Method of installing a longitudinally offset multi-layer mat in an exhaust gas aftertreatment or acoustic device

1. A method of installing a mat within an exhaust gas aftertreatment or acoustic device having two adjacent surfaces, the mat having laterally spaced side edges, the method comprising the steps of:

tapering each of said side edges at a predetermined angle;

wrapping the mat completely around the one of the two adjacent surfaces to completely encircle the one surface;

continuing to wrap the mat completely around itself a plurality of times telescopically such that with each successive wrap of the mat its side edges are offset a distance from the side edges of the previous underlying wrap whereby each of said side edges of the continued wrapping together are generally in the shape of a truncated cone;

compressing the mat between the two adjacent surfaces of the device, said compressing step including translating the two adjacent surfaces relative to one another with the wrapped mat therebetween, whereby the tapered edges on the continued wrapping of the mat are shifted so that their edges are generally perpendicular to said adjacent surfaces and the offset edges on the continued wrapping of the mat are shifted into the direction of the translation so that the edges of each mat wrapping are generally aligned with the edges of the other mat wrappings in a plane perpendicular to the adjacent surfaces.

2. The method of claim 1 wherein the one of two adjacent surfaces is defined by a core of the device and the other of the two adjacent surfaces is defined by a housing of the device.

3. The method of claim 2 wherein the two adjacent surfaces are cylindrical.

4. A method of installing a mat within an exhaust gas aftertreatment or acoustic device having a first surface surrounded by and facing a second surface, said first and second surfaces extending in the direction of an axis, the method comprising the steps of:

providing a mat having laterally spaced side edges tapered at a predetermined angle;

installing the mat so that the mat encircles the first surface with a first complete wrap having said side edges generally aligned with a first set of spaced planes which are perpendicular to said first surface;

subsequently wrapping the mat around the first complete wrap for a plurality of wraps such that the side edges of each successive wrap of the mat are offset relative to the immediately underlying wrap in the direction of the axis;

wrapping the mat to encircle all underlying mat wrappings with a final complete wrap having said side edges generally aligned with a second set of spaced planes which are perpendicular to said first surface, said second set of spaced planes being offset from said first set of spaced planes;

compressing the mat between the first and second surfaces of the device, said compressing step including translating the first and second surfaces relative to one another with the wrapped mat therebetween, whereby the tapered edges on the plurality of wraps of the mat are shifted so that their edges are generally perpendicular to said first and second surfaces and the offset edges of the plurality of wraps are shifted into the direction of the translation so that the edges of each mat wrapping are generally aligned with the edges of the other mat wrappings in a plane perpendicular to the adjacent surfaces.

5. The method of claim 4 wherein the compressing step comprises translating the first and second surfaces relative to each other in the direction of the axis to align the offset wraps of the mat such that the first set of planes and second set of planes are translated relative to each other so as to align with each other.

6. The method of claim 4 wherein the first surface is defined by a core of the device and the second surface is defined by a housing of the device.

7. The method of claim 6 wherein the first complete wrap and the final complete wrap each comprise wrapping the mat around the core 360° to 370°.

8. A method of installing a mat within an exhaust gas aftertreatment or acoustic device having a core and a housing, both being cylindrical about an axis with said core having an outer surface facing an inner surface of said housing, the method comprising the steps of:

providing a mat having a top face spaced from a bottom face with side edges tapered at a predetermined angle whereby said bottom face is laterally shifted relative to said top face;

installing the mat so that the mat encircles the core with a first complete wrap having said side edges generally aligned with a first set of spaced planes which are perpendicular to said axis, said mat bottom face being the inner face of said first complete wrap and said top face being the outer face;

continuing to wrap the mat around the core so that the inner face of X additional complete wraps surround the outer face of the immediately underlying mat wrap with each additional complete wrap having its side edges offset in the axial direction relative to the immediately underlying wrap, wherein X is greater than 2;

wrapping the mat around the core with a final complete wrap having said side edges generally aligned with a second set of spaced planes which are perpendicular to said first surface, said second set of spaced planes being offset from said first set of spaced planes;

compressing the mat between the core and the housing while translating the core and housing relative to each other in the direction of the axis to align the offset wraps of the mat such that the edges of all of the wraps on each side lie in substantially the same plane perpendicular to the axis.