Abstract: A catalytic reactor, used as the ignition stage for a multi-stage combustor, is made by the following method. Alternate sides of a metal strip are first coated with a combustion catalyst, in such a manner that at any point on the strip, one side is coated and the other side is not coated. Then the strip is folded back and forth upon itself in a zigzag pattern, to produce the reactor. The strip has corrugations which keep adjacent portions of the strip spaced apart when the strip has been folded. The reactor made by this method has an extended useful life, in part because it does not become so hot that the catalyst becomes deactivated.

Abstract: This invention includes a multiple-stage combustion apparatus which can be used in a high-temperature environment, such as with a gas turbine. In particular, the invention includes a novel structure for the first stage of such apparatus, and a method of making that first stage. The first stage, which is an ignition stage, is a reactor formed of a metal strip which is coated with a catalyst on only one side. The strip is also corrugated with a herringbone pattern. The strip is then folded back and forth upon itself to form a reactor of a desired cross-section. The reactor has rows of channels that are formed between the layers of the metal. The single coated side of the metal defines the walls of the channels in every other row. The fuel-air mixture that flows through the coated channels is combusted. The fuel-air mixture that flows through the uncoated channels is not combusted, and cools the catalyzed surfaces.

Abstract: A catalytic reactor serves as the ignition stage for a multi-stage combustor. In one embodiment, the catalytic reactor includes a stack of corrugated metal strips, each strip having a catalyst coating on exactly one side, wherein a coated side of one strip faces an uncoated side of the adjacent strip. Thus, the reactor defines channels each having two walls, exactly one of which bears a catalyst coating. Another embodiment takes the form of a spiral formed by winding two strips, each strip having a catalyst coating on one side. The coated side of one strip faces the uncoated side of the other. Thus, the spiral includes channels having a catalyst coating on only one wall. In still another embodiment, a single strip has bands of coated and uncoated regions on both sides. At any given point on the strip, one side of the strip has a catalyst coating and the other side has no coating.

Abstract: A metal substrate contains a barrier which functions as an electrical insulator. One can thus use the substrate to make an electrically heated catalytic converter, in which one must electrically isolate a catalyst-bearing strip from adjacent strips. One forms the substrate by first coating the substrate with a thin first layer of alumina washcoat and heating the substrate to a temperature of about 800.degree. to 1000.degree. C. This heating step produces the barrier, which may constitute a spinel. One can then apply a catalyst to the substrate, either by applying one or more secondary layer(s) of washcoat, having greater thickness than the first layer, and impregnating the second layer with the catalyst, or by coating the substrate with a washcoat which already contains the catalyst. Alternatively, one can omit the step of applying the catalyst, and can use the strips to form a heater for a stream of gas. One can use the heater in conjunction with a main catalytic heater, or as a stand-alone heater.

Abstract: A catalytic air cleaner purifies air in enclosed spaces, such as in an aircraft or spacecraft. The air cleaner includes a pair of metal strips, wound into a double spiral. The strips have projections, affixed to the strips, to maintain the spacing between turns of the spiral. The spiral defines a core which accommodates an electrically heated catalytic converter. The strips themselves have no catalyst coating. A pair of ports at the periphery of the spiral allows air to enter and leave the spiral through inlet and outlet channels. Air entering the spiral through the inlet channel receives heat, by heat exchange, from air leaving the spiral, and then enters the core, where the electrically heated catalytic converter burns off various impurities. The air then leaves the spiral through the outlet channel, and becomes cooled by transferring its heat to the incoming air.

Abstract: This invention includes a multiple-stage combustion apparatus which can be used in a high-temperature environment, such as with a gas turbine. In particular, the invention includes a novel structure for the first stage of such apparatus, and a method of making that first stage. The first stage, which is an ignition stage, is a reactor formed of a metal strip which is coated with a catalyst on only one side. The strip is also corrugated with a herringbone pattern. The strip is then folded back and forth upon itself to form a reactor of a desired cross-section. The reactor has rows of channels that are formed between the layers of the metal. The single coated side of the metal defines the walls of the channels in every other row. The fuel-air mixture that flows through the coated channels is combusted. The fuel-air mixture that flows through the uncoated channels is not combusted, and cools the catalyzed surfaces.

