AU3518101A - Catalytic converter for a tailpipe including apparatus for relieving back pressure - Google Patents

Description

1,7/04/2'001 14: 33 17/4/261 14:33 +613-990-1337 A PATENT ATT/H&H INSUR PAGE 04/55 (I +613 9890 1337

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD

PATENT

ORIGINAL

Applicant(s): MARK TIMKO Actual Inventor(s): Mark Timko Address for Service: PATENT ATTORNEY

SERVICES

26 Ellingworth Parade Box Hill Victoria 3128 Australia Title: CATALYTIC CONVERTER FOR A TAILPIPE INCLUDING APPARATUS FOR RELIEVING BACK PRESSURE Associated Provisional Applications: No(s).: The following statement is a full description of this invention, including the best method of performing it known to me/us:- RECEIVED TIME RCIE TME 17. A PR. 14 :4 2 PRINT TIME 17. APR. 15 :17 1,7/04/2,001 14:33 +613-9890--1337 1 PATENT ATT/H&H INSUR PAGE 05/55 +613 9890 1337 la CATALYTIC CONVERTER

FOR

A TAILPIPE INCLUDING

APPARATUIS

This invention relates to a tailpipe catalytic! converter for exhaust gases from an internal combustion engine, and in particular, the catalytic converter is disposed at the open endof th taipipe tofurther reduce emissions from standard vehicle emission systems.

BACKGROUIND F

IVENTION

The exhaust emission gases generated by internal combustion engines found in automobiles,, trucks, vans, and .10 motorcycles are exhausted through a standard exhaust system.

The standard exhaust system typically includes small diameter :exhaust pipes extending from the engine block manifold to a *catalytic converter; the catalytic converter is attached to a muffler device by a small connecting exhaust pipe; and an extended tailpipe is connected to the remote end of the muffler, the tailpipe having an open end to exhaust the emission gases to the atmosphere.

In recent years, emission standards issued by federal and state governments for vehicles have become increasingly stricter, so that the exhaust system catalytic converter is required to eliminate unburned hydrocarbons from the exhaust 0: gases. The catalytic converters come in a variety of designs but typically have a precious metal catalyst, such as platinum, palladium, and/or rhodium, all plated over alumina or on a substrate of extruded ceramics. The catalytic converter designs are typically simple housings containing catalytic alumina pellets and, in some cases, have more complex containment systems, including honeycombed or meshed RECEIVED TIME 17.APR. 14:42 RECEVED IME 7. AR. 1:42PRINT TIME 17. APR. 15:17 r7/04/?,01 14:33 +613-9890-1337 A PATENT ATT/H&H INSUR PAGE 06/55 +613 9890 1337 Passageways Containing a datalytic substrate.I l.css the Catalytic Converter acts to oxidize the hydrlcarbon emissions which reduces thholuatyeitdrocathe atmosphere. h oltnseitdt h ~Because of the stricter standards, a need exists fortan improved emission exhaust system which further reduces te hydrocarbon emissions in order to meet the new vehicle federal and state standards for emission levels of NOX, 11C, CO, and NMHC. None of the prior art methods of reducing vehicle emissions for meeting the new federal and state emission guidelines discloses a tailpipe catalytic Converter disposed in or at the open.end of the tailpipe.

*DESCRPTIO PRIOR ART Catalytic converters of various dsgsand composite construction for vehicles have been dsledin the prior art for many years. For example, U.S. Patent No. 3,492,098 to DePalma et al discloses a catalyst device having spherical discs with the active' catalyst located between the engine manifold admflra/o inthe exhaust pipe section.

20 U.S. Patent Nos. 3,771,967 and 3,861,981 to Nowak disclose a honeycomb.j catalyst element located between the engine manifold exhaust system and muffler. U.S. Patent No.

3,905,775 to Sowards et al discloses a cylindrical catalytic honeycombed module located between the engine manifold 25 exhaust system and the muffler. U.S. Patent No. 5,110,561 to Hitachi et al discloses a honeycomb core catalyst device that is generally installed at an intermediate, point of an exhaust pipe. These aforementioned patents do not disclosedipsn the catalytic converter at the open end of the tailpipe, as in the present invention, for the further reduction of exhaust emissions.

RECEIVED TIME 17. APR. 14:42PR ITME 1.A. 1:7 PRINT TIME 17. APR. 15: 17 i,1~j 4:JJ +blJ-9890-1337 PATENT ATT/H&H INSUR PAGE 07/55 +613 9890 1337 3 U.S. Patent No. 4,530,418 to Currie discloses an improved catalytic exhaust system which uses the entire length of the system from the engine exhaust manifold to the end of the tailpipe opening. This system would replace the standard automotive catalytic converter and muffler and perform the essential functions of muffling noise an .d converting unburned hydrocarbons. U.S. Patent No. 4,920,746 to Gebelius discloses a catalytic exhaust system which uses the entire length of the exhaust system from the engine exhaust manifold to the end of the tailpipe. This system would also replace standard catalytic converters and mufflers on cars. U.S. Patent No. 5,218,817 to Urata discloses a silencer 2 having a catalyst 16 disposed therein. U.S. Patent No. 4,020,539 discloses a catalytic reactor having an 15 inlet and an outlet. These patents do not disclose a V catalytic converter disposed in or at the tailpipe end section, as in the present invention.

German Patent No. DE3518756Al discloses a catalytic converter to be disposed in the exhaust system at the joint of the muffler to the exhaust system. This patent does not 0% 0 disclose a catalytic converter adjacent to the open end of the tailpipe., as in the present invention.

Accordingly, it is an object of the present invention to provide a catalytic converter disposed in or at the end of the tailpipe to further reduce exhaust gas emissions to meet federal and state emission standards.

A preferred object of the present invention is to provide a catalytic converter disposed in or at the end of the tailpipe that is easy and simple to connect to the end of a tailpipe by mounting clamps, .hose clamps, muffler Clamps, compression fittings, mounting brackets, mounting screws, welding, crimping, or the like.

RECEIVED TIME ITAPR. 14:42 RECIVD IM 17 AR.1442PRINT TIME 17. APR. 15 :17 +613 9890 1337 A preferred object of the resent invention is to rovide a catalytic converter that can be mounted internally in the open end of the tailpipe, or s a ext e u the open end of the tailie or as an extension to the end of the tailpipe.

Another preferred object of the present invention is to provide a catalytic converter thatin operational use performs with no reduction or loss of horsepower to a vehicle n o o hosepower o ao performs wi th Aother cobject of the present invention is to provide a catalytic converter that in operational use can provide substantially cleaner air emissions for a vehicle having installed the tailpipe catalytic converter of the present i nvention.

Another object of the present invention is to provide a tailpipe catalytic converter having a back ressurerelief means, s uch as a valve that maintains the back ressure f the emission 15 system at a predetermined level.

Another preferred object of the present invention is to provide a tailpipe catalytic converter having back pressure relief valve that allows excess back pressure to be diverted from the tailpipe catalytic converter and to bypass the inner core to 20 maintain the efficiency of the system c o r e t Another preferred object of the present invention is to provide a tailpipe catalytic onverter having a b Pss convr valveter havi n a b a c k p r e s sure S relie valve that is in the form of either a bleed valve, or a miniature check valve, or a miniature pressure relief valve for relieving any build-up of pressure within the emission system at the inlet side of the tailpipe catalytic converter to maintain the efficiency of the system. c maintain th A further preferred object of the present invention is to provide a catalytic converter for a tailpipe that may be changed only at every 50,000 to 100,000 miles of driving use.

A still further preferred object of theresent invention is to provide a catalytic converter for a tailipe which ca in be mass produced in an automated and economical manner and is relatively inexpensive and long lasting.

RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR, 15:17 17/04/ 001 14:33 +613-9890-1337 A PATENT ATT/H&H INSUR PAGE 09/55 +613 9890 1337 SUMMARY OF THE INVENTION The present invention provides a catalytic converter for a tailpipe which further reduces vehicle exhaust emissions from exhaust emission systems exh a u st emissions from exhaust emission systems and that will meet the more stringent emission requirements of state and federal government regulatin The tailpipe catalytic converter may omprise a ceramic or stee housing of relatively small Size, having a diameter in the range of inch to 8 inches and a length of inches to 11 inches. The housing may include a matrix core of catalytic layered materials which react with the exhaust c at l y t i c l a y e r e d maeil which react with the exhaust emission pollutants, such as NO NMHC, HC, and CO. These Pollutants are further reduced and xidized by thecatalytic converter in the tailpipe by the typical S 5 c atalin aterials f latinum, palladium, rhodium, or the like contained with in the honeycombed or meshed layers of the matrix core. The catalytic converter is lodged within the interior of the tailpipe adjacent the open end or as an tin to the end of the tailpipe. The tailpipe catalytic converter t o t hel n d o f te any suitable eans, uch s y be held in place by any suitable means, such as a clamp, mounting screws, mounting 20 brackets, or the like. The converter includes a device for S relieving back pressure. Also, the tailpipe catalytic converter can be used for other vehicles, such as trucks and motorcycles or other gas compression engines, lawn mowers.

