3/16/2017 PatentUS5909916MethodofmakingacatalyticconverterGooglePatents

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Methodofmakingacatalyticconverter Publicationnumber US5909916A

US5909916A Publicationtype Grant
Applicationnumber US08/932,713
Publicationdate 8Jun1999
ABSTRACT
Filingdate 17Sep1997
Prioritydate 17Sep1997
Amethodofmanufacturinganovalshapedcatalyticconverterthatreducesthe
Feestatus Lapsed
amountofmaterialandnumberofpartsthatarerequiredforpermittingthe
Alsopublishedas DE69810128D1,4More
catalyticconvertertotreattheexhaustgasesofaninternalcombustionengine
andalsoimprovesthestructuraldurabilityoftheconverterforhightemperature Inventors MichaelRalphFoster,4More

applicationsbymaintainingahighermatdensityalongtheminoraxisofthe OriginalAssignee GeneralMotorsCorporation

converterhousing. ExportCitation BiBTeX,EndNote,RefMan
PatentCitations(11),NonPatentCitations(4),Referencedby(39),
Classifications(10),LegalEvents(7)

ExternalLinks:USPTO,USPTOAssignment,Espacenet
IMAGES (5)

DESCRIPTION CLAIMS (9)

TECHNICALFIELD Weclaim:

Thisinventionconcernscatalyticconvertersand,moreparticularly,isdirectedto
acatalyticconverterstructurehavinganovalshapedcatalystcoatedsubstrate
fortreatingtheexhaustgasesofaninternalcombustionengineandtoamethod
ofmanufacturingthecatalyticconverterstructure.
BACKGROUNDOFTHEINVENTION
Oneformofcatalyticconverterpresentlybeingmanufacturedhasanovalshaped
catalystcoatedsubstratemadefromanextrudedceramiclocatedwithinanoval
shapedhousingwithdualwallendcones.Theendconescooperatetoformair
chambersattheopposedendsoftheconverterthatservetoreducetheoutside
temperatureoftheconverterandalsoservetoblockthehotexhaustgasesfrom
impingingdirectlyonamatmateriallocatedbetweenthesubstrateandthe
housing.
1.Amethodofmanufacturingacatalyticconverterstructureforthetreatmentof
theexhaustgasesofaninternalcombustionengineandwhichincludesa
housinghavinganovalshapedcatalystcoatedsubstratemountedthereinwith
itsoutersurfaceprovidedwithasheetofflexiblematerial,saidmethod
comprisingthestepsof:
formingasheetofmetalintoanovalshapedhousingthatterminatesateach
endwithanovalshapedperipheraledgedefininganovalopeninglocatedin
aplaneextendingtransverselytothelongitudinalcenteraxisofsaidhousing
anddimensionedsowhensaidsubstratealoneiscentrallylocatedwithin
saidovalopeningthegapbetweentheinsidesurfaceofsaidhousingand
theoutsidesurfaceofsaidsubstratealongtheminoraxisofsaidoval
openingislessthanthegapbetweentheinsidesurfaceofsaidhousingand
theoutsidesurfaceofsaidsubstratealongthemajoraxisofsaidoval

Oneproblemwithaconverterofthistypeisthat,whenthesubstratetogether opening,

withthematmaterialisstuffedintotheovalhousing,theouterovalconfiguration
applyingaforcetosaidhousingsothattheinsidesurfacesofsaidhousing
ofthehousingcandistort.Asaresult,theouterendconeswhichfitontothe
alongsaidminoraxisincreaseindistanceandcausetheinsidesurfacesof
opposedopenendsofthehousingarerequiredtohavelargetolerancesto
saidhousingalongsaidmajoraxistodecreaseindistancesoastoprovide
accommodatethevaryingouterconfigurationsofthehousing.Thisthen,causes
atemporarilydeformedovalcavitywithinsaidhousing,
somedifficultyinweldingtheendconestothehousing.Anotherproblemisthat
duringhightemperatureoperationoftheconverter,thereisatendencyforthe placingsaidsheetofflexiblematerialonthebodyofsaidsubstratetocover
housingtoexpandalongtheminoraxissoastoreducethedensityofthemat thelatterandprovideasubstrateflexiblematerialassembly,
which,inturn,reducesthelifeofthematmaterial.
insertingsaidsubstrateflexiblematerialassemblyintosaiddeformedoval
Ithasbeenproposed(seeSAETechnicalPaper922340,entitled"Effectof cavitywithinsaidhousing,
HeaderTruncationonMonolithConverterEmissionControlPerformance",
relievingsaidforcesoastocausesaidinsidesurfacesofsaidhousing
authoredbyDanielW.Wendlandet.al.andpresentedinOctober1992atthe
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alongsaidminoraxisandalongsaidmajoraxistospringbacktowardtheir

