Patent Publication Number: US-7708953-B2

Title: Apparatus and system for ensuring proper assembly of an exhaust system

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to exhaust treatment systems and more particularly relates to apparatus, systems, and methods for ensuring proper assembly of an exhaust system. 
     2. Description of the Related Art 
     Engine performance is becoming increasingly important under a growing demand for safe, reliable, and environmentally friendly transportation. Pursuant to achieving safe, reliable, and environmentally friendly transportation, is the implementation of effective exhaust treatment systems. Properly assembling exhaust treatment systems is a necessary component to providing effective exhaust treatment systems. 
       FIG. 1  is a perspective view on a prior art exhaust treatment system  100 . The depicted system  100  includes an inflow subassembly  140 , a first intermediate subassembly  130 , a second intermediate subassembly  120 , an outflow subassembly  110 , a set of subassembly fasteners  160 . The system  100  also includes a pressure sensing member  150  for sensing the pressure in the inflow subassembly  110  and the second intermediate subassembly  130 . 
     The performance of the exhaust treatment system  100  is dependent upon proper ordering (or sequencing) and rotational alignment of the various subassemblies  110 ,  120 ,  130 , and  140 . For example, in an embodiment where the first intermediate subassembly  130  is a catalytic converter and a second intermediate subassembly  120  is a filter, erroneously placing the filter  120  before the catalytic converter  130  would render the exhaust treatment system  100  useless from an emissions control standpoint. Also, as the pressure sensor  150  is substantially linear in shape and enters both the outflow subassembly  110  and the first intermediate subassembly  130  at openings that are similarly rotationally aligned. Accordingly, the outflow subassembly  110  and first intermediate subassembly  130  must be properly aligned for the pressure sensor to be able to properly enter the subassemblies  110 ,  130 . In a scenario wherein the various subassemblies  110 ,  120 ,  130 , and  140 , are improperly ordered or aligned, the effectiveness of the exhaust treatment system  100  is forfeited. 
     From the foregoing discussion, it should be apparent that a need exists for an apparatus and system for ensuring proper assembly of exhaust treatment systems. Beneficially, such an apparatus and system would ensure proper assembly of exhaust subassemblies by requiring proper subassembly ordering and alignment. 
     SUMMARY OF THE INVENTION 
     The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available solutions. Accordingly, the present invention has been developed to provide an apparatus and system for ensuring proper assembly of an exhaust system that overcome many or all of the above-discussed shortcomings in the art. 
     In a first aspect of the invention, an apparatus for ensuring proper assembly of an exhaust system includes an exhaust treatment unit that receives exhaust from an upstream unit and provides exhaust to a downstream unit. The exhaust treatment unit includes a first mating perimeter that mates with a mating perimeter of an upstream unit. The exhaust treatment unit further includes a second mating perimeter that mates with a mating perimeter of a downstream unit. At least one mating perimeter of the first and second mating perimeters comprises a docking element sized, shaped, and placed to mate with a docking element of a particular exhaust treatment unit and thereby selectively mate and rotationally align the exhaust treatment unit with a particular exhaust treatment unit. 
     In certain embodiments, the first and second mating perimeters each comprise a docking element. In one embodiment, one docking element is a recess that selectively receives a projection from a particular subassembly unit and the other docking element is a projection that selectively mates with a recess of a particular subassembly unit. The exhaust treatment unit may be one of a variety of subassembly units that perform a specific function such as a catalyst subassembly and a filter subassembly. The apparatus may also include a gasket to facilitate mating of the exhaust treatment unit with the at least one other exhaust subassembly unit. 
     A system of the present invention is also presented for proper assembly of exhaust subassemblies. The system may include an inflow subassembly that receives engine exhaust, at least one intermediate subassembly that selectively mates and rotationally aligns with the inflow subassembly and receives engine exhaust therefrom. Also, the at least one intermediate subassembly selectively mates and rotationally aligns with an outflow subassembly. The outflow subassembly receives engine exhaust from the at least one intermediate subassembly. 
     In certain embodiments, the at least one intermediate subassembly is a plurality of intermediate exhaust subassemblies that each selectively mate and rotationally align with adjacent subassemblies. In certain embodiments, the at least one intermediate subassembly includes a recess that selectively receives a projection from the inflow subassembly. In such embodiments, the at least one intermediate subassembly may also include a projection configured to selectively mate with a recess of the outflow subassembly. In other embodiments, the at least one intermediate subassembly includes a recess that selectively receives a projection from the outflow subassembly. In such embodiments, the at least one intermediate subassembly may also include a projection configured to selectively mate with a recess of the inflow subassembly. 
     The various embodiments of the present invention provide corresponding features and advantages. Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment. 
     Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention. 
