Dual-Friction Mounting Mat for Fragile Emissions Substrates
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Solution Overview
Problem
Conventional pollution control device mounting techniques face challenges in applying sufficient pressure to secure pollution control elements within housings without causing damage, due to the fragility of these elements and variations in manufacturing tolerances and material choices, which can lead to issues like cracking and corrosion.
Innovation Solution
A mounting mat with alternating higher and lower friction surfaces is used, where the higher friction surface is made of inorganic materials with a friction-inducing material and the lower friction surface is designed to degrade or be physically disrupted during use, allowing for secure mounting with reduced pressure and minimizing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mounting materials with high friction are used to secure pollution control elements, then mounting pressure is sufficient to prevent movement, but the materials cause wear and damage during the assembly process
Solution Approach 1:
The mounting mat is segmented into two distinct functional layers: a lower friction layer for assembly and a higher friction layer for mounting. This segmentation allows each layer to perform its specific function optimally without compromising the other, resolving the contradiction between assembly safety and mounting security.
Solution Approach 2:
Different regions of the mounting mat have different friction properties tailored to their specific functions. The exposed surface has low friction to protect during assembly, while the hidden surface has high friction to secure during mounting. This local differentiation resolves the contradiction by providing appropriate friction characteristics in each location.
2Reliability
If high mounting pressure is applied to prevent element movement, then mounting security is improved, but the pollution control element may be crushed due to its fragile nature
Solution Approach 1:
The lower friction layer acts as a cushioning layer that is applied beforehand during assembly. It protects the fragile pollution control element from direct contact with high-friction materials during handling and assembly, preventing damage before the mounting phase occurs.
Solution Approach 2:
The lower friction layer serves as an intermediary between the assembly tools and the pollution control element during assembly. It mediates the interaction to prevent damage, while still allowing the higher friction layer to provide secure mounting pressure when needed.
3Adaptability or versatility
If the gap between housing and pollution control element varies due to manufacturing tolerances, then adaptability is required, but maintaining consistent mounting pressure becomes difficult
Solution Approach 1:
The mounting mat system is designed to be dynamic in its friction characteristics. The lower friction layer allows for adjustment and accommodation during assembly as the gap varies, while the higher friction layer provides consistent mounting pressure once assembly is complete. This dynamic behavior allows the system to adapt to different gap conditions.
Solution Approach 2:
The friction parameter of the mounting mat changes depending on which layer is exposed. During assembly, the low-friction parameter is active to accommodate gap variations. During mounting, the high-friction parameter is active to provide consistent pressure. This parameter change allows the system to handle both adaptability and pressure consistency requirements.
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
This solution enables secure mounting of pollution control elements with lower required pressure and reduced risk of damage, maintaining effective friction over the device's operational life while allowing for the use of less resilient or more expensive inorganic materials.
Implementation Method 1
a lower friction layer disposed so as to cover at least a portion of the higher friction area and define an exposed surface area of the mounting mat, with the exposed surface area exhibiting a lower static coefficient of friction than that of the higher friction area
Implementation Method 2
a friction-inducing material disposed on at least a portion of the major surface area, of at least one of the sides of the at least one inorganic layer, so as to define a higher friction area exhibiting a static coefficient of friction higher than that of the inorganic materials
Data Source
AI summary
A mounting mat (16) comprising at least one inorganic layer (18) comprising inorganic materials suitable for mounting a pollution control element in a pollution control device. A friction-inducing material (20) is disposed on at least one side of the inorganic layer (18). The deposited friction-inducing material (20) defines a higher friction area exhibiting a static coefficient of friction higher than that of the inorganic materials. A lower friction layer (20) is disposed so as to cover at least a portion of the higher friction area and define an exposed surface area of the mounting mat (16). The exposed surface area exhibits a lower static coefficient of friction than that of the higher friction area. The lower friction layer (20) no longer covers a substantial portion of the higher friction area, after the mounting mat (16) mounts a pollution control element (14) in a pollution control device (10).