Description:FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10, Rule 13]

TITLE OF INVENTION
A Mounting Assembly for an Exhaust After Treatment System of a Vehicle

APPLICANT
MAHINDRA & MAHINDRA LIMITED, an Indian company, having its address at Mahindra & Mahindra Limited, Mahindra Research Valley, Mahindra World City, Plot No:41/1, Anjur P.O., Chengalpattu, Tamil Nadu – 603004

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

FIELD OF THE INVENTION
[001] The present invention relates to a mounting assembly for an Exhaust After Treatment System. More particularly, the present invention relates to a mounting assembly for an Exhaust After Treatment System of a vehicle.

BACKGROUND OF THE INVENTION
[002] Conventionally in motor vehicles, especially in diesel powered motor vehicles, an exhaust aftertreatment system (EATS) is provided to reduce the harmful exhaust emissions from the internal combustion engines and to ensure that the exhaust from the engines meet emission regulations. Typically, an EATS has a diesel oxidation catalyst portion, a mixer portion and a diesel particulate filter portion. With the increasingly stringent emission norms, the EATS have become increasingly bulkier and heavier.
[003] The EATS is required to be mounted in the vicinity of the engine. The EATS being a bulky and heavy part especially in engines with higher power configuration, and having to be overhung around the engine, make the EATS susceptible to severe vibrations during operation of the engine. To prevent the EATS from these vibrations during the operation of the engine, the EATS needs to be properly bracketed to the base of the engine or other parts of the vehicle.
[004] In one existing mounting arrangement for the EATS, the mixer portion of the EATS is supported by means of a sheet metal bracket and the diesel particulate filter portion is supported by means of a sheet metal bracket attached to a heavy cast iron bracket. In this arrangement, most of the load bearing is done by the heavy cast iron bracket. To ensure enough rigidity in the brackets, the cast iron bracket needs to be thicker and heavier, which results in the total weight of the bracketing system for mounting of the EATS being approximately 3.5 kg, which is a substantial additional weight for the vehicle.
[005] In another conventional mounting arrangement of the EATS, the mixer portion of the EATS is supported by means of a bulky sheet metal bracket and the diesel particulate filter portion is supported by means of multiple split bracket arrangements provided at different locations on the diesel particulate filter. In this arrangement, most of the load bearing is done by the multiple split brackets. Although, this arrangement reduces the overall weights of the brackets to approximately 2Kg, the presence of multiple split brackets leads to an increase in the complexity and cost of mounting of the EATS.
[006] Thus, there is a need in the art for a mounting assembly for an Exhaust After Treatment System of a vehicle which addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[007] In one aspect, the present invention provides a mounting assembly for an Exhaust After Treatment System of a vehicle. The mounting assembly includes a top mounting bracket having a first member extending horizontally and being configured to allow the Exhaust After Treatment System to be mounted on the first member. A second member extends vertically downwards from the first member and is configured to be mounted to the vehicle. A reinforcement member extends vertically along the second member and is configured to be attached to the second member. The reinforcement member has a flange that extends away from the second member, thereby imparting rigidity to the second member of the top mounting bracket.
[008] In an embodiment of the invention, the Exhaust After Treatment System includes a diesel oxidation catalyst (DOC) chamber which extends horizontally and is fluidly connected to a turbocharger of the vehicle, a selective catalyst diesel particulate filter (sDPF) chamber which extends vertically, and a mixer chamber connecting the DOC chamber to the sDPF chamber. Herein, the first member of the top mounting bracket is configured to allow the mixer chamber of the Exhaust After Treatment System to be mounted on the first member.
[009] In another embodiment of the invention, the mounting assembly has a supporting flange extending outwardly from the mixer chamber, and the first member of the top mounting bracket is configured to receive the supporting flange.
[010] In a further embodiment of the invention, the top mounting bracket includes a third member extending obliquely upwards from the first member and the third member is configured to support a delta pressure sensor.
[011] In a further embodiment of the invention, a profile of the reinforcement member is configured to match with a profile of the second member.
[012] In a further embodiment of the invention, a bending radius of the flange of the reinforcement member is at least 0.2 times of a thickness of the reinforcement member.
[013] In a further embodiment of the invention, a height of the flange of the reinforcement member is at least 1.2 times the thickness of the reinforcement member.
[014] In a further embodiment of the invention, the second member of the top mounting bracket is configured to be mounted on a cylinder head of an internal combustion engine of the vehicle.
[015] In a further embodiment of the invention, the second member and the reinforcement member of the top mounting bracket have a longitudinal slot for receiving a fastener for mounting the second member on the vehicle.
[016] In a further embodiment of the invention, the mounting assembly has a bottom mounting bracket configured for supporting the sDPF chamber of the Exhaust After Treatment System.
[017] In a further embodiment of the invention, the bottom mounting bracket extends across a width of the sDPF chamber, and the bottom mounting bracket includes through holes on the ends of the bottom mounting bracket for mounting the bottom mounting bracket on the vehicle.
[018] In a further embodiment of the invention, the bottom mounting bracket is provided at a first inclination from a mid plane axis of the sDPF chamber.

