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. 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.

Abstract: The device for removing pollution from the exhaust gases of an internal combustion engine includes an exhaust box (12) containing, in series, a catalytic purification unit (18) and a particle filter (20). The exhaust box (12) includes means (36; 60) providing access to the upstream face of the particle filter (20). Application to removing pollution from automobile vehicle diesel engines in particular.

Abstract: A holding material for a catalytic converter is interposed in a gap between a catalyst carrier and a metal casing receiving the catalyst carrier. The holding material includes a mat including alumina fiber and mullite fiber, wherein the alumina fiber and the mullite fiber are unitarily collected to form the holding material having a predetermined thickness.

Abstract: A holding material for a catalytic converter includes a catalyst carrier, a metal casing for receiving the catalyst carrier, and a holding material interposed in a gap between the catalyst carrier and the metal casing while wound on the catalyst carrier. The holding material is constituted by a molding of inorganic fiber molded with fibrillated fiber into a predetermined shape.

Abstract: A holding material is provided for a catalytic converter having a catalyst carrier, a casing for receiving the catalyst carrier. The holding material is interposed in a gap between the catalyst carrier and the casing while wound on the catalyst carrier. The holding material is constituted by a sewn product of a mat material formed by collection of not smaller than 100 cc/5 g by wet volume of inorganic fiber without use of any binder.

Abstract: A catalyst assembly includes a housing having at least first and second recesses with side surfaces, and a catalyst carrier body fixed in said housing. The catalyst carrier body has a casing tube and a honeycomb body through which an exhaust gas can flow. The casing tube has at least first and second protuberances with side surfaces and said casing tube is connected to said honeycomb body at least in a partial region. The protuberances extend at least partially into said recesses to form a fixed mounting and at least one floating mounting with an axial mounting play. The assembly ensures that the catalyst carrier body is permanently fixed, in particular during structure-borne vibrations that occur in the exhaust system of an internal combustion engine.

Abstract: Disclosed herein is a catalyst, an emission control device, and a method for treating exhaust gas. In one embodiment, the catalyst comprises: a catalytic metal component and a macro-pore component. The macro-pore component comprises an oxygen storage component and an aluminum oxide component, wherein the oxygen storage component, the aluminum oxide component, or both comprise pores, and wherein greater than or equal to about 40% of a macro-pore component pore volume, based on a total macro-pore component pore volume, is associated with pores greater than 120 Å in diameter. In one embodiment, the method for treating an exhaust gas comprises: contacting the exhaust gas with the catalyst at a temperature and for a period of time sufficient to reduce the concentration of a material in the exhaust gas.

Abstract: An exemplary embodiment of the present invention is a method for manufacturing a catalytic converter. A plurality of catalyst substrates having a periphery, an intake area and an outlet area, and comprising a catalyst, is longitudinally aligned. A mat support material is wrapped about the periphery of the catalyst substrates to form a subassembly. The subassembly is concentrically disposed within a shell. The shell is formed to have a non-linear geometry.

Abstract: A catalyst carrier holding mat is rolled around a catalyst carrier so as not to wrinkle when rolled, and the catalyst carrier is thereby uniformly compressed.

Abstract: A pollution control device has a metal housing, a solid pollution control device disposed within the metal housing, and a mounting mat disposed between the pollution control element and the housing for positioning the pollution control element and for absorbing mechanical and thermal shock. The mounting mat includes a layer of intumescent material having at least one insert formed of a resilient, flexible, fibrous non-intumescent material. The insert is positioned along at least a portion of at least one lateral edge of the mounting mat to prevent erosion of the intumescent material and to provide a seal between the pollution control element and the housing.

Abstract: A carrier supporting mat for exhaust converter for supporting a catalyst carrier is structured in having heat insulating mat members on an inner side as to direct contact with the catalyst carrier, an expansible mat member including a vermiculite on an outer side of the heat insulating mat members, and at least one heat insulating sheet member disposed among the mat members. Heats from exhaust gas is cut off by the heat insulating mat members, and expansion of a metal casing of the exhaust converter due to heats is followed by the expansible mat member. The sheet member creates sliding when the carrier supporting mat is lapped on the catalyst carrier because the mat members and sheet member can move correlatively and smoothly, thereby preventing wrinkles and tears from occurring.

