An exhaust assembly for a vehicle

Abstract

The present subject matter relates to an exhaust assembly (100) for a vehicle (10). The exhaust assembly (100) comprises an exhaust pipe (102), a muffler (104), a first catalytic converter (110a) and one or more second catalytic converters (110b). The one or more second catalytic converters (110b) are configured downstream to the first catalytic converter (110a) in the exhaust path at a first pre-defined distance (f') from the first catalytic converter (102). The exhaust assembly (100) further comprises a first sensing member (112a) configured upstream of the first catalytic converter (110a), and a second sensing member (112b) configured downstream of the one or more second catalytic converters (110b) at a second pre-defined distance (s').

Description

TITLE OF INVENTIONAN EXHAUST ASSEMBLY FOR A VEHICLETECHNICAL FIELD

[0001] The present invention relates to an exhaust assembly for a vehicle. More particularly, the present invention relates to disposition of one or more catalytic converters and one or more sensors in the exhaust assembly.BACKGROUND

[0002] In internal combustion engine-based vehicles there is a rising concern on escalated pollution levels owing to exhaust from the vehicle. The internal combustion engine combusts the available fuel and transforms the chemical energy of the fuel into mechanical work at the wheels of the vehicle. The combustion process of fuel yields undesirable exhaust which may include oxides of nitrogen, oxides of carbon, as well as hydrocarbons. The internal combustion engine is coupled to an exhaust assembly, whereby the byproducts of combustion, i.e., the exhaust, is released into the atmosphere. The exhaust gas constituents beyond permissible limits raise imperative concerns of global warming.

[0003] A catalytic converter provided in the exhaust assembly treats the constituents of the exhaust. The catalytic converter typically comprises a metal, whereon the toxic constituents of the exhaust leaving the internal combustion engine is converted into less-toxic exhaust. The role of catalytic converter in treating the exhaust gases to permissible toxicity limits, yields maintenance and performance monitoring of the catalytic converter imperative to ensure proper treatment of the exhaust gases. In other words, monitoring the efficacy of the catalytic converter would ensure release of less-toxic exhaust into the atmosphere.

[0004] The exhaust assembly of an internal combustion engine-based vehicle typically comprises a single catalytic converter situated in the exhaust pipe or muffler. The catalytic converter typically comprises of metals such as palladium, platinum or rhodium which are relatively expensive and are susceptible to the heat of the exhaust. The veracity of the exhaust heat depends on the operational statusof the internal combustion engine. Therefore, upon detection of any anomaly in the catalytic converter’s performance, the vehicle user has no back-up or alternative available for treating the exhaust leaving the internal combustion engine.

[0005] Therefore, monitoring of operation of the catalytic converters is required. The performance of the catalytic converter infers whether the catalytic converter is permissible for further use or requires replacement The placement of catalytic converters is crucial for their performance and durability. If catalytic converter is positioned too close to the exhaust port of the internal combustion engine, the catalytic converter can be damaged. Conversely, if the catalytic converter is placed too far from the exhaust port, the exhaust gases are not treated effectively, reducing the efficiency and effectiveness of the conversion process. Therefore, the location of catalytic converters is critical to ensure proper treatment of exhaust gases, as well as the durability and efficiency of the catalytic converters. In addition, the disposition of the sensor too close to the catalytic converter may also raise durability concerns, while too far from the catalytic converter may lead to error in detection of operation / health of the catalytic converter.

[0006] Therefore, there arises a need in the art to provide an exhaust assembly which can solve the above-mentioned problems.

[0007] Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of described systems with some aspects of the present disclosure, as set forth in the remainder of the present application and with reference to the drawings.SUMMARY OF THE INVENTION

[0008] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

[0009] In accordance with embodiments illustrated herein, the present subject, provide a solution to suitably locate catalytic converters and sensors, such asoxygen sensors, in an exhaust flow path of an exhaust assembly such that optimal function of the catalytic converters and the sensors are maintained, without any disruption in the vehicle layout. Also, the present invention also improves efficiency and effectiveness of the catalytic converters and the sensors.

[0010] In accordance with an embodiment, the present subject matter relates to an exhaust assembly for a vehicle. The exhaust assembly comprises an exhaust pipe, a muffler, at least one first catalytic converter, one or more second catalytic converters, a first sensing member and a second sensing member. The exhaust pipe is coupled to an exhaust port of an internal combustion engine of the vehicle. The muffler coupled to the exhaust pipe. The exhaust pipe and muffler are configured in an exhaust path of exhaust exiting from the exhaust port. The first catalytic converter in the exhaust path is configured in the exhaust pipe. The one or more second catalytic converters are configured downstream to the first catalytic converter in the exhaust path at a first pre-defined distance from the first catalytic converter. The first sensing member is configured upstream of the first catalytic converter. The second sensing member is configured downstream of the one or more second catalytic converters at a second pre-defined distance from the one or more second catalytic converters.

