CN217999696U

CN217999696U - Exhaust system for vehicle

Info

Publication number: CN217999696U
Application number: CN202221279601.7U
Authority: CN
Inventors: R·霍斯特; E·J·诺卡; T·J·拉科维茨; S·D·诺曼; T·辛格; M·科拉雷诺
Original assignee: Ford Global Technologies LLC
Current assignee: Ford Global Technologies LLC
Priority date: 2021-06-08
Filing date: 2022-05-26
Publication date: 2022-12-09
Anticipated expiration: 2032-05-26
Also published as: DE202022102929U1

Abstract

The present disclosure provides an "exhaust system for a vehicle". An exhaust system includes a catalytic converter assembly including a housing and a catalytic converter block. The exhaust system includes a deflector/diffuser at an outlet end of the exhaust pipe. The deflector/diffuser is located within an inlet cone of the housing and includes a deflector portion and a diffuser portion. The deflector is axially aligned with the exhaust flow, partially blocks the exhaust gas and partially deflects the exhaust gas to the diffuser. The deflector portion defines a plurality of first openings that direct a first portion of the exhaust gas axially toward a central portion of the catalytic converter, and the diffuser portion defines a plurality of second openings that direct a second portion of the exhaust gas toward the inlet cone. The second portion of the exhaust gas is redirected through the inlet cone to an outer portion of the catalytic converter block radially outward of the central portion.

Description

Exhaust system for vehicle

Technical Field

The present disclosure relates to an engine exhaust system and a catalytic converter for a vehicle.

Background

A catalytic converter is an exhaust emission control device that reduces toxic gases and pollutants in exhaust gas from an internal combustion engine to less toxic pollutants through a catalytic oxidation-reduction reaction. One type of gas catalyzed by catalytic converters includes NOx compounds. One problem with existing systems is increased NOx emissions at higher engine loads during steady state cruise conditions.

The present disclosure is intended to solve the above problems and other problems outlined below.

SUMMERY OF THE UTILITY MODEL

The utility model provides a prior art's technical problem.

Stringent automotive emission standards require new solutions for gas treatment systems to achieve higher efficiencies. Reducing NOx emissions at higher engine loads during steady state cruise conditions requires uniform flow distribution, controlled space velocity, and timing of exhaust pulses through the exhaust catalyst bricks.

According to one aspect of the present disclosure, an exhaust system for a vehicle is disclosed. The exhaust system includes: an exhaust pipe that receives exhaust gas from an internal combustion engine; and a catalytic converter assembly including a housing and a monolithic catalytic converter block, wherein the housing includes an inlet cone that receives exhaust gas from the exhaust pipe. The exhaust system also includes a deflector/diffuser disposed at an outlet end of the exhaust pipe. The deflector/diffuser is located within the inlet cone and includes a deflector disposed in the inlet cone axially aligned with the direction of exhaust flow to partially block and partially deflect the exhaust gas to the diffuser. The deflector defines a first plurality of openings that direct a first portion of the exhaust gas axially toward a central portion of the monolithic catalytic converter. The diffuser is disposed in the inlet cone and defines a plurality of second openings that direct a second portion of the exhaust gas toward the inlet cone. The second portion of the exhaust gas is redirected through the inlet cone to an outer portion of the monolithic catalytic converter block radially outward of the central portion.

According to other aspects of the present disclosure, the deflector may further include a planar plate disposed transverse to a direction of the exhaust flow from the exhaust pipe. The diffuser may further include a tubular portion of the exhaust pipe disposed within the inlet cone. The deflector/diffuser may also include a planar plate disposed transverse to the exhaust flow from the exhaust pipe, and a tubular portion of the exhaust pipe disposed within the inlet cone. Alternatively, the deflector/diffuser may be a cup-shaped member having a planar plate disposed transverse to the direction of the exhaust flow from the exhaust pipe, and a tubular portion of the exhaust pipe disposed within the inlet cone.

The deflector/diffuser may be a portion of the exhaust pipe disposed within the inlet cone, wherein an end of the exhaust pipe defines the plurality of second openings.

The deflector/diffuser may be attached to the exhaust pipe by mechanical attachment (e.g. by welding, fastening) or by deforming part of the exhaust pipe.

