Core element for catalytic converter

Claim 2

A core element for a core of a catalytic converter comprising (a) a corrugated thin metal strip and (b) oppositely directed bent metal tabs secured to each end of said strip, each of said tabs being generally rectangular in shape and having opposed shorter edges and opposed longer edges, said longer edges being coextensive in dimension with the width of said corrugated thin metal strip, each of said tabs being secured to said corrugated thin metal strip along one of the longer edges, the opposite edge being free, and each of the tabs being bent along one or more lines parallel to the longer edges of the tab.

Claim 3

A core element for a catalytic converter as defined in claim 1 wherein the tabs are segments of a circle including from 10 degrees to 45 degrees of arc, and each having substantially the same radius of curvature.

Claim 4

A core element as defined in claim 1 wherein at least one tab has a notch in the free edge dimensioned and configured to accommodate passage of an insulator tape.

Claim 5

A core element as defined in claim 1 wherein the corrugated thin metal strip has a centrally located flat portion with respect to the ends of the strip.

Claim 6

A core element as defined in claim 1 wherein the corrugated thin metal strip is corrugated in a herringbone pattern.

Claim 7

A core element as defined in claim 1 wherein the corrugated thin metal strip has corrugations having a triangular cross-section in which the apices are rounded.

Claim 8

A core element as defined in claim 1 wherein the corrugated thin metal strip includes a catalyst.

Claim 9

A core element for a catalytic converter as defined in claim 1 wherein the tabs are bent at an angle of from about 15 degrees to about 35 degrees along a single centrally located line lying longitudinally of the tab.

Claim 10

A core element as defined in claim 8 wherein the corrugated thin metal strip has a centrally located flat portion with respect to the ends of the strip.

Claim 11

A core element as defined in claim 1 wherein the corrugated thin metal strip is a high temperature resistive, oxidation resistant metal strip.

Claim 12

A core element as defined in claim 10 wherein the thin metal strip is a thin ferritic stainless steel strip.

Claim 13

A core element as defined in claim 10 wherein the thin metal strip is a nickel/chromium/aluminum/iron alloy metal strip.

Claim 14

A core element as defined in claim 1 wherein the corrugated thin metals strip has a coating of a refractory metal oxide on a surface thereof.

Claim 15

A core element as defined in claim 13 wherein the refractory metal oxide comprises alumina.

Claim 16

A core element as defined in claim 13 wherein the refractory metal oxide is an alumina/ceria mixture.

Claim 17

A core element as defined in claim 13 wherein the refractory metal oxide is a magnesia/ziconia mixture.

Claim 18

A core element as defined in claim 13 wherein the refractory metal oxide comprises titania.

Claim 19

A core element as defined in claim 13 wherein the refractory metal oxide coated corrugated thin metal strip includes a catalyst on the surface thereof.

Claim 20

A core element as defined in claim 18 wherein the catalyst is a noble metal catalyst.

Claim 21

A core element as defined in claim 19 wherein the noble metal is selected from the group consisting of palladium, platinum, rhodium, ruthenium and mixtures of two or more such metals.

Claim 22

A core for a catalytic converter comprising a bifurcated central pin having a pair of legs, a plurality of corrugated thin metal strips each having oppositely directed bent tabs secured to each end of each strip, said tabs being generally rectangular in shape and having shorter edges and longer edges, each of said tabs being secured to said corrugated thin metal strips along one of the longer edges, the opposite edge being free, and each of said tabs being angularly being along one or more lines lying longitudinally of the tab and generally normal to the shorter edges, said strips being located between the legs of said bifurcated pin, and said strips being spirally wound about said bifurcated pin whereby the tabs are in partially overlapped relation, and means for securing said partially overlapped tabs in said partially overlapped relation, and said secured partially overlapped tabs defining at least two electrically isolated generally circular segments.

Claim 23

A core for a catalytic converter comprising a bifurcated central pin having a pair of legs, a plurality of corrugated thin metal strips each having oppositely directed bent tabs secured to each end of each strip, said tabs being generally rectangular in shape and having shorter edges and longer edges, each of said tabs being secured to said corrugated thin metal strips along one of the longer edges, the opposite edge being free, and each of said tabs being angularly being along one or more lines lying longitudinally of the tab and generally normal to the shorter edges, said strips being located between the legs of said bifurcated pin, and said strips being spirally wound about said bifurcated pin whereby the tabs are in partially overlapped relation, and means for securing said partially overlapped tabs in said partially overlapped relation, and said secured partially overlapped tabs defining at least two electrically isolated generally circular segments.

Claim 24

A core as defined in claim 21 including woven ceramic tape strips at least partially surrounding the legs of said bifurcated central pin and electrically isolating said corrugated thin metal strips from contact therewith.

