Corning Incorporated

Paul S Schmitt

Robert John Locker

Douglas A Aranda

G Daniel Lipp

Thomas Adam Collins

Lawrence S Rajnik

Alfred N Mack

Robert A Morse

A catalytic converter for purifying exhaust gases from an internal combustion engine includes a monolithic ceramic substrate having a peripheral surface encircled by a non-intumescent supporting mat material. A metal shell comprising a wider portion which is adjacent to and encloses the mat material and the substrate. The metal shell further comprises a narrower portion which overlaps and is attached to the outer surface of the wider metal shell portion. The wider and narrower metal shell portions combine to exert a compressive force on the wrapped substrate.

Catalytic converter for use in an internal combustion engine

Disclosed is a method of manufacturing a catalytic converter for purifying exhaust gases from an internal combustion engine wherein the converter exhibits a monolithic ceramic substrate surrounded by a supporting mat. The method generally includes the steps of: Forming a catalytic converter utilizing a compressive closing method generally involves wrapping the substrate in a sufficient amount of supporting mat material and inserting the wrapped substrate into generally cylindrical metal container, compressively closing the container around the wrapped substrate sufficiently to provide a gas tight seal and to hold the imparted compressive stress. The present invention further discloses an improvement involving compressively closing the container around the wrapped substrate by resizing the container over substantially the entire portion of its length which is occupied by the wrapped substrate to a predetermined metal shell/container outside diameter OD. The predetermined outside diameter is characterized by the equation OD&equals;D&plus;2T &plus;2T , wherein D is a diameter measure of the substrate, T is the supporting mat target thickness and T is a container wall thickness measure.

Method of making a catalytic converter for use in an internal combustion engine

The invention is directed at a method of manufacturing these catalytic converters having non-round honeycomb substrates and comprises the following steps: (1) wrapping a non-round monolithic ceramic substrate, having a major and minor orthogonal axis, in a sufficient amount of the supporting mat material whereby the substrate's peripheral surface is substantially covered; (2) inserting the wrapped substrate into a metal shell, having a plurality of nodal points, which substantially surrounds the wrapped substrate; (3) placing the metal shell in a resizing die having a plurality of fingers, and associated gaps therebetween, extending axially along substantially the entire surface of the metal shell whereby the nodal points of the metal shell are positioned along a portion of a die finger and the placement of the metal shell and wrapped substrate, within the resizing die is such that the axes of the resizing die are angularly offset from the major and minor axes of the substrate; (4) compressively closing the container around the wrapped substrate by displacing the fingers of the resizing die radially inward to provide a gas tight seal and to hold the compressive stress by; and, (5) securing the metal shell to provide a gas tight seal and to hold the compressive stress.

A catalytic converter for purifying exhaust gases from an internal combustion engine includes a monolithic ceramic substrate having a peripheral surface encircled by a non-intumescent supporting mat material. A metal shell comprising a wider portion which is adjacent to and encloses the mat material and the substrate. The metal shell further comprises a narrower portion, preferably triangularly shaped, that overlaps and is attached to the outer surface of the wider metal shell portion. The wider and narrower metal shell portions combine to exert a compressive force on the wrapped substrate.

Catalytic converter for use in an internal combustion engine and a method of making

A method of manufacturing a catalytic converter for purifying exhaust gases from an internal combustion engine wherein the converter exhibits a monolithic ceramic substrate surrounded by a supporting mat. The method includes the steps of: wrapping the substrate in a sufficient amount of supporting mat material and inserting the wrapped substrate into the metal shell; forming a cylindrical metal shell having an inner surface exhibiting substantially the same curvature as the wrapped substrate; compressively closing the metal shell around the wrapped substrate to an optimized mat density range thereby resulting in the supporting mat exhibiting a substantially uniform and maximum safe compressive stress on the substrate; and, securing together metal shell to provide a gas tight seal and to hold the compressive stress. The optimized mat density range determined by plotting the mat density-mat holding pressure relationship and the mat density-retained cyclic strength ratio relationship of the supporting mat material on a common graph and selecting an optimized range on the mat density-mat holding pressure, and thereafter obtaining the corresponding optimized mat density range.

Method of making a catalytic converter for use in an internal combustion

Disclosed is method of manufacturing catalytic converters having a ceramic honeycomb surrounded by a supporting mat and located within a housing, comprising the following steps: (1) forming a cylindrical metal shell exhibiting a uniform curvature and having a lap joint exhibiting substantially the same curvature as the outer surface of the metal shell; (2) wrapping the honeycomb in a sufficient amount of supporting mat material and inserting the wrapped honeycomb into the metal shell; (3) compressively closing the metal shell around the wrapped honeycomb thereby, eating a substantially uniform compressive stress on the honeycomb by the supporting mat.

A method of manufacturing a catalytic converter having a non-round monolithic ceramic substrate comprising the steps of: wrapping a non-round monolithic ceramic substrate in a sufficient amount of the supporting mat material whereby the substrate peripheral surface is substantially covered; inserting the wrapped substrate into a metal shell which substantially surrounds the wrapped substrate; placing at least one force redistribution plug on the peripheral surface of the metal shell and compressively closing the metal shell around the substrate; and securing the metal shell to provide a gas tight seal and to hold the compressive stress.

A lead construction for a fluid heater such as an electrically heated catalytic converter, is set forth including a mineral insulated cable having a central core connected to the heater element of the fluid heater, an outer metal sheath connected to an enclosing housing for the fluid heater, and electrical insulation between the central core and the outer sheath.

Electrical leads for a fluid heaters

A metal honeycomb heater is protectively mounted in an axially assembled enclosure comprising opposing tubular enclosure sections incorporating internal bore stops and a resilient mounting material to support the heater. An axial force of predetermined magnitude is applied to the sections during assembly, preloading the resilient mounting material and generating a selected spring tension and preloading force on the honeycomb. The sections are fastened together under this force so that the preloading force and spring tension are retained during subsequent use of the assembly.

Axially assembled enclosure for electrical fluid heater and method

Glass optical elements are molded by moving molds toward one another to press the glass and controlling the movement of the molds to balance the complete formation of the molded surfaces. A first mold is moved to a position short of contact with the glass and parked. A second mold is moved into contact with the glass to drive the glass into contact with the molding surface of the first mold. This changes the shape of the optical surface in contact with the second mold so that continued movement of the first and second molds results in balanced molding with the voids between the molding surfaces and the glass being equivalent for both surfaces.

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Big Flats, NY, United States of America

Paul S Schmitt