Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
  • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
  • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
  • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
  • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
  • F01N3/28—Construction of catalytic reactors
  • F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
  • F01N3/2853—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing
  • F01N3/2857—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration using mats or gaskets between catalyst body and housing the mats or gaskets being at least partially made of intumescent material, e.g. unexpanded vermiculite
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D49/00—Sheathing or stiffening objects
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D53/00—Making other particular articles
  • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
  • F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
  • F01N2450/02—Fitting monolithic blocks into the housing

Definitions

• the present invention relates to an apparatus and method for encasing an object in a case More particularly, the present invention relates to an apparatus and method for encasing objects having non-circular contours in a case
• Exhaust processors are part of a vehicle exhaust system that cleans and quiets exhaust gas produced by a vehicle engine
• the exhaust processors typically include ⁇ substrate or object encased within a metal sheet
• the size and contour of the exhausl processors depends in large part on the space available for the exhaust processor in the vehicle exhaust system on the underside of the vehicle
• a machine is provided to clamp a case around an object having a contour
• the machine includes a spacer mount, an actuator coupled to the spacer mount to move the spacer mount between first and second positions, and a spacer coupled to the spacer mount to move with the spacer mount between the first and second positions
• the spacer mount defines an encasement region and is adapted to receive the object and case in the encasement region
• the spacer includes a first surface coupled
• a method for encasing an object having a contom within a case An encasement machine is provided having an actuator and a plurality of strap units
• the plurality of strap units include an inner surface adapted to face toward the object and the inner surface includes a contour
• One of the plurality of strap units is selected that includes an inner surface having a contour substantialK similar to the contour of the object
• the selected strap unit is coupled to the actuator
• the object is placed within the case
• the object and case are placed within the encasement machine so that the inner surface of the one of plurality of strap units faces toward the case and object
• the actuator is operated to move the selected strap unit so that the strap unit clamps the case on the object
• Fig 1 is an exploded perspective view of an encasement machine and an exhaust processor body including an outer case loosely wrapped around a substrate and mat, the encasement machine including spaced-apart jaws and a "horseshoe-shaped" strap unit positioned to extend between the spaced-apart jaws and formed to define an encasement region sized to receive the exhaust processor body so that the body can be clamped in the encasement machine during welding on the body the strap unit including a spacer mount a wall and spacer s positioned between the wall and spacer mount and sized to cause the encasement region to match the size and shape of the exhaust processor body,
• Fig 2 is another perspective view of the encasement machine of Fig 1 prior to insertion of an exhaust processor body into the encasement region formed in the encasement machine,
• Fig 3 is a perspective view of a portion of the horseshoe-shaped strap unit and a portion of the spaced-apart jaws supporting the strap unit,
• Fig 4 is a side elevation view of the encasement machine of Figs 1 and 2 showing the exhaust processor body positioned in an encasement region defined by the strap unit and between the spaced-apart jaws while the outer case is wrapped loosely around the substrate prior to clamping the exhaust processor body in the encasement region,
• Fig 5 is a top plan view with portions cutaway of the exhaust processor body positioned in the strap unit and between the spaced-apart jaws showing an exhaust processor body positioner included in the encasement machine and configured to position the exhaust processor body properly within the encasement region formed in the encasement machine,
• Fig 6 is a side elevation view similar to Fig 4 showing the spaced-apart jaws in a compressed position so that the strap unit clamps and wraps the outer case around the mat and substrate, a mechanism swinging down onto the outer case to hold ends of the outer case in a fixed position, and a welder coupling the ends of the outer case to each other, the spacer and wall includes a contour in the compressed position that is substantially identical to the contour of the exhaust processor body.
