Abstract: A catalytic combustor for a gas turbine includes a stack of metal strips, each strip having an inlet end and an outlet end. The inlet ends of both sides of the strip are uncoated, to limit the temperature and maintain rigidity of the strip at the inlet end. In one embodiment, both sides of the strip have a light-off band, coated with catalyst, and adjacent to the uncoated inlet band. One side of the strip (Side A) also includes at least one combustion band, while the other side (Side B) has no corresponding coated band. The strips are arranged such that Side A of a given strip inside the stack faces Side A of an adjacent strip, and Side B of a strip inside the stack faces Side B of an adjacent strip. The resulting structure prevents overheating of the combustor, maintains its rigidity, and reduces the pressure drop through the combustor.

Abstract: A compact steam reformer produces hydrogen to power a fuel cell, such as can be used in a vehicle. The steam reformer includes a first channel, at least partly coated with a steam reforming catalyst, and a second channel, at least partly coated with a combustion catalyst, the channels being in thermal contact with each other. Heat from the combustion is used in the steam reforming reaction. The steam reformer may be provided as a stack of strips defining steam reforming channels which alternate with combustion channels. The reformer may also include a set of modules, connected in series, each module including a stack of strips as described above. The steam reformer preferably also includes a channel wherein a water-gas shift reaction occurs, to convert carbon monoxide, produced by the reformer, into carbon dioxide.

Abstract: A compact steam reformer produces hydrogen to power a fuel cell, such as can be used in a vehicle. The steam reformer includes a first channel, at least partly coated with a steam reforming catalyst, and a second channel, at least partly coated with a combustion catalyst, the channels being in thermal contact with each other. Heat from the combustion is used in the steam reforming reaction. In another embodiment, the gas streams feeding the reforming and combustion channels pass through a valve which reverses the gas streams periodically. The combustion channel becomes the reforming channel, and vice versa, so that carbon deposits in the former reforming channel are burned off. This arrangement enables the reforming reaction to continue indefinitely at peak efficiency.

Abstract: A monolith for imparting swirl to a gas stream includes a stack of alternating flat and corrugated strips defining channels for gas flow. The strips are attached, at an angle, to a carrier. Also, the corrugations of the corrugated strips may be skewed. The carrier defines a cylindrical shell for the strips, and the strips extend from the carrier to a central region. The strips are curved, typically having substantially the shape of involutes, and substantially fill the space between the central region and the shell. Due to the angle of attachment between the strips and the carrier, the gas flow channels are oriented in different directions, at different locations on the outlet face of the monolith. This structure therefore imparts swirl to gas flowing through the monolith.

Abstract: A catalytic combustor includes a plurality of channels formed by corrugated and flat strips, some of the channels being coated with a catalyst and others being uncoated. In the vicinity of the inlet end of the combustor, the boundary of each coated channel has a thermal barrier, to inhibit the flow of heat from the coated channel to an adjacent uncoated channel. Also in the vicinity of the inlet end, the coated channels may include one or more additional coated members, to enhance catalytic combustion in the light-off zone. The combustor of the present invention lights off at a relatively low temperature, and quickly reaches a stabilized and controlled operating temperature.

Abstract: A catalytic combustor is formed from a stack of flat and corrugated metal strips. The stack may or may not be wound into a spiral or formed into some other curved structure. Some of the strips are displaced, or offset, relative to other strips, such that some strips do not extend as far as the end faces of the stack. The latter feature increases the effective height of the corrugations, at the end faces, and makes it feasible to weld the strips together. In one embodiment, there are high-amplitude corrugated strips and low-amplitude corrugated strips. The low-amplitude corrugated strips increase the effective cell density, but are displaced from the end faces of the stack so as to permit convenient welding. The resulting combustors therefore have very high cell density, yet can be manufactured economically.

Abstract: There is provided an improved converter body formed of thin metal core elements and a housing. The thin metal core elements have a distal end and a proximal end The distal ends are secured to the housing, and at least some, preferably all, of the proximal ends are free of attachment to any rigid member. This structure results in improved durability in severe automotive tests.

Abstract: A catalytic converter is constructed by assembling a plurality of non-nestable foil leaves, each having opposite proximal and distal ends defining a leaf length. The proximal ends of the foil leaves are interconnected to provide a continuous flexible strip of overlapping foil leaves in which the distal ends of the leaves extend freely. The strip of foil leaves is subsequently formed to arrange the leaves to lie in curved paths radiating inwardly from the interconnected proximal ends toward a central area.

