Corrugated Retention System for Aftertreatment Catalyst Stability
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Solution Overview
Problem
Existing retention systems for aftertreatment modules with multiple catalysts face challenges in maintaining individual catalyst support, stability, and desired shape due to bulging and increased pressure, making it difficult to stack and package effectively.
Innovation Solution
A retention system comprising support mats and plates with corrugated portions and tabs, along with an outer sleeve, which secures catalyst substrates and absorbs pressure, ensuring stability and maintaining the module's shape for efficient stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple catalysts are packaged together using a simple frame structure, then packaging efficiency is improved, but individual catalyst support and stability deteriorate
Solution Approach 1:
The retention system divides the support structure into multiple independent corrugated plates, each individually supporting a catalyst. This segmentation allows each catalyst to have dedicated support while maintaining overall packaging efficiency through the modular arrangement of multiple catalysts within the same structure.
2Stability of the object's composition
If catalysts are retained individually with multiple support structures, then catalyst stability is improved, but device complexity increases
Solution Approach 1:
The corrugated plates serve multiple functions simultaneously: they provide individual support for each catalyst, absorb thermal expansion stresses, maintain the desired shape of the package, and enable stable stacking of multiple catalysts. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in device complexity.
3Temperature
If catalysts are subjected to increased temperatures during operation, then catalytic activity is improved, but catalyst bulging and pressure increase causing damage
Solution Approach 1:
The corrugated plates are designed with a compressible structure that can absorb thermal expansion stresses before they cause damage to the catalysts. The corrugation geometry allows the plates to deform elastically under thermal load, cushioning the catalysts against bulging and structural failure during high-temperature operation.
4Shape
If a rigid frame structure is used to contain catalysts, then shape retention is improved, but adaptability to thermal expansion deteriorates
Solution Approach 1:
The corrugated plates utilize changes in their geometric parameters (compression and expansion of the corrugation) to accommodate thermal expansion of catalysts. This parameter change allows the structure to adapt to thermal loads while maintaining the overall desired shape of the catalyst package, as the corrugations can deform within controlled limits without compromising the external geometry.
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 system provides enhanced support and stability to individual catalysts, absorbs pressure, and maintains the overall shape of the aftertreatment module, enabling efficient packaging and stacking of multiple catalysts.
Implementation Method 1
The retention system may also include at least one support plate having a corrugated portion disposed on the first support mat
Implementation Method 2
the catalysts can bulge when subject to increased temperatures during operation, and the bulging can result in additional problems when packaging multiple catalysts together
Data Source
AI summary
A retention system for use with an aftertreatment module is disclosed. The retention system may include a first support mat disposed on at least one surface of the at least one catalyst substrate. The retention system may also include at least one support plate having a corrugated portion disposed on the first support mat. The retention system may further include a second support mat disposed on the corrugated portion.