• Fig 7 is a top plan view, with portions cutaway, showing the exhaust processor body being ejected or pushed out of the encasement region defined by the strap unit and onto a shelf,
• Fig 8 is a side elevation view of another strap unit including a set of spacers that are shaped and sized differently from the spacers shown in Figs 1, 2, 4, and 6, the strap unit being coupled to the spaced-apart jaws and arranged to clamp an exhaust processor body received in the encasement region of the encasement machine, the strap unit having spacers sized to have a contour in the compressed position that is substantially identical to the contour of the exhaust processor body being clamped by the encasement machine
• Fig 9 is a side elevation view, with portions cutaway, of an exhaust processor including an exhaust processor body and spaced-apart first and second end caps (in phantom) positioned to abut an inner surface of the case,
• Fig 10 is a side elevation view of an alternative embodiment of an encasement machine and an exhaust processor body positioned to lie between spaced- apart jaws of the encasement machine,
• Fig 1 1 is a perspective view of the exhaust processor body positioned to lie in the encasement machine of Fig 10 showing the exhaust processor body including an outer case loosely wrapped around a mat and substrate, the outer case including spaced- apart ends, and one of the ends of the outer case including a raised lip; and
• Fig 12 is a side elevation view similar to Fig 10 showing the spaced-apart jaws closed to clamp the outer case around the mat and substrate so that the raised lip of the outer case overlaps the other end of the outer case, a mechanism engaged with an end of the outer case and abutting the raised lip of the outer case, and a welder coupling the ends of the outer case
• An encasement machine is provided to clamp a case about an object to press and fasten the case about the object
• the encasement machine may clamp cases about objects of various contours and sizes
• the encasement machine includes a spacer mount that clamps the object and a spacer positioned between the object and spacer mount to position the spacer mount at a selected distance from the object
• the spacer includes a surface facing the object that has a contour that is substantially similar to the contour of the object to be clamped
• the object is an exhaust processor body used in a vehicle exhaust system (not shown)
• the exterior size and contour of the exhaust processor body varies depending on the particular vehicle for which the exhaust processor body is intended because exhaust processor bodies have to be adapted to the configuration of the floor pan of the vehicle
• the spacer used in the encasement machine is selected to match the size and exterior contour of the particular exhaust processor body to be produced.
• Encasement machine 10 used to clamp an exhaust processor body 12 is shown, for example, in Figs 1 and 2 so that body 12 can be welded or otherwise finished
• the encasement machine 10 includes first and second clamp jaws 14, 16 and a strap unit 18 that extends between jaws 14, 16
• Strap unit 18 includes a spacer mount 20 that extends between jaws 14, 16, a wall 24 that extends between jaws 14, 16, and a spacer 22 coupled to spacer mount 20
• Spacer mount 20 and wall 24 define a spacer container region 23 and spacer 22 is positioned to lie between spacer mount 20 and wall 24 in spacer container region 23
• the strap unit 1 8 defines an encasement region 26 in which a partly finished exhaust processor body 12 is positioned when exhaust processor body 12 is clamped
• a partly finished exhaust processor body 12 is shown, for example, in Fig. 1 before insertion of body 12 in direction 13 into encasement region 26
• Exhaust processor body 12 Before exhaust processor body 12 is placed within encasement region 26 of encasement machine 10, exhaust processor body 12 must be partially assembled.
• Exhaust processor body 12 includes a ceramic honeycomb substrate 28, a support or anchor mat 30 wrapped around substrate 28, and an outer case 32
• the substrate 28 may be a single block, or it may be implemented as two or more separate blocks or units which may be arranged axially together or axially spaced Mat 30 is made of an intumescent material or other suitable material
• the substrate 28 and mat 30 are positioned within outer case 16 using any suitable technique
• the case 32 is in a loose, open-sided form so that substrate 28 and mat 30 may be slid within case 32
• the case 16 includes spaced-apart first and second ends 34, 36 First end 34 is flared upwardly compared to second end 36 as shown in Fig 1
• the loose case 32 may be formed by bending a generally flat metal sheet
• exhaust processor body 12 is placed within encasement machine 10 to press and wrap case 32 around substrate 28 and mat 30 and firmly hold case 32 so that it can be welded or otherwise finished
• the strap unit 1 8 is made of metal (for example, steel) and is arranged in a generally circular configuration
• the strap unit 1 8 includes spaced-apart ends 38, 40 that are turned away from each other to define a gap 42 as shown, for example, in Fig 1
• Each of the jaws 14, 1 6 have tips oi lugs 44 around which ends 38. 40 of strap unit 1 8 pass, and to which ends 38.
• the term "strap" as used in this application is intended to be interpreted broadly, and includes any suitable device(s) or member(s) for bracing or embracing the sheet metal case
• the strap may be formed by a flexible (or capable of flexing) wall or sheet, or by a plurality of discrete parallel filaments, or by a web, or a chain.