Abstract: A relieved support material for a catalytic converter has a strip of support material with one or more relief cuts. This is used to insulate a segment of catalyst along with one or more inner end-cones positioned at the beginning and end of the converter. The support material is wrapped around the catalyst and the one or more inner end-cones. The wrapped support material is then covered with an outer-layer shell.

Abstract: An electrically heatable honeycomb body, in particular for cleaning exhaust gas originating in an internal combustion engine. The honeycomb body has at least two zones arranged in series in the flow direction with different coatings. The honeycomb body preferably has a first zone and a second zone which is arranged downstream, the first zone having an adsorbing coating, and the second zone having a catalytically active coating. The electrically heatable honeycomb body serves in particular as a trap for pollutants, preferably hydrocarbons or nitrogen oxides, which are contained in the exhaust gas. The configuration of the adsorbing first zone is matched to the light-off performance of the electrically heatable honeycomb body.

Abstract: The present invention includes a manifold catalytic converter. The catalytic converter is positioned immediately adjacent the manifold. The manifold and the converter end cone are cast from a single integral piece. The manifold/converter end cone casting includes an end cone portion having an end cone wall having a shoulder formed therein for engaging the front face of a catalytic converter substrate. A lip or ledge extends from the shoulder and surrounds and engages the outer surface of the ceramic substrate immediately adjacent the front face of the substrate. A metal shell is connected to the end cone and is spaced apart from the ceramic substrate. A support material is provided between the ceramic substrate and the metal shell. A second end cone is connected to the shell.

Abstract: An assembly includes a honeycomb body secured by an inner casing tube in a housing, in particular a housing of an exhaust system of an internal combustion engine. The inner casing tube has an overall length which is bounded axially by two edges and is substantially smaller than the axial length of the honeycomb body. The inner casing tube is also disposed in an approximately axially central position around the honeycomb body and is connected, in particular brazed, thereto in at least one axial connection region. The inner casing tube has a region within the axial connection region in which it is connected to the honeycomb body on the inside or attached directly adjacent the latter on the outside and is connected to the housing. Regions of the inner casing tube which are not connected to the housing but are connected to the honeycomb body toward the inside are constructed as radially elastic spring elements.

Abstract: The instant invention provides a new high temperature catalytic monolith support system which can be effectively utilized for sealing between the catalytic monolith and the housing of a catalytic converter, as well as physically cushioning the catalytic monolith within the housing. The support system preferably is made form wire mesh and a non-intumescent thermoresistant paper, in which the wire mesh and thermoresistant paper are integral and crimped together to produce a multi-herringbone configuration, providing multiple perpendicular barriers that prevent the gas-flow from bypassing the monolith.

Abstract: One embodiment for making an exhaust emissions control device comprises: disposing a mat support material around at least a portion of a substrate, disposing a shell on a side of the mat support material opposite the substrate, and adhesively bonding the mat support material to at least one of the substrate and the shell with a material comprising an inorganic binder.

Abstract: An immobilizing structure for use in immobilizing a ceramic monolith in a catalytic converter employs a molding which comprises finely divided metal oxide and fibers which do not represent a health risk, has a density of 100-240 kg/m3, and has a compression to at least 96% of its original thickness at a pressure of 1 bar applied for a period of 5 minutes, and exhibits a recovery of this compression to more than 70% of its initial value within about one minute after removal of the pressure.

Abstract: An exhaust gas purification apparatus for an automotive internal combustion engine. The apparatus comprises a casing that forms a part of an exhaust gas passage of the engine. A substrate, disposed in the casing, carries a substrate to purify exhaust gas. A supporting mat is provided to support the substrate in the casing by being located between the substrate and the casing. The supporting mat has a depression to trap foreign matters at an upstream-side end of the supporting mat, the upstream-side end facing upstream side of exhaust gas flow in the exhaust gas passage.

