US20170226913A1 - Mounting mat for a pollution control element or a chemical reactor - Google Patents

Mounting mat for a pollution control element or a chemical reactor Download PDF

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Publication number
US20170226913A1
US20170226913A1 US15/501,447 US201515501447A US2017226913A1 US 20170226913 A1 US20170226913 A1 US 20170226913A1 US 201515501447 A US201515501447 A US 201515501447A US 2017226913 A1 US2017226913 A1 US 2017226913A1
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US
United States
Prior art keywords
substrates
substrate
mounting mat
pollution control
control element
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US15/501,447
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English (en)
Inventor
Christoph Rochaz
Nicole Gervers
Claus Middendorf
Ulrich E. Kunze
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3M Innovative Properties Co
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3M Innovative Properties Co
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Filing date
Publication date
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Publication of US20170226913A1 publication Critical patent/US20170226913A1/en
Assigned to 3M INNOVATIVE PROPERTIES COMPANY reassignment 3M INNOVATIVE PROPERTIES COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KUNZE, ULRICH E., Gervers, Nicole, MIDDENDORF, CLAUS, Rochaz, Christoph
Abandoned legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2422—Mounting of the body within a housing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/0211—Arrangements for mounting filtering elements in housing, e.g. with means for compensating thermal expansion or vibration
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
    • F01N3/2842—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration specially adapted for monolithic supports, e.g. of honeycomb type
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
    • F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2068—Other inorganic materials, e.g. ceramics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0006—Honeycomb structures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0006—Honeycomb structures
    • C04B38/0016—Honeycomb structures assembled from subunits
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2350/00—Arrangements for fitting catalyst support or particle filter element in the housing
    • F01N2350/02—Fitting ceramic monoliths in a metallic housing
    • F01N2350/04—Fitting ceramic monoliths in a metallic housing with means compensating thermal expansion
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the invention relates to a mounting mat for holding a ceramic substrate of a pollution control element or a chemical reactor, the pollution control element or chemical reactor comprising more than one substrate.
  • the invention also relates to a pollution control element or chemical reactor comprising such a mounting mat and the invention relates to a method of assembling a pollution control element or chemical reactor with such a mounting mat.
  • Pollution control devices may be employed on for example motor vehicles, ships or other engines, e.g. stationary industrial engines, to control atmospheric pollution.
  • Such devices may include catalytic converters and diesel particulate filters or traps.
  • Catalytic converters typically contain a ceramic monolithic structure which supports the catalyst (e.g. a catalyst carrier or element).
  • Diesel particulate filters or traps are typically wall flow filters which have honeycombed monolithic structures typically made from porous crystalline ceramic material (i.e., filter element).
  • Each of these devices usually has a metal housing (typically stainless steel) in which the pollution control element or several pollution control elements is or are contained.
  • a mat comprising ceramic fibers is typically used to mount and protect the pollution control element within the housing.
  • Ceramic monolithic structures coated with a catalyst can also be used in chemical reactors, specifically in flow-through reactors for reaction in the gas phase.
  • US 2001/0030355 A1 discloses a catalytic converter cartridge comprising multiple square, rectangular or other flat sided catalyst coated substrates, each substrate of which has each of its flat sides covered by a compressible mat material. These multiple mat covered substrates or modules are arranged into a multiple module array enclosed within a metal shell with each module preferably separated from adjacent modules by sheet metal spacers. In addition to the mats and the metal spacers corner assembly aids, which may be left in place as the metal spacers, are foreseen.
  • DE 30 46 921 A1 discloses a catalytic converter comprising multiple flat sided substrates having a rectangular cross section.
  • rigid L-shaped holding elements are provided that are positioned on both ends of the substrate.
  • the holding elements provide additional holding edges extending perpendicular to the respective holding element.
  • WO2012084609A1 discloses a chemical reactor utilizing multiple ceramic substrates as carrier for the catalyst.
  • the present invention provides a mounting mat for holding a substrate of a pollution control element or chemical reactor.
