Claims:
1. A flow guiding element (200) for improving Surface Uniformity (SUI) of a catalytic converter, the element (200) comprising:
at least one support member (202) configured for securely mounting the flow guiding element (200) to an inner surface of a downpipe (100);
at least one deflector plate (206) configured for guiding flow of exhaust gas at the desired location;
at least one flexible element (204) configured for connecting the support member (202) and the deflector plate (206);
at least one dampening component (210) configured for providing desired movement of the deflector plate (206); and
at least one seat (208) configured for mounting the dampening component (210).

2. The flow guiding element (200) as claimed in claim 1, wherein the flow guiding element (200) is configured for improving the SUI of an EAS component by mounting it at the onset of the diffuser section.

3. The flow guiding element (200) as claimed in claim 1, wherein the deflector plate (206) is configured to vary its mounting angle with the varying flow rate/force of the exhaust gas by compression and expansion of the dampening component (210).

4. The flow guiding element (200) as claimed in claim 1, wherein the dampening component (210) is configured to get compressed for improved flow distribution in higher flow rate of the exhaust gas.

5. The flow guiding element (200) as claimed in claim 1, wherein the spring/dampening component (210) is configured to prevent the fluttering of the deflector plate (206) with the change in the flow rate of the exhaust gas.

6. The flow guiding element (200) as claimed in claim 1, wherein the flexible element (204) is configured for providing relative motion between the deflector plate (206) and the support member (202).

7. The flow guiding element (200) as claimed in claim 1, wherein the support member (202) is configured as a base element of the flow guiding element (200).

8. The flow guiding element as claimed in claim 1, wherein said flow guiding element (200) is configured for channelizing the incoming exhaust flow evenly into the substrate face to improve the uniformity index without any change in the existing layout.

9. The flow guiding element as claimed in claim 1, wherein said deflector plate (206) with dynamically changing angle with respect to the incoming flow is configured for effectively channelizing the incoming exhaust flow for a wide range of exhaust gas flow rates.

10. The flow guiding element as claimed in claim 1, wherein said dampening component (210) is a compressible spring.

, Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of invention:
A FLOW GUIDING ELEMENT TO IMPROVE SURFACE UNIFORMITY (SUI) OF A CATALYTIC CONVERTER

Applicant:
Tata Motors Limited
A company Incorporated in India under the Companies Act, 1956
Having address:
Bombay House, 24 Homi Mody Street,
Hutatma Chowk, Mumbai 400001,
Maharashtra, India

The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION
[001] The present subject matter described herein generally relates to an exhaust after-treatment system, more specifically it relates to a spring-loaded flow guiding element to improve Surface Uniformity (SUI) of a catalytic converter in vehicles.

BACKGROUND
[002] Surface Uniformity (SUI) plays a crucial role in ensuring enhanced catalyst effectiveness in an exhaust after-treatment system of a vehicle. The SUI is adversely affected as the exhaust flow enters through an angular guideway. Reduction in the SUI causes improper utilization of the Platinum Group Materials (PGM) and reduces conversion efficiency. Hence, optimizing the SUI across the operating exhaust flow rates is crucial in ensuring required catalyst functioning.
[003] While analysing the surface uniformity at the substrate face for a flow that is coming through an angular downpipe of the exhaust after-treatment system, it is observed that majority of the flow is concentrated at the bottom patch of the substrate. This results in improper flow distribution of the exhaust gases. It affects the thermal durability of the core and improper utilization of the catalyst coated over the peripheral surfaces.
[004] The conventionally available devices for exhaust flow distribution consist of a plate sort of an arrangement that is used to channelize the exhaust flow to the desired surface. However, these plates often end up serving as an obstacle, increasing the flow blockage area, thus resulting in an increase in the pressure drop. Also, these devices ensure optimized results in terms of better flow distribution/uniformity at a particular flow rate only. Furthermore, such devices also result in swirling motion of the exhaust gas.
OBJECTS OF THE INVENTION
[005] An object of the present subject matter is to provide a proper flow distribution of the incoming flow of exhaust gas, particularly after the onset of an angular downpipe evenly into the substrate face.
[006] Another object of the present subject matter is to provide a peripheral flow guiding element in an angular downpipe for proper flow distribution of the incoming flow of exhaust gas, particularly after the onset of an angular downpipe.
[007] Yet another object of the present subject matter is to provide a peripheral flow guiding element in an angular downpipe to channelize the incoming flow of the exhaust gas evenly into the substrate face.
[008] Another object of the present subject matter is to provide a peripheral flow guiding element whose deflector plate angle changes dynamically with respect to the incoming flow of the exhaust gas.
[009] Yet another object of the present subject matter is to provide a peripheral flow guiding element whose deflector plate ensures enhanced effectiveness for a wide range of exhaust gas flow rates.
[0010] Another object of the present subject matter is to provide a flow guiding element at the onset of the diffuser section for improving the SUI of an exhaust after-treatment system.

