Patent Publication Number: US-8540793-B2

Title: Exhaust processing device and manufacturing method thereof

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This national phase application claims priority to Japanese Patent Application No. 2008-127147 filed on May 14, 2008. The entire disclosure of Japanese Patent Application No. 2008-127147 is hereby incorporated herein by reference. 
     TECHNICAL FIELD 
     The present invention relates to an exhaust processing device and a manufacturing method thereof. 
     BACKGROUND ART 
     The well-known types of the internal combustion engine have an exhaust processing device in an exhaust path. The exhaust processing device is configured to capture particulate materials in an exhaust gas exhausted from the internal combustion engine (e.g., the diesel engine) or reduce a volume of NO x  in the exhaust gas. An exemplary exhaust processing device is described in Japan Laid-Open Patent Application Publication No. JP-A-2003-090214. The exhaust processing device includes an inlet tube, an outlet tube, and a main body tube portion. The inlet tube and the outlet tube are disposed on the both ends of the main body tube portion. The inlet and outlet tubes are radial-outwardly protruded from the outer peripheral surface of the main body tube portion. Further, the inlet tube and the outlet tube are inserted into the main body tube portion. Exhaust gas enters the main body tube portion from the internal combustion engine through the inlet tube. Then, the exhaust gas is discharged from the main body tube portion through the outlet tube. The main body tube portion contains a carrier in the inside thereof. The carrier supports a catalyst. The carrier purifies the exhaust gas passing therethrough. 
     SUMMARY 
     The aforementioned exhaust processing device is manufactured by joining plural components, including the inlet tube, the outlet tube, and the main body tube portion, in combination. In view of increase in yield rate and reduction in manufacturing cost, however, an easily manufacturable exhaust processing device has been demanded. 
     The present invention addresses a need for producing an easily manufacturable exhaust processing device and a manufacturing method thereof. 
     An exhaust processing device according to a first aspect of the present invention includes a main body tube portion and a closing tube portion. The main body tube portion includes an opening in an axial end thereof. The main body tube portion houses a main body exhaust path in an inside thereof. The main body exhaust path allows an exhaust gas to pass therethrough. The closing tube portion includes a plate portion and a tubular portion. The plate portion covers the opening of the axial end of the main body tube portion. The tubular portion radially outwardly protrudes from an outer peripheral surface of the main body tube portion. The tubular portion is integrated with the plate portion. The tubular portion houses an exhaust path in an inside thereof The exhaust path communicates with the main body exhaust path. 
     According to the exhaust processing device of the first aspect of the present invention, the closing tube portion includes a plate portion, and the plate portion covers the opening of the axial end of the main body tube portion. Therefore, the closing tube portion is appropriately positioned with respect to the main body tube portion when the plate portion is attached to the main body tube portion under a condition that the plate portion closes the opening of the axial end of the main body tube portion. Further, the closing tube portion and the main body tube portion can be easily welded by executing welding along the opening of the axial end of the main body tube portion. Accordingly, the exhaust processing device can be easily manufactured. 
     An exhaust processing device according to a second aspect of the present invention relates to the exhaust processing device according to the first aspect of the present invention. In the exhaust processing device, the tubular portion includes a first split half portion and a second split half portion. The first split half portion is integrally molded with the plate portion, whereas the second split half portion is joined to the first split half portion. The first and second split half portions include convex and concave portions on joint surfaces thereof. The convex portion and the concave portion are configured to be engaged for appropriately positioning the first and second split half portions. 
     According to the exhaust processing device of the second aspect of the present invention, the first split half portion is appropriately positioned with respect to the main body tube portion by attaching the plate portion to the main body tube portion under a condition that the plate portion closes the opening of the axial end of the main body tube portion. Further, the second split half portion is appropriately positioned with respect to the first split half portion by attaching the first split half portion and the second split half portion under the condition that the convex portion and the concave portion are engaged. Accordingly, the closing tube portion and the main body tube portion can be easily assembled. 
