Method for manufacturing a wound foil structure comprising distinct catalysts

Claim 1

A method for manufacturing a gas treating catalyst structure from at least one foil member, said method comprising applying a first catalyst composition to a predetermined first foil surface, applying a second catalyst composition different from the first to a distinct predetermined second foil surface, but not to the first surface, and forming the foil to bring the first surface to face the second surface and to form a gas passage therebetween, said passage thereby comprising distinct catalysts in facing relation isolated from each other for concurrently treating gases flowing therethrough.

Claim 2

A method for manufacturing a gas treating catalyst structure from at least one foil member, said method comprising applying a first catalyst composition to a predetermined first foil surface, applying a second catalyst composition different from the first to a distinct predetermined second foil surface, but not to the first surface, and forming the foil to bring the first surface to face the second surface and to form a gas passage therebetween, said passage thereby comprising distinct catalysts in facing relation isolated from each other for concurrently treating gases flowing therethrough.

Claim 3

A method for manufacturing a wound foil catalyst structure for treating gases, said method comprising applying a first catalyst to substantially one half lengthwise only of a side of a metal foil, applying a second catalyst different from the first to the remaining half only of the first foil side, said halves bordering along a transverse axis, applying the first catalyst to substantially one half lengthwise only of an opposite side of the foil, applying the second catalyst to the remaining half only of the opposite foil side, winding the foil about the axis to form a generally cylindrical structure having axial passages therethrough, said winding being carried out so that the first half of each side faces the second half of the same side and the axial passages comprise the first and second catalysts isolated on facing surfaces for treating gases caused to flow therethrough.

Claim 4

A method for manufacturing a wound foil catalyst structure for treating gases, said method comprising applying a first catalyst to substantially one half lengthwise only of a side of a metal foil, applying a second catalyst different from the first to the remaining half only of the first foil side, said halves bordering along a transverse axis, applying the first catalyst to substantially one half lengthwise only of an opposite side of the foil, applying the second catalyst to the remaining half only of the opposite foil side, winding the foil about the axis to form a generally cylindrical structure having axial passages therethrough, said winding being carried out so that the first half of each side faces the second half of the same side and the axial passages comprise the first and second catalysts isolated on facing surfaces for treating gases caused to flow therethrough.

Claim 5

A method for manufacturing a wound foil catalytic converter structure suitable for treating automotive exhaust gases, said method comprising applying a first catalyst, but not a second catalyst, to substantially one half in length of first and second surfaces on opposite sides of a corrugated metal foil, applying the second catalyst, but not the first catalyst, to the remaining half in length of the first and second foil surfaces, said halves of said surfaces bordering along a transverse axis, folding the foil substantially in half lengthwise along the axis, whereupon one half of the first surface faces the other half of the first surface and the corrugations form passages extending through the fold, and winding the folded foil about the axis to form a generally cylindrical structure, whereupon one half of the second surface faces the other half of the second surface and the corrugations form additional passages, whereby the passages formed by folding and winding are defined by facing foil surfaces separately carrying the first and second catalysts.

Claim 6

A method for manufacturing a wound foil catalytic converter structure suitable for treating automotive exhaust gases, said method comprising applying a first catalyst, but not a second catalyst, to substantially one half in length of first and second surfaces on opposite sides of a corrugated metal foil, applying the second catalyst, but not the first catalyst, to the remaining half in length of the first and second foil surfaces, said halves of said surfaces bordering along a transverse axis, folding the foil substantially in half lengthwise along the axis, whereupon one half of the first surface faces the other half of the first surface and the corrugations form passages extending through the fold, and winding the folded foil about the axis to form a generally cylindrical structure, whereupon one half of the second surface faces the other half of the second surface and the corrugations form additional passages, whereby the passages formed by folding and winding are defined by facing foil surfaces separately carrying the first and second catalysts.

Claim 7

A method for manufacturing a wound foil catalytic converter structure suitable for treating automotive exhaust gases, said method comprising applying a first catalyst composition comprising platinum, but not palladium, to substantially one half in length of first and second surfaces of a gamma alumina-coated metal foil corrugated in zig-zag pattern, applying a second catalyst composition comprising palladium, but not platinum, to the remaining second half in length of first and second surfaces of the foil, the platinum-bearing half and the palladium-bearing half bordering along a transverse axis, folding the foil substantially in half lengthwise along the axis, whereupon the first half of the first surface faces the second half of the first surface and the zig-zag corrugations form passages extending through the fold, and winding the folded foil about the axis to form a generally cylindrical structure, whereupon the first half of the second surface faces the second half of the second surface and the zig-zag corrugations form axial passages having facing surfaces separately carrying platinum and palladium catalyst for concurrently treating exhaust gases flowing therethrough.

Claim 8

A method for manufacturing a wound foil catalytic converter structure suitable for treating automotive exhaust gases, said method comprising applying a first catalyst composition comprising platinum, but not palladium, to substantially one half in length of first and second surfaces of a gamma alumina-coated metal foil corrugated in zig-zag pattern, applying a second catalyst composition comprising palladium, but not platinum, to the remaining second half in length of first and second surfaces of the foil, the platinum-bearing half and the palladium-bearing half bordering along a transverse axis, folding the foil substantially in half lengthwise along the axis, whereupon the first half of the first surface faces the second half of the first surface and the zig-zag corrugations form passages extending through the fold, and winding the folded foil about the axis to form a generally cylindrical structure, whereupon the first half of the second surface faces the second half of the second surface and the zig-zag corrugations form axial passages having facing surfaces separately carrying platinum and palladium catalyst for concurrently treating exhaust gases flowing therethrough.

Claim 9

A method for manufacturing a gas treating catalyst structure from a catalytically coated foil member comprising applying a first catalyst to a first selected portion of a foil surface, applying a second catalyst different from the first catalyst to a second selected portion of the foil surface different from the first portion, and forming the foil so as to bring the selected portions of the surface into facing relationship and to define a gas passage between said surface portions, said passage thereby having different catalysts on separate passage-defining surfaces facingly arranged for concurrently treating gases caused to flow therethrough.

Claim 10

A method for manufacturing a gas treating catalyst structure from a catalytically coated foil member comprising applying a first catalyst to a first selected portion of a foil surface, applying a second catalyst different from the first catalyst to a second selected portion of the foil surface different from the first portion, and forming the foil so as to bring the selected portions of the surface into facing relationship and to define a gas passage between said surface portions, said passage thereby having different catalysts on separate passage-defining surfaces facingly arranged for concurrently treating gases caused to flow therethrough.