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.

Abstract: An electrically heatable converter body formed of thin metal core elements and a housing. The thin metal core elements have a distal end and a proximal end. The distal ends are secured to the housing, and at least some, preferably all, of the proximal ends are free of attachment to any rigid member.

Abstract: There is provided an improved core element for use in converters, especially catalytic converters. The core is characterized by two portions one of which portions is capable of being electrically heated, and the other of which is isolated from the first portion electrically and thermally and is called a light-off portion. A plurality of core elements is wrapped about a central rigid metallic pin and the assembly tightly spirally wound about the pin to form the core, part of which is electrically heatable and the other of which is not heated electrically. The core is formed from a plurality of composite core elements, each including a corrugated strip backed up with a flat two-member strip, one band of the two-member flat strip being of generally relatively narrow width, contiguous with the leading portion of the corrugated strip, and the other band contiguous with the trailing portion of the corrugated strip and usually being of relatively greater width.

Abstract: There is provided an improved converter body core element having a corrugated thin metal strip having, parallel to and close to a longitudinal marginal edge thereof, a recess dimensioned and configured to receive a heater band. In specific embodiments, the heater band is desirably lightly corrugated, i.e., having an amplitude of the corrugations which is from one tenth to one third the amplitude of the corrugations in the strip containing the recess, and the heater band is dimensioned and configured to fit into the recess.

Abstract: There is provided an electrically heatable converter body including a multicellular metallic honeycomb characterized by a plurality of first thin metal strips and a plurality of second thin metal strips in layered alternating relation, and wherein the first thin metal strips have a leading edge portion and a trailing edge portion, the leading edge portion of the first thin metal strips being longer than the trailing edge of said first thin metal strips.

Abstract: There is provided an improved combined electrically heatable and light-off converter which is characterized by an integral intertwining structure wherein thin metal strips form a multicellular converter body. A first plurality of the thin metal strips extend the entire axial length of the converter body and are usually corrugated, and a second plurality of thin metal strips usually flat, alternating with the first plurality, extend less than the full axial length of the converter body.

Abstract: An exhaust system for an internal combustion engine adapted to correct the problem of pollution occurring at start-up and during at least initial engine running, and characterized by an electrically heatable catalytic converter and, desirably, a separate unheated conventional catalytic converter in tandem relation. The system also provides means for providing electrical power greater than 500 watts for 2 seconds or more whereby the temperature of the catalyst is raised and maintained at least 650 F. An advantage of preferred embodiments is that there is provided a substantially improved means for augmenting conventional catalytic converter exhaust systems for modern requirements by inserting in the exhaust system an electrically heatable catalytic converter for conversion of pollutant material operative prior to, during and after start-up.

Abstract: The disclosure relates to an improved catalytic converter core which is characterized by a plurality of spaced rigid centrally located pins about which are wrapped a plurality of corrugated thin metal strips. The configuration of the resulting core is determined by the number of centrally located pins, for example, with two pins the configuration is oval. Electric power may be selectively applied to effect heating of the core. Catalyst may be applied to the surface or surfaces of the corrugated thin metal strips to aid in converting undesirable materials in a gas stream to more acceptable materials.

Abstract: There is provided an improved reinforced corrugated thin stainless steel strip in which either or both of the longitudinal edges are overfolded to increase the thickness and stiffness of the foil to better resist the tendency to failure in a severe hot-shake screening test. There is also provided a core and an electrically heatable catalytic converter containing the core for use in the exhaust line of an internal combustion engine.

Abstract: There is provided an improved electrically heatable catalytic converter formed of an electrically heatable corrugated thin metal monolith and having a collimator axially spaced upstream of the electrically heatable monolith, said collimator having the purpose of straightening and subdividing the gas flow to minimize the tendency of the leading edges of the corrugated thin metal monolith to be folded over in use.

Abstract: There is provided an improved electrically heatable core for an electrically heatable catalytic converter. The core is characterized by corrugated thin metal strips and flat thin metal strips in alternating relation with each other and secured to an electrically conductive central core or tube. Alternating with the corrugated thin metal strips and the flat thin metal strips are areas of brazing metal in an axially staggered pattern. These strips are spirally wound and fused to braze them together in a unified monolith. A retainer shell is supplied to hold the monolith together. The core is placed in a housing fitted with insulated means for conducting electric current to the monolith to effect heating. The housing is then inserted in an exhaust line where it is effective to control start-up pollution, and where the monolith is constrained against telescoping.