Exhaust gas treatment device, especially for an exhaust gas flow path of an internal combustion engine, and method for manufacturing an exhaust gas treatment device

Abstract

An exhaust gas treatment device for an exhaust gas flow path of an internal combustion engine, includes a tubular carrier body (12) extending along a longitudinal axis (L) of the carrier with a first axial end area (18) and with a second axial end area (20) and at least one exhaust gas treatment element (34) carried in the carrier body (12) with the interposition of at least one fiber material layer (36). The carrier body (2) includes carrier elements (14, 16) connected to one another in a first connection area (22) and in a second connection area (24) that extend from the first axial end area (18) to the second axial end area (20). At least one connection area (22, 24) does not extend in parallel to the longitudinal axis (L) of the carrier from the first axial end area (18) to the second axial end area (20).

Claims

1. An exhaust gas treatment device for an exhaust gas flow path of an internal combustion engine, the exhaust gas treatment device comprising: a tubular carrier body extending along a carrier longitudinal axis between a first axial end area and a second axial end area; at least one exhaust gas treatment element carried in the carrier body; and at least one fiber material layer interposed between the tubular carrier body and the at least one exhaust gas treatment element, wherein the carrier body comprises a first carrier element and a second carrier element connected to one another in a first connection area and in a second connection area, the first connection area and the second connection area extend from the first axial end area to the second axial end area, at least one of the connection areas does not extend in parallel to the carrier longitudinal axis from the first axial end area to the second axial end area.

2. An exhaust gas treatment device in accordance with claim 1, wherein: the first connection area extends at an angle in relation to a reference plane containing the longitudinal axis of the carrier from the first axial end area to the second axial end area; and the second connection area extends at an opposite angle relative to the first connection area in relation to the reference plane from the first axial end area to the second axial end area.

3. An exhaust gas treatment device in accordance with claim 2, wherein: the carrier body has an cylindrical design with a circular circumferential contour; the first connection area and the second connection area extend helically in the same direction around the circumference of the carrier body from the first axial end area to a second axial end area.

4. An exhaust gas treatment device in accordance with claim 1, wherein: the carrier body has a cylindrical design with a circular circumferential contour; and the first connection area and the second connection area extend helically in the same direction around the circumference of the carrier body from the first axial end area to a second axial end area.

5. An exhaust gas treatment device in accordance with claim 1, wherein the first carrier element and the second carrier element comprise a connection section each extending radially outwardly in the first connection area and in the second connection area.

6. An exhaust gas treatment device in accordance with claim 1, wherein the first carrier element and the second carrier element are mutually identical shaped sheet metal parts.

7. An exhaust gas treatment device in accordance with claim 1, wherein the first carrier element and the second carrier element are connected to one another by welding in the first connection area and in the second connection area.

8. An exhaust gas treatment device in accordance with claim 1, wherein at least one of: the at least one exhaust gas treatment element comprises a soot particle filter element; and at least one exhaust gas treatment element comprises a catalytic converter element.

9. A method for manufacturing an exhaust gas treatment for an exhaust gas flow path of an internal combustion engine, wherein the exhaust gas treatment device comprises a tubular carrier body having a circular circumferential contour comprised of a half shell first carrier element and a half shell second carrier element and extends along a longitudinal axis of the carrier body, with a first axial end area and with a second axial end area, and at least one exhaust gas treatment element carried in the tubular carrier body with the interposition of at least one fiber material layer, the method comprising the steps of: providing the half shell first carrier element with a first connection section and with a second connection section, such that the first connection section and the second connection section extend in parallel to the longitudinal axis of the carrier body from the first axial end area to the second axial end area; providing the half shell second carrier element with a third connection section and with a fourth connection section, such that the third connection section and the fourth connection section extend in parallel to the longitudinal axis of the carrier body from the first axial end area to the second axial end area; arranging the half shell first carrier element such that the first connection section and the second connection section are located offset in relation to one another in a merging motion direction; arranging the half shell second carrier element such that the third connection section and the fourth connection section are located offset in relation to one another in the merging motion direction; and moving the half shell first carrier element and the half shell second carrier element towards one another in the merging motion direction such that the first connection section comes into contact with the third connection section and the second connection section comes into contact with the fourth connection section.

10. The method in accordance with claim 9, wherein when carrying out the step of moving, the first connection section comes into contact with the third connection section and the second connection section comes into contact with the fourth connection section simultaneously, the half shell first carrier element comprising a half shell first carrier element half circle contour, the half shell second carrier element comprising a half shell second carrier element half circle contour.

11. The method in accordance with claim 10, wherein the method further comprises the step of, prior to the step of moving, positioning at least one exhaust gas treatment element, enclosed by at least one layer of fiber material, in the first carrier element or in the second carrier element, the half shell first carrier element and the half shell second carrier element forming the tubular carrier body, wherein the circular circumferential contour of the tubular carrier body is defined by the half shell first carrier element and the half shell second carrier element.