[0011] In an embodiment, each of the first sensing member and the second sensing member is an oxygen sensor. The first sensing member and the second sensing member are communicatively connected to a control unit of the vehicle.

[0012] In an embodiment, the first pre-defined distance and the second pre-defined distance being associated with a dimension of the first catalytic converter.

[0013] In an embodiment, the one or more second catalytic converters being configured in the exhaust pipe.

[0014] In another embodiment, the one or more second catalytic converters being configured in the muffler.

[0015] In an embodiment, the exhaust pipe comprising a plurality of bends and at least one linear pipe segment being configured between two adjacent bends of theplurality of bends. The first catalytic converter and the one or more second catalytic converters are configured in the at least one linear pipe segment of the exhaust pipe.

[0016] In an embodiment, a diameter (d) of the first catalytic converter being in a range of 20mm to 90mm.

[0017] In an embodiment, a length (1) of the first catalytic converter being in a range of 40mm to 130mm.

[0018] In an embodiment, the first predefined distance being in a range of 0 to 2 times a diameter of the first catalytic converter.

[0019] In an embodiment, the second predefined distance being in a range of 1 to 7 times a length of the first catalytic converter.

[0020] In an embodiment, the second predefined distance being in a range of 1 to 10 times a diameter of the first catalytic converter.

[0021] In an embodiment, the first predefined distance being in a range of 2mm to 250mm.

[0022] In an embodiment, the second predefined distance being in a range of 0mm to 200mm.

[0023] In an embodiment, a sensing face of each of the first sensing member and the second sensing member interfacing exhaust gases flow along the exhaust path. A mounting portion of each of the first sensing member and the second sensing member is provided along an external surface of the exhaust assembly.BRIEF DESCRIPTION OF DRAWINGS

[0024] The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and therein. Although the invention is generally described in context of these embodiments illustrated in the drawings, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.

[0025] The detailed description is described with reference to the accompanying figures, which is related to an exhaust assembly. However, the present subject matter is not limited to the depicted embodiment(s). In the figures, the same or similar numbers are used throughout to reference features and components.

[0026] Figure 1 (a) illustrates a perspective view of an exhaust assembly of a vehicle, in accordance with an embodiment of the present disclosure.

[0027] Figure 1 (b) illustrates a perspective view of an exhaust assembly of a vehicle, in accordance with another embodiment of the present disclosure.

[0028] Figure 1 (c) illustrates a perspective view of an exhaust assembly of a vehicle, in accordance with another embodiment of the present disclosure

[0029] Figure 2 illustrates a side view of a saddle type vehicle, in accordance with an embodiment of the present disclosure.DETAILED DESCRIPTION

[0030] The present disclosure may be best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the methods and systems may extend beyond the described embodiments. For example, the teachings presented, and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown.

[0031] References to “one embodiment,” “at least one embodiment,” “an embodiment,” “one example,” “an example,” “for example,” and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic,property, element, or limitation. Further, repeated use of the phrase “in an embodiment” does not necessarily refer to the same embodiment.

[0032] The present invention now will be described more fully hereinafter with different embodiments. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather those embodiments are provided so that this disclosure will be thorough and complete, and fully convey the scope of the invention to those skilled in the art.

[0033] Embodiment explained of the present subject matter, provide a solution to suitably locate catalytic converters and sensors, such as oxygen sensors, in an exhaust flow path of an exhaust assembly such that optimal function of the catalytic converters and the sensors are maintained, without any disruption in the vehicle layout. Also, the present invention also improves efficiency, effectiveness and durability of the catalytic converters and the sensors

[0034] It is an objective of the present subject matter to provide an exhaust assembly for a vehicle and the exhaust assembly comprising at least one first catalytic converter and one or more second catalytic converters configured in the exhaust assembly for treatment / conversion of exhaust gases of the vehicle.

[0035] To this end, the present disclosure provides at least one first catalytic converter configured in the exhaust pipe of the exhaust assembly, and one or more second catalytic converters configured downstream of the first catalytic converter. The one or more second catalytic converters may be configured in at least one of: the exhaust pipe and the muffler. During vehicle operation, to avoid deterioration of the noble metal contained in the first catalytic converter since the first catalytic converter serves as a first interfacing component due to exposure of heat of the exhaust, the first catalytic converter and the second catalytic converters are provided with a predefined dimension and suitably located in the exhaust assembly to efficiently treat or perform conversion of the exhaust gases without any damage to the catalytic converters. In addition, even a failure of the first catalytic converter is addressed by configuration of the one or more second catalytic convertersdownstream of the first catalytic converter. The treatment of the exhaust is therefore retained and addressed despite failure of the first catalytic converter.

