Erosion Resistant Mounting Material for Pollution Control Devices
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Solution Overview
Problem
Ceramic monoliths in pollution control devices are fragile and prone to damage from road shock and thermal expansion differences, requiring additional materials like ceramic mats or intumescent sheets to prevent erosion and mechanical failure, and existing erosion-resistant methods are messy and inefficient.
Innovation Solution
A flexible erosion-resistant mounting material with inorganic fibers and a reinforcing composition, specifically a layer of compounds like phosphoric acid or phosphate salts, applied along the peripheral edges to provide erosion resistance without contacting the majority of the mounting material, allowing for easy wrapping around monoliths and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic mat or intumescent sheet materials are disposed between the ceramic monolith and the metal housing to prevent erosion and mechanical failure, then the monolith is protected from damage, but the mounting material becomes more complex and difficult to handle
Solution Approach 1:
The patent combines ceramic fibers (for heat resistance and erosion protection) with organic binder materials (for flexibility and adhesion) to create a composite mounting material that integrates the protective functions previously requiring separate layers. This composite structure maintains monolith protection while simplifying the overall mounting material design and handling.
Solution Approach 2:
The invention merges the previously separate ceramic mat layer and intumescent sheet layer into a single integrated mounting material composition. This combines the erosion resistance of ceramic mats with the thermal protection of intumescent materials, reducing the number of components and simplifying the canning process.
2Reliability
If rigidizing solution is applied to the leading peripheral edge of mounting mat during canning to reduce erosion, then erosion resistance is improved, but the process becomes messy and the material loses flexibility
Solution Approach 1:
The patent incorporates erosion-resistant ceramic fiber content concentrated at the leading peripheral edges of the mounting material, while the bulk of the material maintains its flexible composition. This localized enhancement provides erosion protection where needed most without compromising the overall flexibility and handleability of the mounting material during installation.
Solution Approach 2:
The erosion-resistant properties are built into the mounting material during manufacturing, with ceramic fibers pre-distributed throughout the composition and concentrated at edge regions. This eliminates the need for subsequent application of rigidizing solutions during the canning process, maintaining flexibility while providing proactive erosion protection.
3Reliability
If the mounting material is made more rigid to resist erosion from hot exhaust gases, then erosion resistance is improved, but the material becomes prone to cracking when wrapped around monoliths
Solution Approach 1:
The composite structure combines rigid ceramic fibers (providing erosion resistance) with flexible organic binder materials (maintaining flexibility). The ceramic fibers create a rigid framework for erosion protection while the organic matrix maintains flexibility, allowing the material to be wrapped around monoliths without cracking.
Solution Approach 2:
The patent optimizes the ratio and distribution of ceramic fiber content to balance rigidity and flexibility. By controlling the ceramic fiber concentration (particularly at edge regions versus the bulk material), the mounting material achieves sufficient rigidity for erosion resistance while maintaining the flexibility needed for proper installation around monoliths.
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 provides enhanced erosion resistance to hot exhaust gases, maintains flexibility to prevent breakage, and eliminates the need for additional rigidizing solutions during the canning process, making the mounting material easier to handle and install in pollution control devices.
Implementation Method 1
a layer of reinforcing composition inwardly disposed on the mounting material along the entire first peripheral edge... provides enhanced erosion resistance to hot exhaust gases
Implementation Method 2
to avoid damage to the ceramic monolith from road shock and vibration
Implementation Method 3
to compensate for the thermal expansion difference
Data Source
Figure 1
Figure 2
AI summary
An erosion resistant mounting material comprises: a mounting material comprising inorganic fibers and having a peripheral edge; and a layer of reinforcing composition inwardly disposed on the inorganic fibers along the peripheral edge. The reinforcing composition comprises at least one compound represented by the formula: (Mm+)d ((ZpOq(OH)r)n-)e ∙ (H2O)f M represents a cationic species other than H+; O represents oxygen; Z represents phosphorus; f is a real number greater than or equal to zero; d, n, q, and r are integers greater than or equal to zero; e, m, and p are integers greater than or equal to one; and d times m equals e times n. The mounting material is useful in pollution control devices. A method of making the mounting material is also disclosed.