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Home Metal Working Catalytic-converter-with-metallic-carrier-and-method-for-producing-same

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 Catalytic converter with metallic carrier and method for producing same

Details
Inventors: Nishizawa, Kimiyoshi; Yamada, Takashi; Ehara, Hideharu;
Assignee: Nissan Motor Co., Ltd. (Yokohama, JP)
Primary Examiner: Hart; Douglas
Assistant Examiner:
Attorney, Agent or Firm: Foley & Lardner

A catalytic converter for purifying exhaust gas from an automotive vehicle engine. The catalytic converter is composed of a metallic carrier for catalyst metal, disposed inside a casing. The metallic carrier is constructed of a main sheet metal structure which is formed by turning up an elongate flat sheet metal in a zigzag manner in cross-section, so that the main sheet metal structure has a plurality of parallel flat portions. The adjacent flat portions define therebetween a space. The main sheet metal structure is coated over all of its surfaces with an electrically insulative alumina layer. A plurality of corrugated sheet metal spacers are disposed and secured in the respective spaces thereby to define fine gas passages through which exhaust gas flows. Thus, the main sheet metal structure is electrically insulated from the corrugated sheet metal spacers, so that electric current is passed only through the main sheet metal structure. The main sheet metal structure serves as a heater element for promoting activation of the catalyst metal.

DETAILED DESCRIPTION It is an object of the present invention to provide an improved catalytic converter including a metallic carrier which serves also as an effective heater element for promoting activation of catalyst metal carried on the metallic carrier.
Another object of the present invention is to provide an improved catalytic converter including a metallic carrier having a sheet metal which is sufficiently high in resistance so as to serve as an effective heater element.
A further object of the present invention is to provide an improved catalytic converter including a metallic carrier which has electrically insulating layers, in which electrically insulating materials are effectively prevented from peeling off from the electrically insulating layers.
An aspect of the present invention resides in a catalytic converter composed of a monolithic metallic carrier for catalyst metal, disposed in a casing.
The metallic carrier includes a main sheet metal structure formed by successively turning up an elongate sheet metal a plurality of times in opposite directions.
The main sheet metal structure is generally zigzag in cross-section and has a plurality of generally flat portions which are generally parallel with each other so that the adjacent two generally flat portions are separate from each other by a predetermined distance and define therebetween a space.
The main sheet metal structure has first and second end portions which respectively correspond to opposite end portions of the elongate sheet metal.
The first and second end portions serve as electric terminals, respectively.
An electrically insulative layer is formed on a surface of the main sheet metal structure.
Additionally, a plurality of heat resistant corrugated spacers are provided so that each corrugated spacer is disposed in the space and in contact with the adjacent generally flat portions to define a plurality of fine gas passages between each corrugated spacer and each generally flat portion of the main sheet metal structure



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