DESC:TECHNICAL FIELD
[001] The embodiments herein generally relate to exhaust system in vehicles and more particularly, to a deflector in an exhaust after treatment device of a vehicle and a method for uniform distribution of exhaust gas flow along at least a portion of at least one catalyst substrate in an exhaust after treatment device.
BACKGROUND
[002] Generally, catalytic converter is an exhaust after treatment device, which is fitted right after the exhaust port in an internal combustion engine. This device shall control the toxic pollutants of the engine exhaust gas by catalytic reaction (oxidation or reduction). General guideline for choosing catalytic converter (herein after catcon) brick volume in gasoline engine is approx. equivalent size of volume of engine. Though Nobel materials are used in the catalytic converters to control the pollutants, the cost of the material is very high. Catalytic converter size and shape are playing major role in engine emission, performance and packaging.
[003] In larger bore engines, the higher mass flow rate of exhaust gas through the small diameter exhaust pipe will lead to higher velocity of exhaust gas. This higher velocity of exhaust gas will flow through the catalytic convertor (catcon) in some particular area. The flow of higher velocity exhaust gases is non-uniform.
[004] The harmful emissions from engines (such as oxides of nitrogen, hydrocarbons, and carbon monoxide) are because of incomplete combustion. In recent, the catalytic converters substrate is coated with platinum, rhodium, or palladiums which are noble metals. Due to non-uniform exhaust gas flow inside the catalytic converter, the outer most region of catalyst substrate is less reactant to the emission thereby leading to reduced conversion rate of harmful gases which is undesirable.
[005] In a 625 cc single cylinder gasoline engine, the bore size is big i.e. 93mm, because of the bigger bore size of the engine, the velocity of the exhaust gases is high. Though exhaust gas velocity can be reduced by increasing the exhaust pipe diameter, the exhaust pipe diameter is limited by valve diameter. Further, bigger diameter of exhaust pipe affects the performance of the engine. Because of exhaust gas higher velocity, exhaust gases are passing through only center portion of catalytic convertor (catcon) substrate thereby resulting in incapable to utilize the maximum volume of substrate (high precious material) to get the maximum efficiency of the catalytic converter. With less uniformity index, meeting emission regulations is challenging. As the high velocity exhaust gas is flowing particularly through the center portion of the catalyst substrate, the catcon substrate is eroding. One of the ways to address this issue is by increasing the catalyst substrate size. By increasing the size of catalyst substrate, the cost of catcon goes high since precious material (platinum, rhodium and palladium) is used. Increasing the size of the catalyst substrate also leads to increase in the back pressure of the engine which effects performance of the engine. So the better way to address this is increasing the uniformity index as much as possible which is difficult and is one of the challenges faced by the original equipment manufacturers.
[006] Therefore, there exists a need for a deflector in an exhaust after treatment device, which obviates the aforementioned drawbacks. Further, there exists a need for a method for uniform distribution of exhaust gas flow along at least a portion of at least one catalyst substrate in an exhaust after treatment device. Furthermore, there exists a need for a catalytic converter, which obviates the aforementioned drawbacks.

OBJECTS
[007] The principal object of an embodiment of this invention is to provide a deflector in an exhaust after treatment device, which deflects the exhaust gas flow in the after treatment device to facilitate uniform distribution of exhaust gases flow along at least a portion of at least one catalyst substrate in the exhaust after treatment device.
[008] Another object of an embodiment of this invention is to provide a method for uniform distribution of exhaust gas flow along at least a portion of at least one catalyst substrate in an exhaust after treatment device.
[009] Another object of an embodiment of this invention is to provide a deflector in an exhaust after treatment device, which increases the life of catalyst substrate in the exhaust after treatment device.
[0010] Another object of an embodiment of this invention is to provide a deflector in an exhaust after treatment device, which increases the efficiency of the exhaust after treatment device.
[0011] Another object of an embodiment of this invention is to provide a deflector for improving uniformity index in an exhaust after treatment device.
