Abstract
Mounting mat (4) for holding a substrate (2) of a pollution control element or chemical reactor (10), the pollution control element or chemical reactor (10) comprising more than one substrate (2), wherein the substrate (2) comprises a front face (2f), a rear face (2r) and at least three flat side faces (4) extending between the front (2f) and the rear face (2r), and wherein the mounting mat (4) is shaped such that it covers at least partially an edge (5) enclosed by two flat side faces (4).
Claims
1. Mounting mat for mounting a pollution control element or chemical reactor comprising two or more substrates, with each substrate comprising a front face, a rear face and at least three flat side faces extending between the front and the rear face, wherein the mounting mat is shaped such that it covers at least partially two of the flat side faces and at least partially an edge enclosed by the two flat side faces, and between the two substrates only one mounting mat is positioned.
2. Mounting mat according to claim 1, wherein the mounting mat is a non-woven mounting mat comprising inorganic fibers.
3. Mounting mat according to claim 1, wherein the substrate is a ceramic substrate.
4. Mounting mat according to claim 1, wherein the substrate comprises four flat side faces that extend between the front and the rear face and wherein the substrate comprises a squared cross section.
5. Mounting mat according to claim 1, wherein the mounting mat is shaped such that it covers at least partially three flat side faces and at least partially the two edges enclosed by two respective flat side faces of the substrate.
6. Mounting mat according to claim 1, wherein the mounting mat covers the entire two or three flat side faces that enclose an edge up to an adjacent edge of the substrate.
7. Mounting mat according to claim 6, wherein the mounting mat may extend over the adjacent edge of the substrate.
8. Pollution control element or chemical reactor comprising more than one substrate as well as a mounting mat according to claim 1.
9. Pollution control element or chemical reactor according to claim 8, wherein the pollution control element comprises four substrates arranged in two rows of two substrates.
10. Pollution control element or chemical reactor according to claim 8, wherein the pollution control element comprises nine substrates arranged in three rows of three substrates.
11. Pollution control element or chemical reactor according to claim 8, wherein the number of substrates in a row is identical to the number or rows.
12. Pollution control element or chemical reactor according to claim 11, wherein when z is the number of substrates in a row and the number of rows; when x is the number of 3-side wrapped substrates; and when y is the number of 2-side wrapped substrates; x is equal to 2 times z and y is equal to (z−2) multiplied with z or when u is the number of substrates in a row, when v is the number of rows, when x is the number of 3-side wrapped substrates when y is the number of 2-side wrapped substrates than x is equal to u+v and y is equal to u*v−x.
13. Method of assembling a pollution control element or chemical reactor, the pollution control element or chemical reactor comprising more than one substrate, the method comprising the following steps a) providing more than one substrate, wherein the substrate comprises a front face, a rear face and at least three flat side faces extending between the front and the rear face; b) providing a mounting mat according to claim 1; c) wrapping the mat around the substrate such that it covers at least partially an edge enclosed by two flat side faces of the substrate and fastening it; d) repeating step c) as often as substrates are needed to assemble the pollution control element or chemical reactor; e) placing the wrapped substrates next to each other so that all substrates' flat side walls are placed next to a mounting mat and f) placing the substrates inside a housing.
14. Mounting mat according to claim 2, wherein the substrate is a ceramic substrate.
15. Mounting mat according to claim 14, wherein the substrate comprises four flat side faces that extend between the front and the rear face and wherein the substrate comprises a squared cross section.
16. Mounting mat according to claim 4, wherein the mounting mat is shaped such that it covers at least partially three flat side faces and at least partially the two edges enclosed by two respective flat side faces of the substrate.
17. Mounting mat according to claim 5, wherein the mounting mat covers the entire two or three flat side faces that enclose an edge up to an adjacent edge of the substrate.
18. Pollution control element or chemical reactor according to claim 9, wherein the pollution control element comprises nine substrates arranged in three rows of three substrates.
19. Pollution control element or chemical reactor according to claim 9, wherein the number of substrates in a row is identical to the number or rows.