SUMMARY
[0011] Before the present subject matter is described, it is to be understood that this application is not limited to the particular machine or device, as there can be multiple possible embodiments that are not expressly illustrated in the present disclosures. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only and is not intended to limit the scope of the present application. This summary is not intended to identify essential features of the proposed subject matter nor is it intended for use in determining or limiting the scope of the proposed subject matter.
[0012] The present subject matter describes a flow guiding element to improve Surface Uniformity (SUI) of a catalytic converter. The flow guiding element comprises at least one fixed support configured for mounting the flow guiding element to the inner surface of the downpipe. At least one deflector plate is configured for guiding the flow at the desired section along the substrate face. The flexible element is configured for connecting the fixed support and the deflector plate. At least one spring is configured for providing the angular movement of the deflector plate, wherein a spring seat is configured for mounting of the spring. The deflector plate is configured to vary its mounting angle with the force of the exhaust gas flow for ensuring better catalyst performance over the entire engine operation.

BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The foregoing summary, as well as the following detailed description of embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the disclosure, there is shown in the present document example constructions of the disclosure, however, the disclosure is not limited to the specific methods and device disclosed in the document and the drawings. The detailed description is described with reference to the following accompanying figures.
[0014] Figure 1 illustrates a view of a conventional plate arrangement that is used to channelize flow to a desired surface of an exhaust after-treatment system (prior art).
[0015] Figure 2 illustrates a schematic view of a down pipe of an exhaust after-treatment system with a flow guiding element mounted in the downpipe, as per present invention.
[0016] Figure 3 illustrates a schematic view of a flow guiding element mounted in a down pipe of an exhaust after-treatment system, as per present invention.
[0017] Figure 4(a) illustrates a schematic view of a down pipe of an exhaust after-treatment system as per conventional method. (Prior art)
[0018] Figure 4(b) illustrates a schematic view of a down pipe of an exhaust after-treatment system with a flow guiding element mounted in as per present invention.
[0019] The figures depict various embodiments of the present disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures illustrated herein may be employed without departing from the principles of the disclosure described herein.

REFERRAL NUMERALS:

Element Description Reference Numeral
Downpipe 100
Flow guiding element 200
Fixed Support 202
Flexible element 204
Deflector plate 206
Spring seat 208
Spring 210