  • the pollution control element or chemical reactor comprising more than one substrate, wherein the substrate comprises a front face, a rear face and at least three flat side faces extending between the front and the rear face, and wherein the mounting mat is shaped such that it covers at least partially an edge enclosed by two flat side faces (enclosed edge).
  • Enclosed edge in the sense of the invention is the edge that is enclosed by the two flat side faces that are covered by the mounting mat in a preassemble stage.
  • Adjacent edge in the sense of the invention is the edge that is enclosed by a flat side face that is covered by a mounting mat and a flat side face that is not covered by a mounting mat in a preassembled stage.
  • Preassembled stage means the stage when the mounting mats are already attached to the substrates but the substrates with mounting mats are not yet integrated into a housing.
  • a pollution control element according to the invention can be an element used in e.g. motor vehicles, ships or other engines, such as e.g. stationary industrial engines for example gas turbines, to control the atmospheric pollution.
  • pollution control elements can include catalytic converters and diesel particulate filters.
  • Other examples can be selective catalytic reduction elements or chemical reactors including substrates, e.g. ceramic substrates.
  • a chemical reactor according to the invention is a system for carrying out chemical reactions. If for these chemical reactions catalysts are needed, it can be possible to use ceramic substrates inside the chemical reactor carrying the catalysts for the reaction.
  • Pollution control elements usually comprise a substrate.
  • Chemical reactors may comprise substrates as well.
  • Catalytic converters for example comprise a flow-through substrate, e.g. a ceramic flow-through substrate.
  • Diesel particulate filters typically comprise wall-flow filters which have honeycombed monolithic structures, for example made from porous crystalline ceramic materials.
  • the holding and sealing function gets more complex compared to systems with only one substrate, since holding and sealing does not only need to be performed between a substrate and a housing of a pollution control element or chemical reactor but also between two substrates.
  • the invention relates to substrates that comprise a front face, a rear face and at least three flat side faces extending between the front and the rear face.
  • the substrates comprise four flat side faces.
  • the front and the rear face are those faces of the substrate that are oriented substantially perpendicular to the flow of gas inside the substrate. In other words they either face the entering gas flow or they face the exiting gas flow of the substrate.
  • the side faces are oriented substantially parallel to the flow of gas inside the substrate and they may be oriented substantially perpendicular to the front and the rear face.
  • the invention is not limited to the above described substrates. It is also possible that the side faces are oriented in an angle not perpendicular to the front and/or the rear face. It is also possible that the front and the rear face are oriented in an angle other than 90° relative to the flow of gas inside the substrate.
  • the side faces are substantially flat or plain in a geometrically sense. That means that two flat side faces enclose an edge, wherein the enclosed edge is defined as an essentially linear line joining the two flat side faces. It is of cause possible that the enclosed edge comprises—due to manufacturing reasons—a slightly rounded shape, which extends in a linear direction.
  • the side faces may comprise any suitable shape such as for example rectangular or square.
  • the mounting mat is shaped such that it covers—at least partially—an edge enclosed by two flat side faces.
  • the mounting mats are shaped such that they may cover more than only one flat side face. This may reduce the number of mounting mats needed for one pollution control element or chemical reactor. If less mounting mats are needed, less steps for assembling a pollution control element or chemical reactor are needed as well. This saves time and costs in the production process. Covering the enclosed edge at least partially means that the mounting mat may extend from the front face to the rear face and cover the entire enclosed edge. It is also possible that the mounting mat only extends partially between the front and the rear face.
  • the mounting mat does not extend completely up to the edge between side face and front/rear face.
  • Such a configuration helps that in the assembled stage (substrate inside a housing) the mounting mat does not swell out of the housing.
  • more than one, e.g. two mounting mats are arranged parallel to each other each mat covering the enclosed edge partially.
  • the mounting mat is a non-woven mounting mat comprising inorganic fibers.
  • mounting mats can be used that are flexible and heat-resistant and that are able to hold the substrate of the pollution control element or chemical reactor in place and to seal the area around a substrate to isolate the substrate.
  • Commonly known mounting mats comprise ceramic and/or glass fibers.
  • the mounting mats may be intumescent mats or non-intumescent mats. If they are intumescent mats they may also include blowing agents like vermiculite or graphite.