[0036] In an embodiment, the first catalytic converter is configured in the exhaust pipe, and a second catalytic converter is configured downstream of the first catalytic converter in the muffler or the exhaust pipe. A first sensing member is disposed upstream of the first catalytic converter and a second sensing member is disposed downstream of the second catalytic converter. During vehicle operation, the difference between the values transmitted by the first and second sensing members provides the efficacy of both the catalytic converter. The first conversion member due to its proximity to the exhaust port may be susceptible to the elevated temperatures of the engine, therefore to improve life cycle or durability of the first catalytic converter is suitably packed and provided with predefined dimension in the exhaust pipe. In addition, even in the event of failure of the first catalytic converter, the exhaust is adequately treated by the one or more second catalytic converters, which are relatively isolated from the engine heat and exhaust temperature leaving the exhaust port. Further, the difference in values between the first and second sensing members not only monitors the efficacy of the second catalytic converter but may also be used to alert the vehicle user of the any issue or failure of the first catalytic converter. However, until replacement, the second catalytic converter continues supporting the reduction in toxicity of the exhaust.

[0037] It is an objective of the present disclosure to configure a first sensing member and a second sensing member relative to the first catalytic converter and the one or more second catalytic converters.

[0038] To this end, the first sensing member is configured upstream of the first catalytic converter, and the second sensing member is configured downstream of the one or more second catalytic converters. The disclosed configuration permits transmittal of an overall conversion performance of the first catalytic converter along with the one or more second catalytic converters in treatment of the exhaust received from the internal combustion engine.

[0039] The first sensing member is provided in a cylinder head in vicinity of the exhaust port of the engine. Further, the second sensing member is provided downstream of the one or more second catalytic converters at a second pre-defined distance. The second pre-defined distance ensures that the exhaust heat passing the one or more second catalytic converters does not directly interface with the sensing face of the second sensing member, but rather travels some distance in the exhaust path before interfacing to reduce the impact of the heat on the sensing face. However, disposition of the sensing member too far from the second catalytic converter may lead to errors in oxygen concentration determination, hence the second pre-defined distance provides an appropriate range of disposition of the sensing member vis-a-vis the second catalytic converter which protects the sensing face of the second sensing member and does not lead to transmittal of error values.

[0040] It is an objective of the present subject matter to configure a first catalytic converter and one or more second catalytic converters in the exhaust assembly without any disruption in the exhaust layout.

[0041] The exhaust assembly as per an embodiment comprises multiple bends. The exhaust leaving the exhaust port by the time it reaches the muffler through the various bends and contours of the exhaust gases has a reduced temperature, which impact on the operation of the catalytic converters. A linear pipe segment may be configured between adjacent bends for ease of assembly of the catalytic converters. The first catalytic converter and the one or more second catalytic converters are configured in the linear pipe segment so as to minimize design and manufacturing variations in accommodating the respective catalytic converters in the existing exhaust assembly layout.

[0042] The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein recitingprinciples, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.

[0043] Figure 1 (a) illustrates a perspective view of an exhaust assembly for a vehicle, in accordance with an embodiment of the present disclosure. Figure 1 (b) illustrates a perspective view of an exhaust assembly for a vehicle, in accordance with another embodiment of the present disclosure. Figure 1 (c) illustrates a perspective view of an exhaust assembly for a vehicle, in accordance with another embodiment of the present disclosure.

[0044] For the sake of brevity, Figures 1(a), 1(b) and 1(c) are explained in conjunction. With reference to Figures 1(a), 1(b) and 1(c), 100 denotes an exhaust assembly, 102 denotes an exhaust pipe, 102b denotes one or more bends of the exhaust assembly, 1021 denotes linear pipe segments of the exhaust assembly, 104 denotes a muffler, 104 denotes an exhaust inlet port, 108 denotes a tail pipe, 110a denotes a first catalytic converter, 110b denotes one or more second catalytic converters, 112a denotes a first sensing member, 112b denotes a second sensing member, 114m denotes a mounting portion of the sensing members, 114s denotes a sensing face of the sensing members, f denotes a first pre-defined distance and s’ denotes a second pre-defined distance.

[0045] In addition, referring to Figure. 2, in an embodiment, the internal combustion engine 180 comprises a cylinder head, a cylinder block and a crankcase. An exhaust port 106 may be coupled to the cylinder head of the engine 180.

[0046] In an aspect, the internal combustion engine 180 includes the cylinder block coupled to the cylinder head. The cylinder head may comprise at least one intake port (not shown) and at least one exhaust port. The intake port transmits a mixture of air and fuel into a combustion chamber of the cylinder block. During the combustion process, a spark plug provided in the cylinder head ignites the air fuel mixture. The combustion of the air-fuel yields a reciprocal motion of the piston contained in the cylinder block. The reciprocal motion of the piston is then transformed into rotational movement of a crankshaft provided in the crankcase via a connecting rod. The crankcase may enclose the crankshaft and a transmissionassembly. A transmission assembly (not shown) comprising gears, sprockets and chains may be used in the internal combustion engine for operating cam shafts, or valves, or even the speed of rotation of the crankshaft. Post combustion of the air fuel, the by-products of combustion known as exhaust or exhaust gases leaves the combustion chamber and reached the exhaust port 106 the cylinder head of the engine 180 and from the exhaust port 106 reached to the exhaust assembly 100.

