After-Treatment System

Abstract

An after-treatment system includes a Selective Catalytic Reduction (SCR) catalyst or a similar aftertreatment unit or brick that may be inserted into the opened end of a sleeve. The aftertreatment brick includes a substrate matrix with catalytic material that extends between a first face and a second face. A mantle is disposed around the substrate matrix and extends between a first rim proximate the first face and a second rim proximate the second face. The mantle may include a overhang extension that extends the first rim of the mantle beyond the first face of the substrate matrix. To enable retrieval of the SCR catalyst from the sleeve, a retrieval feature is disposed on a readily accessible, inner surface of the overhang extension.

We claim: 
     
         1 . An aftertreatment brick for removable insertion into a sleeve disposed in an aftertreatment module, the aftertreatment brick configured as a flow-through device and further comprising:
 a substrate matrix extending between a first face and an opposed second face, the substrate matrix configured as a flow-through device for the catalytic conversion of exhaust gases flowing from the first face to the second face;   a tubular mantle disposed around the substrate matrix, the mantle extending between an open first rim proximate the first face and an open second rim proximate the second face, the mantle including an overhang extension extending the first rim beyond the first face; and   a retrieval feature disposed on an inner surface of the overhang extension, the retrieval feature enabling retrieval of the aftertreatment brick from the sleeve.   
     
     
         2 . The aftertreatment brick of  claim 1 , wherein the substrate matrix is cylindrical and the first face and the second face are circular; and wherein the tubular mantle is disposed around the cylindrical substrate matrix so that the first rim and the second rim are circular. 
     
     
         3 . The aftertreatment brick of  claim 2 , wherein the retrieval feature is a slot radially disposed in the inner surface of the overhang extension of the tubular mantle, the slot adapted to engage a retrieval tool enabling retrieval of the aftertreatment brick from the sleeve. 
     
     
         4 . The aftertreatment brick of  claim 3 , wherein the slot is an elongated and narrow slot radially disposed in the overhang extension between the first face of the substrate matrix and the first rim of the mantle. 
     
     
         5 . The aftertreatment brick of  claim 2 , where the retrieval feature includes a first slot and a second slot each radially disposed into the inner surface of the overhang extension and diametrically opposed to each other. 
     
     
         6 . The aftertreatment brick of  claim 5 , wherein the retrieval tool is an inverted tong having a first leg and a second leg pivotally joined together to articulate with respect to each other, the retrieval tool further including a first rib formed at a first distal end of the first leg and a second rib formed at a second distal end of the second leg, the first and second ribs configured to be received in the respective first and second slots when the first and second legs are articulated. 
     
     
         7 . The aftertreatment brick of  claim 3 , wherein the slot is laser-cut completely through the overhang extension. 
     
     
         8 . The aftertreatment brick of  claim 2 , wherein the retrieval feature includes a pocket-like catch disposed on and protruding radially inward from the inner surface of the overhang extension, the pocket-like catch defining an inner pocket directed away from the first rim. 
     
     
         9 . The aftertreatment brick of  claim 8 , wherein the pocket-like catch is configured to receive in the inner pocket a hook-like catch disposed on a retrieval tool inserted in the first rim. 
     
     
         10 . The aftertreatment brick of  claim 2 , wherein the substrate matrix is a thin-walled lattice, honeycombed, or meshed structure and the tubular mantle is a relatively thicker sheet metal material. 
     
     
         11 . A method of servicing an aftertreatment module comprising:
 providing an aftertreatment module including at least one sleeve extending between an upstream end and a downstream end along a longitudinal axis, the at least one sleeve including an axially aligned opening formed at the upstream end;   providing a first aftertreatment brick including:
 (i) a substrate matrix configured for catalytic conversion of exhaust gasses and configured as a flow-through device between a first face and an opposing second face, 
 (ii) a tubular mantle disposed around the substrate matrix and extending between an opened first rim proximate the first face and an opened second rim proximate the second face, the tubular mantle including an overhang extension extending the first rim beyond the first face, and 
 (iii) a retrieval feature disposed on an inner surface of the overhang extension; 
   accommodating the first aftertreatment brick in the at least one sleeve, the first aftertreatment brick axially aligned along the longitudinal axis; and   retrieving the first aftertreatment brick from the at least one sleeve by engaging the retrieval feature and removing the first aftertreatment brick through the opening of the at least one sleeve.   
     
     
         12 . The method of  claim 11 , wherein the retrieval feature is a slot radially disposed in the inner surface of the overhang extension between the first face of the substrate matrix and the first rim of the tubular mantle. 
     
     
         13 . The method of  claim 12 , wherein the step of retrieving includes receiving a retrieval tool into the slot to pull the first aftertreatment brick from the at least one sleeve. 
     
     
         14 . The method of  claim 11 , wherein the retrieval feature includes a first slot and a second slot radially disposed into the inner surface of the overhang extension between the first face and the first rim, the first slot and the second slot diametrically opposed to each other. 
     
     
         15 . The method of  claim 14 , further comprising providing a retrieval tool in the form of a inverted tong including a first leg and a second leg pivotally joined to articulate with respect to each other, the first leg including a first rib at a first distal end and the second leg including a second rib at a second distal end. 
     
     
         16 . The method of  claim 15 , wherein the step of retrieving includes inserting the retrieval tool into the first rim and articulating the first and second legs to engage the first and second ribs with the respective first and second slots radially disposed in the overhang extension. 
     
     
         17 . The method of  claim 11 , wherein the retrieval feature includes a pocket-like catch disposed onto an inner surface of the overhang extension between the first face and the first rim, the pocket-like catch defining an inner pocket directed away from the first rim. 
     
     
         18 . The method of  claim 17 , wherein the step of retrieving includes inserting a hook-like retrieval tool into the first rim and engaging the hook-like retrieval tool with the pocket-like catch.