System and method for deterrence of catalytic converter theft

A system and method for deterring catalytic converter theft are described. A variety of devices are described which can be installed as needed on the underside of a vehicle as part of a system to prevent easy access to the points where a catalytic converter is connected to the vehicle, thus deterring theft, or to prevent a catalytic converter from being removed from the vehicle after being disconnected from the exhaust system. The method comprises installing said devices to prevent this access. The devices may be installed separately or combined to protect multiple catalytic converters as needed and as dictated by the particular design of the exhaust system of a particular vehicle.

Not Applicable.

BACKGROUND

This disclosure relates generally to the field of devices designed for vehicles. It is more specifically related to devices designed to deter the theft of catalytic converters from vehicles.

Catalytic converters contain several precious metals, including platinum, palladium, and rhodium. The existence of these precious metals, in sufficient quantity makes catalytic converters an attractive target for theft by criminals. Vehicles which tout a “zero-emissions” status, such as hybrid vehicles, typically possess the highest content of precious metals, and are an especially valuable target for crime. For example, a brand-new catalytic converter replacement for the Toyota® Prius,® can cost more than $2000 USD. In general, a catalytic converter can generate a significant payment from a scrap dealer. An efficient team of two thieves, with the correct tools, can remove a converter in less than two minutes. In one night, such a team could make several thousand dollars during a few hours of illicit activity.

The problem of catalytic converter theft is a massive one. In Northern California alone, crime statistics put the number of thefts into the many thousands per month, and in some months, topping ten thousand per month. Given that converter theft is such a lucrative illicit enterprise, these numbers are unlikely to drop. As such, it is up to the individual vehicle owner to find a way to protect his vehicle from this type of crime.

As catalytic converter theft is common, a number of solutions have been proposed. Some solutions propose that a vehicle owner weld the catalytic converter to the frame of the vehicle. Other disadvantageous approaches have emerged which serve to act as a deterrence. One approach is set forth in U.S. Pat. No. 7,971,676 which includes a cable cage design that surrounds the catalytic converter with aircraft grade wire rope. While potentially effective, it is very complicated and very difficult to install. Other approaches include the Cat Strap device (www.catstrap.net as of Feb. 11, 2021), which is comprised of a strap that is attached across the catalytic converter and an adjacent exhaust pipe. The strap has a multi-cable construction which is difficult to cut through, and is connected to a high decibel auditory alarm which is set off when the cables are breached.

Another requirement for any device to prevent catalytic converter theft is that it allow for a visual inspection of the catalytic converter, as a number of jurisdictions require that the device be periodically visually inspected. Easy visual access to the information on the catalytic converter is essential to the ease of use of any solution to deter catalytic converter theft. Furthermore, not hindering airflow can be important as well.

The earlier solutions described herein fall short in their complexity of design, failing to deny the thief access to the catalytic converter or some other failure. A need therefore exists for a catalytic converter theft deterrence device which achieves simplicity of design while denying a thief access to the converter as much as possible.

In addition, different vehicles have different construction and different solutions are required. The Toyota Prius varies in its model years in the collection of components around the catalytic converter, with different model years and models having different components immediately around the catalytic converter, requiring differently-shaped covers. Other vehicles, for example, a Nissan® NV-200 cargo van, produced by Nissan North America Inc., (see https://www.nissanusa.com/vehicles/commercial/nv200-compact-cargo.html as of Feb. 11, 2021, which is incorporated herein in its entirety by this reference) which is often used as a fleet vehicle, has two catalytic converters which are easily accessible from multiple points. What is required is a solution that is effective to deter catalytic converter theft in a variety of vehicles.

SUMMARY OF THE DISCLOSURE

The present disclosure comprises a novel system and method of protecting the catalytic converter of a vehicle, and in several specific illustrative embodiments, the catalytic converters of various generations of Toyota Prius and of a Nissan NV-200 but it will be understood that the principles taught herein can readily be applied to any number of different vehicles and different catalytic converters.

The inclusion of any dimensions in the accompanying drawings or in the present specification is merely illustrative or exemplary and cannot be limiting of the present disclosure.

DETAILED DESCRIPTION

Before the devices, systems, processes and methods will be disclosed and described, it is to be understood that this disclosure is not limited to the particular configurations, process steps, and materials disclosed herein as such configurations, process steps, and materials may vary somewhat. It is also to be understood that the terminology employed herein is used for the purpose of describing particular illustrative embodiments only and is not intended to be limiting since the scope of the disclosure will be limited only by the appended claims and equivalents thereof.

In describing and claiming the subject matter of the disclosure, the following terminology will be used in accordance with the definitions set out below.

As used herein, the terms “comprising,” “including,” “containing,” “characterized by,” “having” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps.

For convenience in describing the method and use of the current disclosure, singular masculine or feminine pronouns have been used to describe the person executing the methods described. It is to be understood that no limitation of the invention to use by one gender or the other is intended by such use.

In describing the illustrative embodiments of this disclosure, it will be understood that a number of techniques and steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps or applications in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the claims.