[0047] In an embodiment, the exhaust assembly 100 comprise an exhaust pipe 102 and a muffler 104. The exhaust pipe 102 may refer to a tubular member coupled to an exhaust outlet port of the internal combustion engine 180. The exhaust pipe 102 serves as a passage of the exhaust exiting the combustion chamber via the exhaust port 106. The exhaust pipe 102 may comprise multiple bends so as to increase the length of traversal of the exhaust / exhaust gases. The bends in the exhaust pipe 102 change the path of exhaust traversal between vehicle front-rear, vehicle left-right as well as vehicle up-down. Alternately, the exhaust pipe 102 may be linearly oriented. The exhaust pipe 102 may be composed of a metal to permit heat radiation from the exhaust towards the external air via the surface of the exhaust pipe 102. The exhaust pipe 102 is coupled to a muffler 104 at an opposite end.

[0048] In an aspect, the muffler 104, alternately referred to as a silencer, is a noise attenuating device. The muffler 104 is configured to restrain pulsation in the exhaust gas thereby restraining the volume of exhaust sound generated by the exhaust gas. The muffler 104 is coupled to a tail pipe 108 which serves as the end portion for the release of the exhaust or exhaust gas into the external atmosphere. The path the exhaust traverses between the exhaust port 106 of the internal combustion engine 180 and the tail pipe 108 is deemed the exhaust path. The tail pipe 108 is a tubular structure extending from the muffler 104.

[0049] In an aspect, at least one first catalytic converter 110a and the one or more second catalytic converters, such as but not limited to the second catalytic converter 110b, purify the exhaust gases alternately referred to as the “exhaust”, which are by-product of the combustion process. For instance, The first catalytic converter 110a and the one or more second catalytic converter 110b may include a hollowcylindrical casing which forms a part of the muffler 104 or the exhaust pipe 102. The first catalytic converter 110a and the one or more second catalytic converter 110b may be a three-way catalyst removing three constituents of the exhaust, i.e hydrocarbons, carbon monoxide and nitrogen oxide. The first catalytic converter 110a and the one or more second catalytic converters 110b may be an oxidationreduction catalyst. The first catalytic converter 110a and the one or more second catalytic converters 110b may include a base and catalytic materials formed of a carrier and noble metal. The carrier supports the noble metal. The noble metal may include platinum, palladium and rhodium or any other metal known to remove hydrocarbons, oxides of carbon and oxides of nitrogen. The first catalytic converter 110a and the one or more second catalytic converters 110b may comprise a porous structure resembling a honeycomb. The first catalytic converter 110a and the one or more second catalytic converters 110b may be a metal -base or ceramic base catalyst. The first catalytic converter 110a and the one or more second catalytic converters 110b can have any suitable shape based on requirement.

[0050] In an aspect, the first sensing member 112a and the second sensing member 112b can be any of oxygen sensors or air fuel ratio sensors disposed upstream and downstream of the first catalytic converter 110a and the one or more second catalytic converters 110b. In a preferred embodiment, each of the first sensing member 112a and the second sensing member 112b can be any of oxygen sensors is an oxygen sensor. The first sensing member 112a and the second sensing member 112b may detect the amount of oxygen present or the oxygen density of the exhaust exiting the combustion chamber of the internal combustion engine 180.

[0051] In the description, the term “upstream” indicates the upstream direction in which exhaust gas flows. The term “downstream” indicates the downstream direction in which exhaust gas flows. Furthermore, the term “path direction” indicates the direction in which exhaust gas flows. For the sake of clarity “exhaust path” refers to the direction of movement of the exhaust from the exhaust port 106 through the exhaust assembly 100 and into the atmosphere via the tail pipe 108. Theexhaust path has been marked in Figure 1(b) using arrows to denote the direction in which the exhaust flows into the atmosphere.

[0052] In an embodiment, the first sensing member 112a (shown in Figure lb) is provided upstream to the first catalytic converter 110a interacting with the exhaust leaving the exhaust port 106. The second sensing member 112b is provided downstream of any of the one or more second catalytic converters 110b. Therefore, the second sensing member 112b can provide the efficacy or performance of the entire catalytic converter assembly comprising the first catalytic converter 110a and the one or more second catalytic converters 110b.

[0053] In an embodiment, the first catalytic converter 110a in the exhaust path is configured in the exhaust pipe 102. The one or more second catalytic converters 110b is configured downstream to the first catalytic converter 110a in the exhaust path at a first pre-defined distance (f ) from the first catalytic converter 102. The one or more second catalytic converters 110b is configured in at least one of the muffler 104 and the exhaust pipe 102.