Abstract: A catalytic converter includes a metal honeycomb catalyst support which is anchored in a canister so that it cannot telescope or blow out. The honeycomb catalyst support is made by folding a strip of metal back and forth upon itself. The lines of folding are inclined to the perpendicular to the axis of the strip. The repeating sequence of the inclinations is left, right, right, left, etc. Folding the strip in this manner produces a honeycomb that has a taper in both of two directions so that it can be anchored in the canister. The canister has a taper which coincides with the taper of the honeycomb. The invention also includes a method and apparatus for making crease lines on the strip, so that the strip can be folded.

Abstract: An air conditioner for an automobile includes two pairs of hydrogen storage cells. Each cell includes a hydride-forming material, which absorbs hydrogen while generating heat, and releases hydrogen while absorbing heat. One pair of cells operates as an air conditioner, absorbing heat from the interior of the automobile and discharging heat to the outside. The other pair of cells, is regenerated by supplying heat from the engine exhaust to one of the cells, while allowing heat generated at the other cell of the pair to be discharged to the outside. After a given pair of cells has been regenerated, the cells are cooled to approach the temperature at which they will again operate as an air conditioner. A system of valves is arranged to provide four distinct stage. In Stage 1, the first cell pair is an air conditioner while the second cell pair is being regenerated. In Stage 2, the second cell pair is cooled. In Stage 3, the second cell pair is an air conditioner while the first cell pair is being regenerated.

Abstract: A catalytic converter includes a metal honeycomb catalyst support which is anchored in a canister so that it cannot telescope or blow out. The honeycomb catalyst support is made by folding a strip of metal back and forth upon itself. The lines of folding are inclined to the perpendicular to the axis of the strip. The repeating sequence of the inclinations is left, right, right, left, etc. Folding the strip in this manner produces a honeycomb that has a taper in both of two directions so that it can be anchored in the canister. The canister has a taper which coincides with the taper of the honeycomb. The invention also includes a method and apparatus for making crease lines on the strip, so that the strip can be folded.

Abstract: An air conditioner for an automobile includes two pairs of hydrogen storage cells. Each cell includes a hydride-forming material, which absorbs hydrogen while generating heat, and releases hydrogen while absorbing heat. One pair of cells operates as an air conditioner, absorbing heat from the interior of the automobile and discharging heat to the outside. The other pair of cells is regenerated by supplying heat from the engine exhaust to one of the cells, while allowing heat generated at the other cell of the pair to be discharged to the outside. A system of valves is arranged such that one cell pair is always functioning as an air conditioner while the other cell pair is being regenerated.

Abstract: The invention is a catalytic air cleaner made from a double spiral formed by winding together two strips of metal. The strips are coated with a combustion catalyst. One spiral passage leads into the core of the spiral and the other passage leads out of the core. An electric resistance heater supplies heat at the core of the spiral. The outflowing air transfers this heat to the inflowing air, through the walls of the spiral. Because of this heat exchange, the difference between the temperature of the air at the core and the air entering the spiral can be many times the difference between the temperature of the air entering and leaving the spiral. Contaminants in the air are burned on the catalytic surface with a minimum input of heat. The invention also includes a method of designing a spiral having optimum characteristics.

Abstract: There is provided a washcoat for applying a catalyst coating to a catalyst support. The washout includes alumina and a catalyst metal from the platinum group. Thus, the alumina and the catalyst metal are applied to the support in a single coating. The invention also includes a method of making the washcoat. The washcoat made by the present invention is economical to apply, and it has the additional advantage that it adheres tightly to a metal support.

Abstract: This invention relates to catalyst supports, such as are used in catalytic converters for vehicles, and in other applications, such as diesel particulate traps. The invention discloses a novel composition for a catalyst support, and a method of making it. The support includes a base material, such as a stainless steel. If the base material is a metal, it can be rolled down to the thickness of a foil and then coated with a layer of aluminum. The coating is done by a vapor deposition technique, so that the aluminum coating is thin and substantially uniform. The base material can be almost any substance capable of withstanding the high temperatures expected in the catalytic converter or other application. Because the material is already of foil thickness when it is coated, it is not necessary to select a material which is capable of being rolled down after being coated with aluminum. Thus, the invention makes it possible to use a much wider variety of materials than have been used in the prior art.