As used herein, “security fasteners” means any of a number of devices which are used as fasteners which include special security precautions making it difficult to remove them without a specific security tool. This may include both screws and bolts, or other types of fasteners that require some type of security tool to remove. For example, a screw may have a an oddly shaped drive, or require a special tool to fasten, while a security nut or bolt may have a smooth head which can only be gripped by a specific tool. A variety of types of security fasteners are known in the art, and additional types of security fasteners may be possible. As examples, devices described as “security screws,” “tamperproof screws,” screws having a “one-way slot drive,” or devices requiring a “snake eyes spanner drive” to remove or tighten may be included as “security fasteners”; however, the term is not meant to be limiting. While specific embodiments of the instant disclosure may call for a particular type of security fastener, this is not intended to limit the type of security fastener which may be used, and indeed said security fastener may be substituted for a different type of security fastener which fits the situation. As such, the term “security fastener” is used to describe any of the variety of fasteners possible which are designed to prevent easy removal without a security tool. When a more specific term is used, it is to be understood that the substitution of another type of security fastener is intended to be within the instant disclosure. “Security Fasteners” may also include devices described as tamper-proof hardware, tamper proof screws, and other tamper proof fasteners.

A novel device, system, and method of deterring catalytic converter theft is described. It will be appreciated that the main goal of the system is to make theft of the catalytic converter(s) of a vehicle difficult enough that a potential thief moves on to another target, while appreciating that no system can prevent theft in all cases. Furthermore it will be appreciated that due to differing designs, cosmetic changes may be required to the appearance of the device and the locations of specific anchoring bolts and devices. Several individual embodiments are described, including embodiments which protect the catalytic converters on various generations of the Toyota® Prius,® as well as a specific illustrative embodiment of the system and method of protecting the catalytic converters of a Nissan® NV-200 is described. However, it will be appreciated that many of the principles and disclosures herein may apply to many other vehicles.

The instant disclosure illustrate vehicle-specific devices to deter catalytic converter theft which provides benefits not previously available. Each device described herein is adapted for a particular vehicle, based on the principles set forth in this disclosure. It will be appreciated that the specific embodiment created for one vehicle will not be installable on a different vehicle. Specific embodiments disclosed in this application include an embodiment designed to fit on a Toyota® Prius®, model year 2004-2009, shown at least inFIG.11, an embodiment designed to fit on a Toyota® Prius®, model year 2010-2015, shown at least inFIG.14, and an embodiment designed to fit on a Nissan® NV-200 Cargo van, shown at least inFIG.10. While elements of these embodiments may be incorporated into embodiments which will apply to other specific vehicles, the specific elements will generally not be directly transferable to different vehicles.

The specialization of the device as a vehicle specific device allows for better protection, as a different vehicles may require protection in different areas, or different types of protection in order to deter catalytic converter theft. For example, in the case of a Toyota® Prius®, a plate cut to fit the specific configuration of the lower portion of the vehicle will generally suffice to deter catalytic converter theft while, though in some vehicles additional rails or plates may be added to provide additional deterrence. However, unlike a Toyota® Prius®, a Nissan® NV-200 has two catalytic converters, neither of which is easily covered by a plate as the Toyota® Prius®, and as such a different arrangement of the system is required to provide adequate theft deterrence.

A number of devices offer generic protection for a catalytic converter; however, these devices cannot be incorporated as specifically into the vehicle, and may not provide the same level of theft deterrence with the minimal interference with the vehicle itself. Some embodiments of the instant invention may be installed with the vehicle specific hardware already present on a given vehicle, which is difficult or impossible to accomplish using a generic type of catalytic converter protection. As such, the instant invention represents a significant improvement over the prior art.

A novel system for deterring catalytic converter theft includes one or more devices designed to be installed on the underside of a vehicle in order to prevent easy access to a catalytic converter, whether by preventing a potential thief from easily accessing the catalytic converter itself, or by preventing a potential thief from easy access to points where the catalytic converter and exhaust system are attached to the vehicle, or can be cut free from the vehicle. In addition, the system may prevent a potential thief from easily removing the catalytic converter from the vehicle. Indeed, the system prevents easy access to the catalytic converter, presenting such a level of impracticality to a thief, that a potential thief moves on and does not take the time and effort which removing the catalytic converter would take.

In one embodiment the disclosed device attaches to the underside of a vehicle and covers the catalytic converter, which is often exposed to easy access by a potential thief. The device may take the form of a plate which attaches to the underside framing of the vehicle and covers the catalytic converter. In some embodiments, the catalytic converter will also be surrounded by other vehicle components, preventing easy access to the catalytic converter from other locations and allowing a simple plate to prevent all easy access. In other embodiments, the vehicle may have no other components close to the catalytic converter, or there may be few attachment points for a device, necessitating a device which encloses the catalytic converter from more than just below, perhaps including side plates or a complete box. In other embodiments, there may be locations where the exhaust system of the vehicle can be easily detached at locations far removed from the catalytic converter, requiring additional covers to protect areas of void in the underside of the vehicle which grant access to the catalytic converter through longer tools or simply unbolting portions of the exhaust system.

