Abstract
An emission treatment component support structure for an exhaust system, the support structure comprising: an insulating layer configured to support a substrate of the emission treatment component within a housing; and one or more resistive metal elements provided at least partially within the insulating layer.
Claims
1. An emission treatment component support structure for an exhaust system, the support structure comprising: an insulating layer configured to support a substrate of the emission treatment component within a housing; and one or more resistive metal elements provided at least partially within the insulating layer.
2. The support structure of claim 1, further comprising means for applying an electrical current through the one or more resistive metal elements.
3. The support structure of claim 1, wherein the one or more resistive metal elements comprise a plurality of continuous metal elements incorporated at least partially within the support structure in a regular pattern.
4. The support structure of claim 1, wherein the one or more resistive metal elements comprise a plurality of metal filings and the metal filings are incorporated at least partially within the support structure in a continuous regular pattern.
5. The support structure of claim 1, wherein the one or more resistive metal elements comprise a plurality of continuous metal elements incorporated at least partially within the support structure in an irregular manner.
6. The support structure of claim 1, wherein the one or more resistive metal elements comprise a plurality of metal filings and the metal filings are incorporated at least partially within the support structure in a continuous, irregular manner.
7. The support structure of claim 1, wherein the one or more resistive metal elements comprise a continuous mesh that is incorporated at least partially within the support structure.
8. The support structure of claim 1, wherein the one or more resistive metal elements is a continuous mesh layer and at least a part of the continuous mesh layer is attached to a surface of the support structure.
9. The support structure of claim 1, wherein the support structure comprises a first support structure portion and a second support structure portion and wherein the one or more resistive metal elements is a continuous mesh layer located between the first support structure portion and the second support structure portion.
10. The support structure of claim 1, wherein the insulating layer is not electrically conductive.
11. A method of heating an emission treatment component of an exhaust system, the method comprising: providing a support structure for the emission treatment component, the support structure comprising an insulating layer configured to support a substrate of the emission treatment component within a housing, and one or more resistive heating metal elements; and applying an electrical current through the one or more resistive metal elements.
12. An exhaust system comprising at least one emission treatment component support structure according to claim 1.
13. A vehicle comprising at least one of the emission treatment component support structures of claim 1.
Description
FIGURES
[0021] The above and other objects and advantages of the disclosure will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which:
[0022] FIG. 1a shows a top view of a support structure and an emission treatment component, in accordance with an example of the disclosure.
[0023] FIG. 1b shows a side view of a support structure and an emission treatment component, in accordance with an example of the disclosure.
[0024] FIG. 1c shows a cross-sectional view of a support structure and an emission treatment component, in accordance with an example of the disclosure.
[0025] FIG. 2a shows a top view of a support structure and an emission treatment component, in accordance with an example of the disclosure.
[0026] FIG. 2b shows a side view of a support structure and an emission treatment component, in accordance with an example of the disclosure.
[0027] FIG. 2c shows a cross-sectional view of a support structure and an emission treatment component, in accordance with an example of the disclosure.
[0028] FIG. 3 is a schematic diagram of a support structure and an emission treatment component being inserted into a part of an exhaust system, in accordance with an example of the disclosure.
[0029] FIG. 4a is a schematic diagram showing a cross-sectional view of a support structure comprising a plurality of continuous metal elements arranged in a regular pattern, in accordance with an example of the disclosure.
[0030] FIG. 4b is a schematic diagram showing a cross-sectional view of a support structure comprising a plurality of metal filings arranged in a continuous regular pattern, in accordance with an example of the disclosure.
[0031] FIG. 4c is a schematic diagram showing a cross-sectional view of a support structure comprising a plurality of continuous metal elements arranged in an irregular pattern, in accordance with an example of the disclosure.
[0032] FIG. 4d is a schematic diagram showing a cross-sectional view of a support structure comprising a plurality of metal filings arranged in a continuous irregular pattern, in accordance with an example of the disclosure.
[0033] FIG. 4e is a schematic diagram showing a cross-sectional view of a support structure comprising a continuous mesh, in accordance with an example of the disclosure.