• the strap may be, for example, a band, plate, or loop for binding objects together or for clamping an object in position
• the spacer 22 includes a plurality of elongated spacer members 46 secured to spacer mount 20 by nuts and bolts 48 Each of the elongated spacer members 46 include an inner surface 52 facing wall 24, a pointed outer end or surface 54 engaging spacer mount 20, and a side surface 56 Any suitable mounting device or connector may be used to mount elongated members 46 to spacer mount 20 Such connectors may include, for example, clips, screw-threaded fasteners, lugs, and slide channels Spacer 22 permits encasement machine 10 to tighten and clamp cases 16 having a contour different than the contour of spacer mount 20 closely and accurately
• spacer mount 20 is circular or near-circular shaped as shown in Figs 1 -4 and 6
• the exhaust processor body 12 to be clamped by encasement machine 10 is generally oval-shaped or non-circular shaped as shown, for example, in Figs 1 , 4, and 6
• the inner surface 52 of spacer members 46 includes an oval-shaped contour for receiving and tightening exhaust processor body 12 illustrated in
• spacer 22 avoids the need to design a specially shaped spacer unit for each shape of exhaust processor
• the spacer mount 20 can have a standard shape, for example circular or near circular, and be adapted to the shape of exhaust processor body 12 by spacer 22
• the wall 24 is positioned to lie adjacent to inner surface 52 of elongated spacer members 46
• the wall 24 is made of metal (e g steel) and is coupled to spacer mount 20
• the spacer mount 20 and wall 24 include spaced-apart ends 58, 59 that wrap over tips of jaws 14, 1 6 and are coupled to jaws 14, 1 6 by bolts 60
• the wall 24 serves to smooth the contour of the contact pressure exerted on exhaust processor body 12 when elongated spacer members 46 do not form a continuous pressure surface over exhaust processor body 12 Size variations in a particular substrate 28 and mat 30 can result in variation in the size of case 32, and the spacers 46 may be spaced apart a small distance to allow for such variation in size about an average size
• strap unit 1 8 includes regions 62 in which no spacer 46 is positioned between spacer mount 20 and wall 24 due to the small space available between spacer mount 20 and wall 24 In these regions 62, the wall 24 ensures that a smooth pressure is applied to exhaust processor body 12
• the wall 24 also serves to reduce wear of spacer 22 and to reduce strain on spacer mount 20 A small spacer may be used in these regions 62
• the wall 24 may be removed so that spacer 22 bears directly against case 16
• the exhaust processor body 12 is slid into encasement region 26 defined by strap unit 18 when jaws 14, 16 are in a spaced-apart position so that strap unit 18 is relaxed as
• Encasement machine 10 further includes a mechanism 88 that engages flared end 34 to hold flared end 34 on the other end 36 of case 32 as shown in Figs 1, 2, and 6
• the mechanism 88 engages flared end 34 after flared end 34 of case 32 overlaps the other end 36 of case 32
• the mechanism 88 moves from the position shown in dotted lines to the position shown in solid lines to engage flared end 34 as shown in Fig 6
• Encasement machine 10 further includes a welder 90 as shown in Figs 1 , 2, and 6 Once flared end 34 is held securely against the other end 36 of case 32, welder 90 couples ends 34 36 of case 32 to provide a tightly wrapped exhaust processor body 12
• the jaws 1 , 16 are operated bv levers 92 94 respectively, mounted by pivots 96
• the levers 92 94 are driven by a hydraulic cylinder 98
• Pressurized fluid is supplied to hydraulic cylinder 98 by a hydraulic control circuit 1 10, which includes a control valve 1 12, a pressure sensor 1 14, and a reservoir 1 16 as shown in Fig 4
• the fluid is supplied to circuit 1 10 from a pressurized fluid source 1 18 such as, for example, a hydraulic power pack (reservoir and pump)
• the jaws 14, 16, levers 92, 94, hydraulic cylinder 98 and hydraulic control circuit 1 10 comprise an actuator that moves strap unit 1 8 between a relaxed position and a clamped position
• the jaws mav be operated by any
• any cross-sectional shape of substrate 28 can be accommodated simply by using a spacer 22 of the correct contour to match the contour of substrate 28
