Exhaust gas treatment device with insulated housing construction

• US 20070119156A1
• Filed: 11/30/2005
• Published: 05/31/2007
• Est. Priority Date: 11/30/2005
• Status: Active Grant

• Current Assignee: Benteler Automotive Corporation (Benteler International AG)
• Original Assignee: Benteler Automotive Corporation (Benteler International AG)
• Inventors: Hill, Frederick, Studabaker, John, Schneemann, Brad, Salmonowicz, Joseph
• Granted Patent: US 7,765,801 B2
• Time in Patent Office: Days
• US Class Current: 60/302
• CPC Class Codes: F01N 13/008 Mounting or arrangement of exhaust sensors in or on exhaust apparatus sensor arrangements for engine control F02D41/1439
• CPC Class Codes: F01N 13/0097 the purifying devices are arranged in a single housing
• CPC Class Codes: F01N 13/14 having thermal insulation exhaust manifolds F01N13/102
• CPC Class Codes: F01N 13/1894 the parts being assembled in longitudinal direction
• CPC Class Codes: F01N 2450/22 by welding or brazing
• CPC Class Codes: F01N 3/2853 using mats or gaskets between catalyst body and housing
• CPC Class Codes: Y10T 29/49345 Catalytic device making
• CPC Class Codes: Y10T 29/49361 Tube inside tube
• CPC Class Codes: Y10T 29/49398 Muffler, manifold or exhaust pipe making
• CPC Class Codes: Y10T 29/49861 Sizing mating parts during final positional association
• CPC Class Codes: Y10T 29/49879 Spaced wall tube or receptacle
• CPC Class Codes: Y10T 29/49893 Peripheral joining of opposed mirror image parts to form a hollow body
• CPC Class Codes: Y10T 29/49904 Assembling a subassembly, then assembling with a second subassembly
• CPC Class Codes: Y10T 29/49909 Securing cup or tube between axially extending concentric annuli
• CPC Class Codes: Y10T 29/49915 Overedge assembling of seated part
• CPC Class Codes: Y10T 29/49927 Hollow body is axially joined cup or tube
• CPC Class Codes: Y10T 29/49968 Metal fusion joining

Abstract

An exhaust gas treatment device for internal combustion engines and the like includes inlet and outlet end caps, two catalyst substrates, and a two-piece housing. A first, cylindrically-shaped housing member has a hollow interior in which one of the substrates is retained, a first end sealingly connected with the inlet end cap, and an opposite second end with a radially reduced section. A second cylindrically-shaped housing member has a hollow interior in which the other one of the substrates is retained, a first end sealingly connected with the outlet end cap, and an opposite second end with a radially enlarged section sized to receive therein the second end of the first housing member, whereby the reduced section of the first housing member and the enlarge section of the second housing member are spaced radially apart a predetermined distance to define an annularly-shaped space or gap which thermally insulates the associated portion of the exhaust gas treatment device.

Claims

1. An exhaust gas treatment device for internal combustion engines and the like, comprising:

an inlet end cap configured for communication with incoming exhaust gas;

an outlet end cap configured for communication with exiting exhaust gas;

first and second substrates adapted to treat exhaust gas flowing through said exhaust gas treatment device;

a gas sensor adapted to measure at least one characteristic of exhaust gas flowing through said exhaust gas treatment device;

a cylindrically-shaped first housing member having a hollow interior receiving and retaining therein said first substrate, a first end thereof operably connected with said inlet end cap to form an airtight seal therebetween, and an opposite second end thereof with a radially reduced section having a first radially extending aperture configured to receive a portion of said gas sensor therethrough; and

a cylindrically-shaped second housing member having an interior receiving and retaining therein said second substrate, a first end thereof operably connected with said outlet end cap to form an airtight seal therebetween, and an opposite second end thereof with a radially enlarged section having a second radially extending aperture aligned with said first aperture, and configured to receive a portion of said gas sensor therethrough;

said enlarged section being sized to receive said second end of said first housing member therein to form an airtight seal therebetween, whereby said reduced section of said first housing member and said enlarged section of said second housing member are spaced radially apart a predetermined distance to define therebetween an annularly-shaped space which thermally insulates an associated portion of said exhaust gas treatment device.

2. An exhaust gas treatment device as set forth in claim 1, including:

an insulator mat disposed within and extending around at least a portion of said annularly-shaped space for improved thermal insulation.

