Abstract:
A new and improved exhaust system as described herein, wherein the catalytic cartridge is selectively replaceable. The catalytic cartridge, which contains the catalyst, is located within the baffle tube. The baffle tube is easily inserted and removed from the housing assembly of the exhaust system, thereby making it simple and efficient to remove and replace the catalytic cartridge.

Description:
This application claims priority to U.S. Ser. No. 60/353,767, entitled REPLACEABLE CATALYST FOR EXHAUST SYSTEM, filed Jan. 31, 2002. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to an exhaust system for a two-cycle engine, and more particularly to a catalytic cartridge for a two-cycle engine, and even more particularly to a replaceable catalytic converter cartridge for a two-cycle engine. 
     2. Description of the Related Art 
     Current exhaust systems have the catalytic cartridge, which contains the catalyst, enclosed within the housing assembly of the exhaust system. The catalyst cartridge is securely in place within the housing assembly, and cannot be easily removed. In fact, in the current state of the art, if the catalytic cartridge needs to be replaced, the entire housing assembly needs to be replaced, because the catalytic cartridge cannot be easily removed. Therefore, it is the object of this invention to make an easily replaceable, and removable catalytic cartridge for a two-cycle engine. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the present invention, an exhaust system for a two-cycle engine includes a housing assembly, the assembly having a first housing section and a second housing section, a housing opening, a baffle tube, the baffle tube being received by the housing opening, a mounting plate, the mounting plate fixedly attached to the baffle tube, a catalytic cartridge, the catalytic cartridge located within the baffle tube, a catalyst, the catalyst located within the catalytic cartridge, an alum gasket, an intake, the intake having an intake plate and a side intake opening, and connecting means for connecting the intake plate, the gasket, and the mounting plate to the housing front via receiving means. 
     In accordance with another aspect of the present invention, an exhaust system for an engine comprising a housing, and a selectively replaceable catalytic cartridge. 
     In accordance with still another aspect of the present invention, the system further comprises a baffle tube, the baffle tube being selectively removable from the housing, and a catalyst, the catalyst located within the catalytic cartridge. 
     In accordance with yet another aspect of the present invention, the system the system further comprises an intake, a mounting plate, an alum gasket, with the intake, mounting plate, and gasket all being connected to the housing. 
     In accordance with another aspect of the present invention, the housing further includes a first and second section a housing opening, and a baffle, the baffle containing diffuser openings, the baffle located within the housing. 
     In accordance with still another aspect of the present invention, a muffler for a two cycle engine, the muffler comprising a housing, an intake, a baffle tube, a catalytic cartridge, the cartridge located within the baffle tube, and a catalyst, the catalyst located within the catalytic cartridge, the cartridge being selectively removable. 
     In accordance with yet another aspect of the present invention, the baffle tube is located within the housing, the muffler further includes a first housing section, a second housing section, and a baffle, the baffle containing diffuser openings, the baffle located within the housing. 
     In accordance with another aspect of the present invention, the muffler further comprises a front plate, a gasket ring, the gasket ring being circumferentially enclosed within the gasket, connecting sleeves for connecting the housing sections and the baffle, an exhaust flange, the exhaust flange located on a front plate, the front plate containing the intake, and a side intake opening. 
     In accordance with another aspect of the present invention a method for replacing a catalytic cartridge, include the steps of removing an associated baffle tube from an associated housing, removing the catalytic cartridge from the baffle tube, and inserting a second catalytic cartridge. 
     In accordance with another aspect of the present invention the method further comprises the steps of removing an associated intake and removing an associated gasket. 
     In accordance with another aspect of the present invention a method for replacing a catalytic cartridge, includes the steps of providing a housing assembly, the housing assembly having first and second section, providing a baffle, the baffle having diffuser openings, assembling the first and second sections, the baffle located within the assembly; providing a catalyst within a catalytic cartridge, inserting the cartridge into a baffle tube, inserting the baffle tube into the assembly, attaching a gasket to the baffle tube, attaching an intake to the gasket, detaching the intake from the gasket, detaching the gasket from the baffle tube, removing the baffle tube from the assembly, removing the cartridge from the baffle tube, and inserting a second catalytic cartridge. 
     These and other objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best mode for carrying out the invention when taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may take physical form in certain parts and arrangement of parts, several embodiments of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein: 
         FIG. 1  is a perspective view of the new exhaust system, showing the replaceable catalyst; 
         FIG. 1A  is a perspective view of the housing; 
         FIG. 2  is a front view of the exhaust system; 
         FIG. 3  is a cross-sectional view of line C—C in  FIG. 2 ; 
         FIG. 3A  is a cross-sectional view of line C—C in  FIG. 2 , showing the path of the exhaust; 
         FIG. 4  is a perspective view of the alum gasket; 
         FIG. 5  is a side view of the alum gasket; 
         FIG. 6  is a perspective view of the baffle tube; 
         FIG. 7  is an exploded view of portion A of  FIG. 6 ; 
         FIG. 8  is a front view of the mounting plate; 
         FIG. 9  is a front view of the intake; 
         FIG. 10  is a top view of the intake; 
         FIG. 11  is a side view of the intake; 
         FIG. 12  is a perspective view of another embodiment of the exhaust system; 
         FIG. 13  is front view of the exhaust system of  FIG. 12 ; and, 
         FIG. 14  is a cross-sectional view along line C—C of FIG.  13 . 
     
