Title of Invention

"AN UNDERFLOOR CATALYST ASSEMBLY FOR AN AUTOMOBILE"

Abstract The invention provides for an underfloor catalyst assembly (10) for an automobile, comprising: • a catalyst carrier (11) of a honeycomb structure for purifying an exhaust gas by means of a catalyst coated thereon; • a mat (12) for supporting the catalyst carrier; • a sealing member (13) for preventing corrosion of the mat; • a shell (14) encompassing the catalyst carrier and the mat therein; • a cover (15) for protecting the catalyst assembly from thermal damages and impacts; • a front flange part (16) connected to an exhaust pipe of said automobile in a longitudinal direction of the automobile; and • a front pipe (16b) connecting the front flange to the shell, wherein the front flange slants toward the catalyst carrier for approach of a working tool from a lower side when the catalyst assembly is attached to an exhaust pipe of said automobile. Figure 1
Full Text THE PRESENT INVENTION RELATES TO AN
UNDERFLOOR CATALYST ASSEMBLY FOR AN AUTOMOBILE
CR0SS-R15FERENCE TO RELATED APPLICATION{S) [001] This application claims priority of Korean Application No. 10-20()3-0101441, filed on December 31, 2003, the disclosure of which is incorporated fully herein by reference.
TECHNICAL FIELD OF THE INVENTION
[002] Generally, the present invention relates to an undertloor catalyst assembly for an automobile. More particularly the underfloor catalyst assembly includes a compact-structured flange that allows relatively easy access from a side of the catalyst assembly and positioning of the catalyst assembly close to an engine so that the catalyst rapidly reaches Light-Off Temperature (LOT). Furthermore, the calalyst assembly includes a catalyst carrier having a circular cross-section for uniform How distribution of exhaust gasses.
BACKGROUND OF THE INVENTION
[003] Typically, an underfloor catalyst assembly of an automobile is exposed under
extreme circumstances, such as noise, thermal expansion due to high temperature,
corrosion by exhaust gasses, etc. Taking these conditions into consideration, various
kinds of catalyst assemblies have been developed. For example, in .lapancsc
patent laid-open No. 2002-97942, there is provided a cylindrical catalyst converter for prc\enting a shroud and an outer container from being damaged by thermal expansion.
[004] According to Japanese patent laid-open No. 1 1 -270335, there is provided a calahst converter capable of reducing noise and enhancing insulation. Furthermore, this design absorbs the difference of themial expansion between diffuscrs and the catalyst converter by eliminating a procedure of integrally welding the front and rear diffusers to the catalyst converter.
[005] Japanese patent laid-open No. Hei 11-50839 discloses a cover for a catalyst converter having a mounting flange, which enables reduction in noise and weight while ensuring sufficient mechanical strength. Furthermore, according to Japanese patent laid-open No. Hei 7-180544, there is provided a catalyst converter capable of achieving a desired air-tight casing without addition of component by providing a protector with the casing.
[006] Accordingly, a conventional underflloor catalyst assembly includes two catalyst carriers of a honeycomb structure for purification of exhaust gas by means of a catalyst coated thereon. Two mats that are capable of supporting the catalyst carriers, four sealing members capable of preventing corrosion of the mats configured in such a manner that the mats are not exposed to the exhaust gas, Furthemiore, a shell encompasses the catalyst earners and the mats while a cover prevents thermal and impact damage to the assembly. A rear flange part and a front flange part connect to the exhaust pipe in a substantially longitudinal direction of the vehicle and a pipe. [007] Because purification performance of an underfloor catalyst assembly is generally optimized at over 350 °C, it is preferable to dispose the catalyst assembly close to the engine in order to reduce a preheating time. It is further preferable to reduce themial capacity of the catalyst assembly so as to minimize any loss of heat. |008| In the conventional underfloor catalyst assembly, because fabrication of the catalyst assembly is generally