Structure for converter body

• US 5,846,495 A
• Filed: 06/26/1997
• Issued: 12/08/1998
• Est. Priority Date: 07/12/1995
• Status: Expired due to Fees

• Current Assignee: Engelhard Corporation (BASF SE)
• Original Assignee: Engelhard Corporation (BASF SE)
• Inventors: Sheller, David Thomas, Whittenberger, William A.
• Primary Examiner(s): TRAN, HIEN THI
• Application Number:
  US08/883,264
• Time in Patent Office: 530 Days
• Field of Search: 422/171, 422/177, 422/174, 422/180, 422/199, 422/211, 422/222, 60/299, 55/DIG. 30, 502/439, 502/527.18, 428/116, 428/593-594
• US Class Current: 422/180
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: F01N 2330/44 made of stacks of sheets, plates or foils that are folded in S-form
• CPC Class Codes: F01N 3/2026 directly electrifying the catalyst substrate, i.e. heating the electrically conductive catalyst substrate by joule effect
• CPC Class Codes: F01N 3/281 Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
• CPC Class Codes: F01N 3/2842 specially adapted for monolithic supports, e.g. of honeycomb type F01N3/2853 - F01N3/2871 take precedence
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y10S 55/30 Exhaust treatment
• CPC Class Codes: Y10T 428/1234 Honeycomb, or with grain orientation or elongated elements in defined angular relationship in respective components [e.g., parallel, inter- secting, etc.]
• CPC Class Codes: Y10T 428/12347 Plural layers discontinuously bonded [e.g., spot-weld, mechanical fastener, etc.]
• CPC Class Codes: Y10T 428/24149 Honeycomb-like

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.

Claims

1. A converter body comprising (a) a housing, and (b) a core, said core comprising a plurality of thin metal core elements defining a plurality of cell passages between two adjacent elements, each of said core elements having a distal end and a proximal end, the distal ends being secured to said housing, and the proximal ends being free from attachment within the body.

2. A converter body as defined in claim 1 wherein a portion of the thin metal core elements are flat and in alternating relation with another portion of the thin metal core elements which are corrugated.

3. A converter body as defined in claim 1 wherein all of the thin metal core elements are corrugated in a nonnesting pattern.

4. A converter body as defined in claim 1 wherein the thin metal core elements are precoated with a refractory metal oxide coating.

5. A converter body as defined in claim 4 wherein the refractory metal oxide coating comprises alumina.

6. A converter body as defined in claim 4 wherein the refractory metal oxide coating has a noble metal catalyst supported thereon.

7. A converter body as defined in claim 6 wherein the noble metal catalyst is selected from the group consisting of platinum, palladium, rhodium, ruthenium, indium and mixtures of said metal catalysts.

8. A converter body as defined in claim 2 wherein the corrugations of each of the corrugated thin metal core elements have a decreasing amplitude toward the proximal end.