It is disclosed a honeycomb catalyst substrate core having non-linear flow channels that are geometrically shaped. The honeycomb catalyst substrate’s core could contain helical flow channels. In another embodiment, the honeycomb catalyst substrate core contains sinusoidal flow channels. Another embodiment of the honeycomb catalyst substrate is that it has sinusoidal flow channels and the helical flow channels. The honeycomb catalyst substrate is comprised of a number of parallel non-linear flow channels arranged along the longitudinal axis co-symmetry of the catalyst substrate, each channel is configured to allow eddies to occur in the course of exhaust gas flow through engines. Also disclosed is a method to create a ceramic honeycomb having non-linear flow channels. This includes the steps extrusion soft ceramic material using a die whilst the die is moved across six degrees of freedom around the an axis of symmetry. Three-dimensional printing can be used to make a honeycomb of ceramic that has non-linear flow channels.

The main cause of air pollution is mobile sources that emit noxious gases from internal combustion engines. The most significant pollutants are nitrogen oxides (NOX) and hydrocarbons (HC), carbon monoxide (CO) and volatile organic compounds (VOC). A catalytic converter functions to decrease the levels of CO and NOX, and other contaminants that are present in exhaust gases from engines. Catalytic converters render harmful CO and NOX, HC into harmless compounds such as CO.sub.2, N.sub.2 and water.Catalytic converters can be used to control emissions and minimize the toxic emissions from internal combustion engines, like in cars, trucks, diesel-electric “genset” locomotives as well as agricultural and construction equipment and marine vessels. Non-linear (non-straight) geometric channels differ from traditional linear (straight) channels because liquids or exhaust gases travel differently on the surfaces of a solid catalyst applied to the channel walls. Non-linear geometric catalytic converters may have more than just automotive uses. They are able to be utilized in various other fields of science and industry, such as refineries for chemical and petrochemicals pharmaceuticals, pharmaceuticals and fine food and beverage flavors as well as aroma fragrances and scents and production of dietary supplements and many more.

The majority of catalytic converters come with honeycomb cores. The core is coated with catalyst-based formulation. Sometimes, it may also include the metal oxide washing coat. Linearchannels have square cross-sections in the majority of ceramic substrate cores. E.g. Check U.S. Pat. Nos. 3,790,654 and 5,866,079 Metallic honeycomb cores for honeycomb substrates could be different in cross sectional shapes because of the malleability of metal. The metal substrate cores are able to be constructed in U-shaped parallel channels, with the catalyst embedded within the washcoat. The substrate core is wrapped in a mat that retains it and is protected by an outer metal shell. E.g., U.S. Pat. No. 8,071,505 issued toEbener et al. The invention is a metal catalytic converter support body which has a longitudinal axis and contains a honeycomb body as well as a housing. The honeycomb body is comprised of at least three metal layers that are arranged one over one another, and wound around their edges in each case beginning at a common central point and then dividing into layers that lie one above each other in a spiral form in a housing sleeve. The corrugated sheath forms straight and parallel channels through which exhaust flows.

The conventional structure of a catalytic converter relies on a substrate base which is comprised of thousands or hundreds of small, narrow long, identical-sized channels that resemble ducts or cells within a honeycomb-like structure. The flow channels are typically many inches long with channel openings that measure roughly 1/ inch (about one millimeter). The length of the channel as well as its opening can vary depending on the catalytic sub-substance used for the application. When exhaust flows, harmful substances like CO, NOX, and HC diffuse across the channel and interact with the catalyst coated on the walls of the channel and are eliminated into CO.sub.2,N.sub.2 and H.sub.2O. For conventional catalytic honeycomb substrates, diffusion is the predominant mode of transport of species across flow streamlines. Thus, catalytic reactions are rate-limited by overall diffusioncoefficients. The gradient of concentration of reactants in the exhaust flow is usually higher near the centerline of the channel as opposed to near the walls of the channel. It’s also lower near the channel walls (i.e. near the catalytic coating), which limits catalytic efficiency within linear channels.

Catalytic efficiency can be increased inter alia by offsetting diffusion’s rate-limiting element by increasing the length of the honeycomb channels, or by increasing the amount of flow channels in a honeycomb or by increasing the amount of catalytic substrate material that is embedded within the washcoat. These methods have the disadvantage of increasing the honeycomb’s weight and packaging size and increasing the cost of production. This disclosure offers an alternative cost-saving approach to increasing catalytic efficiency. The present disclosure is designed to boost the catalytic efficiency of converters through the use of non-linear substrate core channels that create flow vortical forces that increase the amount of convection and infusion across the flow channels. Non-linear channel geometries are included in the present disclosure to increase catalytic efficiency over traditional linear substrate channels.

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A patent search is the very first step towards obtaining your patent. You can do a google patent search or do a USPTO search. Patent-pending is the term for the product covered by the patent application. You can use for the public pair to locate the patent application. Once the patent office approves the patent application, you will be able to perform a patent search to locate the issued patent which means that your product will now be patented. It is also possible to use the USPTO search engine. Read on for more details. You can get help from an attorney for patents. In the US patents are granted by the US trademark and patent office or by the United States patent and trademark office, which is also responsible for examining trademark applications.

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Write down a concise, but precise explanation of your invention. Do not use generic terms such as “device”, “process,” or “system”. Instead, consider synonyms to the terms you selected initially. Next, take note of significant technical terms, as well as key words.

Utilize the following questions to help you identify key words or concepts.

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2. These terms will allow you to look up pertinent Cooperative Patent Classifications using the Classification Search Tool. To determine the most suitable classification for your invention, go through the resulting classification’s class Schemes (class schedules). You may want to consider substituting the terms that you’re using for describing your invention, if you do not receive any results from the Classification Text Search with synonyms like the ones you used in the first step.

3. Review 3. Review the CPC Classification Definition to determine the validity of the CPC classification that you have found. If the classification you have selected is a blue box that has the letter “D” at its left, the link will direct you to the CPC classification description. CPC classification definitions can assist you in determining the classification’s scope so that you can select the one that is most appropriate. These definitions may also include search tips or other suggestions that can be useful for further investigation.

4. The Patents Full-Text Database and the Image Database allow you to find patent documents that are accompanied by the CPC classification. You can look through and find the relevant patent documents by first focusing on abstract and drawings representative of.

5. Utilize this selection of most relevant patent publications to study each one in depth for any similarities to your own invention. Pay close attention to the specification and claims. You may find additional patents by referring to the patent examiner and applicant.

6. It is possible to find published patent applications that match the CPC classification you chose in Step 3. You can use the same method of search as in Step 4. You can narrow your search results to the most pertinent patent application by looking at the abstract and drawings on each page. Next, carefully examine the patent applications that have been published and pay particular attention to the claims and additional drawings.

7. You can look up additional US patent publications using keyword search in AppFT or PatFT databases, and also search for patents classified as that are not issued by the United States according to below. Additionally, you can use web search engines to search non-patent patent disclosures in literature about inventions. Here are some examples:

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