JPS6146648B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an improved catalytic converter assembly for a motor vehicle exhaust system.

Many known catalytic converters have upper and lower housing portions. Each of the housing portions has a flange formed around its outer edge to allow the two housings to meet and be welded together to form a complete assembly. This flange-type structure is suitable for use with electron beam welding or seam welding manufacturing techniques.

Because the converter catalyst must be heated to and maintained at a fairly high temperature for effective catalytic action, the catalytic converter assembly must be located close to the engine, such as in the engine compartment of an automobile. It is desirable to do so. Therefore, the size of the catalytic converter has become extremely important. If the flange could be removed from this assembly, the overall size of the converter assembly could be reduced. This facilitates locating the converter within the engine compartment.

According to the invention, a converter assembly is provided in which the objective of reducing the size of the converter assembly by removing the flange is achieved.

It is an object of the present invention to provide a converter assembly in which two housing parts are connected in a manner that does not require flanges.

Another object of the invention is to provide a catalytic converter assembly in which one housing part is inserted with a predetermined force into the other housing part.

Another object of the invention is to provide a catalytic converter assembly in which one housing part is inserted to a predetermined depth into the other housing part.

In the inventive assembly described above, a circumferentially extending ridge is formed on one housing part to support the other housing part during the manufacturing process and to apply the necessary forces to the other housing part. the other housing part with a predetermined force or to a predetermined depth.

The catalytic converter assembly of the present invention supports one housing part and a catalyst support carrier or monolith, and the other housing part is inserted into one housing part with a predetermined force or a predetermined depth to accommodate the monolith. metal inert gas (MIG)
Both housing parts are bonded together using a spotting solution. Typically, the monolith is placed in a support sleeve or mat mount before being loaded into one housing section. During manufacture, this sleeve acts as a pressure absorbing medium between the housing part and the catalyst, protecting the fragile monolith. In many converters, this sleeve helps seal the monolith to the converter housing to prevent blow-by of unreacted exhaust gases.
−by).

One important advantage of the invention lies in the shoebox-like construction of the converter housing, in which the catalyst support carrier is separated into two housing parts by lip insertion of one housing part into the other. It can be caught evenly between the two, much like placing a lid on a shoebox. According to the structure of this shoebox-like housing,
The pressure is uniformly distributed over both housing parts, allowing uniform compression loading of one housing part into the other housing part. The housing has one housing portion and another housing portion spaced apart along a longitudinal plane of the housing so that forces perpendicular to the longitudinal plane are applied to substantially all of the housing portions. can be applied uniformly around the periphery of the housing and both housing parts can be pressed together uniformly. An even distribution of force is provided to achieve uniform charging. Uniform loading ensures that the carrier is captured between both housing parts and is in working condition (usually chucking).
This prevents dislocation of the carrier under chucking (referred to as chucking) and ensures a tight seal between both housing parts and the carrier to prevent exhaust gas blow-by.

Another advantage of the catalytic converter assembly of the present invention is its size. The shoebox-like structure eliminates the need for two flanges to connect both housing parts;
Therefore, it is desirable to reduce the overall size of the catalytic converter assembly. Moreover, the catalytic converter assembly of the present invention is less expensive to manufacture than conventional assemblies.

A conventional clamshell catalytic converter assembly has two housing parts, each of which has a flange formed around its outer edge; were matched and welded together to form a complete assembly. Traditionally, these flanges have been edge welded or electron beam welded. Since the relationship between the two housing parts is predetermined by the mating of the respective flanges, the carrier can be preliminarily held by filling the gap between both housing parts and the carrier with a dense mesh support. was. Traditionally, the charge was determined by the dimensions of the net support and both housings, but in the present invention, the charge is determined by the actual compressive force uniformly distributed over both housing parts. It is based.

The present invention allows for precise control of charging force. The traditional clam shell-shaped converter is
It provided a charging force determined by the dimensions of the mesh support and both housing parts.

The features and advantages of the invention will become more apparent from the following detailed description of embodiments of the invention, as well as the accompanying drawings which illustrate the invention.

As mentioned above, automobile manufacturers have learned that it is desirable to locate catalytic converter assemblies close to the engine. Because of the typical manufacturing method of catalytic converter assemblies, the assemblies have protruding flanges that increase the overall size of the assembly. These flanges take up space and it has been difficult to reallocate useful space within the engine compartment closer to the vehicle engine. Both parts of the converter assembly housing have previously been welded together using this flange.

