Method for producing a cartridge for purifying exhaust gas

Claim 1

Process for producing a cartridge for purifying exhaust gases comprising a catalyst support matrix of wound metal foil and a metal jacket housing said support matrix wherein a press fit is formed between the exterior of the support matrix and the interior of the jacket and the support matrix and jacket are secured together in the area of the press fit, wherein the cross-sectional configuration of the cartridge is oval or elliptical in shape, comprising the steps of spirally winding the metal foil into a catalyst support matrix having a circularly cylindrical body; thereafter pressing the wound matrix between opposed tools provided with corresponding semi-elliptical dies to form the wound matrix to an oval or elliptical cross-sectional configuration; and inserting the wound matrix into the metal jacket housing.

Claim 6

A method for manufacturing a cartridge for purifying exhaust gases, comprising a catalyst support matrix comprised of spirally wound, alternately disposed smooth and corrugated metallic sheets defining a plurality of exhaust gas passageways therebetween, said catalyst support matrix comprising an oval transverse cross-sectional configuration, defined by opposing parallel straight side circumferential segments of a length S and opposing semi-circular end circumferential segments each having a radius R, and wherein said spirally wound metallic sheets from the top half and the bottom half of said oval configuration contiguously abut along a central interface line having a length S; a metal jacket housing said catalyst support matrix, the interior of said metal jacket holding said catalyst support matrix by means of a press fit relationship with the exterior of said catalyst support matrix along at least a circumferential portion of its length; and a bond between the exterior of said catalyst support matrix and the interior of said metal jacket formed in said circumferential portion, said method comprising the steps of spirally winding said metallic sheets around a circular core having a diameter D 2 to form a circular winding having a diameter D 1 , where D.sub.2 =2S/π and D.sub.1 =2R+2S/π; removing the circular core; compressing the circular winding into said oval configuration; inserting the oval winding into a metal jacket; producing said press fit between said jacket and said winding; and bonding the exterior of said oval winding to the interior of said metal jacket.

Claim 7

A method for manufacturing a cartridge for purifying exhaust gases, comprising a catalyst support matrix comprised of spirally wound, alternately disposed smooth and corrugated metallic sheets defining a plurality of exhaust gas passageways therebetween, said catalyst support matrix comprising an oval transverse cross-sectional configuration, defined by opposing parallel straight side circumferential segments of a length S and opposing semi-circular end circumferential segments each having a radius R, and wherein said spirally wound metallic sheets from the top half and the bottom half of said oval configuration contiguously abut along a central interface line having a length S; a metal jacket housing said catalyst support matrix, the interior of said metal jacket holding said catalyst support matrix by means of a press fit relationship with the exterior of said catalyst support matrix along at least a circumferential portion of its length; and a bond between the exterior of said catalyst support matrix and the interior of said metal jacket formed in said circumferential portion, said method comprising the steps of spirally winding said metallic sheets around a circular core having a diameter D 2 to form a circular winding having a diameter D 1 , where D.sub.2 =2S/π and D.sub.1 =2R+2S/π; removing the circular core; compressing the circular winding into said oval configuration; inserting the oval winding into a metal jacket; producing said press fit between said jacket and said winding; and bonding the exterior of said oval winding to the interior of said metal jacket.