[0012] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF DRAWINGS
[0013] The embodiments of the invention are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0014] Fig. 1 depicts a perspective view of a deflector provided inside an inlet cone of a catalytic converter, according to an embodiment of the invention as disclosed herein;
[0015] Fig. 2 depicts a perspective view of the deflector and a portion of the catalytic converter, according to an embodiment of the invention as disclosed herein; and
[0016] Fig. 3 depicts a flowchart showing the steps of a method for uniform distribution of exhaust gas flow in an exhaust after treatment device, according to an embodiment of the invention as disclosed herein.


DETAILED DESCRIPTION
[0017] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0018] The embodiments herein achieve a deflector in an exhaust after treatment device, which deflects the exhaust gas flow in the after treatment device to facilitate uniform distribution of exhaust gases flow along at least a portion of at least one catalyst substrate in the exhaust after treatment device. Referring now to the drawings, and more particularly to Figs. 1 through 3, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0019] Fig. 1 depicts a perspective view of a deflector 100 provided inside an inlet cone 10I of a catalytic converter 10, according to an embodiment of the invention as disclosed herein. Fig. 2 depicts a perspective view of the deflector 100 and a portion of the catalytic converter 10, according to an embodiment of the invention as disclosed herein. In an embodiment, the deflector 100 is used to deflect the exhaust gas flow in the after treatment device 10 to facilitate uniform distribution of exhaust gas flow along at least a portion of at least one catalyst substrate in the exhaust after treatment device 10. In an embodiment, the deflector 100 has a main deflecting body 102, a plurality of deflecting baffles 104 and a plurality of mounting legs 106. For the purpose of this description and ease of understanding, the deflector 100 is configured to be provided inside an inlet cone 10I of an exhaust after treatment device 10 such as a catalytic converter. However, it is also within the scope of the invention to provide the deflector 100 in any other exhaust after treatment devices for deflecting the exhaust gas flow inside the exhaust after treatment device without otherwise deterring the intended function of the deflector 100 as can be deduced from the description and corresponding drawings.
[0020] In an embodiment, the main deflecting body 102 and the plurality of deflecting baffles 104 are adapted to deflect the exhaust gas flow in the exhaust after treatment device 10 to facilitate uniform distribution of exhaust gas flow along at least a portion of at least one catalyst substrate in the exhaust after treatment device 10. The main deflecting body 102 of the deflector 100 substantially defines a cone shape configuration. It is also within the scope of the invention to provide the main deflecting body 102 in any other shape and configuration without otherwise deterring the intended function of the main deflecting body 102 as can be deduced from the description and corresponding drawings. Each deflecting baffle 104 is parallel and spaced away with respect to the other. Each deflecting baffle 104 is configured to extend between corresponding inner portion of the main deflecting body 102. The plurality of mounting legs 106 is used to mount the deflector 100 inside the inlet cone 10I of the exhaust after treatment device 10. Each mounting leg 106 is configured to outwardly extend from the main deflecting body 102 in a direction towards corresponding inner portion of the inlet cone 10I of the exhaust after treatment device 10. The exhaust after treatment device 10 is at least a catalytic converter 10. In another embodiment, the catalytic converter 10 includes at least one inlet cone 10I, at least one catalyst substrate (not shown) and a deflector 100.
[0021] Fig. 3 depicts a flowchart showing the steps of a method 200 for uniform distribution of exhaust gas flow in an exhaust after treatment device 10, according to an embodiment of the invention as disclosed herein. In an embodiment, the method 200 for uniform distribution of exhaust gas flow in an exhaust after treatment device 10 is as follows. The method 10 comprising, deflecting the exhaust gas flow in the exhaust after treatment device 10 through at least one deflector 100 to facilitate uniform distribution of exhaust gas flow along at least a portion of at least one catalyst substrate in the exhaust after treatment device 10 (step 12). Further, the method 200 comprises, providing the deflector 100 with at least one main deflecting body 102 and a plurality of deflecting baffles 104 for deflecting the exhaust gas flow in the exhaust after treatment device 10 to facilitate uniform distribution of exhaust gas flow along at least a portion of at least one catalyst substrate of the exhaust after treatment device 10 (step 12a). Furthermore, the method 200 comprises, providing the deflector 100 with a plurality of mounting legs 106 adapted to mount the deflector 100 inside an inlet cone 10I of the exhaust after treatment device 10 (step 12b).
