Abstract: An intumescent catalyst mounting mat is provided by cutting a single piece of mat into a desired profile and cutting a slit about 1/2 way through the thickness of the mat at a selected fold line. The mat is then easily folded upon itself to create a double thickness mat that is already secured to the next layer and may have any desired profile.

Abstract: A catalytic converter for use in the exhaust system of an internal combustion engine, said catalytic converter including a housing having a cavity formed therein and having a gas inlet end and a gas outlet end, a pair of end members, each of said end members having an opening for allowing exhaust gases to pass therethrough, one of said end members sealingly connected to the gas inlet end of said housing and the other of said end members sealingly connected to the gas outlet end of said housing, a catalyst coated substrate located within said cavity and having a gas inlet face and a gas outlet face, a first mat of material which is expandable in an axially direction when heated positioned between said housing and a first portion of the catalyst coated substrate, and a second mat of material which is expandable in a radial direction surrounding a second portion of the catalyst coated substrate.

Abstract: A low profile catalytic converter for use with an internal combustion engine that has a canister provided with a plurality of smooth foil sections arranged in substantially perpendicular relationship with the top and bottom walls of the canister. The smooth foil sections are spaced from each other so as to form a plurality of substantially rectangular passages providing axially extending flow paths for the exhaust gas emanating from the engine. At least one corrugated foil strip is located in each of the passages and an arm is formed with each of the smooth foil sections that is secured together with a portion of the corrugated foil strip by separate welds to the top and bottom walls of the canister.

Abstract: A catalytic converter for an internal combustion engine having a housing provided with an exhaust gas by-pass tube and a valve arrangement that causes the exhaust gas to selectively flow through a catalyst coated substrate to be treated thereby or through the tube so as to exist the converter in an untreated state and in which an actuator is in a sealed relationship with the housing so as to prevent exhaust gas leakage while providing for movement of the valve.

Abstract: A method of manufacturing an oval shaped catalytic converter that reduces the amount of material and number of parts that are required for permitting the catalytic converter to treat the exhaust gases of an internal combustion engine and also improves the structural durability of the converter for high temperature applications by maintaining a higher mat density along the minor axis of the converter housing.

Abstract: A catalytic converter in which a catalyst coated substrate is positioned within a housing and is constructed with end portions thereof extending into close proximity to the end members attached to the housing so as to improve the durability of a mat of intumescent material that is wrapped around and serving to support the substrate within the housing.

Abstract: An exhaust gas management apparatus including: a first substrate coated with an oxidizing catalyst, wherein the first substrate includes an axial opening and a body portion radially exterior of the axial opening, wherein the axial opening comprises at least part of a bypass passage; an air source located downstream in an exhaust flow path of the axial opening; an air pump unit responsive to a control signal forcing air through the air source wherein, during an activation of the pump unit, the bypass passage is valved shut; and a second substrate coated with an oxidizing catalyst located in the path of exhaust downstream of the first substrate.

Abstract: A vehicular catalytic converter (10) is disclosed having a plurality of catalytic monoliths (24,26). The first (24) and second (26) catalytic monoliths are connected to each other at an angle. Any number of catalytic monoliths may be serially connected at angles to increase the gas-to-catalyst contact within the catalytic converter (10) thus creating a more efficient catalytic converter.