US Patent 7452512 Converter assembly with insulated sensor boss

A converter assembly includes an outer shell defining an internal cavity that receives first and second catalyst substrates, which are spaced apart from each other to form a gap. A solid inner ring with a sensor boss is installed within the internal cavity. The solid inner ring is positioned in the gap between the first and second catalytic substrates. The solid inner ring provides insulation within the gap. The sensor boss extends radially outwardly beyond an outer surface of the outer shell. The sensor boss is welded to the outer surface of the outer shell to prevent exhaust gas leakage.