Alternatively, the deflector/diffuser may be a casting attached to the outlet end of the exhaust pipe.

In accordance with another aspect of the present disclosure, an exhaust system for a vehicle is disclosed that includes an exhaust pipe that receives exhaust gas from an internal combustion engine. A catalytic converter assembly includes a housing and a monolithic catalytic converter block. The housing includes an inlet cone that receives exhaust gas from the exhaust pipe. The deflector/diffuser is disposed at an outlet end of the exhaust pipe. The deflector/diffuser is located within the inlet cone and may include a convex tip disposed in the inlet cone, the convex tip defining a plurality of openings that deflect a first portion of the exhaust gas toward a central portion of the monolithic catalytic converter. The deflector/diffuser diffuses a second portion of the exhaust gas toward the inlet cone, the second portion being redirected by the inlet cone toward an outer portion of the monolithic catalytic converter block radially outward of the central portion.

The convex tip may have a conical sidewall portion and a rounded tip portion that are symmetrical with respect to an axis, wherein the axis is aligned with a direction of exhaust flow in the exhaust pipe.

The convex tip may have a conical sidewall portion and a rounded tip portion that are symmetrical with respect to an axis disposed at an acute angle with respect to a direction of exhaust flow in the exhaust pipe.

The exhaust pipe may be assembled to the inlet cone without extending into the inlet cone. The deflector/diffuser may be assembled to the outlet end of the exhaust pipe with the deflector/diffuser extending into the inlet cone.

In accordance with another aspect of the present disclosure, an exhaust system for a vehicle is disclosed having an exhaust pipe receiving exhaust from an internal combustion engine, and a catalytic converter assembly including a housing and a monolithic catalytic converter block. The housing includes an inlet cone that receives an exhaust flow from the exhaust pipe. A nozzle receives exhaust gas from the exhaust pipe. The nozzle is located within the inlet cone and has a plurality of vanes arrayed around a central opening. The vanes are oriented to diffuse a first portion of the exhaust flow toward the inlet cone. A second portion of the exhaust flow is directed through the central opening directly toward the monolithic catalytic converter block.

The plurality of vanes may taper inwardly from the exhaust duct and converge toward the central opening at distal ends of the vanes.

The exhaust pipe may extend into the inlet cone, the plurality of vanes may be formed on the exhaust pipe, and the vanes may be spaced apart from the monolithic catalytic converter block.

The exhaust pipe may extend into the inlet cone, the plurality of vanes may be assembled to a distal end of the exhaust pipe, and the vanes may be spaced apart from the monolithic catalytic converter block.

The vanes may direct the first portion of the exhaust flow radially outward within the inlet cone.

The above and other aspects of the present disclosure will be described below with reference to the accompanying drawings.

Drawings

FIG. 1 is a graph showing simulated emissions of NOx over time at steady state operation at 50mph speed during steady cruise conditions (higher exhaust warm end flow rate) at higher engine loads.

FIG. 2 is a computational fluid dynamics representation of a monolithic catalytic converter block that averages the flow profile across all cylinders, illustrating the velocity of the exhaust flow through the monolithic catalyst block.

FIG. 3 is a top plan view of a portion of an exhaust system for a vehicle.

FIG. 4 is a partial perspective view of one embodiment of a deflector/diffuser connected to an exhaust pipe and within an inlet cone of a catalytic converter housing.

Fig. 5 is a front view of the embodiment of fig. 4.

Fig. 6 is an exploded perspective view of the embodiment of fig. 4.

Fig. 7 is a partial front view of a deflector/diffuser including a diffuser secured to the deflector by welding.

Fig. 8 is a partial front view of the deflector/diffuser secured to each other with fasteners.

FIG. 9 is a partial front view of the deflector/diffuser secured to each other and within the inlet cone of the catalytic converter housing by hammering the end of the exhaust pipe deformation caused by connection to the exhaust pipe.

FIG. 10 is a diagrammatic view of another embodiment of a cast deflector/diffuser attached to an end of an exhaust pipe within an inlet cone of a catalytic converter housing.

FIG. 11 is a diagrammatic cross-sectional view of another embodiment of a deflector/diffuser including vanes formed on or mounted to an exhaust duct within an inlet cone of a catalytic converter housing.