[0054] In an embodiment, the first sensing member 112a is configured upstream of the first catalytic converter 110a. The second sensing member 112b is configured downstream of the one or more second catalytic converters 110b at a second predefined distance (s’) from the one or more second catalytic converters 110b.

[0055] In an embodiment, the first pre-defined distance (f ) and the second predefined distance (s’) can be associated with a dimension of the first catalytic converter 110a.

[0056] In an embodiment, the exhaust pipe 102 can include a plurality of bends 102b and at least one linear pipe segment 1021 configured between two adjacent bends of the plurality of bends 102b. The first catalytic converter 110a and the one or more second catalytic converters 110b are configured in the linear pipe segment 1021 of the exhaust pipe 102.

[0057] In an embodiment, the first predefined distance (f ) can be in a range of 0 to 2 times a diameter (d) of the first catalytic converter 110a.

[0058] In another embodiment, the second predefined distance (s’) can be in a range of 1 to 7 times a length (1) of the first catalytic converter 110a.

[0059] In another embodiment, the second predefined distance (s’) can be in a range of 1 to 10 times a diameter (d) of the first catalytic converter 110a.

[0060] In another embodiment, the first predefined (f ) distance being in a range of 2mm to 275mm.

[0061] In another embodiment, the second predefined distance (s’) or the distance between the second sensing member 112b and the second catalytic converter 110b can be in a range of 0mm to 200mm.

[0062] In another embodiment, in an exhaust assembly of one type of vehicle, for instance scooters, the second predefined distance (s’) or the distance between the second sensing member 112b and the second catalytic converter 110b can be 2 to 80 mm.

[0063] In another embodiment, in an exhaust assembly of one type of vehicle, for instance in motorcycles, the second predefined distance (s’) or the distance between the second sensing member 112b and the second catalytic converter 110b can be 2 to 200 mm.

[0064] In an embodiment, the diameter (d) of the first catalytic converter 110a can be in a range of 20mm to 90mm.

[0065] In an embodiment, the length (1) of the first catalytic converter 110a can be in a range of 40mm to 130mm.

[0066] In an embodiment, the positioning of the second sensing member 112b closer to the second catalytic converter 110b reduces the error rate in the sensor signal and reduce error in the sensor signal.

[0067] Figure 1(a) illustrates an embodiment where the first catalytic converter 110a is disposed in the linear pipe segment and distanced from the second catalytic converter 110b via a bend 102b of the exhaust pipe 102. The first pre-defined distance f marked in the figure maps with the arc of the bend in the exhaust pipe102. In this configuration, both the first catalytic converter 110a and the second catalytic converter 110b are provided or disposed in the exhaust pipe 102. The first sensing member 112a (not shown in Figure 1(a)) is provided upstream of the first catalytic converter 110a in vicinity of the exhaust port 106. The second sensing member 112b is positioned downstream of the second catalytic converter 110b at a second pre-defined distance s’. The exhaust post detection by the second sensing member 112b enters the muffler 104 and exits through the tail pipe 108.

[0068] Figure 1(b) illustrates another embodiment where the first catalytic converter 110a and the second catalytic converter 110b are disposed in the same linear pipe segment 1021 of the exhaust pipe 102. The first sensing member 112a is upstream of the first catalytic converter 110a. The second sensing member 112b is provided in the linear pipe segment succeeding or downstream or consequent to the linear pipe segment 1021 accommodating the catalytic converters 110a, 110b. The second sensing member 112b is at a second pre-defined distance s’ to the second catalytic converter 110b.

[0069] In a preferred embodiment depicted in Figure 1(a) and 1(b) the first sensing member 112a and the second sensing member 112b are configured in the linear pipe segments of the exhaust pipe 102.

[0070] Figure 1(c) illustrates the bends 102b and linear pipe segments 1021 of the exhaust pipe 102. Similar to Figure 1(b), the first catalytic converter 110a and the second catalytic converter 110b are disposed in the same linear pipe segment 1021 of the exhaust pipe 102. The bends 102b refer to any arcs developed or observed in the contour of the exhaust pipe 102.

[0071] The accommodation of the first catalytic converter 110a and the second catalytic converter 110b in the linear pipe segment 1021 of the exhaust pipe 102 provides ease of assembly and minimum design modifications in the exhaust layout. The catalytic converters need not be modified to be fitted into an arced portion. Even mounting of the sensing member is easier, since the sensing face 114s is normal to the direction of the exhaust path providing a uniform surface of interference for exhaust constituent detection.

