US20200332692A1 - Direct spray exhaust mixer system - Google Patents

Direct spray exhaust mixer system Download PDF

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Publication number
US20200332692A1
US20200332692A1 US16/387,697 US201916387697A US2020332692A1 US 20200332692 A1 US20200332692 A1 US 20200332692A1 US 201916387697 A US201916387697 A US 201916387697A US 2020332692 A1 US2020332692 A1 US 2020332692A1
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Prior art keywords
inlet
outlet
flow path
distribution pipe
fluid
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US16/387,697
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US10794252B1 (en
Inventor
Eric Ker
Anthony Burnett
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Faurecia Emissions Control Technologies USA LLC
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Faurecia Emissions Control Technologies USA LLC
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Priority to US16/387,697 priority Critical patent/US10794252B1/en
Assigned to FAURECIA EMISSIONS CONTROL TECHNOLOGIES, USA, LLC reassignment FAURECIA EMISSIONS CONTROL TECHNOLOGIES, USA, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BURNETT, ANTHONY, KER, ERIC
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • F01N3/2066—Selective catalytic reduction [SCR]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
    • B01F23/20—Mixing gases with liquids
    • B01F23/21—Mixing gases with liquids by introducing liquids into gaseous media
    • B01F23/213—Mixing gases with liquids by introducing liquids into gaseous media by spraying or atomising of the liquids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
    • B01F23/20—Mixing gases with liquids
    • B01F23/21—Mixing gases with liquids by introducing liquids into gaseous media
    • B01F23/213—Mixing gases with liquids by introducing liquids into gaseous media by spraying or atomising of the liquids
    • B01F23/2132—Mixing gases with liquids by introducing liquids into gaseous media by spraying or atomising of the liquids using nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
    • B01F25/30—Injector mixers
    • B01F25/31—Injector mixers in conduits or tubes through which the main component flows
    • B01F25/313—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit
    • B01F25/3133—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced in the centre of the conduit characterised by the specific design of the injector
    • B01F25/31332—Ring, torus, toroidal or coiled configurations
    • B01F3/04021—
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2892—Exhaust flow directors or the like, e.g. upstream of catalytic device
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
    • F01N2240/20—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a flow director or deflector
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2610/00—Adding substances to exhaust gases
    • F01N2610/02—Adding substances to exhaust gases the substance being ammonia or urea
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2610/00—Adding substances to exhaust gases
    • F01N2610/14—Arrangements for the supply of substances, e.g. conduits
    • F01N2610/1453—Sprayers or atomisers; Arrangement thereof in the exhaust apparatus
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather
    • Y02A50/20—Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • This invention generally relates to a vehicle exhaust system that provides a direct spray of a reduction liquid or gas into an exhaust gas stream.
  • an exhaust system conducts hot exhaust gases generated by an engine through various exhaust components to reduce emissions and control noise.
  • the exhaust system includes an injection system that injects a NOx reduction fluid such as urea, NH3 carbonate, or any reduction gas or liquid that is a solution of urea and water for example, upstream of a selective catalytic reduction (SCR) catalyst.
  • the injection system includes a doser or injector that sprays the injected fluid into the exhaust stream. The spray is typically concentrated in one area and then spreads out to mix with the exhaust gases.
  • the urea from the injected fluid should be transformed as much as possible into ammonia (NH3) before reaching the SCR catalyst.
  • mixer for a vehicle exhaust system includes an outer housing defining an exhaust gas flow path, wherein the outer housing includes an inlet opening and an outlet opening.
  • a distribution pipe is configured to deliver a reduction fluid directly into the exhaust gas flow path.
  • the distribution pipe has an inlet end associated with the inlet opening and an outlet end associated with the outlet opening.
  • the distribution pipe comprises a fluid flow path that is coiled about a center of the exhaust gas flow path.
  • the distribution pipe includes a plurality of orifices through which the reduction fluid is directly introduced into the exhaust gas flow path.
  • coils of the fluid flow path have an increasing radius about the center of the exhaust gas flow path.
  • the coils are substantially circular.
  • one of the inlet and outlet ends of the distribution pipe extends from the inlet opening toward the center of the exhaust gas flow path to a radially innermost coil, and wherein the other of the inlet and outlet ends of the distribution pipe extends from a radially outermost coil to the outlet opening.