Empirical data had been obtained (shown below) on different vehicles, with and without a catalytic converter in the tailpipe, to show the advantages of the present invention.

RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR. 15:17 I 3 3 +613-9890-1337 A PATENT ATT/H&H INSUR PAGE 10/55 +613 9890 1337 WO 97/35099 PCT/US97/0 4 3 0 4 6 BRIEF DESCRIPTION OF THE DRAWINGS Further objects, features, and advantages of the present invention will become apparent upon consideration of the detailed description of the presently-preferred embodiments, when taken in conjunction with the accompanying drawings, wherein: Figure 1 is a .bottom plan view of a standard vehicle exhaust system incorporating the catalytic converter disposed in the tailpipe of the present invention; Figure 1A is a bottom plan view of a standard vehicle exhaust system incorporating the catalytic converter with a back pressure relief device in the tailpipe of the present invention; Figure 2 is a perspective view of the tailpipe catalytic converter having a honeycomb matrix; Figure 3 is a perspective view of a second embodiment of the tailpipe catalytic converter disposed within the tailpipe section; Figure 4 shows the third embodiment of the present invention; Figure 5 shows the fourth embodiment of the present invention; Figure 6 shows the fifth embodiment of the present invention; Figure 7 shows the sixth embodiment of the present invention; Figure 8 shows the seventh embodiment of the present invention; Figure 9 shows the eighth embodiment of the present invention; Figure 10 shows the ninth embodiment of the present invention; RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR. 15:17 upi 14:33 +613-9898-1337 A PATENT ATT/H&H INSUR PAGE 11/55 +613 9890 1337 WO 97/35099 PCT/US97/04304 7 Figure 11 shows the tenth embodiment of the resent invention;sent Figure 12 shows the eleventh embodiment of the present invention; Figure 13 shows the twelfth embodiment of the present invention; Figure 14 shows the thirteenth embodiment of the present invention; Figure 15 shows the fourteenth embodiment of th resent in invention; ande present Figure 16 shows the cross-sectional view of the fourteenth embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTs 15 One embodiment of the present invention provides a catalytic converter 30 disposed within a tailpipe 22 section as represented in Figures 1, 2 and 3 Figure 1 shows a standard and conventional exhaust system 10 for a typical motor vehicle. This exhaust system 10 comprises an exhaust manifold duct 14 connected to an internal combustion engine 12, and the manifold duct 14 is also connected to the primary catalytic converter 16 having an exhaust pipe 18. Exhaust pipe 18 is connected to a conventional muffler 20 and an elongated tailpipe 22. The tailpipe catalytic converter 25 is disposed within the open end of tailpipe 22 adjacent opening 28, as depicted in Figures 1 and 2 of the drawings.

The end 30a of catalytic converter 30 is preferably spaced about 1 inch from the tailpipe opening 28, but may be spaced up to 6 inches from opening 28.

The primary catalytic converter 16 is held in place by mounting clamps 24, the muffler 20 is held in place by mounting clamps 26, and the tailpipe catalytic converter RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR. 15:16 17/04/2001 14:33 +613-9890-1337 APATENT ATT/H&H INSUR PAGE 12/55 +613 9890 1337 WO.97/3SO99 PCT/US97/0 43 o 4 8 is held -in place by a mounting clamp 38 for exhaustsse tsse The tailpipe catalytic Conver~ter 30, as depicted in Figures 2 and 3, is of generally conventional construction and includes a cylindrical housing 32 having a matrix core 34 of catalytic layered material 36, which reacts with emission gaseous pollutants, Such as THC, NO., NMHC, and Co. Housing 32 is made of ceramic, steel, stainless steel, chrome, or other suitable materials. The core matrix 34 is made of mesh, honeycomb or other suitable pass aeway designs for containing th -ctal ytic lyered 6 h the d A Ta Th catalytic layerA 36 have a precious metal catalyst contained .thereon. Typical catalysts used are platinum, palladium, *rhodium, and/or nickel. The housing 32 of catalytic converter 30 is typically dimensioned so that the outside .*diameter closely approximates the inside diameter of tailpine 22. The diameter size may be in the range of 112 inches to a incesand the housing 32 may have a length Of 3/4 nhst 11 inches, depending upon the application, such as in a car, truck, motorcycle, lawn mower, and/or gasoline-.type The preferred specification of matrix core 34 includes a diameter which matches the tailpipe of 1-3/4 inches and a length of 1-3/4 inches and having a range of 200 to 700 cells 25 per square inch. Typically, two, three, or four of such matrix cores 34 are stacked together to make the catalytic converter 30, with a preferred length of 6 inches.. The matrix core 34 is coated with alumina to about 1% (weight to weight) and has a catalytic layered A .rt l~.n 36 of palladium and platinum in the range of 30 to 50 grams per cubic foot with a ratio of palladium to platinum in the range of 2:1 to 6:1.

RECEIVED TIME 17. APR. 14:4 2 PRINT TIME 17. APR. 15:16 1,/041'201 14:33 +613-9890-1337 I PATENT ATT/H&H INSUR PAGE 13/55 +613 9890 1337 WO 97/35099 PCT/US97/0 4 3 0 4 9 The catalytic converter 30 is held in place in tailpipe 22 by a suitable mounting clamp 38, as depicted in Figures 1 to 3. It can also be securely held by other suitable means, such as hose clamps, muffler clamps, compression fittings, mounting brackets, mounting screws, welding, crimping, and the like.

Figure 3 shows a second embodiment in which the catalytic converter 30 is disposed about 6 inches from open end 28. The catalytic converter 30 is clamped in the same manner, as previously discussed for the first embodiment.

In operation, catalytic converter 30 reaches a temperature of approximately 500oF to burn off the pollutants before they are exhausted to the atmosphere.

oTh The present invention has been tested on different S 15 vehicle exhaust systems 10, such as a 1990 Mazda Miata, a 1991 Ford Bronco, and a 1993 Dodge Intrepid. In these tests, the tailpipe catalytic converter 30 had a housing 32 which C •measured 6 inches in length and had a.diameter of 2 inches, which closely approximates the inside diameter of the tailpipe 22. The catalytic converter 30 was installed in tailpipe 22 and was placed and clamped with end approximately 1 inch from opening 28. The test results are tabulated below in Tables 1 to 4 and show a substantial reduction in exhaust emissions when tailpipe catalytic 25 converter 30 is mounted at the end of tailpipe 22, as shown in Figures 1 and 2 of the drawings. The test results also show that there was no adverse affect on gas mileage when using the catalytic converter RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR. 15:16 17/04/82001 14:33 +613-9890-1337 PATENT ATT/H&H INSUR +613 9890 1337 PAGE 14/55 WO 97/35099 PCT/US97/ 04304 Table 1 Vehicl Test N 2488 2490 2492 2495 2496

REDU

2497 2498 2499 2509 2510 2511 2512

REDUX

2501 2503 2504 2505 2507

REDUX

e MIATA o0 With/ Wo

WO

w0

WITH

WO

WO

X

WO

Wo

WO

wo

WTHO

WITH

WITH

WITH

WO

WO

WO

WITH

WITH

W(TH

THC

0.099 0.126 0.067 0.141 0.12 1 44.9692 0.141 0.142 0-174 0.061 0.096 0.059 0.06 54.7046 0.04 0.039 0.035 0.031 0.029 21.05263 6

CO

1.511 1.73 1.219 2.007 1.645 29.26157 1.704 2.043 1.858 1.07 1.335 0.811 1.064 42.72971 0.46 0.23 0.514 0.181 0.124 2.00166 1 1990 Mazda Miata TEST TYPE NOx 1.388 1.544 1.33 1.497 1.509 10.40754 1.285 1.331 1.372 0.595 0.731 0.811 0.84 t4.01329 1.251 1.524 1.223 1.081 1.194 1.64482 3 I/M-240 CO2 309.552 3 11.98E 314.649 309.46 314.339 -1-06477 HOT 505 308.281 314.004 308.207 306.198 309.498 305.571 306.839 1.011562

HWFET

256.664 277.761 256.556 255.082 256.055 .069037

NMHC

0.07 0.086 0.04 0.06o 0.08 53.21637 0.105 0.103 0.134 0.037 0.061 0.03 0.034 65.78947 0.027 0.026 0.022 0.019 0.018 26

MPG

28.4 28.14 27.99 28.33 27.95 0.762276 28.48 27.92 28.45 28.64 28.29 28.84 28.58 -1 07 543 34.44 31.88 34.44 1 34.71 1 34.5, 3.16594 Date 11/9/94 11/9/94 11/9/94 17/9/94 11/9/94 11/10/94 11/10/94 11/10/94 11/10/94 11/10/94 11/10/94 11/10/94 11/10/94 1/10D/94 1/10/94 1/10/94 Table 2 Vehicle Test No.

