Abstract: There is provided a core element for an electrically heatable catalytic converter, and an electrically heatable catalytic converter containing the same, the core element being characterized by a corrugated thin metal foil strip, preferably herringbone corrugated, and in laminar relationship therewith, a flat thin metal foil strip of either stainless steel or brazing metal, or a combination of both, the flat thin metal foil strip having a width less than the width of the corrugated thin metal foil strip. The strips are then spirally wound, or accordion folded to form a monolith, and suitably connected to a voltage source to supply electrical power to the unit.

Abstract: There is provided an electrically heatable catalytic converter insert for insertion in a current internal combustion engine exhaust line. The device described includes a housing and a polycellular corrugated thin metal foil monolith disposed therein, and having a central core. The monolith includes a noble metal catalyst disposed of the inner surface of the cells. There are also provided a positive terminal and a negative terminal for attachment to a voltage source. The positive terminal is attached to the central core, and the negative terminal is attached to the housing, the foil providing a heatable resistance member enabling heating of the device by electrical power. The positive and negative terminals are electrically insulated from each other and each has a radially projecting arm for attachment of cables from a voltage source.

Abstract: There is provided a composite catalytic converter for removing pollutant materials from an exhaust gas stream. The converter is composed of an electrically heatable catalytic converter and a conventional ceramic catalytic converter in juxtaposed or embedded axial relationship whereby axial movement in a downstream direction of the electrically heatable catalytic converter core is resisted.

Abstract: There is provided an improved electrically heatable core for an electrically heatable catalytic converter. The core is characterized by a plurality of corrugated thin metal strips secured to an electrically conductive central core or tube. Alternating with the corrugated thin metal strips are narrow strips 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.

Abstract: There has been provided a catalytically active insert assembly for insertion in an exhaust pipe and characterized by a metal support having at least one layer of a catalytically active thin metal foil applied to and secured to the surface or surfaces thereof. The foil may be corrugated or not. The assemblies hereof are inexpensive to manufacture, easy to install, and are effective to reduce pollutants contained in exhaust gas to environmentally acceptable levels.

Abstract: There is provided an improved electrically heated accordion folded corrugated thin metal catalytic converter for hydrocarbon or alcohol fueled engine exhaust, particularly internal combustion engine exhaust, having a simplified construction and characterized in that the entire corrugated thin metal monolith, or monoliths, serves as a resistance heater to bring the catalyst up to optimum operating temperature quickly and thereby reduce the escape of pollutants into the atmosphere upon start-up, and which does not depend upon conduction as a mdoe of heat transfer to achieve such temperature.

Abstract: A converter for treating gases to remove pollutants or particulate matter having layers of normally nesting corrugated thin metal foil, with or without a catalyst supported thereon, and characterized by spaced strands of wire or nonvitreous inorganic ceramic thread interposed between the layers to maintain them in spaced relation for the passage of gas, e.g., exhaust gas from an engine or plant, therethrough. The principal advantages are the relatively high particulate trap efficiency, the relatively low back pressure, and the low cost of manufacture.

Abstract: There is provided a novel core member for use in a catalytic converter characterized by a corrugated nonnesting thin metal foil having a given length and a given width, which strip is overfolded to provide portions of about equal length. Along the fold line is attached a wire or rod, as, for example, by welding. The wire containing ends are gathered and secured to form a central core. This core may by spirally wound to fit within a peripheral housing, and the free ends of the core members secured to the housing, as by welding. This assembly may be used in a catalytic converter and may be equipped to be electrically heated from a battery using the resistance of the corrugated thin metal strip portions to effect heating thereof.

Abstract: There is provided a relatively large unitized monolithic catalyst panel especially adapted for use in the exhaust lines or conduits of stationary power plants to remove pollutants from the exhaust, especially those using hydrocarbon fuels as a source of power. The panels are characterized by top, bottom and side frame plates in rectangular relation, front and rear stiffener bars extending between the top and bottom plates, separator plates at intervals and in parallel relation extending between the side frame plates to define a grid, and corrugated thin metal foil layers disposed within and filling the spaces within the frame, which foil has a catalytically active surface formed thereon. These devices are useful in removing such pollutants as NO.sub.X from exhaust gas streams.

Abstract: A regenerable particulate trap for continuously separating particulates from, for example, the exhaust gas from a diesel engine, is characterized by a rotatable trap member mounted for rotation in the exhaust gas stream. Disposed over the face of the rotatable trap member on the upstream side is an enclosed, stationary chamber which isolates a portion of the rotatable trap member from the exhaust gas stream and directs a regenerating fluid through the rotating trap member, co-currently to the exhaust gas stream, to continuously remove the trapped particles by, e.g. burning in an oxygen-containing gas.

Abstract: There is provided a particulate trap for reducing the amount of particulates emanating from the exhaust of an internal combustion engine. The device utilizes a wound or accordion folded corrugated metal strip. The corrugations are characterized by a plurality of isolated projecting geometric configurations, such as a V-shaped chevrons spaced along a straight line extending between the parallel marginal edges of the thin metal strip. The apices of the metal strip pass through the corrugating rolls to place such apices in compression rather than in tension. These devices are not subject to nesting and are effective to remove diesel exhaust particulates.

Abstract: There is provided a substantially nonnesting corrugated catalytically active thin metal foil suitable for making a monolith which when encased in a housing and inserted in the exhaust line, e.g., an automobile exhaust line, will remove pollutants in the exhaust. The device is rendered substantially nonnesting by forming the corrugations according to guidelines and which corrugations are perpendicular to the longitudinal marginal edges of the metal foil. The pressure drop through the device is thus minimized and the necessity for a flat foil co-laminate is avoided.

Abstract: There is provided a fluid conduit comprising a housing, at least a pair of accordion folded corrugated thin metal elements disposed in the housing, and at least one longitudinally extending metal strut for reinforcing the core members against twisting and consequent axial displacement.

Abstract: There is provided a method for optimizing the stacking characteristics of a thin metal foil corrugated in a chevron pattern and folded in an accordion fashion or zig-zag manner to form a stack useful as a catalyst support member for catalytic converters for treating exhaust gases from internal combustion engines. This method provides a more stable and stronger stack.