  • an inlet tube extends outward of the housing from the inlet opening and an outlet tube extends outward of the housing from the outlet opening, and wherein the inlet end of the distribution pipe is in fluid communication with the inlet tube and the outlet end of the distribution pipe is in fluid communication with the outlet tube.
  • the inlet tube and outlet tube are immediately adjacent to each other on one side of the housing.
  • the inlet and outlet tubes extend parallel to each other at the inlet and outlet openings.
  • the inlet and outlet tubes are fluidly connected to a fluid supply of the reduction fluid.
  • the outer housing comprises an exhaust pipe.
  • a vehicle exhaust system in another exemplary embodiment, includes an upstream exhaust component having a housing defining an exhaust gas flow path, wherein the housing includes an inlet opening and an outlet opening, and a downstream exhaust component that includes an exhaust aftertreatment component, wherein the upstream component is connected to the downstream component.
  • a distribution pipe is positioned within the upstream exhaust component and is configured to deliver a reduction fluid directly into the exhaust gas flow path.
  • the distribution pipe has an inlet end associated with the inlet opening and an outlet end associated with the outlet opening, and the distribution pipe comprises a fluid flow path that is coiled about a center of the exhaust gas flow path.
  • the inlet and outlet tubes are fluidly connected to a fluid supply of the reduction fluid.
  • the distribution pipe includes a plurality of orifices through which the reduction fluid is directly introduced into the exhaust gas flow path.
  • the coils are substantially circular, and wherein coils of the fluid flow path have an increasing radius about the center of the exhaust gas flow path.
  • one of the inlet and outlet ends of the distribution pipe extends from the inlet opening toward the center of the exhaust gas flow path to a radially innermost coil, and wherein the other of the inlet and outlet ends of the distribution pipe extends from a radially outermost coil to the outlet opening.
  • an inlet tube extends outward of the housing from the inlet opening and an outlet tube extends outward of the housing from the outlet opening, and wherein the inlet end of the distribution pipe is in fluid communication with the inlet tube and the outlet end of the distribution pipe is in fluid communication with the outlet tube.
  • the inlet and outlet tubes are fluidly connected to a fluid supply of the reduction fluid, and wherein the inlet tube and outlet tube are immediately adjacent to each other on one side of the housing such that the inlet and outlet tubes extend parallel to each other at the inlet and outlet openings.
  • a method in another exemplary embodiment, includes: providing an outer housing that defines an exhaust gas flow path, wherein the outer housing includes an inlet opening and an outlet opening; associating an inlet end of a distribution pipe with the inlet opening; associating an outlet end of a distribution pipe with the outlet opening, wherein the distribution pipe comprises a fluid flow path that is coiled about a center of the exhaust gas flow path; and forming a plurality of orifices in the distribution pipe along the fluid flow path such that reduction fluid enters through the inlet end and is directly introduced into the exhaust gas flow path via the plurality of orifices with any remaining fluid exiting the outlet end.
  • the method further includes extending one of the inlet and outlet ends of the distribution pipe from the inlet opening toward the center of the exhaust gas flow path and to a radially innermost coil, and extending the other of the inlet and outlet ends of the distribution pipe from a radially outermost coil to the outlet opening.
  • the method further includes extending an inlet tube outward of the outer housing from the inlet opening and extending an outlet tube outward of the outer housing from the outlet opening, and fluidly connecting the inlet and outlet tubes to a fluid supply of the reduction fluid.
  • FIG. 1 is a schematic view of a vehicle exhaust system with a mixer incorporating the subject invention.
  • FIG. 2 is a schematic side view of the mixer of FIG. 1 .
  • FIG. 3 is a perspective view of the mixer of FIG. 1 .
  • FIG. 4 is an end view of a distribution pipe of the mixer of FIG. 3 .
  • a vehicle exhaust system 10 includes an engine 12 that generates exhaust gases that are conveyed through various upstream exhaust components 14 .
  • the upstream exhaust components 14 can include components such as pipes and exhaust aftertreatment components such as particulate filters, catalysts, etc.