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InternationalFuelsandLubricantsMeetingandExposition)toshortenthe
distancebetweentheinletandoutlettubeandthesubstratetoapproximatelyone
inch.Thesinglewallendconedesignprevalentatthattime,however,presentsa
furtherprobleminthatthematmaterialsupportingthesubstrateisexposedto
hotexhaustgaseswhich,ifthecatalyticconverterisplacedinalocationclose
tothevehicleenginewheretheexhaustgastemperatureattheinletofthe
catalyticconverterissufficientlyhigh,willtendtoerodethematresultingina
lossofsubstrateretentionandheatinsulatingcapabilityofthematmaterial.
SUMMARYOFTHEINVENTION
Accordingly,anobjectofthepresentinventionistoprovideanewandimproved
catalyticconverterandmethodofmanufacturethatreducestheamountof
materialandnumberofpartsthatarerequiredforpermittingthecatalytic
convertertotreattheexhaustgasesofaninternalcombustionengineandalso
improvesthestructuraldurabilityoftheconverterbymaintainingahighermat
densityalongtheminoraxisoftheconverterhousing.
Anotherobjectofthepresentinventionistoprovideanewandimproved
converterandmethodofmanufacturethatutilizesanovalshapedhousingofa
predeterminedconfigurationthatisinitiallydeformedbyanappliedforcesoasto
increasethesizeoftheovalhousingalongitsminoraxisanddecreasethesize
oftheovalhousingalongitsmajoraxisfollowedbytheinsertionwithintheoval
openingofamatwrappedcatalystcoatedsubstrateafterwhichtheforceapplied
tothehousingisrelievedallowingtheinsidesurfacesofthehousingtomove
towardstheirpredeformedpositionswiththeresultthattheinsidesurfacesof
thehousingalongtheminoraxisexertincreasedpressureonthematand
therebyprovideanincreaseddensityofthemat.
Afurtherobjectofthepresentinventionistoprovideanewandimproved
catalyticconverterandmethodofmanufacturethatutilizesanovalshaped
housingofapredeterminedconfigurationthathasamatwrappedsubstrate
positionedthereinandafterwardsisdeformedbyapplicationofacompressive
forceappliedalongtheminoraxisoftheovalopeninginthehousingsoasto
decreasethesizeoftheovalopeningwithinthehousingalongthisaxisfollowed
bysecuringapairofendmemberstotheopposedendsofthehousingsoasto
maintainthefinalconfigurationofthehousingandtheincreasedpressureapplied
tothematbythecompressiveforce.
Astillfurtherobjectofthepresentinventionistoprovideanewandimproved
catalyticconverterhavingaovalshapedhousinginwhichamatwrapped
substratemadeofafrangiblematerialiscentrallylocatedandissupportedfrom
axialmovementrelativetothehousingsolelybyamatmadeofaresilient
intumescentmaterialandinwhichthehousingterminatesatitsopposedends
withanovalopeningthatisclosedbyaplanarendplateformedwithanopening
throughwhichhotexhaustgasescanflowandinwhichapluralityoflocatorsare
providedforpositioningtheendplaterelativetotheovalopening.
Theaboveobjectsandothersarerealizedinaccordancewiththepresent
inventionbyacatalyticconverterwhichincludesanovalshapedhousing
terminatingateachendwithanovalshapedperipheraledgedefininganoval
openinglocatedinaplaneextendingtransverselytothelongitudinalcenteraxis
ofsaidhousing.Acatalystcoatedsubstratemadeofafrangiblematerialis
adaptedtobelocatedwithinthehousingandhasacrosssectionalconfiguration
similartotheovalshapedconfigurationofthehousing.Thesubstrateisofa
smallersizethantheovalopeninginthehousingandisdimensionedsowhen
thesubstratealoneiscentrallylocatedwithintheovalopeningofthehousing,
thegapbetweentheinsidesurfaceofthehousingandtheoutsidesurfaceofthe
substratealongtheminoraxisoftheovalopeningislessthanthegapbetween
theinsidesurfaceofthehousingandtheoutsidesurfaceofthesubstratealong
themajoraxisofsaidovalopening.Aninsulatingmatmadeofaresilient
intumescentmaterialisadaptedtobewrappedaroundthesubstrateandtogether
therewithadaptedtobeinsertedintothehousingwhilethehousingisdeformed
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originalpositionsandprovideadesiredpressuretosaidsheetofflexible
materialalongsaidminoraxisandsaidmajoraxis,and
securinganendmembertosaidovalshapedperipheraledgeateachendof
saidhousingwherebysaiddesiredpressurealongsaidminoraxisandsaid
majoraxisismaintained.
2.Themethodofclaim1whereinsaidforceisacompressiveforce
appliedtotheoutsideofsaidhousingalongsaidmajoraxisofsaid
housing.
3.Themethodofclaim1whereinsaidsheetofflexiblematerialis
securedtosaidsubstrateusingadoublefacedadhesive.
4.Themethodofclaim1,whereinsaidsubstratehasafrontfaceanda
rearfaceandthebodyofthesubstrateiswrappedwithsaidsheetof
flexiblematerialaboutthecircumferenceofsaidsubstratesoasto
coversubstantiallytheentiresubstrateexceptsaidfrontfaceandsaid
rearface.
5.Themethodofclaims1whereinsaidsheetofflexiblematerial
providesacoveronsaidsubstratethatpriortoinsertionintosaidcavity
isofuniformthicknessaboutthecircumferenceofsaidsubstrate.
6.Themethodofclaim1whereinsaidgapissubstantiallyuniform
aboutthecircumferenceofsaidsubstratewhensaidsubstratealoneis
centrallypositionedwithinsaidovalopeninginsaidhousingafter
applicationofsaidforceandpriortoinsertionofsaidsubstrateflexible
materialintosaidhousing.
7.Themethodofclaim1whereinsaidendmemberisplanarin
configurationandissecuredtosaidhousingbyaweldingoperation.
8.Themethodofclaim7whereinsaidendmemberisprovidedwitha
pluralityofspacedlocatorsandsaidlocatorsservetopositioneachof
saidendmembersrelativetosaidovalshapedperipheraledgepriorto
weldingsaidendmembertosaidhousing.
9.Amethodofmanufacturingacatalyticconverterstructureforthetreatmentof
theexhaustgasesofaninternalcombustionengineandwhichincludesa
housinghavinganovalshapedcatalystcoatedsubstratemountedthereinwith
itsoutersurfaceprovidedwithasheetofflexiblematerial,saidmethod
comprisingthestepsof:
formingasheetofmetalintoanovalshapedhousingthatterminatesateach
endwithanovalshapedperipheraledgedefininganovalopeninglocatedin
aplaneextendingtransverselytothelongitudinalcenteraxisofsaidhousing
anddimensionedsowhensaidsubstratealoneiscentrallylocatedwithin
saidovalopeningthegapbetweentheinsidesurfaceofsaidhousingand
theoutsidesurfaceofsaidsubstrateisuniformaboutthecircumferenceof
saidsubstrate,
placingsaidsheetofflexiblematerialonthebodyofsaidsubstrateto
substantiallycoverthelatterandprovideasubstrateflexiblematerial
assembly,
insertingsaidsubstrateflexiblematerialassemblythroughsaidovalopening
intosaidhousing,
applyingaforcetosaidhousingsothattheinsidesurfacesofsaidhousing
alongsaidminoraxisdecreaseindistancesoastoprovideincreased
pressureontosaidsheetofflexiblematerialtoincreasethedensityofsaid
sheetalongsaidminoraxiswithoutpermanentlydeformingsaidhousing,
and
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byanappliedforcesoastocausetheinsidesurfacesofthehousingalongthe securinganendmembertosaidovalshapedperipheraledgeateachendof
minoraxisoftheovalopeningtomoveradiallyoutwardly.Inaddition,apairof saidhousingtopreventsaidinsidesurfacesfromspringingbacktotheir
endmembers,eachofwhichisformedwithanopeningthroughwhichexhaust originalpositionswhensaidforceisrelievedwherebysaidincreased
gasescanflow,areadaptedtobesecuredtotheopposedendsofthehousingby pressurealongsaidminoraxisandtheresultantincreaseddensityofsaid
aweldingoperationaftertheappliedforceonthehousingisrelievedsoasto sheetofflexiblematerialalongsaidminoraxisismaintainedpermanently.
causetheinsidesurfacesalongtheminoraxisoftheovalopeningtobe
maintainedinastressedconditiontoapplyincreasedpressuretothematalong
theminoraxisoftheovalopeningandtherebyincreasethedensityofthemat.