20. Pollution control element or chemical reactor according to claim 10, wherein the number of substrates in a row is identical to the number or rows.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0039] The invention will now be described in more detail with reference to the following Figures exemplifying particular embodiments of the invention:
[0040] FIG. 1 is a front view of a pollution control element or a chemical reactor according to the invention;
[0041] FIG. 2 is a perspective view of the pollution control element or chemical reactor according to the invention;
[0042] FIG. 3 schematically shows a preassembled component of a pollution control element or chemical reactor comprising a substrate and a mounting mat that is shaped such that it covers three flat side faces and the edges enclosed by two respective side faces;
[0043] FIG. 4 schematically shows a preassembled component of a pollution control element or chemical reactor comprising a substrate and a mounting mat that is shaped such that it covers two flat side faces and the edge enclosed by two respective side faces;
[0044] FIG. 5 is another embodiment of a preassembled component of a pollution control element or chemical reactor comprising a substrate and a mounting mat that is shaped such that it covers three flat side faces and the edges enclosed by two respective side faces;
[0045] FIG. 6 is another embodiment of a preassembled component of a pollution control element or chemical reactor comprising a substrate and a mounting mat that is shaped such that it covers two flat side faces and the edge enclosed by two respective side faces;
[0046] FIG. 7 schematically shows four preassembled components oriented such as to be placed in a housing in order to build a pollution control element or chemical reactor;
[0047] FIG. 8 schematically shows the steps of a method for assembling a pollution control element or chemical reactor;
[0048] FIG. 9 schematically shows nine preassembled components oriented such as to be placed in a housing in order to build a pollution control element or chemical reactor with mounting mats according to the invention;
[0049] FIG. 10 schematically shows nine different preassembled components oriented such as to be placed in a housing in order to build a pollution control element or chemical reactor with mounting mats according to the invention;
[0050] FIG. 11 schematically shows the four preassembled components of FIG. 3 with additional sealing elements;
[0051] FIG. 12 schematically shows additional embodiments of preassembled components oriented such as to be placed in a housing in order to built a pollution control element or chemical reactor with mounting mats according to the invention;
[0052] FIG. 13 schematically shows another embodiment of preassembled components oriented such as to be placed in a housing in order to built a pollution control element or chemical reactor with mounting mats according to the invention and
[0053] FIG. 14 schematically shows yet another embodiment of preassembled components oriented such as to be placed in a housing in order to build a pollution control element or chemical reactor with mounting mats according to the invention.
[0054] Herein below various embodiments of the present invention are described and shown in the drawings wherein like elements are provided with the same reference numbers.
DETAILED DESCRIPTION
[0055] FIG. 1 shows a pollution control element or chemical reactor 10 with four substrates 2 wrapped by mounting mats 3 according to the invention. FIG. 2 is a dimensional view of the four substrates 2 with their mounting mats as they are positioned in the pollution control element or chemical reactor 10 of FIG. 1. The substrates comprise a front face 2f, a rear face 2r and four side 4 faces (here covered with mourning mats). With reference to the following figures it will be explained how the substrates 2 get wrapped with the mounting mats according to the invention and how the pollution control element or chemical reactor 10 gets assembled.
[0056] FIG. 3 schematically shows a preassembled component 1 of a pollution control element or chemical reactor 10 as utilized in the pollution control element or chemical reactor shown in FIG. 1. The preassembled component 1 comprises a substrate 2 and a mounting mat 3. In FIG. 3 they are shown in a cross sectional view. The substrate 2 comprises a squared cross section. It also comprises a front face and a rear face (as shown in FIG. 2) as well as four flat side faces 4. The mounting mat 3 is shaped such that it covers three flat side faces 4 entirely and the edges 5 enclosed by two respective side faces 4 (enclosed edge). The fourth flat side face 4 of the substrate 2 is not covered by a mounting mat. The mounting mat 3 covers the substrate 2 over its entire length, from the front to the rear face. It is possible to leave a little bit of space at the front and at the rear in order to prevent the mounting mat 3 from being squeezed out of the housing when the pollution control element or chemical reactor is assembled.
[0057] FIG. 4 schematically shows a preassembled component 1 of a pollution control element or chemical reactor 10 as shown in FIG. 1, that differs from the one shown in FIG. 3 in that the mounting mat 3 covers only two flat side faces 4 of the substrate 2 instead of three. The two other flat side faces 4 are not covered with a mounting mat 3.
