Channel type reducing agent mixing device

Abstract

A reductant impact device includes a proximal end having an impact pin with a convex surface; and a distal end having a body concentric with a longitudinal axis of the impact pin. The distal end includes a first surface and a second surface opposite to the first surface. A plurality of inner channels connect the first surface and the second surface, and a plurality of outer channels connect the first surface and the second surface, wherein the plurality of inner channels are arranged in a circular array at a first radial distance from the longitudinal axis of the impact pin, and the plurality of outer channels are arranged in a circular array at a second distance from the longitudinal axis of the impact pin.

Description

Technical Field

[0001] The present invention relates to an exhaust gas treatment system, and more particularly, to a nozzle for injecting a reductant solution into a fluid path within an exhaust gas treatment system. Background Art

[0002] Internal combustion engines, such as diesel engines, gasoline engines, gaseous fuel-powered engines, and other engines known in the art, emit a complex mixture of components into the environment. These components may include nitrogen oxides (NOx), such as NO and NO2. Due to increasing attention to avoiding environmental pollution, exhaust emission standards have become more stringent, and in some cases, the amount of NOx emitted from the engine may be adjusted according to engine size, engine category, and / or engine type. In order to ensure compliance with regulations for these components, as well as to reduce environmental impact, some engine manufacturers implement a strategy known as selective catalytic reduction (SCR). Selective catalytic reduction is a process in which a gaseous and / or liquid reductant, most commonly urea ((NH2)2CO)), is selectively added to the engine exhaust using one or more nozzles. The injected reductant decomposes into ammonia (NH3), reacts with NOx in the exhaust gas, and forms water (H2O) and diatomic nitrogen (N2).

[0003] U.S. Patent No. 8,356,473 issued to Blomquist on January 22, 2013 (hereinafter referred to as the '473 reference) describes an injection device having a first conduit for supplying compressed gas and a second conduit arranged outside the first conduit for supplying a liquid agent. At least one hole extends between the first conduit and the second conduit. As discussed in the '473 reference, the liquid agent flows into the compressed air through the at least one hole. The liquid agent is atomized by the compressed gas, mixed with the compressed gas, and delivered through the outlet of the injection device to be dispersed into the exhaust line.

[0004] Although the injection device of the '473 reference may attempt to increase the atomization of the liquid reagent, the operation of the injection device may not be optimal. For example, the injection device described in the '473 reference is relatively small in size, and due to the low turbulence and mixing characteristics, it may be difficult to achieve effective mixing of the liquid reagent. In addition, the '473 reference describes an injection device with multiple different and assembled parts, and this device configuration can increase the size, complexity, assembly time and / or manufacturing cost of the nozzle. Such multi-part devices are also generally difficult to clean and may become easily blocked.

[0005] Exemplary embodiments of the present invention are directed to overcoming one or more of the above-mentioned disadvantages. Summary of the invention

[0006] According to one embodiment of the present invention, a nozzle including a nozzle body is described. The nozzle body includes a proximal end and a second inlet, the proximal end having a first inlet arranged in the direction of the longitudinal axis of the nozzle, and the second inlet having a first air inlet channel arranged at an angle perpendicular to the longitudinal axis of the nozzle. The nozzle includes a distal end arranged opposite to the proximal end along the longitudinal axis of the nozzle, and the distal end has an outlet. The interior of the nozzle is arranged between the proximal end and the distal end, and includes a fluid impact chamber connected to the first inlet and the second inlet fluid, and a mixing chamber connected to the outlet fluid at the distal end. The nozzle also includes an impact device that fluidly connects the fluid impact chamber and the mixing chamber. The impact device includes an impact pin, the impact pin having a pin body and a convex surface arranged at the end of the impact pin. The convex surface is concentric with the longitudinal axis of the nozzle.

