PROCESS FOR MANUFACTURING AN EXHAUST GAS TREATMENT DEVICE

• US 20200131975A1
• Filed: 10/24/2019
• Published: 04/30/2020
• Est. Priority Date: 10/25/2018
• Status: Active Grant

• Current Assignee: Purem GmbH
• Original Assignee: Eberspacher Exhaust Technology GmbH
• Inventors: REYER, Bernhard, MULLER, Bernd, HABERLE, Jurgen, HARTMANN, Sylvia, KRAUSE, Michael
• Granted Patent: US 11,274,593 B2
• Time in Patent Office: Days
• CPC Class Codes: F01N 13/18 Construction facilitating manufacture, assembly, or disassembly
• CPC Class Codes: F01N 13/1805 Fixing exhaust manifolds, exhaust pipes or pipe sections to each other, to engine or to vehicle body pipe joints in general F16L; fixing auxiliaries in motor vehicles in general B60K
• CPC Class Codes: F01N 13/185 the connection being realised by deforming housing, tube, baffle, plate, or parts thereof
• CPC Class Codes: F01N 13/1888 the housing of the assembly consisting of two or more parts, e.g. two half-shells
• CPC Class Codes: F01N 13/1894 the parts being assembled in longitudinal direction
• CPC Class Codes: F01N 2330/04 Methods of manufacturing
• CPC Class Codes: F01N 2450/02 Fitting monolithic blocks into the housing
• CPC Class Codes: F01N 2450/22 by welding or brazing
• CPC Class Codes: F01N 3/021 by means of filters
• CPC Class Codes: F01N 3/0211 Arrangements for mounting filtering elements in housing, e.g. with means for compensating thermal expansion or vibration
• CPC Class Codes: F01N 3/2853 using mats or gaskets between catalyst body and housing
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

A process manufactures an exhaust gas treatment device including a tubular circumferential wall (14) elongated along a longitudinal axis (L) with two axial end areas, an exhaust gas treatment unit (52) arranged in the circumferential wall and a closing element (20, 38) connected to the circumferential wall at the two axial end areas. The exhaust gas treatment unit is held at the circumferential wall by a supporting material layer (54) enclosing the exhaust gas treatment unit and supporting same in relation to the circumferential wall. The process includes arranging a first of the two closing elements at one of the axial end areas of the circumferential wall, pushing the exhaust gas treatment unit enclosed by the supporting material layer into the circumferential wall from the other axial end area (18), and arranging a second of the closing elements at the other axial end area of the circumferential wall.

Claims

1. A process for manufacturing an exhaust gas treatment device comprising a tubular circumferential wall elongated in the direction of a longitudinal axis with two axial end areas, an exhaust gas treatment unit arranged in a tubular space within the circumferential wall and closing elements, with each of the closing elements connected to the circumferential wall at one of the two axial end areas, wherein the exhaust gas treatment unit is held at the circumferential wall by a supporting material layer, which encloses the exhaust gas treatment unit and supports same in relation to the circumferential wall, wherein the process comprises the steps of:

arranging a first of the two closing elements at one of the axial end areas of the circumferential wall;

subsequent to said step of arranging, pushing, at the other axial end area of the circumferential wall, the exhaust gas treatment unit, enclosed by the supporting material layer, into the tubular space within the circumferential wall; and

subsequent to said step of pushing, arranging a second of the closing elements at the other axial end area of the circumferential wall.

2. A process in accordance with claim 1, wherein:

the first closing element has a first closing element tubular circumferential wall connection area;

the first closing element tubular circumferential wall connection area is pushed, during said step of pushing, onto the tubular circumferential wall such that the first closing element tubular circumferential wall connection area extends around an one axial end area of the tubular circumferential wall radially on an outside and is connected to the tubular circumferential wall by a connection in substance.

3. A process in accordance with claim 1, wherein with the step of arranging a first of the two closing elements at one of the axial end areas of the circumferential wall, the circumferential wall is deformed with a radial widening, to provide a desired dimension after mounting the first closing element at the circumferential wall.