[0072] In a preferred embodiment, where a main catalyst and sub-catalyst configuration exists in the vehicle 10, the first sensing member 112a is configured upstream to the first catalytic converter 110a and the second sensing member 112b is configured downstream of the second catalytic converter 110b. Any of the first catalytic converter 110a and the second catalytic converter 110b may be either of the main catalyst or sub-catalyst. The second catalytic converter 110b is the last conversion member interacting with the exhaust prior release of the exhaust into the atmosphere. In this embodiment, the total efficacy of the first and second catalytic converters are detected by the sensing members 112a, 112b irrespective of a failure or deterioration in either of the catalytic converters 110a 110b. Therefore, the vehicle user as well as servicemen are at all times aware of the efficacy of the catalytic converters 110a 110b. Further, variance in detected sensor values may be used to adjudge or predict deterioration of a conversion member of the catalytic converters 110a 110b. The sensing members 112a, 112b are connected to a control unit of the vehicle and send the sensed to the control unit, which determine the health or operating condition of the catalytic converters 110a 110b based on the sensed data.

[0073] In an embodiment, the sensing members 112a, 112b may be disposed upstream and downstream of each catalytic converter 110a, 110b of the exhaust assembly 100 to detect the efficacy of each catalytic converter. The vehicular component, such as the control unit, based on the received oxygen values from the sensing members 112a, 112b may be configured to detect deterioration or failure of the respective catalytic converters 110a 110b and alert the vehicle user or servicemen.

[0074] In an aspect, the sensing portion or sensing face 114s of the sensing member 112a, 112b is inserted into the exhaust path of the exhaust assembly 100 while the mounting portion 114m of the sensing members 112a, 112b is provided in the external casing or external surface of the exhaust assembly 100 comprising the exhaust pipe 102 and the muffler 104.

[0075] a sensing face (114s) of each of the first sensing member (112a) and the second sensing member (112s) being interfacing with the exhaust path so that the sensing face (114s) of each of the first sensing member (112a) and the second sensing member (112s) remain in contact of the exhaust gases. A mounting portion (114m) of each of the first sensing member (112a) and the second sensing member (112b) being provided along an external surface of the exhaust assembly (100)

[0076] To this end, the external casing may comprise a mounting provision configured to receive the sensing member 112a, 112b. The mounting provision may comprise a slot permitting ingress of a portion of the sensing member 112a, 112b into the exhaust path of the exhaust pipe 102 and / or the muffler 104. The mounting provision may comprise a cup like structure sealing a periphery of the mounting portion 114m. A mounting boss may then be inserted into the openings of the mounting provision. The mounting boss is configured to secure or mount a portion of the sensing member 112a, 112b. More specifically, while the mounting portion 114m of the sensing member 112a, 112b occurs in the external casing, the sensing portion 114s of the sensing member 112a, 112b protrudes, extends or is inserted into the exhaust pipe 102 and / or the muffler 104.

[0077] In an aspect, exit portion of the tail pipe 108 is oriented in a direction away or opposite to the disposition of the sensing member 112a, 112b to ensure that the exhaust does not affect the operation of the sensing member 112a, 112b. More specifically, at least one of the one or more sensing members 112a, 112b is oriented opposite to a direction of exhaust exiting from the tail pipe 108 of the exhaust assembly 100. The tail pipe 108 is connected to the muffler 104 at a downstream portion.

[0078] In an aspect, the first catalytic converter 110a and the one or more second catalytic converters 110b may comprise a main or master catalyst and a sub-catalyst configuration.

[0079] In an embodiment, the configuration of main or master catalyst and subcatalyst does not relate to an efficacy of a catalytic converter being superior to the other, but rather the probability of failure of one catalytic converter against anotherunder vehicle operating conditions. The vehicle operating conditions, as per the present configuration, leads to undesirable proximity of heated zones of the internal combustion engine 180 and the exhaust to the catalytic converters, which deem the first catalytic converter 110a prone to premature failure.

[0080] In another embodiment, the configuration of main or master catalyst and sub-catalyst relates to an efficacy of a catalytic converter being superior to another, whereby the main catalyst has higher conversion efficacy of the exhaust in comparison to the sub-catalyst.

[0081] In the one embodiment, the first or master catalyst 110a is provided in the exhaust pipe 102 and a sub or second catalyst 110b is configured in one of the muffler 104 and the exhaust pipe 102. The impact on the first catalyst 110a due to the heat of the internal combustion engine 180 is therefore graver than that on the second catalyst 110b. During vehicle operations, the heat impact on the first catalyst 110a may lead to deterioration or part failure of the first catalyst 110a in comparison to the second catalyst 110b. Therefore, the majority of the catalytic conversion may have to be undertaken by the second catalyst 110b. In this configuration, even if the first catalyst 110a is subjected to part failure, the second catalyst 110b can support the first catalyst 110a in continued catalytic conversion of the exhaust. In this configuration, equal amount of noble metal or efficacy may be associated with both the catalytic convertors i.e. the first catalyst 110a and the second catalyst 110b.

