Catalytic Converters - Gasoline
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Gasoline Engines

The trend in catalytic converter design is to locate the converter closer to the engine in order to meet increasingly stringent emissions regulations. When converters are located closer to the engine, engine-out gases lose less heat through the exhaust pipe before reaching the catalytic converter, so the unit reaches temperature in less time. This allows the catalyst to light off more quickly after start-up. However, the increased temperatures and vibration near the engine place greater demands on the durability of the converter.

Close Coupled Converters (CCC)
(pre-converters or light off converters)

Are connected directly to the engine manifold with the aim of reducing gaseous emissions. The converter operates at high gas temperatures directly from the engine at approx. 900 – 1050°C.

Close Coupled Converters allow faster light off. Thus reduces emissions by allowing the catalyst to reach the activation temperature faster. The majority of gaseous emissions occur in the first 2 minutes after starting the engine. As the converter is attached directly to the engine manifold, it will need to withstand the associated vibration forces. Higher gas temperature means the outer shell will also get hotter and thus expand more and contract back to the original canned gap. The mat needs to act like a spring (resiliency) to absorb this change.

Ecoflex products are considered the mat of choice for CCC converters and is an Enabling Technology for thin (600/3) and ultra thin (900/2) wall substrates.

Ecoflex is ideal for Ultra Thin Wall Substrates

Feature:  Non Intumescent

Benefit:   Holding pressure does not exceed Isostatic Strength of Substrate

Enables: Increased goemetric surface area which increases catalyst efficiency
Enables: Reduced precious metal content
Enables: Faster light-off due to lower thermal mass
Enables: Reduced package space

Ecoflex is ideal for Close Coupled Converters

Feature:  High Temperature Durability & Low Thermal Conductivity

Benefit:   Reduced Outer Shell Temperatures

Enables: Reduced Canned Gap Change Due to Temperature
Enables: Increased Mat lifetime & Holding Force
Enables: Vibration resistance in CCC positions

Toe Board Converters (TB)
Toe Board converters are considered by most companies to be an under body converter.

Under body Converters (UB)
Are situated underneath the main body of the car and operate at lower temperatures (approx. 700 – 750°C) and lower vibration forces.

Ecoflex is ideal for Under Body Converters

Feature:  Constant Holding Force with Temperature & Excellent Exhaust Gas Erosion Properties

Benefit:   Reduced System Cost with Ecoflex Converter Systems

Enables: Removal of Converter pre-baking during manufacture
Enables: No requirement for Edge Seals