FIG. 12 is a diagrammatic cross-sectional view of another embodiment of a male nozzle deflector/diffuser attached to an end of an exhaust pipe within an inlet cone of a catalytic converter housing.

Detailed Description

The illustrated embodiments are disclosed with reference to the accompanying drawings. However, it is to be understood that the disclosed embodiments are intended merely as examples that may be embodied in various and alternative forms. The figures are not necessarily to scale; and some features may be exaggerated or minimized to show details of particular components. Specific structural and functional details disclosed are not to be interpreted as limiting, but as a representative basis for teaching one skilled in the art how to practice the disclosed concepts.

Referring to FIG. 1, a graph is provided to illustrate an example of one test point where vehicle speed equals 50mph at steady cruise conditions over time. The NOx control was under control in the first 3 minutes of the simulation test, but after 3 minutes the NOx control started to increase and the NOx level increased significantly during the next 3 minutes of the test. The graph shows that long steady-state operation at higher speeds is shown to degrade simulated NOx emissions test results over time.

Referring to FIG. 2, a Computational Fluid Dynamics (CFD) simulation analysis of fluid flow in the monolithic catalytic converter block 10 (block) shows high velocity fluid flow in the center of the block 10 at 50mph vehicle speed at higher engine loads during steady cruise conditions (higher exhaust hot end flow rate). Engine calibration under these conditions has indicated high NOx levels during testing when the engine air-fuel ratio is unevenly distributed.

Referring to FIG. 3, an exhaust system 12 of an internal combustion engine 14 of a vehicle is partially shown and includes a pair of exhaust manifolds 16 and a pair of exhaust pipes 18 that supply exhaust gas to a catalytic converter assembly 20. The catalytic converter assembly 20 includes a housing 22 for at least one monolithic catalytic converter block 10 (shown in FIG. 2). The exhaust pipe 24 receives exhaust gas from the catalytic converter assembly 20 and delivers the exhaust gas to the atmosphere.

Referring to fig. 4-6, one example of a deflector/diffuser 26 is shown attached to the outlet end of the exhaust pipe 18 and disposed within an inlet cone 28 of the catalytic converter housing 22. The deflector/diffuser 26 is spaced from the face of the block 10.

The deflector/diffuser 26 includes a deflector 30 disposed in the inlet cone 28 in axial alignment with the direction of exhaust flow to partially block and partially deflect the exhaust gas to a diffuser 32. The deflector 30 defines a first plurality of openings 34 that axially direct a first portion of the exhaust gas toward a center portion 36 (shown in FIG. 2) of the monolithic catalytic converter block 10. The diffuser 32 is disposed in the inlet cone 28 and defines a plurality of second openings 38 that direct a second portion of the exhaust gas toward the inlet cone 28, where the second portion of the exhaust gas is redirected by the inlet cone 28 toward an outer portion 40 (shown in FIG. 2) of the monolithic catalytic converter block 10 radially outward of the central portion 36.

In the embodiment shown in fig. 4-6, the deflector 30 is a flat plate disposed transverse to the direction of exhaust flow from the exhaust pipe 18 including the opening 34. The diffuser 32 comprises a tubular portion of the exhaust pipe 18 or a tubular attachment to the exhaust pipe 18 disposed within the inlet cone 28 of the catalytic converter housing 22.

Referring to fig. 4 to 6, the deflector/diffuser 26 is a cup-shaped member comprising a deflector 30 in the form of a planar plate attached to a diffuser 32 in the form of a tubular section. The face plate 30 defines a plurality of openings 34 that direct exhaust gas axially through the openings 34 toward a center portion 36 of the monolithic catalytic converter block 10. A portion of the exhaust gas is deflected by the planar plate 30 to flow through the openings 38 in the diffuser 32. The diffuser 32 or tubular section defines a plurality of openings 38 that direct the exhaust gas radially outward through the openings 34 toward the inlet cone 28, which in turn reflects the exhaust gas toward an outer portion 40 of the monolithic catalytic converter block 10. In the embodiment of fig. 4-6, the opening 38 is a rectilinear opening.