• the spacer 22 may be replaced individually or separate from spacer mount 20 and wall 24 (leaving spacer mount 20 and wall 24 in place) or an entire strap unit 1 8 might be replaced
• different strap units 18 may be provided for different exhaust processor bodies 12 having substrates 28 of varying cross section or contour
• the jaws 14, 16 may also be replaced with strap unit 1 8 to accommodate different size and contoured exhaust processor bodies 12 If either or both of jaws 14, 16 is replaced with strap unit 18 to accommodate different size and contoured exhaust processor bodies 12, then jaws 14, 16 are considered to be part of strap unit 18
• the encasement machine 1 0 may be operated either to tighten case 32 to a fixed size or to a fixed pressure It is preferred to tighten case 32 to a fixed pressure, and thus achieve
• valve 1 12 To tighten case 32 to a controlled pressure the valve 1 12 is opened until the hydraulic pressure detected by sensor 1 14 reaches a predetermined level corresponding to the desired tightening pressure of case 32 This predetermined hydraulic pressure can be calculated easily taking into account the mechanical advantage of the pivoted levers 92, 94 Once the predetermined pressure has been reached, the control valve 1 12 is closed to prevent possible damage from being caused by over-tightening case 32
• an electronic feedback circuit may be used in the hydraulic control circuit to monitor the hydraulic pressure and to open the control valve to admit more gas if the hydraulic pressure drops below a predetermined threshold
• the encasement machine 10 may be operated repeatedly or cycled several times, before •J O- removing the exhaust processor body 12 from encasement machine 1 0, until no further creeping, or collapsing, of mat 30 is observed
• Jaws 14, 1 6 may be driven by other drive arrangements, for example, electric motors It is preferred that such other drive arrangements compensate for creep of mat 30, for example, in a similar manner to the techniques described above
• jaws 14. 16 have been illustrated for tightening the clamping strap unit 18, any suitable tightening device coupled to the strap may be used When jaws are used, one of the jaws may, if desired, be fixed in position, such that the tightening is achieved by movement of the non-fixed jaw
• the travel limit positions of jaws 14, 16 are controlled by adjustable stops
• Mechanism 88 includes a plurality of fingers 124, a support bar 126, and an actuator 128 that moves fingers 124 in and out of gap 42 defined by ends 38, 40 of strap unit 18 and engagement with flared end 34
• Mechanism 88 is coupled to jaw 14 and moves with jaw 14 as jaw 14 compresses and releases exhaust processor body 12
• the mechanism 88 is actuated to cause fingers 124 to press on flared end 34 of outer case 32 during the final closing movement of the jaws 14, 16
• the fingers 124 press flared end 34 of case 32 inwardly against opposing end 36 of case 32 to cause ends 34, 36 of case 32 to slide relative to each other Fingers 124 press overlapping ends 34, 36 of outer case 32 against mat 30 as shown in Fig 4
• the mechanism 88 could be moving during the whole closing process of jaws 14, 16, but only make contact with flared end 34 of case 32 during the final part of the closing movement of jaws 14, 16
• the mechanism 88 typically contacts case 32 for the final quarter of the closing movement of jaws 14, 16
• case 32 is welded to secure case 32 in its tightened condition
• the gap 42 between ends 38, 40 of strap unit 1 8 permits good access to perform the welding operation
• the case 32 is not welded completely along the length of case 1 6 while in encasement machine 10 but is simply spot welded at one or more locations depending on the axial length of the case 32
• the spot welds simply serve to hold case 32 in its tightened position until the case 32 is later permanently welded
• the spot welding may be performed manually, or by welder 80 as shown in Fig 5
• the case 16 can be welded along its entire length while still in encasement machine 30
• the welding can be performed manually, or by welder 80 which is lowered into gap 42 and moved along the length of case 32
• Encasement machine 10 further includes an ejector mechanism 130 which pushes exhaust processor body 12 onto a shelf 1 32 as shown for example in Fig 7 Shelf 132 includes ramps 136 that support exhaust processor body 12 as shown, for example, in Fig 5