3. An exhaust gas treatment device as set forth in claim 2, including:

a first support mat disposed between an exterior surface of said second substrate and an interior surface of said second housing member and extending around the same to support said second substrate.

4. An exhaust gas treatment device as set forth in claim 3, wherein:

said reduced section has an outer edge portion thereof abuttingly engaging said first support mat to form a seal therebetween.

5. An exhaust gas treatment device as set forth in claim 4, including:

a second support mat disposed between an exterior surface of said first substrate and an interior surface of said first housing member and extending about the same to support said first substrate.

6. An exhaust gas treatment device as set forth in claim 5, including:

a boss rigidly connected with said enlarged section of said second housing member, and including a threaded aperture therein, which is radially aligned with said first and second apertures, and shaped to removably retain said gas sensor therein.

7. An exhaust gas treatment device as set forth in claim 5, including:

a weld extending between an outer edge portion of said enlarged section on said first housing member and said second end of said first housing member to define said airtight seal therebetween.

8. An exhaust gas treatment device as set forth in claim 7, wherein:

said weld defines a first weld; and

including

a second weld extending between an upper edge of said outlet end cap and said first end of said second housing member to define said airtight seal therebetween.

9. An exhaust gas treatment device as set forth in claim 8, including:

a third weld extending between a lower edge of said inlet end cap and said first end of said first housing member to define said airtight seal therebetween.

10. An exhaust gas treatment device as set forth in claim 9, wherein:

said outlet end cap has a dual wall construction defined at least in part by first and second radially spaced apart walls.

11. An exhaust gas treatment device as set forth in claim 10, including:

a second insulator mat disposed between said first and second walls of said outlet end cap.

12. An exhaust gas treatment device as set forth in claim 11, wherein:

said second wall of said outlet end cap has an edge portion thereof abuttingly engaging said second support mat to form a seal therebetween.

13. An exhaust gas treatment device as set forth in claim 12, wherein:

said inlet end cap has a single wall, clamshell construction.

14. An exhaust gas treatment device as set forth in claim 13, including:

an annularly-shaped insulator ring disposed in said space in a radially aligned relationship with said first and second apertures, and receiving a portion of said gas sensor therethrough to insulate the same.

15. An exhaust gas treatment device as set forth in claim 14, wherein:

said gas sensor defines a first gas sensor; and

including

a second gas sensor mounted on said inlet end cap, and extending into an interior portion thereof to measure at least one characteristic of exhaust gas flowing into said exhaust gas treatment device.

16. An exhaust gas treatment device as set forth in claim 15, wherein:

said inlet end cap includes an aperture configured to receive a portion of said second gas sensor therethrough.

17. An exhaust gas treatment device as set forth in claim 16, wherein:

said boss defines a first boss; and

including

a second boss rigidly connected with said inlet end cap, and including a threaded aperture therein, which is aligned with said aperture in said inlet end cap, and shaped to removably retain said second gas sensor therein.

18. An exhaust gas treatment device as set forth in claim 1, including:

a support mat disposed between an exterior surface of said second substrate and an interior surface of said second housing member and extending around the same to support said second substrate; and

wherein

said reduced section has an outer edge portion thereof abuttingly engaging said support mat to form a seal therebetween.

19. An exhaust gas treatment device as set forth in claim 1, including:

a boss rigidly connected with said enlarged section of said second housing member, and including a threaded aperture therein, which is radially aligned with said first and second apertures, and shaped to removably retain said gas sensor therein.

20. A maniverter for vehicles having an internal combustion engine, comprising:

an exhaust manifold configured for operative connection with the internal combustion engine to route exhaust gas therefrom;

an inlet end cap operatively connected with said exhaust manifold, and communicating with incoming exhaust gas;

an outlet end cap adapted for operative connection with an exhaust pipe portion of the vehicle, and communicating with exiting exhaust gas;

first and second substrates adapted to treat exhaust gas flowing through said maniverter;

a gas sensor adapted to measure at least one characteristic of exhaust gas flowing through said maniverter;

a cylindrically-shaped first housing member having a hollow interior receiving and retaining therein said first substrate, a first end thereof operably connected with said inlet end cap to form an airtight seal therebetween, and an opposite second end thereof with a radially reduced section having a first radially extending aperture configured to receive a portion of said gas sensor therethrough; and