  • binders may be used and/or they may be compressed by mechanical processes such as for example needling.
  • the substrate is a ceramic substrate. Any known ceramic substrates may be used for the invention. Depending on the application of the substrate it may for example provide a flow-through characteristic or a wall-flow characteristic. They may comprise a catalyst coated on the substrate or integrated into the substrate.
  • the substrate may be a catalyst coated ceramic substrate or a ceramic substrate including catalyst like acting particles, like vanadium pentoxide.
  • the ceramic substrate may in this case for example comprise titan dioxide with vanadium pentoxide and wolfram oxide.
  • the pollution control element is a diesel particulate filter
  • the substrate may comprise silicium carbide, aluminium titanat or cordierite.
  • the substrate is a honeycomb catalyst, it may comprise titanium oxide, tungsten oxide and vanadium pentoxide.
  • the required mechanical strength of the substrate may be achieved by adding for example glass fibers.
  • the substrate according to the invention may comprise four flat side faces that extend between the front and the rear face and the substrate may comprise a squared cross section.
  • the four flat side faces may all comprise the same shape. They may be rectangular or square. It is also possible that at least two of the four flat side faces comprise the same shape.
  • the mounting mat may be shaped such that it covers at least partially two flat side faces (2-side wrapped substrate) and at least partially the edge enclosed by the two flat side faces of the substrate (enclosed edge). All possible configurations are meant to be claimed where the mounting mat covers at least partially two flat side faces and at least partially the edge between the two flat side faces.
  • the mounting mat may for example extend along the entire width of two flat side faces from the enclosed edge up to each adjacent edge and along the entire length of the substrate from the front face towards the rear face.
  • Another option is that the mounting mat according to the invention extends over the edge between two flat side faces (enclosed edge) along the entire length of the substrate but only covers parts of the width of the substrates and therewith of the two flat side faces, e.g. from the enclosed edge towards the middle of the flat side faces. It is also possible that one side face is covered completely and the other side face is covered partially.
  • the mounting mat may be shaped such that it covers at least partially three flat side faces (3-side wrapped substrate) and at least partially the two edges enclosed by two respective flat side faces of the substrate (enclosed edge). All possible configurations are meant to be claimed where the mounting mat covers at least partially three flat side faces and at least partially the two edges between two respective flat side faces.
  • the mounting mat may for example extend along the entire width of three flat side faces from the enclosed edges to the adjacent edges and along the entire length of the substrate from the front face towards the rear face. Another option is that the mounting mat according to the invention extends over the two edges between three flat side faces (enclosed edges) along the entire length of the substrate but only covers parts of the two outer flat side faces. It is also possible that one or two of the flat side faces are covered completely and the remaining side faces are covered partially.
  • the mounting mat may cover the entire two or three flat side faces (2-side wrapped or 3-side wrapped substrates) that enclose an edge up to the adjacent edges of the substrate.
  • the entire flat side faces means that the mounting mat extends substantially over the entire surface of the flat side faces from the front face to the rear face and from the enclosed edge to the adjacent edges.
  • the mat may thereby extend exactly from the front to the rear face and from one edge between two flat side faces to the other edge between two flat side faces. It is also possible as already pointed out above to leave a space at each edge of the front and the rear face in order to avoid the mat being squeezed out when being assembled with the substrate in a housing.
  • the 2-side wrapped substrates and the 3-side wrapped substrates can be used as preassembled components in the production process of pollution control elements or chemical reactors. With those preassembled components it is possible to assemble all kind of different pollution control configurations, e.g. different ways of arranging substrates in rows. For doing that only a minimum amount of different components is needed: a) the substrate, b) a mounting mat shaped such that it at least partially covers two flat side faces and at least partially the edge between them and c) a mounting mat shaped such that it at least partially covers three flat side faces and at least partially the two edges between two respective flat side faces.
  • the reduced number of different parts needed reduces the complexity of the whole production process. It reduces the number of process steps and the complexity of handling parts during the assembly process. All these facts reduce the costs of the process and make the process more reliable since the risk for potential operator mistakes is also reduced.
  • the mounting mat only extends up to a defined width or distance before an adjacent edge.
