Mounting mat for a pollution control element or a chemical reactor

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 ( 2 f ), a rear face ( 2 r ) and at least three flat side faces ( 4 ) extending between the front ( 2 f ) and the rear face ( 2 r ), 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 ).

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.