Abstract: A spiral-wound metal catalyst support is disclosed, wherein the layers of the spiral cannot telescope outwardly in either direction. The support is formed by first winding together a flat strip and a corrugated strip, the strips being wound on a mandrel. The mandrel is removed to leave an axial hole. The catalyst support is then flattened at each end, so as to close the axial hole at each end. The flattening is done in mutually perpendicular directions, so that the catalyst support has tapers in both of two directions. The tapers prevent telescoping of the layers of the support. The catalyst support can be placed in a tube before it is flattened, and then the tube and the support can be flattened together, so that the support becomes firmly anchored in the tube. In an alternative embodiment, a second, tapered mandrel is inserted into the support before flattening, the tapered mandrel having a shape conforming to the inner cavity defined by the flattened support.

Abstract: A catalytic converter includes a metal honeycomb catalyst support which is anchored in a canister so that it cannot telescope or blow out. The honeycomb catalyst support is made by folding a strip of metal back and forth upon itself. The lines of folding are inclined to the perpendicular to the axis of the strip. The repeating sequence of the inclinations is left, right, right, left, etc. Folding the strip in this manner produces a honeycomb that has a taper in both of two directions so that it can be anchored in the canister. The canister has a taper which coincides with the taper of the honeycomb. The invention also includes a method and apparatus for making crease lines on the strip, so that the strip can be folded.

Abstract: The catalytic converter comprises a metal honeycomb catalyst support which is anchored in a canister so that it cannot telescope or blow out. The honeycomb catalyst support is formed by folding a strip of metal back and forth upon itself. There are slots in the strip along the lines of folding. When the strip is folded to form the honeycomb, the slots become notches, the notches being aligned so as to define grooves on the periphery of the honeycomb. The canister has internal ridges that mate with the grooves on the honeycomb and anchor the honeycomb.