4. A process in accordance with claim 2, wherein with the step of pushing:

the exhaust gas treatment unit enclosed with the supporting material layer is pushed into the circumferential wall to an extent that the supporting material layer extends in an axial area of the connection in substance of the first closing element to the circumferential wall;

or

the exhaust gas treatment unit enclosed with the supporting material layer is pushed into the circumferential wall to an extent that the supporting material layer extends axially to overlap the circumferential wall connection area of the first closing element;

or

the exhaust gas treatment unit enclosed with the supporting material layer is pushed into the circumferential wall to an extent that the supporting material layer extends in an axial area of the connection in substance of the first closing element to the circumferential wall and to an extent that the supporting material layer extends axially to overlap the circumferential wall connection area of the first closing element.

5. A process in accordance with claim 1, wherein with the step of pushing the exhaust gas treatment unit enclosed with the supporting material layer is pushed into the circumferential wall to the extent that the exhaust gas treatment unit does not extend beyond the one axial end area of the circumferential wall.

6. A process in accordance with claim 5, wherein with the step of pushing the exhaust gas treatment unit enclosed with the supporting material layer is pushed into the circumferential wall to the extent that the exhaust gas treatment unit ends essentially flush with an end of the circumferential wall.

7. A process in accordance with claim 1, wherein with the step of pushing the exhaust gas treatment unit enclosed with the supporting material layer is pushed into the circumferential wall to the extent that the exhaust gas treatment unit extends beyond the one axial end area of the circumferential wall into a closing element interior space formed in the first closing element.

8. A process in accordance with claim 7, wherein the exhaust gas treatment unit is not enclosed by the supporting material layer in an exhaust gas treatment unit length area extending into the closing element interior space.

9. A process in accordance with claim 1, wherein with the step of arranging a second of the closing elements at the other axial end area of the circumferential wall, a tubular circumferential wall connection area of the second closing element is pushed into the other axial end area of the circumferential wall and is connected to the circumferential wall by connection in substance.

10. A process in accordance with claim 1, wherein at least one closing element comprises a funnel-like tapering area between a tubular circumferential wall connection area and a tubular exhaust gas pipe connection area.

11. A process in accordance with claim 1, wherein the first closing element is provided as an inlet closing element positioned upstream in relation to the circumferential wall in relation to an exhaust gas flow direction.

12. A process in accordance with claim 1, wherein a closing element interior space formed in the first closing element does not have an inner funnel element therein, or/and an inner funnel element is arranged in a closing element interior space formed in the second closing element.

13. A process in accordance with claim 1, wherein after the step of arranging a first of the two closing elements at one of the axial end areas of the circumferential wall, the first closing element is enclosed with an insulating material layer and with a thin-wall insulation covering the insulating material layer on an outer side thereof.

14. A process in accordance with claim 1, wherein the supporting material layer comprises a fiber material mat wound around the outer circumference of the exhaust gas treatment unit.

15. A process in accordance with claim 1, wherein the exhaust gas treatment unit comprises a particle filter.

16. An exhaust gas treatment device comprising:

a tubular circumferential wall elongated in the direction of a longitudinal axis with two axial end areas;

a first closing element, which overlaps the circumferential wall radially on an outside with a circumferential wall connection area at one of the axial end areas of the circumferential wall and is fixed at the circumferential wall by a connection in substance;

a second closing element fixed at the circumferential wall at another of the axial end areas of the circumferential wall with a circumferential wall connection area by connection in substance;

a supporting material layer; and

an exhaust gas treatment unit enclosed with the supporting material layer and held by the supporting material layer at the circumferential wall, wherein;

the supporting material layer extends in the one axial end area of the circumferential wall in an axial area of the connection in substance of the first closing element to the circumferential wall or/and the supporting material layer axially overlaps the circumferential wall connection area of the first closing element;

or/and

the exhaust gas treatment unit extends beyond the one axial end area of the circumferential wall into a closing element interior space formed in the first closing element;

or/and

a closing element interior space formed in the first closing element does not have an inner funnel element.

17. An exhaust system, comprising an exhaust gas treatment device in accordance with claim 16, wherein the exhaust gas treatment device is formed by the steps of:

arranging a first of the two closing elements at one of the axial end areas of the circumferential wall;

subsequent to said step of arranging pushing, at the other axial end area of the circumferential wall, the exhaust gas treatment unit, enclosed by the supporting material layer, into the tubular space within the circumferential wall; and

subsequent to said step of pushing, arranging a second of the closing elements at the other axial end area of the circumferential wall.