Method of fabricating a catalyst converter

• US 6,598,294 B2
• Filed: 03/06/2002
• Issued: 07/29/2003
• Est. Priority Date: 03/21/2001
• Status: Active Grant

• Current Assignee: Calsonic Kansei Corporation
• Original Assignee: Calsonic Kansei Corporation
• Inventors: Nogami, Yasuhiro, Yamaguchi, Fumihisa
• Primary Examiner(s): ROSENBAUM, IRENE CUDA
• Application Number:
  US10/090,765
• Publication Number:
  US 20020133947A1
• Time in Patent Office: 510 Days
• Field of Search: 298/90, 295/57, 228/135, 228/151, 228/144, 228/173.4, 228/173.6, 219/653, 219/59.1, 219/61, 219/121.44, 219/121.64
• US Class Current: 29/890
• CPC Class Codes: F01N 13/1838 characterised by the type of connection between parts of exhaust or silencing apparatus, e.g. between housing and tubes, between tubes and baffles
• CPC Class Codes: F01N 13/1861 the assembly using parts formed by casting or moulding
• CPC Class Codes: F01N 2450/22 by welding or brazing
• CPC Class Codes: F01N 3/2842 specially adapted for monolithic supports, e.g. of honeycomb type F01N3/2853 - F01N3/2871 take precedence
• CPC Class Codes: Y10T 29/49345 Catalytic device making
• CPC Class Codes: Y10T 29/49995 Shaping one-piece blank by removing material

Abstract

A method of fabricating a catalyst converter includes the steps of: obtaining a tubular member by rolling up a metallic plate member of a rectangular shape having ear portions at four corners thereof such that opposing ones of the ear portions abut against each other, and by effecting butt welding for both ends of the plate member; cutting off projecting portions formed by the ear portions at both ends of a weld of the tubular member; incorporating a catalyst carrier into the tubular member with the projecting portions cut off; effecting drawing for both end portions of the tubular member with the catalyst carrier incorporated therein; and attaching a pair of flanges, respectively, to the both end portions of the tubular member subjected to drawing.

Claims

1. A method of fabricating a catalyst converter, characterized by comprising the steps of:

obtaining a tubular member by rolling up a metallic plate member of a rectangular shape having ear portions at four corners thereof such that opposing ones of said ear portions abut against each other, and by effecting butt welding for both ends of said plate member;

cutting off projecting portions formed by said ear portions at both ends of a weld of said tubular member;

incorporating a catalyst carrier into said tubular member with said projecting portions cut off;

effecting drawing for both end portions of said tubular member with said catalyst carrier incorporated therein; and

attaching a pair of flanges, respectively, to said both end portions of said tubular member subjected to drawing.

2. The method according to claim 1, wherein each of said projecting portions formed by said ear portions has a substantially trapezoidal shape.

3. The method according to claim 2, wherein the amount of projection of said ear portions is longer than a burn through portion formed in butt welding.