Method of making catalytic converters for exhaust gases

Claim 1

The method of making a catalytic converter for use in the exhaust systems of combustion engines which comprises assembling an annular layer of resilient fibers around the outer periphery of a porous monolithic refractory catalyst element so that an end portion of the layer extends axially a short distance beyond one end of the eklement, inserting the combined element and layer into a tubular metal shell by moving it axially with respect to the shell and positioning it axially in the shell so that an end portion of the shell extends axially a shorte distance beyond said end portion of the layer, bending said end portions of the layer and shell inwardly so that the layer portion extends radially across the adjacent corner of the element to act as a mechanical barrier against axial movement of the element, and attaching inlet and outlet headers to the shell and located respectively at opposite ends of the element to provide for passage of gas through the element by fitting annular end sections at the respective downstream and upstream ends of the headers around the exterior end peripheral surfaces of the shell and welding them thereto.

Claim 2

The method of making a catalytic converter for use in the exhaust systems of combustion engines which comprises assembling an annular layer of resilient fibers around the outer periphery of a porous monolithic refractory catalyst element so that an end portion of the layer extends axially a short distance beyond one end of the eklement, inserting the combined element and layer into a tubular metal shell by moving it axially with respect to the shell and positioning it axially in the shell so that an end portion of the shell extends axially a shorte distance beyond said end portion of the layer, bending said end portions of the layer and shell inwardly so that the layer portion extends radially across the adjacent corner of the element to act as a mechanical barrier against axial movement of the element, and attaching inlet and outlet headers to the shell and located respectively at opposite ends of the element to provide for passage of gas through the element by fitting annular end sections at the respective downstream and upstream ends of the headers around the exterior end peripheral surfaces of the shell and welding them thereto.

Claim 3

The method of making a catalytic converter for use in the exhaust systems of combustion engines which comprises assembling an annular layer of resilient fibers around the outer periphery of a porous monolithic refractory catalyst element so that opposite end portions of the layer extend axially a short distance beyond the adjacent ends of the element, inserting the combined element and layer into a tubular metal shell by moving it axially with respect to the shell and positioning it axially in the shell so that opposite end portions of the shell extend axially a short distance beyond the respective end portions of the layer, bending said end portions of the layer and shell inwardly so that the layer portions extend radially across the adjacent end corners of the element to act as mechanical barriers against axial movement of the element, and attaching inlet and outlet headers to the shell and located respectively at opposite ends of the element to provide for passage of gas through the element by fitting annular end sections at the respective downstream and upstream ends of the headers around the exterior end peripheral surfaces of the shell and welding them thereto.

Claim 4

The method of making a catalytic converter for use in the exhaust systems of combustion engines which comprises assembling an annular layer of resilient fibers around the outer periphery of a porous monolithic refractory catalyst element so that opposite end portions of the layer extend axially a short distance beyond the adjacent ends of the element, inserting the combined element and layer into a tubular metal shell by moving it axially with respect to the shell and positioning it axially in the shell so that opposite end portions of the shell extend axially a short distance beyond the respective end portions of the layer, bending said end portions of the layer and shell inwardly so that the layer portions extend radially across the adjacent end corners of the element to act as mechanical barriers against axial movement of the element, and attaching inlet and outlet headers to the shell and located respectively at opposite ends of the element to provide for passage of gas through the element by fitting annular end sections at the respective downstream and upstream ends of the headers around the exterior end peripheral surfaces of the shell and welding them thereto.