Abstract: An emission treatment system including a catalyzed soot filter comprising a wall flow monolith and a catalyst comprising at least two types of support particles is described. The first support particle contains at least a platinum component, the second support particles contains at least a palladium component. The wall flow monolith may be washcoated with a slurry comprising at least two types of particles without applying a passivation layer to the wall flow monolith.

Abstract: A filtering catalytic substrate including a non-woven fibrous refractory body, a plurality of channels formed in the body, a washcoat layer at least partially coating the channels, and a catalyst material at least partially coating the washcoat. The body is substantially composed of interlocking fibers fabricated using methods of forming a rigid matrix of ceramic fibers to provide a porous substrate for filtration applications.

Abstract: A method of forming a porous honeycomb substrate including a non-woven fibrous ceramic body is provided herein. The fibrous ceramic body is substantially composed of intertangled ceramic fiber forming a rigid three-dimensional matrix. Washcoat and catalyst materials can be applied to at least partially coat the honeycomb channels. The porous honeycomb substrate provides an improved substrate for use in filtration applications such as exhaust particulate filtration of internal combustion engines.

Abstract: A reactor cartridge includes a plurality of spaced-apart monoliths, formed along a tube or other mandrel. Each monolith is formed of a pair of flat and corrugated metal strips, spirally wound around the tube. These strips could be made of solid or screen material. The corrugations are skewed, such that the monolith imparts a swirl to gases flowing through it. The corrugations of the strips in adjacent monoliths are oriented differently, so that successive monoliths impart different swirls to the gases, so as to promote mixing of gases and better heat transfer from the exterior to the interior of the cartridge. An insertion and removal tool simplifies the procedure for stacking such cartridges in a long pipe, or for removing cartridges from the pipe. The all-metal construction facilitates heat transfer through the entire reactor, and avoids the problems associated with packed ceramic beds.

Abstract: A method for gluing and brazing a honeycomb structure includes at least one partially structured foil with a pitch and a wave height. The method includes the steps of choosing a mean brazing material diameter of a powder brazing material, said diameter being 15% smaller than the height of the wave; determining a minimum thickness of the glue strip according to equation; gluing at least partially structured foil within the width of the glue strip on at least part of the wave crests formed by the undulation; brazing the honeycomb structure. The invention also relates to a corresponding honeycomb structure that ensures satisfactory joint connections even when said structure is used in the exhaust systems of automobiles.

Abstract: In an exhaust gas treatment component with a ceramic body for the purification of exhaust gases and a method for making such a component, the ceramic body is disposed in a sheet metal housing consisting of a housing base from which housing sections extend which are hinged to the housing base by webs and which form together a tubular slotted housing part surrounding the ceramic body, the housing sections being tiltable outwardly about the webs for facilitating insertion of the ceramic body into the housing.

Abstract: The present invention relates a substrate having corrugated sheet(s) and channel(s) for treating exhaust gases of combustion engines. The present invention also relates to methods for manufacturing and using said substrate having said open channel(s). The substrate (1) comprises at least one corrugated sheet (3) having depressions (3d) and one flat wire mesh sheet (2) having depressions (2d) which is connected to said corrugated sheet (3) and between said flat wire mesh sheet (2) and said corrugated sheet (3) there are at least partially open channels (POC) for exhaust gas (EG) flow, and the depth of depression (2d) of said flat wire mesh sheet (2) is 0.05-0.5 mm smaller than the height of the corrugation (3c) of said corrugated sheet (3).

Abstract: Multi-tubular reactors for fluid processing incorporate reactor tubes containing thermally conductive monolithic catalyst structures with relative dimensions and thermal expansion characteristics effective to establish both a non-interfering or slidably interfering fit between the monolith structures and the reactor tubes at selected monolith mounting temperatures, and geometries at reactor operating temperatures such that the operating gaps between tubes and monoliths under the conditions of reactor operation do not exceed about 250 ?m over tube sections where high heat flux to or from the monoliths is required.

