Abstract: A method of making a catalytic converter includes providing a catalyst substrate having a substrate periphery and a mat support disposed thereon. The method also includes providing a metal shell having a shell wall having a shell periphery and a bore that is configured to receive the catalyst substrate and mat support. It further includes inserting the catalyst substrate and mat support into the bore of the metal shell in slidable engagement therewith. Still further it includes reducing the shell periphery while applying an axial force sufficient to cause translation of the catalyst substrate and mat support relative to the bore until the force reaches a predetermined retention force threshold, whereupon the reducing of the shell periphery and translation of the catalyst substrate is stopped.

Abstract: A method of making a catalytic converter includes providing a catalyst substrate having a substrate periphery and a mat support disposed thereon. The method also includes providing a metal shell having a shell wall having a shell periphery and a bore that is configured to receive the catalyst substrate and mat support. It further includes inserting the catalyst substrate and mat support into the bore of the metal shell in slidable engagement therewith. Still further it includes reducing the shell periphery while applying an axial force sufficient to cause translation of the catalyst substrate and mat support relative to the bore until the force reaches a predetermined retention force threshold, whereupon the reducing of the shell periphery and translation of the catalyst substrate is stopped.

Abstract: A method and apparatus for spin forming a portion of a workpiece includes at least two rollers rotatable about a spin axis. Each one of the rollers is axially and radially offset from the others. An axial drive mechanism reciprocates the rollers or workpiece to causes the first roller and then the second roller to sequentially engage the workpiece. A higher reduction ratio is achieved which enables improved efficiency. The present invention reduces floor space requirements as the forming operation may be completed on a single machine.

Abstract: A method and apparatus for spin forming a portion of a workpiece where the formed portion has a formed axis that is non-coaxial with the non-processed axis of the workpiece includes at least two rollers rotatable about a spin axis. Each one of the rollers is axially and radially offset from the others. An axial drive mechanism reciprocates the rollers or workpiece to causes the first roller and then the second roller to sequentially engage the workpiece. A pivoting mechanism rotates the rollers or workpiece about a pivot point from a first angular position to a second angular position during a forming operation to create a formed portion that is oblique to the non-processed portion or is substantially curved. A higher reduction ratio is achieved which enables improved efficiency. The present invention reduces floor space requirements as the forming operation may be completed on a single machine.

Abstract: Exhaust emission control devices utilizing pelletized retention material and methods of making the same are disclosed herein. In one embodiment, the method comprises: disposing a treatment element within a shell, dispensing a pelletized retention material between the shell and the treatment element, and securing the retention material between the shell and the treatment element.

Abstract: The catalytic converter comprises a shell having a curled edge. When assembling the catalytic converter, the curled edge is inserted into the mat support material of the mat support material/catalyst substrate subassembly disposed in the shell. Once inserted, the curled edge and mat support material form an airgap that can thermally insulate and mechanically isolate the mat support material.

Abstract: In one embodiment, a method for manufacturing a device comprises disposing a first end around a second end, disposing an induction coil around the first end, discharging a current through the induction coil, forming eddy currents on the surface of the first end, and magnetic impulse sizing the first end and the second end together. The first end disposed around the second end comprises a tube end disposed around an end of the device or the first end disposed around the second end comprises the device end disposed around the tube end.

Abstract: The present disclosure relates to a stuffing cone apparatus, method for making a gas treatment device, and the device made therefrom. In one embodiment, the stuffing cone apparatus comprises: a funnel having a first end and a second end, with the second end having a smaller diameter than the first end, a pusher detail comprising a pusher disc perpendicularly disposed on an end of a pusher arm, wherein the pusher detail is slideable within the funnel, and a retainer detail comprising a retainer disc perpendicularly disposed to an end of a retainer arm, wherein the retainer detail is slideable within the funnel. The retainer disc and the pusher disc are capable of physically contacting opposite sides of a substrate within the funnel.

Abstract: An improved emission control device of the type comprising a substrate contained within a metallic housing. The substrate is positioned within the housing and in use a gas is directed through the substrate by a gasket. The improvement provides several embodiments for reduced frequency of substrate failure and reduced wear on the gasket in use.

Abstract: In one embodiment, a method for manufacturing a device comprises disposing a first end around a second end, disposing an induction coil around the first end, discharging a current through the induction coil, forming eddy currents on the surface of the first end, and magnetic impulse sizing the first end and the second end together. The first end disposed around the second end comprises a tube end disposed around an end of the device or the first end disposed around the second end comprises the device end disposed around the tube end.

Abstract: A method for manufacturing a catalytic converter comprising disposing a first end around a second end and disposing an induction coil around the first end. Discharging a current through the induction coil and forming eddy currents on the surface of the first end. This magnetic impulse welds the first end and the second end together such that the first end disposed around the second end comprises a tube end disposed around an end of a catalytic converter or such that the first end disposed around the second end comprises the catalytic converter end disposed around the tube end. The method can be used to weld pieces of the catalytic converter, as well as sizing the catalytic converter for a desired mat density.

Abstract: A method for manufacturing a catalytic converter comprising disposing a first end around a second end and disposing an induction coil around the first end. Discharging a current through the induction coil and forming eddy currents on the surface of the first end. This magnetic impulse welds the first end and the second end together such that the first end disposed around the second end comprises a tube end disposed around an end of a catalytic converter or such that the first end disposed around the second end comprises the catalytic converter end disposed around the tube end. The method can be used to weld pieces of the catalytic converter, as well as sizing the catalytic converter for a desired mat density.