  • the upstream exhaust components 14 are connected to a mixer 16 that is used to direct a mixture of reduction fluid and engine exhaust gases into a downstream exhaust aftertreatment component 18 such as a catalyst substrate 24 , e.g. a SCR substrate, for example.
  • a downstream exhaust aftertreatment component 18 such as a catalyst substrate 24 , e.g. a SCR substrate, for example.
  • Downstream of the exhaust aftertreatment component 18 there may be various additional downstream exhaust components 20 .
  • the various downstream exhaust components 20 can include one or more of pipes, mufflers, resonators, etc.
  • the downstream exhaust components 20 direct the exhaust gases to an outlet to atmosphere via a tailpipe 22 .
  • the mixer 16 includes an outer housing 30 that has an internal open cavity 32 that defines an exhaust gas flow path F.
  • the outer housing 30 comprises a pipe or a tube.
  • the pipe or tube has a circular cross-section.
  • a fluid supply 34 is used to supply a NOx reduction fluid such as urea, NH3 carbonate, or any reduction gas or liquid that is a solution of urea and water, for example, directly into the exhaust gas flow path such that the fluid can mix with the exhaust gas prior to entering the exhaust aftertreatment component 18 .
  • a distribution pipe 36 is in fluid communication with the fluid supply 34 to directly introduce the fluid into the exhaust gas flow path.
  • the outer housing 30 has a center axis A and defines the exhaust gas flow path F as shown in FIG. 2 .
  • the outer housing 30 includes an inlet opening 38 and an outlet opening 40 that are in fluid communication with the fluid supply 34 .
  • the distribution pipe 36 has an inlet end 42 associated with the inlet opening 38 and an outlet end 44 associated with the outlet opening 40 .
  • the distribution pipe 36 comprises a fluid flow path that is coiled about a center of the exhaust gas flow path F.
  • the distribution pipe 36 includes a plurality of orifices 46 through which the reduction fluid is directly introduced into the exhaust gas flow path.
  • coils 48 of the distribution pipe 36 that form the fluid flow path have an increasing radius about the center of the exhaust gas flow path F. In one example, the coils 48 are substantially circular.
  • the inlet end 42 of the distribution pipe 36 extends from the inlet opening 38 toward the center of the exhaust gas flow path F to a radially innermost coil 48 a
  • the outlet end 44 of the distribution pipe 36 extends from a radially outermost coil 48 b to the outlet opening 40 .
  • the inlet end could comprise the outlet end and vice versa.
  • the inlet tube 50 that extends outward of the housing 30 from the inlet opening 38 and an outlet tube 52 that extends outward of the housing 30 from the outlet opening 40 .
  • the inlet 50 and outlet 52 tubes are fluidly connected to the fluid supply 34 of the reduction fluid.
  • the inlet end 42 of the distribution pipe 36 is in fluid communication with the inlet tube 50 and the outlet end 44 of the distribution pipe 36 is in fluid communication with the outlet tube 52 .
  • the inlet tube 50 and outlet tube 52 are immediately adjacent to each other on one side of the housing 30 .
  • the inlet 50 and outlet 52 tubes extend parallel to each other at the inlet 38 and outlet 40 openings as indicated at 54 .
  • the inlet 50 and outlet 52 tubes can also be apart from each other at any angle depending on vehicle mounting space limitation.
  • an inner collar 60 is positioned at an inner surface of the housing 30 .
  • One or more supports 62 extend inwardly from the collar 60 to provide support for the distribution pipe 36 .
  • the supports 62 extend in a radially inward direction from the collar 60 and can have varying radial lengths to support different coils 48 of the distribution pipe 36 as needed.
  • the supports 62 allow the outermost coil 48 b to be spaced inwardly of the inner surface of the housing 30 such that no part of the outermost coil 48 is in contact with the inner surface of the housing 30 .
  • the subject invention provides a direct spray system with a distribution pipe 36 to spray NOx reduction liquid or gas into the exhaust gas stream.
