Described herein are catalytic converter substrates or cores based on triply periodic minimal surfaces (TPMS) geometries, along with methods of making and using the same.

A process manufactures an exhaust gas treatment device including a tubular circumferential wall (14) elongated along a longitudinal axis (L) with two axial end areas, an exhaust gas treatment unit (52) arranged in the circumferential wall and a closing element (20, 38) connected to the circumferential wall at the two axial end areas. The exhaust gas treatment unit is held at the circumferential wall by a supporting material layer (54) enclosing the exhaust gas treatment unit and supporting same in relation to the circumferential wall. The process includes arranging a first of the two closing elements at one of the axial end areas of the circumferential wall, pushing the exhaust gas treatment unit enclosed by the supporting material layer into the circumferential wall from the other axial end area (18), and arranging a second of the closing elements at the other axial end area of the circumferential wall.

A perforated metallic base material for purging exhaust is obtained by laminating a wavy foil having pores and a flat foil having pores and forming the same into a cylindrical shape, wherein the wavy foil and/or the flat foil has axially perforated portions having pores throughout the axial direction of the cylindrical shape and axially non-perforated portions not having pores overall in the axial direction of the cylindrical form.

The invention provides: an exhaust-gas-purifying metal substrate capable of achieving both low pressure loss and high purification performance; and an exhaust gas purification device using the metal substrate. The invention relates to an exhaust-gas-purifying perforated metal substrate in which a corrugated foil and a flat foil are layered and made into a cylindrical shape, wherein: the perforated metal substrate includes from 50/in.sup.2 to 800/in.sup.2 of cells; the corrugated foil includes a plurality of first holes having an area that is from 2.0 to 50 times the average opening area of the cells; the flat foil includes a plurality of second holes having an area that is from 3.0 to 100 times the average opening area of the cells; and the average value of the area of the first holes in the corrugated foil is smaller than the average value of the area of the second holes in the flat foil.

A method for producing a honeycomb body for a catalytic converter for treating exhaust gases, the honeycomb body having a plurality of flow ducts, through which gas flows from an inlet end to an outlet end. The honeycomb body is formed from a plurality of metal layers lying one on top of the other. The honeycomb body is produced by forming corrugated sections in a metal strip, wherein the corrugated sections follow one another directly or are spaced apart by smooth sections, creating a pre-bend of the metal strip in the end region of each section, folding the individual sections of the metal strip onto one another to create a layer stack, wherein the individual sections are alternately folded onto one another in opposite directions, inserting the layer stack in a housing, and joining the layer stack to the housing in contact regions between the layer stack and the housing.

A metallic film includes: a top side; a flat electrical conductor; and a base insulation layer configured to attach the flat electrical conductor to the top side, the base insulation layer having: a cover layer covering the conductor in an electrically insulating manner. The film has at least one edge region without the electrical conductor and without either the base insulation layer or the cover layer, and the combined total thickness (D) of the electrical conductor, the base insulation layer and the cover layer, is less than 80 μm.

A method for producing a honeycomb structure having at least one at least partially structured metal foil, such that, in subregions of the honeycomb structure, a portion of the at least one metal foil is arranged spaced apart from an adjacently arranged portion of the at least one metal foil so as to be electrically insulated by an air gap therebetween, includes: providing the at least one metal foil; providing a forming plate having a bearing surface and having at least one first web structure extending from the bearing surface in an axial direction, the first web structure extending in a plane parallel to the bearing surface and defining the air gap to be produced in the honeycomb structure; and arranging the at least one metal foil on the bearing surface in the first web structure.

A heating disk for heating up a stream of exhaust gas and/or a component for exhaust gas aftertreatment has a honeycomb body, wound from a plurality of smooth and corrugated metal layers stacked on top of one another. The honeycomb body is received within a carrier shell and an electrical contact is fed through the carrier shell. The honeycomb body is connected to a current source via the electrical contact. The electrical contact has a contact strip within the carrier shell extending in the circumferential direction of the carrier shell. An insulating region is formed between the carrier shell and the contact strip. A plurality of stacks of layers are electrically insulated from one another. Each of the stacks of layers are formed from the plurality of smooth and corrugated metal layers, and which are arranged directly adjacent to one another and conductively connected to the contact strip.

A honeycomb body for exhaust gas aftertreatment includes a plurality of interconnected metal foils stacked on one another. The honeycomb body has a central first flow channel running in the axial direction of the honeycomb body, as an inflow section, and has a plurality of second flow channels between in each case two mutually adjacent metal foils. The first flow channel is in fluid communication with the second flow channels. The second flow channels formed between two mutually adjacent metal foils run in a straight line and parallel to one another along a radial direction of the honeycomb body.

A metallic honeycomb body with channels through which a gas may flow, made up of layers of at least partially structured sheet metal, the layers of sheet metal having at least in subregions at least two different structures, of which the first structure, with a greater structure height (H), determines the size of the channels and the second structure has a much smaller structure height (h) between troughs and peaks and the form and/or the structure height (H) of the second structure being chosen such that a ceramic coating applied later may fill the troughs of the second structure on average to at least 10%, in particular at least 50%, of their structure height (h). With the honeycomb body according to the invention, more coating material per unit of volume is durably attached in a metallic honeycomb body without excessively increasing the pressure loss. This is of advantage particularly for applications for reducing nitrogen oxides (NOx) in diesel exhaust gases.