2477 2478 2479 2480 2481 2482 2483 2484 2485 2488 2487

BRONCO

With/ Wo

WITH

WITH

WITH

WITH

WO

WO

Wo Wo

WITH

WITH

wo

THC

0.248 0.301 0.479 0.31 0.43 0.457 0.512 0.531 0.36? 0.404 0.438 1991 Ford Bronco TEST TYPE CO NOx 2.382 2.268 3.623 1.902 11.372 1.701 2.801 1.892 6.768 1.98 11.557 1.965 11.795 1.866 11.604 1.993 6.164 1.744 7.096 t 728 8.163 354 I/M-240 C02 524,732 524.763 521.147 535.879 573.886 557.284 573.85 573.708 529.409 530.284 576.438

NMHC

0.172 0.216 0.365 0.236 0.318 0.345 0.393 0.397 0.257 0.29 0.334

MPG

16.76 16.71 18.41 16.38 15.14 15.37 14.93 14.94 16.41 16.34 15.01 MARKPAT1.XLS RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR. 15 :16 17/04/2?001 14:33 +613-9890-1337 +613 9890 1337 A PATENT ATT/H&H INSUR PAGE 15/55 WO 97/35099 PCT/US97/ 0 4 3 0 4 1993 Dodge Intrepid VIN 2 B3ED46TXPH558 6 88 Odometer approx 102000 miles With Tail Pipe Cat Test No THC

CO

2882 0.407 3.422 2886 0.387 3.902 2889 0.394 3.022 2893 0.401 3.333 2894 0.386 3.167 AVG 0.395 3.369 Baseline No Device 2872 0.448 3.813 2900 0.466 3.265 2901 0.448 3.560 2907 0.587 4.148 AVG 0.487 3.697 REDUX 18.93279 8.854322 Table 3 All units are in Grams/Mile Test Type- FTP (Federal Test Procedure) NOx 0.355 0.357 0.378 0.396 0.372 0.372 0.460 0.628 0.571 0.575 0.559 C02 345.276 344.835 337.576 344.287 349.412 344.277 439.263 444.114 442.133 434.548 440.015

NMHC

0.358 0.338 0.353 0,354 0.340 0.349 0.398 0.412 0.396 0.524 0.433

MPG

25.23 25.21 25.84 25.31 24.97 25.31 19.88 19.70 19.77 20.05 19.85 -27.5164 18.69 21.75776 19.39884 Table 4 1990 Mazda Miata VIN JM NA3515L0105501 Odometer 32600 miles approx 2803 2819 Baseline No Device 0.322 3.104 0.744 332.781 0.293 With Device 0.262 26.22 27.24 2.536 0.564 321.179 0.229 REDUX 18.63354 18.29897 24.19355 3.486377 21.843 -3.89016

MARK.XLS

RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR, 15: 16 RECEIVED TIME '17. APR. 14:42 PRINT TIME 17. APR. 15:16 //4/2~r1i 14:33 +613-9890-1337 A PATENT ATT/H&H INSUR PAGE 16/55 +613 9890 1337 WO 97/35099 PCT/US97/ 0 4 3 04 12 DETAILED DESCRIPTION

OF

THE THIRD EMBODIMENT 100 The third embodiment 00 of the tailpipe catalytic converter is depicted in Figure 4 of the drawings. The third embodieent rawings. The third embodiment 00 includes a tailpipe catalytic converter 130 which is the same as the first embodiment of catalytic converter 30, except for the canister-type housing 131 containing a core housing 132 having a matrix core 134. End 138 of housing 131 is slightly tapered having neck section 140 for fitting into the open end 28' of tailpipe 22'.

Housing 131 of catalytic converter 130 is secured to tailpipe S22' by means of clamp 38', crimping, welding or other previously mentioned securing devices.

15 The physical specifications for housing 131 generally match the dimension of the tailpipe 22'. The diameter is in the range of 3/4 inches to 8 inches and the overall length is in the range of 3/4 inches to 11 inches, with a preferred diameter of 2 to 4 inches and a preferred length of 5 to 6 S 20 inches. Housing 131 has a slightly tapered end 138 having a diameter of less than 2 inches and a neck length of 2 inches for fitting neck portion 140 into tailpipe opening 28' of tailpipe 22' for a proper fit. The preferred physical specification for the core housing 132 having matrix core 134 is a diameter of 1 3/4 inches and a length of 6 inches.

DETAILED DESCRIPTION

OF

THE FOURTH EMBODIMENT The fourth embodiment 200 of the tailpipe catalytic converter 230 is depicted in Figure 5 of the drawings. The fourth embodiment 200 includes a tailpipe catalytic converter 230 which is the same as tailpipe catalytic converter 130, except for the number and spacing of core housings 132 and RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR. 15:16 17/04/2001 14:33 +613-9890-1337 A PATENT ATT/H&H INSUR PAGE 17/55 +613 9890 1337 WO 97/35099 PCT/US97/ 0 4 3 0 4 13 matrix cores 134 within the tailpipe 22'. Cataytic converter 230 has three spaced-apart core housings 232 each having a length of 2 inches and each having a matrix core 234. A one inch length metal spacing collar 236 has an annular shape and separates each matrix core 234 a shown in Figure 5. The two spacing collars 236 allow for a lowering of back pressure caused by the catalytic converter 230.

Preferably, spacing collar 236 has a 3/4 inch diameter and a 1 inch length. In addition, the air space 238 between each matrix core 234 allows for further catalytic conversion of the exhaust gases at each matrix core 234. When exhaust gases pass through each matrix core 234 from a subseqent air space 238, the process of catalytic conversion takes place each time. Each matrix core 234 can be secured in place by 15 a mounting clamp 38' or other suitable means, such as hose clamps, muffler clamps, compression fittings, mounting brackets, mounting screws, welding, crimping, or the like.

The physical specifications for the catalytic converter 230 within tailpipe 22' are preferably a diameter of 2 inches and an overall length of 8 inches including the two spacing collars 236. However, the length may vary from 2 1/2 inches to 11 inches.

DETAILED DESCRIPTION

OF

THE FIFTH EMBODIMENT_ 0 25 The fifth embodiment 300 of the tailpipe catalytic converter 330 is depicted in Figure 6 of the drawings. The fifth embodiment 300 includes a tailpipe catalytic converter 330 which is the same as the fourth embodiment 200 of tailpipe catalytic converter 230, except for the canistertype housing 331 containing three spaced-apart core housings 332 each having a matrix core 334 and a spacing collar 336 between them. .Housing 331 has at one end a slightly tapered RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR. 15:16 17/4//001i 14:33 +613-9890-1337 A PATENT ATT/H&H INSUR PAGE 18/55 +613 9890 1337 WO 97/35099 PCT/US97/04304 14 end 338 and a neck section 340 for slidably fitting into tailpipe 22'. Housing 331 may be secured to tailpipe 22' by clamp 38' or by crimping, welding, or other previously mentioned securing devices.

The physical specifications for converter 330 are a diameter of 2.3 inches, and an overall length of 2 to 8 inches. Housing 331 has an overall length of 13 inches and a slightly tapered end 338 having a diameter of less than 2 inches. The length of neck 340 is 2 inches for inserting neck portion 340 into tailpipe opening 28' of tailpipe 22' for a proper fit.

DETAILED DESCRIPTION OF o. THE SIXTH EMBODIMENT 400 The sixth embodiment 400 of the tailpipe catalytic 15 converter 430 is depicted in Figure 7 of the drawings. The sixth embodiment 400 includes a tailpipe catalytic converter 430 which is the same as the fifth embodiment 300 of tailpipe catalytic converter 330, except for a larger sized canistertype housing 431 having larger diameter core housings 432 and matrix cores 434 and larger diameter spacing collars 436.