FIG.11shows one embodiment of the instant disclosure which is a planar, plate-like structure, which is designed to specifically fit over catalytic converter and the portions of the exhaust system of the vehicle which are exposed. In this embodiment, the device prevents easy removal of the catalytic converter. The embodiment shown inFIG.11is designed to deter theft of a catalytic converter from a 2004-2009 Toyota Prius. In one embodiment, the device may include an additional structure, such as a dog-ear corner16which covers the oxygen sensor of the vehicle, thus preventing theft of the oxygen sensor as well.

FIG.11, additionally, shows one embodiment the device comprises a window cutout18placed in the device at a strategic location to allow for viewing the catalytic converter's associated manufacturing information such as serial number or part number. In many states of the United States, emissions authorities require that associated manufacturing information on the surface of the catalytic converter be accessible for an inspection. This window may be a simple rectangular window or it may take the shape of a particular design which is desired by the manufacturer.

Still referring toFIG.11, in one embodiment the theft deterrence device is cut from an aluminum plate. In addition to being light and resisting corrosion, when cut with a radial saw or other saw-like cutting tool aluminum tends to form small particles which fill in the gaps between the teeth of the cutting tool, slowing progress and making it more difficult to cut through. While the preferred embodiment is cut from an aluminum plate, it will be understood that simply by being present the plate will slow the progress of a potential thief, and any material which will significantly slow the process of accessing and removing the catalytic converter will serve a similar function and this disclosure is not intended to limit the potential materials out of which the device can be constructed. For example, stainless steel could be used to construct a plate or theft-deterrence system which would be effective.

In one embodiment, still referring toFIG.11, the theft deterrence device also comprises a number of through-holes14around the perimeter12of the device. These through-holes are used for attaching the device to the underside of the vehicle. As shown inFIG.12, wherein the components on the underside of the vehicle are shown with dotted lines and the device is shown in solid lines, the device10is installed on the bottom of the vehicle20by attaching it to the frame of the vehicle. In one embodiment, the front through-holes13are mounted on existing factory studs (also at13) where an OEM splash guard17is mounted after removing the splash guard and replacing it over the device. In one embodiment, the device is further secured to the bottom of the vehicle by attaching it at the side attachment points15to the frame rails24on the bottom of the vehicle around the catalytic converter. In one embodiment the cover10is secured to the frame rails24using a combination of rivets and security fasteners. In one embodiment, eight rivets are used along with six security screws (four rivets and three security screws on each side). In one embodiment the through-holes are only drilled as the device is attached to the vehicle.

In one embodiment, a device for deterring catalytic converter theft also includes a vent11which allows for the circulation of air around the catalytic converter and the exhaust system of the vehicle. This maintains proper cooling of the exhaust system and helps to prevent overheating.

In another embodiment of a system to deter catalytic converter theft shown inFIGS.13A-B, additional plates or security rails may be installed along with the plate shown inFIG.11to prevent a potential thief from accessing the catalytic converter through other areas under the vehicle.FIG.13Ashows a first (rear) security rail12placed in back of the plate10shown inFIG.11. The security rail extends perpendicularly from the plate and has a space for the exhaust pipe14to pass through the rail. The rear security rail prevents access to the space between the cover10and the bottom of the vehicle, further deterring catalytic converter theft.

FIG.13Bshows a front security plate16installed in a void in the front of the vehicle which prevents access to the exhaust system and hence the catalytic converter through that void. In one embodiment, the security rails and additional security plates further restrict access to the exhaust system and catalytic converter by covering and protecting areas from which the catalytic converter and exhaust system may be indirectly accessed. In one embodiment, these plates and rails are specifically designed to cover the vulnerable locations in a specific vehicle. The embodiments shown inFIG.13show embodiments designed for a Toyota Prius 2004-2009 model year. However, additional embodiments are possible for other vehicles but must be specifically designed for those vehicles for optimal protection. In some cases the plate itself may be sufficient to deter theft, as access to the catalytic converter with the plate installed is much more difficult than without the plate installed, but additional plates or security rails may increases the difficulty of accessing the catalytic converter and thus further deter theft of said catalytic converter.

Another embodiment of a system to deter catalytic converter theft, shown inFIGS.14A-B, is designed to apply to a 2010-2015 Toyota Prius vehicle. In one embodiment the theft deterrent device must be shaped differently in order to properly fit on the bottom of the vehicle and cover up the catalytic converter to deter theft. This embodiment comprises a front plate22, shown inFIG.14A, and a rear plate24, shown inFIG.14B. In this embodiment the front and rear plate together prevent access to the catalytic converter while also deterring a thief from removing the heat extractor behind the catalytic converter. In one embodiment there is a window26to allow easy viewing of the catalytic converter manufacturing information. Furthermore, vents28are provided which allow air to flow around the catalytic converter area, facilitating cooling of the converter and the exhaust system. In this embodiment the device attaches to points on the vehicle underbody. Again, in one embodiment of a method for deterring catalytic converter theft the devices are attached to the vehicle using a combination of rivets and security fasteners secured through holes30located around the perimeter20of the device. These rivets and security fasteners prevent the device from being easily removed and better deter catalytic converter theft. In one embodiment the security fasteners are security screws which require a special tool to fasten and remove.

