Exhaust treatment apparatus and method of making

Abstract

An exhaust treatment apparatus including a core having a substrate contained within an outer casing is disclosed. The exhaust treatment apparatus also includes a sizing structure that projects radially outwardly from the outer casing of the core. The sizing structure has an outer size that corresponds to the inner size of a muffler or other structure into which it is desired to mount the exhaust treatment apparatus.

What is claimed is:  
     
         1 . An exhaust treatment apparatus comprising: 
 a casing having first and second open ends;    a substrate positioned within the casing; and    sizing structures positioned at the first and second ends of the casings, the sizing structures including portions that extend radially outwardly from the casing.    
     
     
         2 . The apparatus of  claim 1 , wherein the sizing structures are unitary with the casing and are bent so as to extend radially outwardly.  
     
     
         3 . The apparatus of  claim 1 , wherein the sizing structures are positioned at axial end faces of the casing.  
     
     
         4 . The apparatus of  claim 1 ,  2  or  3 , wherein the casing is oval.  
     
     
         5 . The apparatus of  claim 4 , wherein the substrate is a corrugated metal substrate.  
     
     
         6 . The apparatus of  claim 1 , wherein an outer shape of each sizing structure is oval, and an outer shape of the casing is round.  
     
     
         7 . The apparatus of  claim 1 , wherein an outer shape of each sizing structure is round, and an outer shape of the casing is oval.  
     
     
         8 . The apparatus of  claim 1 , wherein an outer shape of each sizing structure is round, and an outer shape of the casing is round.  
     
     
         9 . The apparatus of  claim 1 , wherein an outer shape of each sizing structure is oval, and an outer shape of the casing is oval.  
     
     
         10 . The apparatus of  claim 1 , further comprising an outer shell, wherein the sizing structures extend radially between the shell and the outer casing.  
     
     
         11 . The apparatus of  claim 10 , wherein an interference fit exists between the sizing structures and the outer shell.  
     
     
         12 . An exhaust treatment apparatus comprising: 
 an outer shell;    an open-ended casing positioned within the shell;    a substrate positioned within the casing; and    a water retaining structure located at one end of the casing, the water retaining structure defining a water retention space for preventing condensation on an inner surface of the outer shell from moistening the substrate.    
     
     
         13 . The exhaust treatment apparatus of  claim 12 , wherein the water retention space is defined between the water retaining structure and the outer shell.  
     
     
         14 . The apparatus of  claim 12 , wherein the water retaining structure includes at least a first portion that is integral with the casing.  
     
     
         15 . The apparatus of  claim 14 , wherein the first portion curves radially inwardly from a main body of the casing.  
     
     
         16 . The apparatus of  claim 15 , wherein the water retaining structure further comprises a second portion that extends upwardly from the first portion.  
     
     
         17 . The apparatus of  claim 16 , wherein the second portion is welded to the first portion.  
     
     
         18 . The apparatus of  claim 17 , wherein the second portion is a cylindrical ring that is parallel to the main body of the casing.  
     
     
         19 . The apparatus of  claim 12 , wherein the casing defines a central axis, and wherein water-retaining structure includes a primarily radial portion connected to a primarily axial portion.  
     
     
         20 . The apparatus of  claim 12 , wherein the water retention space has a cross-sectional area greater than 0.0135 inches.  
     
     
         21 . The apparatus of  claim 20 , wherein the cross-sectional area is at least 0.05 inches.  
     
     
         22 . The apparatus of  claim 21 , wherein the cross-sectional area is at least 0.1 inches.  
     
     
         23 . The apparatus of  claim 22 , wherein the cross-sectional area is at least 0.3 inches.