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An aftermarket catalytic converter for motor vehicle exhaust gas systems has a clamshell housing with an upper heat shield and stainless steel inlet and outlet bushings and contains a catalyst coated substrate cushioned and supported inside of it by a heat expandable mat, the features and parts of t

An aftermarket catalytic converter for motor vehicle exhaust gas systems has a clamshell housing with an upper heat shield and stainless steel inlet and outlet bushings and contains a catalyst coated substrate cushioned and supported inside of it by a heat expandable mat, the features and parts of the converter being constructed and arranged to enable one converter construction to be used as a replacement converter in a substantial number of different applications for the original equipment converters.

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A motor vehicle exhaust gas system aftermarket catalytic converter suitable as a replacement for a variety of original equipment (“O.E.”) catalytic converters, said aftermarket catalytic converter comprising a clamshell housing comprised of upper and lower halves each about 10 inches long and having

A motor vehicle exhaust gas system aftermarket catalytic converter suitable as a replacement for a variety of original equipment (“O.E.”) catalytic converters, said aftermarket catalytic converter comprising a clamshell housing comprised of upper and lower halves each about 10 inches long and having a peripheral rim including semicircular rim sections at opposite ends and longitudinal rim sections extending between said semicircular rim sections, said longitudinal rim sections being welded together and said halves being shaped to jointly form a housing having a centrally located longitudinally extending catalyst substrate chamber about 5.75 inches long, said semicircular rim sections fitting together to define a circular inlet flange and a circular outlet flange, said housing including an inlet chamber increasing in cross-section in a direction extending from the circular inlet flange to an upstream end of said substrate chamber, said housing including an outlet chamber decreasing in cross-section in a direction extending from a downstream end of the substrate chamber to said circular outlet flange, a cylindrical inlet bushing having a downstream end fitting in and welded to said circular inlet flange, a cylindrical outlet busing having an upstream end fitted in and welded to said circular outlet flange, said bushings having a diameter of about 2.0 to 2.5 inches and projecting outwardly about 1.5 to 2.0 inches from said semicircular rim sections whereby the overall length of the housing is about 13 to 14 inches, said housing being substantially symmetrical about a longitudinal axis and said circular flanges and said bushings being substantially concentric with said longitudinal axis, a clamshell heat shield conforming in shape to the upper half of said housing, said heat shield including flat longitudinal side flanges welded to the longitudinal rim sections of said housing and a semicircular section extending laterally between the side flanges and completely spaced from and unconnected to the semicircular rim sections of the housing to provide an uninterrupted insulation space between the opposite ends of the shield, and oval-shaped flat ended catalyst substrate of the catalyst coated honeycomb-type disposed in said substrate chamber, an annular uniform thickness substrate support mat surrounding the entire outer peripheral surface of said substrate and in engagement with the wall of the chamber to centrally locate and support the substrate in the chamber and substantially uniformly space the outer peripheral surface of the substrate about 0.125 inch from the walls of the chamber, said support mat being composed of a heat expandable vermiculite base material and compressed between the walls of the chamber and the outer peripheral surface of the substrate to about one-half of its preassembled free state thickness, said substrate being about 4.25 inches long and having a major height of about 3.0 inches, a major width of about 4.75 inches, and a volume of about 55 cubic inches, said substrate having a multiplicity of longitudinally extending exhaust gas passage honeycomb cells at a density of substantially 400 cells per square inch, the walls of said cells being coated with a catalyst effective in the reduction of oxides of nitrogen and the oxidation of hydrocarbons and carbon monoxide, said catalyst comprising substantially five parts palladium and one part rhodium applied in a coating of about 20 grams per cubic foot of substrate.