Inanalternatemethodofmanufacturingthecatalyticconverter,anovalshapedhousingisprovidedthat,initsnormalstate,
hasanovalopeningdimensionedsowhenthesubstratealoneiscentrallylocatedwithintheovalopeningofthehousing,the
radialdistancebetweentheinsidesurfaceofthehousingandtheoutsidesurfaceofthesubstrateisuniformaboutthe
circumferenceofthesubstrate.Thesubstrateiswrappedwithamatofintumescentmaterialandinsertedthroughtheoval
openingintothecavityofthehousing.Afterwards,thehousingcontainingthematwrappedsubstrateisplacedinafixture
andacompressiveforceisappliedtothehousingalongtheminoraxisoftheovalopeningtodeformthehousingand
increasethepressuretoobtainahighlycompressedmatalongthisaxis.Thisisthenfollowedbysecuringtheendmembers
totheopposedendsofthehousingwhilethecompressiveforceisbeingappliedsoastoretainthecompressedshapeof
thehousingalongtheminoraxisandtherebymaintaintheincreasedpressureonthemattoincreasethedensitythereof
alongtheminoraxis.

BRIEFDESCRIPTIONOFTHEDRAWINGS

Otherobjects,advantages,andfeaturesofthepresentinventionwillbecomeapparentfromthefollowingdetaileddescription
oftheinventionwhenconsideredinconjunctionwiththefollowingdrawingsinwhich:

FIG.1isasideelevationalviewofacatalyticconvertermadeinaccordancewiththeinventionwithsomepartsbroken
awaytoshowtheinterioroftheconverter

FIG.2isasectionalviewofthecatalyticconvertertakenonline22ofFIG.1

FIG.3isanendviewofthecatalyticconvertertakenonline33ofFIG.2

FIG.4isaplanviewofacatalyticconvertersimilartothatseeninFIGS.13exceptfortheadditionofaninnercone
memberintheinterioroftheconverter

FIG.5isasectionalviewtakenonline55ofFIG.4

FIG.6isaperspectiveviewshowingasheetofstainlesssteelbeingformedintoanovalconfigurationwhichsubsequently
canbeusedasthehousingforthecatalyticconverterseeninFIGS.15