The assembly of the present invention uses a technology that can be compared to a shoe box. In this assembly, the other housing part is inserted with a predetermined force or with a predetermined depth inside one housing part.

Referring now to FIGS. 1-4, the catalytic converter of the present invention is constructed from chrome steel approximately 1.4 mm (0.055 inch) thick. Assembly 1
0 has one housing part 12, which part 12 has an intermediate part 14 with a groove 16. The grooved intermediate portion 14 separates the non-grooved end portions 18 . The groove 16 is formed in the circumferential direction of one housing part 12.

One housing portion 12 further includes a circumferentially extending ridge 20 .
is formed at a slightly lower part of the outer peripheral edge 21 at the upper part of one housing part 12 and completely encircles it. Raised portion 20
assembly 10 in a manner described in detail below.
It serves to support one housing part 12 when it is manufactured. An outwardly bent peripheral lip 22 is formed on one housing part 12 between the ridge 20 and the peripheral edge 21. Peripheral lip 22
is approximately 4.75 mm (0.187 inch) wide as measured from the outer surface of one housing portion 12. This peripheral lip 22 is the only protrusion on assembly 10.

The assembly 10 further has another housing part 30 with a grooved intermediate part 32, which grooved intermediate part 32 is connected to both housing parts 1.
2 and 30 are aligned to form the grooved intermediate portion 14 of one housing portion 12 when assembled to form the assembly 10. The grooved intermediate portion 32 has a groove 34 formed to extend circumferentially in the other housing portion 30 and aligned with a groove 16 formed in one housing portion 12. It's becoming like that. The grooveless portion 36 is connected to the other housing portion 3
0 is provided at both ends.

As best seen in FIG. 4, a circumferentially extending ridge 38 is formed slightly above and completely around the edge 39 of the other housing portion 30. By means of the method described below, the other housing part 3 is
0 and insert the other housing part 30 into one housing part 12. Immediately below the raised portion 38 of the other housing portion 30 is formed a downwardly projecting peripheral portion 40 having a flat portion. The length of the flat peripheral portion 40 is approximately 11.86
mm (0.467 inch) and is adapted to contact the inside of one housing portion 12 between the ridge 20 and the peripheral lip 22. In one embodiment, the lower portion 41 of the peripheral portion 40 is approximately 3.17 mm.
(0.125 inch) long on one housing section 1
It is in contact with 2. both housing parts 12,
The surface area of the flat peripheral portion 40 in contact with one housing portion 12 is such that the other housing portion 30 is inserted into one housing portion 12 when the monolith with support sleeve is arranged between the housing portions 30 and 30 . is determined by the force applied to the other housing part 30. Once the other housing section 30 has been inserted into one housing section 12 with the desired force or to the desired depth, the two housings are assembled into a metal Joined by inert gas (MIG) welding. Peripheral lip 22 is provided on one side for retaining a weld layer 42 to be welded into the crevice formed between flat peripheral portion 40 of the other housing portion 30 and peripheral lip 22 of one housing portion 12. It only needs to be wide enough to provide a surface adjacent the periphery 21 of the housing portion 12. Peripheral lip 22 can thus take any shape that minimizes the overall dimensions of assembly 10 while providing a means for retaining weld layer 42.

As shown in FIGS. 1 and 2, the other housing portion 30 includes an exhaust gas inlet 44 and an exhaust gas outlet 46. As shown in FIGS. The shape of assembly 10 is for illustrative purposes only. The exhaust gas inlet 44 and outlet 46 can be formed in one housing part 12, or one inlet and outlet can be formed in the other housing part 30 and the other inlet and outlet can be formed in one housing part 12. may be formed. Additionally, the overall shape of assembly 10 may differ from that illustrated without departing from the scope of the invention.