In one embodiment of a method of deterring catalytic converter theft, the location of the catalytic converter is assessed on the underside of the vehicle, along with the position of points at which easy access to the exhaust system can be gained. A metallic plate is then cut out to cover the catalytic converter and easily attach to the frame or body of the underside of the vehicle. In some embodiments covering the access points to the catalytic converter and exhaust system may require additional plates or coverings. In one embodiment each of these coverings may have vents cut into it to allow for air circulation. In another embodiment, the plate which covers the catalytic converter itself has a window cut into it to allow viewing of the data on the catalytic converter without removal of the plate. In one embodiment of the device, it may be attached to the vehicle with a combination of rivets and security fasteners, preventing the plate from being quickly removed by a potential thief and further deterring catalytic converter theft.

It will be understood that different vehicles may require differently-shaped devices or different combinations of devices to properly deter catalytic converter theft. Devices with different shapes are anticipated and expected by this disclosure, which is not meant to limit the shape of the device being used to prevent catalytic converter theft. Even for the specific models of vehicle disclosed herein, variations in size and shape of the device may be possible.

In another illustrative embodiment of the present disclosure, a device is designed to deter theft of a catalytic converter located in a position where it cannot be shielded by a simple plate. When a catalytic converter is surrounded by other components of the vehicle, a simple plate can protect the converter and the rest of the exhaust system, preventing it from being cut away and preventing the catalytic converter from being removed.

However, in some cases, the catalytic converter is located in a position where a simple plate cannot deter theft of the catalytic converter. This may be because the catalytic converter is easily accessed or is simply located on the bottom of the vehicle. One example of a catalytic converter located in such a position is shown inFIG.1A, which shows a catalytic converter101connected to an exhaust pipe102, which is exposed on all sides and is easily accessible to potential thieves.FIG.1Bshows the same catalytic converter protected by one embodiment of the present disclosure103.

FIG.1Bshows one illustrative embodiment of the present disclosure, being a box103which is bolted to the vehicle as described below. The box prevents the catalytic converter from being easily removed from the vehicle. Even if the catalytic converter is detached from the exhaust system of the vehicle, it cannot be removed from the box103, which is securely attached to the frame of the vehicle. The box103, has openings104through which the exhaust pipe102passes through, and in one embodiment may have vents105to promote proper air circulation and cooling. As such, the illustrated embodiment is designed to deter theft by hindering a thief from being able to remove the catalytic converter and carry it away from the vehicle.

Another illustrative embodiment of the present disclosure involves a method of installing said box using security hardware, to prevent the easy removal of the box. In one illustrative embodiment of the present disclosure the box is constructed out of stainless steel to prevent the box from being cut into or easily cut off of the vehicle. The box greatly increases the time which a thief must spend in attempting to remove the catalytic converter, thus deterring the theft of the catalytic converter, as it both decreases the likelihood that a thief will attempt to steal the catalytic converter of a particular vehicle and increases the likelihood that someone will notice, as the time to get at the catalytic converter is greatly increased.

In another illustrative embodiment of the present disclosure, the box is comprised of four distinct components. The first component of this embodiment is shown inFIGS.2A-D. The first component is the top portion of the box and comprises a piece of sheet metal which can be attached to the vehicle. In one illustrative embodiment for the Nissan NV-200 van, a bracket may be attached to the frame of the vehicle as shown inFIG.1B, to which the first component is attached. The first component is attached to the vehicle in a way which makes it difficult to remove. For example, the first component, and the bracket it is attached to, may be securely attached using rivets, security fasteners, or whatever other type of connecting device which prevents the easy removal of the bracket and top portion of the device from the vehicle.

FIG.2Ashows a top down view of the first component which is attached to the underside of the vehicle. In one embodiment the first component may be 9 inches along a first side201and 12 inches along a second side202, while the distance between the first and second side along a third side206may be 9.86 inches but many other dimensions may be used in accordance with the vehicle the present disclosure is applied to. These measurements may be adopted for the best fit depending on the vehicle. Both sides201,202may have a perpendicular lip203seen inFIGS.2C and2D, which is designed to be attached to the other components of this embodiment. This lip203may be one inch wide. In another embodiment, a lesser or greater width may be used in order for the side to be an appropriate width to install proper connecting hardware to connect the first component200to the second component300.FIG.2Bshows an orthogonal view of the first component, whileFIG.2Cshows a side view from the direction of the second side202.

FIG.2Dshows a side view looking from the direction of the third side206. This component has through holes204on the top edges which are used to attach the first component to the vehicle with rivets, security fasteners, or another type of connecting device that prevents easy removal. It also has through holes205on the perpendicular lip203which are used to secure the first component200to the second component300.

