Angled Sensor Mount Air Gap for Aftertreatment Thermal Management

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Solution Overview

Problem

Current aftertreatment systems for internal combustion engines are complex, costly, and require multiple components, making them difficult to design and maintain, particularly in reducing NOx emissions effectively.

Innovation Solution

A single module aftertreatment system with an angled sensor mount and insulation to reduce heat transfer and simplify the system configuration, incorporating a dosing module for reductant delivery and a SCR catalyst to convert NOx emissions, while minimizing the number of parts and system footprint.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single module aftertreatment system is used, then system complexity and cost are reduced, but thermal management becomes more challenging

Engineering Contradiction:

Improvesystem complexityVSAvoidthermal management

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The system is divided into distinct functional modules (catalyst chamber, dosing module, sensor mount) that can be independently designed and thermally managed. The sensor mount is separated from the catalyst chamber with an air gap to isolate thermal environments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An air gap is introduced as an intermediary between the hot catalyst chamber and the sensor mount, acting as a thermal barrier. This air gap reduces conductive heat transfer while maintaining the compact single-module structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If an angled sensor mount with air gap is used, then heat transfer to sensor is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improveheat transfer to sensorVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The sensor mount is integrated directly into the catalyst chamber assembly as a unified component. The angled mounting portion and attachment legs are formed as a single piece, reducing the number of separate parts and simplifying manufacturing while maintaining the thermal barrier air gap.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sensor mount utilizes a composite structure combining metal attachment legs for structural integrity with an angled mounting portion that creates an insulating air gap, effectively managing heat transfer while maintaining manufacturability.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If multiple extensions are used to reduce conductive heat transfer, then thermal isolation is improved, but device complexity increases

Engineering Contradiction:

Improveconductive heat transferVSAvoiddevice complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Instead of adding multiple complex thermal barriers, the design inverts the approach by creating a simple air gap through the angled mounting geometry. The heat transfer is reduced by removing direct contact rather than adding multiple insulating extensions.

Inventive Principle:

Principle #13The other way round (Inversion)

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 reduces system size, cost, and complexity, enhancing NOx emission reduction efficiency and simplifying design and maintenance by integrating key components into a compact, thermally managed module.

Implementation Method 1

the first attachment leg, the second attachment leg, and the angled mounting portion form an air gap relative to the casing

Methodology Applied

Scientific EffectConductive heat transfer: Conduction (thermal)

Implementation Method 2

The single module aftertreatment system may also include insulation positioned within at least a portion of the air gap formed by the first attachment leg, the second attachment leg, and the angled mounting portion

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

a catalyst within the casing... The catalyst may be included in a catalyst chamber of an exhaust system... to convert the NOx compounds into more neutral compounds

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS10267199B2Angled sensor mount for use with a single module aftertreatment system or the like

Publication Date: 2019.04.23 CUMMINS EMISSION SOLUTIONS INC

AI summary

Implementations described herein relate to features for a single module aftertreatment system. The single module aftertreatment system includes a casing, a catalyst within the casing, and a sensor mount coupled to the casing. The sensor mount is angled relative to a portion of the casing at a position where the sensor mount is coupled to the casing. The sensor mount includes a first attachment leg, a second attachment leg, and an angled mounting portion. The angled mounting portion connects the first attachment leg to the second attachment leg. The sensor mount is coupled to the casing by the first attachment leg and the second attachment leg such that the first attachment leg, the second attachment leg, and the angled mounting portion form an air gap relative to the casing.