a cylindrically-shaped second housing member having an interior receiving and retaining therein said second substrate, a first end thereof operably connected with said outlet end cap to form an airtight seal therebetween, and an opposite second end thereof with a radially enlarged section having a second radially extending aperture aligned with said first aperture, and configured to receive a portion of said gas sensor therethrough;

said enlarged section being sized to receive said second end of said first housing member therein to form an airtight seal therebetween, whereby said reduced section of said first housing member and said enlarged section of said second housing member are spaced radially apart a predetermined distance to define therebetween an annularly-shaped space which thermally insulates an associated portion of said maniverter.

21. A maniverter as set forth in claim 20, including:

an insulator mat disposed within and extending around at least a portion of said annularly-shaped space for improved thermal insulation.

22. A maniverter as set forth in claim 21, including:

a first support mat disposed between an exterior surface of said second substrate and an interior surface of said second housing member and extending around the same to support said second substrate.

23. A maniverter as set forth in claim 22, wherein:

said reduced section has an outer edge portion thereof abuttingly engaging said first support mat to form a seal therebetween.

24. A maniverter as set forth in claim 23, including:

a second support mat disposed between an exterior surface of said first substrate and an interior surface of said first housing member and extending about the same to support said first substrate.

25. A maniverter as set forth in claim 24, including:

a boss rigidly connected with said enlarged section of said second housing member, and including a threaded aperture therein, which is radially aligned with said first and second apertures, and shaped to removably retain said gas sensor therein.

26. A maniverter as set forth in claim 25, wherein:

said outlet end cap has a dual wall construction defined at least in part by first and second radially spaced apart walls; and

including

a second insulator mat disposed between said first and second walls of said outlet end cap.

27. A maniverter as set forth in claim 26, wherein:

said second wall of said outlet end cap has an edge portion thereof abuttingly engaging said first support mat to form a seal therebetween.

28. A maniverter as set forth in claim 27, wherein:

said inlet end cap has a single wall, clamshell construction.

29. A maniverter as set forth in claim 28, including:

an annularly-shaped insulator ring disposed in said space in a radially aligned relationship with said first and second apertures, and receiving a portion of said gas sensor therethrough to insulate the same.

30. An exhaust gas treatment device for internal combustion engines and the like,

comprising:

an inlet end cap configured for communication with incoming exhaust gas;

an outlet end cap configured for communication with exiting exhaust gas;

first and second substrates adapted to treat exhaust gas flowing through said exhaust gas treatment device;

a cylindrically-shaped first housing member having a hollow interior receiving and retaining therein said first substrate, a first end thereof operably connected with one of said inlet end cap and said outlet end cap to form an airtight seal therebetween, and an opposite second end thereof with a radially reduced section; and

a cylindrically-shaped second housing member having an interior receiving and retaining therein said second substrate, a first end thereof operably connected with the other of said inlet end cap and said outlet end cap to form an airtight seal therebetween, and an opposite second end thereof with a radially enlarged section being sized to receive said second end of said first housing member therein to form an airtight seal therebetween, whereby said reduced section of said first housing member and said enlarged section of said second housing member are spaced radially apart a predetermined distance to define therebetween an annularly-shaped space which thermally insulates an associated portion of said exhaust gas treatment device.

31. An exhaust gas treatment device as set forth in claim 30, including:

an insulator mat disposed within and extending around at least a portion of said annularly-shaped space for improved thermal insulation.

32. An exhaust gas treatment device as set forth in claim 31, including:

a first support mat disposed between an exterior surface of said second substrate and an interior surface of said second housing member and extending around the same to support said second substrate.

33. An exhaust gas treatment device as set forth in claim 32, wherein:

said reduced section has an outer edge portion thereof abuttingly engaging said first support mat to form a seal therebetween.

34. An exhaust gas treatment device as set forth in claim 33, including:

a second support mat disposed between an exterior surface of said first substrate and an interior surface of said first housing member and extending about the same to support said first substrate.

35. An exhaust gas treatment device as set forth in claim 34, wherein:

said outlet end cap has a dual wall construction defined at least in part by first and second radially spaced apart walls.

36. An exhaust gas treatment device as set forth in claim 35, including:

a second insulator mat disposed between said first and second walls of said outlet end cap.

