A honeycomb body includes wound and/or stacked layers having a geometric center axis, a cavity rotationally symmetrically around the center axis and an outer lateral surface. Each layer extends approximately concentrically around the axis. At least one of the layers is at least partially structured forming channels through which a fluid can flow. The channels extend from the cavity outward to the outer lateral surface at a non-right cone angle to the axis. The channels have a cross-section changing along the channels from inside to outside. At least one structured layer and at least one intermediate layer are alternatingly disposed and helically layered. The structure height of the structured sheet-metal layer forming the channels is substantially constant and channel cross-sectional areas increase from inside to outside. The intermediate layer can be made of simple wires or of specially cut or folded smooth sheet-metal layers.

Various structures for catalytic convertors are disclosed herein. The device includes an outer housing enclosing a catalytic core. The catalytic core can be formed in a myriad of ways. Flow paths through the core are constructed so that they are not straight-line paths from the inlet of the device to the outlet of the device. Pleated conformations and stacked core arrays are described that maximize the catalytic surface area in a given volume of housing. The application of the core to exhaust from diesel engines is also disclosed.

Various structures for catalytic convertors are disclosed herein. The device includes an outer housing enclosing a catalytic core. The catalytic core can be formed in a myriad of ways. Flow paths through the core are constructed so that they are not straight-line paths from the inlet of the device to the outlet of the device. Pleated conformations and stacked core arrays are described that maximize the catalytic surface area in a given volume of housing. The application of the core to exhaust from diesel engines is also disclosed.

A metal substrate for catalytic converter for purifying an exhaust gas includes a honeycomb core with metal flat foil and corrugated foil stacked in layers, and an oxide film having a thickness of 0.1 m or more and 10 m or less is formed in a predetermined range including an exposed end surface exposed toward the gas inlet side. The oxide film contains at least a first alumina including -alumina and a Fe oxide. The -alumina contains -alumina with solid-solved Fe and -alumina with no solid-solved Fe. In the oxide film, the content of the first alumina is 30% by mass or more and 99.5% by mass or less, the content of the Fe oxide is 0.5% by mass or more and 40% by mass or less, and the content of Fe is more than 7% by mass and 35% by mass or less.

Provided are metal foil matrices formed of corrugated metal foil with oblique angles. The metal foil matrices are capable of providing turbulent gas flow there through. The matrices may contain a catalytic coating. The matrices may be employed in a catalytic converter for treatment of exhaust gas emissions of an internal combustion engine.

A metal substrate for catalytic converter for purifying an exhaust gas includes a honeycomb core with metal flat foil and corrugated foil stacked in layers, and an oxide film having a thickness of 0.1 m or more and 10 m or less is formed in a predetermined range including an exposed end surface exposed toward the gas inlet side. The oxide film contains at least a first alumina including -alumina and a Fe oxide. The -alumina contains -alumina with solid-solved Fe and -alumina with no solid-solved Fe. In the oxide film, the content of the first alumina is 30% by mass or more and 99.5% by mass or less, the content of the Fe oxide is 0.5% by mass or more and 40% by mass or less, and the content of Fe is more than 7% by mass and 35% by mass or less.

A filtering media member is formed of porous material. A first edge portion includes an upstream edge. A second edge portion is spaced apart from the first edge portion and includes a downstream edge. A main portion is arranged intermediate the first and second edge portions. The edge portions and the main portion together define a generally planar first surface. A plurality of channels is formed on the first surface. Each of the channels is arranged adjacent to one another and has a length. Each of the channels includes an inlet disposed proximate to the first edge portion so that, in use, fluid flows from the upstream edge through the inlet to the respective channel, and each of the channels has a width in the lateral direction that decreases across its length so that the channels taper between the first and second edge portions.

A catalytic converter apparatus for use in an exhaust system of an internal combustion engine includes a housing having a gas inlet and a gas outlet, and at least one catalytic substrate element disposed in the housing. The at least one substrate element is divided into a plurality of zones or sections, the zones at least partially separated from one another to inhibit heat flow. The zones can be at least partially separated with walls. The walls can include insulating material for reducing the mobility of heat radially outwardly. Each of the zones defines a generally separate flow passage connecting the inlet and outlet in fluid communication. The apparatus can heat more rapidly from a cold start compared with conventional catalytic converters.