Catalytic converter for exhuast gases

Claim 2

A converter as set forth in claim 1 wherein the adjacent end of the shell has a shoulder adjacent the bent end portion of the fibrous layer to hold said bent layer portion in place over said corner.

Claim 3

A converter as set forth in claim 3 wherein said fibrous layer contains a differentially dispersed solid material deposited on the fibers in heavy concentrations adjacent the exposed surfaces of the layer and adjacent the outer layer surfaces in juxtaposition to said element and shell surfaces and in materially less concentration in the center portion of the layer whereby said center portion is resilient, said deposited material serving to harden and seal said exposed and outer layer surfaces and to bond the outer layer surfaces to said element and shell.

Claim 4

A converter as set forth in claim 4 wherein said fibrous layer is in contact with and bonded to said shell surface and said element surface and in compression between them and serves to seal the outside of the element.

Claim 5

A subassembly for use in a catalytic converter for purifying the exhaust gases of an internal combustion engine comprising a tubular metal shell having a longitudinal axis and opposite longitudinal end portions, a cylindrical fluid pervious frangible catalyst element having a longitudinal axis and longitudinally separated inlet and outlet end faces each with an outer circumferential corner, said element having an outer surface and said shell having an inner surface larger in cross section than said element outer surface, said element being positioned inside of said shell so that said axes are substantially coaxial and to provide a substantially uniform width annular space between said surfaces forming a substantially annular chamber with an axis substantially coaxial with said axes, an annular resilient nonmetallic fibrous insulating member in said annular chamber and serving to resiliently mount said element in said shell, fluid flow through said shell being substantially parallel to said axes, said shell end portions extending longitudinally beyond said inlet and outlet end faces of said element to protect said corners during handling of the subassembly, and flange means mechanically holding the shell, element, and member in substantially permanent longitudinal positions with respect to each other including radially extending portions of said fibrous member extending across and engaging said circumferential corners.

Claim 6

A combination as set forth in claim 6 wherein said flange means includes radially extending portions of said shell engaging and holding said fibrous member portions against said circumferential corners.

Claim 7

A catalytic converter for purifying the exhaust gases of internal combustion engines comprising a housing including a tubular shell, a frangible gas pervious refractory catalyst element inside said shell having inlet and outlet end faces with outer circumferential end corners and arranged so that flow through the element and faces is substantially axial with respect to the axis of the shell, means resiliently mounting said element inside said shell so thaT the outer surface of the element is spaced from the inner surface of the shell, an inlet means at one end of the shell, an outlet means at the other end of the shell, said resilient mounting means comprising a nonmetallic resilient fibrous insulating layer in the space between said surfaces having an axially and circumferentially extending portion axially overlapping an end face of the element and radially extending over the adjacent circumferential end corner of the element, said housing including means holding said layer portion over said corner.

Claim 8

A converter as set forth in claim 8 wherein said axially and circumferentially extending portion overlaps the inlet end face of the element and extends over the inlet end corner.

Claim 9

A converter as set forth in claim 8 wherein said axially and circumferentially extending portion overlaps the outlet end face of the element and extends over the outlet end corner.

Claim 10

A converter as set forth in claim 10 including a second axially and circumferentially extending portion axially overlapping the inlet end face of the element and radially extending over the inlet end corner, said housing including second means holding said second layer portion over said inlet corner.

Claim 11

A catalytic converter for purifying the exhaust gases of an internal combustion engine comprising a tubular metal shell having an outer cylindrical surface of substantially round uniform diameter cross section along most of the length of the shell, a gas pervious refractory catalyst element inside said shell and arranged so that flow through the element is substantially axial with respect to the axis of the shell, means resiliently mounting said element inside said shell so that the outer surface of the element is spaced from the inner surface of the shell, an inlet conduit having a flange fitting around the outside of and welded to said round outer cylindrical surface at one end of the shell, an outlet conduit having a flange fitting around the outside of and welded to said round outer cylindrical surface at the other end of the shell.

Claim 12

A converter as set forth in claim 12 including flange means engaging the outer circumferential corner at the outlet end of the element and providing a mechanical holding means against substantial axial displacement of the element in a downstream direction, said flange means comprising a fibrous layer in contact with said corner and a radial flange on the shell in contact with the fibrous layer.

Claim 13

A converter as set forth in claim 12 wherein said resilient mounting means includes a fibrous sleeve in the space between the element and shell, and flange means engaging the outer portion of the outlet end of the element and providing a mechanical holding means against substantial axial displacement of the element in a downstream direction, said flange means comprising a radially inwardly extending flange formed on the end of the shell, said flange means further comprising a radially inwardly extending flange formed on the fibrous sleeve and sandwiched between the shell flange and the element.

Claim 14

A converter as set forth in claim 12 including retainer means supported by said shell engaging the outer circumferential corner of the element at the outlet end thereof to resist substantial downstream displacement of the element.

Claim 15

A catalytic converter for purifying the exhaust gases of an internal combustion engine comprising a tubular metal shell, a gas pervious refractory catalyst element inside said shell and arranged so that flow through the element is substantially axial with respect to the axis of the shell, said element having a downstream end, means resiliently mounting said element inside said shell so that the outer surface of the element is spaced from the inner surface of the shell, an inlet conduit at one end of the shell, an outlet conduit at the other end of the shell, and flange means reacting against the downstream end of the element and providing a mechanical holding force against downstream axIal displacement of the element in one direction and comprising a fibrous layer extending radially inwardly from the outer surface of the element and in contact with the downstream end of the element and a radial flange formed integrally on the shell in contact with the fibrous layer.

Claim 16

A subassembly for use in a catalytic converter for purifying the exhaust gases of an internal combustion engine comprising a tubular metal shell having a longitudinal axis and opposite longitudinal end portions, a cylindrical fluid pervious frangible catalyst element having a longitudinal axis and longitudinally separated inlet and outlet end faces each with an outer circumferential corner, said element having an outer surface and said shell having an inner surface larger in cross section than said element outer surface, said element being positioned inside of said shell so that said axes are substantially coaxial and to provide a substantially uniform width annular space between said surfaces forming a substantially annular chamber with an axis substantially coaxial with said axes, a fibrous member in said annular chamber and serving to resiliently mount said element in said shell, fluid flow through said shell being substantially parallel to said axes, said shell end portions extending longitudinally beyond said inlet and outlet end faces of said element to protect said corners during handling of the subassembly, and flange means mechanically holding the element against movement in a downstream direction in the shell including a radially extending portion of said fibrous member extending across and engaging said outlet circumferential corner and a radially extending portion of said shell engaging said radially extending fibrous member portion.