     An exhaust processing device according to a third aspect of the present invention relates to the exhaust processing device according to the second aspect of the present invention. In the exhaust processing device, the first split half portion includes a flange portion disposed along an edge thereof and the second split half portion includes a flange portion disposed along an edge thereof. Further, the exhaust processing device further includes an annular member. The annular member is configured to be fitted onto the tubular portion with the annular member abutting ends of the flange portions for integrating the first split half portion and the second split half portion. 
     According to the exhaust processing device of the third aspect of the present invention, the first split half portion and the second split half portion are integrated by the annular member. Further, the annular member is appropriately positioned by the ends of the flange portions of the first split half portion and the second split half portion. Therefore, the closing tube portion can be easily assembled. 
     An exhaust processing device according to a fourth aspect of the present invention relates to the exhaust processing device according to the first aspect of the present invention. In the exhaust processing device, the main body tube portion includes a plurality of protrusions on an inner peripheral surface thereof. The protrusions are radially inwardly protruding from the inner peripheral surface of the main body tube portion. The protrusions are circumferentially aligned on the inner peripheral surface of the main body tube portion. The exhaust processing device further includes a meshed flow regulation member. The flow regulation member is joined to the inner peripheral surface of the main body tube portion with the flow regulation member being hooked on the protrusions. 
     According to the exhaust processing device of the fourth aspect of the present invention, the main body tube portion is disposed on the plate portion, and the flow regulation member is further disposed from above into the main body tube portion in assembling the exhaust processing device. The flow regulation member is thereby appropriately positioned under a condition that the flow regulation member is engaged with the protrusions. Therefore, the exhaust processing device can be easily assembled. 
     An exhaust processing device according to a fifth aspect of the present invention relates to the exhaust processing device according to the first aspect of the present invention. In the exhaust processing device, the plate portion includes a stepped portion dented to be matched with an edge of the axial end of the main body tube portion. Further, the axial end of the main body tube portion is appropriately positioned by the stepped portion abutted thereto. 
     According to the exhaust processing device according to the fifth aspect of the present invention, the plate portion can be appropriately positioned with respect to the end of the main body tube portion under a condition that the end of the main body tube portion is abutted to the stepped portion of the plate portion. Accordingly, the closing tube portion and the main body tube portion can be further easily assembled. 
     An exhaust processing device according to a sixth aspect of the present invention relates to the exhaust processing device according to the first aspect of the present invention. In the exhaust processing device, the main body tube portion includes an inner tube portion, a heat insulator, and an outer tube portion. The inner tube portion is joined to the plate portion. The heat insulator covers the outer peripheral surface of the inner tube portion. The outer tube portion covers an outer periphery of the heat insulator. The outer tube portion is axially longer than the inner tube portion. 
     According to the exhaust processing device of the sixth aspect of the present invention, the inner tube portion and the plate portion are joined in assembling the closing tube portion and the main body tube portion. The heat insulator is then attached to the outer peripheral surface of the inner tube portion. Subsequently, the outer tube portion is attached onto the inner tube portion that the heat insulator is attached thereto. Therefore, the inner tube portion and the closing tube portion, of relatively small sizes, can be assembled first. In other words, the closing tube portion and the main body tube portion can be easily assembled. 
     An exhaust processing device according to a seventh aspect of the present invention relates to the exhaust processing device according to the first aspect of the present invention. In the exhaust processing device, the tubular portion has a diameter that becomes larger towards the main body tube portion. 
     According to the exhaust processing device of the seventh aspect of the present invention, airflow resistance of exhaust gas can be reduced in the closing tube portion. Therefore, smooth flow of exhaust gas is achieved from the closing tube portion to the main body tube portion. 