Housing 431 has at one end a tapered end 438 with a neck portion 440 for inserting into tailpipe 22". Catalytic converter housing 431 has four core housings 432 having matrix cores 434 and one inch length metal spacing 25 collars 436 separating each matrix core 434, as shown in Figure 7. Housing 431 is secured to tailpipe 22" by means of clamp 38", welding, crimping, or the like. The design of housing 431 insures that there is adequate exhaust gas flow with no back pressure being produced when catalytic converter 430 is attached to tailpipe 22".

The physical specifications for canister housing 431 are a diameter. of 2.3 inches and a length of 13 inches.

RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR. 15 :16 17/04/2zl1 14:33 +613-9890-1337 PATENT ATT/H&H INSUR PAGE 19/55 +613 9890 1337 WO 97/35099 PCT/US97/04304 Housing 431 has a tapered end 438 having a diameter of less than 2 inches and a neck length of 2 inches for inserting neck portion 440 into tailpipe 22" for a proper fit. The physical specifications for each housing 432 having matrix core 434 are a diameter of 2.3 inches by 2 inches in length.

The physical specification for each spacing collar 436 is a diameter of 2.3 inches by 1 inch in length. Thus, converter 430 has an overall length of 11 inches.

This embodiment was tested on a 1989 Jeep Wrangler.

In these tests, housings 432 and matrices 434 had lengths of 2, 4, 6, and 8 inches, and were tested at speeds of 55 mph and 30 mph. The test results are tabulated below in Table S.The matrix core 434 in the Jeep Wrangler was coated with alumina to about 12% (weight to weight) and had a catalytic 15 layered substrate plating 435 of platinum and rhodium to about 50 grams per cubic foot with. a ratio of platinum to rhodium of 5:1. This is a low light- off type of catalyst which achieves light off at 400 0 F instead of 900 0 F, to thereby further increase the efficiency of the tailpipe catalytic converter of the present invention as shown in Table *oooo *ooo RECEIVED TIME 17. APR. 14:42 PRINT TIME 17, APR. 15 :16 2.7"04/?001 14:33 +613-9890-1337 A PATENT ATT/H&H INSUR +613 9890 1337 PAGE 20/55 WO 97/35099 IPCT/US97/04304 Table Study of formulation on a 1989 Jeep Wrangler Formula 501 ratio platinum to rhodium coated to 50 grams per cubic foot These are Steady State tests 55 mph and 30 mph reductions are based on the final baseline test.

VIN 2.J4FY1 9E1KJ1 57111 Mileage 18877 Date February 14. 1996 Ambient conditions Baro THC CO 746.2 17.71 10.11 NOx 0.07 C02 0.046 NMHC Temp Dry Temp wet 8.3 70 68 Baseline 55 mph in fifth gear 42-49 111-123 16-20 2 inches of substrate installed 55 mph 23-27 34-40 9.0-19.0 Reduc. 39% 51-90% 26% 1.921 16-17 1 .93 1.871 10.11 11.3 Reduc.

Rleduc.

4 inches of substrate installed 55 mph 22-25 32-35 1.9-3.5 1 42% 56% 6 inches of substrate installed 55 mph 17.9-26 29-35 1.9-2.2 46% 58% 89% 1.82 11.3-13.3 8 inches of substrate installed 55 mph 20-25 35-80 1.3-1.5 1.83 Reduc- 45% 38% 92% Baseline 55 mph 37-45 69-85 16-22 Baseline 30 mph in third gear 21-23 63-85 4.0-6.0 2 inches of substrate installed at 30 mph 19-24 27-100 0.9-3.1 %Reduc. 15% 36.50% 71% 1 .9 1.034 0.972 13 1 4 inches of 18-24 Reduc. 17-60% substrate installed 30 mph 40-55 0.8-1.2 0.939 52% 86% 6 inches substrate insalled 30 mph 17.9-19.1 46-68 0.2-0.9 Reduc. 27.50% 46% 93% 0.929 8 inches of substrate installed 30 mph 15.3-19.2 38.57 0.3-0.6 0.981 Reduc, 32,20% .52% 93% Baseline 30 mph 24-27 90-110 6.0-8.0 1.14 10.8

JEEP.XLS

RECEIVED TIME 17.APR. 14:42 PITTM 1 P,1:1 PRINT TIME 17. APR. 15 16 i7/04/u201 14:33 +613-9890-1337 A PATENT ATT/H&H INSUR PAGE 21/55 +613 9890 1337 WO 97/35099 PCT/US97/04304 17 DETAILED DESCRIPTION OF THE SEVENTH EMBODIMENT 500 The seventh embodiment 500 of the tailpipe catalytic converter 530 is depicted in Figure 8 of the drawings. The seventh embodiment 500 includes a tailpipe catalytic converter 530 which is the same as the sixth embodiment 400 of tailpipe catalytic converter 430, except for a shorter length of canister-type housing 531 having a single integral core housing 532 for housing a single integral matrix core 534. The design of housing 531 also insures that there is adequate exhaust gas flow with no back pressure being produced because of catalytic converter 530 being attached to tailpipe 22".

Housing 531 has a diameter of 1/4 inches to 4 inches oo 15 larger than the inside diameter of the tailpipe 22", and preferably 1/2 inch to 1 inch larger than the inside diameter of the tailpipe. The preferred physical specifications for housing 531 are a diameter of 2 3/4 inches and a length of 12 inches. Housing 531 has a tapered end 538 having a diameter of less than 2 inches and a neck length of 2 inches for inserting neck portion 540 into tailpipe 22" for a proper fit. Converter 530 has an overall length of 8 inches.

DETAILED DESCRIPTION

OF

THE EIGHTH EMBODIMENT 600 The eighth embodiment 600 of the tailpipe catalytic converter 630 is depicted in Figure 9 of the drawings. The eighth embodiment 600 includes a tailpipe catalytic converter 630 disposed in a housing 631 which is the same as the sixth embodiment 400, except for the tapered and conical end 642 with an exhaust opening 644. The tapered and conical end 642 allows for the creation of back pressure within housing 631 which generates more heat for increased catalytic RECEIVED TIME 17, APR. 14:42 PRINT TIME 17. A PR. 15 a/ u./Cui .4 14: 33 +613-9890-1337 a PATENT ATT/H&H INSUR PAGE 22/55 +613 9890 1337 WO 97/3099 PCT/US97/04304 18 conversion of vehicle exhaust gases by the core housings 632 having matrix cores 634 of catalytic converter 630. In addition, the tapered and conical configuration 642 of housing 631 also reduces noise and becomes an additional vehicle muffler.

The physical specifications for housing 631 has an overall diameter in the range of 2 1/4 to 2 3/4 inches and overall length in the range of 15 to 17 inches, with a preferred overall diameter of 2 1/2 inches and a preferred length of 16 inches. Housing 631 has a tapered end 638 having a diameter of less than 2 inches and a neck length of 2 inches for inserting neck portion 640 into tailpipe 22" for a proper fit. The tapered and conical end 642 has a 2 inch length with an exhaust hole diameter opening 644 of 2 inches.

15 The physical specification for each core housing 632 and matrix core 634 has an overall diameter of 2 3/8 inches by 2 inches in length. The physical specification for spacing collar 636 has an overall diameter of 2 3/8 inches by 1 inch in length. Thus, converter 530 has an overall length of 11 inches.

DETAILED DESCRIPTION OF THE NINTH EMBODIMENT 700 The ninth embodiment 700 of the tailpipe catalytic converter 730 is depicted in Figure 10 of the drawings. The 25 ninth embodiment 700 includes a tailpipe catalytic converter 730 disposed in a canister housing 731 which is the same as the seventh embodiment 500, except for the tapered and conical end 742 with an exhaust opening.744. The tapered and conical end 742 also allows for the creation of back pressure within housing 731 which generates more heat for increased catalytic conversion of vehicle exhaust gases by the single core housing 732 having a single integral matrix RECEIVED TIME 17. APR. 14:42 PRINT TIME 17, APR. 15 1"V/0I4/2001 14:33 +613-9890-1337 £PATENT ATT/H&H INSUR PAGE 23/55 +613 9890 1337 WO 97/35099 PCT/US97/04304 19 core 734. In addition, this tapered and conical configuration 742 of housing 731 also reduces noise and becomes an additional vehicle muffler.

The physical specifications for housing 731 are a diameter in the range of 2 1/4 to 2 3/4 inches and overall length in the range of 13 to 15 inches, with a preferred overall diameter of 2 1/2 inches and a pref erred length of 14 inches. Housing 731 has a tapered end 738 having a diameter of less than 2 inches and a neck length of 2 inches for inserting neck portion 740 into tailpipe 221, for a proper fit. The tapered and conical end 742 has a 2 inch length *with an exhaust hole diameter opening 744 of 2 inches.- The physical specification for core housing 732 having matrix core 734 has an overall diameter of 2 3i/8 inches by 7 inches in length.

