Removable Catalyst Housing for Parallel SCR Substrates
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Solution Overview
Problem
Existing aftertreatment modules for internal combustion engines face challenges in managing NOx emissions due to the need for large, expensive SCR substrates that restrict exhaust flow and are difficult to service, leading to increased packaging complexities and performance issues.
Innovation Solution
The aftertreatment module features a removably connected catalyst housing with multiple parallel-mounted SCR substrates, an oblique mounting arrangement, and a design that allows for efficient exhaust flow and easy replacement of the catalyst housing, reducing packaging constraints and service costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large SCR substrate is used to ensure sufficient surface area for NOx reduction, then the effectiveness of NOx reduction is improved, but the exhaust backpressure increases and packaging space requirements increase
Solution Approach 1:
The patent divides the SCR substrate into multiple smaller substrates arranged in parallel within the catalyst housing. This segmentation allows the exhaust flow to be distributed across multiple pathways, reducing the restriction on exhaust flow and thereby lowering backpressure while maintaining the total active surface area required for effective NOx reduction.
2Reliability
If a large SCR substrate is used to ensure sufficient surface area for NOx reduction, then the effectiveness of NOx reduction is improved, but the packaging space requirements increase
Solution Approach 1:
The patent arranges multiple SCR substrates in a parallel configuration within a compact catalyst housing, utilizing three-dimensional space efficiently. The substrates are positioned to maximize space utilization while maintaining adequate flow passages, thereby achieving the required total surface area for NOx reduction without increasing the overall packaging volume.
3Strength
If a fixed catalyst bank is used in the aftertreatment module, then the structural integrity is maintained, but the serviceability and replacement capability deteriorates
Solution Approach 1:
The patent separates the catalyst housing from the main aftertreatment module housing, creating a removable and replaceable catalyst assembly. This segmentation allows the catalyst substrates to be easily removed and replaced without replacing the entire aftertreatment module, thereby improving serviceability while maintaining structural integrity through proper connection interfaces.
4Stability of the object's composition
If the catalyst housing is permanently integrated into the aftertreatment module, then the structural stability is improved, but the maintenance cost and complexity increases
Solution Approach 1:
The patent designs the catalyst housing with removable connections to the main module housing, transitioning from a fixed integrated structure to a dynamically separable structure. This allows the catalyst housing to be easily detached for maintenance and replacement, reducing maintenance complexity and costs while maintaining structural stability during operation through secure connection interfaces.
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
This configuration improves packaging efficiency, maintains engine performance by minimizing exhaust backpressure, and allows for cost-effective and timely replacement of catalyst substrates, ensuring compliance with stringent NOx emission regulations.
Implementation Method 1
The injected urea solution decomposes into ammonia (NH3), which reacts with NOx in the exhaust gas to form water (H2O) and diatomic nitrogen (N2)
Data Source
AI summary
An aftertreatment module is disclosed for use with an engine. The aftertreatment module may have an inlet housing at least partially defining an inlet passage for exhaust, and at least one mixer disposed in the inlet passage. The aftertreatment module may also have an outlet housing at least partially defining an outlet passage for exhaust, and a catalyst housing removably connected between the inlet housing and the outlet housing. The aftertreatment module may further have a plurality of catalyst substrates configured to be mounted in the catalyst housing, to receive exhaust from the inlet passage in parallel, and to discharge exhaust to the outlet housing in parallel.