Abstract: An exhaust gas treatment device, which includes an outer layer, an inner layer that is at least in part disposed within the outer layer, and an insulation material disposed in an enclosed space between the outer layer and the inner layer, where at least one reservoir disposed with the insulation material is connected to the enclosed space and in fluid communication therewith and a manufacturing method that includes placing an insulation material into an enclosed space between an inner layer and an outer layer for an exhaust gas treatment device and placing the insulation material into a reservoir connected to the enclosed space and in fluid communication therewith.

Abstract: A method is provided for installing a multi-layer mat (24) in an exhaust gas aftertreatment or acoustic device. The method includes the steps of wrapping the mat (24) around an inner surface of the device along the same plane for at least a complete wrap around the inner surface; subsequently wrapping the mat (24) around the already completed wrap such that each of the successive wraps of the mat (24) are offset a constant distance from the plane of the previous wrap; a final wrap of the mat (24) wherein the mat is wrapped along a final plane for at least a complete wrap around the catalyst; and installing the mat (24) in the device (18) after the wrapping steps.

Abstract: A method is provided for installing a multi-layer mat (24) in an exhaust gas aftertreatment or acoustic device. The method includes the steps of wrapping the mat (24) around an inner surface of the device along the same plane for at least a complete wrap around the inner surface; subsequently wrapping the mat (24) around the already completed wrap such that each of the successive wraps of the mat (24) are offset a constant distance from the plane of the previous wrap; a final wrap of the mat (24) wherein the mat is wrapped along a final plane for at least a complete wrap around the catalyst; and installing the mat (24) in the device (18) after the wrapping steps.

Abstract: A method is provided for installing a multi-layer mat (24) in an exhaust gas aftertreatment or acoustic device. The method includes the steps of wrapping the mat (24) around an inner surface of the device along the same plane for at least a complete wrap around the inner surface; subsequently wrapping the mat (24) around the already completed wrap such that each of the successive wraps of the mat (24) are offset a constant distance from the plane of the previous wrap; a final wrap of the mat (24) wherein the mat is wrapped along a final plane for at least a complete wrap around the catalyst; and installing the mat (24) in the device (18) after the wrapping steps.

Abstract: A method is provided for installing a multi-layer mat (24) in an exhaust gas aftertreatment or acoustic device. The method includes the steps of wrapping the mat (24) around an inner surface of the device along the same plane for at least a complete wrap around the inner surface; subsequently wrapping the mat (24) around the already completed wrap such that each of the successive wraps of the mat (24) are offset a constant distance from the plane of the previous wrap; a final wrap of the mat (24) wherein the mat is wrapped along a final plane for at least a complete wrap around the catalyst; and installing the mat (24) in the device (18) after the wrapping steps.

Abstract: A method is provided for installing a multi-layer mat (24) in an exhaust gas aftertreatment or acoustic device. The method includes the steps of wrapping the mat (24) around an inner surface of the device along the same plane for at least a complete wrap around the inner surface; subsequently wrapping the mat (24) around the already completed wrap such that each of the successive wraps of the mat (24) are offset a constant distance from the plane of the previous wrap; a final wrap of the mat (24) wherein the mat is wrapped along a final plane for at least a complete wrap around the catalyst; and installing the mat (24) in the device (18) after the wrapping steps.

Abstract: A method is provided for installing a multi-layer mat (24) in an exhaust gas aftertreatment or acoustic device. The method includes the steps of wrapping the mat (24) around an inner surface of the device along the same plane for at least a complete wrap around the inner surface; subsequently wrapping the mat (24) around the already completed wrap such that each of the successive wraps of the mat (24) are offset a constant distance from the plane of the previous wrap; a final wrap of the mat (24) wherein the mat is wrapped along a final plane for at least a complete wrap around the catalyst; and installing the mat (24) in the device (18) after the wrapping steps.

Abstract: An outer housing and method of forming a mounting boss therein, the outer housing comprising: an elongated housing portion defining an inlet opening and an outlet opening, the elongated housing portion having a thickened area defined by an overlapping portion of the elongated housing; a sensor mounting boss formed in the overlapping portion with only displaced portions of the overlapping portion; and a plurality of threads disposed in the sensor mounting boss.

Abstract: Disclosed herein is a method of making a catalytic converter; forming a shell having a welding deformation detail; inserting and housing a catalyst substrate inside the shell, wherein a mat support material is disposed between the shell and the catalyst substrate; welding an end cone having a flange to the shell by applying a deformation force to the flange causing deformation of welding deformation detail.