• the ejector mechanism 130 includes a driver 1 34 that is coupled to stop 72 During the ejection process stop 72 extends into encasement region 26 to push exhaust processor body 12 onto shelf 132
• the exhaust processor body 12 is part of an exhaust processor 140 as shown in Fig 9
• Exhaust processor 140 includes exhaust processor body 12 and end caps 142 shown in phantom in Fig 9
• the end caps 142 are generally cone (or frusto-cone) shaped and are formed to include ports 144 to enable exhaust processor 140 to be installed in a vehicle exhaust system
• exhaust processor are intended to refer to various types of diesel particulate filters and other traps, purifiers or substrates in connection with which this invention may be used
• the words ' exhaust processor specifically refer to a catalytic device (for example a catalytic converter or a catalytic trap) for use with gasoline engines
• encasement machine 10 may clamp exhaust processor bodies 12 of various size and contour by adjusting the size and contour of spacer 22
• encasement machine 10 may include a spacer 150 that is sized, shaped, and contoured to clamp a non-symmetrical polygonal type cross section shape or contour exhaust processor body 152 as shown in Fig 8
• the spacer mount 20 of strap unit 18 is circular or near circular and this maintains an optimum radial or near radial, force on exhaust processor bod ⁇ 1 52 during compression
• Another preferred encasement machine 1 60 that clamps an exhaust processor bod ⁇ 162 is shown in Figs 10 and 12
• Encasement machine 160 is identical to encasement machine 1 0 except that encasement machine 160 includes a mechanism 176 that interacts with exhaust processor body 162 in a different manner than mechanism 88 of encasement machine 10 interacts with exhaust processor body 12 All other components of encasement machine 10 are identical to encasement machine 160 and are numbered identically
• the exhaust processor body 162 includes a substrate 164, a mat 166, and an outer case 168 as shown in Fig 1 1
• the outer case 168 includes spaced-apart ends 170, 172 and one of the ends 170 is lifted or bent to form a lip 174
• the lip 174 may, for example, be formed by pressing the sheet metal along an edge prior to bending the sheet metal into case 168
• Substrate 164 mat 166, and outer case 168 are assembled as described above in reference to exhaust processor body 12
• the exhaust processor body 162 is positioned within encasement region 26 of encasement machine 10 in the same manner as exhaust processor body 12
• case 1 68 is tightened and clamped by jaws 14 16 and strap unit 18
• lip 174 of end 170 overlaps the other confronting end 1 2 of case 168
• the mechanism 176 holds end 172 of case 168 down as strap unit 18 clamps outer case 168 about mat 166 and substrate 164 and lip 174 overlaps end 172
• the mechanism 1 76 also provides the secondary function of maintaining the position of lip 1 74 adjacent to gap 42 defined between ends 38, 40 of strap unit 18 so that welder 80 has access to lip 1 74
• Mechanism 1 76 can act as a stop if lip 174 abuts fingers 124 during the clamping process to prevent lip 1 74 from rotating away from gap 42.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Mechanical Engineering (AREA)
• Health & Medical Sciences (AREA)
• Toxicology (AREA)
• Combustion & Propulsion (AREA)
• General Engineering & Computer Science (AREA)
• Basic Packing Technique (AREA)
• Automatic Assembly (AREA)
• Auxiliary Devices For And Details Of Packaging Control (AREA)
• Laminated Bodies (AREA)

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• 1998
  • 1998-09-15 CN CNB98811187XA patent/CN1161208C/zh not_active Expired - Fee Related
  • 1998-09-15 EP EP98947011A patent/EP1037798B1/de not_active Expired - Lifetime
  • 1998-09-15 PT PT98947011T patent/PT1037798E/pt unknown
  • 1998-09-15 BR BR9812341-6A patent/BR9812341A/pt not_active IP Right Cessation
  • 1998-09-15 WO PCT/US1998/019147 patent/WO1999014119A2/en active IP Right Grant
  • 1998-09-15 ES ES98947011T patent/ES2232025T3/es not_active Expired - Lifetime
  • 1998-09-15 AT AT98947011T patent/ATE280079T1/de not_active IP Right Cessation
  • 1998-09-15 CA CA002304088A patent/CA2304088A1/en not_active Abandoned
  • 1998-09-16 AR ARP980104587A patent/AR017114A1/es not_active Application Discontinuation

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