Mat Member Heating Element for Exhaust Gas Treating Apparatus
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Solution Overview
Problem
Conventional mat members in exhaust gas treating apparatuses experience positional displacement due to frictional forces and thermal expansion, leading to a decrease in holding force over time, which compromises the effectiveness of exhaust gas treatment.
Innovation Solution
Incorporating a heating element on the mat member's surfaces that emits heat through exothermic chemical reactions, causing the casing and mat member to form a molten-solidified layer, enhancing bonding strength and reducing positional displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If latex is provided on both sides of the mat member to control frictional force, then press-fitting operation is facilitated, but the holding force decreases with time due to latex burning away from exhaust gas heat
Solution Approach 1:
The patent applies this principle by using latex as a temporary friction-control layer that is intentionally designed to be consumable. The latex is applied only during the press-fitting process to facilitate installation, and its temporary nature (burning away from exhaust heat) is accepted as part of the design. This resolves the contradiction by making the friction-control function temporary and disposable, rather than requiring a permanent solution that would compromise holding force.
2Ease of manufacture
If the mat member is pressed into the casing, then the exhaust gas treating apparatus is assembled, but frictional force causes positional displacement of the mat member
Solution Approach 1:
The patent applies this principle by introducing latex as an intermediary substance between the mat member and the contact surfaces. The latex layer modifies the friction characteristics during press-fitting, acting as a mediator that reduces excessive frictional force. This intermediary layer prevents the mat member from displacing positionally while still allowing the press-fitting operation to complete successfully.
3Duration of action of stationary object
If the mat member receives repeated compression loads from thermal expansion, then the apparatus operates through temperature cycles, but the holding force decreases due to fiber damage
Solution Approach 1:
The patent applies this principle by providing the latex layer in advance on the mat member surfaces before the mat member is installed in the exhaust system. This pre-applied latex layer serves as a cushioning element that moderates the impact of repeated thermal expansion and compression loads. The latex absorbs and distributes the mechanical stress from temperature cycling, protecting the inorganic fibers from damage before the damage can occur.
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 positional displacement of the mat member, maintaining effective exhaust gas treatment for a longer period by increasing bonding strength between the mat member and the casing, even as inorganic fibers deteriorate over time.
Implementation Method 1
a heating element configured to emit heat, the heating element being provided on at least one of the first main surface and the second main surface, in which the heating element emits the heat in response to an exothermic chemical reaction
Implementation Method 2
causing the casing and mat member to form a molten-solidified layer
Data Source
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AI summary
The present invention relates generally to exhaust gas treating apparatuses and mat members used in exhaust gas treating apparatuses. More particularly, the present invention relates to a mat member (24), comprising a first main surface (250), a second main surface (260), inorganic fiber, and a heating element (80,90) configured to emit heat, the heating element being provided on at least one of the first main surface (250) and the second main surface (260), wherein the heating element emits the heat in response to an exothermic chemical reaction, wherein a metal or an alloy, and an inorganic compound are used as starting materials for the chemical reaction.