12. The method in accordance with claim 10, wherein the method further comprises the step of, after the step of moving, connecting the first connection section to the third connection section and the second connection section to the fourth connection section by welding.

13. The method in accordance with claim 10, wherein the steps of providing the first carrier element and providing the second carrier element comprise providing the first carrier element and the second carrier element as mutually identical shaped sheet metal parts.

14. The method in accordance with claim 9, wherein the method further comprises the step of, prior to the step of moving, positioning at least one exhaust gas treatment element, enclosed by at least one layer of fiber material, in the first carrier element or in the second carrier element, the half shell first carrier element and the half shell second carrier element forming the tubular carrier body, wherein the circular circumferential contour of the tubular carrier body is defined by the half shell first carrier element and the half shell second carrier element.

15. The method in accordance with claim 9, wherein the method further comprises the step of, after the step of moving, connecting the first connection section to the third connection section and the second connection section to the fourth connection section by welding.

16. The method in accordance with claim 9, wherein the steps of providing the first carrier element and providing the second carrier element comprise providing the first carrier element and the second carrier element as mutually identical shaped sheet metal parts.

17. The method in accordance with claim 9, wherein the first connection section extends at an angle in relation to a reference plane containing the longitudinal axis of the carrier from the first axial end area to the second axial end area, the second connection second extending at an opposite angle relative to the first connection section in relation to the reference plane from the first axial end area to the second axial end area.

18. The method in accordance with claim 9, wherein the first connection section is connected to the third connection section in a plane and the second connection section is connected to the fourth connection section in the plane, wherein the plane is inclined relative to the longitudinal axis.

19. The method in accordance with claim 9, wherein the first connection section is offset from the second connection section by rotating the first carrier element about a first carrier element longitudinal axis of the first carrier element, the third connection section being offset from the fourth connection section by rotating the second carrier element about a second carrier element longitudinal axis of the second carrier element.

20. An exhaust gas treatment device for an exhaust gas flow path of an internal combustion engine, the exhaust gas treatment device comprising: a tubular carrier body extending along a carrier longitudinal axis between a first axial end area and a second axial end area; an exhaust component arranged in the carrier body; and at least one fiber material layer interposed between the tubular carrier body and the at least one exhaust gas treatment element, wherein the carrier body comprises carrier body components connected to one another in a first connection area and in a second connection area, the first connection area and the second connection area extend from the first axial end area to the second axial end area, at least one of the connection areas extending in a direction from the first axial end area to the second axial end area, the direction being different from a direction of the carrier longitudinal axis.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the drawings:

(2) FIG. 1 is an axial view of an exhaust gas treatment device with a tubular carrier body and with an exhaust gas treatment element, which is arranged therein and is surrounded by fiber material;

(3) FIG. 2 is a side view of the exhaust gas treatment device according to FIG. 1 in viewing direction II in FIG. 1;

(4) FIG. 3 is the two carrier elements of the carrier body of an exhaust gas treatment device of an alternative design before connection of said carrier elements to one another;

(5) FIG. 4 is the two carrier elements of the carrier body according to FIG. 3 after connection of said carrier elements to one another; and

(6) FIG. 5 is a side view of the carrier body shown in FIG. 4 in viewing direction V in FIG. 4.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(7) Referring to the drawings, FIGS. 1 and 2 show a first embodiment of an exhaust gas treatment device generally designated by 10. The exhaust gas treatment device 10 comprises a carrier body 12, which is formed from two carrier elements 14, 16 of an essentially mutually identical design in the example being shown. The two carrier elements 14, 16, which are generally also called half shells, are preferably provided as shaped sheet metal parts and form together a carrier body 12 of an essentially tubular, cylindrical shape, for example, with circular or elliptical circumferential contour.

(8) The carrier body 12 extends along a longitudinal axis L of the carrier, which is directed essentially at right angles to the drawing plane in FIG. 1 and is in the drawing plane in FIG. 2. The carrier body 12 has a first axial end area 18 and a second axial end area 20. The carrier body 12 can be connected in these axial end areas 18, 20 to additional areas of the line of an exhaust gas flow path of an internal combustion engine.

(9) The two carrier elements 12, 14 are permanently connected to one another at two connection areas 22, 24 located essentially diametrically opposite each other in relation to the longitudinal axis L of the body. In these connection areas 22, 24, the first carrier element 14 has a first connection section 26 for the first connection area 22, which connection section extends essentially radially outwardly in relation to the longitudinal axis L, as well as a second connection section 28 for the second connection area 24. The second carrier element 16 correspondingly has a third connection section 30 extending essentially radially outwardly in relation to the longitudinal axis L for the first connection area 22 and a fourth connection section 32 for the second connection area 24. The first connection section 24 of the first carrier element 14 is in contact with the third connection section 30 of the second carrier element 16 in the assembled state. The second connection section 28 of the first carrier element 14 is correspondingly in contact with the fourth connection section 32 of the second carrier element 16. The two carrier elements 14, 16 are permanently connected to one another, preferably by welding, in the area of these connection sections 26, 30 and 28, 32, which are preferably flatly in contact with one another.