FIG.7isaviewtakenonline77ofFIG.6

FIG.8isaviewtakenonline88ofFIG.8showingoneofthepreliminarystepsinformingofthesheetofstainlesssteel
intotheovalconfiguration

FIG.9isaviewtakenonline99showingthefinalstepintheformationofthesheetofstainlesssteelintotheovalshaped
configuration

FIG.10isaviewoftheovalshapedhousingofthecatalyticconverteraccordingtothepresentinventionbeingdeformed
intoapredeterminedoptimumconfigurationbyaviselikedevice

FIG.11isaviewshowingthecatalystcoatedsubstratewhichformsapartofthecatalyticconverterbeingwrappedwitha
matofinsulatingmaterial

FIG.12isaplanviewofthedeviceofFIG.10showingthewrappedsubstratebeingstuffedintothehousingwhilethelatter
isinthedeformedstate

FIG.13isanendviewofthesubstrateusedinthecatalyticconverteraccordingtothepresentinventionand

FIG.14isanendviewoftheovalshapedhousingusedinthecatalyticconverterofFIGS.15havingtheoptimum
configurationpriortodeformationbytheapparatusseeninFIG.10.

DETAILEDDESCRIPTIONOFTHEDRAWINGS

ReferringtothedrawingsandmoreparticularlytoFIGS.13thereof,acatalyticconverter10madeinaccordancewiththe
inventionisshownthatisintendedforuseineliminatingtheundesirableconstituentsintheexhaustgasesofaninternal
combustionengine.Thecatalyticconverter10hasanovalcrosssectionalconfigurationprovidingalowprofileconfiguration
forinstallationunderthevehiclefloororanyotherspaceconstrainedlocation.Thecatalyticconverter10generally
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comprisesanovalshapedhousing12whichterminatesateachendwithanovalshapededge14defininganovalopening
locatedinaplaneextendingtransverselytolongitudinalcenteraxis16ofthehousing12.Thehousing12ismadefroma
sheetofstainlesssteelprovidingauniformovalcrosssectionalcavitywithinthehousingalongitsentireaxiallength.Also,
thesheetofstainlesssteelisofuniformthicknessandservestoencloseamonolithorsubstrate18madeofafrangible
materialsuchasceramicthatisextrudedwithanidenticalhoneycombcrosssectionandanovalperiphery.Theceramic
substrate18iswashcoatedwithahighsurfaceareamaterialandcatalyzedwithapreciousmetalsuchasplatinumand/or
palladiumand/orrhodium.Thecatalystservestopurifytheexhaustgasesexitingtheinternalcombustionengineand
enteringthefrontface20ofthesubstrateandexitingtherearface22ofthesubstratebyreductionandoxidationprocesses
wellknowntothoseskilledintheart.

AsbestseeninFIG.2,thesubstrate18iscentrallyretainedandsolelysupportedwithinthehousingbyamat24intheform
ofanovalshapedsleeve.Themat24ismadefromaresilient,flexibleandheatexpandableintumescentmaterialsuchas
thatknownbythetradename"Interam"andismanufacturedbyTechnicalCeramicsProductsDivisionofthe3MCompany.
AsseeninFIGS.1and2,themat24coversessentiallytheentireoutersurfaceofthesubstrate18andisinterposed
betweentheinsidesurface26ofthehousing12andtheovaloutersurface28ofthesubstrate18.Themat24,asa
supportingstructureforthesubstrate18,functionsasasealbetweenthehousing12andthesubstrate18andalsoasan
insulatorforlimitingheattransferbetweenthesubstrate18andthehousing12duringthetimethatthehotexhaustgases
flowthroughthecatalyticconverter10.Ithasbeenfoundthatunlessthemat24isunderapredeterminedpressureduring
operation,thecatalyticconverter10mustbeplacedinalocationwherethepeaktemperatureofexhaustgassesislimited,
forexample,tonomorethan850C.attheinletofcatalyticconverter10becausehighertemperatureexhaustgaseswill
causethemat24toeroderesultinginthemat24losingitsinsulatingandsupportingcapabilities.

Theopposedopenendsofthehousing12areclosedbyanovalshapedinletendmemberorplate28andanidentically
formedoutletendmemberonplate30soastoprovideaninletchamber32adjacentthefrontface20ofthesubstrate18
andanoutletchamber34adjacenttherearface22ofthesubstrate18.Theinletendplate28includesacircularinlet
opening36definedbyaradiustransition38whichisadaptedtoberigidlyconnectedtoacylindricalgasinletpipe(not
shown).Similarly,theoutletendplate30hasacircularoutletopening40providedbyaradiustransition42whichisadapted
tobesecuredtoacylindricalexhaustgasoutletpipe(notshown)leadingtothemuffler(notshown)formingapartofthe
exhaustsysteminwhichthecatalyticconverter10islocated.Normally,theoutletendplate30needstheradiustransition
42tominimizeflowrestrictionacrossthistransition.Althoughtheinletendplate28alsoincludesaradiustransition38in
thisinstance,itwillbenotedthattheradiustransition38isnotrequired.Inotherwords,theradiustransition38couldbe
removedfromtheinletendplate28andhavetheexhaustgasinletpipeextendintotheresultingopeningformedintheinlet
endplate28.Theendplates28and30areessentiallyplanarinconfigurationprovidingaflatplanarinnersurface44for
engagementwiththeovalperipheraledge14oftheovalopeningateachendofthehousing12.Moreover,eachoftheend
plates28and30ismadethickerthanthesidewallsofthehousing12soastowithstandthebendingstressesofthe
exhaustsystemand,asseenFIGS.1and2,arelocatedinparallelplaneswhichareperpendiculartothelongitudinalcenter
axis16ofthehousing12.Itshouldbeapparentthattheendplates28and30canassumeothertransversepositions
relativetothelongitudinalcenteraxis16dependinguponthelocationofthecatalyticconverter10inthevehicleexhaust
system.Forexample,theendplates28and30canbeangledrelativetothelongitudinalcenteraxis16asseeninFIG.1or
angledrelativethesameaxisasseeninFIG.2.