[0007] According to another embodiment of the present invention, an impact device includes an impact pin and a device body coaxial with the longitudinal axis of the impact pin. The device body is arranged on the impact pin at the distal end of the impact device. The impact pin includes a convex surface located at the proximal end of the device. The device body includes a first surface, a second surface opposite to the first surface, and a plurality of inner channels connecting the first surface and the second surface. The plurality of inner channels are arranged in a first circular array at a first radial distance from the longitudinal axis of the impact pin. The device body further includes a plurality of outer channels connecting the first surface and the second surface. The plurality of outer channels are arranged in a second circular array at a second radial distance from the longitudinal axis of the impact pin.

[0008] According to yet another embodiment, an exhaust system is described. The exhaust system includes an exhaust pipe configured to receive exhaust from an engine, a compressed air source, a reductant source, and a nozzle fluidly connected to the exhaust pipe. The nozzle is configured to receive air from the compressed air source and reductant from the reductant source. The nozzle includes an impact pin and a device body coaxial with the longitudinal axis of the impact pin. The device body is disposed on the impact pin at the distal end of the impact device. The impact pin includes a convex surface located at the proximal end of the device. The device body includes a first surface, a second surface opposite to the first surface, and a plurality of inner channels connecting the first surface and the second surface. The plurality of inner channels are disposed in a first circular array at a first radial distance from the longitudinal axis of the impact pin. The device body further includes a plurality of outer channels connecting the first surface and the second surface. The plurality of outer channels are disposed in a second circular array at a second radial distance from the longitudinal axis of the impact pin. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a perspective view of a reducing agent nozzle of an exhaust system according to an embodiment of the present invention.

[0010] Figure 2 The method for Figure 1 Perspective view of a reducing agent impingement device in a reducing agent nozzle.

[0011] Figure 3 The embodiment according to the present invention is shown Figure 2 A top view of the reducing agent impact device is shown.

[0012] Figure 4 According to an embodiment of the present invention Figure 2 A front view of the reducing agent impact device is shown.

[0013] Figure 5 Describes an embodiment of the present invention Figure 2-4 A cross-sectional view of the inner channel of the reducing agent impact device.

[0014] Figure 6 Describes an embodiment of the present invention Figure 2-4 Cross-sectional view of the outer channel of the reducing agent impact device.

[0015] Figure 7 is a schematic diagram of an exhaust system having a reductant nozzle according to an embodiment of the present invention. DETAILED DESCRIPTION

[0016] The present invention generally relates to a nozzle for injecting a mixture of a reducing agent and air into an exhaust gas flow. Wherever possible, the same reference numerals will be used throughout the drawings to represent the same or similar features. In the drawings, the leftmost digit of a reference numeral identifies the drawing in which the reference numeral first appears.

[0017] Figure 1 An exemplary nozzle 100 is shown. For purposes of the present invention, the nozzle 100 is shown and described for use with a diesel fueled internal combustion engine. However, the nozzle 100 may be implemented as a reductant nozzle operable as part of any exhaust system that may be used with any other type of combustion engine, such as a gasoline or gas fuel powered engine, or an engine fueled by compressed or liquefied natural gas, propane, or methane.

[0018] Selective catalytic reduction is an active emission control technology system that injects a liquid reductant into the exhaust stream of a diesel engine through a catalyst. The reductant source is typically automotive grade urea, otherwise known as diesel exhaust fluid (DEF). In some embodiments, the reductant may include DEF, ammonia, liquefied anhydrous ammonia, ammonium carbonate, an ammonia salt solution, a hydrocarbon such as diesel fuel, or another solution. In the DEF reaction, the DEF produces a chemical reaction that converts nitrogen oxides into nitrogen, water, and a small amount of carbon dioxide (CO2), a natural component of the air we breathe, which is then discharged through the vehicle tail pipe. Embodiments of the present invention can reduce emissions, thereby improving the efficiency of the selective catalytic reduction system in the emission control of diesel engines.