Abstract: High temperature resistant materials, one including between approximately 45 and 55 dry weight percent of high temperature resistant Silica fibers, and the other including between approximately 50 and 60 dry weight percent of magnesium silicate, that have improved physical properties, such as being capable of withstanding temperatures in excess of 2,000° F., effective sealing, and being sufficiently resiliently compressible for cushioning a monolithic catalyst structure against breakage due to external physical shocks.

Abstract: An electrically heatable catalytic converter has first and second, electrically conductive and electrically separated components and an electrically insulating, stabilizing supporting structure being mechanically loadable in all directions for metallic bonding to the components. The supporting structure includes a first metallic structure, a second metallic structure, and an electrically insulating, ceramic material being disposed between the first and second metallic structures and being three-dimensionally pressed-in from substantially all sides. The first and second metallic structures are shaped to exert pressure from substantially all sides onto said ceramic material, without touching one another, and they are respectively secured to the first and second components for fixing the components relative to one another.

Abstract: A casing tube is provided for a honeycomb element used for exhaust gas treatment. The casing tube is provided with a first area which is located close to a first front face and a third area which is located to close a second front face. The casing tube has a first inner diameter in the first and third area and is provided with a second area that is disposed between the first and the third area. The second area has a second inner diameter that is larger than the first inner diameter. The casing tube is characterized in that the axial length of the first area is less than 5 mm, preferably less than 3 mm. The relatively narrow first area enables the honeycomb to be permanently fixed and ensures that only a small amount of heat is transmitted to the casing tube. As a result, a significant improvement is achieved in the cold start performance of a catalytic converter.

Abstract: A device for purifying an exhaust gas contains at least one first and one second component with a respective shell and core through which the exhaust flows, as well as with two front faces each. At least one of the front faces of the first component and at least one front face of the second component has a predetermined profile with elevations and depressions. The elevations of the front face of the first component extend into the depressions of the front face of the second component and vice versa, thereby configuring a penetration section. The first component is disposed electrically insulated from the second component. The components have a potential difference between them and plasma is generated in the penetration section. The compact plasma reactor reduces the pollutant concentration in the exhaust gas of an internal combustion engine operated in the lean mode, especially when combined with an oxidation catalyst.

Abstract: An exhaust treatment device comprises: a substrate; an end-cone with a first end disposed about an end of the substrate and a second end comprising a snorkel; a mat support disposed over at least a portion of the end-cone, wherein the mat support comprises a slit in operable communication with a snorkel slot and a keyhole disposed at the opposite end of the slit as the snorkel slot, and wherein at least a portion of the snorkel protrudes through the snorkel slot; and a shell disposed around the mat support.

Abstract: An end cone for an exhaust emission control device is provided. The end cone comprises an outer shell and an end cone insulator. The outer shell has an inner surface. The end cone insulator comprises insulation and binder defining a passage therethrough. The end cone insulator has a first surface being disposed adjacent to the inner surface, and a second surface, at least a portion of which is exposed to the passage.

Abstract: The exhaust component has an exhaust manifold with at least two inlet lines, and, for example, also a catalytic converter and a wall with two composite wall elements. The two wall elements together, in cross section, surround interior spaces of all the inlet lines and, if appropriate, also the catalyst means of the catalytic converter. Each wall element has two single-piece metal shells and a layer of heat-insulating material which is arranged between these shells, so that each wall element provides good thermal insulation. During the production of a wall element, the shells belonging to this element, as well as the layer of insulating material arranged between them, are together subjected to plastic deformation. This allows inexpensive production of the wall.

Abstract: In an exhaust gas purifying catalyst, an acid material with a high affinity with respect to an absorbing agent is dispersed and mixed in a catalyst layer, to which the absorbing agent is added, or a layer of the acid material is formed inside the catalyst layer in order to prevent the absorbing agent from moving from the catalyst layer into the carrier. This reduces the permeation of the absorbing agent added to the catalyst layer into a carrier, the evaporation and splash of the absorbing agent from the catalyst, and the deterioration in the durability and the exhaust gas purifying performance of the catalyst.