Referring to fig. 7-9, examples of three different ways of attaching the deflector 30 to the diffuser 32 are shown. In the embodiment of fig. 7-9, the opening 42 is an arcuate opening formed in the end of the exhaust pipe 18. The openings 42 may alternatively be linear, circular, or may be provided in various shapes. In fig. 7, the flat plate 30 is welded to the tubular section 32 by any of several welding processes. In fig. 8, fasteners 44 are shown for attaching the flat plate 30 to the tubular section 32. In fig. 9, the protrusion 46 formed by or attached to the end of the exhaust pipe 18 is shown as being peened or deformed on the planar plate 30.

Referring to fig. 10, another embodiment is shown that includes a cast deflector/diffuser 50. A cast deflector/diffuser 50 is attached to the end of the exhaust pipe 18. Exhaust gas flowing through openings in the deflector 52 (shown in fig. 4-6 and designated by reference numeral 34), indicated by arrow "a", is directed axially toward the central portion 36 (shown in fig. 2) of the monolithic catalytic converter block 10. A portion of the exhaust gas indicated by arrow "R" is directed through an opening 54 in a diffuser 56 toward an inlet cone 58 of the catalytic converter housing 22 (shown in fig. 3 and 5-6) after being deflected by the deflector 52. This portion of the exhaust gas is then directed to the outer portion 40 (shown in FIG. 2) of the monolithic catalytic converter block 10.

Referring to FIG. 11, another embodiment is shown that includes a plurality of vanes 60 formed on the end of the exhaust pipe 18. The vanes 60 define a central opening 62 through which a first portion of the exhaust gas flows in an axial direction toward the central portion 36 of the monolithic catalytic converter block 10 (shown in FIG. 2). The vanes 60 taper inwardly toward the central opening 62 and the monolithic catalytic converter block 10. The second portion of the exhaust gas is diffused by the vanes 60 in a radially outward direction toward the inlet cone 64, which redirects the exhaust gas flow toward the outer portion 40 of the monolithic catalytic converter block 10.

Referring to fig. 12, an alternative embodiment is shown that includes a male nozzle 70 that extends into an inlet cone 72 of the catalytic converter housing 22 (as shown in fig. 3 and 5-6). The shape of the male nozzle 70 may be parabolic or may be part spherical. A plurality of openings 74 are defined in the nozzle 70 and are oriented to spread the exhaust flow in different directions from the axial direction to the radial direction. The size, number, and orientation of the openings 74 defined by the diffuser may be varied to evenly distribute the exhaust gas over the face of the monolithic catalytic converter block 10.

The embodiments described above are specific examples in which all possible forms of the disclosure are not described. Features of the illustrated embodiments can be combined to form further embodiments of the disclosed concept. The words used in the specification are words of description rather than limitation. The appended claims are broader than the specifically disclosed embodiments and also include modifications to the illustrated embodiments. Additionally, features of various implementing embodiments may be combined to form further embodiments of the invention.

According to the utility model discloses, an exhaust system for vehicle is provided, exhaust system has: an exhaust pipe that receives exhaust gas from an internal combustion engine; a catalytic converter assembly comprising a housing and a monolithic catalytic converter block, wherein the housing comprises an inlet cone that receives exhaust from the exhaust pipe; and a deflector/diffuser disposed at an outlet end of the exhaust pipe, the deflector/diffuser disposed within the inlet cone, the deflector/diffuser including a deflector disposed in the inlet cone axially aligned with a direction of exhaust flow to partially block and partially deflect the exhaust gas to a diffuser, the deflector defining a plurality of first openings that axially direct a first portion of the exhaust gas toward a central portion of the monolithic catalytic converter block, wherein the diffuser defines a plurality of second openings that direct a second portion of the exhaust gas toward the inlet cone, wherein the second portion of the exhaust gas is redirected by the inlet cone toward an outer portion of the monolithic catalytic converter block radially outward of the central portion.

According to one embodiment, the deflector further comprises: a planar plate disposed transverse to the direction of the exhaust flow from the exhaust pipe.

According to one embodiment, the diffuser further comprises: a tubular portion of the exhaust pipe disposed within the inlet cone.

According to one embodiment, the deflector/diffuser further comprises: a planar plate disposed transverse to the exhaust flow from the exhaust pipe; and a tubular portion of the exhaust pipe disposed within the inlet cone.

According to one embodiment, said deflector/diffuser is a cup-shaped member tube arranged within said inlet cone, wherein said deflector/diffuser comprises a planar plate arranged transverse to said direction of said exhaust flow from said exhaust pipe, and a tubular member attached to said exhaust pipe.

