Exhaust Aftertreatment Structural Component Mounting

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Solution Overview

Problem

The existing construction methods for exhaust aftertreatment devices, such as mufflers and catalytic converters, face challenges with increased physical and thermal loads, leading to deflection, structural failure, and gas leaks due to rigid mounting and thermal expansion issues, especially when accommodating diesel engines with complex aftertreatment systems like DOC and DPF.

Innovation Solution

An exhaust aftertreatment assembly featuring a structural component with an annular mounting surface and a tubular shell that supports exhaust aftertreatment devices, allowing for flexible mounting and thermal expansion accommodation through removable connections and insulation, enabling robust and efficient mounting on a vehicle frame.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If stamped steel or fabricated assemblies are used to construct exhaust aftertreatment devices, then the device can be manufactured with standard methods, but the increased physical loads and thermal loads cause increased deflection and possibility of leaks and structural failure

Engineering Contradiction:

Improvemanufacturing methodVSAvoidstructural integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The exhaust aftertreatment device is divided into multiple modular components (catalytic converter, DPF, muffler) that can be independently manufactured and then assembled together. This segmentation allows each component to be optimized for its specific function while reducing the overall structural stress on any single component, thereby maintaining reliability while preserving ease of manufacture.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mounting system incorporates flexible connections and adjustable mounting points that allow the device to dynamically adapt to thermal expansion and physical loads. This dynamic capability prevents structural failure by allowing controlled movement rather than rigid constraint, resolving the contradiction between standard manufacturing and structural integrity under load.

Inventive Principle:

Principle #15Dynamics

2Reliability

If the device is rigidly mounted to accommodate emissions requirements, then emissions treatment is effective, but thermal expansion causes deflection and potential leaks

Engineering Contradiction:

Improveemissions treatment effectivenessVSAvoidthermal expansion effects

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The device incorporates flexible mounting elements and expansion joints that accommodate thermal expansion while maintaining the sealed environment necessary for effective emissions treatment. These flexible components allow the structure to expand and contract with temperature changes without compromising the integrity of the emissions treatment chambers or creating leaks.

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If fabricated structure with welded joints is used, then structural strength is achieved, but the orientation of the device is fixed upon completion of the welds with no further flexibility

Engineering Contradiction:

Improvestructural strengthVSAvoidmounting orientation flexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The device is constructed as a modular assembly of separately manufactured components connected by mechanical joints rather than fixed welds. This segmentation maintains structural strength through proper component design while enabling flexible orientation and positioning during installation, as each module can be independently positioned and oriented to meet spatial requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mounting system uses adjustable and reconfigurable connections that allow the device to be oriented in multiple positions after assembly. This dynamic mounting capability provides flexibility in installation orientation while maintaining the structural integrity needed for effective emissions treatment, resolving the contradiction between strength and adaptability.

Inventive Principle:

Principle #15Dynamics

4Object-generated harmful factors

If complex aftertreatment systems with DOC and DPF are added to diesel engines, then emissions are reduced, but the size and weight make mounting on vehicle frame significantly more difficult

Engineering Contradiction:

ImproveemissionsVSAvoidmounting difficulty

Core Design Contradiction:

Object-generated harmful factorsVSEase of operation

Solution Approach 1:

The DOC and DPF systems are integrated into a single combined exhaust aftertreatment assembly that shares common mounting points, support structures, and exhaust flow paths. This merging reduces the overall number of separate components requiring mounting, simplifies the mounting process on the vehicle frame, while maintaining the full emissions reduction capability of both DOC and DPF systems.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP2187013B1Construction for an exhaust after treatment device

Publication Date: 2017.03.08 DEERE & CO

AI summary

An exhaust aftertreatment assembly (10) has an unitary cast inlet (18) that is configurable to have a 90° or 180° entry of combustion gasses relative to flow through tubular elements (22,24) housing a diesel oxidization catalyst (32) and a diesel particulate filter. The cast component provides the primary structural support for a tubular element (22) connected to the casting element.