     A method of manufacturing an exhaust processing device according to an eighth aspect of the present invention is a method of manufacturing an exhaust processing device including a main body tube portion and a tubular portion. The method includes the steps of assembling a closing tube portion and attaching the closing tube portion to a main body tube portion. The main body tube portion having an opening in an axial end thereof. The main body tube portion houses a main body exhaust path in an inside thereof. The main body exhaust path allows an exhaust gas to pass therethrough. The tubular portion radially inwardly protrudes from an outer peripheral surface of the main body tube portion. The tubular portion houses an exhaust path in an inside thereof. The exhaust path communicates with the main body exhaust path. In the step of assembling the closing tube portion, a second split half portion is attached to a first component. The first component includes a plate portion and a first split half portion integrally molded with the plate portion. The first split half portion and the second split half portion form the tubular portion. Then, the closing tube portion is attached to the main body tube portion to cover the opening of the axial end of the main body tube portion. 
     According to the method of manufacturing an exhaust processing device, the closing tube portion includes the plate portion. The closing tube portion is appropriately positioned with respect to the main body tube portion by attaching the plate portion to the main body tube portion under a condition that the plate portion closes the opening of the axial end of the main body tube portion. Further, the closing tube portion and the main body tube portion can be easily welded by executing welding along the opening formed in the axial end of the main body tube portion. Therefore, the exhaust processing device can be easily manufactured by the method of manufacturing an exhaust processing device. 
     Overall, according to the exhaust processing device of the present invention, the closing tube portion includes the plate portion, and the plate portion is configured to close the opening formed in the axial end of the main body tube portion. Therefore, the closing tube portion is appropriately positioned with respect to the main body tube portion by attaching the plate portion to the main body tube portion under a condition that the plate portion closes the opening formed in the axial end of the main body tube portion. Further, the closing tube portion and the main body tube portion can be easily welded by executing welding along the opening formed in the axial end of the main body tube portion. Accordingly, the exhaust processing device can be easily manufactured. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of an exhaust processing device. 
         FIG. 2  is a cross-sectional side view of the exhaust processing device. 
         FIG. 3  is a flowchart for showing a series of manufacturing steps of an inlet unit. 
         FIG. 4  is an oblique view of a first component. 
         FIG. 5  is an oblique view of the first component that a second component is attached thereto. 
         FIG. 6  is an enlarged view of flange portions of the first and second components. 
         FIG. 7  is an oblique view of an inlet tube portion. 
         FIG. 8  is an oblique view of the inlet tube portion that an inner tube portion is attached thereto. 
         FIG. 9  is an oblique view of the inner tube portion that a flow regulation member is attached thereto. 
         FIG. 10  is an oblique view of the inner tube portion that a ring member is attached thereto. 
         FIG. 11  is an oblique view of the inner tube portion that a heat insulator is wrapped therearound. 
         FIG. 12  is an oblique view of the inner tube portion and an outer tube portion, both of which are separated from each other. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     Structure of Exhaust Processing Device 
       FIGS. 1 and 2  illustrate an exhaust processing device  1  according to an exemplary embodiment of the present invention.  FIG. 1  is a side view of the exhaust processing device  1 , whereas  FIG. 2  is a cross-sectional side view of the exhaust processing device  1 . The exhaust processing device  1  is a diesel particulate filter device configured to purify exhaust gas exhausted from the internal combustion engine (e.g., the diesel engine). The exhaust processing device  1  includes an inlet unit  2 , a processing unit  3 , and an outlet unit  4 . 
     Inlet Unit  2   
     The inlet unit  2  is disposed upstream of the processing unit  3  in an exhaust gas flow. The inlet unit  2  is connected to an exhaust path (not illustrated in the figure) of the internal combustion engine. The inlet unit  2  includes a first main body tube portion  5  and an inlet tube portion  6  (closing tube portion). 
     The first main body tube portion  5  is a tubular member configured to be joined to the second main body tube portion  31 . The first main body tube portion  5  is disposed coaxial to a second main body tube portion  31  (described below) of the processing unit  3 . As illustrated in  FIG. 2 , the first main body tube portion  5  houses a main body exhaust path R 1  in the inside thereof. The main body exhaust path R 1  allows the exhaust gas to pass through. Further, the first main body tube portion  5  has axial ends opened. One of the axial ends of the first main body tube portion  5  is closed by a plate portion  26  (described below), whereas the other of the axial ends of the first main body tube portion  5  communicates with an exhaust path R 2  disposed within the processing unit  3 . The first main body tube portion  5  includes an inner tube portion  9 , a flow regulation member  10  (see  FIG. 9 ), a heat insulator  11 , and an outer tube portion  12 . 
