Exhaust treatment device with sensor and method of making

A method for providing an exhaust treatment device with a mid-mount gas sensor, the method comprising:

• inserting a first catalyst brick into a shell of the exhaust treatment device;
• inserting a second catalyst brick into the shell of the exhaust treatment device, wherein an inlet end of the second catalyst is butted against an outlet end of the first catalyst;
• and
• providing an opening in the shell and a complimentary sensor receiving area in at least one of the first and second catalyst bricks by drilling into the shell after the first and second catalyst bricks have been inserted therein.

An exhaust treatment device, comprising:

• a shell portion defining an inlet opening and an outlet opening;
• at least one catalyst brick inserted within the shell portion;
• an insulative material disposed between the shell portion and the at least one catalyst brick;
• and
• a sensor receiving area formed in at least one catalyst brick.

A method for providing an exhaust treatment device with a mid-mount gas sensor, the method comprising:

• coating a first portion of a catalyst brick with a first washcoat comprising a first catalyst;
• coating a second portion of the catalyst brick with a second washcoat comprising a second catalyst, the first catalyst being different from the second catalyst;
• inserting the catalyst brick into a shell of the exhaust treatment device;
• and
• forming an opening in the shell and a complimentary sensor receiving area in the catalyst brick by drilling into the shell and the catalyst brick after the catalyst brick has been inserted in the shell, the sensor receiving area being located in an area of the catalyst brick where the first portion coated with the first washcoat ends and the second portion with the second washcoat begins.

An exhaust treatment device, comprising:

• a shell portion defining an inlet opening and an outlet opening;
• a pair of catalyst bricks inserted within the shell portion, one of the pair of catalyst bricks is coated with a washcoat comprising a first catalyst and the other one of the pair of catalyst bricks is coated with a washcoat comprising a second catalyst, the second catalyst being different from the first catalyst;
• a ceramic spacer disposed between the catalyst bricks;
• an insulative material disposed between the shell portion and the pair of catalyst bricks;
• and
• a sensor receiving area formed the ceramic spacer.