U.S. patent application number 11/022067 was filed with the patent office on 2005-07-14 for one piece catalytic converter with integral exhaust manifold.
Invention is credited to Kalish, Martin W., McAllister, Clinton J., Purdy, Robert B..
Application Number | 20050150222 11/022067 |
Document ID | / |
Family ID | 34742406 |
Filed Date | 2005-07-14 |
United States Patent
Application |
20050150222 |
Kind Code |
A1 |
Kalish, Martin W. ; et
al. |
July 14, 2005 |
One piece catalytic converter with integral exhaust manifold
Abstract
The present invention relates to exhaust system assemblies and,
more particularly, to a one piece catalytic converter can with an
integral exhaust manifold. Disposed within the catalytic converter
can are the catalytic conversion components. Coupled to the one
piece converter can and integral exhaust manifold is a second end
cone to provide a substantially air tight seal to the assembly.
Inventors: |
Kalish, Martin W.; (Livonia,
MI) ; Purdy, Robert B.; (Wingham, CA) ;
McAllister, Clinton J.; (Woodstock, CA) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Family ID: |
34742406 |
Appl. No.: |
11/022067 |
Filed: |
December 23, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60533233 |
Dec 30, 2003 |
|
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Current U.S.
Class: |
60/302 ;
60/323 |
Current CPC
Class: |
F01N 3/2857 20130101;
F01N 13/10 20130101; F01N 3/24 20130101 |
Class at
Publication: |
060/302 ;
060/323 |
International
Class: |
F01N 003/00; F01N
007/10; F01N 003/10 |
Claims
What is claimed is:
1. An exhaust system component comprising: a one piece catalytic
converter can with integral exhaust manifold, said converter can
including an opening for receiving catalytic conversion
components.
2. The exhaust system component of claim 1, wherein said one piece
catalytic converter can with integral exhaust manifold is formed by
casting.
3. The exhaust system component of claim 2, wherein said casting is
formed from SiMo iron.
4. The exhaust system component of claim 1, wherein said integral
exhaust manifold includes at least one transition pipe and an inlet
cone.
5. The exhaust component of claim 4, wherein said inlet cone
includes an inner wall which is narrower along the transition point
with said at least one transition pipe and wider along the
transition point with said converter can.
6. The exhaust component of claim 5 wherein the inner wall of the
inlet cone includes an annular inwardly projecting portion in
proximity to the transition point with said converter can.
7. The exhaust system component of claim 1, further comprising a
mounting mat disposed adjacent an inner wall of said converter can
and a filtering substrate disposed within said mounting mat.
8. The exhaust system component of claim 7, wherein said filtering
substrate includes multiple substrate pieces having varying
catalytic properties.
9. The exhaust system component of claim 7, further comprising a
second end cone which is coupled to said converter can.
10. The exhaust system component of claim 8, wherein said second
end cone is coupled to the converter can by welding along a
coupling joint.
11. The exhaust system component of claim 10, wherein said coupling
joint includes a recess occurring along the opening of said
converter can which receives the leading end of the second end cone
in a close fit relationship.
12. A method of manufacturing an exhaust system assembly comprising
the steps of: a) providing catalytic conversion components; b)
providing a one piece catalytic converter can and integral exhaust
manifold, said converter can including an opening for receiving
said catalytic conversion components and said integral exhaust
manifold including a first end cone; c) disposing the catalytic
converter components within the opening of said catalytic converter
can; and d) attaching a second end cone to said catalytic converter
can to capture the catalytic converter components within said
catalytic can.
13. The method of claim 12, wherein said one piece catalytic can
and integral exhaust manifold is formed by casting.
14. The method of claim 13, wherein said casting is formed from
SiMo iron.
15. The method of claim 12, wherein said second end cone is
attached via welding along a coupling joint.
16. The method of claim 15, wherein said coupling joint includes a
recess occurring along the opening of said converter can which
receives the leading end of the second end cone in a close fit
relationship.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/533,233, filed on Dec. 30, 2003. The
disclosure(s) of the above application(s) is (are) incorporated
herein by reference.
FIELD OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates to catalytic converters and,
more particularly to a one piece catalytic converter can with an
integral exhaust manifold. Preferably the integral catalytic
converter can and exhaust manifold are formed as a unitary casting.
While numerous materials may be suitable for casting the one piece
catalytic converter and exhaust manifold, cast irons and,
preferably SiMo cast irons are preferred.
[0004] In addition to the one piece catalytic converter with
integral exhaust manifold, the present invention also relates to a
method of welding an end cone to the one piece catalytic converter
and integral exhaust manifold.
[0005] 2. Discussion of Prior Art
[0006] Catalytic converter assemblies are typically formed by
mechanically fastening stamped or otherwise machined inlet cones,
outlet cones and converter housings together to contain the
conversion materials. Among the perceived drawbacks to this type of
catalytic converter assembly are the costs associated with
assembling multiple pieces to arrive at a useful component and the
inherent gas leak paths associated with multi-piece components,
especially those employing mechanical fasteners to join the
pieces.
SUMMARY OF THE INVENTION
[0007] In a first instance, the present invention addresses the
above described drawbacks, among others, by providing a catalytic
converter assembly employing a one-piece catalytic converter can
and integral exhaust manifold to limit the number of overall
components in the assembly.