[0082] In another embodiment, the main or master catalyst 110b may be configured in the muffler or rear portion of the exhaust pipe 102 and the sub catalyst 110a may be configured in an upstream portion of exhaust pipe 102. In this configuration, there may be a distribution of efficacy between the main catalyst 110b and the sub catalyst 110a whereby the amount of noble metal in the main catalyst 110b may be higher than that of the sub catalyst 110a. In other words, the main catalyst 110b has a higher efficacy than the sub catalyst 110a. The main catalyst 110b being protected in the muffler or rear portion of the exhaust pipe ensures that the major proponent of catalytic conversion remains isolated from the heat of the internal combustion engine 180, while the sub catalyst 110a may have asacrificial nature in reducing the impact of the exhaust heat or heat contained in the exhaust directly onto the main catalyst 110b.

[0083] Both the first embodiment and the second embodiment supports the creation of a durable exhaust assembly supporting exhaust emission control in a saddle type vehicle 10. It is observed that by the time the exhaust exiting the internal combustion engine 180 reaches the muffler 104 or rear portion of the exhaust pipe 102 via traversing the exhaust path of the exhaust pipe 102, the temperature of the exhaust may reduce to up to 100 degrees Celsius.

[0084] Figure 2 illustrates a side view of a saddle type vehicle in accordance with an embodiment of the present disclosure.

[0085] The vehicle 10 described herein can encompass various embodiments, including but not limited to internal combustion (IC) engine vehicles and hybrid electric vehicles (HEVs), and any other suitable configurations known in the automotive industry comprising an internal combustion engine and an exhaust assembly.

[0086] The vehicle 10 includes a frame assembly (not shown) to support different parts of the vehicle 10. In an upper portion of the frame assembly (not shown), a handlebar assembly 115 is rotatably integrally connected to the steering shaft (not shown). The handlebar assembly 115 is used to steer the vehicle 10 and is connected to a front wheel 185 through the steering shaft (not shown) and a front fork assembly (not shown). An upper portion of the front wheel 185 is covered by a front fender 190 which prevents mud and water from getting deflected towards the steering shaft (not shown). Further, the front fork assembly 195 is supported on the front fender 190 by means of a brace fender (not shown).

[0087] In a front portion of the frame assembly (not shown) a fuel tank assembly 120 is arranged immediately behind the handlebar assembly 115 and is disposed over a first power source, for example an internal combustion engine 180. A seat assembly 125 is placed behind the fuel tank assembly 120. The seat assembly 125 includes a front rider seating portion and a pillion rider seating portion. The pillionrider seating portion is placed on the rear part of the frame assembly (not shown), where the rear part of the frame assembly (not shown) is covered by the tail cover assembly (not labelled).

[0088] For the safety of the rider and in conformance with the traffic rules, a headlamp assembly 105 that includes a headlamp 113 and front indicator lights 140a are provided in the front portion of the vehicle 10. On the rear portion of the two wheeled vehicle 10 a tail lamp (not labeled) and rear indicator light 140b are provided on the rear portion of the tail cover assembly (not shown). Above a tail cover assembly 130 and behind the seat assembly 125 a pillion handle 135 is provided for the pillion rider to grab.

[0089] Suspension systems are provided for comfortable steering of the two wheeled vehicle 10 on the road. A front suspension assembly 195 serves as rigidity component for the front portion of the vehicle 10 just like the frame assembly (not shown). The front suspension assembly 195 clamped to the head tube (not shown) through an upper bracket (not labelled) and a lower bracket (not labelled) is capable of being moved to the left and right. Further, a rear suspension system 160, which is a hydraulic damped arrangement, is connected to the frame assembly (not shown). The rear suspension system 160 comprises of at least one rear suspension 160 preferably disposed centrally in the longitudinal mid plane of the vehicle 10. However, in a vehicle 10 with two rear suspensions, the same may be disposed on the left side and the right side respectively of the vehicle 10.

[0090] The first power source, for example the internal combustion engine 180 is mounted to a front lower portion of the frame assembly (not shown) by means of an engine mounting bracket (not shown). The internal combustion engine 180 is partially covered on the lower side of the internal combustion engine 180 by an engine cover 175. The internal combustion engine 180 is equipped with an exhaust system that includes an exhaust pipe connected to the internal combustion engine 180 and an exhaust assembly 100 connected to the exhaust pipe. The exhaust assembly 100 extends rearwards along the right side of the rear wheel 150.

[0091] Further, a swing arm 200 extending rearwards is swingably connected to a lower rear portion of the vehicle 10. The rear wheel 150 is rotatably supported at a rear end of the swing arm 200. Power from the internal combustion engine 180 is transmitted to the rear wheel 150 through a power drive mechanism, such as a drive chain, so as to drive and rotate the rear wheel 150. A center stand 165 is provided in between the front wheel 185 and the rear wheel 150 for parking the vehicle 100.