The first component200is designed to be attached to the second component of the box300, shown inFIG.3, which comprises the sides and bottom of the box. It will be appreciated that again, this connection may be accomplished with whatever secure method of connecting may be known in the art. For example, security fasteners may be used to make it more difficult to remove the box and catalytic converter. The first component is attached to the vehicle in a location above the catalytic converter, allowing the second component to be attached in such a way as to surround the catalytic converter.

The second component of the box comprises two sides of the box and the bottom of the box, as shown inFIGS.3A-D.FIG.3Ashows the bottom of the second component, which may be 10 inches along a first side301and 13.5 inches along a second side302. The second component may have a window in it303located in the center of the bottom side which is 2.3 inches along a first side304and broadens to approximately 3.4 inches along a second side305. The window may be approximately 6.7 inches in length306.

FIG.3Bshows a side view of the second component, showing the second side302. It also shows that the second component is taller along a first end307with a height of approximately seven inches, while having a height of approximately five and three-quarters inches along a second end308.FIG.3Cshows a three-dimensional view of the second component300.FIG.3Dshows the second component as it is cut, showing lines309where the sides are folded up ninety degrees from the bottom to produce the box shown inFIG.3C. The notches310are cut out to provide an optimal fit. There are also through-holes311which are used to connect the second component300to the first component200. It should also be noted that the exemplary slots312along the first306and second307ends are designed to accept tabs from the two side components to create a finished box.

The size of the second component is whatever size will efficiently cover the catalytic converter without interfering with the functioning of the vehicle, while the size of the window is designed to allow viewing of the catalytic converter and the information on it, while not allowing the catalytic converter to fit through the window. The window may be covered with a grating which still allows easy visual access to the information on the catalytic converter. The sizes stated here may be modified according to these principles. The top edges of the two sides are designed to attach securely to the first component of the box, while the empty sides are designed to have the third and fourth components of the box fitted in to create a complete box around the catalytic converter. The second component of the box will have a window cut out of the bottom portion of the box which is too small for the catalytic converter to fit through, but allows for technicians to view the catalytic converter and the information present on it and verify information and legality of the catalytic converter. Examples of information which may be present on the catalytic converter are OEM factory markings, or aftermarket part numbers or California Executive Order numbers or other information which is used to verify that the catalytic converter is legal for use on a specific vehicle. As noted above, the second component of the box may be attached to the first component of the box through any secure means which will secure it to the vehicle and prevent the easy removal of the box. In general, this may include security fasteners, rivets, or other secure hardware.

The third and fourth components of the box, shown inFIGS.4-5are end caps. The third component400, shown inFIG.4, is attached to the front of the second component. The third component400may have a height406of approximately 5.875 inches including the tabs402on the bottom, and is designed to fit snugly on the front side of the second component300of the box when it is fitted to the first component of the box200. The third component has a gap401which is designed to fit around the exhaust pipe when installed, but is also small enough to prevent the catalytic converter from being removed from the box. This gap is designed so that it fits around the exhaust system without actually touching it, giving the system proper clearance. In one embodiment this gap has a length404of three and a quarter inches wide with a 0.375 inch distance405between it and the bottom side of the third component. The gap may begin a distance407of approximately 3.125 inches from one side of the third component. It will be appreciated that such dimensions are merely exemplary and many other dimensions can be used in accordance with the present disclosure.

Still referring toFIG.4, the third component400also has tabs402on the sides which are designed to fit into the slots on the second component of the box, securing the two components together. The tabs402may be bent over once the two components are fitted together to help secure the components together. In addition, the third component may have vents403which allow for airflow around the exhaust system.

FIG.5shows the fourth component of the box500. This component is similar to the third component400, and is of similar size, but is designed to fit on the rear portion of the second component300. The fourth component500also has a gap501, but the gap may have a width504of only two and three quarter inches, and may be a distance505of a full inch from the bottom of the component. The fourth component500also has tabs502to secure it to the second component300in the same manner as the third component400. In addition, the fourth component may have vents503which are cut out to allow for the proper circulation of air.

It will be appreciated that the box formed of these components does not prevent a thief from attempting to cut through the exhaust system of the vehicle to remove the catalytic converter. However, it does make simply cutting through the exhaust system fruitless, as the catalytic converter remains inside the box, which is securely attached to the vehicle and cannot be easily removed. Therefore the box deters catalytic converter theft by preventing the catalytic converter from being taken in any amount of time acceptable to a thief.

It will also be appreciated that the embodiment of the box as shown is one illustrative embodiment of the present disclosure, which is designed to precisely protect the rear catalytic converter of a Nissan NV-200 cargo van. However, a similar box could be used to protect the catalytic converter of any vehicle with an exposed converter with few other vehicle components around it. It will also be appreciated that other similar or partial configurations are possible which fit specifically with catalytic converters located in similar positions on other vehicles.