     These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which: 
         FIG. 1  is a perspective view of one embodiment of a prior art exhaust treatment system; 
         FIG. 2  is a perspective view of one embodiment of an exhaust treatment system in accordance with the present invention; 
         FIG. 3  is a perspective view of one embodiment of an exhaust treatment subassembly in accordance with the present invention; 
         FIG. 4  is a cross sectional view of one embodiment of an exhaust treatment subassembly in accordance with the present invention; and 
         FIG. 5  is a perspective view of one embodiment of an exhaust treatment subassembly in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. 
       FIG. 2  is a perspective view of one embodiment of an exhaust treatment system  200  in accordance with the present invention. The depicted system  200  includes an inflow subassembly  240 , a first intermediate subassembly  230 , a second intermediate subassembly  220 , an outflow subassembly  210 , subassembly gaskets  260 , and subassembly fasteners  250 . In certain embodiments, the system  200  may also include a pressure sensing member similar to the pressure sensing member  150  of  FIG. 1 . The various components of the system  200  ensure proper assembly of the subassemblies  210 ,  220 ,  230 ,  240  according to a pre-selected subassembly order (or sequence) and rotational alignment. When fully assembled, in certain embodiments, the exhaust treatment system  200  appears substantially similar to the system of  FIG. 1 . 
     The inflow subassembly  240  receives engine exhaust. The first intermediate subassembly selectively mates and rotationally aligns with the inflow subassembly  240  and receives exhaust therefrom. Similarly, the second intermediate subassembly  220  selectively mates and rotationally aligns with the first intermediate subassembly  230  and receives exhaust therefrom. Also, the outflow subassembly  210  selectively mates with the second intermediate subassembly  220  according to a pre-selected alignment and receives exhaust therefrom. 
     As further taught in  FIGS. 3 ,  4 , and  5 , in certain embodiments, the subassemblies  210 ,  220 ,  230 , and  240  ensure proper assembly via a docking element (such as a projection or recess) sized, shaped, and positioned to mate with a docking element (such as a corresponding recess or projection) of a specific, adjacent subassembly. Before the subassemblies  210 ,  220 ,  230 ,  240  are mated, a gasket  260  may be positioned at the mating point of each subassembly  210 ,  220 ,  230 ,  240  so as to ensure no gaseous leakage will occur. Once the subassemblies  210 ,  220 ,  230 ,  240  are mated and the gasket  260  is in place, a fastener  250  or similar device may be place over each gasket and fasten the mating of each subassembly  210 ,  220 ,  230 ,  240  (see  FIG. 1 ). In the depicted embodiment, each fastener  250  includes a clamping member  254  that tightens the fastener  250  over the perimeter of adjoining subassemblies. 
       FIG. 3  is a perspective view of one embodiment of an exhaust treatment subassembly  300  in accordance with the present invention. The depicted subassembly  300  includes an exhaust treatment unit  310 , a first mating perimeter  320 , a projection  322 , a second mating perimeter  330 , a recess  332 , and a recess rim  334 . The various components of the exhaust treatment subassembly  300  ensure proper assembly by requiring selective mating according to a pre-selected subassembly order and rotational alignment with adjacent subassemblies  340 ,  350 . 
     When mated, the exhaust treatment unit  310  receives exhaust from an upstream unit  340  and provides exhaust to a downstream unit  350 . The exhaust treatment unit  310  may include a variety of exhaust treatment subassemblies such as a catalytic converter or a filter. Accordingly, a particular emissions functionality of the exhaust treatment unit  310  is not a necessary aspect of the present invention. 
     The first mating perimeter  320  selectively mates with an upstream mating perimeter  346  of the upstream exhaust treatment subassembly  340 . In the depicted embodiment, the first mating perimeter  320  includes a docking element in the form of a projection  322  and the upstream mating perimeter  346  includes a docking element in the form of an upstream recess  342  and upstream recess rim  344 . The upstream recess  342  is specifically sized, shaped, and placed to receive the projection  322  of the exhaust treatment unit  310  as opposed to the projection  352  of the downstream exhaust treatment unit  350 . 
     Similarly, the second mating perimeter  330  of the exhaust treatment unit  310  mates with a downstream mating perimeter  354  of the downstream exhaust treatment unit  350 . The depicted second mating perimeter  330  includes docking element in the form of a recess  332  and a recess rim  334 . The recess  332  is specifically sized to receive the down stream projection  352 , similar to the projection  322  and upstream recess  342 . Accordingly, the size of the projections  322 ,  352  and recesses  332 ,  342  function to ensure selective mating and rotational alignment of the subassemblies  310 ,  340 ,  350 . In an embodiment involving multiple subassemblies, each subassembly may implement a similar strategy to ensure proper assembly of each subassembly in the entire exhaust treatment system  200  (see  FIG. 2 ). 