perfonned at a side of an exhaust pipe, it is necessary to ensure a working space of approximately 20()mm m length in order to prevent an interference between a working tool and other elements of the vehicle, such as a power-steering gear box, a stabilizer bar, and a drive shaft. This means the catalyst assembly should be inevitably located away from an engine by at least 200 mm, Considering the fact that two catalyst carriers are often disposed withm a certain interval, there is a possibility to compact the structure of the catalyst assembly. furrthermore, the conventional catalyst assembly is disadvantageous in that the outlay increases due to the additional sealing member in comparison with a catalyst assembly having one catalyst earner.
[0091 Since flow distribution of exhaust gasses is not uniform in a cross section of a conventional catalyst carrier having an elliptical shape, a desired preheating effect of the catalyst assembly and a desired puriflcability of the exhaust gasses is not achieved. In order to compensate the preheating effect and puriflcability, an increase of volume is additionally required. However, an increase in the overall volume of the catalyst assembly leads to a disadvantage in aspects of economy. Furthermore, the typical clinching mechanism of couphng structure for the shell and the cover is not secure and the components often loosen during use.
SUMMARY OF THE INVENTION
[0010] Embodiments of the present invention provide an underlloor catalyst assembly for an automobile capable of overcoming the disadvantages in the conventional art. A primary object of the present invention is to provide an underlloor catalyst assembly for an automobile having a compact-structured flange which allows easy access by a working tool from a side of the catalyst assembly when the flange of the catalyst assembly is coupled to an exhaust pipe. The catalyst assembly is also positioned close to an engine so that a catalyst coated thereon rapidly reaches a LOT. [00ll] Another objection of the present invention is to provide an underfloor catalyst assembly having a catalyst carrier with a circular cross-section for uniform How distribution of an exhaust gas therein. Thereby, the purificability of the catalyst assembly is improved while the overall volume is reduced and production cost is reduced.
10012] According to an embodiment of the underfloor catalyst assembly a catalyst carrier of a honeycomb structure capable of purifying an exhaust gas by means of a catalyst coated thereon includes a mat for supporting the catalyst earner and a seahng member for preventing corrosion of the mat. A shell encompasses the catalyst carrier and the mat therein and a cover prevents thermal and impact damages from being transferred to the catalyst assembly. A front pipe and a front llange part are connected to an exhaust pipe in a substantially longitudinal direction of the vehicle, wherein the front flange slants toward the catalyst carrier such that easy access for a working tool from a lower side is generated when the catalyst assembly is attached to an exhaust pipe. Furthermore, the front pipe is integrally formed with the front llange.
[0013] The catalyst carrier is fonned in a single structure so that the numbers of relevant components, such as the mat for supporting the catalyst carrier and the sealing member for preventing corrosion of the mat can be reduced, the catalyst carrier preferably has a substantially circular cross section for achieving a uniform flow distribution in its cross section. The corner portions of both sides of the shell and the cover are surrounded by a fixing part of the cover in a clinching structure.
The present invention provides for an underfloor catalyst assembly for an automobile, comprising:
• a catalyst carrier of a honeycomb structure for purifying an exhaust gas by means of a catalyst coated thereon;
• a mat for supporting the catalyst carrier;
• a sealing member for preventing corrosion of the mat;
• a shell encompassing the catalyst carrier and the mat therein;
• a cover for protecting the catalyst assembly from thermal damages and impacts;
• a front flange part connected to an exhaust pipe of said automobile in a longitudinal direction of the automobile; and