It will be appreciated that other embodiments may be necessary to protect catalytic converters in other locations on the vehicle. For example, the front catalytic converter of a Nissan NV-200 is located in a part of the vehicle where it is difficult to surround with a box, and which is not easily covered with a plate due to other components. Furthermore, the front portion of the connection is easily un-bolted from the vehicle, allowing the catalytic converter to be removed easily.FIG.6Ashows this catalytic converter601and the void around it602, while also showing the vehicle components603which make it difficult to install a box or flat plate around this catalytic converter.FIG.6Bshows the void602without the catalytic converter.FIG.6Cshows a void604at the front of the vehicle where the exhaust system can be easily accessed to remove the front catalytic converter of the Nissan NV-200. This void602and the front void604allow easy access to the front exhaust flange. The catalytic converter601can be easily un-bolted from the vehicle at the front exhaust flange. One illustrative embodiment of the present disclosure requires covering the voids where a thief can gain access to the catalytic converter and exhaust system with metal plates which are themselves another embodiment of the present disclosure.

FIGS.7A-7Bshow the middle void covered by a metal plate701, which is another embodiment of the present disclosure, from two different angles:FIG.7Alooking straight at the plate andFIG.7Blooking at the plate from a lower angle. This plate701makes access to the catalytic converter702difficult, preventing access to the front flange where a catalytic converter can be unbolted from the middle of the vehicle, while still allowing for an inspector or technician to see the parts of the converter that need to be seen for inspection. The plate701may be formed of aluminum or another, appropriately strong, material which will prevent easy cutting and removal of the plate or catalytic converter, such as stainless steel.

FIGS.8A-8Dshow the configuration of a plate which fills the void as shown inFIGS.7A and7B, showing that the plate is cut to fit around the catalytic converter and the other cords and components of the vehicle in close proximity to it.FIG.8Ashows a side view of the plate, showing the semi-circular cut-out801which fits around the catalytic converter. This cut-out may extend to a distance810of 0.69 inches from the bottom of the plate. Other cut-outs802are designed to fit around the other components of the vehicle near the catalytic converter. Vents803are also present, and exemplary fastening points804, where the plate may be secured to the vehicle. In one embodiment, designed for a Nissan NV-200 cargo van, the plate may have a length805of approximately 26.75 inches and a height at its greatest point806of approximately 8.875 inches.FIG.8Bshows the bottom of the plate, showing two large through-holes807which can be used to secure the plate to the vehicle. In one embodiment of the plate, the bottom has a width808of 5.5 inches. It will be appreciated that other dimensions may be readily used in accordance with the principles taught herein and to best apply to a particular vehicle.

FIG.8Dshows the arrangement of the plate as cut out, showing the line809, on which the plate is bent to form the finished component800shown inFIG.8C. The line809may be located as need to produce the finished form with the distances expressed in the previous figures.

FIG.6Cshows the front void604, where in a Nissan NV-200 a thief may also gain access to the front exhaust flange to unbolt the catalytic converter,FIG.7Cshows the void604covered by the front plate703, which is fitted around a front void in the components of the engine and prevents easy access to the front exhaust flange, thus preventing the catalytic converter from being unbolted easily.

FIG.9shows a diagram of one embodiment of the front plate designed to fit around the front void of a Nissan NV-200, as seen inFIG.6C. The plate as installed is shown inFIG.7C.FIG.9Bshows an orthogonal view of the plate900, showing a lip901designed to allow the plate to be secured to the vehicle.FIG.9Ashows the lip with two through holes902through which the plate may be installed on the vehicle.FIG.9Cshows a top down view of the plate, showing a vent903which may be present in one embodiment of the invention.FIG.9Dshows the plate from the side, showing the lip901used to install the plate, whileFIG.9Eshows the plate as cut out, showing the line904which is folded at a ninety degree angle to create the lip901. The front plate900is installed in the vehicle as shown and described inFIG.7C. The through holes902are used to attach the shield to two factory bolts so that it can prevents access to the void shown inFIG.6C.

FIGS.9A-9Dshow a diagram of the front plate designed to fit the Nissan NV-200, but again it will be appreciated that a similar plate could be constructed to deny access to the front exhaust flange and prevent the catalytic converter from being removed from any vehicle, by modifying the part to fit the particular vehicle. The embodiment shown inFIGS.7A-C,8A-D &9A-E is designed to fit a particular vehicle, the Nissan NV-200, but it will be appreciated that similar principles may be applied to other vehicles to deny access to the voids where a catalytic converter may be removed easily from the exhaust system of a vehicle.

