Infinitely variable aftertreatment systems and manufacturing process

Abstract

Gas treatment systems are described that allow for modular development of gas treatment systems, for example exhaust gas aftertreatment systems, using generally standardized parts. A number of subsections are provided, including a treatment subsection containing an exhaust gas treatment device for treating exhaust gas. The treatment subsection is designed to be connectable to an inlet subsection, an outlet subsection, or other subsections in a manner that allows the positions, both longitudinally and rotationally, of the treatment subsection relative to adjacent subsections to be adjusted as required during assembly. This permits an infinite number of length and/or clocking configurations for the aftertreatment system to be manufactured.

1 . A gas treatment system for use with an engine, comprising:
 a treatment subsection that includes a housing having a first end portion, a second end portion, a gas flow path through the housing generally from the first end portion to the second end portion, and a gas treatment device disposed within the housing between the first end portion and the second end portion and disposed within the gas flow path for treating gas in the flow path, at least one of the first end portion and the second end portion is configured for telescoping connection to an adjacent subsection of the gas treatment system;   a second subsection that includes an end section that is fastened to the first end portion of the treatment subsection;   a third subsection that includes an end section that is fastened to the second end portion of the treatment subsection; and   at least one of the end sections of the second and third subsections is telescoped with the respective first end portion or the second end portion.   
     
     
         2 . The gas treatment system of  claim 1 , wherein the system is an aftertreatment system for treating exhaust gas from the engine. 
     
     
         3 . The gas treatment system of  claim 2 , wherein the gas treatment device comprises an emissions treatment device. 
     
     
         4 . The gas treatment system of  claim 3 , wherein the emissions treatment device comprises a substrate with a catalyst or comprises a filter. 
     
     
         5 . The gas treatment system of  claim 1 , wherein the end sections of the second and third subsections are telescoped with the respective first end portion and the second end portion. 
     
     
         6 . The gas treatment system of  claim 1 , wherein the second subsection is an inlet subsection that includes an inlet opening through which gas flow enters the second subsection, and the inlet opening of the second subsection extends through an end of the inlet subsection or through a side of the inlet subsection; and
 the third subsection is an outlet subsection that includes an outlet opening through which gas flow exits the third subsection, and the outlet opening of the third subsection extends through an end of the outlet subsection or through a side of the outlet subsection.   
     
     
         7 . The gas treatment system of  claim 1 , wherein the third subsection includes a gas treatment device disposed therein for treating the gas. 
     
     
         8 . The gas treatment system of  claim 1 , at least one of the first end portion and the second end portion includes a flange. 
     
     
         9 . The gas treatment system of  claim 5 , wherein the first end portion and the second end portion are generally cylindrical, and the end sections of the second and third subsections are generally cylindrical. 
     
     
         10 . A treatment subsection suitable for connection to adjacent subsections for use in constructing a gas treatment system for use with an engine, comprising:
 a housing having a first end portion defining an inlet of the subsection, a second end portion defining an outlet of the subsection, a gas flow path through the housing generally between the first end portion and the second end portion, at least one of the first end portion and the second end portion is configured for telescoping connection to an adjacent subsection of the gas treatment system; and   a gas treatment device disposed within the housing between the first end portion and the second end portion and disposed within the gas flow path for treating gas in the flow path.   
     
     
         11 . The treatment subsection of  claim 10 , wherein the treatment subsection is an aftertreatment subsection for use in constructing an aftertreatment system for treating exhaust gas from the engine. 
     
     
         12 . The treatment subsection of  claim 10 , wherein the gas treatment device comprises an emissions treatment device. 
     
     
         13 . The treatment subsection of  claim 12 , wherein the emissions treatment device comprises a substrate with a catalyst or comprises a filter. 
     
     
         14 . The treatment subsection of  claim 10 , wherein both the first end portion and the second end portion are configured for telescoping connection to an adjacent subsection of the gas treatment system. 
     
     
         15 . The treatment subsection of  claim 10 , at least one of the first end portion and the second end portion includes a flange. 
     
     
         16 . The treatment subsection of  claim 14 , wherein the first end portion and the second end portion are generally cylindrical. 
     
     
         17 . A method of manufacturing a gas treatment system for use with an engine, comprising:
 obtaining a treatment subsection having a housing with an end that is configured to be assembled with an end of an adjacent subsection of the gas treatment system, a gas flow path through the housing, and a gas treatment device secured within the housing in the gas flow path for treating gas in the flow path; and   assembling the treatment subsection with the adjacent subsection in a manner that permits adjustment in the combined length of the treatment subsection and the adjacent subsection once assembled.   
     
     
         18 . The method of  claim 17 , wherein assembling comprises telescoping the end of the treatment subsection and the end of the adjacent subsection. 
     
     
         19 . The method of  claim 18 , wherein the treatment subsection comprises a first subsection telescoped with a second subsection. 
     
     
         20 . The method of  claim 18 , wherein assembling further comprises assembling the treatment subsection with the adjacent subsection in a manner that permits rotational adjustment of the treatment subsection and the adjacent subsection relative to one another. 
     
     
         21 . The method of  claim 17 , further comprising fastening the treatment subsection and the adjacent subsection together once the desired length is achieved to prevent further adjustment in the combined length.