Catalyst Element Interlocking Side Walls for Emission Sealing
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Solution Overview
Problem
Existing catalytic emission reduction systems for internal combustion engines face challenges such as temperature range limitations, fouling and clogging risks, and significant space requirements, particularly in heavy fuel oil engines, where sealing gaps between catalyst elements is inefficient with current methods like fiber tape or steel profiles.
Innovation Solution
A catalyst element with gas-tight side walls and outward extensions that interlock with adjacent elements, forming a secure assembly by folding inward and outward extensions to seal gaps effectively, manufactured from impermeable sheet material, allowing efficient gas flow and preventing movement between elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fiber tape or steel profile is used to block gaps between catalyst elements, then the gap sealing is achieved, but the device complexity increases and reliability decreases due to loose fibers or parts
Solution Approach 1:
The sealing function is merged with the catalyst element structure itself. The side walls of adjacent catalyst elements directly form the gap sealing through their arrangement, eliminating the need for separate sealing components like fiber tape or steel profiles. This integration reduces device complexity while maintaining sealing reliability.
Solution Approach 2:
The catalyst elements perform their own sealing function through their geometric configuration. The side walls are designed to interface directly with adjacent elements, creating self-sealing gaps without requiring external sealing materials or additional fastening components.
2Productivity
If multiple catalyst elements are arranged side by side to fill cross sectional area, then the catalytic performance is improved, but the space requirements increase and assembly complexity increases
Solution Approach 1:
The catalytic system is segmented into multiple discrete catalyst elements that can be independently manufactured and then assembled. Each element contains a catalyst core within a structured body, allowing modular deployment to achieve required catalytic performance while simplifying assembly through standardized interfaces.
Solution Approach 2:
Multiple functional aspects are merged into the catalyst element structure. The body provides both structural support and gap sealing, while the catalyst core provides the catalytic function. This integration reduces the number of separate components needed and simplifies the overall assembly process.
3Ease of manufacture
If catalyst elements are assembled with gaps between them, then the manufacturing is simplified, but fouling and clogging risks increase
Solution Approach 1:
The side walls are designed with specific local geometric features that create effective gap sealing at the interfaces between elements. The local configuration of the side walls ensures that gaps are sealed in the critical regions where fouling and clogging would occur, while maintaining manufacturing simplicity.
Data Source
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AI summary
Invention relates to catalyst element (12) to be used in a catalyzer assembly as emission control device for gas, comprising a body (18) to which a catalyst core (16) is assembled, and which element comprises gas tight side walls (14) and two opposite ends (23) bordered by edges of the side wall, via which ends gas may be arranged to flow into and out from the catalyst core. At the end (23) of the catalyst element the body comprises an outward extension (22) of its side wall (14) edge folded from the plane of the side wall.