Claims:We claim:
1. A supporting structure (100) mounted on an inlet cone (101) of a catalytic converter (102) for reducing thermal stress and mechanical stress, the supporting structure (100) comprising:
a housing (103) forming a dome shaped structure that is welded on an inclined surface of the inlet cone (101) of the catalytic converter (102),
wherein the housing (103) has an outer edge (104) that includes a first portion (104a), a second portion (104b), a third portion (104c), and a fouth portion (104d), wherein the first portion (104a) is opposite to the second portion (104b) and orthogonal to the third portion (104c) and the fouth portion (104d), the third portion (104c) is opposite to the fourth portion (104d), wherein each of the first portion (104a) and the second portion (104b) have curved ends, a first curved end of each of the first portion (104a) and the second portion (104b) is connected with the third portion (104c), and a second curved end of each of the first portion (104a) and the second portion (104b) is connected with the fourth portion (104d), wherein the third portion (104c) and the fouth portion (104d) are inclined inwards in the middle, and wherein the first portion (104a), the second portion (104b), the third portion (104c), and the fouth portion (104d) form a close circuit.
2. The supporting structure (100) as claimed in claim 1, wherein a depression (204) is formed on the top region (203) and a flat surface (205) is formed on the front region (201), and wherein the flat surface (205) of the front region (201) has a plurality of holes (206, 207).
3. The supporting structure (100) as claimed in claim 2, comprises a stiffener bracket (301) that is connected to the housing (103), and is mounted to a cylinder head (302).
4. The supporting structure (100) as claimed in claim 3, wherein a first hole (206) of the plurality of holes (206, 207) secures the housing (103) to the stiffener bracket (301) using a nut and bolt (303).
5. The supporting structure (100) as claimed in claim 3, wherein a first portion (301a), of the stiffener bracket (301), that is attached to the housing (103) is of a triangular shape, wherein a second portion (301b) of the stiffener bracket (301) is of a regtangular shape and is connected to the cylinder head (302) by a plurality of fasteners (304), and wherein the first portion (301a) and the second portion(301b) are perpendicular to each other.
6. The supporting structure (100) as claimed in claim 2, wherein the second hole (207) of the plurality of holes (206, 207) is used for venting.
7. The supporting structure (100) as claimed in claim 1, wherein the housing (103) is welded with a weld bead forming a structure similar to a structure of the outer edge of the housing (103).

Description:TECHNICAL FIELD
[0001] The present subject matter described herein relates to a structure to support a catalytic converter to a cylinder head for an automobile. In particular, the present subject matter relates to a structure mounted on an inlet cone of a catalytic converter for reducing thermal stress and mechanical stress.

BACKGROUND
[0002] The emission control systems for internal combustion engines, and in particular for internal combustion engines for motor vehicles, use a catalytic converter linked between the exhaust manifold and the muffler in the engine exhaust. In general, catalytic converters take the form of a gas expansion housing containing a mixture of metal mesh and catalyst capable of exothermally decreasing nitrogen oxides while oxidizing carbon monoxide and hydrocarbons found in the engine's exhaust gases.
[0003] The catalytic converter housing is made of heavy gauge steel material, a stainless steel material, and shallow embossed ribs are often provided to enable the housing to be subject to successive expansion and contraction cycles without cracking.
[0004] Catalytic converters are protected by supporting brackets and are positioned as close to the engine as possible, in a significantly horizontal location below the frame. The catalytic converter housing consists of two half-shells that are welded together to form the entire housing. For connection to the exhaust pipe and a pipe connecting the catalytic converter to the muffler, each half-shell contains a half part of an integrally shaped annular inlet neck and outlet annular neck.
[0005] However, after a period of time, a progressive deterioration of the converter housing, of the support bracket itself, and more specifically of the weld connecting the support bracket to the converter housing on an outlet collar is observed.
[0006] In time, in view of the difference in the metallurgy of the bracket, the converter housing, fatigue, and corrosion are accelerated more precisely at the weld in the cone area that causes the support bracket and the converter outlet collar to separate. Ultimately, due to the reduction in strength of the fatigued and corroded metal of the support bracket itself, the combined effect of shock and vibrations can result in support bracket breakage.
[0007] The fix that is available when a catalytic converter support bracket fails is the complete replacement of the entire converter by a new one with an acceptable welded-on support bracket, which, in view of the high cost of catalytic converters, is a very expensive process. The support bracket welding on the catalytic shell of the catalytic converter leads to thermal stresses in weld beads, which can lead to failure under engine operating conditions.
[0008] Therefore it is required to come with a design of a structure that transfers minimum mechanical stress and thermal stress on the catalytic converter and the engine.

OBJECTS OF THE DISCLOSURE
[0009] It is therefore the object of the present disclosure to overcome the aforementioned and other drawbacks in prior method/product/apparatus.
[0010] It is a primary object of the present disclosure to provide a supporting structure to reduce thermal stress and mechanical stress on an inlet cone of a catalytic converter.
[0011] It is another object of the present disclosure to provide the supporting structure to meet the extra load bearing requirements.
[0012] It is another object of the present disclosure to make the supporting structure stiffer.
