Method of forming a catalytic converter from a radially deformed pre-form member

Abstract

A method is provided for manufacturing a catalytic converter. A metallic tubular member is provided. A section of the metallic tubular member is deformed radially inward to form a neck portion. The neck portion has a diameter less than an initial diameter of the metallic tubular member. The tubular member is separated at substantially an axial midpoint of the neck portion for obtaining a first pre-form member having a first conical-shaped end. At least one catalytic element is inserted in the first pre-form member. An outer surface of the first pre-form member is deformed radially inward for securing the catalytic element within the first pre-form member. The first pre-form member is spin-formed for forming a second conical-shaped end opposite the first conical-shaped end.

1 . A method of manufacturing a catalytic converter comprising the steps of:
 providing a metallic tubular member;   deforming a section of said metallic tubular member radially inward to form a neck portion, said neck portion having a diameter less than an initial diameter of said metallic tubular member;   separating said tubular member at substantially an axial midpoint of said neck portion for obtaining a first pre-form member having a first conical-shaped end;   inserting a catalytic element in said first pre-form member;   deforming radially inward an outer surface of said first pre-form member for securing said catalytic element within said first pre-form member; and   spin-forming said first pre-form member for forming a second conical-shaped end opposite said first conical-shaped end.   
     
     
         2 . The method of  claim 1  further comprising the steps of:
 providing a second pre-form member having a first conical-shaped end formed from said separation of said tubular member at said midpoint of said neck portion;   inserting a respective catalytic element in said second pre-form member;   deforming radially inward an outer surface of said second pre-form member that is radially aligned with said respective catalytic element for securing said respective catalytic element within said second pre-form member; and   spin-forming said second pre-form member for forming a second conical-shaped end at an opposing end from said first conical-shaped end of said second pre-form member.   
     
     
         3 . The method of  claim 2  wherein said step of deforming a section of said metallic tubular member is performed by a swage operation. 
     
     
         4 . The method of  claim 2  wherein said swage operation includes a rotary swage operation. 
     
     
         5 . The method of  claim 2  wherein said step of deforming a section of said metallic tubular member is performed by a roll forming operation. 
     
     
         6 . The method of  claim 1  wherein said step of separating said tubular member at an axial midpoint is pre-formed by a laser cut operation. 
     
     
         7 . The method of  claim 1  wherein said step of separating said tubular member at an axial midpoint is pre-formed by a milling operation. 
     
     
         8 . The method of  claim 1  wherein said step of separating said tubular member at an axial midpoint is pre-formed by a cutting operation. 
     
     
         9 . The method of  claim 1  wherein metallic tubular is formed from wrapped sheep metal strip having a welded seam. 
     
     
         10 . A method of manufacturing a plurality of catalytic converters from a metallic tubular member, said method comprising the steps of:
 (a) forming a plurality of axially spaced neck portions by deforming a section of said metallic tubular member, said plurality of axially spaced neck portions each having a diameter less than an initial diameter of said metallic tubular member;   (b) cutting substantially a midpoint of said neck portions;   (c) cutting substantially a midpoint between said neck portions;   (d) inserting at least one respective catalytic element in a respective pre-form member;   (e) deforming radially inward an outer surface of said respective pre-form member for securing said respective catalytic element within said respective pre-form member; and   (f) spin-forming said respective pre-form member for forming a second conical-shaped end opposite said first conical-shaped end.   repeating steps (d)-(f) for each respective pre-form member formed from said metallic tubular member.   
     
     
         11 . The method of  claim 10  wherein said step of forming said neck portions is performed by a swage operation. 
     
     
         12 . The method of  claim 11  wherein said swage operation includes a rotary swage operation. 
     
     
         13 . The method of  claim 12  wherein said step of forming said neck portions is performed by a roll forming operation. 
     
     
         14 . The method of  claim 10  wherein said step of separating said tubular member at an axial midpoint is pre-formed by a laser cut operation. 
     
     
         15 . The method of  claim 10  wherein said step of separating said tubular member at an axial midpoint is pre-formed by a milling operation. 
     
     
         16 . The method of  claim 10  wherein said step of separating said tubular member at an axial midpoint is pre-formed by a cutting operation. 
     
     
         17 . The method of  claim 10  wherein metallic tubular is formed from wrapped sheep metal strip having a welded seam.