Patent ID: 6701617
Filing Date: 2004-03-09
Classification: B21D,F01N,Y10T

Abstract:
A method for forming a catalytic converter comprising a catalyst substrate having a substrate axis and a noncircular circumference about the substrate axis, an insulative layer about the catalyst substrate, and a metal housing disposed about the insulative layer, said method comprising:measuring the catalyst substrate to determine radial dimensions of the noncircular circumference relative to the substrate axis, arranging the catalyst substrate and a compressible mat within a metal tube such that the compressible mat is interposed between the metal tube and the catalyst substrate, and spin-forming the metal tube about the catalyst substrate to form the metal housing and to compress the compressible mat between the catalyst substrate and the metal housing to form the insulative layer, said spin-forming comprising rotating the metal tube about the substrate axis and concurrently radially urging a metal-forming tool against the metal tube, said spin-forming further comprising programming the metal-forming tool to follow a metal-forming path corresponding to the radial dimensions of the substrate circumference plus a predetermined radial distance, thereby forming a metal housing having a noncircular circumference corresponding in shape to the substrate and spaced apart therefrom by the insulative layer.