Abstract: The invention discloses a method of binding a metal, capable of forming a metal hydride, to a surface. The invention also includes a composition which can be applied to a surface, and which can be repeatedly hydrided and dehydrided. According to the invention, a metal capable of forming a metal hydride is pulverized, mixed with a binder, and coated onto a support. The choice of the binder is an important aspect of the invention. Because of the expansion and contraction of the metal, due to the hydriding and dehydriding, the binder must be quite elastic. The binder must also be permeable to hydrogen, and must be heat stable. Silicone rubbers meet these requirements, and can be used as binders.

Abstract: A catalytic converter includes a metal honeycomb catalyst support which is anchored in a canister so that it cannot telescope or blow out. The honeycomb catalyst support is made by folding a strip of metal back and forth upon itself. The lines of folding are inclined to the perpendicular to the axis of the strip. The repeating sequence of the inclinations is left, right, right, left, etc. Folding the strip in this manner produces a honeycomb that has a taper in both of two directions so that it can be anchored in the canister. The canister has a taper which coincides with the taper of the honeycomb. The invention also includes a method and apparatus for making crease lines on the strip, so that the strip can be folded.

Abstract: There is provided a washcoat for applying a catalyst coating to a catalyst support. The washcoat includes alumina and a catalyst metal from the platinum group. Thus, the alumina and the catalyst metal are applied to the support in a single coating. The invention also includes a method of making the washcoat. The washcoat made by the present invention is economical to apply, and it has the additional advantage that it adheres tightly to a metal support.

Abstract: There is provided a process and apparatus for making, preferably continuously, a catalytic converter element or core especially adapted for the treatment of exhaust from an internal combustion engine, whether spark or compression ignited. The converter element may be a fan-folded or accordion folded thin metal strip or a spirally wound element which carries strongly adhered to the surface thereof a catalyst, e.g. a noble or precious metal catalyst such as platinum and/or palladium and/or rhodium. The metal strip entering the process is an aluminum coated ferritic ribbon between 0.001 and 0.003 inches thick, and 1 inch to 30 inches wide. The strip is preferably annealed and perforated at predetermined intervals. Thereafter, the strip is corrugated and given a washcoat of a refractory metal oxide which is calcined onto the surface. One or more precious metal catalysts are supplied and dried.

Abstract: A spiral-wound metal catalyst support is disclosed, wherein the layers of the spiral cannot telescope outwardly in either direction. The support is formed by first winding together a flat strip and a corrugated strip, the strips being wound on a mandrel. The mandrel is removed to leave an axial hole. The catalyst support is then flattened at each end, so as to close the axial hole at each end. The flattening is done in mutually perpendicular directions, so that the catalyst support has tapers in both of two directions. The tapers prevent telescoping of the layers of the support. The catalyst support can be placed in a tube before it is flattened, and then the tube and the support can be flattened together, so that the support becomes firmly anchored in the tube. In an alternative embodiment, a second, tapered mandrel is inserted into the support before flattening, the tapered mandrel having a shape conforming to the inner cavity defined by the flattened support.

Abstract: A catalytic converter includes a metal honeycomb catalyst support which is anchored in a canister so that it cannot telescope or blow out. The honeycomb catalyst support is made by folding a strip of metal back and forth upon itself. The lines of folding are inclined to the perpendicular to the axis of the strip. The repeating sequence of the inclinations is left, right, right, left, etc. Folding the strip in this manner produces a honeycomb that has a taper in both of two directions so that it can be anchored in the canister. The canister has a taper which coincides with the taper of the honeycomb. The invention also includes a method and apparatus for making crease lines on the strip, so that the strip can be folded.

Abstract: A catalytic converter for a diesel engine comprises a labyrinth made of metal foil. The foil is coated with an oxidation catalyst. When exhaust gas flows through the labyrinth, the gas is forced to make right-angle turns at intervals as short as about 5 mm. The number of right-angle turns can be as great as 30 turns per cubic centimeter of labyrinth. These abrupt turns cause particulates in the gas to be deposited on the foil. At intervals, fuel is injected into the exhaust gas. The fuel burns on the catalyzed surface and heats the converter sufficiently to burn the trapped particulates. In an alternative embodiment, there are two converters, and fuel is automatically injected into that converter which has more trapped particulates than the other, so as to burn the particulates trapped in that converter.