  • the subject invention comprises a configuration that simplifies reduction fluid mixing so that there is no surface impingement prior to introduction of the mixture of fluid and exhaust gas into the SCR catalyst. Thus, this eliminates deposit formation and reduces exhaust backpressure.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Exhaust Gas After Treatment (AREA)

Abstract

A mixer for a vehicle exhaust system includes an outer housing defining an exhaust gas flow path, wherein the outer housing includes an inlet opening and an outlet opening. A distribution pipe is configured to deliver a reduction fluid directly into the exhaust gas flow path. The distribution pipe has an inlet end associated with the inlet opening and an outlet end associated with the outlet opening. The distribution pipe comprises a fluid flow path that is coiled about a center of the exhaust gas flow path.

Description

    TECHNICAL FIELD
  • This invention generally relates to a vehicle exhaust system that provides a direct spray of a reduction liquid or gas into an exhaust gas stream.
    • BACKGROUND OF THE INVENTION
  • An exhaust system conducts hot exhaust gases generated by an engine through various exhaust components to reduce emissions and control noise. In one traditional configuration, the exhaust system includes an injection system that injects a NOx reduction fluid such as urea, NH3 carbonate, or any reduction gas or liquid that is a solution of urea and water for example, upstream of a selective catalytic reduction (SCR) catalyst. The injection system includes a doser or injector that sprays the injected fluid into the exhaust stream. The spray is typically concentrated in one area and then spreads out to mix with the exhaust gases. The urea from the injected fluid should be transformed as much as possible into ammonia (NH3) before reaching the SCR catalyst.
  • When large amounts of fluid are injected into the exhaust stream from a single injector it has a cooling effect and can result in fast cooling along the walls of the injection location. Further, the injection force can direct the fluid toward a certain location on the walls to form an impingement area. The fast cooling along the walls and at the impingement area can lead to urea deposit formation at these locations, which can adversely affect system performance. Further, current mixers can have an inherently high exhaust backpressure due to their current design configuration. The combination of high backpressure and deposit formation can lead to higher engine loads and inefficient utilization of reduction fluid.
    • SUMMARY OF THE INVENTION
  • In one exemplary embodiment, mixer for a vehicle exhaust system includes an outer housing defining an exhaust gas flow path, wherein the outer housing includes an inlet opening and an outlet opening. A distribution pipe is configured to deliver a reduction fluid directly into the exhaust gas flow path. The distribution pipe has an inlet end associated with the inlet opening and an outlet end associated with the outlet opening. The distribution pipe comprises a fluid flow path that is coiled about a center of the exhaust gas flow path.
  • In a further embodiment of the above, the distribution pipe includes a plurality of orifices through which the reduction fluid is directly introduced into the exhaust gas flow path.
  • In a further embodiment of any of the above, coils of the fluid flow path have an increasing radius about the center of the exhaust gas flow path.
  • In a further embodiment of any of the above, the coils are substantially circular.
  • In a further embodiment of any of the above, one of the inlet and outlet ends of the distribution pipe extends from the inlet opening toward the center of the exhaust gas flow path to a radially innermost coil, and wherein the other of the inlet and outlet ends of the distribution pipe extends from a radially outermost coil to the outlet opening.
  • In a further embodiment of any of the above, an inlet tube extends outward of the housing from the inlet opening and an outlet tube extends outward of the housing from the outlet opening, and wherein the inlet end of the distribution pipe is in fluid communication with the inlet tube and the outlet end of the distribution pipe is in fluid communication with the outlet tube.
  • In a further embodiment of any of the above, the inlet tube and outlet tube are immediately adjacent to each other on one side of the housing.
  • In a further embodiment of any of the above, the inlet and outlet tubes extend parallel to each other at the inlet and outlet openings.
  • In a further embodiment of any of the above, the inlet and outlet tubes are fluidly connected to a fluid supply of the reduction fluid.
  • In a further embodiment of any of the above, the outer housing comprises an exhaust pipe.
  • In another exemplary embodiment, a vehicle exhaust system includes an upstream exhaust component having a housing defining an exhaust gas flow path, wherein the housing includes an inlet opening and an outlet opening, and a downstream exhaust component that includes an exhaust aftertreatment component, wherein the upstream component is connected to the downstream component. A distribution pipe is positioned within the upstream exhaust component and is configured to deliver a reduction fluid directly into the exhaust gas flow path. The distribution pipe has an inlet end associated with the inlet opening and an outlet end associated with the outlet opening, and the distribution pipe comprises a fluid flow path that is coiled about a center of the exhaust gas flow path.