  • This space or receiving portion where a flat side face of the substrate is not covered with a mounting mat, may for example be used as a receiving portion for a mounting mat or a part of an adjacent substrate of the pollution control element or chemical reactor.
  • the mounting mat may also extend over the adjacent edge and be placed in an above described receiving portion, when being assembled.
  • the part of the mounting mat extending over the adjacent edge may be used for additional sealing purposes.
  • the invention also relates to a pollution control element or chemical reactor comprising more than one substrate as well as a mounting mat as described above.
  • the pollution control element or chemical reactor may comprise four substrates arranged in two rows of two substrates.
  • the pollution control element or chemical reactor may comprise nine ceramic substrates arranged in three rows of three substrates. These two configurations are commonly used configurations of substrates in pollution control systems. For theses configurations the below is a way to calculate the needed number of preassembled components (2-side wrapped and 3-side wrapped substrates).
  • the invention can also include systems, with only one row of substrates.
  • the invention can also include systems with at least one substrate that is entirely wrapped with one mat (e.g. 4-side wrapped). And the invention can also include systems with at least one substrate that is not wrapped with a mounting mat at all.
  • the invention also relates to a method for assembling a pollution control element or chemical reactor, the pollution control element or chemical reactor comprising more than one substrate, the method comprising the following steps:
  • the substrate comprises a front face, a rear face and at least three flat side faces extending between the front and the rear face;
  • step c) repeating step c) as often as substrates are needed to assemble the pollution control element or chemical reactor;
  • Fastening of the mounting mat can for example be done by means of an adhesive. It is possible to apply the adhesive while assembling the pollution control element or chemical reactor.
  • the adhesive may be applied in the form of a liquid adhesive, e.g. while assembling the pollution control element or chemical reactor.
  • the adhesive may also be applied in the form of a tape, e.g. a double sided tape.
  • the tape may include a liner. Therefore it would be possible to have a mat with a tape and a liner as a component for assembling the pollution control element or chemical reactor.
  • All typical methods for placing a substrate inside a housing may be used, such as for example stuffing, placing the substrates into the housing and closing the housing around the substrates followed by welding the housing etc.
  • FIG. 1 is a front view of a pollution control element or a chemical reactor according to the invention
  • FIG. 2 is a perspective view of the pollution control element or chemical reactor according to the invention.
  • FIG. 3 schematically shows a preassembled component of a pollution control element or chemical reactor comprising a substrate and a mounting mat that is shaped such that it covers three flat side faces and the edges enclosed by two respective side faces;
  • FIG. 4 schematically shows a preassembled component of a pollution control element or chemical reactor comprising a substrate and a mounting mat that is shaped such that it covers two flat side faces and the edge enclosed by two respective side faces;
  • FIG. 5 is another embodiment of a preassembled component of a pollution control element or chemical reactor comprising a substrate and a mounting mat that is shaped such that it covers three flat side faces and the edges enclosed by two respective side faces;
  • FIG. 6 is another embodiment of a preassembled component of a pollution control element or chemical reactor comprising a substrate and a mounting mat that is shaped such that it covers two flat side faces and the edge enclosed by two respective side faces;
  • FIG. 7 schematically shows four preassembled components oriented such as to be placed in a housing in order to build a pollution control element or chemical reactor;
  • FIG. 8 schematically shows the steps of a method for assembling a pollution control element or chemical reactor
  • FIG. 9 schematically shows nine preassembled components oriented such as to be placed in a housing in order to build a pollution control element or chemical reactor with mounting mats according to the invention
  • FIG. 10 schematically shows nine different preassembled components oriented such as to be placed in a housing in order to build a pollution control element or chemical reactor with mounting mats according to the invention
  • FIG. 11 schematically shows the four preassembled components of FIG. 3 with additional sealing elements
  • FIG. 12 schematically shows additional embodiments of preassembled components oriented such as to be placed in a housing in order to built a pollution control element or chemical reactor with mounting mats according to the invention
  • FIG. 13 schematically shows another embodiment of preassembled components oriented such as to be placed in a housing in order to built a pollution control element or chemical reactor with mounting mats according to the invention
  • FIG. 14 schematically shows yet another embodiment of preassembled components oriented such as to be placed in a housing in order to build a pollution control element or chemical reactor with mounting mats according to the invention.