DETAILED DESCRIPTION OF THE TENTH EMBODIMENT The tenth embodiment 800 of the tailpipe catalytic converter 830 is depicted in Figure 11 of the drawings. The 20 tenth embodiment 800 includes a tailpipe catalytic converter isthe same as th ir4 ~odmn.130, except is disposed in a smaller sized canister-type housing 831 having a smaller diameter core housing 632 and matrix core 834.

This catalytic converter 830 is used for scooters, 25 motorcycles, lawn mowers, gasoline electrical generators, and the like. Housing 831 can be slid into open end 828 of tailpipe 822 and secured by means of clamp 836, welding, crimping, or the like.

The physical specifications for housing 831 are an overall diameter in the range of 1/2 inches to 1 inch and an overall length in the range 3 to 5 inches, with a preferred overall diameter of 3/4 of an inch and a preferred length of RECEIVED TIME 17. APR. 14:42 RTTIE 1.A.1:1 PRINT TIME 17. APR. 15 17/04/2001 14:33 +613-9890-1337 A PATENT ATT/H&H INSUR PAGE 24/55 +613 9890 1337 WO 97/35099 WO 97/35099 PCT/US97/04304 4 inches. Housing 831 has a tapered end 838 having a diameter of less than 3/4 of an inch and a neck length of 1 inch for inserting neck portion 840 into tailpipe opening 828 of tailpipe 822 for a proper fit. The physical specifications of matrix core 834 are an overall diameter of 23/32 of an inch by 2 inches in length.

DETAILED DESCRIPTION

OF

THE ELEVENTH EMBODIMENT 900 The eleventh embodiment 900 shows a tailpipe catalytic converter 930 in Figure 12 of the drawings, having a core housing 932 and a matrix core 934 disposed in a canister-type :housing 931 which is connected to tailpipe 22 via clamp 936.

Matrix core 934 is an electrically heated catalyst having embedded therein a thermocouple 940 having a sensor 942. The S. 15 other end of the thermocouple is connected to a main computerized electronic control unit. Also embedded in the center of matrix core 934 is a heating element 950 connected to canister-type housing 931 by a ceramic nut 952. The end 954 is connected to a battery cable (not shown) for heating up the heating element 950. Electrical energy is supplied by the alternator of the vehicle.

Present matrix substrates start working at a temperature of about 400OF when the exhaust gases reach that temperature. Typically, this takes 3 to 4 minutes, depending S 25 on the driving speed. Light off occurs when the substrate temperature is at 400DF and is working at 50% efficiency.

In the present invention, when the electric heating element 950 is energized, the temperature of 400 0 F is reached in approximately 10 seconds, so that light off starts earlier, and further increases efficiency.

RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR. 15:15 17/04/2001 14: 33 +613-9890-1337 1 PATENT ATT/H&H INSUR PAGE 25/55 +613 9890 1337 WO 97/35099 PCT/US971043 04 21 Thermocouple 940 senses the temperature of matrix core 934. When the vehicle is started, or at any time the temperature of core 934 is less than 4000F, thermocouple 940 senses this temperature below 400 0 F, and causes heating element 950 to be energized to immediately heat up the core 934. When the temperature reaches 4500F, light off has been achieved and thermocouple 940 turns off the heating element 950.

DETAILED DESCRIPTION

OF

THE TWELFTH EMBODIMENT 1000 The twelfth embodiment 1000 shows a tailpipe catalytic converter 1030 in Figure 13 of the drawings. The tailpipe catalytic converter 1030, as depicted in Figure 13, is of generally conventional construction and includes a cylindrical housing 1032 having disposed therein a matrix core 1034 of catalytic layered material 1036, which reacts with the emission of gaseous pollutants, such as THC1 NO., NMHC, and CO. The matrix core 1034 has an inlet side or end 1034a. and an outlet side or end 1034b. Within matrix core 20 1034 there is embedded a small diameter outlet tube 1040 having an inlet end 1042 and an outlet end 1044. A back pressure relief device 1050 is mounted at the inlet end 1042 and has inlet and outlet opening 1052 and 1054 for relieving any build-up of excess back pressure at the inlet end 1034a.

The back pressure relief device 1050 can be in the form of a bleed valve, a miniature check valve, a miniature pressure release valve, or any other suitable devices. in this twelfth embodiment 1000 the back pressure relief device 1050 is in the form of a bleed valve 1050. Bleed valve 1050 is always open and is dimensionally sized such that the exhaust gases only pass through inlet tube 1060 when the back pressure at the inlet end 1034a of catalytic converter 1030 RECEIVED TIME 17. A PR. 14:4 2 PRINT TIME 17. APR. 15:15 iwz/ d 4el q14:j +bl3-898-1337 a PATENT ATT/H&H INSUR PAGE 26/55 +613 9890 1337 WO 9735099 PCT/US97/04304 22 excess 7 inches of water. If a check valve or pressure release valve is employed, they are normally closed and only open when the back pressure exceed 7 inches of water. There is an additional inlet tube 1060 connected to the inlet opening 1052 of pressure relief device 1050 for receiving of the exhaust gases in order to lower the back pressure of those aforementioned exhaust gases, when the tailpipe catalytic converter 1030 was placed within the exhaust emission system 10, as shown in Figure lA of the drawings.

In using a tailpipe catalytic converter without a back pressure relief device within an exhaust emission system it is observed that when an excess back pressure of gases above a predetermined level is reached (greater than seven inches of water pressure), the operation of the exhaust 15 emission system 10 is hindered and the efficiency of the emission system 10 is reduced, as shown in Table 6. When using a tailpipe catalytic converter 1030 having a back pressure relief device 1050 it allows the exhaust gases to flow more evenly without any reduction in the efficiency of reducing exhaust gas emissions, as shown in Table 6. Some conditions that cause an increase in the back pressure of exhaust emission system 10 are heavy acceleration of the motor vehicle,wide open throttle operation, a sudden increase in vehicle load (climbing a steep hill), and the like.

25 It is also been observed that when the tailpipe catalytic converter 1030 is in use, the converter 1030 will slow the travel time of exhaust gases throughout the main catalytic converter 16, such that the added residence time through the main catalytic converter 16 further reduces the emission of gaseous pollutants from the exhaust emission system 10 during the operational use of the motor vehicle.

Back pressure of the exhaust gases should be in the range of RECEIVED TIME 17. APR. 14:42 PRINT TIME 17, APR. 15 i7/04/2001 14:33 +613-9890-1337 A PATENT ATT/H&H INSUR PAGE 27/55 +613 9890 1337 WO 97/35099 PCT/US97/04304 23 2 to 7 inches of water within the exhaust system 10 for proper efficiency in reducing exhaust gas emissions.

Housing 1032 is made of ceramic, steel, stainless steel, chrome, or other suitable materials. The core matrix 1034 is made of mesh, honeycomb, or other suitable passageway designs for containing the catalytic layered substrates 1036.

The catalytic layers 1036 have a precious metal catalyst contained thereon. Typical catalysts used are platinum, palladium, rhodium, and/or nickel. The housing 1032 of tailpipe catalytic converter 1030 is typically dimensioned so that the outside diameter closely approximates the inside diameter of tailpipe 22. The diameter size of housing 1032 may be in the range of 1/2 inches to 8 inches, and the housing 1032 may have a length of 3/4 inches to 11 inches, depending 15 upon the application, such as in a car, truck, motorcycle, lawn mower, gasoline-type generator, and/or stationary internal combustion engine.

The preferred specification of matrix core 1034 includes a diameter which matches the tailpipe of 1-3/4 inches and a length of 1-3/4 inches and having a range of 200 to 700 cells per square inch. Typically, two, three, or four of such matrix cores 1034 are stacked together to make the tailpipe catalytic converter 1030 or with a preferred single integral matrix core 1034 having a length of 6 inches. The 25 matrix core 1034 is coated with alumina to about 12% (weight to weight) and has a catalytic layered substrate plating 1036 of palladium and platinum in the range of 30 to 50 grams per cubic foot with a ratio of palladium to platinum in the range of 2:1 to 6:1.

The tailpipe catalytic converter 1030 is held in place in tailpipe 22 by a suitable mounting clamp 38, as depicted in Figures lA, and 13. It can also be securely held by other RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR. 15 1-7/04/2001 14: 33 +613-9890-1337 A PATENT ATT/H&H INSURPAE PAGE 281/55 +613 9890 1337 WO 97135099 PCTIUS97/04304 24 suitable means, such as hose clamps, muffler clamps, compression fittings, mounting brackets, mounting screws, welding, crimping, and the like.