  • In a further embodiment of any of the above, the inlet and outlet tubes are fluidly connected to a fluid supply of the reduction fluid.
  • In a further embodiment of any of the above, the distribution pipe includes a plurality of orifices through which the reduction fluid is directly introduced into the exhaust gas flow path.
  • In a further embodiment of any of the above, the coils are substantially circular, and wherein coils of the fluid flow path have an increasing radius about the center of the exhaust gas flow path.
  • In a further embodiment of any of the above, one of the inlet and outlet ends of the distribution pipe extends from the inlet opening toward the center of the exhaust gas flow path to a radially innermost coil, and wherein the other of the inlet and outlet ends of the distribution pipe extends from a radially outermost coil to the outlet opening.
  • In a further embodiment of any of the above, an inlet tube extends outward of the housing from the inlet opening and an outlet tube extends outward of the housing from the outlet opening, and wherein the inlet end of the distribution pipe is in fluid communication with the inlet tube and the outlet end of the distribution pipe is in fluid communication with the outlet tube.
  • In a further embodiment of any of the above, the inlet and outlet tubes are fluidly connected to a fluid supply of the reduction fluid, and wherein the inlet tube and outlet tube are immediately adjacent to each other on one side of the housing such that the inlet and outlet tubes extend parallel to each other at the inlet and outlet openings.
  • In another exemplary embodiment, a method includes: providing an outer housing that defines an exhaust gas flow path, wherein the outer housing includes an inlet opening and an outlet opening; associating an inlet end of a distribution pipe with the inlet opening; associating an outlet end of a distribution pipe with the outlet opening, wherein the distribution pipe comprises a fluid flow path that is coiled about a center of the exhaust gas flow path; and forming a plurality of orifices in the distribution pipe along the fluid flow path such that reduction fluid enters through the inlet end and is directly introduced into the exhaust gas flow path via the plurality of orifices with any remaining fluid exiting the outlet end.
  • In a further embodiment of any of the above, the method further includes extending one of the inlet and outlet ends of the distribution pipe from the inlet opening toward the center of the exhaust gas flow path and to a radially innermost coil, and extending the other of the inlet and outlet ends of the distribution pipe from a radially outermost coil to the outlet opening.
  • In a further embodiment of any of the above, the method further includes extending an inlet tube outward of the outer housing from the inlet opening and extending an outlet tube outward of the outer housing from the outlet opening, and fluidly connecting the inlet and outlet tubes to a fluid supply of the reduction fluid.
  • These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a schematic view of a vehicle exhaust system with a mixer incorporating the subject invention.
  • FIG. 2 is a schematic side view of the mixer of FIG. 1.
  • FIG. 3 is a perspective view of the mixer of FIG. 1.
  • FIG. 4 is an end view of a distribution pipe of the mixer of FIG. 3.
    •  DETAILED DESCRIPTION
  • A vehicle exhaust system 10 includes an engine 12 that generates exhaust gases that are conveyed through various upstream exhaust components 14. The upstream exhaust components 14 can include components such as pipes and exhaust aftertreatment components such as particulate filters, catalysts, etc. In one example configuration, the upstream exhaust components 14 are connected to a mixer 16 that is used to direct a mixture of reduction fluid and engine exhaust gases into a downstream exhaust aftertreatment component 18 such as a catalyst substrate 24, e.g. a SCR substrate, for example. Downstream of the exhaust aftertreatment component 18 there may be various additional downstream exhaust components 20. The various downstream exhaust components 20 can include one or more of pipes, mufflers, resonators, etc. The downstream exhaust components 20 direct the exhaust gases to an outlet to atmosphere via a tailpipe 22. These upstream 14 and downstream 20 components can be mounted in various different configurations and combinations dependent upon the type of application and available packaging space.
  • The mixer 16 includes an outer housing 30 that has an internal open cavity 32 that defines an exhaust gas flow path F. In one example, the outer housing 30 comprises a pipe or a tube. In the example shown, the pipe or tube has a circular cross-section. A fluid supply 34 is used to supply a NOx reduction fluid such as urea, NH3 carbonate, or any reduction gas or liquid that is a solution of urea and water, for example, directly into the exhaust gas flow path such that the fluid can mix with the exhaust gas prior to entering the exhaust aftertreatment component 18. A distribution pipe 36 is in fluid communication with the fluid supply 34 to directly introduce the fluid into the exhaust gas flow path.