The device shown inFIGS.8A-Dblocks access to the front exhaust flange from the middle of the vehicle. The device shown inFIGS.9A-Eprevents access to the front exhaust flange from the front of the vehicle. The combination of the two plates prevents the catalytic converter from being easily unbolted from the vehicle at the front exhaust flange. It will be appreciated that in some illustrative embodiments, depending on the vehicle and the location of the catalytic converter and the other components on the underside of the car, one, or both of the devices will be used to prevent the catalytic converter from being removed. In one embodiment, used on the Nissan NV-200, both components are used to prevent the front catalytic converter from being removed. It will also be appreciated that in some cases, such as where the catalytic converter is completely exposed, an embodiment as shown inFIGS.1A-B,2A-D.3A-D &4will be the more effective way to deter catalytic converter theft. In one embodiment, particularly used to deter catalytic converter theft on the Nissan NV-200, but which can be adapted for use in similar vehicles with two catalytic converters, a system is used to deter catalytic converter theft which comprises a box as shown inFIGS.1A-B,2A-D.3A-D &4positioned around the rear catalytic converter while the plates shown inFIGS.7A-C,8A-D &9A-E are placed to deter theft of the front catalytic converter.

One embodiment of a system to deter catalytic converter theft, shown inFIG.10, is installed on a Nissan NV 200.FIG.10shows the underside of the vehicle, including the exhaust pipe1010and the catalytic converters1020and1030, only portions of which are visible due to the installed system. The system comprises the box1040formed of the components shown and described inFIGS.1A-B,2A-D.3A-D &4and assembled as described to deter theft of the rear catalytic converter1020. Also shown are the mid-shield plate1050described inFIGS.8A-Dand the front shield1060described inFIGS.9A-E, which are installed as described to protect the front catalytic converter1030. As a whole, the system is designed to deter theft of either catalytic converter by preventing a potential thief from easily accessing the catalytic converters and the areas of the vehicle where the catalytic converters can be easily removed from the vehicle. As such, in order to remove a catalytic converter, a would-be thief would have to devote far more time than removing the catalytic converter from an un-protected vehicle, causing a thief to either give up and move on or perhaps be caught in the additional time required.

The embodiments described may be constructed out of an appropriate metal, such as stainless steel, more specifically out of stainless steel plating, which is cut into the shapes required and fitted to the vehicle. Such plating can be 14 gauge, 16 gauge or another suitable thickness as will be know to those filled in the art. It will be noted, though, that this disclosure is not meant to be limiting on the thickness of the plating used, as thicker or thinner materials may work as well or may be required with different vehicles. Furthermore, while stainless steel plating may be desirable for specific embodiments, in other embodiments, aluminum may be the preferred material in some applications. Furthermore, while metals are preferred, other materials such as a high-temperature plastic or polymer may be adapted for the purpose. This disclosure is not meant to be limiting on the thickness or type of materials.

In another illustrative embodiment of the present disclosure, a method of deterring catalytic converter theft is proposed. Said method involves preventing easy access to the voids on the underside of the vehicle where easy access to the catalytic converter and the components attaching the catalytic converter to the vehicle are located. In one illustrative embodiment, these components may be portions of the exhaust system which are easily cut through. In another illustrative embodiment they may be portions of the exhaust system where the catalytic converter can be easily unbolted, such as the front exhaust flange.

Another illustrative embodiment of the present disclosure involves installing a device which prevents the catalytic converter from being removed from the vehicle even if it is detached from the rest of the exhaust system. This deters theft because a thief will realize that even if the catalytic converter can be easily detached from the exhaust system, the thief will likely not realize any benefits as the catalytic converter can not easily be taken. In this embodiment, the system should be designed such that it is clear to the thief that they will not be able to access the catalytic converter. Hence installing a box which is securely bolted to the car around the catalytic converter. This will hopefully deter the thief before the thief cuts into the exhaust system and damages the vehicle.

In another illustrative embodiment of the present disclosure, shown inFIGS.9A-E, the system is designed to protect the catalytic converters of a Nissan NV-200. In this embodiment, there are three distinct areas of protection. The first area of protection for the Nissan NV-200 is a void at the front of the vehicle where the front catalytic converter is bolted at the front exhaust flange. The first area of protection is covered by a plate shaped and designed to deny access to front void.

The second area of protection is the mid-section void. The system protects this void through a formed plate that attaches to a crossmember, then folds up to block easy access to the voids and surround the catalytic converter. This prevents a common tool from being used to unbolt the front flange and remove the catalytic converter from the mid-section void. Therefore, the first two areas of protection prevent the front catalytic converter from being removed from the vehicle by preventing it from being unbolted from the front flange. While a thief could still attempt to cut behind the front catalytic converter, a thief cannot access any portion of the front connection of the catalytic converter to the vehicle, thus preventing easy removal of the catalytic converter.

The second catalytic converter of the Nissan NV-200, located under the main body of the vehicle, is protected by the box shown inFIGS.1A-B,2A-D.3A-D &4. This catalytic converter is very easily accessible to thieves. To deter theft of the second catalytic converter, a bracket is attached to the existing frame rails on the underside of the vehicle, to which a stainless steel box is attached to surround the catalytic converter. This stainless steel box as shown is attached using security fasteners and is attached to the bracket and the underside of the vehicle. The front and end caps go around the exhaust tubing, while the main box comprises the bottom three sides of the box and surrounds the catalytic converter. The top component of the box is a bracket which attaches to the frame on which the box is mounted. The main box also comprises a viewing window which allows the catalytic converter to be viewed and authenticated in an inspection. The rear protective device prevents the catalytic converter from being removed from the vehicle. Therefore, even if the converter is severed from the rest of the exhaust line, it is still contained in the box and cannot be removed without removing the security fasteners and the box itself. Desirably, as represented inFIG.10, the present disclosure provides three distinct areas of protection, which together provide advantages and benefits which are not otherwise available in the art.

