Catalytic converter with metallic carrier and method for producing same

A catalytic converter comprising:

• a casing;
• and
• a monolithic metallic carrier for catalyst metal, disposed in said casing, said metallic carrier including
• a main sheet metal structure formed by successively turning up an elongate sheet metal a plurality of times in opposite directions, said main sheet metal being generally zigzag in cross-section and having a plurality of generally flat portions which are generally parallel with each other so that adjacent two generally flat portions are separated from each other by a predetermined distance and define therebetween a space, said main sheet metal structure having first and second end portions which respectively correspond to opposite end portions of said elongate sheet metal, said first and second end portions serving respectively as electric terminals through which electric current flows;
• a first electrically insulative layer formed on a surface of said main sheet metal structure, and
• a plurality of heat resistant corrugated spacers each of which is disposed in said space and in contact with said first electrically insulative layer on the respective adjacent generally flat portions to define a plurality of fine gas passages between each corrugated spacer and each generally flat portion of the main sheet metal structure.