(10) It is clearly seen in FIGS. 1 and 2 that the two connection areas 22, 24 and hence also the connection sections 26, 30 and 28, 32 do not extend in parallel to the longitudinal axis L of the body. The two connection areas 22, 24 are positioned at an angle, i.e., in an angulated manner, in relation to a reference plane E, which contains the longitudinal axis L of the body and is intersected, for example, by the two connection areas 22, 24 in the central longitudinal area thereof. The two connection areas 22, 24 are positioned at opposite angles in relation to this reference plane E, so that the two connection areas 22, 24 extend essentially helically and in the same direction along the circumference of the carrier body 12 because of the essentially circular circumferential contour of the carrier body 12.

(11) It becomes possible, especially because of the essentially diametrically opposite arrangement of the two connection areas 22, 24, for the two carrier elements 14, 16 to have an essentially mutually identical design. This leads to comparatively low manufacturing costs. The oblique position of the two connection areas 22, 24 ensures that fibers of the fiber material, which covers the exhaust gas treatment element 34 shown as a section only and is generally also called mounting mat and is provided, for example, as a fabric-like or nonwoven-like ceramic material, will not accumulate in the mutual junction area of the connection sections 26 and 30 as well as 28 and 32 in the manufacturing process of the exhaust gas treatment device 10 when the two carrier elements 14, 16 are moved towards one another in a merging motion direction Z. It rather ensures by the oblique position of the connection areas 22, 24 that the fibers will be pressed inwardly during the motion of the carrier elements 14, 16 towards one another in the merging motion direction Z. Manual finishing operations for removing fibers from the junction area of the two carrier elements 14, 16 prior to welding said carrier elements can thus be eliminated.

(12) An alternative embodiment of an exhaust gas treatment device will be described below with reference to FIGS. 3 through 5. Components that correspond to previously described components in terms of design and mode of operation are designated by the same reference numbers with an “a” added.

(13) In the embodiment of an exhaust gas treatment device 10a shown in FIGS. 3 through 5, the carrier body 12a is designed with two half shell-like carrier elements 14a and 16a, which are of an essentially mutually identical design and are provided, for example, as shaped sheet metal parts. The connection sections 26a, 28a, 30a and 32a providing the connection areas 22a and 24a, respectively, extend essentially in parallel to the longitudinal axis L of the carrier and are preferably located diametrically opposite each other in relation to said longitudinal axis.

(14) When assembling this embodiment variant of an exhaust gas treatment device 10a, for example, the first carrier element 14a is positioned first such that its connection sections 26a, 28a are located offset in relation to one another in the merging motion direction and thus have, for example, an offset V1. Before or after positioning the carrier element 14 in this manner, the exhaust gas treatment element 34a enclosed by the fiber material 36a can be positioned in the carrier element 14a.

(15) The second carrier element 16a is subsequently moved towards the first carrier element 14a in the merging motion direction Z. At least at the end of this merging motion, the second carrier element 16a is likewise positioned such that its connection sections 30a and 32a have an offset V2 in the merging motion direction Z, which is preferably essentially identical to the offset V1 of the two connection sections 26a, 28a of the carrier element 14a. The consequence of this is that because of the two carrier elements 14a, 16a being offset in the same direction, the respective connection sections 26a, 30a and 28a, 32a that are each to be brought into contact with one another will have essentially the same distance in the course of the motion towards one another, at least during the final phase of the motion, i.e., when the second carrier element 16a is being pushed over the exhaust gas treatment element 34a arranged in the first carrier element 14a and over the fiber material 36a. As a consequence, the connection sections 26a and 30a providing the first connection area 22a as well as the connection sections 28a, 32a providing the second connection area 24a will come mutually into contact essentially simultaneously. After establishing this contact, the two carrier elements 14a can be connected to one another permanently and in a gas-tight manner by welding in the two connection areas 22a, 24a.

(16) Pinching of fibers of the fiber material 36a between the connection sections 26a, 30a and 28a, 32a located each opposite each other can also be very extensively avoided with the arrangement shown in FIGS. 3 through 5 because of the offset of the connection sections 26a, 28a and 30a, 32a in relation to one another, which offset is present during the motion of the two carrier elements 14a, 16a towards one another. Processing operations for pressing fiber material inwardly can thus be avoided.

(17) It should finally be pointed out that the principles of the present invention may, of course, also be applied in another embodiment of the exhaust gas treatment device. For example, two or more exhaust gas treatment elements could be arranged in one carrier body. The carrier body could also have, in principle, a contour tapering in the direction of the longitudinal axis L of the body or a curved shape with correspondingly curved longitudinal axis of the body.

(18) While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.