Patent ID: 6096682
Filing Date: 2000-08-01
Classification: B01J,F01N

Abstract:
A method of producing a catalyst body for catalytic treatment of exhaust gas from an internal combustion engine and comprising at least one sleeve containing a packet of coated sheet metal members, the method comprising the steps of:producing the at least one sleeve having a substantially quadrilateral cross-section defined by substantially parallel, spaced from each other, first and second walls and third and fourth walls, with the first and second walls having substantially flat and smooth inner surfaces facing one another;producing flat sheet metal members and corrugated sheet metal members, with each of the flat and the corrugated sheet metal members having a shape of a parallelogram and opposite straight first and second edges spaced from each other by at most 50 mm in plan view, with corrugations of each of the corrugated sheet metal members being provided along an entire length thereof and extending parallel to the first and second edges of respective corrugated sheets, with each of the flat and corrugated sheet metal members having a metallic core with two opposite surfaces and a core thickness of at most 0.1 mm and smaller than a thickness of the walls of the at least one sleeve, and with each of the two opposite surfaces being completely covered with a coating containing a catalytically active material;forming, in the at least one sleeve, the packet of the coated sheet metal members by arranging alternatively the flat and corrugated sheet metal members so that the first and second edges of the sheet metal members face respective inner surfaces of the first and second walls of the at least one sleeve, that the flat sheet metal members contact summits of corrugations of respective corrugated sheet metal members, and that the inner surfaces of the first and second walls continuously extend over the first and second edges, respectively, of all of the flat and corrugated sheet metal members; andconnecting the sheet metal members to the first and second walls of the at least one sleeve at at least one edge region of each of the first and second edges of the sheet metal members, respectively, by applying heat to respective sides of the first and second walls remote from the sheet metal members in such a manner that metallic wall material is temporarily being melted and by flowing the melted metallic wall material between coated edge regions of essentially all of the adjacent sheet metal members, forming a bond between the sheet metal members and the first and second walls of the at least one sleeve.