     As illustrated in  FIGS. 2 and 12 , the inner tube portion  9  is a tubular member disposed as the inner peripheral surface of the first main body tube portion  5 . One of the axial ends of the inner tube portion  9  (hereinafter referred to as “a first inner end  13 ”) is opened. The opening is closed when the first inner end  13  is joined to the plate portion  26 . As illustrated in  FIGS. 2 and 11 , a ring member  15  is attached to the other of the axial ends of the inner tube portion  9  (hereinafter referred to as “a second inner end  14 ”). The ring member  15  prevents detachment of the heat insulator  11 . Further, the second inner end  14  includes a cutout  16  recessed towards the first inner end  13 . The cutout  16  is formed for avoiding contact between the second inner end  14  and a boss  17  (see  FIG. 2 ) disposed on the inner peripheral surface of the outer tube portion  12 . As illustrated in  FIGS. 2 and 8 , plural protrusions  18  are disposed on the inner peripheral surface of the inner tube portion  9 . The protrusions  18  are circumferentially aligned on the inner peripheral surface of the inner tube portion while being radial inwardly protruded. 
     The flow regulation member  10  is configured to regulate a flow of exhaust gas transferred into the inlet unit  2 . As illustrated in  FIGS. 2 and 10 , the flow regulation member  10  is formed in a meshed pattern. The flow regulation member  10  is joined to the inner peripheral surface of the main body tube portion while being hooked by the protrusions  18 . 
     The heat insulator  11  is a mat member having a heat insulation property. As illustrated in  FIGS. 2 and 12 , the heat insulator  11  is disposed for covering the outer peripheral surface of the inner tube portion  9 . The heat insulator  11  is axially retained by the ring member  15  attached to the inner tube portion  9  and a flange portion  29  (described below) of the plate portion  26 . 
     The outer tube portion  12  is a tubular member axially longer than the inner tube portion  9 . As illustrated in  FIGS. 2 and 12 , the outer tube portion  12  covers the inner tube portion  9  that the heat insulator  11  is wrapped therearound. In other words, the outer tube portion  12  is attached to the heat insulator  11  while covering the outer periphery of the heat insulator  11 . As illustrated in  FIG. 12 , one of the axial ends of the outer tube portion  12  (hereinafter referred to as “a first outer end  19 ”) is joined to the flange portion  29  of the plate portion  26 . Further, the other end of the axial ends of the outer tube portion  12  (hereinafter referred to as “a second outer end  21 ”) has a flange portion  22 . The flange portion  22  is radial outwardly protruded from the second outer end  21 . The flange portion  22  of the outer tube portion  12  is fixed to a flange portion  32  (see  FIGS. 1 and 2 ) of the processing unit  3  by means of fixation members (e.g., a bolt and a nut) while being abutted thereto. It should be noted that the outer tube portion  12  includes the boss  17  (see  FIG. 2 ) on the inner peripheral surface thereof for allowing a pressure sensor to pass therethrough and the boss  17  is opposed to the aforementioned cutout  16  of the inner tube portion  9 . 
     The inlet tube portion  6  is a member allowing exhaust gas to pass therethrough for transferring the exhaust gas to the first main body tube portion  5 . The inlet tube portion  6  is connected to the exhaust path (not illustrated in the figure) of the internal combustion engine. As illustrated in  FIG. 7 , the inlet tube portion  6  includes a first component  23  (see  FIG. 4 ), a second component  24  (second split half portion), and an annular member  25 . 
     As illustrated in  FIG. 4 , the first component  23  includes the plate portion  26  and a first split half portion  27 . 