AsseeninFIG.3,eachoftheendplates28and30isformedwithsixidenticallocators46,twoofwhicharecenteredon
themajoraxisoftheovalopeninginthehousing12withtheotherfourlocatorsbeingpositionedinpairsalongspaced
imaginaryverticallineswhichareperpendiculartothemajoraxisanessentiallyintersectthemajoraxisatapointwhichis
thecenterofthearadiusdefiningtheendcurvatureoftheinsidesurface28ofthehousing12.Eachofthelocators46take
theformofabuttonwhich,asseeninFIG.2,projectsinwardlytowardsthesubstrate18andispositionedsothatit
contactstheinsidesurface26ofthehousing12atthesemicircularendofthehousing12.Aswillbemorefullyexplained
hereinafter,thelocators46arelocatedinpositionswhichdefinethefinalconfigurationoftheovalopeninginthehousing12
and,asseeninFIG.3,servetopositioneachendplatesothataportionthereofextendsradiallyoutwardlybeyondthe
outsidesurfaceofthehousingforacceptingaweld50forsecuringtheendplatetothehousing12.Eachendplate28and
30isweldedtothehousing12aroundtheentirecircumferenceofthehousing12adjacenttheovalshapededge14.

FIGS.4and5discloseacatalyticconverter52whichisessentiallythesameinconstructionasthecatalyticconverter10
exceptfortheadditionofaninletconemember54andanoutletconemember56.Accordingly,allpartsofthecatalytic
converter52thatareidenticaltopartsofthecatalyticconverter10areidentifiedbythesamereferencenumeralsbut
primed.

AsseeninFIGS.4and5,theconemember54isformedwithacylindricalsection58whichdefinesacircularinletopening
60.Thecylindricalsection58issecuredtotheradiustransition38'byaweldandisintegrallyformedwithafunnelsection
61whichgraduallyincreasesincrosssectionalareaasitextendsfromtheendplate28'towardsthefrontface20'ofthe
substrate18'andterminateswithanovalshapedopeningdefinedbyanovaledge62.AsseeninFIG.4,theedge62is
locatedinaplaneextendingtransverselytothelongitudinalcenteraxis16'ofthehousing12'andisperpendicularthereto.In
addition,theedge62isslightlyflaredradiallyoutwardlytofacilitatematingwiththefrontfaceportionofthesubstrate18'.
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Accordingly,theovalshapedopeningdefinedbytheedge62oftheconemember54isslightlylargerthanthecross
sectionalsizeofthesubstrate18'so,whenthetwomate,aclosefitisprovidedaroundtheperipheryofthesubstrate18'.

Theconemember56isidenticalinconstructiontotheconemember54andisalsoformedwithacylindricalsection64
which,inthiscase,definesacircularoutletopening66.Thecylindricalsection64isrigidlyfixedtotheradiussection42'by
aweldandisintegrallyformedwithafunnelsection68terminatingwithanovalshapededge70thatencompassestherear
faceportionofthesubstrate18'.

Oneadvantageinprovidingtheconemembers54and56inthehousing12'isthattheyformairchambers72and74with
theendplates28'and30',respectively.Theairchambers72and74surroundthefunnelssectionsoftheconemembers54
and56,respectively,andcooperatewiththemat24'toprovideadditionalinsulatingcapabilitytolimitheattransferbetween
thesubstrate18'andthehousing12'.Thisthenwouldallowthecatalyticconverter52tobepositionedwithintheexhaust
systematapointclosertotheenginethanthecatalyticconverter10whichdoesnotenjoytheenhancedinsulationprovided
bytheuseoftheconemembers54and56.Anotheradvantagewouldbetoallowtheuseoflowercostmaterialssuchasa
thinnerhousingorlessmatforequivalentdurability,ortoallowtheconvertertooperateundermoreseveretemperature
conditions.

Althoughnotshown,itwillbeunderstoodthatthecylindricalsections58and64oftheconemembers54and56,
respectively,canbemadeasseparatepartsandbeweldedtotheassociatedfunnelsections.Also,ifdesiredthetransition
radius38'and42'ontheendplates28'and30'canbeeliminatedwitheachcylindricalsectionweldeddirectlytothe
associatedendplate.