[0019] engine( Figure 1The nozzle 100 may generate an exhaust gas flow 102. The nozzle 100 may inject a reductant into the exhaust gas flow 102. The nozzle 100 is configured to spray a reductant solution (or other compound) into the exhaust gas flow 102. The nozzle 100 may include a proximal end 104 and a distal end 106 disposed opposite the proximal end 104. The nozzle 100 may be fluidly connected to a supply line ( Figure 1 The nozzle 100 may include a first inlet 108 (not shown) at the proximal end 104 of the nozzle 100 and supplying a reductant (not shown) to the first inlet 108, which may be an inlet for the reductant, via one or more fittings or couplings (not shown). The nozzle 100 may include a compressed air inlet passage 142, which may be fluidly connected to a compressed air source for supplying compressed air 116 to the second inlet 110. As explained in more detail below, the nozzle 100 may be configured to mix the reductant solution 114 and the compressed air 116 in an extreme thermal environment so that the reductant maintains an operating temperature without crystallization of the reductant that may clog the nozzle.

[0020] In some embodiments, the nozzle 100 can be manufactured using 3D printing technology or other types of additive manufacturing (e.g., cast molding) and include a single piece of material. However, it is contemplated that one or more of the components of the nozzle 100 described above and discussed herein can alternatively be manufactured by other processes including manual machining, computer numerical control (CNC) machining, or other methods. In addition, the nozzle 100 can be made of a variety of materials, including chrome, nickel, stainless steel, alloys, ceramics, etc. These materials can also be corrosion-resistant and anti-stick to prevent the accumulation of reducing agent on and / or in the nozzle 100.

[0021] At the proximal end 104 of the nozzle 100, the nozzle 100 may include one or more inlets configured to receive the reductant and / or air from the first air inlet passage 142. For example, the nozzle 100 may include a first inlet 108 for supplying a reductant solution 114 to the nozzle 100 and a second inlet 110 for supplying compressed air 116 to the nozzle 100.

[0022] In some examples, at the distal end 106 of the nozzle 100 , the nozzle 100 may include one or more spray channel outlets 112 . According to embodiments described herein, the reductant / air solution 120 may enter the exhaust gas flow 102 through the one or more spray channel outlets 112 .

[0023] As discussed in detail herein, the nozzle 100 can facilitate mixing of the reductant solution 114 and the compressed air 116 to mix, aerate, separate and / or atomize the reductant solution 114. According to one embodiment, the interior 118 of the nozzle 100 includes a structure of the nozzle 100, wherein the structure includes various passages and channels formed at least in part by the body of the nozzle 100. More specifically, within the nozzle interior 118 of the nozzle 100, the air and the reductant can be mixed together to form a reductant / air solution 120. This process can cause the reductant solution 114 to break into fine particles or droplets at an interior first end 122 of the nozzle interior 118 and mix with the compressed air 116 at an interior second end 124 of the nozzle interior 118. As described above, the nozzle 100 can disperse and / or otherwise direct the reductant / air solution 120 into the exhaust gas flow 102 through one or more spray channel outlets 112 disposed at the distal end 106 of the nozzle 100. Thus, when the reductant / air solution 120 is dispersed into the exhaust gas flow 102 , the reductant / air solution 120 may react with NOx (eg, NO and / or NO 2 ) to form water (H 2 O) and elemental nitrogen (N 2 ).

[0024] According to one embodiment, the nozzle interior 118 may be divided into two or more main chambers (e.g., a fluid impingement chamber 426 and a mixing chamber 128) by an impingement device 130. In some aspects, the impingement device 130 may fluidly connect the fluid impingement chamber 426 and the mixing chamber 128 via a plurality of orifices 138 that provide a passage for the reductant / air solution 120 to pass from the fluid impingement chamber 426 to the mixing chamber 128. More specifically, the impingement device body 132 may be configured as a substantially flat disk or plate having an impingement pin 134 at the center of the impingement device body 132, wherein the impingement device body 132 seals against one or more mating surfaces such that the reductant solution 114, the compressed air 116, and / or the reductant / air solution 120 may not pass through the impingement device 130 from the fluid impingement chamber 426 to the mixing chamber 128 except through the plurality of orifices 138.

