Abstract: The substrate is used in a catalytic converter can to which a cylindrical inlet pipe leads and has an inner catalytic zone portion, an outer catalytic zone portion and an insulation material thermally separating the portions. The insulation extends through the substrate and has a uniform cross-section substantially defined by the intersection of two notional cylinders and the upstream face of the substrate, each notional cylinder having: a nominal diameter that is between 1.08 and 1.20 of the diameter of the inlet pipe; a thickness of 1-4 mm; and an axis aligned with the gas direction at the point of maximum velocity at the intersection of the inlet pipe and the can. One of the cylinders is associated with the gas flow at the lower limit of the operating range and the other of the cylinders is associated with the gas flow at the upper limit of the operating range.

Abstract: A catalytic converter apparatus for use in an exhaust system of an internal combustion engine includes a housing having a gas inlet and a gas outlet, and at least one catalytic substrate element disposed in the housing. The at least one substrate element is divided into a plurality of zones or sections, the zones at least partially separated from one another to inhibit heat flow. The zones can be at least partially separated with walls. The walls can include insulating material for reducing the mobility of heat radially outwardly. Each of the zones defines a generally separate flow passage connecting the inlet and outlet in fluid communication. The apparatus can heat more rapidly from a cold start compared with conventional catalytic converters.

Abstract: An improved catalytic substrate for use with a can in an automotive exhaust system. The improvement includes an insulation material thermally separating the substrate into a central zone and an outer zone surrounding the central zone. The insulation material, central zone and outer zone collectively defining a modified substrate. The insulation material is adapted such that in an operating condition, the gas flow through the modified substrate is characterized by a static pressure that, on the upstream-facing surface of the modified substrate has a peak at a point generally central to the upstream-facing surface of the modified substrate; as the upstream-facing surface extends radially away from the point to the periphery, decreases, but for a surge after the upstream-facing surface extends beyond the insulation material.

Abstract: An improved catalytic substrate for use with a can in an automotive exhaust system, the substrate being of the type which is disposed in use in the can, the improvement comprising: an insulation material thermally separating the substrate into a central zone and a tubular outer zone surrounding the central zone, the insulation material, central zone and outer zone collectively defining a modified substrate, the insulation material being adapted such that, in an operating condition, the temperature difference across the insulation material is at least 25° C.

Abstract: A catalytic converter apparatus for use in an exhaust system of an internal combustion engine includes a housing having a gas inlet and a gas outlet, and at least one catalytic substrate element disposed in the housing. The at least one substrate element is divided into a plurality of zones or sections, the zones at least partially separated from one another to inhibit heat flow. The zones can be at least partially separated with walls. The walls can include insulating material for reducing the mobility of heat radially outwardly. Each of the zones defines a generally separate flow passage connecting the inlet and outlet in fluid communication. The apparatus can heat more rapidly from a cold start compared with conventional catalytic converters.

Abstract: The substrate is used in a catalytic converter can to which a cylindrical inlet pipe leads and has an inner catalytic zone portion, an outer catalytic zone portion and an insulation material thermally separating the portions. The insulation extends through the substrate and has a uniform cross-section substantially defined by the intersection of two notional cylinders and the upstream face of the substrate, each notional cylinder having: a nominal diameter that is between 1.08 and 1.20 of the diameter of the inlet pipe; a thickness of 1-4 mm; and an axis aligned with the gas direction at the point of maximum velocity at the intersection of the inlet pipe and the can. One of the cylinders is associated with the gas flow at the lower limit of the operating range and the other of the cylinders is associated with the gas flow at the upper limit of the operating range.

Abstract: A catalytic converter apparatus for use in an exhaust system of an internal combustion engine includes a housing having a gas inlet and a gas outlet, and at least one catalytic substrate element disposed in the housing. The at least one substrate element is divided into a plurality of zones or sections, the zones at least partially separated from one another to inhibit heat flow. The zones can be at least partially separated with walls. The walls can include insulating material for reducing the mobility of heat radially outwardly. Each of the zones defines a generally separate flow passage connecting the inlet and outlet in fluid communication. The apparatus can heat more rapidly from a cold start compared with conventional catalytic converters.