BRIEF DESCRIPTION OF THE DRAWINGS
[019] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates an Exhaust After Treatment System, in accordance with an embodiment of the invention.
Figure 2 illustrates a perspective view of a mounting assembly for the Exhaust After Treatment System, in accordance with an embodiment of the invention.
Figure 3 illustrates a perspective view of a top mounting bracket of the mounting assembly, in accordance with an embodiment of the invention.
Figure 4 illustrates an exploded view of the top mounting bracket of the mounting assembly, in accordance with an embodiment of the invention.
Figure 5 illustrates a side view of the top mounting bracket of the mounting assembly, in accordance with an embodiment of the invention.
Figure 6 illustrates a perspective view of the mounting assembly, in accordance with an embodiment of the invention.
Figure 7 illustrates the top bracket being mounted on a cylinder head, in accordance with an embodiment of the invention.
Figure 8 illustrates a bottom mounting bracket and the Exhaust After Treatment System, in accordance with an embodiment of the invention.
Figure 9 illustrates the bottom mounting bracket, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION
[020] The present invention is directed towards a mounting assembly for an Exhaust After Treatment System of a Vehicle. The mounting assembly of the present invention is typically used for a four wheeled vehicle or other multi-wheeled vehicles as required. However, it should be understood that the mounting assembly as illustrated may find its application on any other automotive or non-automotive application using an Exhaust After Treatment System.
[021] Figure 1 illustrates an Exhaust After Treatment System 10 for a Vehicle in accordance with an embodiment of the invention. As illustrated, the Exhaust After Treatment System 10 comprises a diesel oxidation catalyst (DOC) chamber 20 which extends horizontally and is fluidly connected to a turbocharger of the vehicle. The DOC chamber 20 receives the exhaust gases leaving the turbocharger. The exhaust gases that are emitted from an internal combustion engine of the vehicle are used to power a turbine of the turbocharger, and the exhaust gases are then transmitted to the DOC chamber 20. In the DOC chamber 20, the exhaust gases react with a catalyst which results in reduction of Hydrocarbon and Carbon Monoxide levels in the exhaust gases. The Exhaust After Treatment System 10 further has a mixer chamber 40 which receives the treated exhaust gases from the DOC chamber 20. In the mixer chamber 40, a diesel exhaust fluid, which comprises primarily of urea, is mixed with the exhaust gases, leading to formation of ammonia and Carbon Dioxide.
[022] The mixer chamber 40 is further connected to a selective catalyst diesel particulate filter (sDPF) chamber 30 which extends vertically. The mixer chamber 40 thus connects the DOC chamber 20 to the sDPF chamber 30. In an embodiment, the sDPF chamber 30 houses a selective catalyst, due to which, ammonia causes reduction of NOx gases in the exhaust gas to be reduced to Nitrogen Dioxide and water. Further the sDPF chamber 30 comprises particulate filters which absorb the particulate matters in the exhaust gases, after which the residual exhaust gases can be safely released into the atmosphere.
[023] Figure 2 and Figure 3 illustrates a mounting assembly 100 for the Exhaust After Treatment System 10. As illustrated, the mounting assembly 100 has a top mounting bracket 110. The top mounting bracket 110 has a first member 120 that extends horizontally. The first member 120 is configured to allow the Exhaust After Treatment System 10 to be mounted on the first member 120.
[024] The top mounting bracket 110 further has a second member 130 that extends vertically downwards from the first member 120. The second member 130 is configured to be mounted to the vehicle, thereby supporting the first member 120 and thus the Exhaust After Treatment System 10 on the vehicle. The top mounting bracket 110 further has a reinforcement member 140 that extends vertically along the second member 130. The reinforcement member 140 is configured to be attached to the second member 130. In an embodiment, the reinforcement member 140 is attached to the second member 130 by means of a welded joint. The attachment of the reinforcement member 140 to the second member 130 thus leads to an increase in cumulative thickness of the second member 130 as being the sum of thickness of the second member 130 and thickness of the reinforcement member 140, thereby leading to an increase in the rigidity of the top mounting bracket 110. In an embodiment, a profile of the reinforcement member 140 is configured to match with a profile of the second member 130.
[025] As further illustrated in Figure 4, the reinforcement member 140 further has a flange 142 that extends away from the second member 130. The flange 142 bending away from the second member 130 means that at the location of the flange 142, the cumulative local thickness of the second member 130 is increased as being the sum of thickness of the second member 130 thickness of the reinforcement member 140, and height of the flange 142. The increased cumulative local thickness thus imparts rigidity, and in particular flexural rigidity to the second member 130 of the top mounting bracket 110.
[026] In an embodiment, the flange 142 is bent away from the second member 130 such that a bending radius of the flange 142 is lower than a thickness of the reinforcement member 140. In a preferred embodiment, the bending radius of the flange 142 of the reinforcement member 140 is at least 0.2 times of the thickness of the reinforcement member 140. As a result of this, the flange 142 extends cumulative perpendicular to the reinforcement member 140. Such a sharp bend and the perpendicular extension of the flange 142 from the reinforcement member 140 ensures high strength and rigidity against bending. In an embodiment, the thickness of the second member 130 and the reinforcement member 140 ranges from 1mm to 10mm. In an embodiment, thickness of the second member 130 is 4mm, thickness of the reinforcement member 140 is 4mm, and thus the bending radius of the flange 142 is approximately 1mm. As illustrated in Figure 5, such an arrangement also allows the flange 142 to be perpendicular to a bending plane (Y-Y’) of the top mounting bracket 110, which mitigates any bend amplitude, thus providing added flexural rigidity to the top mounting bracket 110. Further, in this embodiment, a height of the flange 142 of the reinforcement member 140 is greater than the thickness of the reinforcement member 140. In an embodiment, the height of the flange 142 is at least 1.2 times of the thickness of the reinforcement member 140. In an embodiment, thickness of the second member 130 is 4mm, thickness of the reinforcement member 140 is 4mm, and thus the height of the flange 142 is approximately 5mm. As a result, the approximate cumulative local thickness of the second member 130 at the location of the flange 142 is 13mm (4mm + 4mm + 5mm), thus imparting rigidity, and in particular flexural rigidity to the second member 130 of the top mounting bracket 110.