DETAILED DESCRIPTION OF THE THIRTEENTH EMBODIMENT 1100 The thirteenth embodiment 1100 of the tailpipe catalytic converter 1130 is depicted in detail in Figure 14 of the drawings. Tailpipe catalytic converter 1130 includes a large sized canister-type housing 1131 having a large sized diameter core housing 1132 having a single integral matrix core 1134 of catalytic layered material 1136 (as described in the twelfth embodiment). Housing 1131 has at the inlet 0 0 opening 1138 a tapered end 1140 with a neck portion 1142 for slidably inserting into the end opening 28 of the tailpipe section 22; and at the outlet opening 1144 a tapered end 1146 with a neck portion 114'8 for the discharging of the exhaust gases to the atmosphere. In addition, housing 1131 at the oooo side of the inlet opening 1138, as shown in Figure 14 of the oo~o drawings, includes a circular hole opening 1150 for receiving 0: 20 an L-shaped inlet tube 1152 having an outlet section 1154 for receiving the back pressure relief device 1050'.

0600 The back pressure relief device 1050' can be in the :00-0form of a bleed valve, a miniature check valve, a miniature 0 pressure release valve, or any other suitable devices. In this thirteenth embodiment 1100 the back pressure relief device is in the form of a miniature check valve 1050'.

Check valve 1050' is normally in the closed position and only opens to release the excess exhaust gases when the back pressure at the inlet tube opening 1152a of L-shaped inlet .tube 1152 exceeds the 7 inches of water back pressure. If a bleed valve is employed, the valve is always opened and is dimensionally sized such that the excess exhaust gases only RECEIVED TIME 17. APR. 14:42 RTTIE1.A.1:5 PRINT TIME 17. APR. 15 17./04/2001 14: 33 +613-9890-1337 £PATENT ATT/H&H INSUR PAGE 29/55 ±613 9890 1337 WO 97/35099 PCT/t7S97/04304 pass through when the back pressure exceeds 7 inches Of water. If a pressure relief valve is employed, the valve is normally closed and only opens when the back pressure exceeds 7 inches of water. Check valve 1050, includes an inlet opening 1052' and an outlet opening 1054', such that inlet opening 1052' connects to the outlet section 1154 of L-shaped tube 1152, and outlet opening 1054' connects to an outlet tube 1156 for discharging the excess back pressure within the exhaust emissions system 10 to the atmosphere. Housing 1131 is secured to the end opening 28 section of the tailpipe section 22 by means of clamps 38, welding, crimping or the *like. In addition-, the tapered and conical configuration of housing 1131 also reduces noise and becomes an additional vehicle muffler.

The physical specifications for housing 1131 has an overall diameter in the range of 31/2 inches to 41/2 inches and o. o.:overall length in the range of 3 inches to 15 inches, with a preferred overall diameter of 41/e inches and a preferred o o length of 4 inches. Housing 1131 has inlet and outlet 20 openings 1138 and 1144 of tapered ends 1140 and 1146 having 0a diameter of less than 2 inches for inserting the neck portion 1142 into the open end 28 of the tailpipe section 22 :*..00for a proper fit. The phys-ical specification for core housing 1132 having a matrix core 1134 has an overall 0: 25 diameter of 4 inch by 4 inches in length.

DETAILED DESCRIPTION OF THE FOURTEENTH EMBODIMENT 1200 The fourteenth embodiment 1200 of the tailpipe catalytic converter 1230 is depicted in detail in Figures and 16 of the drawings. Tailpipe catalytic converter 1230 includes a large sized canister-type housing 1231 having a large sized diameter core housing 1232* having a single RECEIVED TIME 17. A PR. 14:42 PRINT TIME 17, APR. 15: 1-7/04/2001 14:33 +613-9890-1337 PATENT ATT/H&H INSUR PAGE 30/55 +613 9890 1337 WO 97/35099 PCT/US97/04304 26 integral matrix core 1234 of catalytic layered material 1236 (as described in the twelfth embodiment). Housing 1231 has at the inlet opening 1238 a tapered end 1240 with a neck portion 1242 for slidably inserting into the open end 28 of the tailpipe section 22; and at the outlet opening 1244 a tapered end 1246 with a neck portion 1248 for the discharging of the exhaust gases to the atmosphere. In addition, housing 1231 at the side of inlet neck portion 1242, as shown in Figure 16 of the drawings, includes a first circular hole opening 1250 for receiving an L-shaped inlet tube 1252 having an outlet end 1254 for receiving the back pressure relief "device 1050"; and the outlet neck portion 1248 side includes a second circular hole opening 1260 for receiving an L-shaped outlet tube 1262 having an inlet end 1264 in which to receive 15 the back pressure relief device 1050" or relief valve 1050".

The back pressure relief device 1050" can be in the form of a bleed valve, a miniature check valve, a miniature pressure release valve, or any other suitable devices. In this fourteenth embodiment 1200 the back pressure relief device is in the form of a miniature pressure release valve 1050". Pressure release valve 1050" is normally in the closed position and only opens to release the excess exhaust gases when the back pressure at inlet opening 1250 of Lshaped inlet tube 1252 is over the 7 inches of water back 25 pressure. If a bleed valve is employed, the valve is always opened and is dimensionally sized such that the excess exhaust gases only pass through when the back pressure exceeds 7 inches of water. If a check valve is employed, the valve is normally closed and only opens when the back pressure exceeds 7 inches of water. Back pressure release valve 1050" includes inlet and outlet openings 1052" and 1054", such that inlet opening 1052" connects to the outlet RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR. 15:15

I

/zui 14:33 +613-9890-1337 PATENT ATT/H&H INSUR PAGE 31/55 +613 9890 1337 WO 97/35099 PCT/US97/04304 27 end 1254 of L-shaped inlet tube 1252 and outlet opening 1054" connects to the inlet end 1264 of outlet tube 1262 for discharging the excess back pressure within the exhaust emissions system 10. Housing 1231 is secured to the open end 28 section of the tailpipe section 22 by means of clamps 38, welding, crimping or the like. In addition, the tapered and conical configuration of housing 1231 also reduces noise and becomes an additional vehicle muffler.

In addition, the .tailpipe catalytic converter 1230 further includes an insulation layer 1270 that surrounds the exterior of housing 1231. Insulation layer 1270 is held in place by an outer canister-type shell 1272, as depicted in Figures 15 and 16 of drawings.

In operation, the emission removal efficiency was increased from baseline by using an insulated tailpipe catalytic converter 1230 because the emission exhaust gases were still maintained at a relatively high temperature (500 0

F

to 600°F) within the matrix core 1234 of the tailpipe catalytic converter 1230. Shell 1272 is made of steel, stainless steel, chrome or other suitable materials.

Insulation layer 1270 can be made of high temperature fiberglass, silicon fiberglass, intumescent coated materials, asbestos, and the like.

The physical specifications for housing 1231 has an overall diameter in the range of 31/2 inches to 41/2 and overall length in the range of 3 inches to 15 inches, with a preferred overall diameter of 41/a and a preferred length of 4 inches. Housing 1231 has inlet and outlet openings 1238 and 1244 of tapered ends 1240 and 1246 having a diameter of less than 2 inches for inserting the neck portion 1242 into the open end 28 of the tailpipe section 22 for a proper fit.

The physical specification for core housing 1232 having a RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR. 15:14 i I/ U4/,.eUO1 14: 33 +613-9890-1337 PATENT ATT/H&H INSUR PG PAGE 32/55 +613 9890 1337 WO 97/35099 PCTUS97/04304 28 matrix core 1234 has an overall diameter of 4 inches by 4 inches in length. The insulation Jlayer.1270 is approximately 1/2 of an inch in thickness. The overall diameter of the insulated auxiliary catalytic converter 1230 is in the range of 41/2 to 51/2 inches, with a preferred overall diameter of 51/a inches.

The present invention of a catalytic converter with a back pressure relief device has been tested on different vehicle exhaust systems 10, such as a 1992 Chrysler Cherokee, a 1989 Mitsubishi Raider, and a 1989 Dodge Aires LE. In these tests, as shown in Table 6, the catalytic converter 1230 of the fourteenth embodiment 1200 had a housing 1232 which measured 8 inches in length and had a diameter of inches with a back pressure bleed valve 1050" having an orifice diameter of 0.015 inches (orifice 15 in Table or 0.017 inches (orifice 17 in Table The matrix core 1234 had a substrate diameter of 3.66 inches with 400 cells per inch of catalytic layered material 1236 having a ratio of palladium to platinum of 2:1. in test groups A through F, the catalytic converter 1230 was located and clamped by clampF 38 at the end 28 of the tailpipe 22. Test groups C andXAIa A catalytic converter 1230 with and without insulation layer 1270 (referred to as "No Insul' or "W/Insul" in Table 6) on housing 1232, as shown in Figure 16. In Table 6, "13.66" 25 refers to the 3.66 inch diameter of matrix core 1234 and "Baseline" refers to test groups A through F where there was no catalytic converter at all used in measuring the exhaust emissions. in test groups A and F "Dummy (Uncoated) Cat" refers to matrix core 1234 having no reactive substrate layers 1236 of palladium to platinum thereon.