Abstract: A catalytic converter apparatus for use in an exhaust system of an internal combustion engine includes a housing having a gas inlet and a gas outlet, and at least one catalytic substrate element disposed in the housing. The at least one substrate element is divided into a plurality of zones or sections, the zones at least partially separated from one another to inhibit heat flow. The zones can be at least partially separated with walls. The walls can include insulating material for reducing the mobility of heat radially outwardly. Each of the zones defines a generally separate flow passage connecting the inlet and outlet in fluid communication. The apparatus can heat more rapidly from a cold start compared with conventional catalytic converters.

Abstract: A catalytic converter apparatus for use in an exhaust system of an internal combustion engine includes a housing having a gas inlet and a gas outlet, and at least one catalytic substrate element disposed in the housing. The at least one substrate element is divided into a plurality of zones or sections, the zones at least partially separated from one another to inhibit heat flow. The zones can be at least partially separated with walls. The walls can include insulating material for reducing the mobility of heat radially outwardly. Each of the zones defines a generally separate flow passage connecting the inlet and outlet in fluid communication. The apparatus can heat more rapidly from a cold start compared with conventional catalytic converters.

Abstract: A catalytic converter apparatus for use in an exhaust system of an internal combustion engine includes a housing having a gas inlet and a gas outlet, and at least one catalytic substrate element disposed in the housing. The at least one substrate element is divided into a plurality of zones or sections, the zones at least partially separated from one another to inhibit heat flow. The zones can be at least partially separated with walls. The walls can include insulating material for reducing the mobility of heat radially outwardly. Each of the zones defines a generally separate flow passage connecting the inlet and outlet in fluid communication. The apparatus can heat more rapidly from a cold start compared with conventional catalytic converters.

Abstract: An improved catalytic substrate for use with a can in an automotive exhaust system, the substrate being of the type which is disposed in use in the can, the improvement comprising: an insulation material thermally separating the substrate into a central zone and a tubular outer zone surrounding the central zone, the insulation material, central zone and outer zone collectively defining a modified substrate, the insulation material being adapted such that, in an operating condition, the temperature difference across the insulation material is at least 25° C.

Abstract: A catalytic converter apparatus for use in an exhaust system of an internal combustion engine includes a housing having a gas inlet and a gas outlet, and at least one catalytic substrate element disposed in the housing. The at least one substrate element is divided into a plurality of zones or sections, the zones at least partially separated from one another to inhibit heat flow. The zones can be at least partially separated with walls. The walls can include insulating material for reducing the mobility of heat radially outwardly. Each of the zones defines a generally separate flow passage connecting the inlet and outlet in fluid communication. The apparatus can heat more rapidly from a cold start compared with conventional catalytic converters.

Abstract: A catalytic converter apparatus for use in an exhaust system of an internal combustion engine includes a housing having a gas inlet and a gas outlet, and at least one catalytic substrate element disposed in the housing. The at least one substrate element is divided into a plurality of zones or sections, the zones at least partially separated from one another to inhibit heat flow. The zones can be at least partially separated with walls. The walls can include insulating material for reducing the mobility of heat radially outwardly. Each of the zones defines a generally separate flow passage connecting the inlet and outlet in fluid communication. The apparatus can heat more rapidly from a cold start compared with conventional catalytic converters.

Abstract: A catalytic converter apparatus for use in an exhaust system of an internal combustion engine includes a housing having a gas inlet and a gas outlet, and at least one catalytic substrate element disposed in the housing. The at least one substrate element is divided into a plurality of zones or sections, the zones at least partially separated from one another to inhibit heat flow. The zones can be at least partially separated with walls. The walls can include insulating material for reducing the mobility of heat radially outwardly. Each of the zones defines a generally separate flow passage connecting the inlet and outlet in fluid communication. The apparatus can heat more rapidly from a cold start compared with conventional catalytic converters.

Abstract: A catalytic converter apparatus for use in an exhaust system of an internal combustion engine includes a housing having a gas inlet and a gas outlet, and at least one catalytic substrate element disposed in the housing. The at least one substrate element is divided into a plurality of zones or sections, the zones at least partially separated from one another to inhibit heat flow. The zones can be at least partially separated with walls. The walls can include insulating material for reducing the mobility of heat radially outwardly. Each of the zones defines a generally separate flow passage connecting the inlet and outlet in fluid communication. The apparatus can heat more rapidly from a cold start compared with conventional catalytic converters.