Abstract: Catalyzed soot filters comprising a wall flow monolith having microcracks and pores and a catalyst comprising support particles with particle sizes greater than about the size of the microcracks and less than about the size of the pores are disclosed. Methods of manufacturing catalyzed soot filters and diesel engine exhaust emission treatment systems are also disclosed.

Abstract: The present invention provides improved methods of manufacturing modular exhaust aftertreatment devices.

Abstract: A manufacturing method of metal substrate catalytic converter and the resulting product. In this method, a multiple layer aluminum and ferritic stainless steel composite material is first made by roll-bonding and then further processed to a final foil thickness. The composite foils are then fabricated to a honeycomb-like converter with air flow channels. The converter is then thermally treated at a high temperature during a necessary converter fabrication process. The monolithic FeCrAl alloy is then obtained in the converter by in-situ diffusion alloying with pre-oxide film on the surfaces. The resulted material has improved oxidation resistance and thermal dimension stability at a high temperature.

Abstract: The present invention includes a catalyst having a layered structure with, (1) a porous support, (2) a buffer layer, (3) an interfacial layer, and optionally (4) a catalyst layer. The invention also provides a process in which a reactant is converted to a product by passing through a reaction chamber containing the catalyst.

Abstract: The present invention relates to a holding and sealing material 2 set between a catalyst carrier 1 and a shell 95 which covering the outside of the catalyst carrier 1 in a catalytic converter for purifying an exhaust gas and manufacturing method thereof. An organic binder 22 on the holding and sealing material 2 has the glass transition point Tg (° c) of less than or equal to approximately 5° C. In addition, an infiltrating step and a drying step are conducted during the manufacturing. In the infiltrating step, the mat-like material is infiltrated with emulsion containing the organic binder. In the drying step, the mat-like material containing the emulsion is dried.

Abstract: A process is provided for manufacturing an exhaust gas treatment device (2), which has an exhaust gas treatment insert (4), which is clamped in a housing (8) by at least one mounting mat (6) enveloping the insert (4). An individual geometry of the housing (8), which geometry is individually adapted to the particular insert (4) and to the particular mounting mat (6), is determined as a function of the weight of the particular insert (4) and of the particular mounting mat (6). The housing (8), the particular insert (4) and the particular mounting mat (6) are mounted as a function of the individual geometry determined. The quality of manufacture can be improved if the geometry is determined such that a predetermined clamping force is present in the mounted state and if the weight of the particular mounting mat (6) is determined separately and is taken into account separately in the determination of the geometry.

Abstract: A method of manufacturing a catalytic converter is described where the catalytic converter is comprised of an outer tube member having a monolith substrate internally compressed therein with a wrapped mat material surrounding the monolith substrate and intermediate the outer tube. One or more monolith members can be applied within the outer tube and heat shields may also be applied internal to the outer tube and adjacent to the monolith substrate. The assembly of the catalytic converter includes measuring the sequence of compression of the mat material to the monolith substrate in order to understand the possible force characteristics which can be applied during the assembly thereof. The mat material is therefore compressed within the outer tube by way of compression jaws, by compression rollers, and/or by spinning. The compression of the mat material can be in single or multiple steps.

Abstract: A housing for a component of an exhaust system, in particular for an exhaust gas purification device, has an envelope that comprises a shrunk clamping portion for the component, a transition portion that adjoins the clamping portion in an axial direction, and a connecting portion that adjoins the transition portion in the axial direction. The diameter of the connecting portion is larger than that of the clamping portion. A method of producing the housing for the component includes providing a tubular envelope, and inserting the component into the envelope. A shrinking step is then carried out in the clamping portion which terminates spaced apart from ends of the envelope as viewed in the axial direction, whereas the axial ends of the envelope are not acted upon.

Abstract: The present invention provides new microreactor systems, catalysts, and chemical processes. Methods of making novel catalysts and reaction apparatus are also described.

