Pollution Control Holding Material Friction Layer

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Solution Overview

Problem

Existing holding materials for pollution control elements, such as catalyst carriers, face challenges with heat resistance, surface pressure holding ability, exhaust gas erosion resistance, and operability, particularly during the press-fitting process, which can lead to separation and displacement issues and increased production costs due to complex manufacturing processes involving high-temperature firing.

Innovation Solution

A holding material with a friction layer comprising inorganic colloidal particles is applied to the surface of the material, increasing the friction coefficient between the holding material and the pollution control element or casing, thereby enhancing the holding force without the need for high-temperature processing, simplifying the manufacturing process and reducing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If a holding material is used without a friction layer, then the manufacturing process is simple, but the holding force is insufficient and the pollution control element may separate or displace

Engineering Contradiction:

Improveholding forceVSAvoidmanufacturing process complexity

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The invention changes the surface friction parameter of the holding material by forming a friction layer with inorganic colloidal particles. This layer increases the coefficient of friction between the holding material and the pollution control element, thereby enhancing the holding force without requiring complex manufacturing processes or high-temperature firing

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The holding material is constructed as a composite structure with a base material (such as ceramic fibers or organic-inorganic composite fibers) and a surface friction layer composed of inorganic colloidal particles. This composite structure combines the thermal stability of the base material with the high friction properties of the surface layer, achieving both heat resistance and enhanced holding force

Inventive Principle:

Principle #40Composite materials

2Temperature

If high-temperature firing is used to process the holding material, then heat resistance is improved, but production costs increase and the manufacturing process becomes complex

Engineering Contradiction:

Improveheat resistanceVSAvoidproduction cost and process simplicity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The invention changes the processing temperature parameter by forming the friction layer at low temperatures (without high-temperature firing). The inorganic colloidal particles are deposited and dried at temperatures significantly lower than traditional firing processes, thereby reducing production costs and simplifying manufacturing while maintaining heat resistance through the selection of heat-resistant base materials

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The friction layer is formed using a cost-effective process that avoids expensive high-temperature firing. The inorganic colloidal particles can be applied through simple coating or spraying methods followed by low-temperature drying, significantly reducing production costs compared to traditional high-temperature processing

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Stress or pressure

If the holding material has high surface pressure holding ability, then the pollution control element is securely held, but the material becomes harder to process and manufacture

Engineering Contradiction:

Improvesurface pressure holding abilityVSAvoidprocessability

Core Design Contradiction:

Stress or pressureVSEase of manufacture

Solution Approach 1:

The invention applies local quality by concentrating the high-friction, high-pressure-holding properties only on the surface of the holding material through the friction layer. The base material can remain relatively soft and easy to process, while the surface layer provides the necessary surface pressure holding ability. This localized approach allows the bulk material to remain manufacturable while the surface provides enhanced holding characteristics

Inventive Principle:

Principle #3Local quality

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 improved heat resistance, surface pressure holding ability, and exhaust gas erosion resistance, preventing separation and displacement of the pollution control element, while simplifying the manufacturing process and reducing production costs by eliminating the need for high-temperature firing.

Implementation Method 1

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentEP1931862B2Holding material for pollution control element and pollution control apparatus

Publication Date: 2013.12.04 3M INNOVATIVE PROPERTIES CO

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AI summary

A holding material (2) for mounting a pollution control element (1) in a pollution control apparatus (10) that provides for a high friction coefficient with the casing (4) and/or the pollution control element and can hold the pollution control element with good stability. The holding material comprises a fiber material (e.g., in the form of a mat) having a thickness and being provided with a friction layer (3) comprising inorganic colloidal particles (5) on an outer peripheral surface and/or an inner peripheral surface of the fiber material.