[0013] These and other objects and advantages of the present subject matter will be apparent to a person skilled in the art after consideration of the following detailed description taken into consideration with accompanying drawings in which preferred embodiments of the present subject matter are illustrated.

SUMMARY
[0014] A solution to one or more drawbacks of existing technology and additional advantages are provided through the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be a part of the claimed disclosure.
[0015] The present disclosure offers a solution in the form of a structure mounted on an inlet cone of a catalytic converter for reducing thermal stress and mechanical stress, including a housing forming a dome shaped structure is welded on an inclined surface of the inlet cone of the catalytic converter, wherein the housing has an outer edge that includes a first portion, a second portion, a third portion, and a fouth portion. The first portion is opposite to the second portion and orthogonal to the third portion and the fouth portion. The third portion is opposite to the fourth portio. Each of the first portion and the second portion have curved ends where a first curved end of each of the first portion and the second portion is connected with the third portion, and a second curved end of each of the first portion and the second portion is connected with the fourth portion, wherein the third portion and the fouth portion are inclined inwards in the middle. The first portion, the second portion, the third portion, and the fouth portion form a close circuit.
[0016] In an aspect of the invention, a depression is formed on the top region, and a flat surface is formed on the front region, and wherein the flat surface of the front region has a plurality of holes.
[0017] In another aspect of the invention, comprises a stiffener bracket that is connected to the housing, and is mounted to a cylinder head.
[0018] In another aspect of the invention, a first hole of the plurality of holes secures the housing to the stiffener bracket using a nut and bolt.
[0019] In another aspect of the invention, a first first portion, of the stiffener bracket, that is attached to the housing is of a triangular shape, a second portion of the stiffener bracket is of the regtangular shape and is mounted to the cylinder head by a plurality of fasteners, and the first portion and the second portion are perpendicular to each other.
[0020] In another aspect of the invention, the second hole of the plurality of holes is used for venting.
[0021] In another aspect of the invention, the housing is welded with a weld bead forming a structure similar to a structure of the outer edge of the housing.
[0022] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS
[0023] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the present disclosure may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:
[0024] Fig. 1 is an illustrative view of the supporting structure mounted on the catalytic converter and connected to the cylinder head.
[0025] Fig. 2 (a) is a top view of the housing.
[0026] Fig. 2 (b) is a perspective view of the housing.
[0027] Fig. 2 (c) is a front view of the housing.
[0028] Fig. 2 (d) is a back view of the housing showing forces on the back region.
[0029] Fig. 2 (e) is a back view of the housing showing forces on the plurality of side regions.
[0030] Fig. 2 (f) is a top view of the housing on the top region.
[0031] Fig. 3 is an illustrative view of the stiffener bracket mounted to the housing and the cylinder head.
[0032] The figures depict embodiments of the present subject matter for illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION
[0033] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0034] It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
[0035] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0036] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0037] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
[0038] Hereinafter, a description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the present disclosure.
[0039] Referring to FIG. 1 of the present invention, it discloses a supporting structure (100) mounted on an inlet cone (101) of a catalytic converter (102) for reducing thermal stress and mechanical stress. The supporting structure (100) supports the catalytic converter (102) to the cylinder head (302). The catalytic converter (102) has an inlet cone (101) which has an inclined shape.
[0040] The supporting structure (100) includes a housing (103) and a stiffener bracket (301). Referring to FIG. 1, the housing (103) forms a dome shaped structure and is welded on the inclined surface of the inlet cone (101) of the catalytic converter (102). The housing (103) is composed of a front region (201), a back region (202), a top region (203), and a plurality of side regions (208). With a dome shaped structure of housing (103) only an outer edge (104) of the housing is in contact with an inlet cone (101) of the catalytical convertoer and and therefore ensure minimum surcat contact with the inlet cone (101).
[0041] Further, as depicted in Fig. 1, the housing (103) has an outer edge (104) that forms a circuit. The outer edge (104) is present at the bottom side of the housing (103) and the outer edge (104) gets welded to the inlet cone (101) of the catalytic converter (102).
[0042] Further, as depicted in Fig. 1, the outer edge (104) includes a first portion (104a), a second portion (104b), a third portion (104c), and a fouth portion (104d). The first portion (104a) is opposite to the second portion (104b) and orthogonal to the third portion (104c) and the fouth portion (104d), the third portion (104c) is opposite to the fourth portion (104d). Further, each of the first portion (104a) and the second portion (104b) have curved ends, a first curved end of each of the first portion (104a) and the second portion (104b) is connected with the third portion (104c), and a second curved end of each of the first portion (104a) and the second portion (104b) is connected with the fourth portion (104d). Moreover, the third portion (104c) and the fouth portion (104d) are inclined inwards in the middle, and the first portion (104a), the second portion (104b), the third portion (104c), and the fouth portion (104d) form a close circuit. The structure of the first portion, the second portion, the third portion, and the fourth portion form a butterfly shape. The width of the housing (103) increases from top to bottom. Therefore, the top region (203) of the housing (103) has the minimum area, and the bottom region of the housing (103) has the maximum area. The outer edge (104) of the housing (103) is bent inwards and therefore results in increasing the outer edge (104) thereby maximize the surcace contact area and weld area along with ensuring sufficient clearance with the outer edge (104) and also ensuring weld gun accessibility. the stiffener bracket will be described in fig 3
[0043] Referring to Fig. 2 (a), 2 (b), 2 (c), it illustrates the housing (103) present on the inlet cone. The housing (103) has the front region (201), the back region (202), the top region (203), and the plurality of side regions (208). The outer edge (104) of the housing (103) forms a circuit and the outer edge has a butterfly shape. The outer edge (104) of the housing (103) is bent inwards to maximize the weld area along with ensuring sufficient clearance with edges and ensuring weld gun accessibility. The butterfly shape helps in covering the maximum area to weld the edge of the housing on the inclined surface of the inlet cone to reduce the stress on the housing and the stiffener bracket. Further, the housing (103) is welded with a weld bead forming a structure similar to a structure of the outer edge of the housing (103).