The monolith 50 supporting the exhaust gas catalyst is arranged in a housing 51 created by the two joined housing parts 12,30.
Monolith 50 includes a plurality of uniformly shaped openings 52 such that exhaust gas enters through inlet 44, passes through monolith 50, contacts and reacts with the catalyst, and exits through outlet 46 of assembly 10. It is now possible to do so. As best shown in FIG. 2, monolith 50 is fixedly disposed in housing 51 between grooved intermediate portions 14,32. The support sleeve 54 is attached to the monolith 5
0 is placed over the monolith 50 and the other housing part 30 and the one housing part 12 are placed over the monolith 50.
is forcibly inserted and fitted. for example,
Support sleeve 54 is constructed from four wires approximately 1.12 mm (0.044 inch) thick. During insertion of the other housing part 30 into one housing part 12, the support sleeve 54 absorbs some of the forces applied to both housing parts 12, 30, thereby providing flexibility and preventing brittle monoliths. 5
I'm trying not to mess with 0. As shown in FIG. 2, when a force is applied to the other housing portion 30, the support sleeve 54 becomes significantly compressed. A seal ring 56 may also be placed around the monolith 50 to prevent exhaust gases from bypassing the catalyst on the monolith 50 from the support sleeve 54.

Charging with a range of forces or at a range of depths prevents bypass, often referred to as "blow-by," and prevents the monolith from entering the housing 51. This is necessary in order to fix it so that it does not displace. Otherwise, such displacements are caused by pressure differentials that develop across the monolith under operating conditions. The phenomenon of displacement of the monolith toward the downstream end of the housing under operating conditions is often referred to as "chucking."

As an example of the forces applied to the other housing portion 30 and the overall cross-sectional dimensions 58 (FIG. 3) of the assembly 10 formed by those forces, the following information is provided. 1270.08 Kg (2800 lb) to 2585.52 Kg for converter assembly 10 with a volume of 1081.55 cubic centimeters (66 cubic inches)
(5700 lbs) of force, giving cross-sectional dimensions ranging from 9.2 cm (3.625 in.) to 10.03 cm (3.950 in.). For a volume of 1229 cubic centimeters (75 cubic inches), from 907.2 Kg (2000 lbs)
8.89cm with a force in the range of 2857.68Kg (6300 lbs)
Cross-sectional dimensions ranging from (3.500 inches) to 9.93 cm (3.91 inches) are given. Applying a force greater than the above maximum value to a particular structure, given its dimensions, will lead to failure of the monolith 50. If a force of less than the above minimum value is applied to a structure of a given size, a cross-sectional dimension that is acceptable for the desired application will not be obtained. Therefore, during the manufacturing process of the converter assembly 10, the forces applied to the other housing section 30 and one housing section 12 are continuously monitored, and when the forces reach the maximum and minimum allowable ranges, both Housing part 3
It is important to combine 0 and 12.

When the other housing part 30 is inserted into one housing part 12 to a predetermined depth, the length of the flat peripheral part 40 of the other housing part 30 and the peripheral part 40 in contact with the one housing part 12 It is necessary to monitor the difference in length of the lower part 41. Other housing part 3
0 is inserted to the desired depth, the peripheral ridge 20 formed on one housing section 12
It has to be noted that can act as a limit stop for the housing part 30 to be inserted into one housing part 12. This is best shown in FIG.

5-8, the catalytic converter assembly 10 of the present invention includes a ridge 3 supporting one housing portion 12 and a monolith 50 and extending circumferentially on the other housing portion 30.
8 by inserting the other housing part 30 into one housing part 12 with a predetermined force or to a predetermined depth. By inserting the other housing part 30 into the one housing part 12 with a predetermined force or to a predetermined depth, the monolith 50 is held in the housing 51 between the grooved intermediate parts 14, 32. Ru. Depending on the size for manufacturing the assembly 10, a ridge 38 extending circumferentially on the other housing part 30;
The force applied or the depth at which one housing part 30 is inserted into the other housing part 12 must be monitored. When a predetermined force or depth is reached, the other housing part 30
are spot welded to one housing section 12 at sections 60, 62, 64, and 66. The welded portions 60, 62, 64, 66 are attached to the other housing portion 30 with the desired force or to the desired depth.
is held in place relative to one housing portion 12 while a metal inert gas (MIG) weld is made completely around the assembly 10, as shown in FIG. In one embodiment, a metal inert gas (MIG) welding system is utilized in an arc tack welding process to
2, 64, and 66 are possible.