a front pipe connecting the front flange to the shell, wherein the front flange slants toward the catalyst carrier for approach of a working tool from a lower side when the catalyst assembly is attached to an exhaust pipe of said automobile.

BRfEF DESCRIPTION OF THE DRAWINGS
[0014] The aforementioned aspects and other features of the present invention will be
explained in the following description, taken in conjunction with the accompanying
drawings, wherein:
[0015] FIG. 1 is a perspective view illustrating an underlloor catalyst assembly for an
automobile according to an embodiment of the present invention;
[0016] FIG. 2 is a front view illustrating an underfloor catalyst assembly for an
automobile according to an embodiment of the present invention;
10017] FIG. 3 is a lateral view illustrating an underlloor catalyst assembly for an
automobile according to an embodiment of the present invention;
[0018] FIG. 4 is a graph of an infirmity index of an exhaust How distribution of an
underlloor catalyst assembly for an automobile according to an embodiment of the
present invention;
[0019[ FIG. 5 is a view illustrating a thermal strain degree of an underfloor catalyst
assembly for an automobile according to an embodiment of the present invention;
[0020] FIG. 6 is a view illustrating a back pressure with respect to a revolution of an
engine of an underfloor catalyst assembly for an automobile according to an
embodiment the present invention;
[0021] FIG. 7 is a view illustrating a connection work of a front flange and a pipe of an
exhaust system of an underfloor catalyst assembly for an automobile according to an
embodiment of the present invention; and
[00221 FIG. 8 illustrates a coupling structure of a shell and a cover oi'an underfloor
catalyst assembly for an automobile according to an embodiment of the present
invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] According to FIG. I, the underfloor catalyst assembly 10 includes a compact structured flange 16 which allows a working tool easy access to the catalyst assembly 10 from the side of the catalyst assembly 10 when the flange 16 of the catalyst assembly 10 is coupled to an exhaust pipe 200 (FIG. 7) of a vehicle. Such a flange 16 further enables the catalyst assembly 10 to be positioned close to an engine so that a catalyst compound within the catalyst assembly 10 rapidly reaches to Light-Off Temperature (LOT). In addition, the catalyst assembly 10 includes a catalyst carrier 11 having a
substantially circular cross-section for uniform flow distribution of exhaust gas therethrough,
[00241 As shown in FIGS. 1-3, the underfloor catalyst assembly 10 includes a catalyst carrier 11 having a honeycomb structure, which purifies exhaust gasses by means of a catalyst coated thereon. A front flange part 16 is connected to an exhaust pipe 200 in a substantially longitudinal direction of the vehicle. A mat 12 is provided to tlmily support the catalyst carrier 11. The mat 12 is furnished with a sealing member 13 capable of preventing corrosion thereof by preventing the mat 12 from being exposed to the exhaust gasses. A cover 15 is further provided to protect the catalyst assembly from thermal and impact damages. Encompassing the catalyst carrier 11 and the mat 12 is a shell 14. A front flange part 16 connected to an exhaust pipe 200 and a rear front flange 17 is formed at both ends of the catalyst assembly 10.
[0025| According to an embodiment the catalyst carrier 11 is implemented in an intensive structure that two constructions are integrated into one construction. Therefore, the mat 12, supporting the catalyst carrier 11, is also formed in a single structure. Two sealing members 13 are installed at both ends of the mat 12 while preventing permeation of an exhaust gas to the mat 12. In the catalyst carrier 11, a circular cross section is adopted in order to achieve a unsform flow distribution in the cross section of the catalyst carrier 11. Therefore, it is possible to reduce the volume of the catalyst carrier 12 as compared to the conventional catalyst carrier having an elliptical cross section. Furthermore, the structure of the catalyst carrier 11 is compacted, so that the numbers of mats 12 and sealing members 13 are decreased, thereby leading to a reduction in the overall size of the underfloor catalyst assembly 10. Also, the sizes of the shell 14 and cover 15 can be accordingly reduced.
[00261 According to FIG. 4, an embodiment of the catalyst assembly 10 employs a substantially circular cross section such that the flow distribution of the exhaust gasses reaches a uniformity index of about 0.972 as compared with the conventional index of about 0.877. Furthermore, the total volume is changed from about 1.8L to about 1.52L in the present invention with a circular cross section structure. As shown in FIG. 5, in view of the thermal strain degree based on the change to the circular cross section structure, it is possible to achieve about 60% improvement (0.S6->0.27: maximum strain degree), such that durability is excessively increased.