Abstract: This invention relates to a sterilisation chamber for use in a sterilisation device or the like, said chamber being adapted to enclose goods to be sterilised during a sterilisation process. The chamber has a self-supported structure being essentially manufactured from a polymeric material.

Abstract: A molding (catalyst structure) for chemical apparatuses which is formed from at least two closed frames and one or more cross-pieces connecting these frames, where the frames are arranged at a distance from one another in a single plane or in a plurality of parallel planes about an (imaginary) molding (structure) axis which is perpendicular to the plane(s) and passes through the center points of the frames. The molding (catalyst structure) is preferably formed from at least four closed frames and one or more cross-pieces connecting these frames, where the frames are arranged one inside the other at a distance from one another in at least two parallel planes about an (imaginary) molding (structure) axis which is perpendicular to the planes and passes through the center points of the frames, and each plane has at least two frames.

Abstract: A gas duct includes a ceramic honeycomb structure includes a metal case, a ceramic honeycomb structure accommodated in the metal case, and a holding member placed between the outer surface of the ceramic honeycomb structure and the inner surface of the metal case. The holding member has, at the two ends, to-be-connected areas engageable to each other and is wound round the outer surface of the ceramic honeycomb structure in such a way that the to-be-connected areas of the two ends are engaged to each other and that the connected area and its vicinity face the partition wall of each cell constituting the honeycomb structure. In the gas duct, even when the ceramic honeycomb structure has thin partition walls, the honeycomb structure is not broken when it is accommodated in a metal case, i.e. during the canning.

Abstract: A catalyst carrier body includes a honeycomb body having sheet-metal layers and an axial extent. The sheet-metal layers are at least partly structured in such a way that the honeycomb body has passages through which an exhaust gas can flow. The sheet-metal layers of the honeycomb body have end regions lying radially outwardly. A tubular jacket has an edge and an axial span shorter than the axial extent of the honeycomb body. The tubular jacket is connected to the honeycomb body in at least one axial partial-region by a joining technique. A sleeve has an axial length shorter than the axial extent of the honeycomb body and is disposed on an outer region of the honeycomb body, in the vicinity of an end surface. The sleeve has an inner shell surface connected by a joining technique to the end regions of the sheet-metal layers at the end surfaces. The honeycomb body projects beyond an edge of the tubular jacket in a projecting section surrounded by the sleeve.

Abstract: An exhaust gas system for an internal combustion engine includes an exhaust gas cleaning installation provided with an entry region, an exit region and a central region. A catalytic converter is disposed in the central region, a first honeycomb body is disposed in the entry region and a second honeycomb body is disposed in the exit region. Exhaust gas can flow through the first and second honeycomb bodies and the catalytic converter. The shape, fastening and/or configuration of at least one of the honeycomb bodies forms thermal insulation. The thermal insulation reduces thermal conduction and/or thermal radiation from the catalytic converter to the remainder of the exhaust gas system. In this manner, the central region is maintained at a temperature required for catalytic conversion for a prolonged period of time so that pollutants are catalytically removed immediately when the internal combustion engine is re-started.

Abstract: A non-thermal plasma reactor is provided. The non-thermal plasma reactor includes a plasma-generating substrate, a housing and a mat. The plasma-generating substrate has one or more flow paths for an exhaust gas. The housing has an inlet and an outlet. The mat retains the plasma-generating substrate in the housing such that the one or more flow paths are in fluid communication with the inlet and the outlet. A voltage is supplied to the plasma-generating substrate to generate a plasma field. An electrically insulating layer is disposed between the plasma-generating substrate and the housing for preventing an arc of electricity from the plasma-generating substrate and/or the voltage to the housing.