  • The outer housing 30 has a center axis A and defines the exhaust gas flow path F as shown in FIG. 2. The outer housing 30 includes an inlet opening 38 and an outlet opening 40 that are in fluid communication with the fluid supply 34. The distribution pipe 36 has an inlet end 42 associated with the inlet opening 38 and an outlet end 44 associated with the outlet opening 40. As shown in FIGS. 3-4 the distribution pipe 36 comprises a fluid flow path that is coiled about a center of the exhaust gas flow path F. As shown in FIG. 4, the distribution pipe 36 includes a plurality of orifices 46 through which the reduction fluid is directly introduced into the exhaust gas flow path.
  • In one example, coils 48 of the distribution pipe 36 that form the fluid flow path have an increasing radius about the center of the exhaust gas flow path F. In one example, the coils 48 are substantially circular.
  • In one example, as shown in FIG. 3, the inlet end 42 of the distribution pipe 36 extends from the inlet opening 38 toward the center of the exhaust gas flow path F to a radially innermost coil 48 a, and the outlet end 44 of the distribution pipe 36 extends from a radially outermost coil 48 b to the outlet opening 40. In an optional arrangement, the inlet end could comprise the outlet end and vice versa.
  • As shown in FIG. 3, there is an inlet tube 50 that extends outward of the housing 30 from the inlet opening 38 and an outlet tube 52 that extends outward of the housing 30 from the outlet opening 40. The inlet 50 and outlet 52 tubes are fluidly connected to the fluid supply 34 of the reduction fluid. The inlet end 42 of the distribution pipe 36 is in fluid communication with the inlet tube 50 and the outlet end 44 of the distribution pipe 36 is in fluid communication with the outlet tube 52. In one example, the inlet tube 50 and outlet tube 52 are immediately adjacent to each other on one side of the housing 30. In this example, the inlet 50 and outlet 52 tubes extend parallel to each other at the inlet 38 and outlet 40 openings as indicated at 54. In other example embodiments, the inlet 50 and outlet 52 tubes can also be apart from each other at any angle depending on vehicle mounting space limitation.
  • As shown in FIG. 3, an inner collar 60 is positioned at an inner surface of the housing 30. One or more supports 62 extend inwardly from the collar 60 to provide support for the distribution pipe 36. The supports 62 extend in a radially inward direction from the collar 60 and can have varying radial lengths to support different coils 48 of the distribution pipe 36 as needed. The supports 62 allow the outermost coil 48 b to be spaced inwardly of the inner surface of the housing 30 such that no part of the outermost coil 48 is in contact with the inner surface of the housing 30.
  • The subject invention provides a direct spray system with a distribution pipe 36 to spray NOx reduction liquid or gas into the exhaust gas stream. The subject invention comprises a configuration that simplifies reduction fluid mixing so that there is no surface impingement prior to introduction of the mixture of fluid and exhaust gas into the SCR catalyst. Thus, this eliminates deposit formation and reduces exhaust backpressure.
  • Although an embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.

Claims (20)

1. A mixer for a vehicle exhaust system comprising:
an outer housing defining an exhaust gas flow path, wherein the outer housing includes an inlet opening and an outlet opening; and
a distribution pipe configured to deliver a reduction fluid directly into the exhaust gas flow path, wherein the distribution pipe has an inlet end associated with the inlet opening and an outlet end associated with the outlet opening, and wherein the distribution pipe comprises a fluid flow path that is coiled about a center of the exhaust gas flow path.
2. The mixer according to claim 1 wherein the distribution pipe includes a plurality of orifices through which the reduction fluid is directly introduced into the exhaust gas flow path.
3. The mixer according to claim 1 wherein coils of the fluid flow path have an increasing radius about the center of the exhaust gas flow path.
4. The mixer according to claim 3 wherein the coils are circular.
5. The mixer according to claim 3 wherein one of the inlet and outlet ends of the distribution pipe extends from the inlet opening toward the center of the exhaust gas flow path to a radially innermost coil, and wherein the other of the inlet and outlet ends of the distribution pipe extends from a radially outermost coil to the outlet opening.
