Exhaust treatment system and method of assembly

Abstract

An exhaust treatment system for an internal combustion engine comprises an insulating and cushioning mat material disposed in the exhaust treatment system and a film laminate sleeve vacuum packed and sealing the insulating and cushioning mat material therein.

What is claimed is: 
     
         1 . A method of assembling an exhaust treatment system for an internal combustion engine comprising a substrate disposed in a canister and an insulating and cushioning mat material interposed between an outer surface perimeter of the substrate and an inner wall of the canister comprising:
 inserting the insulating and cushioning mat material into a film laminate sleeve;   subjecting the insulating and cushioning mat material to a compression process that compresses the mat material to a nominal thickness that is less that that of an uncompressed thickness;   sealing the insulating and cushioning mat material in the film laminate sleeve; and   inserting the mat into the canister.   
     
     
         2 . The method for assembly of an exhaust treatment system of  claim 1 , further comprising:
 operating the internal combustion engine to vaporize, combust or otherwise dissolve the film laminate sleeve in a hot exhaust gas environment to expand the insulating and cushioning mat material.   
     
     
         3 . The method for assembly of an exhaust treatment system of  claim 1 , wherein the compression process comprises applying a vacuum to the insulating and cushioning mat material containing film laminate sleeve. 
     
     
         4 . The method for assembly of an exhaust treatment system of  claim 1 , further comprising:
 wrapping the compressed insulating and cushioning material around the substrate prior to inserting the mat into the canister; and   inserting the mat wrapped substrate into the canister.   
     
     
         5 . The method for assembly of an exhaust treatment system of  claim 1 , further comprising:
 wrapping the uncompressed insulating and cushioning material around the substrate;   subjecting the mat wrapped substrate to a compression process that compresses the mat material to a nominal thickness that is less that that of an uncompressed thickness;   sealing the mat wrapped substrate in the film laminate sleeve; and   inserting the mat wrapped and laminate sealed substrate into the canister.   
     
     
         6 . An exhaust system for an internal combustion engine comprising:
 an exhaust treatment system having a substrate disposed in a canister;   an insulating and cushioning mat material interposed between an outer surface perimeter of the substrate and an inner wall of the canister; and   a film laminate sleeve compressing and sealing the insulating and cushioning mat material to a nominal thickness that is less than that of an uncompressed thickness.   
     
     
         7 . The exhaust system for the internal combustion engine of  claim 6 , wherein the compressing and sealing the insulating and cushioning mat material comprises applying a vacuum to the film laminate sleeve. 
     
     
         8 . The exhaust system for the internal combustion engine of  claim 6 , wherein the film laminate sleeve comprises a film laminate that vaporizes and/or combusts when heated. 
     
     
         9 . The exhaust system for the internal combustion engine of  claim 6 , wherein the film laminate sleeve comprises a Low Organic Film Laminate. 
     
     
         10 . The exhaust system for the internal combustion engine of  claim 6 , wherein the substrate comprises a catalyst coated substrate. 
     
     
         11 . The exhaust system for the internal combustion engine of  claim 6 , wherein the catalyst comprises a precious metal or Platinum group metal catalyst compound, including platinum group metals such as platinum (Pt), palladium (Pd), rhodium (Rh) or other suitable oxidizing catalysts, or combination thereof. 
     
     
         12 . The exhaust system for the internal combustion engine of  claim 6 , wherein the canister further comprises:
 a first, inlet end closed by an inlet end cone that is in fluid communication with an exhaust manifold of a cylinder head of the internal combustion engine; and   a second, outlet end closed by an outlet end cone that is in fluid communication with an exhaust gas conduit of the exhaust system.   
     
     
         13 . An exhaust treatment system for an internal combustion engine comprising:
 an insulating and cushioning mat material disposed in the exhaust gas treatment system; and   a film laminate sleeve vacuum packed and sealing the insulating and cushioning mat material to a nominal thickness that is less than that of an uncompressed thickness.   
     
     
         14 . The exhaust treatment system for the internal combustion engine of  claim 13 , wherein the film laminate sleeve comprises a film laminate that vaporizes and/or combusts when heated. 
     
     
         15 . The exhaust treatment system for the internal combustion engine of  claim 13 , wherein the film laminate sleeve comprises a Low Organic Film Laminate. 
     
     
         16 . The exhaust treatment system for the internal combustion engine of  claim 13 , wherein the film laminate sleeve is vacuum packed and seals the insulating and cushioning mat material and a catalyst substrate therein. 
     
     
         17 . The exhaust treatment system for the internal combustion engine of  claim 16 , wherein the substrate comprises a catalyst coated substrate. 
     
     
         18 . The exhaust treatment system for the internal combustion engine of  claim 17 , wherein the catalyst comprises a precious metal or Platinum group metal catalyst compound, including platinum group metals such as platinum (Pt), palladium (Pd), rhodium (Rh) or other suitable oxidizing catalysts, or combination thereof. 
     
     
         19 . The exhaust treatment system for the internal combustion engine of  claim 16 , further comprising:
 a canister housing the film laminate sleeve, the insulating and cushioning mat material and the catalyst substrate therein;   a first canister inlet end closed by an inlet end cone that is in fluid communication with an exhaust manifold of a cylinder head of the internal combustion engine; and   a second, outlet end closed by an outlet end cone that is in fluid communication with an exhaust gas conduit of an exhaust system.