  • FIG. 1 shows a pollution control element or chemical reactor 10 with four substrates 2 wrapped by mounting mats 3 according to the invention.
  • FIG. 2 is a dimensional view of the four substrates 2 with their mounting mats as they are positioned in the pollution control element or chemical reactor 10 of FIG. 1 .
  • the substrates comprise a front face 2 f, a rear face 2 r and four side 4 faces (here covered with mourning mats). With reference to the following figures it will be explained how the substrates 2 get wrapped with the mounting mats according to the invention and how the pollution control element or chemical reactor 10 gets assembled.
  • FIG. 3 schematically shows a preassembled component 1 of a pollution control element or chemical reactor 10 as utilized in the pollution control element or chemical reactor shown in FIG. 1 .
  • the preassembled component 1 comprises a substrate 2 and a mounting mat 3 . In FIG. 3 they are shown in a cross sectional view.
  • the substrate 2 comprises a squared cross section. It also comprises a front face and a rear face (as shown in FIG. 2 ) as well as four flat side faces 4 .
  • the mounting mat 3 is shaped such that it covers three flat side faces 4 entirely and the edges 5 enclosed by two respective side faces 4 (enclosed edge).
  • the fourth flat side face 4 of the substrate 2 is not covered by a mounting mat.
  • the mounting mat 3 covers the substrate 2 over its entire length, from the front to the rear face. It is possible to leave a little bit of space at the front and at the rear in order to prevent the mounting mat 3 from being squeezed out of the housing when the pollution control element or chemical reactor is assembled.
  • FIG. 4 schematically shows a preassembled component 1 of a pollution control element or chemical reactor 10 as shown in FIG. 1 , that differs from the one shown in FIG. 3 in that the mounting mat 3 covers only two flat side faces 4 of the substrate 2 instead of three. The two other flat side faces 4 are not covered with a mounting mat 3 .
  • FIGS. 5 and 6 schematically show the preassembled components 1 of FIGS. 3 and 4 .
  • the preassembled components 1 of FIGS. 5 and 6 differ from those shown in FIGS. 3 and 4 in that the mounting mats 4 comprise a protrusion 8 at one end, where the mounting mats 4 protrude the edge of the substrate.
  • the protrusion may be used for sealing an assembly of substrates as will be described in more detail with reference to FIGS. 11 and 12 .
  • FIG. 7 schematically shows four of the preassembled components 1 of FIG. 3 oriented such as to be placed in a housing in order to build a pollution control element or chemical reactor 10 .
  • the upper left component 1 a (3-side wrapped component) comprises one flat side face 4 a that is not covered with a mounting mat 3 .
  • This flat side face 4 a is directed to the right of the drawing. All other side faces are covered with a mounting mat 3 a.
  • the upper right component 1 b comprises one flat side face 4 b that is not covered with a mounting mat 3 .
  • This flat side face 4 b is directed to the bottom of the drawing. All other side faces are covered with a mounting mat 3 b.
  • the lower left component 1 c comprises one flat side face 4 c that is not covered with a mounting mat 3 .
  • This flat side face 4 c is directed to the top of the drawing. All other side faces are covered with a mounting mat 3 c.
  • the lower right component 1 d comprises a flat side face 4 d that is not covered with a mounting mat 3 .
  • This flat side face 4 d is directed to the left of the drawing. All other side faces are covered with a mounting mat 3 d.
  • the described arrangement guarantees that all sides of the four substrates 2 a, 2 b, 2 c, 2 d are coved by a mounting mat 3 in an assembled stage.
  • the benefit of the described arrangement is that the pollution control element or chemical reactor can be built up with four identical preassembled components 1 a, 1 b, 1 c, 1 d.
  • the assembly process is very simple and therefore cost effective.
  • Another benefit of the descried arrangement is that due to the reduced number of parts and the reduced process steps, the process is less complex and therefore potential mistakes of an operator may be prohibited.