     The plate portion  26  has an outline identical to that of the first outer end  19  (see  FIG. 12 ) of the outer tube portion  12 . Further, the inner part of the plate portion  26 , excluding the edge of the plate portion  26 , is dented to be matched with the edge of the first inner end  13  of the inner tube portion  9 . A stepped portion  28  is thus formed to be matched with the first inner end  13 . The inner tube portion  9  is appropriately positioned with respect to the first component  23  when the first inner end  13  is abutted to the stepped portion  28  (see  FIG. 8 ). A further inner part of the plate portion  26  continues to the first split half portion  27  while being outwardly bulged from the first split half portion  27 . It should be noted that the plate portion  26  has the flange portion  29  in the edge thereof and the flange portion  29  has a roughly circular outline. Further, a cover member  20  is attached to a part of the outer tube portion  12  (i.e., a part disposed axially outside the plate portion  26 ) while covering the plate portion  26  (see  FIGS. 1 and 2 ). 
     The first split half portion  27  is integrally molded with the plate portion  26 . The first split half portion  27  is formed in a semi-cylindrical shape. 
     As illustrated in  FIGS. 2 and 5 , the second component  24  is formed in a semi-circular shape. The second component  24  corresponds to a second split half portion configured to be joined to the first split half portion  27 . The second component  24  and the first split half portion  27  form a tubular portion  51 . The tubular portion  51  houses a first exhaust path R 3  (see  FIG. 2 ) in the inside thereof. The first exhaust path R 3  communicates with the main body exhaust path R 1 . The tubular portion  51  is radial outwardly protruded from the outer peripheral surface of the first main body tube portion  5 . 
     The first split half portion  27  includes a flange portion  52  formed along the edge thereof, whereas the second component  24  includes a flange portion  53  formed along the edge thereof. As illustrated in  FIG. 5 , the flange portion  52  of the first split half portion  27  and the flange portion  53  of the second component  24  are abutted. The flange portions  52 ,  53  are disposed along the axial direction of the tubular portion  51  from one end of the tubular portion  51  (i.e., an end disposed closer to the first main body tube portion  5 ) to the other end of the tubular portion  51  (herein after referred to as “an inlet end  54 ”). A tip section  55  of the flange portions  52 ,  53  (i.e., a tip section closer to the inlet end  54 ) is positioned closer to the first main body tube portion  5  than the inlet end  54  is. Further, a part of the flange portion  52 , which is closer to the first main body tube portion  5 , continues to the flange portion  29  of the plate portion  26 . Yet further, as illustrated in  FIG. 6 , the first split half portion  27  includes a convex portion  56  on a joint surface of the flange portion  52  thereof, whereas the second component  24  includes a concave portion  57  on a joint surface of the flange portion  53  thereof. The convex portion  56  and the concave portion  57  are engaged for appropriately positioning the first split half portion  27  and the second component  24 . It should be noted in the present exemplary embodiment that the convex portion  56  is formed in the first split half portion  27  whereas the concave portion  57  is formed in the second component  24 . Contrary to this, the concave portion  57  may be formed on the first split half portion whereas the convex portion  56  may be formed on the second component  24 . 
     As illustrated in  FIG. 7 , the annular member  25  is attached onto the tubular portion  51  from the inlet end  54 . The annular member  25  is fitted onto the tubular portion  51  under a condition that the annular member  25  is abutted to the tip section  55  of the flange portions  52 ,  53 . Accordingly, the first split half portion  27  and the second component  24  are integrated. 
     Processing Unit  3  and Outlet Unit  4   
     The processing unit  3  is configured to purify exhaust gas transferred to the exhaust processing device  1 . As illustrated in  FIG. 2 , the processing unit  3  includes the second main body tube portion  31  and a filter  33 . 
     The second main body tube portion  31  is a tubular member including the flange portion  32  and a flange portion  34 . The flange portions  32 ,  34  are radial outwardly protruded from the both ends of the second main body tube portion  31 . The flange portion  32  closer to the inlet unit  2  is fixed to the flange portion  22  of the inlet unit  2  by means of fixation members (e.g., a bolt and a nut) while being abutted to the flange portion  22 . The flange portion  34  closer to the outlet unit  4  is fixed to a flange portion  41  of the outlet unit  4  by means of fixation members (e.g., a bolt and a nut) while being abutted to the flange portion  41 . 