The test results are tabulated below in Table 6, which show a substantial reduction in exhaust emissions of THC, CO RECEIVED TIME 17. APR. 14:42PR TTIE 1.A. 1:4 PRINT TIME 17. APR. 15 14 il~/~114:33 +613-9890-1337 A PATENT ATT/H&H INSUR PAGE 33/55 +613 9890 1331 WO 97/35099 PCTUJS97/04304 29 and NOX when the catalytic convert 1230 is mounted at the end 28 of tailpipe 22. The best overall results occurred in test groups C and F when the catalytic converter 1230 included an insulation layer 1270 on housing 1232, such that the TflC pollutants had a 20.0% and 31.1% reduction over baseline, respectively, the CO pollutant had a 34.1% and 19.2% reduction over baseline, respectively, and the NO., pollutants had a 28.2% and 71.7% reduction over baseline, respectively.

RECEIVED TIME 17.APR. 14:42 PRINT TIME 17. APR. 15 :14 I V 1 ri 14 z ri ID 1 14: jj +bl ;-'3890-1337 &PATENT ATT/H&H INSUR PAGE 34/55 +613 9890 1337 WO 97/35099 PCT/UJS97/04304 Table 6 'refit GrouJp Unit Type A BASELINE DUMMY4UNCOATED) CAT 3.056 W1 ORIPICE 117 aASELINE 3.66 NO ORIFICE 3.60 W1 ORIFICE 115 C BASELINE 3.88 W/ ORF016 NO INSI 3. 6 W1 ORF 5111 W/iNSUI 0 BASELINE OUMMV(UIJCOATED) CAT 3.6(6 W/ORIFICE 117 e BASELINE 3.86 No ORn~CE 3.60 W/ ORIFICE F16 IN BASELINE 3.06 W/ORF 15& NO INSU 3.00 W/OAF 1116 W/INSUL Test I 2 3 Make

CHRYSLER

CHRYSLER

CHRYSLER

1AITSLBISI

MITSUBISHI

MITSUBISHI

DODGE

DO043E

DODGE

CHRYSLER

CHRYSLER

CHRYSLER~

Model TNIC CHEROKEE 0.027 CHEROKEE 0.042 CHEROKEE 0.028 co 1 .130 1.827 0.826 NOx 0.110 D.102 0.077 %EfI TH-C -65.5 3.7

RAIDER

RAIDER

RAIDER

AMRES LE AIRES LE AIMES LE

CHEROKEE

CHEROKEE

CHEROKEE

0.594 0.688 0.625 0.420 0.404 0.338 0.0112 0,054 0.056 0.223 0.220 0.169 S.301 1.328 6.404 0.995 4.011 0.981 9.09 6.998 0.404 0.100 0,270 3.8 20.0 12.9 11.3 161ff CO 16111 NOx -43.9 7.3 26.9 30.0 -1.9 25.1 24.3 27.6 20.1 62.9 34.1 31-7 9.1 16.3 31.9 28.2 6.8 15.9 31,9 4.1 1.65" 0.389 1.443 0,300 1.082 0,265 2.241 0.833 2,111 0,633 1.620 0.807 MITSUBISHI RAIDER MITSLIBISH-I RAIDER MITSUBISHI RAIDER DODGE AIRES LE DODGE AIRES LE DODGE AIRES L.E 0.244 5.709 0.290 0.253 5.529 0.283 0.188 4,811 0.082 3.2 2.4 19.2 71.7 0 0 0 o DEVREDX6.XLS RECEIVED TIME 17. APR. 14:42PRN TIE 1.A, 15 4 PRINT TIME 17. APR, 15: 14 .tr j '/rali 14:33 +613-9890-1337 a PATENT ATT/H&H INSUR PAGE 35/55 +613 9890 1337 WO 97/35099 PCT/US97/04304 31 ADVANTAGES OF THE PRESENT INVENTION Accordingly, the primary advantage of the present invention is that it provides a catalytic converter disposed in or at the end of the tailpipe to further reduce exhaust gas emissions to meet the regulations of federal and state emission standards.

Another advantage of the present invention is that it provides a catalytic converter disposed in or at the end of the tailpipe, such that it is easy and simple to connect the catalytic converter to the end of a tailpipe by hose clamps, muffler clamps, compression fittings, mounting brackets, mounting screws, welding, crimping, or the like.

Another advantage of the present invention is that it provides a catalytic converter that can be mounted internally 15 in the open end of the tailpipe, or as an extension to the end of the tailpipe.

Another advantage of the present invention is that it provides for a catalytic converter that in operational use performs with no reduction or loss of horsepower to a vehicle.

Another advantage of the present invention is that it provides for a catalytic converter that in operational use provides substantially cleaner air emissions for a vehicle having installed the tailpipe catalytic converter of the 25 present invention.

Another advantage of the present invention is that it provides for a tailpipe catalytic converter having a back pressure relief valve that maintains the back pressure of the emission system at a predetermined level.

Another advantage of the present invention is that it provides for a tailpipe catalytic converter having a back pressure relief valve that allows excess back pressure to be RECEIVED TIME 17, APR. 14:42 PRINT TIME 17. APR, 15 :14 1,1/ U4/ 2WO 14: 33 +613-9890-1337 PATENT ATT/H&H INSUR PAGE 36/55 +613 9890 1337 WO 97/35099 PCT/US97/04304 32 diverted from the tailpipe catalytic converter and to bypass the inner core to maintain the efficiency of the system.

Another advantage of the present invention is that it provides for a tailpipe catalytic converter having a back pressure relief valve that is in the form of either a bleed valve, or a miniature check valve, or a miniature pressure relief valve for relieving any build-up of pressure within the emission system at the inlet side of the tailpipe catalytic converter to maintain the efficiency of the system.

A further advantage of the present invention is that it provides for a catalytic converter for a tailpipe that only has to be changed at every 50,000 to 100,000 miles of driving use.

A still further advantage of the present invention is 15 that it provides a catalytic converter for a tailpipe which can be mass produced in an automated and economical manner and is relatively inexpensive and long lasting.

A latitude of modification, change, and substitution is intended in the foregoing disclosure, and in some 20 instances, some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention herein.

RECEIVED TIME 17 APR. 14:42 PRINT TIME 17. APR. 15: 14

Claims (23)

1-'//04/2lU 14:33 +613-9890-1337 a PATENT ATT/H&H INSUR PAGE 37/55 +613 9890 1337 33 The claims defining the invention are as follows: 1. An exhaust system including exhaust piping and an exhaust tailpipe, a main catalytic converter disposed in said exhaust piping, and a tailpipe catalytic converter for installing in said exhaust tailpipe of said exhaust system of a vehicle, said exhaust tailpipe having an open end, said exhaust system including: said tailpipe catalytic converter which includes a hosing and an inner core of catalytic material disposed in said housing; said tailpipe catalytic converter having an inner end and an outer end; said tailpipe catalytic converter being disposed within said tailpipe, said outer end of said tailpipe catalytic converter being disposed in the vicinity of the open end of said tailpipe; S* 15 means for fixedly attaching said tailpipe catalytic converter to said surrounding tailpipe to reduce emissions from the vehicle: and means for relieving back pressure within said tailpipe by diverting exhaust gases to bypass said inner core when the exhaust 20 pressure at said inlet end of said inner core increases above a predetermined pressure level.

2. An exhaust system in accordance with claim 1, wherein said means for relieving back pressure within said exhaust system includes valve means in the form of a bleed valve, a check valve or a pressure relief valve.

3. An exhaust system in accordance with claim 2, wherein said valve means maintains the back pressure at a level above 2 inches of water and below 7 inches of water.