Referring in more detail to FIGS. 6-8, an apparatus 7 for manufacturing the catalytic converter assembly 10 shown in FIGS. 1-5 according to the steps described above.
0 has a movable lower nesting block 72,
Inside this block 72, one housing part 12 is supported during the manufacturing process. The lower nesting block 72 is divided into two end portions 74, 75 and a central portion 76 and is provided with a surface forming a cradle or nest 78, which is shaped and dimensioned by one housing portion 12. It has a shape and dimensions that roughly match the . The lower nesting block 72 is positioned by a lower support bracket 80 with a base 82.
2 is attached to the press 83 by a base mount 84. Lower nesting block 72
is divided by a slot 85 with two fingers 86 having a portion 87 shaped to correspond to the shape and dimensions of one of the housing parts 12.

The finger 86 is connected to a take-out mechanism 89, and the take-out mechanism 89 removes the finger 86 at the end of the tack welding process.
Push out the lower nesting block 72 upward.
The tack welded assembly 10 is taken out from there. The ejector mechanism 89 of the tack weld assembly 10 has a pivot bracket 90 .
0 supports two fingers 86 and base 82
A support bracket 94 connected to the shaft 92
It is supported by A lever 96 is pivotally connected to pivot bracket 90 by a shaft 98. Lever 96 cooperates with a drive mechanism (not shown) that raises and lowers finger 86.

As best shown in FIG. 6, the upper nesting block 100 has a nest 102 for the other housing portion 30. Upper nesting block 100 is supported by upper support bracket 104 which is incorporated into embossing mechanism 106. The embossing mechanism 106 has a pressure piston and cylinder mechanism 108 which movably supports plates 110 with rams, between which a load cell 111 is provided. The reciprocating movement of the plate 110 causes the upper nesting block 100 to move up and down. A force gauge 120 is coupled to load cell 111. force gauge 120
are positioned relative to the manufacturing apparatus 70 such that an operator of the manufacturing apparatus 70 can continuously monitor the force being applied to the other housing portion 30 . Four welding heads 122, two of which are shown in FIG.
when held in the other housing part 3
0 to welded parts 60, 62, 64, 66 (Fig. 5)
It is adapted to be welded to one housing part 12 at the same time. The upper nesting block 100 has four grooves 130 (FIG. 6) that accommodate the welding heads 122 and allow metal inert gas (MIG) welding of these heads to the assembly 10. It is designed to be placed in an appropriate position during the process.

As best shown in FIG. 8, during this manufacturing process it is important to note the position of the upper and lower nesting blocks 100 and 72, respectively, with respect to both housing sections 30 and 12. The upper and lower nests 102 and 78, respectively, are shaped such that forces are applied along selected surfaces of both housing sections. Referring to FIG. 8, one housing portion 12 is connected to the lower nesting block by a peripheral lip 22, a circumferentially extending ridge 20, and surfaces of non-grooved ends 18 of one housing portion 12. Supported within 72. The grooved intermediate portion 14 of one housing portion 12 is supported away from the lower nesting block 72 so that no force is applied to the grooved intermediate portion 14. This minimizes the likelihood of force damage to the monolith supported within the grooved intermediate section 14.

The other housing part 30 is positioned within one housing part 12 when the upper nesting block 100 is in the retracted condition. Before placing one housing part 12 on the other housing part 30, in the lower nesting block 72,
One housing part 12 and a monolith 50 are arranged. As shown in FIG. 8, the upper nesting block 100 is connected to the other housing portion 3.
0 is in contact with the raised portion 38 and the non-grooved portion 36. Since the upper nesting block 100 is not in contact with the grooved intermediate portion 32 of the other housing portion 30, no force is applied to the grooved intermediate portion 32 by the upper nesting block 100. When a force is applied by the embossing mechanism 106 to the other housing part 30, this force is applied to the ridge 3 in contact with the upper nesting block 100.
8 and each non-grooved portion 36. The assembly 10 is manufactured by compressing one housing section 12 into the other housing section 30 in a process similar to the closing of a shoe box.

As shown in FIGS. 6-8, the manufacturing apparatus 70 has been described with an embossing mechanism 106 incorporating an upper support bracket 104, but the manufacturing apparatus 70 has been described with an embossing mechanism 106 incorporating an upper support bracket 104. It is not intended to be limited to placement. In one embodiment of manufacturing apparatus 70, pressure piston and cylinder mechanism 108 is connected to lower support bracket 80 and press 8.
3, and the force is applied from below the upper and lower nesting blocks 100, 72, rather than from above. Plate 110 and load cell 111 are attached as described above, but plate 110
movement is restricted. Therefore, the reciprocating movement of the lower support bracket 80 causes the lower nesting block 72 to move up and down. Other than these notable differences, this manufacturing apparatus 70 is structurally substantially the same as the one described above.