Abstract: A catalytic converter for purifying exhaust gases from an internal combustion engine includes a monolithic ceramic substrate having a peripheral surface encircled by a non-intumescent supporting mat material. A metal shell comprising a wider portion which is adjacent to and encloses the mat material and the substrate. The metal shell further comprises a narrower portion which overlaps and is attached to the outer surface of the wider metal shell portion. The wider and narrower metal shell portions combine to exert a compressive force on the wrapped substrate.

Abstract: A device for catalytically converting at least one component of an exhaust gas, including the exhaust gas from an internal-combustion engine, is described. The device includes a casing and a metallic support body formed from a plurality of layers of sheets. The casing at least partially surrounds the metallic support body and is connected to the metallic support body. The sheets are corrugated sheets or corrugated and smooth metal sheets. The metallic support body has at least two outer layers formed from smooth sheet-metal sections overlapping one another. The at least two outer layers are formed substantially diametrically opposite one another and in each case have connection-free areas with respect to the casing.

Abstract: One embodiment of a gas treatment device comprises: a substrate; a housing disposed concentrically about the substrate, the housing comprising a first portion having a decreasing internal diameter from a first end to a main body portion, the main body portion extending from the first portion; and a mat support material disposed concentrically about the substrate to form a subassembly, wherein the subassembly is at least partially disposed in the main body portion.

Abstract: An improved emission control device of the type comprising a substrate contained within a metallic housing. The substrate is positioned within the housing and in use a gas is directed through the substrate by a gasket. The improvement provides several embodiments for reduced frequency of substrate failure and reduced wear on the gasket in use.

Abstract: A catalytic converter device for use with a device such as an oven is provided. The catalytic converter device includes a catalyst-coated ceramic substrate and a mounting ring. The mounting ring secures the ceramic substrate and is engagable with one or more surfaces of a vent of the oven to secure the catalytic converter within an orifice of the vent such that gases flowing through the vent will pass through the apertures of the substrate. The mounting ring includes a body in the shape of a ring, one or more retaining tabs extending from the body which secure the ceramic substrate within the ring about the circumferential surface of the ceramic substrate, and one or more locking tabs extending from the body. The one or more locking tabs allow the mounting ring to be slid or snapped into place in the vent orifice, thereby eliminating the need to secure the catalytic converter device using screws.

Abstract: The present invention discloses a dual-wall catalytic converter wherein the catalytic canister and the heat shield surrounding the catalytic canister are one integral piece. The method of forming the dual wall catalytic converter includes having two tubes of different diameters, placing one tube inside another and subjecting them to a hydroforming process. The tubes are then hydroformed into the converter geometry having an outer housing and an inner housing. In order to seal the outer housing to the inner housing the end portions of the outer housing are pressed against the surface of the inner housing. The catalytic substrate is added by cutting a portion of the inner housing and the outer housing such that the hollow interior of the inner housing is exposed. The catalytic substrate is then inserted inside and the end portions are welded back to obtain the dual-wall catalytic converter.

Abstract: A short shell highly insulated converter includes a short shell forming a generally tubular body for housing a catalyst substrate. End cones having a wide-open end and a narrow open end comprise an inner wall forming a first opening at the wide-open end for engaging the catalyst substrate. The end cones further comprise an outer wall extending beyond the inner wall to form a second wider opening at the wide-open end for engaging the short shell. The inner wall and outer wall converge at the narrow open end to form a snout. A full-length insulating layer is disposed adjacent the catalyst substrate and is selected based upon the amount of overlap between the end cone and the catalyst substrate, the full-length insulating layer being substantially co-extensive with the catalyst substrate. A partial length insulating layer is disposed between the inner insulating layer and the short shell, the partial length insulating layer being generally co-extensive with the short shell.

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: The present invention provides a support structure for a catalyst disposed within an outer containment. Several unique arrangements and connections of supporting struts that form the structure provide a number of significant advantages and improvements. The support structure provides a very low disturbance of gas flow while maintaining a high amount of contact support with catalyst foils. In addition to a high tolerance of thermal gradients and fewer stress concentrations, strong support in radial and axial directions is also provided.