[0058] FIGS. 5 and 6 schematically show the preassembled components 1 of FIGS. 3 and 4. The preassembled components 1 of FIGS. 5 and 6 differ from those shown in FIGS. 3 and 4 in that the mounting mats 4 comprise a protrusion 8 at one end, where the mounting mats 4 protrude the edge of the substrate. The protrusion may be used for sealing an assembly of substrates as will be described in more detail with reference to FIGS. 11 and 12.
[0059] FIG. 7 schematically shows four of the preassembled components 1 of FIG. 3 oriented such as to be placed in a housing in order to build a pollution control element or chemical reactor 10. The upper left component 1a (3-side wrapped component) comprises one flat side face 4a that is not covered with a mounting mat 3. This flat side face 4a is directed to the right of the drawing. All other side faces are covered with a mounting mat 3a. The upper right component 1b comprises one flat side face 4b that is not covered with a mounting mat 3. This flat side face 4b is directed to the bottom of the drawing. All other side faces are covered with a mounting mat 3b. The lower left component 1c comprises one flat side face 4c that is not covered with a mounting mat 3. This flat side face 4c is directed to the top of the drawing. All other side faces are covered with a mounting mat 3c. The lower right component 1d comprises a flat side face 4d that is not covered with a mounting mat 3. This flat side face 4d is directed to the left of the drawing. All other side faces are covered with a mounting mat 3d. The described arrangement guarantees that all sides of the four substrates 2a, 2b, 2c, 2d are coved by a mounting mat 3 in an assembled stage. The benefit of the described arrangement is that the pollution control element or chemical reactor can be built up with four identical preassembled components 1a, 1b, 1c, 1d. Thus, the assembly process is very simple and therefore cost effective. Another benefit of the descried arrangement is that due to the reduced number of parts and the reduced process steps, the process is less complex and therefore potential mistakes of an operator may be prohibited. Compared to pollution control elements or chemical reactors according to the prior art less material for mounting mats is needed, since every flat side wall is only covered with one layer of mounting mat material. No additional holding or separating means are needed.
[0060] FIGS. 8A, 8B and 8C schematically show one method of assembling a pollution control element or chemical reactor 10 according to the invention. The pollution control element or chemical reactor 10 comprises more than one substrate. As a first step a substrate 2 is provided, wherein the substrate comprises a front face, a rear face and four flat side faces 4 extending between the front and the rear face. In FIGS. 8A, 8B and 8C only a cross section of the substrate 2 is shown. Therefore only the front face is shown in this drawing. As already described with reference to FIG. 3 the substrate 2 is wrapped by a mounting mat 3. The mounting mat is shaped such, that it covers three flat side faces 4 as well as two edges between two respective flat side faces 4 of the substrate 2 (3-side wrapped). The mounting mat 3 is fastened at the substrate 2 by adequate means, e.g. by an adhesive. The above described steps are repeated four times until four substrates 2 are wrapped with mounting mats 3 on three flat side faces 4 of the substrates 2. Each substrate 2 provides one flat side face 4 that is not covered with a mounting mat. 3. Instead of using four identical preassembled components it is also possible to use three identical components as shown in FIG. 7 and one preassembled component with a protrusion 8 as shown in FIG. 5 to seal an opening in the middle that might occur.
[0061] As a next step of the method for assembling a pollution control element or chemical reactor, the preassembled components (wrapped substrates) are placed next to each other such that all substrates' flat side walls are placed next to a mounting mat, either a portion of a mounting mat 3 fixed to that specific substrate or a portion of a mounting mat of an adjacent substrate. One possibility of doing that has been described with reference to FIG. 7.
[0062] Finally all substrates 2 with the mounting mats 3 wrapped around them are placed inside an adequate housing 6. The placing inside of a housing can be done with all generally known methods for placing a substrate 2 in a housing 6, such as stuffing, canning, closing the housing around the substrates with fastening it e.g. by welding.