Abstract: An exhaust system comprising a catalytic converter unit, a bushing element provided in a shell wall of the catalytic converter unit, and an oxygen sensor positioned within exhaust flow of the catalytic converter unit and extending through the bushing element and having a connector disposed in intimate contact with the bushing element, and a method of positioning such an oxygen sensor in an exhaust system component.

Abstract: An embodiment of a method for producing a gas treatment device includes disposing a mat support material about a substrate to form a subassembly; passing at least a portion of the subassembly into a main body portion of a housing that has a first portion having a decreasing internal diameter from a first end to the main body portion, the main body portion extending from the first portion.

Abstract: A variable flow regulator assembly includes a first stationary exhaust pipe, a second stationary exhaust pipe concentrically disposed within the first stationary exhaust pipe, and a movable exhaust pipe concentrically disposed between the first and second stationary exhaust pipes. The first stationary exhaust pipe includes one or more interference tabs concentrically and circumferentially fitted about its interior surface. The movable exhaust pipe includes one or more interference tabs concentrically and circumferentially fitted about its exterior surface. The interference tabs complimentarily interact and restrict the movement of the variable flow regulator so that the flow maldistribution of the exhaust gas stream entering the catalytic converter can be variably controlled.

Abstract: A variable flow regulator assembly comprises a first stationary exhaust pipe, a second stationary exhaust pipe concentrically disposed within the first stationary exhaust pipe, and a movable exhaust pipe concentrically disposed between the first and second stationary exhaust pipes. The first stationary exhaust pipe includes one or more interference tabs concentrically and circumferentially fitted about its interior surface. The movable exhaust pipe includes one or more interference tabs concentrically and circumferentially fitted about its exterior surface. The interference tabs complimentarily interact and restrict the movement of the variable flow regulator so that the flow maldistribution of the exhaust gas stream entering the catalytic converter can be variably controlled.

Abstract: Disclosed herein is a method of making a catalytic converter; forming a shell having a welding deformation detail; inserting and housing a catalyst substrate inside the shell, wherein a mat support material is disposed between the shell and the catalyst substrate; welding an end cone having a flange to the shell by applying a deformation force to the flange causing deformation of welding deformation detail.

Abstract: A gas treatment system comprises a variable flow regulator assembly placed in operable and fluid communication with a shell of a gas treatment device. The variable flow regulator assembly comprises two or more conduit portions comprising a first portion and a second portion, wherein the second portion has a coefficient of thermal expansion greater than a first coefficient of thermal expansion of the first portion. The variable flow regulator assembly structurally changes shape to alter the flow maldistribution of an exhaust gas stream into the gas treatment device when light off is achieved.

Abstract: Disclosed herein is an apparatus and method for manufacturing an exhaust emission control device, and the exhaust emission control device formed thereby. The method of manufacturing an exhaust emission control device, comprises: disposing a viscous-elastic material around at least a portion of a substrate to form a wrapped element. The wrapped element is compressed at a first compression rate and at a second compression rate that is slower than the first compression rate, and the wrapped element is introduced into a housing.

Abstract: Disclosed herein is an apparatus and method for manufacturing an exhaust emission control device, and the exhaust emission control device formed thereby. The method of manufacturing an exhaust emission control device, comprises: disposing a viscous-elastic material around at least a portion of a substrate to form a wrapped element. The wrapped element is compressed at a first compression rate and at a second compression rate that is slower than the first compression rate, and the wrapped element is introduced into a housing.

Abstract: An exhaust system comprising a catalytic converter unit, a bushing element provided in a shell wall of the catalytic converter unit, and an oxygen sensor positioned within exhaust flow of the catalytic converter unit and extending through the bushing element and having a connector disposed in intimate contact with the bushing element, and a method of positioning such an oxygen sensor in an exhaust system component.

Abstract: One embodiment of a gas treatment device comprises: a substrate; a housing disposed concentrically about the substrate, the housing comprising a first portion having a decreasing internal diameter from a first end to a main body portion, the main body portion extending from the first portion; and a mat support material disposed concentrically about the substrate to form a subassembly, wherein the subassembly is at least partially disposed in the main body portion.

Abstract: A variable flow regulator assembly comprises a first stationary exhaust pipe, a second stationary exhaust pipe concentrically disposed within the first stationary exhaust pipe, and a movable exhaust pipe concentrically disposed between the first and second stationary exhaust pipes. The first stationary exhaust pipe includes one or more interference tabs concentrically and circumferentially fitted about its interior surface. The movable exhaust pipe includes one or more interference tabs concentrically and circumferentially fitted about its exterior surface. The interference tabs complimentarily interact and restrict the movement of the variable flow regulator so that the flow maldistribution of the exhaust gas stream entering the catalytic converter can be variably controlled.