[0025] As explained in more detail below, the impact pin 134 includes a convex surface 136 at the proximal end of the impact device 130. In operation, the reductant solution 114 can be pumped or otherwise delivered into the first inlet 108. Thus, when pumped into the nozzle 100, the reductant solution 114 travels through the first inlet 108 and impacts the convex surface 136, wherein a laminar flow of the reductant solution 114 (the laminar flow of the reductant solution 114 and the reductant solution 114, as shown in FIG. Figure 1 The approximate center of the convex surface 136 (approximately) hits the convex surface 136 at the apex of the convex surface 136.

[0026] The shape and position of the convex surface 136 are such that when the convex surface 136 is impacted, the reducing agent solution 114 is dispersed into a mixture of ambient air and reducing agent solution. In some aspects, the orifice 138 connecting the fluid impact chamber (wherein the fluid is broken by the impact pin 134) and the mixing chamber 128 is configured to further disperse the reducing agent and the compressed air solution into smaller discrete droplets. For example, the orifice 138 can be configured to break the reducing agent / air mixture into droplets, partially atomize the reducing agent and the air solution, or otherwise reduce the reducing agent and the solution to an aerosol / droplet mixture. As explained in detail below, the orifice 138 can also be configured to generate turbulence in the mixing chamber 128 to further combine the compressed air 116 and the reducing agent solution 114, and form the reducing agent / air solution 120.

[0027] When the reductant solution is urea or contains urea, in some cases, the urea may react with heat so that crystallization of the reductant solution may occur above certain temperatures. Because the nozzle 100 can operate as part of an exhaust system of an internal combustion engine, the nozzle 100 can reach a temperature ranging from about 200° C. to about 500° C. In some examples, the urea aqueous solution of the reductant solution may crystallize at these high temperatures (e.g., between about 200° C. and about 500° C.) as water evaporates from the solution. When urea crystallizes at high temperatures, urea deposits may form, which may hinder the performance of the exhaust system. For example, the selective catalytic reaction of removing particulates from the exhaust gas flow may be hindered by urea crystal deposits, the nozzle outlet or other fluid ports may be blocked, etc.

[0028] According to one embodiment, in order to prevent the reductant solution 114 from crystallizing, the nozzle 100 can direct the compressed air 116 through the first air inlet channel 142. When mixed with the reductant solution 114, the compressed air 116 can cool the system and prevent urea from crystallizing in the reductant solution 114. Therefore, the first air inlet channel 142 connects the second inlet 110 fluid to the fluid impact chamber 426. The second inlet channel 110 can direct the compressed air 116 into the fluid impact chamber 426 at a predetermined angle relative to the longitudinal axis 140. The predetermined incident angle of the compressed air 116 relative to the impact pin 134 can generate turbulent airflow within the fluid impact chamber 126. For example, the predetermined angle between the axis of the first air inlet channel 142 and the longitudinal axis 140 can be approximately 90° (substantially perpendicular). Figure 1As shown, the first air inlet passage 142 can be disposed opposite the pin body surface of the impingement pin 134 such that a longitudinal center of the first air inlet passage 142 is substantially perpendicular to the curved outer surface of the impingement pin 134 and substantially perpendicular to the longitudinal axis 140. When the compressed air 116 strikes the side of the impingement pin 134 at a predetermined angle, the compressed air 116 can be forced to mix with the reductant solution 116 in a manner that combines and cools the impingement pin 134, the fluid impingement chamber 126, and the reductant solution 114.

[0029] In some aspects, the nozzle 100 may include two or more air inlet passages. For example, the nozzle 100 may include a second air inlet passage 144 disposed opposite the pin body 135 of the impingement pin 134, such that a longitudinal center of the second air inlet passage may be substantially perpendicular to an outer surface of the pin body 135 of the impingement pin 134 and substantially perpendicular to the longitudinal axis 140. In yet another embodiment, two or more air inlet passages may be included at an angle substantially perpendicular to the longitudinal axis 140, such that they are configured opposite the pin body 135. As used herein, the phrase "opposite the pin body 135" means that the pin body 135 may be configured to be directly in the laminar flow and / or turbulent flow of the fluid interacting with the pin body 135.

