Patent Application
20080052907
a and 9b illustrate a perspective view and a side view, respectively, of a housing used to enclose the matching substrates and the support materials according to a second preferred embodiment of the present invention.
a and 10b illustrate perspective view and a side view, respectively, of a housing used to enclose the matching substrates and the support materials according to a third preferred embodiment of the present invention.
The catalytic converter assembly 10 further includes a first catalytic element 14 and a second catalytic element 16. The first catalytic element 14 includes a first substrate 18 and a first support material 20. The second catalytic element 16 includes a second substrate 22 and a second support material 24. An inner surface 26 of the housing 12 is pressed against the first catalytic element 14 and the second catalytic element 16 for securing the first catalytic element 14 and second catalytic element 16 from radial movement therein. The dotted line 28 (shown in
The catalytic converter assembly 10 includes a first conical-shaped end 30 having a first port 32. The first port 32 is coupled to an exhaust pipe of a vehicle (not shown) extending from an internal combustion engine of the vehicle (not shown). The catalytic converter assembly 10 further includes a second conical-shaped end 34 having a second port 36. The second port 36 is coupled to a next portion of the exhaust system (not shown). The conical ends may be formed by deforming the ends to the housing 12 or separately formed conical ends may be coupled to the housing 12. Alternatively, the housing 12 may not include the conical ends and the housing may be attached directly to the exhaust system.
The first port 32 functions as an inlet port for receiving exhaust gases from the internal combustion engine such has hydrocarbons, carbon monoxide, and nitrogen oxides and converts the exhaust gases into carbon dioxide, water, nitrogen, and oxygen. The second port 36 functions as an exhaust port for discharging the converted gases to the discharging portion of the exhaust system (not shown).
As can be seen in
A second substrate 58 and second support material 60 are selected from the plurality of substrates and support materials based on a matching outer profile and weight factor. The second substrate 58 and the second support material 60 are joined by wrapping the second support material 60 around the second substrate 58 as a second pre-assembly for forming a second catalytic element 61.
The sets of respective substrates and support material selected to form the first and second pre-assemblies allow a predetermined and uniform compression to be applied to the housing 12 to secure the first catalytic element 57 and the second catalytic element 61 therein. Selectively matching substrates and support materials allow a same predetermined and uniform compression to be applied to the portions of the housing 12 overlapping the first catalytic element 57 and second catalytic element 61 for securing the contents therein without applying overcompression or undercompression to the respective substrates therein.
A list of matching substrates and supporting materials may be provided in a lookup table for ease of selection or an algorithm may be used to determine a set of a matching components when either a respective substrate having a determined outer diameter is selected or a respective support material having a determined weight factor is selected.
The tables of 5-7 are only representative of a single embodiment for determining a match between the respective substrates and the respective support materials, and other values or characteristics may be utilized in place of those shown in the table. For example, in an alternative embodiment, the actual diameter of the substrate may be used in place of the gap factor for determining a respective match. In yet another embodiment, an algorithm may be used to calculate a match as opposed to utilizing a lookup table. It should be appreciated that various methods may be used to determine the match, however, it is the selective matching of a respective substrate with a respective support material that cooperatively allows the plurality of catalytic elements having varying outer profiles and support materials having varying weight factors to be secured within the housings utilizing a substantially same compression.
In function block 61, the outer profile of a plurality of substrates is determined and sorted according to their outer profile. Alternatively, the plurality of substrates are pre-sorted (i.e., pre-screened) and provided to an assembly process.
In function block 62, a plurality of supporting materials are evaluated and sorted according to their weight factor. Alternatively, the plurality of support materials may be pre-sorted and provided to an assembly process.
In function block 63, a respective substrate is selected along with a respective support material such that the combination of the associated outer profile (or gap factors) and the weight factor are within a target range.
In function block 64, a pre-assembly is made by wrapping the support material around the substrate.
In function block 65, at least one pre-assembly is inserted into the housing.
In function block 66, the compression is applied to the housing to a predetermined dimension.
It should be appreciated that in the above process, evaluating the weight factor of the support material and the determining the outer profile of the substrate may be done concurrently or at off-line sub-assembly operations.
a and 9b illustrate a housing used to enclose the substrates and the support material according to a second preferred embodiment. A clamshell-type housing, shown generally at 70, includes a first housing portion 71 and a second housing portion 72. The first housing portion 71 includes a leg portion 73 and a leg portion 74. Leg portions 73 and 74 are substantially flat and extend lengthwise along opposing sides of the first housing portion 71. The second housing portion 72 includes a leg portion 75 and a leg portion 76. Leg portions 75 and 76 are substantially flat and extend lengthwise along the opposing sides of the second housing portion 72. After the substrates and support materials (not shown) are inserted in one of the respect housing portions, the clamshell-type housing 70 is closed. As the first housing portion 71 and the second housing portion 72 are forced together to close leg portions 73 and 75 are in aligned for abutting one another and leg portions 74 and 76 are aligned for abutting one another. As the clamshell-type housing 70 closes, a compression is exerted on the support material and substrates therein by the first housing portion 71 and the second housing portion 72 for securing the respective catalytic elements therein. The abutting leg portions 73 and 75 and abutting leg portions 74 and 76 allow the first housing portion 71 and the second housing portion 72 to compress the supporting materials therein to a predetermined reduced profile. As a result, there is no reduction in size of the housing using the clamshell-type housing as only the support material is compressed.
a and 10b illustrate a housing used to enclose the substrates and the support material according to a third preferred embodiment. A shoe-box-type housing, shown generally at 80, includes a first housing portion 81 and a second housing portion 82. The first housing portion 81 functions as a lid and the second housing portion 82 functions as a body. The first housing portion 81 includes a leg portion 83 and a leg portion 84. Leg portions 83 and 84 extend in a direction toward the second housing portion 82. The second housing portion 82 includes a leg portion 85 and a leg portion 86. Leg portions 85 and 86 extend in a direction toward the first housing portion 81. The substrates and support materials (not shown) are inserted in the second housing portion 82. The first housing portion 81 is placed over the second housing portion 82 to enclose the catalytic elements therein. A compression is cooperatively exerted on the support material and substrates therein by the first housing portion 81 and the second housing portion 82 for securing the catalytic elements therein. As the first housing portion 81 and the second housing portion 82 compress the contents therein, leg portions 83 and 84 overlap with leg portions 85 and 86, respectively, for variably reducing the size of the shoebox-type housing 80 until the desired size is obtained or a positive stop is reached. As a result, there is no deformation of the housing using the shoebox-type housing as only the support material is compressed.
It should be noted that other types of canning processes may be used without departing from the scope of the invention. For example the same principles and practices may be applied using a tourniquet or stuffing process.
In function block 91, an outer profile of a substrate is determined. A gap factor is determined based on the outer profile.
In function block 92, a respective support material is assigned a weight factor.
In function block 93, the gap factor and the weight factor are combined to produce a compression factor.
In decision block 94, a determination is made whether the compression factor determined in function block 93 is within a targeted range. If a determination is made that the compression factor is not within the target range, the algorithm returns to function block 92 to select and evaluate a next support material. If the determination is made in decision block 94 that the compression factor is within the predetermined range, then the support material is selected for assembly.
In function block 95, a pre-assembly is formed by wrapping the support material around the substrate.
In function block 96, at least one pre-assembly is inserted into the housing.
In function block 97, the housing is deformed by a deforming process to a predetermined dimension.
In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.