Abstract: The invention generally relates to a fuel processor design and a method for manufacture. In one aspect of the invention, a fuel processor assembly has a first plate and a second plate that are mated to form a plurality of reactor housings and channels to direct the reactants. At least one of the first and second plates has an inlet orifice feature adapted to receive a hydrocarbon stream, and at least one of the first and second plates has an outlet orifice feature adapted to exhaust a reformate stream. In some embodiments, a third plate and a fourth plate can be mated to enclose the first and second plates so that a coolant can be circulated between an external surface of the first and second plates and an internal surface of the third and fourth plates.

Abstract: A process for introducing annular coated catalysts K into a reaction tube of a tube bundle reactor, in which adhering pairs of annular coated catalysts K formed in the preparation of the annular coated catalysts K, before the introduction thereof into the reaction tube, are removed at least partly from the annular coated catalysts K.

Abstract: A process is provided for manufacturing an exhaust gas treatment device (1), which contains at least one exhaust gas treatment insert (2) in a tubular housing (4), especially for an exhaust system of an internal combustion engine. A circumferential geometry of the at least one insert (2) is measured in at least one axial section of the particular insert (2). The at least one insert (2) is inserted axially into the housing (4). The measured circumferential geometry of the at least one insert (2) is taken into account during the deformation of the housing (4).

Abstract: A catalytic element may be created by compressing a mesh fabric to reduce its dimension to achieve a desired size and shape. The process begins by braiding or otherwise forming a flat wire into a sheet of mesh fabric and then forming the surface of the sheet with angled ridges. Two sheets are then laid one on top of another with the angled ridges running at an angle to each other. The pair of sheets are then rolled into a cylinder to form a catalytic body. After applying solder to the catalytic body, it is compressed to a desired lesser dimension and then heat is applied to fuse the wires while holding the catalytic body in its compressed size and shape. Next, a precious metal catalytic coating is applied to the fused catalytic body and heat is again applied to bond the precious metal compound to the catalytic body.

Abstract: A method for manufacturing a fuel processor may comprise coupling a plurality of micro-tubes in parallel to form a flow field tube array, each of the plurality of micro-tubes designed to receive a fluid flow, depositing a catalyst layer inside each of the plurality of micro-tubes, and attaching at least one burner to a first end of the flow field tube array.

Abstract: The present invention relates to a spinning apparatus for forming a workpiece. The spinning apparatus includes at least one spinner capable of deforming the workpiece. The apparatus allows for the forming of the workpiece in four different axes. The spinning apparatus includes an arrangement allowing for the vertical arrangement of the workpiece while the spinner is working on the workpiece. The spinning apparatus includes a clamp for holding the workpiece vertically. The spinner is positioned vertically below the clamp and the workpiece.

Abstract: An assembly device of a support mat for a ceramic catalyst carrier includes: a push-in device provided in a vertically movable tool base and capable of pushing a ceramic catalyst carrier together with a support mat into a recession of a shaping die; a first and a second pressing unit pressing both end portions of the support mat from side faces so as to curve the both end portions of the support mat along an arc-shaped upper surface of the ceramic catalyst carrier; first pressing pieces and a second pressing piece provided in tip portions of the first and second pressing units; and a push-up unit provided on a bottom of the recession and capable of pushing up the ceramic catalyst carrier together with the support mat.

Abstract: A spin-capture retention system engages and retains a thermally expanding mat, stabilizer and exhaust aftertreatment element in an exhaust system, and provides secure axial and radial location, and provides protective sealing of the mat.

Abstract: To provide a method for recovering performance of a discharge gas processing apparatus, the method being capable of recovering NOx removal performance of a deteriorated NOx removal catalyst without replacing the deteriorated NOx removal catalyst with a new catalyst and without adding a new catalyst. After a honeycomb catalyst 1 having gas conduits for feeding a gas to be treated has been placed and used in a discharge gas conduit of a discharge gas processing apparatus 10, the honeycomb catalyst 1 is rearranged such that a portion of the honeycomb catalyst 1—the portion being on the upstream side in terms of the flow of the gas to be treated and extending to cover a predetermined range is transferred from the inlet side of the discharge gas conduit.

