Multiple Disc Catalytic Converters - An Innovative Approach for Improved Conversion at Lower Cost

The “Multiple Disc Converter” is an innovative concept. In comparison to conventional catalytic converters, it is significantly less expensive and more compact, at identical conversion efficiency and durability. The catalytic substrate consists of 4 to 5 cylindrical ceramic discs with 62 cells/cm2 (400 cells/inch²). These are assembled in a sheet metal casing, without gaps between the discs, and angularly offset to each other. The flow through the channels is interrupted at the contact surfaces of the individual discs. Hence, the restarted turbulent flow intensifies the transverse mass transfer. Further, the uniformity of the exhaust gas flow is improved, particularly in the first discs. Thus, the conversion of emissions is improved and the durability extended. When the conversion is maintained at the level of conventional converters, then the converter volume can be substantially reduced using the same specific catalyst loading. This is attained by a 10 to 15 % shortening of the total length. The economizing of precious metals, manufacturing savings from the more compact casing and the simplified canning system, all result in up to 10 % lower costs. The basic applicability for large scale production has been proved.