    
    
     DESCRIPTION OF THE INVENTION 
       FIGS. 1-11  illustrate the present invention. In this embodiment, a new exhaust system  10  is shown and described. The exhaust system  10  has a housing  12 , which is comprised of a first housing section  36 , a second housing section  38 , a housing front  64 , receiving means  34 , grooves  30  for adding strength for stamping, a housing opening  32 , a baffle  44 , diffuser openings  46 , sleeves  48 , baffle tube  14 , mounting plate  28 , catalytic cartridge  16 , catalyst  66 , gasket  18 , gasket ring  24 , front plate  20 , exhaust flange  60 , side intake opening  58 , exhaust outlet  26 , and connecting means  22 . 
     As shown in  FIG. 1 , the first and second housing sections  36 ,  38  connect together to form the housing  12 . The baffle tube  14  fits inside the housing  12 , via housing opening  32 . The mounting plate  28  rests against the housing front  64 , and lines up with receiving means  34 . The catalytic cartridge  16 , which contains the catalyst  66 , is inserted into the baffle tube  14 , and gasket  18  is placed over the mounting plate  28 , and is held in place by the front plate  20 . The front plate  20 , gasket  18 , and mounting plate  28  are all connected to the housing  12  at the housing front  64  by connecting means  22 , which in this particular embodiment are screws. It is to be understood that the particular embodiment of this invention is not intended to limit the invention in any manner, but is merely shown to illustrate the invention. It is to be understood that any means of inserting the catalytic cartridge  16  into the exhaust system  10 , such that the catalytic cartridge  16  is easily replaceable, is to be encompassed within this invention. 
       FIG. 3  shows a cross-sectional view of the exhaust system  10 , taken along line C—C of FIG.  2 . The catalyst  66  is inside catalytic cartridge  16 , which in turn is located inside the baffle tube  14 . This particular configuration of the exhaust system  10  allows the catalytic cartridge  16  to be easily replaced. 
     With reference now to  FIG. 3A , the same cross-sectional view as  FIG. 3  is shown. However,  FIG. 3A  shows the movement of the exhaust through the system  10 . The exhaust enters the system  10  through the second housing  38 , and then makes contact with raised portion  50  of the baffle  44 . (The raised portion  50  reduces back pressure when the exhaust enters the system  10 .) The exhaust then passes through the diffusion openings  44  and then travels back toward the opening of the baffle tube  14 . The exhaust travels through the baffle tube  14  into the catalytic cartridge  16 , where it reacts with the catalyst  66 . The exhaust then passes into the exhaust outlet  26  and is deflected outwardly from the system  10  by the exhaust flange  60 . The passage of the exhaust through the exhaust outlet  26  creates a vacuum which draws air through side intake opening  58 . The air entering through the side intake opening  58  cools down the temperature of the exhaust. 
     As can be seen in  FIGS. 1-11 , the catalytic cartridge  16  can be easily removed from the baffle tube  14 , by simply removing the connecting means  22 , the front plate  20 , the gasket  18 , and the baffle tube  14 . This is easily accomplished by unscrewing the connecting means  22  and pulling off the plates  18 ,  20 ,  28 . Once the baffle tube  14  is removed, the catalytic cartridge  16  easily slides out of the baffle tube  14 , and therefore can be replaced with a new catalytic cartridge. 
       FIGS. 12-14  show another embodiment of the exhaust system  10 ′. As can be seen in  FIG. 12 , the exhaust system  10 ′ is similar to the exhaust system  10 . However, the catalyst  42  is located inside the housing assembly  12 ′ and is located between a first baffle  40  and second baffle  44 ′. These baffles  40 ′,  44 ′ are fixedly attached to each other. 
     While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.