Abstract: A thermally-activated exhaust treatment device, such as a catalytic converter, for vehicles includes a core having an inner housing and a catalytic material. A jacket includes an outer housing enclosing the inner housing, but characteristically not contacting the inner housing. The inner and outer housings include walls forming a vacuum-drawn sealed insulation cavity around the inner housing. A temperature-activated variable insulator device is positioned within the outer housing and includes a hydrogen source and controls for controlling the variable insulator device. A vacuum-maintenance device is incorporated into the insulation cavity, and includes a small container, getter material positioned in the container, and a porous member allowing gas in the insulation cavity to communicate with the getter material. A multi-layered radiation shield is positioned in the vacuum space and is loosely coupled to the inner housing. A vacuum detector includes a visible indicator of the vacuum in the insulation cavity.

Abstract: A method of machining a pattern at a plurality of locations in a workpiece includes positioning a shaped electrode including the pattern at the plurality of locations in a sequence. In some embodiments, the sequence is random. The method further includes forming the pattern at each of the plurality of locations by passing electrical charges repeatedly between the shaped electrode and the workpiece and advancing the shaped electrode into the workpiece for a fraction of a full depth of the pattern. The method further includes repeating the positioning and forming steps a plurality of times until the full depth of the pattern has been formed at each of the plurality of locations.

Abstract: An exhaust gas treatment device for an exhaust system of an internal combustion engine includes a housing that is adapted to be tied into the exhaust system and at least one exhaust gas purification insert arranged in the housing. The exhaust gas purification insert includes an insert housing which is open at one end and at least one exhaust gas purification element arranged in the insert housing. The housing has at least one insert bracket which has at least one mounting opening on whose opening edge is supported an end section of the insert housing in the form of a ring. The end section forms a first spherical shell segment and the opening edge forms either a second spherical shell segment that is complementary to the first spherical shell segment or a conical jacket segment that fits the first spherical shell segment.

Abstract: A catalytic converter for an internal combustion engine exhaust system comprises a single-piece, seamless metal housing having tubulated gas inlet and outlet ports and a tubulated intermediate section with at least one catalytic element therein. The converter is manufactured by a multi-step swaging process carried out in a transfer press. The press has a plurality of swaging stations that include swaging die sets that provide a graduated series of swaging steps. The process is operated continuously, with one of the swaging steps being carried out in each station during each press stroke.

Abstract: A catalyst system for an internal combustion engine with at least one cylinder and/or piston is characterized in that the catalyst is arranged in the form of nanoparticles on the cylinder and/or piston.

Abstract: A method for the production of a converter-carrier body having a metallic honeycomb body made of a plurality of metal layers, especially smooth layers and corrugated layers, the layers having layer ends, such that an outer shape of the honeycomb body is formed by the layer ends. At least one stack is produced having several alternately disposed metal layers that are structured such that channels are formed for a fluid to flow through. The at least one stack is transformed into a honeycomb body having a cylindrical form. The honeycomb body is deformed from the cylindrical form so that an outer shape that deviates from the cylindrical form is produced. Additionally, the invention relates to a corresponding converter-carrier body and a tool for the production thereof.

Abstract: Cooling systems for use with computer systems are disclosed herein. In one embodiment, a computer system includes a first computer module spaced apart from a second computer module to define a space therebetween. The computer system further includes a cooling system positioned in the space between the first and second computer modules. The cooling system includes a first heat exchanging portion containing a working fluid that absorbs heat from an electronic device mounted to the first computer module. The cooling system further includes a second heat exchanging portion that receives the heated working fluid from the first heat exchanging portion to cool the heated working fluid. A fluid mover is operably coupled to the first and second heat exchanging portions to circulate the working fluid through the first and second heat exchanging portions.

Abstract: A process is provided for manufacturing a catalytic converter formed from at least one monolith being held in a catalytic converter housing, especially a motor vehicle catalytic converter. A mounting mat (14) is placed on the outer circumferential surface (38) of the monolith (12) in the process, and the monolith (12) is subsequently stuffed together with the mounting mat (14) into the catalytic converter housing. To apply the mounting mat (14) on the monolith (12), the monolith (12) is set into rotation, while the mounting mat (14) is being fed tangentially and is carried by the monolith (12). A plant for carrying out the process is also provided as well as an application device (10).

