Method for making two-piece catalytic converter with double wall mid-section

• US 8,302,306 B2
• Filed: 07/28/2010
• Issued: 11/06/2012
• 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 B. Jr., Salmonowicz, Joseph G. Jr., Schneemann, Brad M., Studabaker, John C.
• Primary Examiner(s): Afzali, Sarang
• Application Number:
  US12/844,890
• Publication Number:
  US 20100307001A1
• Time in Patent Office: 832 Days
• Field of Search: 298/90, 298/900.36, 298/900.8, 294/45, 294/551, 294/64, 294/69, 295/06, 295/09, 295/16, 295/251.4, 602/74, 602/76, 603/02, 602/99, 603/07, 422/171, 422/172, 422/177, 422/179, 422/180
• US Class Current: 29/890
• 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 enlarged section of the 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. A method for making an exhaust gas treatment device for internal combustion engines, 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 of 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.

2. A method as set forth in claim 1, 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.

3. A method as set forth in claim 2, 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.

4. A method as set forth in claim 3, including:

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

5. A method as set forth in claim 4, 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.

6. A method as set forth in claim 5, 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.

7. A method as set forth in claim 6, 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.

8. A method as set forth in claim 7, 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.

9. A method as set forth in claim 8, 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.

10. A method as set forth in claim 9, including:

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

11. A method as set forth in claim 10, including:

forming a second insulator mat; and

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

12. A method as set forth in claim 11, 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.

13. A method as set forth in claim 12, including:

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

14. A method as set forth in claim 13, 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.

15. A method for making an exhaust gas treatment device for internal combustion engines, 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 one of the inlet end cap and the outlet 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 one of the inlet end cap and the outlet 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 other of the inlet end cap and 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 other of the inlet end cap and the outlet end cap to form an airtight seal therebetween;

positioning the enlarged section of 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.

16. A method as set forth in claim 15, 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.

17. A method as set forth in claim 16, 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.

18. A method as set forth in claim 17, including:

positioning an outer edge portion of the reduced section adjacent to the first support mat to at least partially close off said annularly-shaped space.

19. A method as set forth in claim 18, 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.

20. A method as set forth in claim 19, 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.