim 5 , wherein at least said first and second heating conductor meandering fields provided by said separate heating conductor material pieces are arranged in mirror symmetry to one another in relation to a plane of symmetry containing said heating conductor longitudinal axis.

7. The exhaust gas heater of claim 5 , wherein said heating conductor is formed with said first and second heating conductor meandering fields provided by said separate heating conductor material pieces and said first and second heating conductor meandering fields are arranged in mirror symmetry to one another in relation to a plane of symmetry containing the heating conductor longitudinal axis.

8. The exhaust gas heater of claim 5 , wherein the heating conductor is formed with said first and second heating conductor meandering fields and third and fourth heating conductor meandering fields provided by separate heating conductor material pieces and the four heating conductor meandering fields are arranged in corresponding pairs in mirror symmetry to one another in relation to two planes of symmetry which contain the heating conductor longitudinal axis and are orthogonal to one another.

9. The exhaust gas heater of claim 4 , wherein at least said first and second heating conductor meandering fields are provided as separate heating conductor material pieces and are connected to one another in an electrically conducting manner via at least one carrier element supporting the latter on the carrier housing.

10. The exhaust gas heater of claim 1 , wherein said at least one heating conductor meandering field is provided by a single heating conductor material piece.

11. The exhaust gas heater of claim 10 , wherein all of said heating conductor meandering fields are provided by a single heating conductor material piece.

12. The exhaust gas heater of claim 1 , wherein:
said at least one carrier element defines a carrier element longitudinal axis arranged parallel to said exhaust gas heater longitudinal axis.

13. The exhaust gas heater of claim 12 , wherein said electrically insulating material is magnesium oxide material.

14. The exhaust gas heater of claim 12 , wherein at least one of the following applies:
i) said carrier housing as well as said carrier pin and said carrier sleeve of said at least one carrier element are made with metal material; and,
ii) said carrier pin of said at least one carrier element is connected to said housing base by a material connection.

15. The exhaust gas heater of claim 1 , wherein said material connection is a welded connection or solder connection.

16. The exhaust gas heater of claim 1 , wherein said carrier housing has a circumferential wall adjoining said housing base radially on the outside thereof.

17. The exhaust gas heater of claim 16 , wherein said carrier housing is formed in a pot-shaped manner with said housing base and said circumferential wall; and, wherein at least one of the following applies:
i) said at least one heating conductor is on a second axial side and is uncovered by said carrier arrangement; and,
ii) said at least one heating conductor is on the second axial side and projects axially over said circumferential wall.

18. The exhaust gas heater of claim 1 , wherein the undulating structure of the other one of said mutually adjacent meandering sections is interrupted for providing a straight-line extension of the other one of said mutually adjacent meandering sections in the meandering section longitudinal direction (M) adjacent to the one of said wave crests of the one of said two mutually adjacent meandering sections having said carrier sleeve fixed thereto.

19. An exhaust gas system for an internal combustion engine, the exhaust gas system comprising:
at least one exhaust gas treatment unit; and,
at least one exhaust gas heater arranged in an exhaust gas main flow direction upstream relative to said at least one exhaust gas treatment unit;
said at least one exhaust gas heater defining a longitudinal axis and including:
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Assignees

• Purem GmbH

Inventors

• Uysal Fatih
• Höckel Sandra

Classifications

• F01N3/027 Primary

  using electric or magnetic heating means · CPC title

• H05B2203/022

  Heaters specially adapted for heating gaseous material · CPC title

• H05B3/10

  Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor · CPC title

• F01N2240/16

  an electric heater, i.e. a resistance heater · CPC title

• F01N3/2013

  using electric or magnetic heating means · CPC title