Abstract: A method for manufacturing a catalyst carrier body includes producing a honeycomb body having at least partially structured layers forming channels through which a fluid can flow. The honeycomb body has an external extent formed at least partially by ends of the layers. At least one corrugated casing and a housing are also produced. The honeycomb body is inserted into the corrugated casing and the corrugated casing with the honeycomb body is inserted into the housing with the housing at least partially surrounding the honeycomb body. The housing is calibrated by reducing at least an internal contour of the housing and preferably also a profile of the corrugated casing. The honeycomb body is connected to the housing with the corrugated casing disposed between the honeycomb body and the housing. A catalyst carrier body produced by the method is also provided.

Abstract: A catalytic converter includes an inlet. A first sub-section of substrate is located a first distance from the inlet that includes a first catalyst coating having a first density. A second sub-section of substrate is located a second distance from the inlet that includes a second catalyst coating having a second density. The second distance is greater than the first distance and the second density is greater than the first density.

Abstract: A catalytic conventer assembly is provided that includes a metallic tubular member having a first end and a second end. The metallic tubular member includes an aperture centrally formed between the first end and the second end. A sensor is received in the aperture and extends into an interior of the metallic tubular member for sensing a content of gas flowing through the metallic tubular member. At least one substrate is disposed within the metallic tubular member. The at least one substrate has a cavity formed in an exterior surface of the at least one substrate and extends radially inward. The cavity is aligned with the aperture of the metallic tubular member and receives a portion of the sensor extending into the interior of the metallic tubular member.

Abstract: In one embodiment, a catalyst formulation includes a poison adsorbing material and a catalyst material. The poison adsorbing material comprises large particles having an average major diameter of greater than or equal to about 2.0 micrometers. The catalyst material comprises a precious metal support comprising small particles having an average major diameter of less than or equal to about 1.0 micrometers, and a catalyst material comprising at least one of ruthenium and iridium.

Abstract: A filter layer includes at least partially gas-permeable material having a plurality of segments joined to one another in such a way that the filter layer has non-parallel edges. Inexpensive manufacturing methods for such a filter layer, conical honeycomb bodies having the filter layer and particle-filtering exhaust gas purification apparatuses for motor vehicles, are also provided.

Abstract: A catalytic converter assembly is provided that includes a metallic tubular member having a first end and a second end. A first substrate is disposed within the metallic tubular. A second substrate is disposed within the metallic tubular member. A spacer is axially positioned the between the first and second substrate that includes a cylindrical body with a first wall and a second wall formed substantially perpendicular to the cylindrical body. The first wall abuts an end of the first substrate for retaining the first substrate between the first end and the first wall for preventing movement. The second wall abuts an end of the second substrate for retaining the second substrate between the second end and the second wall for preventing movement.

Abstract: A method for the production of a converter-carrier body having a metallic honeycomb body made of a plurality of metal layers, especially smooth layers and corrugated layers, the layers having layer ends, such that an outer shape of the honeycomb body is formed by the layer ends. At least one stack is produced having several alternately disposed metal layers that are structured such that channels are formed for a fluid to flow through. The at least one stack is transformed into a honeycomb body having a cylindrical form. The honeycomb body is deformed from the cylindrical form so that an outer shape that deviates from the cylindrical form is produced. Additionally, the invention relates to a corresponding converter-carrier body and a tool for the production thereof.

Abstract: A substrate assembly is stuffed into a converter outer shell to form a catalytic converter having a desired gap bolt density (GBD) value. The substrate assembly is formed by wrapping and taping a mat around a catalytic substrate. A predetermined pressure is applied to the substrate assembly and an outer diameter of the substrate assembly is measured at this predetermined pressure. A GBD value is predicted based on this measurement and if the GBD value is acceptable the substrate assembly is stuffed into the converter outer shell.

