Catalytic converter substrate and retainer assembly

Claim 1

A metal foil substrate and retainer for a catalytic converter characterized by a stack of unjoined modules individually formed of a single folded smooth sheet of metal foil and a single folded corrugated sheet of metal foil interleaved in alternate and contacting layers so as to define passages therebetween and wherein each said sheet has a fold along one side and unjoined edges along an opposite side extending longitudinally of the converter along opposite sides thereof with said folded side and unfolded side terminating in end corners and wherein one unjoined edge of each said smooth sheet is located in the fold of the corrugated sheet interleaved therewith and wherein one unjoined edge of each said corrugated sheet is located in the fold of the smooth sheet interleaved therewith, said modules having a uniform thickness but various widths so as to conform said stack to a predetermined cross-sectional curved profile but with the combined thickness of said modules being oversize and compressively loadable to completely conform to said predetermined profile whereby said contacting layers are frictionally held together against relative sliding, and retainer means for forcibly encompassing and thereby compressively loading and retaining said stack in said predetermined profile without penetration or joining thereof and also extending inwardly over the corners of the sheets to engage against the ends of their fold and unjoined edges so as to positively prevent longitudinal movement of the sheets relative to the retainer means.