Atthisjuncture,itshouldbenotedthatinasmuchasbothofthecatalyticconverters10and52compriseidenticalparts
exceptfortheadditionoftheconemembers54and56inthecatalyticconverter52,bothcatalyticconverters10and52can
bemanufacturedinaccordancewiththepresentinventionbyamethoddisclosedinFIGS.612.However,inorderto
simplifythedescriptionofthemethodofmanufacture,referencewillonlybemadetothecatalyticconverter10,itbeing
understoodthatthesamestepswouldbefollowedtomakethecatalyticconverter52.

InthisregardandwithreferencetoFIGS.69,thehousing12canbeformedbyatubemillmethodforhighvolumejobsina
mannerwellknowntothoseskilledintheart.Insuchcase,asheet76ofstainlesssteelmetalisdrawnfromasupplyroll
78throughaseriesofpairedrollerssuchasrollers80and82(FIG.8)andisprogressivelybentintothefinaloval
configurationbyapairofrollerssuchasrollers84and86(FIG.9)toprovideaninnerovalcavity88ofpredetermined
desireddimensions.Thedesiredovalconfigurationofthecavitywilldependupontheoutsideovalconfigurationofthe
substrate18andtheradialthicknessofthemat24tobeusedandwouldbedeterminedbytakingbothintoconsiderationas
tobedescribedbelow.Forpresentpurposes,however,itwillsufficetosaythatinonemethodofmakingthecatalytic
converters10and52,accordingtothepresentinvention,theovalcavity88willbesizedsowhenthesubstrate18alone
(withoutthewrappedmat)iscentrallypositionedinthecavity88,theradialdistancebetweentheinsidesurfaceofthe
cavity88andtheoutsidesurfaceofthesubstratealongtheminoraxisoftheovalcavity88islessthantheradialdistance
betweentheinsidesurfaceofthecavity88andtheoutsidesurfaceofthesubstratealongthemajoraxisofthecavity.This
essentiallyprovidesahousinghavingacavitywhichcouldnotacceptthesubstrate18whenitiswrappedwiththemat.

Afterthesheetmetal76isformedintothedesiredovalconfiguration,thefreeends90and92oftheovalshapedsheet
metalarethenweldedtogetherasseeninFIG.9usingatungsteninertgasarrangementwhereinnomaterialisadded.
Afterwards,theovalshapedsheetmetaliscutatanappropriatelengthtoprovidethehousing12ofthecatalyticconverter.

Inasmuchasthecavity88inthehousing12willhavetheovalconfigurationdescribedabove,andasalludedtoabove,itwill
notbepossibletoinsertthematwrappedsubstrateintothecavity88ofthehousing12usingconventionalinsertion
apparatuswithoutseriouslydamagingthematandthesubstrate.Therefore,inordertoaccomplishtheinsertion,thehousing
12isplacedintoaviselikedevice96asshowninFIG.10.Thedevice96includesapairofjaws98and100eachhavinga
verticallyalignedwall102centrallylocatedbetweenthetopsurface104andthebottomsurface106oftheassociatedjaw.
Thewall102mergeswithapairofinwardlyextendingwalls108and110eachofwhichislocatedata45degreeangle
relativetothemajoraxisofthehousing12.Thejaw98canbefixedinpositionwhiletheotherjaw100canbemovableina
horizontalplanethroughanactuator(notshown).

Thehousing12isthenpositionedinthedevice96betweenthejaws98and100asshowninFIG.10,andthejaw100is
forciblymovedbytheactuatorinthedirectionofthearrowapredetermineddistance112causingthehousingtobedeformed
withinitselasticlimitssoastopreventpermanentdeformationofthehousingandassumetheconfigurationshownbythe
dottedlines.Atthistime,thedistancebetweentheinsidesurfacesofthehousing12alongthemajoraxisisdecreasedand
thedistancebetweentheinsidesurfacesofthehousing12alongtheminoraxisisincreased.Ineffect,thedeformedoval
configurationobtainedbythisactionistheconfigurationwhichwouldnormallybeusedforacceptingtheparticularsubstrate
matassembly.

Oncethehousing12isdeformedasdescribedabove,thecavity88ofthehousing12isreadyforaccommodatingthe
substratematassembly.Thesubstrate18isthenwrappedwiththemat24.Themat24canbeasinglesheetof
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equalthethicknessofthesinglesheetandprovidethedesireddensitywheninsertedintothecavity88.Inthiscase,as
showninFIG.11,twosheets114and116ofequalthicknessthatconstitutethemat24areshownwiththefirstsheet114
havingitsendsabuttingeachotherandsecuredtothesubstratebyadoublefacedadhesivetape118.Thesecondsheet
116isshownpositionedabovetheabuttingendsofthefirstsheet114andwouldbewrappedaroundthefirstsheetsothat
itsabuttingendsarelocatedontheoppositesideofthesubstrate.Thesecondsheet116wouldalsobesecuredtothefirst
sheetbyadoublefacedadhesivetape.