[027] As illustrated in Figures 3 and 4, in an embodiment, the top mounting bracket 110 comprises a third member 150 extending obliquely upwards from the first member 120. The third member 150 is configured to support a delta pressure sensor. The delta pressure sensor measures the pressure difference of the exhaust gas before and after the sDPF chamber 30 or in comparison with the external atmospheric pressure. The pressure difference is then utilised to monitor the performance and loading of the sDPF chamber 30. In an embodiment, the third member 150 comprises a mounting hole 152 for receiving the delta pressure sensor and a lug 154 provided diagonally adjacent to the mounting hole 152. The lug 154 prevents any rotation of the delta pressure sensor. In this regard, the lug 154 ensures that the delta pressure sensor is held in position, especially while tightening of a bolt for mounting the delta pressure sensor onto the mounting hole 152.
[028] As illustrated in the embodiment depicted in Figure 6, the first member 120 of the top mounting bracket 110 is configured to allow the mixer chamber 40 of the Exhaust After Treatment System 10 to be mounted on the first member 120. To facilitate the mounting of the mixer chamber 40 on the first member 120, the mounting assembly 100 has a supporting flange 50 that extends outwardly from the mixer chamber 40, and the first member 120 of the top mounting bracket 110 is configured to receive the supporting flange 50, thereby supporting the mixer portion 40 on the first member 120 (shown in Figure 4). In an embodiment, the first member 120 has one or more through holes which align with one or more through holes on the supporting flange 50, thereby allowing fasteners to pass through for attaching the supporting flange 50 to the first member 120.
[029] In an embodiment as illustrated in Figure 7, the second member 130 of the top mounting bracket 110 is configured to be mounted on a cylinder head 60 of the internal combustion engine of the vehicle. To allow the mounting of the second member 130 on the cylinder head 60 or on any other part of the vehicle, the second member 130 and the reinforcement member 140 of the top mounting bracket 110 comprise a longitudinal slot 112 for receiving a fastener, thereby mounting the second member 130 and thus the top mounting bracket 110 on the vehicle.
[030] Reference is made to Figure 6, wherein as illustrated, in an embodiment, the mounting assembly 100 has a bottom mounting bracket 160 configured for supporting the sDPF chamber 30 of the Exhaust After Treatment System 10. In the present invention, since the top mounting bracket 110 has increased rigidity, the top mounting bracket 110 has increased load bearing capabilities, and thus the bottom mounting bracket 160 need to not be a bulky cast iron bracket or have split construction because load bearing requirements of the bottom mounting bracket 160 are relatively low. As further illustrated in Figure 6, and referenced in Figures 8 and 9, the bottom mounting bracket 160 extends across a width of the sDPF chamber 30. The bottom mounting bracket 160 comprises through holes on the ends of the bottom mounting bracket 160, through which the bottom mounting bracket 160 is mounted on the vehicle, thereby further supporting the sDPF chamber 30 on the vehicle.
[031] In an embodiment, as illustrated in Figure 8, the bottom mounting bracket 160 is provided at a first inclination (α) from a mid plane axis (X-X’) of the sDPF chamber 30. Such an arrangement ensures least vibration due to the overhang of the sDPF chamber 30. In an embodiment, in the present invention, the weight of the top mounting bracket is 0.39 Kg, weight of the supporting flange is 0.28Kg, and weight of the bottom mounting bracket is 0.7 Kg. Thus, the overall weight of the mounting assembly is 1.37 Kg, which is substantially lower than weights of the conventional bracket configurations. In an embodiment, the top mounting bracket 110 and the bottom mounting bracket 160 are made up of stainless steel. The top mounting bracket 110 and the bottom mounting bracket 160 can be made up of any other material that can withstand high temperature.
[032] Advantageously, the present invention provides a mounting assembly in which the overall weight of the brackets of the mounting assembly is significantly reduced. Due to the improved load bearing capabilities of the top mounting bracket, the bottom mounting bracket is provided as a simple single long member, thus eliminating the requirement of a bulky cast iron bracket or multiple split construction brackets for supporting the sDPF chamber. This not only reduces the overall weight of the vehicle, but is also more cost effective and easier to assemble.
[033] Further, unlike the split construction brackets for supporting the sDPF chamber, no major modifications to the Exhaust After Treatment System is required to accommodate the bottom mounting bracket.
[034] Furthermore, the mounting assembly of the present invention is more compact and lightweight, which not only reduces vibrations due to operation of the engine but allows for more packaging space for other vehicle components. The provision of mounting the delta pressure sensor on the top mounting bracket itself also eliminates the requirement of an additional bracket for supporting the delta pressure sensor, thus further bringing down the weight, cost and complexity of the mounting assembly.
[035] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.
, Claims:WE CLAIM:
1. A mounting assembly (100) for an Exhaust After Treatment System (10) of a vehicle, comprising:
a top mounting bracket (110) having:
a first member (120) extending horizontally and being configured to allow the Exhaust After Treatment System (10) to be mounted on the first member (120);
a second member (130) extending vertically downwards from the first member (120), the second member (130) being configured to be mounted to the vehicle; and
a reinforcement member (140) extending vertically along the second member (130), the reinforcement member (140) being configured to be attached to the second member (130), the reinforcement member (140) having a flange (142) that extends away from the second member (130), thereby imparting rigidity to the second member (130) of the top mounting bracket (110).