[0030] By injecting the compressed air 116 at an angle perpendicular to the longitudinal axis 140, the flow of the compressed air 116 can interact with the curved outer surface of the impact pin 134 so that the compressed air 116 is dispersed within the fluid impact chamber 426 at a reflection angle. For example, when the air flow interacts with the impact pin 134, the incident angle of the flow of the compressed air 116 flowing linearly is equal to the reflection angle of the flow of the compressed air 116. Therefore, when the radial curved pin body 135 interacts with the laminar flow of the flow of the compressed air 116, the reflection angle of the compressed air 116 spreads throughout the fluid impact chamber 126. The turbulence caused by the compressed air 116 interacting with the curved pin body 135f mixes the compressed air 116 with the reductant solution 114 within the fluid impact chamber 426. In combination with the dispersed reductant solution 114 (dispersed after hitting the convex surface 136), the reductant solution 114 can be cooled by the compressed air 116, and the compressed air 116 can be more turbulent and uniformly mixed with the reductant solution 114. Due to the turbulence created by the combination / configuration of the first air inlet passage 142 and the reductant solution 114 interacting with the convex surface 136 , the interior surface of the nozzle interior 118 may also be cooled to a temperature below the urea crystallization threshold.

[0031] The nozzle 100 may be mounted directly in the exhaust gas flow 102 of an exhaust system (e.g., as Figure 7As shown, discussed in more detail below, in a conventional selective catalytic reduction catalyst system. Therefore, in a conventional exhaust system, a nozzle that sprays diesel exhaust fluid (DEF) forms crystallized deposits of urea, which can clog the exhaust system. In a conventional system, the nozzle may exceed the crystallization temperature threshold of urea in the reductant solution 114. According to one or more embodiments, a combination of elements can provide optimal cooling and mixing characteristics: first, the compressed air 116 can be pressed into the impact pin 134 at an angle relative to the impact pin 134 to produce turbulence, and second, the reductant solution 114 can be dispersed with turbulent air through the convex surface 136 within the fluid impact chamber 426, so that the outer surface of the pin body of the impact pin 134 can be directly opposite to the flow of compressed air 116. According to an embodiment, the configuration of the nozzle 100 can cool both the reductant solution 114 and the nozzle interior 118.

[0032] Figure 2 The method for Figure 1 A perspective view of an exemplary impingement device 130 in a reductant nozzle. Figure 3 The embodiment according to the present invention is shown Figure 2 A top view of the impact device 130 is shown. Figure 4 According to an embodiment of the present invention Figure 2 A front view of the impact device 130 is shown.

[0033] See also Figure 3 According to one or more embodiments, the impact device 130 may include an impact device body 132 and an impact pin 134 disposed to the impact device body 132. The impact device body 132 includes an orifice 138, which may be circumferentially disposed about a longitudinal axis 140 ( Figure 1 ) is circumferentially arranged, and more specifically, around a second longitudinal axis (longitudinal axis 150, such as Figure 4 When the impact pin 134 is configured as a component with the nozzle 100 (e.g., as Figure 1 As shown), the longitudinal axis 140 and the second longitudinal axis 150 are collinear.

[0034] like Figure 2 As shown, the apertures 138 may be configured as through passages disposed circumferentially about the second longitudinal axis 150. In one aspect, the plurality of apertures 138 are substantially equicircumferentially distributed about the longitudinal axis 140 of the nozzle 100 (and substantially equicircumferentially distributed about the second longitudinal axis 150).

[0035] In another aspect, the apertures 138 may be configured in two radial groups, such that one group of channels may be located at a first radial distance 154 and a second group of channels may be located at a second radial distance 158. For example, the plurality of inner channels 152 may be disposed in a circular array at a first radial distance 154 from the second longitudinal axis 150, and the plurality of outer channels 156 may be disposed in a circular array at a second radial distance 158 from the second longitudinal axis 150 of the impact pin 134. In one aspect, the first radial distance may be approximately 1 / 3 of the radial distance of the impact device body 132 from the second longitudinal axis 150 to the outer edge of the impact device body 132. In another aspect, the second radial distance may be approximately 2 / 3 of the radial distance of the impact device body 132 from the second longitudinal axis 150 to the outer edge of the impact device body 132. In other examples, the distance may be greater or less than the radial distance of the impact device body 132, such as 1 / 2 of the radial distance, 11 / 16 of the radial distance, etc.

