Fabrication and assembly of metal catalytic converter catalyst substrate

Claim 1

A method of fabricating and assembling a metal catalytic converter catalyst substrate of predetermined cross-sectional profile comprised of a tubular sheet metal shell containing layers of metal foil, said method comprising the steps of (1) initially forming a strip of sheet metal stock of predetermined width into a concave shape (2) sequentially laying strips of metal foil of predetermined widths onto the concave sheet metal strip so as to assemble layers of foil thereon conforming to said predetermined profile, (3) finally forming the strip of sheet metal stock about the layers of foil into a single seam tube conforming to said predetermined profile, (4) sealingly joining the seam of the tube along the length thereof, and (5) cross-cutting the tube with the layers of foil therein to predetermined lengths so as to form catalyst substrate units therefrom.

Claim 2

A method of fabricating and assembling a metal catalytic converter catalyst substrate of predetermined cross-sectional profile comprised of a tubular sheet metal shell containing layers of metal foil, said method comprising the steps of (1) initially forming a strip of sheet metal stock of predetermined width into a concave shape (2) sequentially laying strips of metal foil of predetermined widths onto the concave sheet metal strip so as to assemble layers of foil thereon conforming to said predetermined profile, (3) finally forming the strip of sheet metal stock about the layers of foil into a single seam tube conforming to said predetermined profile, (4) sealingly joining the seam of the tube along the length thereof, and (5) cross-cutting the tube with the layers of foil therein to predetermined lengths so as to form catalyst substrate units therefrom.

Claim 3

A method of fabricating and assembling a metal catalytic converter catalyst substrate of predetermined cross-sectional profile comprised of a tubular sheet metal shell containing layers of metal foil, said method comprising the steps of (1) initially roll forming a strip of sheet metal stock of predetermined width into a concave shape conforming along the bottom thereof to approximately one-half that of said predetermined profile (2) alternately corrugating and sequentially laying strips of metal foil stock of predetermined widths onto the concave sheet metal strip so as to assemble layers of foil thereon conforming to said predetermined profile, (3) finally forming the strip of sheet metal stock into a single seam tube extending about and compressing the layers of metal foil, (4) welding the seam of the tube along the length thereof, and (5) cross-cutting the seam welded tube with the layers of foil therein to predetermined lengths so as to form catalyst substrate units therefrom.

Claim 4

A method of fabricating and assembling a metal catalytic converter catalyst substrate of predetermined cross-sectional profile comprised of a tubular sheet metal shell containing layers of metal foil, said method comprising the steps of (1) initially roll forming a strip of sheet metal stock of predetermined width into a concave shape conforming along the bottom thereof to approximately one-half that of said predetermined profile (2) alternately corrugating and sequentially laying strips of metal foil stock of predetermined widths onto the concave sheet metal strip so as to assemble layers of foil thereon conforming to said predetermined profile, (3) finally forming the strip of sheet metal stock into a single seam tube extending about and compressing the layers of metal foil, (4) welding the seam of the tube along the length thereof, and (5) cross-cutting the seam welded tube with the layers of foil therein to predetermined lengths so as to form catalyst substrate units therefrom.