Abstract: A cylindrical body of a catalyst container has that overlapped portion of a rolled sheet of metal which is welded in an axial direction of the cylindrical body. A coned portion is welded, at a large diameter portion thereof, to each axial end of the cylindrical body. The large diameter portion of the coned portion has a flange which extends radially outward, and the axial end of the cylindrical body is brought into abutment with an outward end surface of the flange and is fillet-welded along an outer corner which is formed by the flange and the cylindrical body. A heat shield cover is mounted under the casing by connecting a second flange connected to a front end of a downstream exhaust gas pipe to a first flange connected to a rear end of the casing. The heat shield cover is made up of a mounting flange portion and a cover portion. The mounting flange portion is extended so as to abut with an upstream surface of a lower part of the first flange.

Abstract: A heater unit includes a metallic casing, and a honeycomb heater held in the casing via a metallic holding member, comprising a metallic honeycomb structure having a large number of parallel passages extending in the direction of the flow of an exhaust gas passing through the heater unit and at least one electrode for electrical heating of the honeycomb structure, attached to the honeycomb structure. In the heater unit, the holding member has such a structure as (1) is fitted to part of the outer surface of the honeycomb heater to allow the honeycomb heater to have a stable shape and (2) substantially blocks the flow path of exhaust gas between the honeycomb heater and the casing. This heater unit can withstand severe operating conditions such as experienced in automobiles; moreover, in this heater unit, the by-pass flow of exhaust gas is made substantially zero and the whole exhaust gas can pass through the honeycomb heater.

Abstract: An catalytic converter is integrated with a flexible endcone to form an assembly. The assembly comprises a catalytic converter with a flexible endcone integrated connected to one end of the catalytic converter, which is optionally attached to a mounting flange or exhaust pipe. The endcone comprises a flexible bellow containing a plurality of undulating ribs. The flexible bellow is secured to an end of the catalytic converter at one or more interface points along the periphery of the flexible endcone assembly.

Abstract: A catalytic converter subassembly having at least one component inserted during the manufacture of a cast exhaust manifold, thereby eliminating a costly and undesirable manifold to converter weld.

Abstract: An endcone assembly for use with a catalytic converter comprises a conical shaped sidewall extending outward to a shoulder having a first diameter. A mat protection element having a second diameter extends from the shoulder. The mat protection element has a second diameter that is equivalent to or less than the diameter of the conical shaped sidewall. The mat protection element includes a sidewall having at least two ribs or dimples that protrude outwardly from the sidewall to impart additional retention, positioning and alignment properties to the endcone assembly when being placed within a catalytic converter assembly. The edge of the sidewall either contacts a leading edge of the mat support material, or penetrates the leading edge of the mat support material, when the endcone assembly is disposed within the catalytic converter.

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: Disclosed is a method of manufacturing a catalytic converter for purifying exhaust gases from an internal combustion engine wherein the converter exhibits a monolithic ceramic substrate surrounded by a supporting mat. The method generally includes the steps of: Forming a catalytic converter utilizing a compressive closing method generally involves wrapping the substrate in a sufficient amount of supporting mat material and inserting the wrapped substrate into generally cylindrical metal container, compressively closing the container around the wrapped substrate sufficiently to provide a gas tight seal and to hold the imparted compressive stress. The present invention further discloses an improvement involving compressively closing the container around the wrapped substrate by resizing the container over substantially the entire portion of its length which is occupied by the wrapped substrate to a predetermined metal shell/container outside diameter OD.

Abstract: A catalytic converter is constructed by measuring a substrate to be placed within the outer shell or can, wrapping the substrate in a selected mat and loading the package (mat and substrate) into the can. The can is larger than it will be at completion of manufacture to render such loading easier. Subsequent to loading, the measurement of the substrate is used to direct the degree to which the can is reduced in outside dimension such that a selected annulus is created between the substrate and can, said annulus being occupied by said mat.