Flexible Edge Protectant Mounting Mat for Exhaust Gas Erosion
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Solution Overview
Problem
Existing mounting mats for exhaust gas treatment devices, such as catalytic converters and diesel particulate traps, face issues with edge erosion due to hot exhaust gases, leading to degradation and insufficient protection, especially when intumescent mats require complex and expensive edge protection methods.
Innovation Solution
A mounting mat with a flexible edge protectant comprising a non-crosslinkable polymer that thermally decomposes, leaving a gas erosion resisting agent adsorbed on the mat, providing effective protection against edge erosion without the need for additional edge protectants and maintaining flexibility for easy installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting mats are used in exhaust gas treatment devices, then they provide basic thermal insulation and mechanical support, but they suffer from edge erosion due to hot exhaust gases leading to degradation
Solution Approach 1:
The patent applies composite materials by combining inorganic fibers with a flexible edge protectant coating that contains a polymer and gas erosion resisting agent. This composite structure provides both the thermal insulation properties of the inorganic fiber mat and the edge erosion resistance of the protective coating, resolving the contradiction between basic protection and erosion resistance.
Solution Approach 2:
The patent applies local quality by concentrating the edge protectant specifically at the lateral edges of the mounting mat where erosion occurs, rather than treating the entire mat uniformly. This targeted approach provides erosion resistance exactly where needed while maintaining the overall flexibility and insulating properties of the mat.
2Reliability
If intumescent mounting mats are used to provide edge protection, then they offer some erosion resistance, but they require complex and expensive additional edge protection methods
Solution Approach 1:
The patent merges the mounting mat function with the edge protection function by incorporating the edge protectant directly into the mat structure as a coating. This eliminates the need for separate edge protection components and assembly steps, resolving the contradiction between protection capability and device complexity.
Solution Approach 2:
The patent uses composite materials by integrating the polymer-based edge protectant with the inorganic fiber mat through coating or lamination. This creates a single integrated component that provides both structural support and edge protection, avoiding complex multi-component assemblies.
3Reliability
If rigid edge protectants are applied to mounting mat edges, then they provide erosion resistance, but they reduce the flexibility of the mat making installation difficult
Solution Approach 1:
The patent applies parameter changes by selecting a polymer-based edge protectant that maintains flexibility across the operating temperature range. The protective coating is designed to remain柔韧 at installation temperature for ease of application while providing erosion resistance at operating temperature, thus resolving the contradiction between erosion resistance and installation flexibility.
Solution Approach 2:
The patent applies local quality by providing edge protection only at the lateral edges rather than making the entire mat rigid. The flexible inorganic fiber core maintains overall mat flexibility for installation while the localized edge protectant provides erosion resistance where needed.
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 significantly reduces edge erosion and maintains the mat's flexibility, eliminating the need for complex edge protection methods and ensuring effective thermal insulation and mechanical support for fragile structures within exhaust gas treatment devices.
Implementation Method 1
a substantially non-crosslinkable polymer that thermally decomposes leaving a gas erosion resisting agent adsorbed on the mounting mat
Implementation Method 2
leaving a gas erosion resisting agent adsorbed on the mounting mat
Implementation Method 3
provide thermal insulation and an effective gas seal
Data Source
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AI summary
A mounting mat for an exhaust gas treatment device includes first and second major opposite facing surfaces, leading and trailing edges, and opposite lateral edges. At least a portion of one or both of the opposite lateral edges includes an edge protectant that protects the mounting mat against erosion from hot gases encountered during the normal operation of the exhaust gas treatment device. The edge protectant remains flexible after it has been applied to the mounting mat and substantially dried. Also disclosed is an exhaust gas treatment device that includes a housing and a fragile structure mounted within the housing by the mounting mat having the edge protectant deposited thereon. Additionally disclosed are methods of making the mounting mat and an exhaust gas treatment device.