[0008] In addition to catalytic converter assemblies including a
one piece catalytic converter can with integral manifold, the
present invention also relates to a method of manufacturing
catalytic converter assemblies by welding a second end cone or
second end portion of an exhaust manifold to the one piece
catalytic converter can and integral exhaust manifold.
DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a catalytic converter
assembly employing a one piece catalytic converter can and integral
exhaust manifold according to the teachings of the present
invention;
[0010] FIG. 2 is a cross-sectional view of a catalytic converter
assembly employing a one piece catalytic converter housing and
integral exhaust manifold according to the teachings of the present
invention; and
[0011] FIG. 3 is a magnified sectional view of the inlet cone
portion of the assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] Referring to FIGS. 1 and 2, shown is a catalytic converter
assembly 10 employing a one piece catalytic converter can and
integral manifold assembly. The converter can portion is defined by
reference numeral 12 and the manifold is defined by reference
numeral 14. Generally, the catalytic converter can portion 12
houses the components necessary for converting the exhaust gases
prior to discharge from the vehicle to the atmosphere. While not
specifically shown, the converter can and/or the manifold portion
of the assembly can be provided with various sensors to monitor gas
flow through the system.
[0013] As illustrated, the catalytic conversion components inserted
within the converter can portion 12 include a substrate 16 which is
held in place by a mounting mat 18. Z-seals (not shown) which are
known in the art, may be used in association with the mat to assist
in securing the substrate within the converter can. The mounting
mat is disposed adjacent the inner wall 34 of the converter can in
the gap 36 occurring between the inner wall 20 of the converter can
12 and the outer surface 22 of the substrate 16. By employing a
mounting mat in the gap, dimensional variations in converter can,
the substrate or mounting mat material can be accommodated with
what is considered to be a negligible effect on the overall
performance of an exhaust system employing the integral assembly
10. The gap 36 can vary in size but preferably is between 3.5 and
7.5 mm. A properly sized gap allows for adherence to minimize and
maximize pressure requirements both during installation of the
substrate, which are known to be relatively fragile, and during the
systems useful life. Importantly, the gap also allows for the use
of a mounting mat made from a hybrid material of ceramics/metal
which can be a significant cost savings.
[0014] The mounting mat 18 holds, cushions and thermally insulates
the substrate. Mounting mats can be made of intumescent material
such as vermiculite, non-intumescent material such as ceramic
fibers, or a combination of intumescent and non-intumescent
materials bound by an organic compound by way of non-limiting
example. Preferably, the mat is non-intumescent and of a basis
weight suitable to optimize the holding force, cushioning and
insulation of the substrate.
[0015] As should be understood in the art, the substrate 16 is the
filtering or exhaust gas conversion component of the assembly.
While the substrate 16 is shown as a single piece, it should be
understood that the substrate may include multiple pieces which is
sometimes referred to as a "cascaded" system. The substrate pieces
may be made from the same or different materials having varying
catalytic properties. Likewise, the substrate pieces may be of the
same or varying design. Additionally, sensors (not shown) may be
incorporated into the substrate assembly to monitor and control the
flow of exhaust gas through the assembly.
[0016] The integral exhaust manifold portion 14, itself can be
described in terms of two distinct sections, namely the transition
pipes 38, which are typically mounted to an engine block (not
shown) and an inlet cone 40. As should be understood in the art,
the inlet cone 40 is shaped internally along wall 42 to accumulate
the exhaust gas entering from pipes 38 and to direct the gas flow
to and through the substrate. Thus, the inlet cone 40 is narrower
along the transition point with the transition pipes and is wider
at the transition point with the converter housing.
[0017] As shown most clearly in FIG. 3, the inner wall 42 of the
inlet cone 40 is provided with an annular inwardly projecting
portion 44 in proximity to the mat 18 intended to divert exhaust
gas away from the mat 18 and through the substrate 16. By providing
the annular projection 36, the working life of the mat can be
greatly extended.
[0018] Also depicted in FIGS. 1 and 2 is an outlet cone 24 which is
shown as including a flange 46 for connection to a muffler assembly
(not shown). It should be noted, however, that assembly 10 has
applications for direct attachment to a muffler assembly. The one
piece catalytic converter can 12 and integral manifold portion 14
forming assembly 10 when appropriately joined with the outlet cone
24, form a portion of the "hot end" of an exhaust system.
[0019] Coupling of the outlet cone 24 to the integral manifold
assembly may be done mechanically, adhesively and/or via a weld
joint 30. A preferred weld joint 30 is depicted whereby the
converter can includes a first end 26 having a recess 28 for
receiving the leading end 32 of the second cone 24 in a close fit
relationship. Once the outlet cone 24 is inserted into the recess
of the converter can portion, a circumferential weld can be carried
out along the weld joint 30 to seal the assembly. In view of the
fact that the outlet cone may be formed of a material other than
that which is used to cast the integral assembly 10, care should be
taken in selecting the appropriate weld wire material to insure
that a secure weld occurs along the joint.
[0020] Among the numerous advantages of the one piece catalytic
converter with integral exhaust manifold is the elimination of
multiple coupling joints which in turn limits the number of
potential leak paths along the assembly. As the number of coupling
joints increases, the cost to assemble also tends to increase.
Another advantage of the present invention is that the one piece
catalytic converter with integral exhaust manifold can be cast from
a suitable alloy such as SiMo cast iron by way of non-limiting
example. Thus, it is believed that the embodiments presented herein
represent a potential cost savings to the manufacturer.
* * * * *