Exhaust manifold and method of making the same
AssigneeMathson Industries
InventorBoney A. Mathew
Life of this patent
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Abstract
An exhaust manifold (10) of the present invention comprises a liner (12) that includes inner surface (14) defining manifold passages and an outer surface (16). The exhaust manifold (10) includes a shell (18) of a homogeneous and continuous material disposed over the outer surface (16) of the liner (12). The shell (18) and liner (12) of the exhaust manifold (10) include first (60) and second (72) composition formed from ferrous and non-ferrous metal powders (62), ceramic powder (64), and a binder (74) added thereto to form the manifold (10). The invention discloses a method of making the exhaust manifold (80). Accordingly, the exhaust manifold (10) of the subject invention has a reduced weight and dissipates heat energy contained in the exhaust thereby increasing the efficiency of the catalytic converter (42).
Claims51
A method of making an exhaust manifold (70) comprising the steps of:
- forming a liner (12) including inner surface (14) defining manifold passages and an outer surface (16);
- forming a first composition (76) of ceramic powder (72) and a metal powder (74);
- adding a binder (78) to said first composition (76) to form a homogeneous material;
- extruding said homogeneous material through an extruder (83) to form a feedstock (82);
- pelletizing (80) said homogeneous material to form a feedstock (82);
- and
- molding a shell (18) of said homogeneous and continuous material of said feedstock (82) completely encapsulating said outer surface (16) of said liner (12).
An exhaust manifold (10) comprising:
- a liner (12) of a homogeneous and continuous material formed of a metal powder and a ceramic powder to define an inner surface (14) and manifold passages and an outer surface (16);
- and
- a shell (18) of another homogeneous and continuous material formed from extruded pellets of a metal powder bonded to a ceramic powder by a binder and disposed over said outer surface (16) of said liner (12).
Dependencies are inferred from the claim text.