4. An exhaust system in accordance with claim 2 or 3, wherein said means for relieving back pressure includes a pipe extending through said inner core of said tailpipe catalytic converter having a first end disposed at the inner end of said tailpipe catalytic RECEIVED TIME 17, APR. 14:42 PR INT T IME 17. APR. 15 :14 -17/04/2001 14:33 +613-98908-1337 A PATENT ATT/H&H INSUR PAGE 38/55 ±613 9890 1337 34 converter and having a second end disposed at the outer end of said tailpipe -catalytic converter, and said valve means being connected to said first end and being disposed at said inner end of said tailpipe catalytic converter. An exhaust system in accordance with claim 2 or 3, wherein said means for relieving back pressure includes tube having an outer section extending through the wall Of said housing to the atmosphere and is disposed at the inner *end of said, tailpipe catalytic converter, and said valve means being connected to said tube outer section. An exhaust system in accordance with claim 2 or 3, wherein 0 said means for relieving back pressure includes a first tube :extending through the exterior wall of said housing at the inner 15 end of said housing, a second tube extending through the exterior wall of said housing at the outer end of said housing, said valve .**means being connected between said first and second tubes.

7. An exhaust system in accordance with any preceding claim, 0% 0 wherein said catalytic material is of the low light-off type and has a catalytic substrate of platinum and rhodium, or platinum and palladium. B An exhaust system in accordance with any preceding claim, wherein said means for fixedly attaching is selected from the group consisting of hose clamps, muffler clamps, compression fittings, mounting brackets, mounting screws, welding, crimping, and equivalents thereof.

9. An exhaust system in accordance with any preceding claim, said tailpipe catalytic converter having an inner core of catalytic material being an integral unit disposed in said housing.

10. An exhaust system in accordance with any preceding claim, wherein said tailpipe catalytic converter has a diameter in the RECEIVED TIME 17. APR. 14:42PRN TIE 1.A .1:4 PRINT TIME 17, APR. 15 14 1 '/4/2@01 14:33 +613-9890-1337 PATENT ATT/H&H INSUR PAGE 39/55 +613 9890 1337 range of inches to 8 inches and a length in the range of h to 11 inches.

11. An exhaust system in accordance with any one of claims 1 to 9, wherein said tailpipe catalytic converter has a diameter in the range of 31 inches to 4M inches and a length in the range of 3 inches to 15 inches; and a preferred diameter of 4 1/8 inches and a preferred length of 4 inches.

12. An exhaust system including exhaust piping and an exhaust tailpipe, a main catalytic converter disposed in said exhaust piping, and a tailpipe catalytic converter for installing in said 9 exhaust tailpipe of said exhaust system of a vehicle, said exhaust tailpipe having an open end, said exhaust system including: said tailpipe catalytic converter which includes a 15 housing and an inner core of catalytic material disposed in said housing; said tailpipe catalytic converter having an inner end and an outer end; 0** said housing of said tailpipe catalytic converter having a tapered end for insertion of said housing into the open end of 20 the tailpipe, so that the remaining portion of said housing extends from the open end of the tailpipe; means for fixedly attaching said tailpipe catalytic converter to said tailpipe to reduce emissions from the vehicle; and means for relieving back pressure within said tailpipe by diverting exhaust gases to bypass said inner core when the exhaust pressure at said inlet end of said inner core increases above a predetermined pressure level.

13. An exhaust system in accordance with claim 12, wherein said means for relieving back pressure within said exhaust system includes valve means in the form of a bleed valve, a check valve or a pressure relief valve. RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. APR. 15:14 '1i/Ueq/zu 14:33 +613-9890-1337 A PATENT ATT/H&H INSUR PAGE 40/55 +613 9890 1337 36

14. An exhaust system in accordance with claim 13, wherein said valve means maintains the back pressure at a level above 2 inches of water and below 7 inches of water.

15. An exhaust system in accordance with claim 13 or 14, wherein said means for relieving back pressure includes a pipe extending through said inner core of said tailpipe catalytic converter having a first end disposed at the inner end of said tailpipe catalytic converter and having a second end disposed at the outer end of said tailpipe catalytic converter, and said valve means being connected to said first end and being disposed at said inner end of said tailpipe catalytic converter.

16. An exhaust system in accordance with claim 13 or 14, wherein said means for relieving back pressure includes tube having an 15 outer section extending through the wall of said housing to the atmosphere and is disposed at the inner end of said tailpipe catalytic converter, and said valve means being connected to said tube outer section.

17. An exhaust system in accordance with claim 13 or 14, wherein 20 said means for relieving back pressure includes a first tube extending through the exterior wall of said housing at the inner end of said housing, a second tube extending through the exterior wall of said housing at the outer end of said housing, said valve means being connected between said first and second tubes.

18. An exhaust system in accordance with any one of claims 12 to 17, wherein said catalytic material is of the low light-off type and has a catalytic substrate of platinum and rhodium, or platinum and palladium.

19. An exhaust system in accordance with any one of claims 12 to 18, wherein said means for fixedly attaching is selected from the group consisting of hose clamps, muffler clamps, compression RECEIVED TIME 17. APR. 14:42 PRINT TIME 17. AP R. 15 :14 17/04/2001 14:33 +613-9890-1337 PATENT ATT/H&H INSUR PAGE 41/55 +613 9890 1337 37 fittings, mounting brackets, mounting screws, welding, crimping, and equivalents thereof. An exhaust system in accordance with any one of claims 12 to 19, said tailpipe catalytic converter having an inner core of catalytic material being an integral unit disposed in said housing.

21. An exhaust system in accordance with any one of claims 12 to wherein said tailpipe catalytic converter has a diameter in the range of I inches to 8 inches and a length in the range of 1 to 11 inches.

22. An exhaust system in accordance with any one of claims 12 to S 20, wherein said tailpipe catalytic converter has a diameter in the range of 3- inches to 41 inches and a length in the range of 3 inches to 15 inches; and a preferred diameter of 4 1/8 inches and 15 a preferred length of 4 inches.

23. An exhaust system in accordance with any one of claims 12 to 22 wherein the remaining portion of said housing has a diameter larger than the diameter of the tailpipe.

24. An exhaust system in accordance with any one of claims 12 to 20 22, wherein the remaining portion of said housing has a diameter substantially equal to the diameter of the tailpipe.

25. An exhaust system in accordance with any one of claims 12 to 24, wherein said housing has an inlet and an exhaust end which are each tapered to form a reduced size opening for noise reduction and for maintaining the back pressure of the tailpipe catalytic converter above 2 inches of water and below 7 inches of water.

26. An exhaust system in accordance with any one of claims 12 to further including a second housing surrounding said housing and defining a space therebetween; and insulation being disposed in said space for reducing loss of heat from said inner core. RECEIVED TIME 17. APR. 14:42 PRINT TIME. 17. APR. 15:13 1'hI-fL4/ziu 14: J +b1J-99-1337 'PATENT ATT/H&H INSUR PAGE 42/55 +613 9890 1337 38

27. An exhaust system for a vehicle having exhaust piping, said exhaust piping having an exhaust tailpipe with an open end, a main catalytic converter disposed in said exhaust piping, a muffler, and an auxiliary catalytic converter disposed in said exhaust piping, said exhaust system including: said main catalytic converter which is disposed in said exhaust piping; said auxiliary catalytic converter which includes a housing having an exterior wall and an inner core of catalytic material disposed ins aid housing for chemically reducing pollutant gaseous emissions; said auxiliary catalytic converter having an inner end and an outer end; said auxiliary catalytic converter being disposed within said exhaust piping of said exhaust system, and being disposed 15 between said main catalytic converter and the open end of said exhaust tailpipe; wherein said outer end is adjacent to said open end; means for fixedly attaching said auxiliary catalytic converter to said exhaust piping; and means for relieving back pressure within said exhaust system between said main catalytic converter and said auxiliary catalytic converter by diverting exhaust gases to bypass said auxiliary catalytic converter 'when the pressure of said auxiliary catalytic converter when the pressure of said exhaust gases at said inner end of said auxiliary catalytic converter increases above a predetermined pressure level, said means for relieving back pressure being located at said inner end of said auxiliary catalytic converter; wherein said means for relieving back pressure within said exhaust system includes valve means selected from the group consisting of a bleed valve, a check valve, a pressure relief valve, and an elcrncly-oto e flow valve; and wherein said valve means includes mqeans for maintaining the RECEIVED TIME 17. APR, 14:42PRN TIE 1 PR 1:3 PRINT TIME 17, APR. 15 13 i U4/ Zuul 14: 33 +61 3-9890-1 337 +613 9890 1337 APATENT ATT/H&H INSUR PAGE 43/55 back pressure within said exhaust system at a level above 2 inches of water and below 7 inches of water. 26. An exhaust system as claimed in any one of the preceding claims and substantially as hereinbefore described with particular reference to the accompahiying drawings. Dated this 17th day of April 2001 PATENT ATTORNEY SERVICES Attorneys for 10 MARK TJM (O 9* RECEIVED TIME 17. APR. 14:42 PITTM 7 P.1:1 PRINT TIME 17. APR. 15 13