Apparatus and method for manufacturing a catalytic converter

Abstract

Disclosed herein is a method of making a catalytic converter; forming a shell having a welding deformation detail; inserting and housing a catalyst substrate inside the shell, wherein a mat support material is disposed between the shell and the catalyst substrate; welding an end cone having a flange to the shell by applying a deformation force to the flange causing deformation of welding deformation detail.

1 - 9 . (canceled)  
     
     
         10 . A method of making a catalytic converter: 
 forming a shell comprising a welding deformation detail;    inserting and housing a catalyst substrate inside said shell, wherein a mat support material is disposed between said shell and said catalyst substrate;    welding an end cone comprising a flange to said shell by applying a deformation force to said flange causing deformation of welding deformation detail.    
     
     
         11 . The method of  claim 10 , wherein said rib portion is concave.  
     
     
         12 . The method of  claim 10 , wherein said rib portion is convex.  
     
     
         13 . The method of  claim 10 , wherein a mat protection surface is formed by said flange of said end cone.  
     
     
         14 . The method of  claim 10 , wherein a mat protection surface is formed by said rib portion of said shell.  
     
     
         15 . The method of  claim 10 , further comprising an inner end cone.  
     
     
         16 . The method of  claim 10 , further comprising an inner end cone comprising an inner end cone flange abutted and joined to said rib portion, wherein an insulating space is created between said end cone and said inner end cone.  
     
     
         17 . The method of  claim 16 , wherein said end cone flange comprises a plurality of tabs.  
     
     
         18 . The method of  claim 16 , wherein said insulating space is filled with a non-expanding ceramic material, an intumescent material, or a combination of the forgoing materials.  
     
     
         19 - 23 . (canceled)  
     
     
         24 . A method of making a catalytic converter comprising the steps of: 
 forming a generally cylindrical shell defining a characteristic line of elongation, said shell having at least one open end concentrically disposed on said line of elongation and an integrally formed welding deformation detail disposed adjacent said opening, said welding deformation detail including a radially distended circumferential rib portion;    inserting and housing a catalyst substrate inserted within said shell;    inserting and housing mat support material between said catalyst substrate and said shell;    forming an end cone;    aligning said end cone concentrically with the opening of said shell, said end cone defining a generally radially extending circumferential flange configured to substantially matingly abut said rib portion;    applying a deformation force about the circumference of said flange to simultaneously effect deformation of said welding deformation detail about the entire circumference thereof; and    forming a single circumferentially continuous deformation weldment interconnecting said end cone flange with the distended rib portion of said welding deformation detail simultaneously about the entire circumference thereof.