[0027] As shown in FIG. 6, an increase in back pressure is prevented by adopting the
catalyst carrier 11 formed of low cell/thin cell having a lower flow resistance. The
perfonnance of the uiiderfloor catalyst assembly 10 depends on the speed of activation of the catalyst compound. Therefore, it is advantageous that the temperature reaches the activation temperature (LOT) as soon as possible. Accordingly, as shown in FIG. 7, the flange structure and a fixing unit are configured in a compact size in such a manner that a fabricating work is performed at the side of the underfloor catalyst assembly 10 for connecting the front flange unit 16 to the exhaust pipe 200. Therefore, the underlloor catalyst assembly 10 is positioned adjacent the engine of the vehicle without interfering with other components of the vehicle, such as, a power steering gear box, a stabilizer bar, drive shaft, or the like. According to an embodiment, the front flange part 16 is preferably formed by integrally connecting a cast type flange 16a to the front pipe 16b. The front flange part 16 is also preferably connected to the shell 14. [0028] The front flange part 16 slants toward the catalyst assembly 1 ! by approximately 20 degrees such that a working tool 300 (FIG. 7) can be easy inserted or approached from a lower side when the catalyst assembly is attached to the exhaust pipe 200 of the vehicle. Namely, the lower part of the pipe 16b of the front flange part 16 is relatively longer than the upper part of the same so as to facilitate access by the working tool 300. The front end of the pipe 16b has an inclined structure. Mloreover, the pipe 16b and the flange 16a can be integrally formed.
[0029] The front flange 16a is further furnished with a fixing means such as bolts and
nuts for fastening the same to the vehicle, the fastening procedure being perfbmied at
the side of the catalyst assembly 10. Since the underfloor catalyst assembly 10 is
closely positioned to an engine, the LOT performance of the catalyst assembly 10 is improved. Therefore, the catalyst assembly may be substituted by an inexpensive device containing a very small amount of precious metal. According to a preferred embodiment, a Pt catalyst may be substituted by a Pd catalyst, while maintaining the same purificability as that of the conventional art. Consequently, fabrication cost can be reduced.
[0030] As shown in FIG. 8, the clinching method for coupling the cover 15 to the shell 14 is directed to a method in which both sides of the shell 14 are covered by the cover 15. A stable fixing is achieved by changing the position and shape of the clinching portion. Therefore, additional welding work is eliminated in the present invention. Namely, in the conventional art, the cover I 50 is clinched only to a straight 3-secfion (front/center/rear straight sections of shell) at both sides of the slieli I 4, so that the clinched fixing part 151 may be damaged and widened by an exlernal impact and is
escaped from the shell 140 and thereby generates much noise. Therefore, in the conventional art, a certain measurement is urgently needed. How ever, according to an embodiment of the present invention, at least one corner portion (14a) of both sides of the shell 14 is clinched by the fixing part 15a of the cover 15 for thereby achieving a very stable structure so that additional coupling work is not needed.
[0031] According to another embodiment, the underfloor catalyst assembly includes a compact-structured flange which allows a working tool easy access site from the side of the catalyst assembly when the flange of the catalyst assembly is coupled to the exhaust pipe. The compact-structured flange further enables the catalyst assembly to be mounted close up to the engine so that the catalyst rapidly reaches a Light-Off Temperature. In addition, the catalyst assembly comprises a catalyst carrier with a circular cross-section for uniform flow distribution of exhaust gasses therein, whereby the overall volume of the catalyst assembly can be reduced from the conventional catalyst assemblies without lowering of purificability of exhaust gasses. [0032] As compared to the conventional catalyst assemblies, the present invention has the following improvements and advantages. Even though the volume of the catalyst carrier is changed from about 1.8L to about 1.52L, the LOT performance and purificability of the catalyst assembly is improved and the back pressure is maintained at the substantially same level. Furthennore, by reducing the number of mats needing fabrication, the procedure for covering the catalyst carrier with mats can be simplified. A compacted structure of the front flange enables bypassing the welding process between the front flange and the front pipe. Furthermore, additional welding processes are eliminated by improving the structure of the cover clinching structure. By adopting a catalyst carrier of single structure, many of the relevant components, such as mats and sealing members, can be significantly reduced, thereby leading to reduction in the outlay.








