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There is provided a process and apparatus for making, preferably continuously, a catalytic converter element or core especially adapted for the treatment of exhaust from an internal combustion engine, whether spark or compression ignited. The converter element may be a fan-folded or accordion folded

There is provided a process and apparatus for making, preferably continuously, a catalytic converter element or core especially adapted for the treatment of exhaust from an internal combustion engine, whether spark or compression ignited. The converter element may be a fan-folded or accordion folded thin metal strip or a spirally wound element which carries strongly adhered to the surface thereof a catalyst, e.g. a noble or precious metal catalyst such as platinum and/or palladium and/or rhodium. The metal strip entering the process is an aluminum coated ferritic ribbon between 0.001 and 0.003 inches thick, and 1 inch to 30 inches wide. The strip is preferably annealed and perforated at predetermined intervals. Thereafter, the strip is corrugated and given a washcoat of a refractory metal oxide which is calcined onto the surface. One or more precious metal catalysts are supplied and dried. The strip is desirably, albeit optionally, creased in a manner to enable it to be folded back and forth upon itself, severed to size, and folded to build a catalytic converter element. Final steps may include insertion of the catalytic converter element into a housing and affixing end caps to form a complete unit. This process provides a continuous low cost means for making catalytic converters.

대표청구항 ▼

A process for making a metal catalyst support core for a catalytic converter from a continuous metal strip, comprising the steps of: (a) corrugating the metal strips, (b) depositing at least one catalyst material on the corrugated metal strip, (c) impressing fold lines on alternate sides of the stri

A process for making a metal catalyst support core for a catalytic converter from a continuous metal strip, comprising the steps of: (a) corrugating the metal strips, (b) depositing at least one catalyst material on the corrugated metal strip, (c) impressing fold lines on alternate sides of the strip along the entire length thereof, the fold lines extending transversely of the strip, and (d) folding and gathering the strip along the fold lines impressed in step (c) to form a fan-folded metal catalyst support core.