Mat support/substrate subassembly and method of making a catalytic converter therewith

Claim 1

A method of assembling a catalytic converter having a monolithic ceramic substrate mounted by an intumescent mat in a housing with a controlled mount density comprising the steps of: selecting a monolithic substrate from an inventory of such substrates having different peripheral dimensions; measuring the peripheral dimension of the monolithic substrate selected; selecting from an inventory of intumescent mat a length of such mat predetermined by the measurement of such peripheral dimension; wrapping such predetermined length of mat around the monolithic substrate; and installing the wrapped monolithic substrate in the housing, whereby the predetermined length of mat provides a controlled mount density within the housing when the temperature increases during the operating life of the converter.

Claim 2

A method of assembling a catalytic converter having a monolithic ceramic substrate mounted by an intumescent mat in a housing with a controlled mount density comprising the steps of: selecting a monolithic substrate from an inventory of such substrates having different peripheral dimensions; measuring the peripheral dimension of the monolithic substrate selected; selecting from an inventory of intumescent mat a length of such mat predetermined by the measurement of such peripheral dimension; wrapping such predetermined length of mat around the monolithic substrate; and installing the wrapped monolithic substrate in the housing, whereby the predetermined length of mat provides a controlled mount density within the housing when the temperature increases during the operating life of the converter.

Claim 3

A method of controlling the mount density of an intumescent mat around a ceramic substrate of unknown but varied dimension when the substrate is installed in a monolithic catalytic converter housing of fixed dimension comprising the steps of: selecting at random a ceramic substrate; and wrapping sufficient convolute layers of mica mat about the selected ceramic substrate to effect a resultant mat/substrate subassembly of predetermined dimension to compensate for the variations in such substrate dimension whereby the mat mount density remains within predetermined values when installed in such converter irrespective of the variations in the dimension of the substrate selected.

Claim 4

A method of controlling the mount density of an intumescent mat around a ceramic substrate of unknown but varied dimension when the substrate is installed in a monolithic catalytic converter housing of fixed dimension comprising the steps of: selecting at random a ceramic substrate; and wrapping sufficient convolute layers of mica mat about the selected ceramic substrate to effect a resultant mat/substrate subassembly of predetermined dimension to compensate for the variations in such substrate dimension whereby the mat mount density remains within predetermined values when installed in such converter irrespective of the variations in the dimension of the substrate selected.

Claim 5

A method of controlling the mount density of an intumescent mat around a frangible substrate of unknown but varied dimension when the substrate is installed in a monolithic catalytic converter housing of fixed dimension comprising the steps of: selecting at random a frangible substrate; and wrapping sufficient convolute layers of mica mat about the selected frangible substrate to effect a resultant mat/substrate subassembly of predetermined dimension to compensate for the variations in such substrate dimension whereby the mat mount density remains within predetermined values when installed in such converter irrespective of the variations in the dimension of the substrate selected.

Claim 6

A method of controlling the mount density of an intumescent mat around a frangible substrate of unknown but varied dimension when the substrate is installed in a monolithic catalytic converter housing of fixed dimension comprising the steps of: selecting at random a frangible substrate; and wrapping sufficient convolute layers of mica mat about the selected frangible substrate to effect a resultant mat/substrate subassembly of predetermined dimension to compensate for the variations in such substrate dimension whereby the mat mount density remains within predetermined values when installed in such converter irrespective of the variations in the dimension of the substrate selected.