According to one embodiment, the diffuser is a portion of the exhaust pipe disposed within the inlet cone, wherein an end of the exhaust pipe defines the plurality of second openings.

According to one embodiment, the deflector/diffuser is attached to the exhaust pipe by a mechanical attachment selected from the group consisting of: welding; a fastener; and deformation of a portion of the exhaust pipe.

According to one embodiment, the deflector/diffuser is a casting attached to the outlet end of the exhaust pipe, the deflector/diffuser comprising a planar portion defining the plurality of first openings and a cylindrical portion defining the plurality of second openings.

According to the utility model discloses, an exhaust system for vehicle is provided, exhaust system has: an exhaust pipe that receives exhaust gas from an internal combustion engine; a catalytic converter assembly comprising a housing and a monolithic catalytic converter block, wherein the housing comprises an inlet cone that receives exhaust from the exhaust pipe; and a deflector/diffuser disposed at an outlet end of the exhaust pipe, the deflector/diffuser disposed within the inlet cone, the deflector/diffuser including a convex tip disposed in the inlet cone, the convex tip defining a plurality of openings that partially deflect a first portion of the exhaust gas toward a central portion of the monolithic catalytic converter block and partially diffuse a second portion of the exhaust gas toward the inlet cone, wherein the second portion of the exhaust gas is redirected by the inlet cone toward an outer portion of the monolithic catalytic converter block radially outward of the central portion.

According to one embodiment, the convex tip has a conical sidewall portion and a rounded tip portion, wherein the conical sidewall portion is symmetrical with respect to an axis, wherein the axis is aligned with a direction of exhaust flow in the exhaust pipe.

According to one embodiment, the convex tip has a conical sidewall portion and a rounded tip portion, wherein the conical sidewall portion is symmetrical with respect to an axis, wherein the axis is disposed at an acute angle with respect to a direction of exhaust flow in the exhaust pipe.

According to one embodiment, the exhaust pipe is assembled to the inlet cone without extending into the inlet cone.

According to one embodiment, the deflector/diffuser is assembled to the outlet end of the exhaust pipe and extends within the inlet cone.

According to the utility model discloses, an exhaust system for vehicle is provided, exhaust system has: an exhaust pipe that receives exhaust gas from an internal combustion engine; a catalytic converter assembly comprising a housing and a monolithic catalytic converter block, wherein the housing comprises an inlet cone that receives an exhaust gas flow from the exhaust pipe; and a nozzle receiving exhaust gas from the exhaust pipe, the nozzle disposed within the inlet cone and having a plurality of vanes aligned about a central opening, the vanes oriented to diffuse a first portion of the exhaust gas flow toward the inlet cone, wherein a second portion of the exhaust gas flow is directed through the central opening directly toward the monolithic catalytic converter block.

According to one embodiment, the plurality of vanes taper inwardly from the exhaust duct and converge toward the central opening at distal ends of the vanes.

According to one embodiment, the exhaust pipe extends into the inlet cone, and wherein the plurality of vanes are formed on the exhaust pipe, and wherein the vanes are spaced apart from the monolithic catalytic converter block.

According to one embodiment, the exhaust pipe extends into the inlet cone, and wherein the plurality of vanes are assembled to a distal end of the exhaust pipe, and wherein the vanes are spaced apart from the monolithic catalytic converter block.

According to one embodiment, said vanes direct said first portion of said exhaust flow radially outwards within said inlet cone.

Claims

1. An exhaust system for a vehicle, comprising:

an exhaust pipe that receives exhaust gas from an internal combustion engine;

a catalytic converter assembly comprising a housing and a monolithic catalytic converter block, wherein the housing comprises an inlet cone that receives exhaust gas from the exhaust pipe; and

a deflector/diffuser disposed at an outlet end of the exhaust pipe, the deflector/diffuser disposed within the inlet cone, the deflector/diffuser including a deflector disposed in the inlet cone axially aligned with a direction of exhaust flow to partially block and partially deflect the exhaust gas to a diffuser, the deflector defining a plurality of first openings that direct a first portion of the exhaust gas axially toward a central portion of the monolithic catalytic converter block, wherein the diffuser defines a plurality of second openings that direct a second portion of the exhaust gas toward the inlet cone, wherein the second portion of the exhaust gas is redirected by the inlet cone toward an outer portion of the monolithic catalytic converter block radially outward of the central portion.

