Catalytic Converter Substrate

A catalytic converter for modifying the composition of exhaust gas of an engine, the catalytic converter comprising:

• a housing defining an inlet for receiving the exhaust gas from the engine, a main chamber in fluid communication with the inlet, and an outlet in fluid communication with the main chamber for exhausting the modified exhaust gas;
• a substrate body disposed within the central chamber and defining a plurality of flow channels that provide fluid communication between the inlet and the outlet, a first channel of the plurality of flow channels following a path that curves about an axis;
• a first layer of catalyst material lining a first portion of the first channel, the first layer having a first thickness;
• and
• a second layer of catalyst material lining a second portion of the first channel, the second layer having a second thickness that is less than the first thickness, the first portion of the first channel being radially outward of the second portion of the first channel.

A method of manufacturing a substrate body of an catalytic converter, the method comprising:

• constructing a first layer of the substrate body including the steps of:
• depositing substrate particles to define a plurality of channels;
• and
• depositing catalyst particles within the plurality of channels;
• and
• constructing a second layer of the substrate body onto the first layer of the substrate body including the steps of:
• depositing substrate particles onto the first layer of the substrate body, the substrate particles of the first and second layers cooperating to define the plurality of channels;
• and
• depositing catalyst particles onto the first layer of the substrate body, the catalyst particles of the first and second layers cooperating to line a first wall segment of one of the channels with a first thickness of catalyst material and to line a second wall segment of the one of the channels with a second thickness of catalyst material, the first thickness being greater than the second thickness.