Abstract: A catalytic converter as subject of the invention comprises fibers, which fibers have a fiber surface. The converter further comprises catalytic material, substantially all of this catalytic material is present on the fiber surface. The fibers are present in the catalytic converter as discrete fibers. A method for making the catalytic converter comprises providing a bundle of discrete fibers, coating them with catalytic material and inserting the coated bundle into a can.

Abstract: A method for cold-forming a nozzle for a laser includes placing a slug or tube of oxygen-free copper into a die. A mandrel is forced into the copper slug or tube. The resultant compressive force causes the copper to cold flow around the mandrel and the die to define an inner shape and an outer dimension of the part.

Abstract: A method for making catalytic converters with automated crack detection includes forming a rigid housing, providing a substrate shaped for reception in the housing, and forming a mat shaped to cover the exterior surface of the substrate and having a thickness which creates a tight friction fit between the substrate and the housing when the same are assembled. The mat is wrapped around the substrate, and the wrapped substrate is then stuffed into the housing using a reciprocating ram or the like that extends at a relatively constant speed. The stuffing force and the ram position are measured and recorded regularly to define an array of data. The data is analyzed for any abrupt changes in the stuffing force as a function of the ram position indicating a crack in the assembled substrate.

Abstract: A method is provided for assembling a plurality of catalytic substrates and support materials within a catalytic converter housing using a uniform compression. Outer profiles of a plurality of catalytic substrates are determined. Weight factors of a plurality of the support materials are determined. A lookup table containing a list of associated outer profiles of catalytic substrates and weight factors of support materials are provided. A first catalytic substrate and a first support material are joined as a first pre-assembly based on a matching outer profile and weight factor from the lookup table. A second catalytic substrate and a second support material are joined as a second pre-assembly based on a matching outer profile and weight factor from the lookup table. The first and second pre-assemblies are inserted into the catalytic converter housing. The first catalytic element and the second catalytic element are secured within the catalytic converter housing.

Abstract: A catalytic converter for an internal combustion engine exhaust system comprises a single-piece, seamless metal housing having tubulated gas inlet and outlet ports and a tubulated intermediate section with a catalytic element therein. The intermediate section is connected to the inlet port by an inlet transition section and to the outlet port by an outlet transition section. The inlet and outlet ports and the inlet and outlet transition sections are formed by swaging the ends of a seamless tube used to form the housing. Exhaust gas produced by operation of the engine passes into the converter and through the catalytic element. A swaging process is used to form tubulated ends on the converter.

Abstract: This is directed to a processing method for carrying a cell structure (1) with a catalytic component. Information about a mass of the cell structure (1) is displayed on the surface thereof prior to the initiation of a carrying process, and in the carrying process, the information is read and the cell structure (1) is carried with an appropriate amount of the catalytic component on the basis of the information. When cell structures are processed for carrying thereon a catalytic component, each cell structure can carry an appropriate amount of the catalytic component in accordance with the mass of the cell structure, even if there is a variation in the masses of the cell structures.

Abstract: “Noxious substances in the exhaust, including CO, NOx, and incompletely combusted hydrocarbons are converted to more benign substances through the action of the catalytic element, which is preferably a frangible ceramic honeycomb structure having a plurality of internal passages coated with a catalytically active substance.” “The tabulated ends minimize production of turbulence in the gas flow and allow the converter to be connected to the rest of the exhaust system by clamped, welded, or flanged joints. The one-piece, seamless construction of the converter is economical to produce and eliminates welding of housing components that tend to fail when subjected to corrosive exhaust gasses over a prolonged period of time.

Abstract: An assembly device includes: a push-in unit provided in a vertically movable tool base to push a ceramic catalyst carrier together with a support mat into a recession of a shaping die; a first and second pressing units for pressing both end portions of the mat from side faces to curve them along an arc-shaped upper surface of the carrier; pressure rollers provided at the both pressing units to press the both end portions toward the carrier; a tape presser in the push-in unit for pressing an adhesive tape to an upper surfaces of engagement portions of the depression and projection in a gap formed between the both rollers and operating with the push-in unit in pushing the carrier and mat into the recession of the shaping die; and a push-up unit provided on a bottom of the recession to push up the carrier and mat.