We claim:-
1. An underfloor catalyst assembly (10) for an automobile, comprising:
• a catalyst carrier (11) of a honeycomb structure for purifying an exhaust gas by means of a catalyst coated thereon;
• a mat (12) for supporting the catalyst carrier;
• a sealing mernber (13) for preventing corrosion of the mat;
• a shell (14) encompassing the catalyst carrier and the mat therein;
• a cover (15) for protecting the catalyst assembly from thermal damages and impacts;
• a front flange part (16) connected to an exhaust pipe of said automobile in a longitudinal drrection of the automobile; and
• a front pipe (16b) connecting the front flange to the shell, wherein the front flange slants toward the catalyst carrier for approach of a working tool from a lower side when the catalyst assembly is attached to an exhaust pipe of said automobile.

2. The underfloor catalyst assembly as claimed in claim 1, wherein the catalyst carrier is a single structure to reduce the number of the mat supporting the catalyst carrier and the sealing member preventing corrosion of the mat.
3. The underfloor catalyst assembly as claimed in claim 2, wherein the catalyst carrier has a circular cross section for achieving a uniform flow distribution in cross section thereof.
4. The underfloor catalyst assembly as claimed in claim 1, wherein the front flange part comprises a fixing means for coupling to the exhaust pipe.
5. The underfloor catalyst assembly as claimed in claim 1, wherein at least a corner portion of both sides of the shell and the cover is surrounded by a fixing part of the cover in a clinching structure.
6. The underfloor catalyst assembly as claimed in claim 1, wherein the front flange is disposed adjacent to a power steering gear box at a front side of said automobile.
7. The underfloor catalyst assembly as claimed in claim 1, wherein the front flange is disposed adjacent to a stabilizer bar at a front side of said automobile.
8. The underfloor catalyst assembly as claimed in claim 1, wherein the front flange is disposed adjacent to a drive shaft at a front side of said automobile.
9. The underfloor catalyst assembly as claimed in any of claims 1, 2 or 3, wherein said front pipe is integrally formed with the front flange.
10. An underfloor catalyst assembly for an automobile substantially as herein described with reference to the accompanying drawings.

Documents:

2455-del-2004-abstract.pdf

2455-del-2004-claims.pdf

2455-del-2004-complete specification(as files).pdf

2455-del-2004-complete specification(granted).pdf

2455-del-2004-correspondence-others.pdf

2455-del-2004-correspondence-po.pdf

2455-del-2004-description (complete).pdf

2455-del-2004-drawings.pdf

2455-del-2004-form-1.pdf

2455-del-2004-form-19.pdf

2455-del-2004-form-2.pdf

2455-del-2004-form-3.pdf

2455-del-2004-form-5.pdf

2455-del-2004-gpa.pdf

2455-del-2004-petition-137.pdf

2455-del-2004-petition-138.pdf

abstract.jpg


Patent Number 244276
Indian Patent Application Number 2455/DEL/2004
PG Journal Number 49/2010
Publication Date 03-Dec-2010
Grant Date 26-Nov-2010
Date of Filing 09-Dec-2004
Name of Patentee HYUNDAI MOTOR COMPANY
Applicant Address 231, YANGJAE-DONG, SEOCHO-KU, SEOUL, KOREA.
Inventors:
# Inventor's Name Inventor's Address
1 KIM SANG BEOM LG VILLAGE 304-1901, GEUMGOK-DONG 530, GWONSEON-GU, SUWON-SI, GYEONGGI-DO, KOREA.
PCT International Classification Number F01N 3/28
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2003-101441 2003-12-31 Republic of Korea