Entwined Mat Strips for Catalyst Substrate Sealing
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Solution Overview
Problem
The assembly of catalyst substrates into enclosures in internal combustion engines is time-consuming due to size variations, requiring custom cutting of retention mats to prevent gas leakage, which is inefficient and costly.
Innovation Solution
The use of elongate mat strips with tongues and openings that overlap to form a continuous layer around substrates, allowing for uniform matting and sealing without the need for custom cutting, ensuring proper fit and sealing across all lateral surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom cutting of retention mats is performed to meet substrate size variations, then proper fit and sealing are achieved, but assembly time increases and productivity decreases
Solution Approach 1:
The retention mat is pre-cut to a standardized size that is larger than the substrate, and the excess material is folded back to create a self-adjusting retention structure. This preliminary preparation eliminates the need for time-consuming custom cutting during assembly while ensuring proper fit through the folded edges.
Solution Approach 2:
The retention mat is divided into multiple sections with folded edges that can independently adjust to accommodate substrate size variations. The mat includes a body portion and multiple folded edge portions that segment the retention function, allowing each section to adapt to the specific substrate dimensions without requiring custom cutting.
2Reliability
If retention mats are customized to fit each substrate, then sealing performance is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The retention mat is designed as a universal component with a standardized size and folded edge configuration that can accommodate multiple substrate sizes and shapes. The folded edges provide multi-functional retention and sealing action that works across different substrate types, eliminating the need for custom-designed mats for each application.
Solution Approach 2:
The folded edges of the retention mat provide localized retention and sealing action at critical interfaces between the mat and substrate. This local quality approach concentrates the sealing function at the folded portions rather than requiring the entire mat to be custom-shaped, maintaining simplicity while ensuring reliable sealing.
3Manufacturing precision
If excess mat material is manually removed from edges, then overlap between adjacent mats is avoided, but assembly time increases
Solution Approach 1:
The retention mat is pre-formed with folded edges that create self-limiting retention pockets. These folded edges automatically prevent overlap with adjacent mats by forming physical barriers, eliminating the need for manual trimming during assembly while ensuring precise positioning.
Solution Approach 2:
The folded edges of the retention mat serve their own positioning and alignment function without requiring external intervention. The folded structure self-adjusts to prevent overlap with adjacent mats, providing self-service positioning accuracy that eliminates manual trimming operations.
Data Source
AI summary
An after-treatment device includes a first mat having an elongate shape and a second mat having an elongate shape. The first mat and the second mat are entwined, each being in contact with at least three of the four lateral surfaces of each of at least two substrates. Additionally, the first mat and the second mat at least partially overlap such that the first tongue is disposed at least partially in the second opening and the second tongue is disposed at least partially in the first opening to form a continuous layer around all lateral surfaces of each of the at least two substrates placed in an enclosure.