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Method of making a metal honeycomb catalyst support having a double taper
| Details |
Inventors: Retallick, William B.;
Assignee: W. R. Grace & Co.-Conn. (New York, NY)
Primary Examiner: Echols; P. W.
Assistant Examiner: Rawlins; Andrew E.
Attorney, Agent or Firm: Trinker; Steven T.
A catalytic converter includes a metal honeycomb catalyst support which is anchored in a canister so that it cannot telescope or blow out. The honeycomb catalyst support is made by folding a strip of metal back and forth upon itself. The lines of folding are inclined to the perpendicular to the axis of the strip. The repeating sequence of the inclinations is left, right, right, left, etc. Folding the strip in this manner produces a honeycomb that has a taper in both of two directions so that it can be anchored in the canister. The canister has a taper which coincides with the taper of the honeycomb. The invention also includes a method and apparatus for making crease lines on the strip, so that the strip can be folded. |
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DETAILED DESCRIPTION The catalytic converter of this invention is made by folding a strip of metal back and forth upon itself to form a honeycomb catalyst support.
The spacing between the layers in the honeycomb is maintained by corrugations in the strip, such as described in U.
S.
Pat.
Nos.
4,576,800 and 3,183,963.
Each fold is made upon a crease line that extends across the width of the strip.
The crease lines are inclined to the perpendicular to the axis of the strip.
The direction of inclination, relative to the perpendicular, is varied in a repeating sequence.
As a result, the honeycomb made by folding the strip has a taper in both of two directions so that the honeycomb can be anchored in its canister.
The creases are formed by passing the strip between rollers.
One roller has a ridge that mates with a groove on the other roller.
The ridges and grooves are not parallel to the axes of the rollers, but instead they define spirals on the surfaces of the rollers.
When the rollers are pressed against the metal strip, the spiral ridges form creases in the strip, and the creases appear as straight lines inclined to the perpendicular to the axis of the strip.
It is therefore an object of the invention to provide a catalytic converter for an automobile, wherein the converter comprises a metal honeycomb catalyst support anchored in a canister.
It is another object to provide a catalytic converter as described above, wherein the catalyst support cannot telescope or blow out.
It is another object to provide a catalytic converter as described above, wherein the catalyst support can be made from a single strip of metal folded back and forth upon itself.
It is another object to provide a catalytic converter as described above, wherein the strip is free of perforations.
It is another object to provide a prepared metal strip which, upon being folded back and forth upon itself, becomes a multi-layer honeycomb catalyst support having a predetermined cross-section.
It is another object to provide apparatus for creasing the strip for folding
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