Acute-Angle Edge Mounting Mat for Exhaust Monoliths
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Ceramic monoliths used in vehicle exhaust systems are fragile and expensive, requiring secure mounting to prevent damage from differential expansion and vibration, while also needing to maintain high friction and resistance to fluid flow, and existing high basis weight mats are stiff and difficult to wrap around monoliths without damage.
Innovation Solution
A high basis weight mat with a first inorganic fibre layer and a second layer, where the side edges are cut at an acute angle to prevent groove formation and erosion, and the layers are bonded with an adhesive to provide secure holding and insulation, allowing for efficient installation and thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high basis weight mat is used to secure monolith, then holding pressure and friction are improved, but flexibility deteriorates making installation difficult
Solution Approach 1:
The mat is divided into multiple layers with different basis weights - a first layer with higher basis weight (3000-10000 gm-2) for holding pressure and a second layer with lower basis weight (1000-3000 gm-2) for flexibility. This segmentation allows each layer to perform its specific function optimally.
Solution Approach 2:
The mat combines different fibrous materials with complementary properties - the first layer uses materials providing high strength and friction (such as glass fibres or ceramic fibres) while the second layer uses materials providing flexibility and compliance. The composite structure achieves both high holding pressure and adequate flexibility.
2Reliability
If high basis weight mat is used to secure monolith, then friction and holding force are improved, but ease of installation deteriorates
Solution Approach 1:
The mat is divided into multiple layers with different basis weights - a first layer with higher basis weight (3000-10000 gm-2) for holding pressure and a second layer with lower basis weight (1000-3000 gm-2) for flexibility. This segmentation allows each layer to perform its specific function optimally.
Solution Approach 2:
The mat combines different fibrous materials with complementary properties - the first layer uses materials providing high strength and friction (such as glass fibres or ceramic fibres) while the second layer uses materials providing flexibility and compliance. The composite structure achieves both high holding pressure and adequate flexibility.
3Volume of moving object
If monolith size increases, then gap size between monolith and can increases, but mat basis weight must increase which reduces flexibility
Solution Approach 1:
The mat is divided into multiple layers with different basis weights - a first layer with higher basis weight (3000-10000 gm-2) for holding pressure and a second layer with lower basis weight (1000-3000 gm-2) for flexibility. This segmentation allows each layer to perform its specific function optimally.
Solution Approach 2:
Different regions of the mat have different properties - the first layer provides local strength and friction where needed for holding pressure, while the second layer provides overall flexibility. This local differentiation allows the mat to accommodate larger monoliths without sacrificing installability.
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 mat effectively secures the monolith, maintains high friction, and provides thermal insulation while being flexible enough for easy installation, ensuring reliable performance and safety in high-temperature environments.
Implementation Method 1
the layers are bonded with an adhesive to provide secure holding and insulation
Implementation Method 2
provides thermal insulation while being flexible enough for easy installation, ensuring reliable performance and safety in high-temperature environments
Implementation Method 3
maintains high friction
Data Source
AI summary
A mat for mounting a monolith, the mat comprising a first inorganic fiber layer, where the mat has a front edge intended to form a gas facing edge in use, a rear edge opposite thereto and side edges extending between the front and rear edges, wherein the first inorganic fiber layer at a first side edge of the mat, and/or at a second side edge of the mat is cut at an acute angle to the thickness direction of the mat.