2. The mounting assembly (100) as claimed in claim 1, wherein the first member (120) of the top mounting bracket (110) is configured to allow a mixer chamber (40) of the Exhaust After Treatment System (10) to be mounted on the first member (120).

3. The mounting assembly (100) as claimed in claim 2, wherein the first member (120) of the top mounting bracket (110) is configured to receive a supporting flange (50) extending outwardly from the mixer chamber (40).

4. The mounting assembly (100) as claimed in claim 1, wherein the top mounting bracket (110) comprises a third member (150) extending obliquely upwards from the first member (120), the third member (150) being configured to support a delta pressure sensor.

5. The mounting assembly (100) as claimed in claim 1, wherein a profile of the reinforcement member (140) is configured to match with a profile of the second member (130).

6. The mounting assembly (100) as claimed in claim 1, wherein a bending radius of the flange (142) of the reinforcement member (140) is at least 0.2 times of a thickness of the reinforcement member (140).

7. The mounting assembly (100) as claimed in claim 1, wherein a height of the flange (142) of the reinforcement member (140) is at least 1.2 times the thickness of the reinforcement member (140).

8. The mounting assembly (100) as claimed in claim 1, wherein the second member (130) of the top mounting bracket (110) is configured to be mounted on a cylinder head (60) of an internal combustion engine of the vehicle.

9. The mounting assembly (100) as claimed in claim 1, wherein the second member (130) and the reinforcement member (140) of the top mounting bracket (110) comprise a longitudinal slot (112) for receiving a fastener for mounting the second member (130) on the vehicle.

10. The mounting assembly (100) as claimed in claim 2, comprising a bottom mounting bracket (160) configured for supporting the sDPF chamber (30) of the Exhaust After Treatment System (10).

11. The mounting assembly (100) as claimed in claim 10, wherein the bottom mounting bracket (160) extends across a width of the sDPF chamber (30), and the bottom mounting bracket (160) comprises through holes on the ends of the bottom mounting bracket (160) for mounting the bottom mounting bracket (160) on the vehicle.

12. The mounting assembly (100) as claimed in claim 11, wherein the bottom mounting bracket (160) is provided at a first inclination (α) from a mid plane axis (X-X’) of the sDPF chamber (30).

Dated this 11th day of November 2022

Mahindra & Mahindra Limited
By their Agent & Attorney

(Janaksinh Jhala)
of Khaitan & Co
Reg No IN/PA-2193