  • Compared to pollution control elements or chemical reactors according to the prior art less material for mounting mats is needed, since every flat side wall is only covered with one layer of mounting mat material. No additional holding or separating means are needed.
  • FIGS. 8A, 8B and 8C schematically show one method of assembling a pollution control element or chemical reactor 10 according to the invention.
  • the pollution control element or chemical reactor 10 comprises more than one substrate.
  • a substrate 2 is provided, wherein the substrate comprises a front face, a rear face and four flat side faces 4 extending between the front and the rear face.
  • FIGS. 8A, 8B and 8C only a cross section of the substrate 2 is shown. Therefore only the front face is shown in this drawing.
  • the substrate 2 is wrapped by a mounting mat 3 .
  • the mounting mat is shaped such, that it covers three flat side faces 4 as well as two edges between two respective flat side faces 4 of the substrate 2 (3-side wrapped).
  • the mounting mat 3 is fastened at the substrate 2 by adequate means, e.g. by an adhesive.
  • the above described steps are repeated four times until four substrates 2 are wrapped with mounting mats 3 on three flat side faces 4 of the substrates 2 .
  • Each substrate 2 provides one flat side face 4 that is not covered with a mounting mat. 3 .
  • the preassembled components are placed next to each other such that all substrates' flat side walls are placed next to a mounting mat, either a portion of a mounting mat 3 fixed to that specific substrate or a portion of a mounting mat of an adjacent substrate.
  • a mounting mat 3 fixed to that specific substrate or a portion of a mounting mat of an adjacent substrate.
  • the placing inside of a housing can be done with all generally known methods for placing a substrate 2 in a housing 6 , such as stuffing, canning, closing the housing around the substrates with fastening it e.g. by welding.
  • FIG. 9 schematically shows nine preassembled components oriented such as to be placed in a housing in order to build a pollution control element or chemical reactor with mounting mats 3 according to the invention.
  • the assembly of FIG. 9 starts with an assembly that is shown in FIG. 7 —four preassembled components each comprising a 3-side wrapped substrate 2 —and has already been described with reference to FIG. 7 as well as FIGS. 8A, 8B and 8C .
  • the assembly of FIG. 9 comprises three 2-side wrapped substrates 2 ′′ and two 3-side wrapped substrates 2 ′′′. Again the substrates are arranged such that each flat side wall is covered by at least a portion of a mounting mat.
  • the upper row comprises first a 3-side wrapped substrate 2 ′′′ and then two 2-side wrapped substrates 2 ′′; the second row comprises three 3-side wrapped substrates and the third row comprises first a 2-side wrapped substrate 2 ′′ and then two 3-side wrapped substrates 2 ′′′.
  • the way the 2-side wrapped and the 3-side wrapped substrates are arranged can differ, but the number of 2-side wrapped and 3-side wrapped substrates stays the same.
  • u is the number of substrates in a row
  • v is the number of rows
  • x is the number of 3-side wrapped substrates
  • y is the number of 2-side wrapped substrates
  • FIG. 10 schematically shows another embodiment of an assembly with nine different preassembled components oriented such as to be placed in a housing in order to build a pollution control element or chemical reactor with mounting mats according to the invention.
  • this embodiment only one kind of preassembled component—3-side wrapped substrates 2 ′′′—are used as well as one substrate 2 without a mounting mat 3 .
  • the substrate 2 that is not wrapped with a mounting mat 3 is placed in the middle.
  • the 3-side wrapped substrates 2 ′′′ are positioned around the substrate 2 without a mounting mat 3 .
  • the 3-side wrapped substrates 2 ′′′ are oriented such that the respective flat side face 4 that is not covered with a mounting mat 4 faces towards an adjacent 3-side wrapped substrate 2 ′′′. By that all flat side faces of all substrates 2 , 2 ′′′ are covered by at least a portion of a mounting mat 4 .
  • a space or spaces in between the substrates/mounting mats may be sealed.
  • a possible area for such a space may be the area, where four wrapped substrates or preassembled components touch each other.
  • an additional piece of sealing materiel e.g. narrow InteramTM band from roll. This material may for example be cut from a roll into the right length/width to sufficiently seal the space.
