Abstract: A chemical reactor is provided that includes: a plurality of tubes having a catalytic reactor substrate therein, each of the tubes having an inlet at one end for receiving a fluid flow and an outlet at an opposing end for discharging fluid flow, and a longitudinal axis parallel to the direction of fluid flow through the tube, the longitudinal axis of each tube being parallel to one another; and a plurality of heat exchange fins disposed on and extending radially from the exterior surface of each tube; the heat exchange fins on each tube independently having a profile along a cross-section perpendicular to the longitudinal axis of each tube, and the tubes being arranged with respect to one another, such that the heat exchange fin profiles together form a tessellated pattern in a plane that is perpendicular to the longitudinal axes of the tubes.

Abstract: A chemical reactor is provided that includes: a plurality of tubes having a catalytic reactor substrate therein, each of the tubes having an inlet at one end for receiving a fluid flow and an outlet at an opposing end for discharging fluid flow, and a longitudinal axis parallel to the direction of fluid flow through the tube, the longitudinal axis of each tube being parallel to one another; and a plurality of heat exchange fins disposed on and extending radially from the exterior surface of each tube; the heat exchange fins on each tube independently having a profile along a cross-section perpendicular to the longitudinal axis of each tube, and the tubes being arranged with respect to one another, such that the heat exchange fin profiles together form a tessellated pattern in a plane that is perpendicular to the longitudinal axes of the tubes.

Abstract: Disclosed herein is a method of making a catalytic converter; forming a shell having a welding deformation detail; inserting and housing a catalyst substrate inside the shell, wherein a mat support material is disposed between the shell and the catalyst substrate; welding an end cone having a flange to the shell by applying a deformation force to the flange causing deformation of welding deformation detail.

Abstract: A variable flow regulator assembly includes a first stationary exhaust pipe, a second stationary exhaust pipe concentrically disposed within the first stationary exhaust pipe, and a movable exhaust pipe concentrically disposed between the first and second stationary exhaust pipes. The first stationary exhaust pipe includes one or more interference tabs concentrically and circumferentially fitted about its interior surface. The movable exhaust pipe includes one or more interference tabs concentrically and circumferentially fitted about its exterior surface. The interference tabs complimentarily interact and restrict the movement of the variable flow regulator so that the flow maldistribution of the exhaust gas stream entering the catalytic converter can be variably controlled.

Abstract: An exhaust emission control device is manufactured by sizing a housing of over a substrate and intumescent mat subsequently to heating said emission control device. The step of heating causes said intumescent mat to at least reach a temperature at which it swells. If the substrate has a washcoat layer, it may be left unfired until after it is assembled with the housing, in which case the step of heating causes the washcoat layer to sinter.

Abstract: A catalytic converter comprises a catalyst substrate concentrically disposed in a shell and having a mat support material located concentrically in between the catalyst substrate and shell. The catalyst substrate includes structural features located on its outer surface that engage the mat support material. The shear forces exerted between the catalyst substrate and mat support material, in addition to the normally present frictional forces, reduce the axial movement of the catalyst substrate during assembly and operation of the catalytic converter.

Abstract: A variable flow regulator assembly comprises a first stationary exhaust pipe, a second stationary exhaust pipe concentrically disposed within the first stationary exhaust pipe, and a movable exhaust pipe concentrically disposed between the first and second stationary exhaust pipes. The first stationary exhaust pipe includes one or more interference tabs concentrically and circumferentially fitted about its interior surface. The movable exhaust pipe includes one or more interference tabs concentrically and circumferentially fitted about its exterior surface. The interference tabs complimentarily interact and restrict the movement of the variable flow regulator so that the flow maldistribution of the exhaust gas stream entering the catalytic converter can be variably controlled.

Abstract: Disclosed herein is a method of making a catalytic converter; forming a shell having a welding deformation detail; inserting and housing a catalyst substrate inside the shell, wherein a mat support material is disposed between the shell and the catalyst substrate; welding an end cone having a flange to the shell by applying a deformation force to the flange causing deformation of welding deformation detail.

Abstract: A gas treatment system comprises a variable flow regulator assembly placed in operable and fluid communication with a shell of a gas treatment device. The variable flow regulator assembly comprises two or more conduit portions comprising a first portion and a second portion, wherein the second portion has a coefficient of thermal expansion greater than a first coefficient of thermal expansion of the first portion. The variable flow regulator assembly structurally changes shape to alter the flow maldistribution of an exhaust gas stream into the gas treatment device when light off is achieved.

Abstract: An exhaust emission control device is manufactured by sizing a housing of over a substrate and intumescent mat subsequently to heating said emission control device. The step of heating causes said intumescent mat to at least reach a temperature at which it swells. If the substrate has a washcoat layer, it may be left unfired until after it is assembled with the housing, in which case the step of heating causes the washcoat layer to sinter.

Abstract: Disclosed herein is an exhaust emissions control device and method for making the same. The method for manufacturing the exhaust emission control device comprises: disposing a mat support and a substrate in a shell, wherein the mat support is disposed between the substrate and the shell, and wherein the shell has a roughened surface in physical contact with the mat support.

Abstract: A variable flow regulator assembly comprises a first stationary exhaust pipe, a second stationary exhaust pipe concentrically disposed within the first stationary exhaust pipe, and a movable exhaust pipe concentrically disposed between the first and second stationary exhaust pipes. The first stationary exhaust pipe includes one or more interference tabs concentrically and circumferentially fitted about its interior surface. The movable exhaust pipe includes one or more interference tabs concentrically and circumferentially fitted about its exterior surface. The interference tabs complimentarily interact and restrict the movement of the variable flow regulator so that the flow maldistribution of the exhaust gas stream entering the catalytic converter can be variably controlled.

Abstract: A gas treatment system comprises a variable flow regulator assembly placed in operable and fluid communication with a shell of a gas treatment device. The variable flow regulator assembly comprises two or more conduit portions comprising a first portion and a second portion, wherein the second portion has a coefficient of thermal expansion greater than a first coefficient of thermal expansion of the first portion. The variable flow regulator assembly structurally changes shape to alter the flow maldistribution of an exhaust gas stream into the gas treatment device when light off is achieved.

Abstract: A catalytic converter comprises a catalyst substrate concentrically disposed in a shell and having a mat support material located concentrically in between the catalyst substrate and shell. The catalyst substrate includes structural features located on its outer surface that engage the mat support material. The shear forces exerted between the catalyst substrate and mat support material, in addition to the normally present frictional forces, reduce the axial movement of the catalyst substrate during assembly and operation of the catalytic converter.