[0044] Therefore, the support is provided on a larger area of the inlet cone. The outer edge (104) is present at the bottom side of the housing and the outer edge (104) gets welded to the inlet cone (101) of the catalytic converter (102).
[0045] The front region has a plurality of holes. The plurality of holes is present on a flat surface that is given on the first portion. The flat surface is a mounting surface and is flat for better rigidity. The front region (201) has a flat profile and the first hole of the plurality of holes secures the housing (103) to the stiffener bracket (301) using a nut and bolt (303). The first hole is used for mounting the structure to the cylinder head. The second hole is present side by side to the first hole.
[0046] The second hole is used for attaching a jig to the supporting structure (100) for holding and assembling purposes. The second hole is also used as a vent in dispersing out the hot air that gets entrapped in the housing (103). The top region (203) on the housing (103) has a depression (204) that is formed on the top region (203).
[0047] Referring to Fig. 3, a stiffener bracket (301) is connected to the housing (103) and is further mounted to a cylinder head (302). As depicted in Fig. 3, a first portion (301a), of the stiffener bracket (301), is attached to the housing (103) and has a triangular shape. Further, as depicted in Fig. 3, a second portion (301b) of the stiffener bracket (301) is of rectangular shape and is connected to the cylinder head (302) by a plurality of fasteners (304). Further, the first portion (301a) and the second portion (301b) of the stiffener bracket (301) are perpendicular to each other. The stiffener bracket has three holes for mounting. The mounting is done using fasteners such as nuts and bolts. The first hole mounts the housing (103) to the stiffener bracket (301). The other two hole mounts the stiffener bracket (301) to the cylinder head (302).
[0048] The nut and bolt (303) connect the housing (103) to the stiffener bracket (301). Then the forces move from the nut and bolt (303) to the stiffener bracket (301). The stiffener bracket (301) further includes a plurality of fasteners (304) such as nuts and bolts that mount the structure (100) to the cylinder head (302) and provide rigidity. The rigidity is mainly induced from the butterfly-shaped outer edge (104) welding.
[0049] Referring to Fig. 2 (d), 2 (r), 2 (f), it illustrates the movement of the forces to provide rigidity by making use of the structure. In Fig. 2 (d), the back portion and the outer edge (104) of the housing (103) are illustrated. The outer edge (104) forms a butterfly shape. The butterfly shape increases the weld area to reduce the stress on the housing (103) and the stiffener bracket (301).
[0050] The forces derived from the weld area then move from the outer edge (104) and move to the back region (202) and further move towards the top region (203) as illustrated in Fig. 2 (f). The top region (203) has a depression (204) that transfers the forces coming from the back region (202) down to the nut and bolt (303) mounted on the first hole of the stiffener bracket (301). The curved region of the depression (204) transmits and streamlines the forces down to the stiffener bracket (301). The forces from the plurality of side regions (208) move upwards to the nut and bolt (303) mounted on the first hole (206) on the front region (201) of the housing (103). Such movement of the forces along of the structure of the dome shaped structure of the housing (103) results in uniform distribution of stress towards the nut and bolt (303).
[0051] Further, the forces attained from the outer edge (104) move towards the front region (201), the back region (202), the top region (203), and the plurality of side regions (208) and enter the stiffener bracket (301). The forces are transferred to the cylinder head (302) by the plurality of fasteners (304) and thereby the stress from the housing (203) and the stiffener bracket (301) is further reduced and rigidity is maintained on the supporting structure (100).
TECHNICAL ADVANTAGES
[0052] With the help of the solution as proposed herein in the context of the present disclosure, the mounting bracket improves the stiffness and better load-transfer ability for the engine.
[0053] The present disclosure further provides the supporting structure for reducing thermal stress and mechanical stress induced on the cylinder and the catalytic converter, thereby satisfying various structural and operational requirements and parameters.
[0054] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation, no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to disclosures containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. Also, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general, such construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to “at least one of A, B, or C, etc.” is used, in general, such construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
[0055] It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present disclosure contemplates all of these combinations. Also, while a feature of the present disclosure may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present disclosure. The present disclosure also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature.