Inlet Device for a Catalytic Converter

Abstract

An inlet device for a catalytic converter is disclosed, which includes an inner shell, an outer shell and a flange. The inner shell, outer shell and flange each have a fastening end with a fastening opening. The flange is arranged at least partially between the inner shell and outer shell and fastened to the inner shell by a first connection between an outer surface of the inner shell and a front face on the flange, and to the outer shell by a second connection different from the first one between an outer surface of the flange and a front face of the outer shell.

Claims

1-10. (canceled)

11. An inlet device for a catalytic converter comprising: an inner shell having a first fastening end defining a first opening; an outer shell having a second fastening end defining a second opening, wherein the outer shell at least partially surrounds the inner shell; a flange having a third fastening end defining a third opening, wherein the third fastening end is at least partially arranged between the first and second fastening ends; a first connection fastening the inner shell to the flange; and a second connection, which is separate from the first connection, fastening the outer shell to the flange.

12. The inlet device according to claim 11, wherein the first connection is arranged between a first outer surface of the inner shell and a third front face of the flange, and the second connection is arranged between a third outer surface of the flange and a second front face of the outer shell.

13. The inlet device according to claim 11, wherein the first connection comprises a first welded joint between the first outer surface of the inner shell and the third front face of the flange, and the second connection comprises a second welded joint between the third outer surface of the flange and the second front face of the outer shell.

14. The inlet device according to claim 11, wherein the outer shell at least partially covers the first connection.

15. The inlet device according to claim 11, wherein the first fastening opening defines a first cross sectional shape with a first cross sectional dimension, the second fastening opening defines a second cross sectional shape having a second cross sectional dimension, and the third fastening opening defines a third cross sectional shape having a third cross sectional dimension, wherein the first, second and third cross sectional shapes are similarly shaped, and the first, second and third cross sectional dimensions are different.

16. The inlet device according to claim 14, wherein the third cross sectional dimension is less than or equal to the second cross sectional dimension and greater than or equal to the first cross sectional dimension.

17. The inlet device according to claim 11, further comprising an insulating material disposed between the inner and outer shell.

18. A catalytic converter arrangement comprising: a catalytic converter having a housing with an inlet and an outlet; an inlet device according to claim 11 arranged in the inlet of the catalytic converter; and an outlet device arranged in the outlet of the catalytic converter.

19. An inlet device for a catalytic converter comprising: an inner shell having a first fastening end defining a first opening having a first cross sectional shape with a first cross sectional dimension; an outer shell having a second fastening end defining a second opening having a second cross sectional shape with a second cross sectional dimension, wherein the outer shell at least partially surrounds the inner shell; a flange having a third fastening end defining a third opening having a third cross sectional shape with a third cross sectional dimension, wherein the third fastening end is at least partially arranged between the first and second fastening ends; a first welded joint arranged between a first outer surface of the inner shell and a third face of the flange to fasten the inner shell to the flange, wherein the outer shell at least partially covers the first connection; and a second welded joint arranged between a third outer surface of the flange and a second face of the outer shell to fasten the outer shell to the flange, wherein the second front face is longitudinally offset from the third face such that second welded joint is different from the first welded joint; wherein the first, second and third cross sectional shapes are similarly shaped, and the first, second and third cross sectional dimensions are different.

20. A method for manufacturing an inlet device for a catalytic converter comprising: providing an inner shell arranging an inner surface of a flange on an outer surface of the inner shell; forming a first connection between the outer surface of the inner shell and a front face of the flange; arranging an inner surface of an outer shell on an outer surface of the flange such that the outer shell at least partially surrounds the inner shell; and forming a second connection between the outer surface of the flange with the a front face of the outer shell, wherein the second connection is different from the first connection.

21. The method according to claim 19, wherein forming a first connection comprises forming a first welded joint between the outer surface of the inner shell and the front face of the flange, and forming a second connection comprises forming a second welded joint between the outer surface of the flange with the a front face of the outer shell.

22. The method according to claim 19, further comprising disposing an insulating material between the inner and outer shells.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The present disclosure will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements.

[0024] FIG. 1 is a schematic outer view of a catalytic converter with an inlet device;

[0025] FIG. 2 is a schematic side view of an inlet device as known from prior art;

[0026] FIG. 3 is a schematic side view of an inlet device according to an embodiment of the present disclosure;

[0027] FIG. 4 is a detailed view of FIG. 3; and

[0028] FIG. 5 is a flowchart for an embodiment of a method according to the present disclosure.

DETAILED DESCRIPTION

[0029] The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the invention or the following detailed description.

[0030] FIG. 1 presents a schematic outer view of a catalytic converter arrangement 1 including a catalytic converter 10, an inlet device 100 as well as an outlet device 200. The inlet device 100 includes an inner shell (not shown in FIG. 1), an outer shell 120 and a flange 130. The outer shell 120 has a fastening end 121 and a transition end 129. The flange 130 likewise has a fastening end (not shown in FIG. 1) and a transition end 139. The flange 130 has a fastening opening 132, which has a circular cross sectional shape 137. The outer shell is shaped at least partially like a spherical layer, and the flange at least partially like a ring.

[0031] FIG. 2 presents a schematic sectional view of a conventional inlet device 900 having an inner shell 910, an outer shell 920 as well as a flange 930. The inner shell 910, outer shell 920 and flange 930 are here joined together with a single connection 960. An insulating material 990 is at least partially arranged between the inner shell 910 and outer shell 920.

[0032] FIG. 3 presents a schematic side view of an inlet device 100 according to an embodiment of the present disclosure. This inlet device 100 has an inner shell 110, an outer shell 120 as well as a flange 130. The inner shell 110, outer shell 120 and flange 130 here each have a fastening opening 112, 122, 132, respectively having a first, second and third cross sectional dimension 116, 126, 136. The third cross sectional dimension 136 (of the flange 130) is here larger than the first cross sectional dimension 116 (of the inner shell) 110 and smaller than the second cross sectional dimension 126 (of the outer shell 120). The flange is fastened to the inner shell 110 by means of a first connection 140, and to the outer shell 120 by means of a second connection 150 different from the first one. An insulating material 190 is at least partially arranged between the outer shell 120 and inner shell 110.

[0033] FIG. 4 presents a detailed view of an inlet device according to an embodiment of the present disclosure. As evident therein, the inner shell 110, the outer shell 120 as well as the flange 130 each have a fastening end 111, 121, 131 and a transition end 119, 129, 139. The fastening end 131 of the flange 130 is here partially arranged between the fastening end 111 of the inner shell 110 and the fastening end 121 of the outer shell 120. The inner shell 110, outer shell 120 and flange 130 further each have an outer surface 113, 123, 133, an inner surface 114, 124, 134 and a front face 115, 125, 135. The fastening end 131 of the flange 130 is here arranged between the inner surface 124 of the outer shell 120 and the outer surface 113 of the inner shell 110. The flange 130 is fastened to the inner shell by a first connection 140. This first connection 140 is arranged between the front face 135 of the flange 130 and the outer surface 113 of the inner shell 110. The flange 130 is further fastened to the outer shell 120 by a second connection 150 different from the first one. This second connection 150 is arranged between the front face 125 of the outer shell 120 and the outer surface 133 of the flange 130. An insulating material 190 is at least partially arranged between the outer shell 120 and inner shell 110.

[0034] FIG. 5 presents a flowchart for an embodiment of the method according to the present disclosure. An inner shell is here provided in the first step 1001, an outer shell is provided in the second step 1002, and a flange is provided in the third step 1003. The flange is then arranged on the inner shell in the next step 1004, and then joined with the inner shell by a first connection in an ensuing step 1005. This is followed by an optional step 1006, in which the outer shell is divided into two parts, provided the latter has not already been provided in two parts. The two-part outer shell is arranged on the flange in the next step 1007. The flange is joined with the outer shell by means of a second connection different from the first one in the following step 1008, and the outer shell is joined into one piece by a connection in the last step 1009.

[0035] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the various embodiments in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment as contemplated herein. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the various embodiments as set forth in the appended claims.