  • the advantage of using an additional material for sealing purposes is that a space, for example in the centre may be filled and sealed perfectly.
  • FIGS. 5 and 6 could be used, where the mounting mat 4 extends the substrate at one end (extension 8 ). This is shown in FIG. 11 before and in FIG. 12 after assembly.
  • FIG. 14 shows another embodiment of preassembled components oriented such as to be placed in a housing in order to build a pollution control elements or chemical reactors with mounting mats according to the invention.
  • the pollution control elements or chemical reactors comprise one row of four substrates. All four substrates are 3-side wrapped substrates.
  • the side face of the substrate on the right hand side that is not covered by a mounting mat can for example be covered with a mounting mat that is shaped as to cover only one side face. It is also possible to use as the substrate on the right hand side instead of the 3-side wrapped substrate a substrate that is covered on all four sides with a mounting mat.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Exhaust Gas After Treatment (AREA)
US15/501,447 2014-09-04 2015-09-02 Mounting mat for a pollution control element or a chemical reactor Abandoned US20170226913A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP14183508.2A EP2993323B1 (de) 2014-09-04 2014-09-04 Montagematte für ein Verschmutzungskontrollelement oder einen chemischen Reaktor
EP14183508.2 2014-09-04
PCT/US2015/048062 WO2016036802A1 (en) 2014-09-04 2015-09-02 Mounting mat for a pollution control element or a chemical reactor

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US20170226913A1 true US20170226913A1 (en) 2017-08-10

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US15/501,447 Abandoned US20170226913A1 (en) 2014-09-04 2015-09-02 Mounting mat for a pollution control element or a chemical reactor

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US (1) US20170226913A1 (de)
EP (1) EP2993323B1 (de)
JP (1) JP6686001B2 (de)
KR (1) KR20170048534A (de)
CN (1) CN106605047B (de)
DK (1) DK2993323T3 (de)
WO (1) WO2016036802A1 (de)

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Publication number Priority date Publication date Assignee Title
US10024216B2 (en) 2016-12-15 2018-07-17 Caterpillar Inc. Retention system for aftertreatment module
US10036296B1 (en) 2017-03-29 2018-07-31 Caterpillar Inc. Catalyst substrate mounting mat
US10364728B2 (en) 2017-12-12 2019-07-30 Caterpillar Inc. System and method for assembling an exhaust aftertreatment assembly

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US5454845A (en) * 1992-09-25 1995-10-03 Kabushiki Kaisha Toyoda Jidoshokki Seisakusho Heat-resistant filter
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US20120171081A1 (en) * 2009-09-18 2012-07-05 Ulrich Kunze Mounting mat

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JP5968334B2 (ja) 2010-12-21 2016-08-10 ビーエーエスエフ ソシエタス・ヨーロピアＢａｓｆ Ｓｅ 自熱式の気相脱水素化を実施するための反応器
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US4324701A (en) * 1979-12-13 1982-04-13 Mitsubishi Jukogyo Kabushiki Kaisha Rectangular-solid packaged catalyst assembly
US5454845A (en) * 1992-09-25 1995-10-03 Kabushiki Kaisha Toyoda Jidoshokki Seisakusho Heat-resistant filter
US20090000260A1 (en) * 2005-11-16 2009-01-01 Geo2 Technologies, Inc. Fibrous Cordierite Materials
US20110030355A1 (en) * 2009-08-10 2011-02-10 Vconverter Company Catalytic Converter and Process of Manufacture
US20120171081A1 (en) * 2009-09-18 2012-07-05 Ulrich Kunze Mounting mat

Also Published As

Publication number Publication date
KR20170048534A (ko) 2017-05-08
CN106605047B (zh) 2021-03-02
JP6686001B2 (ja) 2020-04-22
EP2993323A1 (de) 2016-03-09
CN106605047A (zh) 2017-04-26
EP2993323B1 (de) 2017-07-19
WO2016036802A1 (en) 2016-03-10
JP2017526859A (ja) 2017-09-14
DK2993323T3 (en) 2017-10-16

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