     The filter  33  is a catalyst carrier configured to purify exhaust gas. The filter  33  is made of a ceramic. The filter  33  is formed in a cylindrical shape. The filter  33  is contained within the second main body tube portion  31  while the outer peripheral thereof is wrapped around by a heat insulator  35 . 
     The outlet unit  4  is disposed downstream of the processing unit  3  in the exhaust gas flow. The outlet unit  4  allows exhaust gas purified by the processing unit  3  to pass therethrough for discharging the exhaust gas out of the exhaust processing device  1 . The outlet unit  4  includes a third main body tube portion  42  and an outlet tube portion  43 . The third main body tube portion  42  has a structure identical to that of the first main body tube portion  5  of the inlet unit  2 , excluding that the third main body tube portion  42  is axially shorter than the first main body tube portion  5 . Further, the outlet tube portion  43  has a structure identical to that of the inlet tube portion  6 . Detailed explanations of the third main body tube portion  42  and the outlet tube portion  43  will be hereinafter omitted for the sake of brevity. 
     Manufacturing Steps of Exhaust Processing Device  1   
     Manufacturing steps of the exhaust processing device  1 , among other things, manufacturing steps of the inlet unit  2  will be hereinafter explained with reference to  FIG. 3 . 
     In Step S 1 , attachment of the second component  24  is firstly executed. The second component  24  is herein attached to the first component  23  (see  FIG. 4 ) as illustrated in  FIG. 5 . Specifically, the second component  24  is disposed on the first split half portion  27  under a condition that the flange portion  52  of the first split half portion  27  is abutted to the flange portion  53  of the second component  24 . The convex portion  56  of the first split half portion  27  and the concave portion  57  of the second component  24  are herein engaged. Accordingly, the second component  24  is appropriately positioned with respect to the first component  23  (see  FIG. 6 ). 
     Next, in Step S 2 , attachment of the annular member  25  is executed. As illustrated in  FIG. 7 , the annular member  25  is herein fitted onto the tubular portion  51 . The annular member  25  is herein abutted to the tip section  55  of the flange portion  52  of the first split half portion  27  and the flange portion  53  of the second component  24 . Accordingly, the annular member  25  is appropriately positioned with respect to the first component  23  and the second component  24 . 
     Next, in Step S 3 , attachment of the inner tube portion  9  is executed. As illustrated in  FIG. 8 , the inner tube portion  9  is herein disposed on the plate portion  26 . The first inner end  13  of the inner tube portion  9  is herein abutted to the stepped portion  28  (see  FIG. 7 ) of the plate portion  26 . Accordingly, the inner tube portion  9  is appropriately positioned with respect to the plate portion  26 , i.e., the inlet tube portion  6 . 
     Next, in Step S 4 , attachment of the flow regulation member  10  is executed. As illustrated in  FIG. 9 , the flow regulation member  10  is herein inserted into the inner tube portion  9 . The flow regulation member  10  is herein hooked by the protrusions  18  disposed on the inner peripheral surface of the inner tube portion  9 . Accordingly, the flow regulation member  10  is appropriately positioned with respect to the inner tube portion  9 . 
     Next, in Step S 5 , attachment of the ring member  15  is executed. As illustrated in  FIG. 10 , the ring member  15  is herein attached to the second inner end  14  of the inner tube portion  9 . The ring member  15  is herein temporarily fixed to the inner tube portion  9  by means of a jig (e.g., a clamper). 