[0092] A rear fender 145 for covering an upper side of the rear wheel 150 is mounted to a rear portion of the vehicle 10 to prevent mud and water splashed by the rotating rear wheel 150 from entering the exhaust assembly 100, the internal combustion engine 180 and other parts disposed close by. To enhance the overall aesthetics of the vehicle 10 and to prevent undesired foreign particles from entering parts of the vehicle 10, a plurality of rear covers (not labeled) is attached to a rear portion of the frame assembly (not shown). The area below the seat assembly 125 and the fuel tank assembly 120 of the vehicle 10 is covered on both sides by a cover frame assembly 170. The cover frame assembly 170 includes the one or more side covers.

[0093] The present disclosure provides a compact packaging of multiple catalytic converters in an existing exhaust assembly without disruption in the vehicle layout. The maintenance of the first pre-defined distance between the first and second catalytic converter, and a second pre-defined distance between the second catalytic converter and second sensing member provides better torque output of the vehicle 10 in a mid-range of vehicle speed. Further, the respective pre-defined distances permits heat dissipation from the exhaust into the atmosphere.

[0094] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter and is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.

[0095] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

[0096] The present teaching includes any and all embodiments including equivalent elements, modifications, omissions, combinations (e.g., of features across various embodiments), adaptations and / or alterations which can be understood by those skilled in the art on the basis of the present disclosure. The limitations in the claims are to be interpreted broadly on the basis of the language used in the claims. The limitations in the claims are not limited to the embodiments described herein or during the prosecution of the application. Such embodiments are to be construed as non-exclusive. For example, the term "preferably" or "preferable" herein is non-exclusive and means "preferably / preferable, but not limited to."

[0097] A person with ordinary skills in the art will appreciate that the systems, modules, and sub-modules have been illustrated and explained to serve as examples and should not be considered limiting in any manner. It will be further appreciated that the variants of the above disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different systems or applications.

[0098] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims.Summary of Reference Numerals:

Claims

We claim,1. An exhaust assembly (100) for a vehicle (10), the exhaust assembly (100) comprising:an exhaust pipe (102) coupled to an exhaust port (106) of an internal combustion engine (180) of the vehicle (10);a muffler (104) coupled to the exhaust pipe (102), the exhaust pipe (102) and muffler (104) being configured in an exhaust path of exhaust exiting from the exhaust port (106);at least one first catalytic converter (110a) in the exhaust path being configured in the exhaust pipe (102);one or more second catalytic converters (110b) being configured downstream to the first catalytic converter (110a) in the exhaust path at a first pre-defined distance (f ) from the at least one first catalytic converter (102);a first sensing member (112a) being configured upstream of the first catalytic converter (110a); anda second sensing member (112b) being configured downstream of the one or more second catalytic converters (110b) at a second pre-defined distance (s’) from the one or more second catalytic converters (110b).

2. The exhaust assembly (100) as claimed in claim 1, wherein the one or more second catalytic converters (110b) being configured in the exhaust pipe (102).

3. The exhaust assembly (100) as claimed in claim 1, wherein the one or more second catalytic converters (110b) being configured in the muffler (104).

4. The exhaust assembly (100) as claimed in claim 1, wherein the exhaust pipe (102) comprising a plurality of bends (102b) and at least one linear pipe segment (1021) being configured between two adjacent bends of the plurality of bends (102b), andthe first catalytic converter (110a) and the one or more second catalytic converters (110b) being configured in the at least one linear pipe segment (1021) of the exhaust pipe (102).

5. The exhaust assembly (100) as claimed in claim 1, wherein a diameter (d) of the first catalytic converter (110a) being in a range of 20mm to 90mm, and wherein a length (1) of the first catalytic converter (110a) being in a range of 40mm to 130mm.

6. The exhaust assembly (100) as claimed in claim 1, wherein the first predefined distance (f ) being in a range of 0 to 2 times a diameter (d) of the at least one first catalytic converter (110a).

7. The exhaust assembly (100) as claimed in claim 1, wherein the second predefined distance (s’) being in a range of 1 to 7 times a length (1) of the first catalytic converter (110a).

8. The exhaust assembly (100) as claimed in claim 1, wherein the second predefined distance (s’) being in a range of 1 to 10 times a diameter (d) of the first catalytic converter (110a).

9. The exhaust assembly (100) as claimed in claim 1, wherein the first predefined (f ) distance being in a range of 2mm to 250mm.

10. The exhaust assembly (100) as claimed in claim 1, wherein the second predefined distance (s’) being in a range of 0mm to 200mm.

11. The exhaust assembly (100) as claimed in claim 1, wherein a sensing face (114s) of each of the first sensing member (112a) and the second sensing member (112s) being interfacing with exhaust gases flow along the exhaust path, and a mounting portion (114m) of each of the first sensing member(112a) and the second sensing member (112b) being provided along an external surface of the exhaust assembly (100), and wherein each of the first sensing member (112a) and the second sensing member (112b) being an oxygen sensor and communicatively connected to a control unit of the vehicle (10).

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