Article of Manufacture for Securing a Catalyst Substrate

Patent metadata

Field	Value
Publication number	US-2016008758-A1
Application number	US-201414769698-A
Country	US
Kind code	A1
Filing date	Feb 24, 2014
Priority date	Feb 27, 2013
Publication date	Jan 14, 2016
Grant date	—

Abstract

An aftertreatment component for use in an exhaust aftertreatment system. The aftertreatment component comprises an aftertreatment substrate and a compressible material. The compressible material may be formed from a plastic thermoset, a rubberized material, or a metal foil which permits for the selective expansion of the substrate within the compressible material, while also reducing cost and manufacturing complexity. In various embodiments, the aftertreatment substrate and The compressible materials may be formed separately and coupled to each other, or they may be formed concurrently via coextrusion.

First claim

1 . An aftertreatment component of an exhaust aftertreatment system, comprising:
an aftertreatment substrate; a compressible material coupled to an outer surface the aftertreatment substrate; and a catalyst washcoat disposed on the aftertreatment substrate, wherein the catalyst washcoat is applied to the aftertreatment substrate after the compressible material is coupled to the aftertreatment substrate.

2 . The aftertreatment component of claim 1 , wherein the compressible material comprises a metal foil.

3 . The aftertreatment component of claim 1 , further comprising a catalyst washcoat disposed on the aftertreatment substrate.

4 . The aftertreatment component of claim 3 , wherein the catalyst washcoat is disposed on a substrate side of the compressible material.

5 . The aftertreatment component of claim 1 , further comprising an outer skin, the outer skin defining the compressible material.

6 . The aftertreatment component of claim 5 , wherein the outer skin at least partially compresses the compressible material against the aftertreatment substrate.

7 . The aftertreatment component of claim 6 , wherein the outer skin applies a selected closure force to the aftertreatment substrate through the compressible material.

8 . The aftertreatment component of claim 1 , wherein the compressible material is in tension, and wherein corrugations in the compressible material are at least partially compressed.

9 . The aftertreatment component of claim 8 , wherein the compressible material applies a selected closure force to the aftertreatment substrate.

10 . The aftertreatment component of claim 1 , wherein the compressible material comprises a polymer-based thermoset.

11 . The aftertreatment component of claim 1 , wherein the compressible material comprises a thermoplastic material.

12 . The aftertreatment component of claim 1 , wherein the aftertreatment substrate and the compressible material are concurrently formed and coupled together via coextrusion.

13 . The aftertreatment component of claim 1 , wherein the compressible material comprises a corrugated material.

14 . A method, comprising:
passing a heated exhaust stream into a aftertreatment substrate; thermally expanding the aftertreatment substrate into a compressible material defining the aftertreatment substrate; and as a result of thermally expanding the aftertreatment substrate into the compressible material defining the aftertreatment substrate, at least partially compressing corrugations of the compressible material.

15 . The method of claim 14 , further comprising confining the compressible material within an outer skin defining the compressible material.

16 . The method of claim 14 , further comprising positioning the aftertreatment substrate within the compressible material, and applying a catalyst washcoat to the aftertreatment substrate after the positioning.

17 . The method of claim 16 , further comprising applying at least a portion of the catalyst washcoat to a substrate side of the compressible material.

18 . The method of claim 14 , wherein the compressible material is defined in part by an outer skin, and wherein the compressible material is at least partially compressed between the outer skin and the aftertreatment substrate.

19 . The method of claim 14 , wherein the compressible material comprises a polymer-based thermoset.

20 . The method of claim 14 , wherein the compressible material comprises a thermoplastic material.

21 . The method of claim 14 , wherein the compressible material comprises a metal foil.

22 . The method of claim 14 , wherein the compressible material comprises a corrugated material.

23 . A method of forming an aftertreatment component of an exhaust aftertreatment system, comprising:
coextruding a first material and a second material through a die, forming, from the coextruded first material and second material, an aftertreatment substrate and a compressible material coupled to an outer surface of the aftertreatment substrate.

24 . The method of claim 23 , further comprising applying a catalyst washcoat to the aftertreatment substrate.

25 . The method of claim 23 , wherein the compressible material comprises a polymer-based thermoset.

26 . The method of claim 23 , wherein the compressible material comprises a rubberized material.

27 . The method of claim 23 , wherein the compressible material comprises a metal foil.

Assignees

• Cummins Emission Solutions Inc

Inventors

• Anderson Matthew
• Somogyvari Arpad

Classifications

• B01D53/86 Primary

  Catalytic processes · CPC title

• F01N3/021

  by means of filters · CPC title

• B32B3/28

  characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence) · CPC title

• B01J21/02

  Boron or aluminium; Oxides or hydroxides thereof · CPC title

• B01D39/00 Primary

  Filtering material for liquid or gaseous fluids · CPC title