     Next, in Step S 6 , welding is executed. The aforementioned components assembled in Steps S 1  to S 5  are joined by means of welding while the first component  23  is fixed by means of a jig. Specifically, continuous welding is executed for: a joint section between the first split half portion  27  and the second component  24 ; and a joint section between the annular member  25  and the tubular portion  51 . On the other hand, intermittent welding is executed for: a joint section between the plate portion  26  and the first inner end  13  of the inner tube portion  9 ; a joint section between the end of the second component  24 , which is closer to the first main body tube portion  5 , and the outer peripheral surface of the inner tube portion  9 ; a joint section between the flow regulation member  10  and the inner peripheral surface of the inner tube portion  9 ; and a joint section between the ring member  15  and the second inner end  14  of the inner tube portion  9 . 
     Next, in Step S 7 , attachment of the heat insulator  11  is executed. As illustrated in  FIG. 11 , the heat insulator  11  in a mat shape is herein wrapped around the outer peripheral surface of the inner tube portion  9 . 
     Next, in Step S 8 , attachment of the outer tube portion  12  is executed. As illustrated in  FIG. 12 , the inner tube portion  9  is herein press-inserted into the outer tube portion  12  while the outer tube portion  12  covers the inner tube portion  9  that the heat insulator  11  is wrapped therearound. 
     Next, in Step S 9 , welding is executed. Continuous welding is herein executed for a joint section between the first outer end  19  of the outer tube portion  12  and the inlet tube portion  6 . 
     It should be noted that the manufacturing steps of the outlet unit  4  is identical to those of the inlet unit  2 . 
     According to the exhaust processing device  1 , the first component  23  of the inlet tube portion  6  functions as a member configured to close the opening of the first main body tube portion  5 . Therefore, the exhaust processing device  1  can be formed by a small number of components. Accordingly, the exhaust processing device  1  can be easily assembled. 
     Further, in the manufacturing steps of the inlet unit  2 , members are sequentially disposed and appropriately positioned based on the first component  23 . Yet further, the members can be appropriately positioned easily without using a separately prepared jig. For example, in the aforementioned manufacturing steps of the exhaust processing device  1 , members can be assembled without using a jig in Steps S 1  to S 4 , S 7 , and S 8 , excluding attachment of the ring member  15  in Step S 5 . Further, welding is not required for temporal attachment of the members. Therefore, the members can be easily assembled. 
     Further, most of the welding sections are outwardly faced in welding. It is thereby possible to avoid contacts between members and a welding torch. This allows a welding robot to easily execute automatic welding. For example, the welding robot can execute automatic welding with respect to the first split half portion  27  and the second component  24  from the outside under the condition that the first split half portion  27  and the second component  24  are coupled to each other as described above. Further, the welding section between the first split half portion  27  and the second component  24  has a linear welding line. Therefore, welding can be easily done for the first split half portion  27  and the second component  24 . Consequently, the inlet tube portion  6  can be easily manufactured. 
     Further, the inlet tube portion  6  and the inner tube portion  9  are manufactured as a sub-unit. Accordingly, the inlet portion  6  and the inner tube portion  9  can be structured under a condition that the welding section thereof is faced to the outside. Yet further, when the inlet tube portion  6  and the inner tube portion  9  are coupled in combination, these components are more compactly formed than the entire inlet unit  2 . Therefore, it is possible to easily avoid contacts between a welding torch and the members in welding of the inlet tube portion  6  and the inner tube portion  9 . A robot is thereby allowed to execute automatic welding. Consequently, manufacturing can be easily done. 
     The exhaust processing device  1  can be easily manufactured by the aforementioned manufacturing steps. 
     Other Exemplary Embodiments 
     In the aforementioned exemplary embodiment, the tubular portion  51  is formed straight along the axial direction. However, the shape of the tubular portion  51  is not limited to this. For example, the tubular portion  51  may be transversely expanded towards the main body tube portion (i.e., a maximum width of the tubular portion becomes larger as it gets towards the main body tube portion). In this case, smooth flow of exhaust gas can be achieved from the inlet tube portion  6  to the first main body tube portion  5 . 
     The above described embodiments have an advantageous effect of easily manufacturing an exhaust processing device. The present invention is therefore useful for an exhaust processing device and a manufacturing method thereof.