Claim 25

A core for a catalytic converter as defined in claim 21 wherein the tabs are bent at an angle of from about 15 degrees to about 35 degrees along a single centrally located line lying longitudinally of the tab.

Claim 26

A core for a catalytic converter as defined in claim 21 wherein the tabs are segments of a circle including from 10 degrees to 45 degrees of arc, and each having substantially the same radius of curvature.

Claim 27

An electrically heatable catalytic converter comprising (1) a housing, (2) end cap adapters for each end of the housing for adapting said converter for insertion in an exhaust line, said converter having an upstream end for contacting inlet exhaust gas containing pollutants, and a downstream end for exiting pollutant depleted exhaust gas; (3) a core for said catalytic converter having an upstream end and a downstream end and comprising (a) a bifurcated central pin having a pair of legs, (b) at least one group of corrugated thin metal strips, each said group including a plurality of corrugated thin metal strips, each strip having (c) oppositely directed bent metal tabs secured to each end of said corrugated thin metal strips, said tabs being generally rectangular in shape and having shorter edges and longer edges and having a length greater than the width thereof, and each of said tabs being secured to said corrugated thin metal strip along one of the longer edges, the other longer edge being free, said tabs being bent along one or more lines lying one or more lines parallel to the longer edges of the tab, said strips being located between the legs of said bifurcated central pin, and said at least one group of corrugated thin metal strips being spirally wound about said bifurcated central pin, whereby the tabs are in partially overlapped relation and define an outer periphery of the core, and (d) means for securing said partially overlapped tabs in said partially overlapped relation, and said partially overlapped tabs defining at least two electrically isolated generally circular segments, (e) woven ceramic fiber tape strips interposed between each leg of said bifurcated central pin and each group of corrugated thin metal strips and isolating said corrugated from contact with any adjacent groups of corrugated thin metal strips, (f) a transverse bar extending across the downstream end of said core welded to said bifurcated pin and having a portion of its surface thereof in contact with said corrugated thin metal strips of said core; (4) insulation means extending from said core and spirally wrapped about the outer periphery of said core and between said core and said housing; (5) a feed-through terminal extending through said housing secured to one of said generally circular segments for attachment to one pole of a voltage source; (6) a second terminal extending through the housing and secured to another of said generally circular segments for attachment to the other pole of a voltage source; and (7) a voltage source.

Claim 28

An electrically heatable catalytic converter comprising (1) a housing, (2) end cap adapters for each end of the housing for adapting said converter for insertion in an exhaust line, said converter having an upstream end for contacting inlet exhaust gas containing pollutants, and a downstream end for exiting pollutant depleted exhaust gas; (3) a core for said catalytic converter having an upstream end and a downstream end and comprising (a) a bifurcated central pin having a pair of legs, (b) at least one group of corrugated thin metal strips, each said group including a plurality of corrugated thin metal strips, each strip having (c) oppositely directed bent metal tabs secured to each end of said corrugated thin metal strips, said tabs being generally rectangular in shape and having shorter edges and longer edges and having a length greater than the width thereof, and each of said tabs being secured to said corrugated thin metal strip along one of the longer edges, the other longer edge being free, said tabs being bent along one or more lines lying one or more lines parallel to the longer edges of the tab, said strips being located between the legs of said bifurcated central pin, and said at least one group of corrugated thin metal strips being spirally wound about said bifurcated central pin, whereby the tabs are in partially overlapped relation and define an outer periphery of the core, and (d) means for securing said partially overlapped tabs in said partially overlapped relation, and said partially overlapped tabs defining at least two electrically isolated generally circular segments, (e) woven ceramic fiber tape strips interposed between each leg of said bifurcated central pin and each group of corrugated thin metal strips and isolating said corrugated from contact with any adjacent groups of corrugated thin metal strips, (f) a transverse bar extending across the downstream end of said core welded to said bifurcated pin and having a portion of its surface thereof in contact with said corrugated thin metal strips of said core; (4) insulation means extending from said core and spirally wrapped about the outer periphery of said core and between said core and said housing; (5) a feed-through terminal extending through said housing secured to one of said generally circular segments for attachment to one pole of a voltage source; (6) a second terminal extending through the housing and secured to another of said generally circular segments for attachment to the other pole of a voltage source; and (7) a voltage source.

Claim 29

An electrically heatable catalytic converter as defined in claim 25 wherein the tabs are bent at an angle of from about 15 degrees to about 35 degrees along a single centrally located line lying longitudinally of the tab.

Claim 30

An electrically heatably catalytic converter as defined in claim 25 wherein the tabs are segments of a circle including from 10 degrees to 45 degrees of arc, and each having substantially the same radius of curvature.