BRIEF DESCRIPTION OF THE INVENTION

[0020] The invention aims at improving Surface Uniformity (SUI) of an exhaust after-treatment system by providing a flow guiding element at an onset of a diffuser section. This invention is particularly of great importance for a system, wherein the flow enters the system in an angular manner. A deflector used in conventional exhaust after-treatment system is mounted at a certain angle. Such deflector can be used to optimize the flow at a particular flow rate only. Hence, in order to further increase the effectiveness of the conventionally known deflector, a spring-loaded deflector is proposed. The deflector of the present invention is advantageous, as an angle of a deflector plate varies with incoming flow rate of exhaust gas.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words "comprising", “having”, and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Although any devices and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary devices and methods are now described. The disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms.
[0022] Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated but is to be accorded the widest scope consistent with the principles and features described herein.
[0023] The present subject matter describes the proposed art for improving Surface Uniformity (SUI) of an exhaust after-treatment system by providing a flow guiding element at an onset of a diffuser section. This invention is particularly of great importance for the exhaust after-treatment system, wherein the flow enters the system in an angular manner from a downpipe.
[0024] While analysing the exhaust flow through the downpipe that is angular with respect to a substrate face, it is observed that the flow gets concentrated at a bottom half of the substrate face, affecting surface uniformity of a surface. This hampers catalyst conversion efficiency and leads to improper utilisation of Platinum Group Materials (PGM). A possible solution to overcome this problem is by providing a straight downpipe before the substrate entrance. However, this solution is not feasible due to packaging constraints and likely interference issues with other vehicle aggregates.
[0025] Hence, to address the above concern of improper flow distribution, particularly after the onset of the angular downpipe, the proposed invention focuses at mounting a peripheral flow guiding element. The flow guiding element is to be placed such that it channelizes the incoming flow of exhaust gas evenly into the substrate face. This enhances uniformity index without any change in the existing layout. Further, the deflector plate is placed such that, its angle changes dynamically with respect to the incoming flow of the exhaust gas. This ensures enhanced effectiveness for a wide range of exhaust gas flow rates.
[0026] Now referring to Figure 2 and Figure 3, the proposed invention is explained. As can be seen from the Figure 2 and Figure 3, a flow guiding element (200) has the following elements:
• Support Member (202): This part is joined permanently to a surface of a downpipe (100). This acts as a base element of the element (200).
• Flexible element (204): This part acts as a connecting media between the support member (202) and a deflector plate (206). It is designed such that it allows relative motion between the deflector plate (206) and the support member (202).
• Deflector plate (206): This is the element for the uniformity enhancement. It is required to guide the flow at the desired section. The mounting angle of this deflector plate (206) varies with respect to the exhaust gas flow, ensuring better catalyst performance over the entire engine operation.
• Seat (208): This space is to be provided for the mounting of a dampening component or spring (210).
• Dampening component (210): Purpose of the dampening component (210) is to allow desired movement of the deflector plate (206) in response to the incoming exhaust flow rate. Wherein the dampening component is a compressible spring (210).
[0027] Accordingly, the present subject matter discloses a flow guiding element (200) to improve Surface Uniformity (SUI) of a catalytic converter comprising: at least one fixed support (202) configured for mounting said flow guiding element (200) to the inner surface of the downpipe (100). At least one deflector plate (206) configured for guiding the flow at the desired section along the substrate face. The flexible element (204) is configured for connecting the fixed support (202) and the deflector plate (206). At least one spring (210) configured for providing the angular movement of the deflector plate (206) wherein a seat (208) is configured for mounting of the spring.
[0028] The primary function of the spring/dampening component (210) is to ensure controlled movement of the deflector plate (206) with respect to the incoming exhaust flow. The movement of the deflector plate (206) is to be regulated in a predetermined way; it compresses/expands the spring (210) in response to varying flow rate. If the flow rate is higher, the spring (210) should get compressed ensuring better flow distribution. Apart from this, the spring/dampening component (210) will also prevent the fluttering of the deflector plate (206) as the flow rate changes.
[0029] The flow guiding element (200) is configured for improving the SUI of an EAS component by providing at the onset of the diffuser section. The deflector plate (206) is configured to vary its mounting angle with the force of the exhaust gas flow for ensuring better catalyst performance over the entire engine operation. The flexible element (204) is configured for providing the angular movement of the deflector plate (204) with the incoming exhaust flow rate to optimize the exhaust flow at a particular flow rate.
[0030] The fixed support (202) is configured to be the base element of the flow guiding element (200). The flow guiding element (200) is configured for channelizing the incoming exhaust flow evenly into the substrate face to enhance the uniformity index without any change in the existing layout.
[0031] The flow deflector plate (206) with dynamically changing angle with respect to the incoming flow is configured for effectively channelizing the incoming exhaust flow for a wide range of exhaust gas flow rates.
[0032] Figure 4(b) shows the images capturing the effect of the proposed flow guide while ensuring the flow diffusion. The first image Figure 4(a) shows the existing configuration wherein majority of the flow gets concentrated at the center which can be seen from the red patch formed on the substrate face
[0033] While the Figure 4(b) shows the flow distribution, with the flow guide. As can be seen from the CFD flow analysis of the substrate face, the flow is better distributed. This can be confirmed by witnessing no hot spot formation (red patch) on the substrate face.