[0034] FIG. 4f is a schematic diagram showing a cross-sectional view of a continuous mesh that is attached to a surface of the support structure, in accordance with an example of the disclosure.
[0035] FIG. 5 shows method steps, in accordance with an example of the disclosure.
[0036] FIG. 6 shows a schematic diagram of a vehicle and an emission treatment component having an emission treatment component support structure, in accordance with an example of the disclosure.
DETAILED DESCRIPTION
[0037] FIG. 1a is a schematic diagram of a top view of a support structure 102 and a substrate 104 of an emission treatment component. The support structure 102 comprises metallic elements, e.g., metallic strands/fibers, and surrounds the substrate 104 of the emission treatment component in a continuous circumferential manner, such that a first surface of the support structure 102 is in contact with a first surface of the substrate 104 of the emission treatment component. However, it is contemplated that in some examples the support structure does not completely surround the emission treatment component. In some examples, the support structure may comprise a plurality of continuous metal elements incorporated within the support structure in a regular or an irregular pattern. In some examples, the support structure may comprise a plurality of metal filings incorporated within the support structure in a continuous regular or irregular pattern. In some examples, the support structure may comprise a mesh incorporated within the support structure. An optional electrical input 106 is coupled to the support structure 102 and is used for applying an electrical current to the metallic elements, and hence generating heat, in use. In use, the generated heat is used to increase the temperature of the emission treatment component, thereby increasing the efficiency of the emission treatment component, e.g., depending on the operating conditions of an exhaust system in which the emission treatment component is incorporated.
[0038] FIG. 1b is a schematic diagram of a side view of the support structure 102 and the substrate 104 of the emission treatment component of FIG. 1a. As can been seen, the substrate 104 of the emission treatment component may extend away from the support structure 102 in a first direction and in an opposing second direction, such that the support structure 102 does not cover the entire first surface of the emission treatment component.
[0039] FIG. 1c is a schematic diagram of a cross-sectional view of the support structure 102 and the substrate 104 of the emission treatment component of FIGS. 1a and 1b.
[0040] FIG. 2a is a schematic diagram of a top view of a support structure and a substrate 204 of an emission treatment component. The support structure comprises a first support structure portion 202a, a metallic element 208 and a second support structure portion 202b. The metallic element 208 is located, e.g., sandwiched, in-between the first and second support structure portions 202. The support structure 202 circumferentially surrounds the substrate 204 of the emission treatment component in a continuous manner, such that a first surface of the first support structure portion 202b is in contact with a first surface of the substrate 204 of the emission treatment component. The depicted support structure 102 comprises a continuous metallic mesh. An optional electrical input 106 is coupled to the mesh and is used for applying an electrical current to the metallic elements, in use. An optional electrical input 206 is coupled to the mesh and is used for applying an electrical current to the mesh, and hence generating heat, in use. In use, the generated heat is used to increase the temperature of the emission treatment component, thereby increasing the efficiency of the emission treatment component.
[0041] FIG. 2b is a schematic diagram of a side view of the support structure 202 and the substrate 204 of the emission treatment component of FIG. 2a. As can been seen, the substrate 204 of the emission treatment component may extend away from the support structure 202 in a first direction and in an opposing second direction, such that the support structure 202 does not cover the entire first surface of the emission treatment component.
[0042] FIG. 2c is a schematic diagram of a cross-sectional view of the support structure 202 and the substrate 204 of the emission treatment component of FIGS. 2a and 2b.
[0043] FIG. 3 is a schematic diagram of a support structure and an emission treatment component being inserted into a part of an exhaust system. In use, the emission treatment component 304 is surrounded by a support structure 302. The support structure 302 and the emission treatment component 304 are placed in a structure 306 in the exhaust system, such as a can. The can contains and directs exhaust gases over and/or through the emission treatment component 304.