2. The exhaust system for a vehicle of claim 1, wherein the deflector further comprises:

a planar plate disposed transverse to the direction of the exhaust flow from the exhaust pipe.

3. The exhaust system for a vehicle of claim 1, wherein the diffuser further comprises:

a tubular portion of the exhaust pipe disposed within the inlet cone.

4. The exhaust system for a vehicle of claim 1, wherein the deflector/diffuser further comprises:

a planar plate disposed transverse to the exhaust flow from the exhaust pipe; and

a tubular portion of the exhaust pipe disposed within the inlet cone.

5. The exhaust system for a vehicle of claim 1, wherein the deflector/diffuser is a cup-shaped member tube disposed within the inlet cone, wherein the deflector/diffuser includes a planar plate disposed transverse to the direction of the exhaust flow from the exhaust pipe, and a tubular member attached to the exhaust pipe.

6. The exhaust system for a vehicle of claim 1, wherein the diffuser is a portion of the exhaust pipe disposed within the inlet cone, wherein an end of the exhaust pipe defines the plurality of second openings.

7. The exhaust system for a vehicle of claim 1, wherein the deflector/diffuser is a casting attached to the outlet end of the exhaust pipe, the deflector/diffuser including a planar portion defining the plurality of first openings and a cylindrical portion defining the plurality of second openings.

8. An exhaust system for a vehicle, comprising:

an exhaust pipe that receives exhaust gas from an internal combustion engine;

a catalytic converter assembly comprising a housing and a monolithic catalytic converter block, wherein the housing comprises an inlet cone that receives exhaust from the exhaust pipe; and

a deflector/diffuser disposed at an outlet end of the exhaust pipe, the deflector/diffuser disposed within the inlet cone, the deflector/diffuser including a convex tip disposed in the inlet cone, the convex tip defining a plurality of openings that partially deflect a first portion of the exhaust gas toward a central portion of the monolithic catalytic converter block and partially diffuse a second portion of the exhaust gas toward the inlet cone, wherein the second portion of the exhaust gas is redirected by the inlet cone toward an outer portion of the monolithic catalytic converter block radially outward of the central portion.

9. The exhaust system for a vehicle of claim 8, wherein the convex tip has a conical sidewall portion and a rounded tip portion, wherein the conical sidewall portion is symmetrical with respect to an axis, and wherein the axis is aligned with a direction of exhaust flow in the exhaust pipe.

10. The exhaust system for a vehicle of claim 8, wherein the convex tip has a conical sidewall portion and a circular tip portion, wherein the conical sidewall portion is symmetrical with respect to an axis, wherein the axis is disposed at an acute angle with respect to a direction of exhaust flow in the exhaust pipe.

11. The exhaust system for a vehicle of claim 8, wherein the exhaust pipe is assembled to the inlet cone without extending into the inlet cone.

12. The exhaust system for a vehicle of claim 11, wherein the deflector/diffuser is assembled to the outlet end of the exhaust pipe and extends within the inlet cone.

13. An exhaust system for a vehicle, comprising:

an exhaust pipe that receives exhaust gas from an internal combustion engine;

a catalytic converter assembly comprising a housing and a monolithic catalytic converter block, wherein the housing comprises an inlet cone that receives an exhaust gas flow from the exhaust pipe; and

a nozzle receiving exhaust gas from the exhaust pipe, the nozzle disposed within the inlet cone and having a plurality of vanes aligned about a central opening, the vanes oriented to diffuse a first portion of the exhaust gas flow toward the inlet cone, wherein a second portion of the exhaust gas flow is directed through the central opening directly toward the monolithic catalytic converter block.

14. The exhaust system for a vehicle of claim 13, wherein the plurality of vanes taper inwardly from the exhaust pipe and converge toward the central opening at distal ends of the vanes.

15. An exhaust system for a vehicle according to claim 13, wherein the exhaust pipe extends into the inlet cone, and wherein the plurality of vanes are formed on the exhaust pipe, and wherein the vanes are spaced apart from the monolithic catalytic converter block.