Afterthetwosheets114and116ofintumescentmaterialarewrappedaroundandsecuredtothesubstrate18,the
substratematassemblyisinsertedintothecavityofthedeformedhousing12inthemannershowninFIG.12.Todoso,a
stuffingcone120havingataperedwall122terminatingwithanovalopening124correspondingtotheovalopeningdefined
bythecavity88inthedeformedhousing12isattachedtothedevice96afterwhichthesubstratematassemblyisforcibly
pushedintothecavity88ofthehousingtocompressthemattoapredetermineddensity.Oncethesubstratematassembly
iscentrallypositionedwithinthehousing12asshowninFIGS.15,thecompressiveforceappliedtothehousing12bythe
device96isrelieved.Theinherentresiliencewithinthemetalofthehousing12thencausestheinsidesurfacesofthe
housingalongtheminoraxisto"springback"andmovefromthedottedlinepositiontowardsthefulllinepositionseeinFIG.
10sothatthepressureexertedonthesheets114and116alongthemajoraxisisdecreasedwhilesimultaneously
increasingthepressureonthesheets114and116alongtheminoraxisofthehousing12.

Withthesheets114and116nowbeingsubjectedtothedesiredpressuresalongthemajorandminoraxesofthehousing
12,suchpressuresaswellasthedesiredshapeoftheovalhousing12aremaintainedbypositioningtheendplates28and
30withtheaidofthelocators46ontotheopposedendsofthehousing12andsecuringthemtotheovalshapededge14
throughtheweldingoperation.Inthecaseofthecatalyticconverter52,theinletconemember54andtheoutletcone
member56wouldfirstbesecuredtotheendplates28'and30'asdescribedabove,andtheendplates28'and30'
combinedwiththeconemembers54and56wouldthenbesecuredtothehousing12.

Inanexampleovalshapedcatalyticconverter,thehousingisdesignedsothat,ifthesubstratealonewerepositioned
centrallywithintheovalcavityoftheconverterhousing,asubstantiallyuniformspacingofapproximately6.06mmbetween
theinsidesurfaceofthehousingandtheoutsidecircumferentialsurfaceofthesubstratewouldbeprovided.Ifthisspacing
wasmaintainedafterthesubstratematassemblyisinsertedintothehousing,thenthetheoreticalmatdensitywouldbe
approximately1.02g/ccandthematpressureagainstthesubstratewouldbeapproximately28psi.However,ithasbeen
foundthatafterinsertionofthesubstratematassemblywithinthehousing,thespacingbetweentheinsidesurfacesofthe
housingalongtheminoraxisincreasesinsizeduetothepressureexertedbythematontheupperandlowerelongated
wallsofthehousing.Thisgrowthbetweenthesubstrateandthehousingresultsintheradialspacingbetweenthesubstrate
andtheinsidesurfaceofthehousingalongtheminoraxisincreasingfrom6.06mmtoapproximately7.22mm.Atthat
spacing,thematdensitydropstoapproximately0.86g/ccandthematpressureagainstthesubstratefallstoapproximately
10psi.Atsuchvalues,acatalyticconverter,suchasseeninFIG.13,thatisdesignedsoastohavethematexposedto
thedirectimpingementofthehotexhaustgasoftheengine,mustbelocatedfarenoughfromthevehicleenginesothatthe
peaktemperatureofexhaustgasesenteringthecatalyticconverterislimited,forexample,to850C.,topreventthe
problemofmaterosionandsubsequentloseofsupportwithinthehousing.

Accordingly,ithasbeendeterminedthatifthesamehousingandsamesubstratereferredtoabove,isprovidedinitsfree
formwithanonuniformspacingbetweenthehousingandthesubstratealonesothat,attheminoraxis,thespacingis
reducedfromthe6.06mmspacingtonominally4.13mmandafterwardssubjectedtothecompressiveforcealongthemajor
axisasdescribedaboveinconnectionwithFIG.10afterwhichthesubstratematassemblyisinsertedintothehousing
(FIG.12)andtheappliedforceisreleased,thedensityofthemataswellasthepressurealongtheminoraxisincreases.
Thisistrueeventhoughthehousingexperiences,insuchcase,asimilargrowthalongtheminoraxis.Thegrowthwouldbe
approximately2.68mmor,inthiscase,anincreasefrom4.13mmto6.81mm.However,thespacingislessthanthe7.22
mmspacingprovidedunderinitialconditionsand,sincetheinherentresiliencywithinthestretchedmetaltendstocausethe
upperandlowerwallsofthehousingtomoveinwardly,ithasbeencalculatedthatthematdensityalongtheminoraxis
wouldincreasefrom0.86g/cctoapproximately0.91g/ccandthematpressurewouldincreasefrom10psitoapproximately
16psi.Atthesevalues,thematcanwithstandthehightemperaturescausedbythehotexhaustgasesandissuitablefor
locationclosertothevehicleenginewherepeakexhaustgastemperaturesarehigher,e.g.,around950C.,without
deterioratingandlosingitsabilitytosupportthesubstratewithinthehousing.