[0022] Therefore, a deflector 100 and a method 200 for deflecting the exhaust gas flow in an exhaust after treatment device 10 for uniform distribution of exhaust gas flow along at least a portion of at least one catalyst substrate in the exhaust after treatment device 10 is provided.
[0023] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
,CLAIMS:We claim,
1. A deflector 100 in an exhaust after treatment device 10, said deflector 100 having:
a main deflecting body 102 adapted to deflect exhaust gas flow in the exhaust after treatment device 10 to facilitate uniform distribution of exhaust gas flow in the after treatment device 10.
2. The deflector 100 as claimed in claim 1 having a plurality of deflecting baffles 104 adapted to deflect exhaust gas flow in the exhaust after treatment device 10 to facilitate uniform distribution of exhaust gas flow along at least a portion of at least one catalyst substrate in the exhaust after treatment device 10.
3. The deflector 100 as claimed in claim 2 wherein each of said deflecting baffle 104 is parallel and spaced away with respect to the other; and
each of said deflecting baffle 104 is configured to extend between corresponding inner portion of said main deflecting body 102.
4. The deflector 100 as claimed in claim 3 having a plurality of mounting legs 106 adapted to mount said deflector 100 inside an inlet cone 10I of the exhaust after treatment device 10.
5. The deflector 100 as claimed in claim 4 wherein each of said mounting leg 106 is configured to outwardly extend from said main deflecting body 102 in a direction towards corresponding inner portion of the inlet cone 10I of the exhaust after treatment device 10.
6. The deflector 100 as claimed in claim 5 wherein said main deflecting body 102 substantially defines a cone shape configuration.
7. The deflector 100 as claimed in claim 6 wherein said main deflecting body 102 and each of said deflecting baffle 104 are adapted to deflect the exhaust gas flow in the exhaust after treatment device 10 to facilitate uniform distribution of exhaust gas flow along at least a portion of at least one catalyst substrate of the exhaust after treatment device 10.
8. The deflector 100 as claimed in claim 7 is configured to be provided inside an inlet cone 10I of a catalytic converter 10.
9. A method 200 for uniform distribution of exhaust gas flow in an exhaust after treatment device 10, said method 200 comprising:
deflecting the exhaust gas flow in the after treatment device 10 through at least one deflector 100 to facilitate uniform distribution of exhaust gas flow in the exhaust after treatment device 10.
10. The method 200 as claimed in claim 9 comprising,
providing the deflector 100 with a main deflecting body 102 and a plurality of deflecting baffles 104 for deflecting the exhaust gas flow in the exhaust after treatment device 10 to facilitate uniform distribution of exhaust gas flow along at least a portion of at least one catalyst substrate of the exhaust after treatment device 10; and
providing the deflector 100 with a plurality of mounting legs 106 adapted to mount the deflector 100 inside an inlet cone 10I of the exhaust after treatment device 10.
11. A catalytic converter 10 comprising:
at least one inlet cone 10I;
at least one catalyst substrate; and
a deflector 100 having a main deflecting body 102 adapted to deflect the exhaust gas flow to facilitate uniform distribution of exhaust gas flow along at least a portion of said catalyst substrate.
12. The catalytic converter 10 as claimed in claim 11, wherein said deflector 100 has,
a plurality of deflecting baffles 104 adapted to deflect the exhaust gas flow to facilitate uniform distribution of exhaust gas flow along at least a portion of said catalyst substrate; and
a plurality of mounting legs 106 adapted to mount said deflector 100 inside said inlet cone 10I.