USE OF INSULATING PAINT ON EXHAUST AFTERTREATMENT SYSTEM COMPONENTS

• US 20160215675A1
• Filed: 01/19/2016
• Published: 07/28/2016
• Est. Priority Date: 01/22/2015
• Status: Active Grant

• Current Assignee: Cummins Emission Solutions Inc.
• Original Assignee: Cummins Emission Solutions Inc.
• Inventors: Muruganantham, Karthik
• Granted Patent: US 10,508,584 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B01D 2251/2062 Ammonia
• CPC Class Codes: B01D 2255/2047 Magnesium
• CPC Class Codes: B01D 2255/20715 Zirconium
• CPC Class Codes: B01D 2255/20753 Nickel
• CPC Class Codes: B01D 2255/2092 Aluminium
• CPC Class Codes: B01D 2258/012 Diesel engines and lean burn gasoline engines
• CPC Class Codes: B01D 2258/018 Natural gas engines
• CPC Class Codes: B01D 53/9418 for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas
• CPC Class Codes: B01D 53/944 Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts three-way-catalysts [TWC] B01D53/9445
• CPC Class Codes: B01D 53/9477 with catalysts positioned on separate bricks, e.g. exhaust systems
• CPC Class Codes: F01N 13/14 having thermal insulation exhaust manifolds F01N13/102
• CPC Class Codes: F01N 2510/02 for thermal insulation
• CPC Class Codes: F01N 2610/02 the substance being ammonia or urea
• CPC Class Codes: F01N 2610/1453 Sprayers or atomisers; Arrangement thereof in the exhaust apparatus
• CPC Class Codes: F01N 3/021 by means of filters
• CPC Class Codes: F01N 3/2066 Selective catalytic reduction [SCR]
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

An apparatus includes an exhaust aftertreatment component. According to various embodiments, the exhaust aftertreatment component is any of a diesel oxidation catalyst, a diesel particulate filter, a decomposition reactor tube, a selective catalytic reduction device, and a reductant injector assembly. The apparatus also includes a ceramic thermal barrier coating applied to a surface of the exhaust aftertreatment component. The surface may, for example, be an outer wall of a housing of the exhaust aftertreatment component.

Claims

1. An apparatus, comprising:

an exhaust aftertreatment component; and

a ceramic thermal barrier coating applied to a surface of the exhaust aftertreatment component.

2. The apparatus of claim 1, wherein the exhaust aftertreatment component is an oxidation catalyst.

3. The apparatus of claim 1, wherein the exhaust aftertreatment component is a particulate filter.

4. The apparatus of claim 1, wherein the exhaust aftertreatment component is a decomposition reactor tube.

5. The apparatus of claim 1, wherein the exhaust aftertreatment component is a selective catalytic reduction device.

6. The apparatus of claim 1, wherein the surface is an outer wall of a housing of the exhaust aftertreatment component.

7. The apparatus of claim 1, wherein the exhaust aftertreatment component is a reductant injector assembly.

8. The apparatus of claim 7, wherein the surface includes a mounting plate of the reductant injector assembly, the mounting plate configured to mount the exhaust aftertreatment component to a decomposition reactor tube.

9. The apparatus of claim 8, wherein the surface includes only an external surface of the mounting plate.

10. The apparatus of claim 7, wherein the surface is an insulating gasket of the reductant injector assembly, the insulating gasket positioned between a mounting plate of the reductant injector assembly and a decomposition reactor tube.

11. The apparatus of claim 7, wherein the surface is a leg of an injector of the reductant injector assembly.

12. A method, comprising:

providing a part to be assembled in an exhaust aftertreatment component;

coating the part with a ceramic thermal barrier coating; and

assembling the exhaust aftertreatment component such that the exhaust aftertreatment component includes the coated part.

13. The method of claim 12, wherein the exhaust aftertreatment component is a particulate filter.

14. The method of claim 12, wherein the exhaust aftertreatment component is a decomposition reactor tube.

15. The method of claim 12, wherein the exhaust aftertreatment component is a selective catalytic reduction device.

16. The method of claim 15, wherein a housing of the exhaust aftertreatment component is coated by the ceramic thermal barrier coating.

17. The method of claim 12, wherein the exhaust aftertreatment component is a reductant injector assembly.

18. The method of claim 17, wherein a mounting plate of the reductant injector assembly is coated with the ceramic thermal barrier coating, the mounting plate configured to mount the exhaust aftertreatment component to a decomposition reactor tube.

19. The method of claim 18, wherein only an external surface of the mounting plate is coated by the ceramic thermal barrier coating.

20. The method of claim 19, wherein an insulating gasket of the reductant injector assembly is coated by the ceramic thermal barrier coating, the insulating gasket to be positioned between a mounting plate of the reductant injector assembly and a decomposition reactor tube.

21. The method of claim 18, wherein a leg of the injector of the reductant injector assembly is coated by the ceramic thermal barrier coating.

22. An aftertreatment system, comprising:

an oxidation catalyst;

a particulate filter positioned downstream of the oxidation catalyst;

a decomposition reactor tube positioned downstream of the particulate filter;

a reductant injector assembly operatively coupled to the decomposition reactor tube; and

a selective catalytic reduction device positioned downstream of the decomposition reactor tube, the selective catalytic reduction device including a catalyst formulated to decompose NOx gases included in an exhaust gas flowing through the aftertreatment system,

wherein a ceramic thermal barrier coating is applied to at least one of the oxidation catalyst, the particulate filter, the reductant injector assembly and the selective catalytic reduction device.

23. The aftertreatment system of claim 22, wherein the reductant injector assembly comprises:

a reductant injector; and

a mounting plate coupled to the decomposition reactor tube, the reductant injector positioned on the mounting plate,

wherein a top surface of the mounting plate on which the reductant injector is positioned is coated with the ceramic thermal barrier coating.

24. The aftertreatment system of claim 23, wherein the reductant injector assembly further comprises:

an insulating gasket positioned between the reductant injector and the mounting plate, the insulating gasket coated with the ceramic thermal barrier coating.

25. The aftertreatment system of claim 23, wherein the reductant injector comprises:

a body positioned on the mounting plate; and

a top cover attached to the body,

wherein at least a portion of the body is coated with the ceramic thermal barrier coating.

26. The aftertreatment system of claim 22, wherein the oxidation catalyst comprises a diesel oxidation catalyst.