Intheaboveexample,thesubstrateasseeninFIG.13wouldhavethefollowingnominaldimensions:A=144.30mm,B=80
mm,C=40mm,D=68.07mm,RadiusE=457.2mm,andRadiusF=32.15mm.AsseeninFIG.14,thehousingwouldbe
madeofasheetof409SS(stainlesssteel)havingathicknessof1.45mm,ayieldstrengthof240Mpaand,inthefreeform
priortocompressionbetweenthejawsofthedeviceofFIG.10,thefollowingnominaldimensions:G=161.04mm,H=41.90
mm,OutsideRadiusI=923.41mm,OutsideRadiusJ=38.62mm,andK=883.80mm.AsseeninFIG.11twolayersor
sheets(eachhavingaweightof3100gramspersquaremeterandathicknessofapproximately4.9mm)ofmatmadeof
intumescentmaterialsuchasdescribedhereinbeforewouldbewrappedaroundthesubstrate.Thehousingwouldbeinserted
intothedeviceofFIG.10andthejawswouldbedrawntogetherinacompressivemodeuntilthefinaldistancebetweenthe
twocentralwallsalongahorizontallinewouldbe159mm.
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Analternatemethodofincreasingthepressureattheminoraxisofthehousingsoastoimprovethedurabilityofacatalytic
converterwouldbetoformthesheetmetalintoanovalshapedhousinghavinganovalcavitydimensionedsothat,when
thesubstrate(describedabove)aloneiscentrallypositionedwithintheovalopeningofthecavity,theradialgapbetweenthe
insidesurfaceofthehousingandtheoutsidesurfaceofthesubstrateisuniformaboutthecircumferenceofthesubstrate
andwouldbeequaltoapproximately6.06mm.Thesubstrateisthenwrappedwiththeintumescentmaterialhavingthe
weightandthicknessdescribedaboveandistheninsertedintothecavityofthehousing.Thisthenwillcausethehousingto
increaseinsizealongtheminoraxis(asalsodescribedabove)and,afterwardsacompressiveforceisapplieduniformly
alongthetopsurfaceandthebottomsurfaceofthehousingthroughaviselikedevice.Thiswouldcausetheinsidetopand
bottomsurfacestomovetowardseachotherapproximately3.5mmsoastoprovideadensityofapproximately1.13g/cc
andapressureofapproximately55psiinthematalongtheminoraxisofthehousing.Whilemaintainingthepressureonthe
outsideofthehousing,theendplateswouldthenbeweldedtotheopposedendsofthehousingsothatthedeformedand,
accordingly,thepressurealongtheminoraxisismaintainedwiththeresultthatahighermatdensityisrealizedalongthetop
andbottomsurfacesofthefinishedconverter,oralternatively,usinglesscompressiveforcetoproduceuniformmatdensity
allaroundthefinishedconverter.

Variouschangesandmodificationscanbemadetotheabovedescribedcatalyticconverterandmethodofmanufacture
withoutdepartingfromthespiritoftheinvention.Forexample,ratherthanhavingendmembersofthetypedescribedin
connectionwiththecatalyticconverter10orthecatalyticconverter52,eachofthesecatalyticconverterscouldbeprovided
withanendmemberthatwouldhaveitsperipherycorrespondinsizewiththefinalsizeoftheovalopeninginthehousing.
Theendmemberthenwouldfitintotheopeningandbeweldedtotheinsidesurfacedefiningtheovalcavityformaintaining
thefinalshapeofthehousingandtheincreasedpressurealongtheminoraxisofthehousing.Analternateconfigurationof
theendmembersthatcouldbeusedwitheitherofthecatalyticconverters10and52wouldhavetheperipheryoftheend
plateprovidedwithanintegrallyformedaxiallyextendingrimwhich,inthiscase,wouldbesizedsoastocorrespondtothe
outsideconfigurationofthehousingattheperipheralovaledgethereof.Therimwouldencloseeachendofthehousingand
beweldedtotheoutsidesurfaceofthehousingformaintainingthefinalshapeofthehousing.Thisalternateconfigurationof
theendmembercouldbeplanarinconfiguration,suchastheendplate28,28'and30,30'orbesimilarindesigntotheend
conemembersifonecouldtoleratetheincreasedsizeandweightofthecatalyticconverter.

Variousotherchangesandmodificationscouldbemadetotheabovedescribedcatalyticconverterandmethodof
manufacturewithoutdepartingfromthespiritoftheinvention.Suchchangesandmodificationsarecontemplatedbythe
inventorsandtheydonotwishtobelimitedexceptbythescopeoftheappendedclaims.

PATENTCITATIONS
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Aktiengesellschaft gases
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CLASSIFICATIONS

U.S.Classification 29/890,29/505
InternationalClassification F01N3/28,F01N13/18
CooperativeClassification F01N13/1872,F01N3/2857,Y10T29/49908,Y10T29/49345
EuropeanClassification F01N3/28C10B,F01N13/18F

LEGALEVENTS
Date Code Event Description
Ownername:GENERALMOTORSCORPORATION,MICHIGAN
Freeformattext:ASSIGNMENTOFASSIGNORSINTERESTASSIGNORS:FOSTER,MICHAEL
17Sep1997 AS Assignment RALPHVANEMAN,GERALDLEROYHEATHER,JESSEALLANAND
OTHERSREEL/FRAME:008719/0761
Effectivedate:19970905

27Nov2002 FPAY Feepayment Yearoffeepayment:4

Maintenancefee
26Dec2002 REMI
remindermailed
13Nov2006 FPAY Feepayment Yearoffeepayment:8
Maintenancefee
10Jan2011 REMI
remindermailed
Lapseforfailureto
8Jun2011 LAPS paymaintenance
fees
Expireddueto
26Jul2011 FP failuretopay Effectivedate:20110608
maintenancefee

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