Abstract: A housing for a catalytic converter for an automotive vehicle engine exhaust system is formed of two deep drawn shells having open inner ends welded together in generally abutting relation. Modified conical outer ends taper to reduced size openings for connection to associated exhaust system pipes. To permit deep drawing, the outer ends as seen in longitudinal cross section are formed with curved surfaces including an intermediate curvature replacing a conventional conical shape and defined by radii of a value between 0.5 and 0.8 times the inner diameter of the tubular body portions of the respective shells which enclose a catalytic element. Connecting radii are preferably not greater than 0.1 times the tubular portion inner diameter. Various alternative forms of welded inner end joints are disclosed.

Abstract: A method of manufacturing an oval shaped catalytic converter that reduces the amount of material and number of parts that are required for permitting the catalytic converter to treat the exhaust gases of an internal combustion engine and also improves the structural durability of the converter for high temperature applications by maintaining a higher mat density along the minor axis of the converter housing.