37. An exhaust gas treatment device as set forth in claim 36, wherein:

said second wall of said outlet end cap has an edge portion thereof abuttingly engaging said first support mat to form a seal therebetween.

38. An exhaust gas treatment device as set forth in claim 37, wherein:

said inlet end cap has a single wall, clamshell construction.

39. An exhaust gas treatment device as set forth in claim 30, including:

a support mat disposed between an exterior surface of said second substrate and an interior surface of said second housing member and extending around the same to support said second substrate; and

wherein

said reduced section has an outer edge portion thereof abuttingly engaging said first support mat to form a seal therebetween.

40. A method for making an exhaust gas treatment device for internal combustion engines and the like, comprising:

forming an inlet end cap configured for communication with incoming exhaust gas;

forming an outlet end cap configured for communication with exiting exhaust gas;

providing first and second substrates adapted to treat exhaust gas flowing through the exhaust gas treatment device;

providing a gas sensor adapted to measure at least one characteristic of exhaust gas flowing through the exhaust gas treatment device;

forming a cylindrically-shaped first housing member with a hollow interior, a first end shaped for operable connection with the inlet end cap, a second end having a radially reduced section, and a first radially extending aperture configured to receive a portion of the gas sensor therethrough;

positioning the first substrate in the interior of the first housing member;

connecting the first end of the first housing member with the inlet end cap to form an airtight seal therebetween;

forming a cylindrically-shaped second housing member with a hollow interior, a first end shaped for operable connection with the outlet end cap, a second end having a radially enlarged section, and a second radially extending aperture configured to receive a portion of the gas sensor therethrough;

positioning the second substrate in the interior of the second housing member;

connecting the first end of the second housing member with the outlet end cap to form an airtight seal therebetween;

positioning the enlarged section at the second housing member telescopingly over the second end of the first housing member, such that the first and second apertures are radially aligned; and

forming an airtight seal between the enlarged section on the second housing member and the first housing member, whereby the reduced section of the first housing member and the enlarged section of the second housing member are spaced radially apart a predetermined distance to define therebetween an annularly-shaped space which thermally insulates an associated portion of the exhaust gas treatment device.

41. A method as set forth in claim 40, including:

forming an insulator mat; and

positioning the insulator mat within and extending around at least a portion of the annularly-shaped space for improved thermal insulation.

42. A method as set forth in claim 41, including:

forming a first support mat; and

positioning the first support mat between an exterior surface of the second substrate and an interior surface of the second housing member and extending around the same to support the second substrate.

43. A method as set forth in claim 42, including:

positioning an outer edge portion of the reduced section abuttingly against the first support mat to form a seal therebetween.

44. A method as set forth in claim 43, including:

forming a second support mat; and

positioning the second support mat between an exterior surface of the first substrate and an interior surface of the first housing member and extending about the same to support the first substrate.

45. A method as set forth in claim 44, including:

providing a boss with a threaded aperture therethrough; and

rigidly connecting the boss with the enlarged section of the second housing member in a radially aligned relationship with the first and second apertures to removably retain the gas sensor therein.

46. A method as set forth in claim 45, including:

forming a weld along an outer edge portion of the enlarged section on the first housing member and the second end of the first housing member to define the airtight seal therebetween.

47. A method as set forth in claim 46, including:

forming a second weld along an upper edge of the outlet end cap and the first end of the second housing member to define the airtight seal therebetween.

48. A method as set forth in claim 47, including:

forming a third weld along a lower edge of the inlet end cap and the first end of the first housing member to define the airtight seal therebetween.

49. A method as set forth in claim 48, including:

forming the outlet end cap with a dual wall construction defined in part by first and second radially spaced apart walls.

50. A method as set forth in claim 49, including:

forming a second insulator mat; and

positioning the second insulator mat between the first and second walls of the outlet end cap.

51. A method as set forth in claim 50, including:

positioning an edge portion of the second wall of the outlet end cap abuttingly against the first support mat to form a seal therebetween.

52. A method as set forth in claim 51, including:

forming the inlet end cap with a single wall, clamshell construction.

53. A method as set forth in claim 52, including:

positioning an annularly-shaped insulator ring in the space in a radially aligned relationship with the first and second apertures to receive a portion of the gas sensor therethrough to insulate the same.