6. The mixer according to claim 1 including an inlet tube extending outward of the housing from the inlet opening and an outlet tube extending outward of the housing from the outlet opening, and wherein the inlet end of the distribution pipe is in fluid communication with the inlet tube and the outlet end of the distribution pipe is in fluid communication with the outlet tube.
7. The mixer according to claim 6 wherein the inlet tube and outlet tube are immediately adjacent to each other on one side of the housing.
8. The mixer according to claim 7 wherein the inlet and outlet tubes extend parallel to each other at the inlet and outlet openings.
9. The mixer according to claim 7 wherein the inlet and outlet tubes are fluidly connected to a fluid supply of the reduction fluid.
10. The mixer according to claim 1 wherein the outer housing comprises an exhaust pipe.
11. A vehicle exhaust system comprising:
an upstream exhaust component having a housing defining an exhaust gas flow path, wherein the housing includes an inlet opening and an outlet opening;
a downstream exhaust component that includes an exhaust aftertreatment component, wherein the upstream component is connected to the downstream component; and
a distribution pipe positioned within the upstream exhaust component and configured to deliver a reduction fluid directly into the exhaust gas flow path, wherein the distribution pipe has an inlet end associated with the inlet opening and an outlet end associated with the outlet opening, and wherein the distribution pipe comprises a fluid flow path that is coiled about a center of the exhaust gas flow path.
12. The vehicle exhaust system according to claim 11 wherein the inlet end and the outlet end are fluidly connected to a fluid supply of the reduction fluid.
13. The vehicle exhaust system according to claim 11 wherein the distribution pipe includes a plurality of orifices through which the reduction fluid is directly introduced into the exhaust gas flow path.
14. The vehicle exhaust system according to claim 13 wherein coils of the fluid flow path have an increasing radius about the center of the exhaust gas flow path, and wherein the coils are circular.
15. The vehicle exhaust system according to claim 13 wherein coils of the fluid flow path have an increasing radius about the center of the exhaust gas flow path, and wherein one of the inlet and outlet ends of the distribution pipe extends from the inlet opening toward the center of the exhaust gas flow path to a radially innermost coil, and wherein the other of the inlet and outlet ends of the distribution pipe extends from a radially outermost coil to the outlet opening.
16. The vehicle exhaust system according to claim 15 including an inlet tube extending outward of the housing from the inlet opening and an outlet tube extending outward of the housing from the outlet opening, and wherein the inlet end of the distribution pipe is in fluid communication with the inlet tube and the outlet end of the distribution pipe is in fluid communication with the outlet tube.
17. The vehicle exhaust system according to claim 16 wherein the inlet and outlet tubes are fluidly connected to a fluid supply of the reduction fluid, and wherein the inlet tube and outlet tube are immediately adjacent to each other on one side of the housing such that the inlet and outlet tubes extend parallel to each other at the inlet and outlet openings.
18. A method comprising:
providing an outer housing that defines an exhaust gas flow path, wherein the outer housing includes an inlet opening and an outlet opening;
associating an inlet end of a distribution pipe with the inlet opening;
associating an outlet end of the distribution pipe with the outlet opening, wherein the distribution pipe comprises a fluid flow path that is coiled about a center of the exhaust gas flow path; and
forming a plurality of orifices in the distribution pipe along the fluid flow path such that reduction fluid enters through the inlet end and is directly introduced into the exhaust gas flow path via the plurality of orifices with any remaining fluid exiting the outlet end.
19. The method according to claim 18 wherein coils of the fluid flow path have an increasing radius about the center of the exhaust gas flow path, and including extending one of the inlet and outlet ends of the distribution pipe from the inlet opening toward the center of the exhaust gas flow path and to a radially innermost coil, and extending the other of the inlet and outlet ends of the distribution pipe from a radially outermost coil to the outlet opening.
20. The method according to claim 18 including extending an inlet tube outward of the outer housing from the inlet opening and extending an outlet tube outward of the outer housing from the outlet opening, and fluidly connecting the inlet and outlet tubes to a fluid supply of the reduction fluid.
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