Abstract: A metal foil leaf assembly for catalytic converters, the leaf assembly including at least two juxtaposed foil leaves, each having opposite ends to establish a leaf length and at least one corrugated leaf segment shorter than the leaf length. At least one of the opposite ends is joined by appropriate technique, such as welding, brazing, or folding. The leaf assembly is incorporated in catalytic converter body having a cylindrical jacket tube. A plurality of radiating foil leaves extend in adjacent curved paths and are joined at the outer ends thereof to the jacket tube. The foil leaves define fluid passage cells between juxtaposed flat and corrugated leaf segments, and each of the foil leaves has at least one corrugated segment.

Abstract: A catalytic converter body having a jacket tube, a plurality of non-nestable foil leaves having inner and outer ends defining a leaf length, the outer ends being connected to the jacket tube and radiating inward to provide flow passages generally transverse to the leaf length, and a pliant central core joined to the inner ends of the radiating foil leaves. The catalytic converter body has a natural frequency of between 10 and 100 hertz. The catalytic converter is formed by assembling a plurality of non-nestable foil leaves by interconnecting proximal ends of the foil leaves to provide a continuous flexible strip of overlapping foil leaves in which opposite the distal ends of the leaves extend freely.