Self-Supporting Holder for Catalytic Converter Modules
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Solution Overview
Problem
Existing exhaust gas cleaning systems face challenges in modularly adapting emission control capacity to internal combustion engines with changing operating conditions, requiring complex and costly assembly of multiple catalyst modules in parallel arrangements, which increases assembly effort and expense.
Innovation Solution
A self-supporting mount for exhaust gas cleaning modules with adjustable retaining plates and beads that allow for flexible arrangement and fixation of multiple modules, reducing production complexity and assembly effort by enabling modular adaptation of emission control capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple emission control modules are arranged in parallel to adapt emission control capacity to engine requirements, then the adaptability and emission control capacity are improved, but the assembly effort and complexity increase significantly
Solution Approach 1:
Multiple emission control modules are merged into a single integrated holder structure, where several catalyst carrier bodies are arranged in parallel and fixed together using common retaining plates. This combining approach maintains the modular adaptability of having multiple modules while reducing assembly complexity through unified fixation mechanisms rather than separate mounting for each module.
Solution Approach 2:
The holder structure serves multiple functions simultaneously: it provides mechanical support for multiple emission control modules, enables modular adaptation of emission control capacity through selective module arrangement, and facilitates simplified assembly through standardized retaining plates that work across different module configurations.
2Productivity
If multiple emission control modules are mounted in the exhaust system, then the emission control capacity is improved, but the assembly effort and additional expenses increase
Solution Approach 1:
The holder combines multiple emission control modules into a pre-assembled unit that can be installed as a single component in the exhaust system. This merging reduces the number of separate assembly operations required and lowers manufacturing costs by enabling standardized production of the holder assembly.
Solution Approach 2:
Multiple emission control modules are pre-arranged and pre-fixed together in the holder structure before final installation in the exhaust system. This preliminary assembly of modules with common retaining plates reduces the assembly effort during final installation and allows for more efficient manufacturing processes.
3Reliability
If retaining plates with recesses are used to fix emission control modules, then the fixation stability is improved, but the device complexity increases
Solution Approach 1:
The retaining plates feature localized recesses positioned at specific locations to receive and fix the bead protrusions of emission control modules. This local quality approach provides stable fixation only where needed (at the bead contact points) while keeping the rest of the plate structure simple and flat, minimizing overall device complexity.
Solution Approach 2:
The bead protrusions on the emission control modules automatically engage with the recesses in the retaining plates during assembly, providing self-aligning and self-fixing functionality. This self-service mechanism improves fixation stability without requiring complex adjustment mechanisms or additional fastening components.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The self-supporting fastener (1) is provided in two emission control modules (2) and two retaining plates (6). Each emission control module has a cross-section (3) and a bead (5) with a specific thickness (8), where the bead rises on the main cross-section. The two emission control modules penetrate a retaining plate in a partial manner, and are fixed between two retaining plates through the bead. An independent claim is also included for an exhaust system for a motor vehicle.