[0063] FIG. 9 schematically shows nine preassembled components oriented such as to be placed in a housing in order to build a pollution control element or chemical reactor with mounting mats 3 according to the invention. The assembly of FIG. 9 starts with an assembly that is shown in FIG. 7—four preassembled components each comprising a 3-side wrapped substrate 2—and has already been described with reference to FIG. 7 as well as FIGS. 8A, 8B and 8C. In addition to the four 3-side wrapped substrates 2, the assembly of FIG. 9 comprises three 2-side wrapped substrates 2″ and two 3-side wrapped substrates 2′″. Again the substrates are arranged such that each flat side wall is covered by at least a portion of a mounting mat. 3, either a portion of a mounting mat 3 fixed to that specific substrate or a portion of a mounting mat of an adjacent substrate. From the left to the right the upper row comprises first a 3-side wrapped substrate 2′″ and then two 2-side wrapped substrates 2″; the second row comprises three 3-side wrapped substrates and the third row comprises first a 2-side wrapped substrate 2″ and then two 3-side wrapped substrates 2′″. The way the 2-side wrapped and the 3-side wrapped substrates are arranged can differ, but the number of 2-side wrapped and 3-side wrapped substrates stays the same.
[0064] The following is a way to calculate the number of 2-side wrapped and 3-side wrapped substrates needed, when you have a pollution control element or chemical reactor with the same number of rows as you have substrates in one row (squared assembly):
[0065] when z is the number of substrates in a row and the number of rows; when x is the number of 3-side wrapped substrates and when y is the number of 2-side wrapped substrates, x is equal to 2 times z and y is equal to (z−2) multiplied with z.
[0066] For the assembly shown in FIG. 9 this means that:
[0067] z=3 therefore
[0068] x=2×3=6 (3-side wrapped substrates 2′″) and
[0069] y=(3−2)×3=3 (2-side wrapped substrates 2″).
[0070] For configurations that are not square and if the number of rows is higher than 2 the following equation can be used to calculate the number of 2-side wrapped and 3-side wrapped substrates:
[0071] u is the number of substrates in a row
[0072] v is the number of rows
[0073] x is the number of 3-side wrapped substrates
[0074] y is the number of 2-side wrapped substrates
[0075] x=u+v and
[0076] y=u*v−x.
[0077] For the assembly shown in FIG. 13 this means that:
[0078] u=4 and
[0079] v=3 therefore
[0080] x=4+3=7 (3-side wrapped substrates 2′″) and
[0081] y=4*3−7=5 (2-side wrapped substrates 2″).
[0082] FIG. 10 schematically shows another embodiment of an assembly with nine different preassembled components oriented such as to be placed in a housing in order to build a pollution control element or chemical reactor with mounting mats according to the invention. In this embodiment only one kind of preassembled component—3-side wrapped substrates 2′″—are used as well as one substrate 2 without a mounting mat 3. The substrate 2 that is not wrapped with a mounting mat 3 is placed in the middle. The 3-side wrapped substrates 2′″ are positioned around the substrate 2 without a mounting mat 3. The 3-side wrapped substrates 2′″ are oriented such that the respective flat side face 4 that is not covered with a mounting mat 4 faces towards an adjacent 3-side wrapped substrate 2′″. By that all flat side faces of all substrates 2, 2′″ are covered by at least a portion of a mounting mat 4.
[0083] Depending on the tolerances of the substrates and the shapes of the mounting mats it is possible, that after placing wrapped substrates next to each other, a space or spaces in between the substrates/mounting mats exist, that needs to be sealed. A possible area for such a space may be the area, where four wrapped substrates or preassembled components touch each other. In order to seal this space, it is possible to use an additional piece of sealing materiel—e.g. narrow Interam™ band from roll. This material may for example be cut from a roll into the right length/width to sufficiently seal the space. The advantage of using an additional material for sealing purposes is that a space, for example in the centre may be filled and sealed perfectly.
[0084] Instead of using a separate piece of sealing material a preassembled component as shown in FIGS. 5 and 6 could be used, where the mounting mat 4 extends the substrate at one end (extension 8). This is shown in FIG. 11 before and in FIG. 12 after assembly.
[0085] FIG. 14 shows another embodiment of preassembled components oriented such as to be placed in a housing in order to build a pollution control elements or chemical reactors with mounting mats according to the invention. The pollution control elements or chemical reactors comprise one row of four substrates. All four substrates are 3-side wrapped substrates. The side face of the substrate on the right hand side that is not covered by a mounting mat can for example be covered with a mounting mat that is shaped as to cover only one side face. It is also possible to use as the substrate on the right hand side instead of the 3-side wrapped substrate a substrate that is covered on all four sides with a mounting mat.