In operation of another embodiment of the manufacturing apparatus 70,
When the lower nesting block 7 is in the retracted state, the other housing part 30 is located within the one housing 12.
0 in one housing part 12,
One housing portion 12 and monolith 50 are located within the lower nesting block 72. The upper and lower nesting blocks 100, 72 contact the raised and non-grooved ends of both housing parts 12, 30, as before, and therefore contact the grooved intermediate portions of both housing parts 12, 30. On the other hand, no force is applied by the lower nesting block 72. The force is applied by the pressure piston and cylinder mechanism 108 to one housing part 1
2, this force is directed to the ridges and non-grooved ends that are in contact with the upper and lower nesting blocks 100, 72, and to the one housing part 1.
2 into which the other housing part 30 is compressed.

[Brief explanation of the drawing]

FIG. 1 is a plan view of a catalytic converter assembly according to the present invention; FIG. 2 is an elevation view of the assembly of FIG. 1 showing the general relationship of the components; FIG. 2 is a cross-sectional view of the assembly of FIGS. 1 and 2 taken along line 3-3 of FIG. 2; FIG. 4 is a detailed enlarged cross-sectional view of the assembly of FIG. 3; 5 is a plan view of the assembly of FIG. 1 showing the manufacturing process; FIG.
7 is a fragmentary, partially sectional view of the apparatus for manufacturing the assembly shown in FIG. 1; FIG.
8 is a cross-sectional view of the apparatus of FIG. 7 taken along line 8--8 of FIG. 7 within the apparatus of FIGS. 6 and 7 for manufacturing the assembly of FIG. 2 is a cross-sectional view of the assembly of FIG. 1 taken along; FIG. 10...Catalytic converter assembly, 12...
One housing part, 14...Middle part with groove, 16...Groove, 18...Both ends without groove, 20...
... ridge, 22 ... peripheral lip, 30 ... other housing part, 32 ... grooved intermediate section, 34
...Groove, 36...Grooveless portion, 38...Protuberance,
50... Monolith.

Claims (1)

Claims: 1. A catalytic converter assembly having a housing and a catalyst support carrier housed within the housing, the housing comprising one housing spaced apart along a longitudinal plane of the housing. and a connecting means connecting the one housing part and the other housing part, wherein the one housing part connects the one housing part together when manufacturing the assembly. a ridge formed around substantially all of said one housing portion parallel to said longitudinal plane for providing support thereon; said one housing portion having a circumferential lip at its periphery; is formed, the other housing portion having a peripheral portion inserted into engagement with a peripheral lip of the one housing portion, and the other housing portion further having an insertion peripheral lip of the other housing portion. said other housing part parallel to said longitudinal plane for uniformly compressingly inserting said part into a peripheral lip of said one housing part perpendicular to said longitudinal plane with a desired force or depth within a predetermined range. a ridge formed around substantially all of the housing portions of the housing portion, the connecting means connecting a peripheral lip of the one housing portion to an insert peripheral portion of the other housing portion; catalytic converter assembly. 2. The peripheral lip of the one housing portion is
an outwardly projecting peripheral edge, the other housing part having a downwardly projecting peripheral part having a flattened portion inserted to engage a peripheral lip of the one housing part; The peripheral lip of the one housing portion and the flat portion of the other housing portion form a gap adjacent the peripheral edge of the one housing portion to retain a weld layer for connecting the housing portions. A catalytic converter assembly according to claim 1, characterized in that the catalytic converter assembly comprises: 3. The one housing portion has non-grooved end portions provided adjacent to the protuberance, and a grooved intermediate portion separating the non-groove end portions, and the other housing portion has non-grooved end portions adjacent to the protuberance. and a grooved intermediate portion separating the grooveless ends, the two grooved intermediate portions being formed around both housing portions; The catalytic converter assembly of claim 1, wherein the flat portion of said other housing portion is aligned upon compression insertion into the peripheral lip of said one housing portion.