A replacement flange for the end of a catalytic converter is provided by a pair of generally L-shaped coupling elements which have their base portions opposed and seated in an elongated channel element which permits one coupling element to slide therein relative to the other.
The opposed edges of the flange coupling elements are generally arcuate to fit about the end pipe of the converter and have recesses to seat the flanges on the sides of the converter body. Assembly is effected by mounting one coupling element to the automobile support structure about the converter end and then sliding the other coupling element sideways into engagement therewith and mounting it to the support structure.
The present invention relates to replacement flanges for catalytic converters, and, more particularly, to such flanges which can be readily assembled by the mechanic about the catalytic converter and to the flange for the exhaust system without extensive disassembly and while all the parts are relatively hot.
As is well known, the catalytic converters on most vehicles are supported by original equipment flanges which are custom designed for a given vehicle, and which are frequently of one piece construction. Unfortunately, corrosion and heat cycling may cause failure of the flanges while the converter is still functional, and cause failure of the connection to the exhaust system. Unless promptly replaced, the converter itself may be damaged and repair of the sealed converters is impracticable.
Replacing the flanges with original equipment flanges may require some disassembly of the exhaust system in order to provide sufficient space for maneuvering the replacement flange into position, and for securing it about the catalytic converter.
It is generally advantageous for garages and the like to stock a limited number of replacement parts which can be utilized on more than one vehicle. Moreover, to reduce the cost of repair, it is desirable that the mechanic be able to install replacement flanges without any major disassembly of other parts, and, in the instance of exhaust system components, without having to wait for a substantial period of time for the parts to cool sufficiently so that the mechanic will not be burned when working thereabout.
It is an object of the present invention to provide a novel replacement flange for the end of catalytic converters which can be assembled quickly and easily about the converter.
It is also an object to provide such a flange which may be fabricated relatively economically from sheet metal stock.
Another object is to provide such a flange which may be installed with limited potential for contact of the mechanic's hands with hot parts of the exhaust system.
Still another object is to provide a method for quickly and easily installing such replacement flanges on vehicles.
It has now been found that the foregoing and related objects and advantages may be readily attained in a novel replacement flange for the end of a catalytic converter. This replacement flange has a pair of opposed coupling elements each having a generally vertically extending leg portion and a generally horizontally extending base portion, and the opposing edges of the coupling elements have a portion of arcuate configuration to seat a portion of the periphery of the outlet pipe of an associated catalytic converter and aligned recesses to seat the side flanges of the catalytic converter. The elements being spaced apart at the upper end of their leg portions, and each of the coupling elements has a plurality of bolt receiving apertures therein for mounting upon the support structure of the associated vehicle and for coupling to the flange of the associated exhaust system of the vehicle. A channel element seats and joins the opposed ends of the base portions of the coupling elements, and it permits horizontal sliding motion therein of one of the coupling elements relative to the other.
Preferably, the channel element is of elongated, generally U-shaped cross section defined by a pair of vertical legs and a base, and one of the legs has a groove in its inside surface extending along the length thereof. The base portion of at least one of the coupling elements has a boss thereon which slidably seats in this groove. Desirably each of the coupling elements has a boss seated in the groove, and the other one of the coupling elements and the channel element are fixedly engaged by staking or the like.
In the preferred embodiment, each of the coupling elements is of generally plate-like configuration with the boss being formed by deformation of the material from which the coupling element is formed, and the apertures for coupling to the exhaust system have internally threaded nuts thereabout to seat threadably the shanks of fasteners.
In the method of mounting the replacement flange on the end of a catalytic converter, a channel element is mounted on the base portion of one coupling element and it projects beyond the end of the base portion. The mounting the upper end of the leg portion of the coupling element is mounted upon the support structure of the vehicle with its arcuate edge extending about a portion of the outlet pipe of the catalytic converter. The other one of the coupling elements is moved horizontally to slidably seat its base portion in the channel and to seat its arcuate edge about another portion of the outlet pipe of the catalytic converter.
As a result, the channel element seats and joins the opposed ends of the base portions of the coupling elements and provides horizontal sliding motion therein of the other coupling element prior to finally securing both coupling elements to the automobile support structure. The upper end of the leg portion of the other coupling element is then mounted on the support structure of the vehicle, and the flange of the exhaust system for the vehicle is coupled to others of the apertures of the coupling elements .
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