One embodiment of a system for deterring theft of a catalytic converter while allowing visual inspection of the catalytic converter includes a cover installed on the underside of a vehicle around the catalytic converter which prevents access to the exposed catalytic converter and exhaust system from the underside of the vehicle. In one embodiment this cover also includes an opening to allow a technician to view the catalytic converter. This opening may be a grate or numerous small slits through which the catalytic converter can be viewed, or it may be a window which is small enough that the catalytic converter can not be removed through it, while being large enough to view the critical information for a smog check on the catalytic converter while also ensuring the legality of the catalytic converter. There may also be vents in the plate which allow for proper air circulation around the catalytic converter and the exhaust system and other components on the underside of the vehicle.

In one embodiment, the cover may be attached to the underside of the vehicle by drilling a series of holes through the frame on the underside of the vehicle and attaching the device to the underside of the vehicle through the use of rivets. In another embodiment security fasteners may be used, and a combination of rivets and security screws may be used to secure the cover to the frame on the underside of the vehicle. In other embodiments, a system for deterring theft of a catalytic converter may be installed directly to the underside of a vehicle. In yet another embodiment, a cover may be secured to existing factory bolts which are a part of the vehicle. These bolts may be used as installed, or additional, longer bolts may be installed in place of the factory bolts in the places where the factory bolts are generally installed.

In another embodiment, a system for deterring catalytic converter theft may also comprise one or more additional plates, in addition to the main cover which prevents direct access to the catalytic converter. These additional plates may be placed to prevent access to one or more voids where the catalytic converter or exhaust system of the vehicle may be accessed and detached from the vehicle in order to remove the catalytic converter from the vehicle. These additional plates may be secured to using the existing bolts in the vehicle (which may be replaced with security fasteners) or they may be secured by screws and/or rivets to the frame of the vehicle.

One embodiment of the device described herein is easy on a vehicle and once installed, covers the catalytic converter and attached exhaust pipe so that a thief is denied access to the converter. The only viable choice for a determined thief encountering the device on the vehicle is to engage in a lengthy disassembly of the device from the underbody of the vehicle, which would be time consuming and impractical. The device achieves its goal of deterrence by presenting such a level of impracticality to a thief, that a savvy thief will move on to other, less protected vehicles.

In one embodiment, the invention is comprised of a plate which is cut to span between the various vehicle underpinnings and attach to them. For example, framed vehicles, such as pickup trucks, have frame rails and cross members; the device would be cut to span between frame rails and attach to them. The device can also be cut to strategically attach to the underpinnings of vehicles employing unibody construction. Regardless of the underpinnings to which the device is attached, the device spans over and covers the area beneath the vehicle, which contains the catalytic converter, adjacent exhaust pipe front, and rear of the converter and oxygen sensor. The final result is a plate covering the catalytic converter and adjacent components, totally denying access to a thief.

In another embodiment the present disclosure comprises a series of plates to cover a variety of voids in the underside of the vehicle which allow access to the catalytic converter. In yet another embodiment the present disclosure comprises a box created to bolt onto the vehicle which prevents a thief from removing the catalytic converter from the vehicle. In addition, two or more of the above embodiments may be combined to provide the best protection for a catalytic converter in a particular vehicle.

The components of the present disclosure may be constructed out of whatever material is easily shaped and withstands the conditions under the vehicle while being difficult to cut through and deter theft. In a preferred embodiment the components are formed out of metal, and in one embodiment out of stainless steel. In another embodiment the components are formed out of aluminum. However, other metals may be used which are not so heavy as to adversely affect the functioning of the vehicle. It is possible that other materials, such as a solid, high temperature plastic or other polymer could be adapted to use in the present disclosure.

While in some cases embodiments have been described for a particular vehicle, it will be appreciated that said embodiments may be adapted to fit vehicles with similar placement of the catalytic converter so as to effectively deter theft of the catalytic converter and prevent damage to the vehicle. As such, one or more embodiments may be used for a particular vehicle depending on the arrangement of vehicle components surrounding the catalytic converter and the ease of access to the catalytic converter.

It will also be understood that different vehicles may require differently-shaped devices or different combinations of devices to properly deter catalytic converter theft. Devices with different shapes are anticipated and expected by this disclosure, which is not meant to limit the shape of the device being used to prevent catalytic converter theft. Even for the specific models of vehicle disclosed herein, variations in size, shape, dimensions and composition of the device is possible in accordance with the principles set forth herein.

Although the present disclosure has been illustrated and described herein with reference to preferred illustrative embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention, are contemplated thereby, and are intended to be covered by the following claims.