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.

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.