[0044] FIG. 4a is a schematic diagram showing a cross-sectional view of a support structure comprising a plurality of continuous metal elements arranged in a regular pattern. The support structure 402a comprises metallic elements 404a. The metallic elements are arranged in a regular pattern, e.g., a pattern that repeats at regular intervals and/or has at least one order of symmetry. Although hexagons are shown in FIG. 4a, the regular pattern may be any regular geometric shape or any other regular pattern. The metallic elements are arranged in a continuous manner as the pattern extends without a break from a first point/area in the support structure to a second point/area in the support structure. The support structure may comprise one or more patterns that are continuous. In some examples, the metallic elements may be arranged in a plurality of discrete patterns of metallic elements. For example, the support structure 402a may comprise a plurality of patterns of metallic elements 404a that do not touch one another.
[0045] FIG. 4b is a schematic diagram showing a cross-sectional view of a support structure comprising a plurality of metal filings arranged in a continuous regular pattern. The support structure 402b comprises metallic filings 404b. The metal filings are arranged in a regular pattern. Although a particular pattern is shown in FIG. 4b, the regular pattern may be any regular geometric shape or any other regular pattern. The metallic filings are arranged in a continuous manner as the pattern extends without a break from a first point/area in the support structure to a second point/area in the support structure. The support structure may comprise one or more patterns that are continuous (e.g., not every metal filing needs to be connected to or touching every other metal filing).
[0046] FIG. 4c is a schematic diagram showing a cross-sectional view of a support structure comprising a plurality of continuous metal elements arranged in an irregular pattern. The support structure 402c comprises metallic elements 404c. The metal elements are arranged in an irregular pattern. An irregular manner is one that forms no obvious pattern and/or does not (intentionally) have any order of symmetry. The metallic elements are arranged in a continuous manner as the irregular pattern extends without a break from a first point/area in the support structure to a second point/area in the support structure. The support structure may comprise one or more patterns that are continuous (e.g., not every metal element needs to be connected to or touching every other metal element).
[0047] FIG. 4d is a schematic diagram showing a cross-sectional view of a support structure comprising a plurality of continuous metal elements arranged in an irregular pattern. The support structure 402d comprises metal filings 404d. The metal filings are arranged in an irregular pattern. The metallic filings are arranged in a continuous manner as the irregular pattern extends without a break from a first point/area in the support structure to a second point/area in the support structure. The support structure may comprise one or more patterns that are continuous (e.g., not every metal filing needs to be connected to or touching every other metal filing).
[0048] FIG. 4e is a schematic diagram showing a cross-sectional view of a support structure comprising a continuous mesh. The support structure 402e comprises a metal mesh 404e.
[0049] FIG. 4f is a schematic diagram showing a cross-sectional view of a continuous mesh that is attached to a surface of the support structure. A first surface of the support structure 402f has a metal mesh 404e attached to it.
[0050] FIG. 5 describes a method 500 of heating an emission treatment component of an exhaust system. At 502, a support structure for the emission treatment component is provided, the support structure comprising an insulating layer configured to support a substrate of the emission treatment component within a housing, and one or more resistive heating metal elements. At 504, an electrical current is applied through the one or more resistive metal elements.
[0051] FIG. 6 shows a schematic diagram of a vehicle 600 having an exhaust system 604 attached to an engine 606. The exhaust system 604 takes exhaust gases away from the engine 606 and comprises a housing 602 containing a support structure and a substrate of an emission treatment component. The support structure supports the substrate of the emission treatment component. The support structure may be as described above.
[0052] The processes described above are intended to be illustrative and not limiting. One skilled in the art would appreciate that the steps of the processes discussed herein may be omitted, modified, combined, and/or rearranged, and any additional steps may be performed without departing from the scope of the disclosure. More generally, the above disclosure is meant to be exemplary and not limiting. Furthermore, it should be noted that the features and limitations described in any one embodiment and/or example may be applied to any other embodiment and/or example herein, and flowcharts or examples relating to one embodiment and/or example may be combined with any other embodiment and/or example in a suitable manner, done in different orders, or done in parallel. In addition, the systems and methods described herein may be performed in real time. It should also be noted that the systems and/or methods described above may be applied to, or used in accordance with, other systems and/or methods.
