Patent ID: 7823285

Claim:
A method of assembling a plurality of catalytic substrates and support materials within a catalytic converter housing, the method comprising the steps of: determining an outer profile of a catalytic substrate; determining a gap factor between the catalytic converter housing and the catalytic substrate; weighing the support material; determining a weight factor based on the measured weight of the support material; determining a compression factor based on the gap factor and the weight factor of the support material; determining whether the compression factor is within a predetermined compression threshold; inserting the catalytic substrate and the support material within the catalytic converter housing in response to the compression factor being within the predetermined compression threshold; determining an outer profile of a next catalytic substrate; determining a gap factor between the catalytic converter housing and the next catalytic substrate; weighing a next support material; determining a next weight factor based on the measured weight of the next support material; determining a next compression factor based on the next gap factor and the next weight factor of the next support material; determining whether the next compression factor is within the predetermined compression threshold; and inserting the next catalytic substrate and the next support material within the catalytic converter housing in response to the next compression factor being within the predetermined compression threshold.