     As the mating between the first mating perimeter  320  and upstream mating perimeter  346  and mating between the second mating perimeter  330  and the downstream mating perimeter  354  are substantially similar in the depicted embodiment, the following will disclose, teach, and enable the mating between the first mating perimeter  320  and upstream mating perimeter  346  and thereby inferentially disclose, teach, and enable the mating between the second mating perimeter  330  and the downstream mating perimeter  354 . 
     Accordingly, once the projection  322  is received by the upstream recess  342 , the upstream recess rim  344  impedes rotation of the two exhaust treatment units  310 ,  340  as the received projection  322  is in contact with the upstream rim  344 . Accordingly, the specifically sized, shaped, and placed projection  322  and corresponding upstream recess  342  ensure proper mating and rotational alignment, as another subassembly with an overly large projection will not fit into the upstream recess  342  and another subassembly with a projection that is too small will allow a slight rotation of the subassemblies indicating an improper order or sequencing of subassemblies. 
     In certain embodiments, the shape of the projection  322  and corresponding upstream recess  342  may be substantially triangular, octagonal, etc, as opposed to substantially rectangular as depicted. Accordingly, the size, shape, and placement of the docking elements (i.e. projection  322  and recess  342 ) need not be specific, so long as the size, shape, and placement ensure selective subassembly mating and rotational alignment. 
       FIG. 4  is a cross-sectional view of one embodiment of an exhaust treatment subassembly  400  in accordance with the present invention. The depicted subassembly  400  includes an exhaust treatment unit  310  with a first mating perimeter  320  and a second mating perimeter  330 . The cross sectional view of the subassembly shown in  FIG. 3  is presented to highlight particular details of one embodiment of the present invention. 
     Accordingly, the projection  322  is received by a specifically sized, shaped, and positioned, upstream recess  342 . The recess  342  is a space created by an upstream recess rim  344  that rotationally aligns and selectively mates the exhaust treatment units  310 ,  340 , as only the projection  322  may properly fit into the upstream recess  342  as opposed to the projection of another exhaust treatment unit (see  FIG. 2 ). 
     In the depicted embodiment, the both the projection  322  and the recess  342  are substantially rectangular in shape and complementary in size. Selective mating, proper ordering or sequencing is achieved as only the projection  322  will properly fit into the recess  342 . All other projections will have a different size, shape, or position. Rotational alignment is achieved as the first mating perimeter  320  and the upstream mating perimeter  346  can only mate if the projection  322  is fitted within the recess  342 . Accordingly, the present invention ensures proper assembly of an exhaust system by requiring selective mating and rotational alignment of the subassemblies within the system. 
       FIG. 5  is a perspective view of one embodiment of an exhaust treatment subassembly  500  in accordance with the present invention. Contrasting the subassembly illustrated in  FIGS. 3 and 4 , the depicted subassembly  500  teaches an embodiment with a plurality of projections  522  and recess  552 . Accordingly, the illustrated embodiment is only one of many possible embodiments that ensure proper assembly of exhaust treatment subassemblies via selective mating and rotational aligning. 
     Similar to the subassembly of  FIG. 3 , the first mating perimeter  520  of the exhaust treatment unit  510  mates with a mating perimeter  544  of an upstream unit  540 . Also, the second mating perimeter  530  of the exhaust treatment unit  510  mates with the mating perimeter  554  of a downstream unit  550 . However, unlike the subassembly of  FIG. 3 , the depicted subassembly  500  illustrates first and second docking element in the form of a first set of projections  522  and second set of recess  532 , respectively. 
     The three projections  522  of the exhaust treatment unit  510  particularly correspond in size, shape, placement, and number to the three upstream recesses  542  of the upstream exhaust treatment unit  540 . Similarly, the four recesses  532  of the exhaust treatment unit  510  particularly correspond in size, shape, placement, and number to the four downstream projections  552  of the down stream exhaust treatment unit  550 . Accordingly, during assembly, the downstream exhaust treatment unit  550  cannot be erroneously ordered or sequenced next to the upstream exhaust treatment unit  540  as the downstream exhaust treatment unit  550  requires four recesses but the upstream exhaust treatment unit  540  only provides three recesses  542 . 
     In certain embodiments, the number and size of projections  522 ,  552  may vary. In other embodiments, the exhaust treatment unit  510  provides docking elements of different styles. For example, one docking element may include a set of projections  522  that correspond to upstream recesses  542  on one side of the exhaust treatment unit  510  (as depicted), and the other docking element may include a serrated edge that corresponds the serrated edge of a downstream exhaust treatment unit (not shown). Accordingly, an exhaust treatment unit having docking elements of different styles may adequately accomplish the task of ensuring proper assembly of the exhaust treatment system via selective mating and mandatory rotational alignment. In other words, the docking elements need not be type or style specific to accomplish the general task of ensuring proper assembly of exhaust treatment systems. 
     The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.