Delphi Technologies, Inc.

Katcon Global S.a.

Jeffrey B Hardesty

Stephen Joe Myers

John Boehnke

Paul E Jankowski

Alan E Kasten

Dana M Serrels

Michael Ralph Foster

David Emil Nelson

Eric C Schultz

Gordon J Rutland

An outer housing and method of forming a mounting boss therein, the outer housing comprising: an elongated housing portion defining an inlet opening and an outlet opening, the elongated housing portion having a thickened area defined by an overlapping portion of the elongated housing; a sensor mounting boss formed in the overlapping portion with only displaced portions of the overlapping portion; and a plurality of threads disposed in the sensor mounting boss.

Gas sensor mounting boss and method of making

A catalytic converter subassembly having at least one component inserted during the manufacture of a cast exhaust manifold, thereby eliminating a costly and undesirable manifold to converter weld. The method and converter subassembly comprise a converter shell for housing a catalyst substrate adapted to be securely attached to an exhaust manifold during manufacture of the manifold to eliminate an undesirable weld between the manifold and converter.

Exhaust manifold with catalytic converter shell tube

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.

Apparatus and method for manufacturing a catalytic converter

An exhaust system comprising a catalytic converter unit, a bushing element provided in a shell wall of the catalytic converter unit, and an oxygen sensor positioned within exhaust flow of the catalytic converter unit and extending through the bushing element and having a connector disposed in intimate contact with the bushing element, and a method of positioning such an oxygen sensor in an exhaust system component.

Catalytic converter with integral oxygen sensor

A catalytic converter comprises an exhaust manifold comprising a manifold wall; a catalytic converter shell, wherein a portion of the catalytic converter shell is disposed within the manifold wall; and a catalyst substrate disposed in the catalytic converter shell.

A filler metal including not more than about 0.1% C, not more than about 1.0% Si; not more than about 0.8% Mn; from about 10.5% to about 13.0% Cr; from about 0.65% to about 4.0% Ni; from about 10(% C) to about 1.5% Ti; not more than about 0.5% each of N, S, P, Mo, Nb, Cu, V, or Co; and balance essentially Fe, wherein a weld test pad of the filler metal contains a microstructure comprising martensite. A method of attaching together two components using a modified filler metal which forms a weld containing an amount of martensite sufficient to increase the volume of the weld thereby at least partially offsetting shrinkage of the weld upon cooling, and articles produced thereby.

Weld filler metal that reduces residual stress and distortion

An exhaust emission control device is manufactured by sizing a housing of over a substrate and intumescent mat subsequently to heating said emission control device. The step of heating causes said intumescent mat to at least reach a temperature at which it swells. If the substrate has a washcoat layer, it may be left unfired until after it is assembled with the housing, in which case the step of heating causes the washcoat layer to sinter.

Exhaust emission control device manufacturing method

In one embodiment, a method for manufacturing a device comprises disposing a first end around a second end, disposing an induction coil around the first end, discharging a current through the induction coil, forming eddy currents on the surface of the first end, and magnetic impulse sizing the first end and the second end together. The first end disposed around the second end comprises a tube end disposed around an end of the device or the first end disposed around the second end comprises the device end disposed around the tube end.

Method of manufacturing an exhaust emission control device

A solid plate of material has an outer side and an inner side. A hole is disposed in and through the solid plate, the hole being capable of receiving from the outer side one end of an exhaust pipe. The inner side of the solid plate has a collar capable of being received within an annular edge of a catalytic converter housing. The outer and inner sides of the end plate have an area outside the circumference of the catalytic converter housing that contains at least one hole capable of receiving a bolt or other fastening mechanism.

Versatile end plate converter design using powder metal

A method for manufacturing a catalytic converter comprising disposing a first end around a second end and disposing an induction coil around the first end. Discharging a current through the induction coil and forming eddy currents on the surface of the first end. This magnetic impulse welds the first end and the second end together such that the first end disposed around the second end comprises a tube end disposed around an end of a catalytic converter or such that the first end disposed around the second end comprises the catalytic converter end disposed around the tube end. The method can be used to weld pieces of the catalytic converter, as well as sizing the catalytic converter for a desired mat density.

Growing community of inventors

Byron, MI, United States of America

Jeffrey B Hardesty