[0036] See also Figure 4 1, the pin body 135 of the impact pin 134 is shown as having a convex surface 136 at the proximal end 146 of the pin body 135. The convex surface 136 of the impact device 130 can be configured to flow in the opposite direction to the fluid flow of the first inlet 108 of the nozzle 100 ( Figure 1 According to one embodiment, the convex surface 136 may be substantially hemispherical. The hemispherical shape is shown to disperse the reductant solution 114 in a manner such that mixing of the reductant solution 114 with the compressed air 116 results in optimal cooling of the reductant / air solution 120 ( Figure 1 ).

[0037] Another advantage of the convex surface 136 is that it is easy to manufacture the impact device 130. In some embodiments, the impact pin 134 can be machined or otherwise manufactured as a single piece relative to the impact device body 132. In another embodiment, the impact pin 134 can be a separate part from the impact device body 132 and removably attached to the impact device body 132 using mechanical fasteners (not shown). In either case, the convex surface 136 can provide optimal dispersion without introducing multiple machining steps or additional parts to assemble.

[0038] Continue to see Figure 4 , the first surface 147 can be configured to seal against the inner edge of the nozzle interior 118 so that the fluid impingement chamber 426 can be fluidly separated from the mixing chamber 128, except for the orifice 138 (which includes the plurality of inner channels 152 and the plurality of outer channels 156). Figure 3 , shows a partial top view of the orifice 138 (more specifically, showing the inner channel 160 and the outer channel 162 of the orifice 138). To simplify the description, Figure 3The top view in FIG. 1 shows only one inner channel 160 and one outer channel 162 , but it should be understood that the plurality of channels (holes 138 ) may include any number of channels.

[0039] The inner channel 160 can be configured to direct a fluid (e.g., the reductant solution 114, the compressed air 116, and / or the reductant / air solution 120) in a direction generally consistent with the channel direction 164. The outer channel 162 can be configured to direct a fluid (e.g., the reductant solution 114, the compressed air 116, and / or the reductant / air solution 120) in a direction generally consistent with the directional arrows showing the channel direction 166. The inner channel 160 can represent the channel direction of all inner channels of the plurality of orifices 138 circumferentially disposed about the second longitudinal axis 150. The inner channel 160 fluidly connects the first surface 147 and the second surface 149.

[0040] According to another embodiment, channel direction 164 and channel direction 166 may be configured in another pattern such that the directions change within the same radial distance at every second channel, every third channel, etc. Other configurations are also contemplated.

[0041] Figure 5 Describes an embodiment of the present invention Figure 2-4 160. A cross-sectional view of an inner channel of a reductant impact device of FIG. 160. A channel direction 164 represents a general trajectory of any fluid passing through the inner channel 160. The inner channel 160 may be configured as a slit having two opposing inner channel walls. In one embodiment, the two inner channel walls may include a first inner channel wall 168, which may be disposed substantially parallel to a second inner channel wall 170. The two opposing channel walls form two sides of the inner channel 160. In one aspect, the first inner channel wall 168 and the second inner channel wall 170 are disposed at a first predetermined angle 172 relative to a longitudinal axis (e.g., the second longitudinal axis 150) of the impact pin 134. In one aspect, the first predetermined angle may be approximately 30°; in another aspect, the first predetermined angle may be another angle, such as, for example, 25° or 35°; or greater than or less than 25° or 35°.

[0042] Figure 6 Describes an embodiment of the present invention Figure 2-4162 according to one embodiment. The impact device body 132 shows a cross-sectional view (section B) of the outer channel 162. The channel direction 166 represents the general trajectory of any fluid passing through the outer channel 162. The outer channel 162 can be configured as a slit having two opposing inner channel walls. In one embodiment, the two outer channel walls can include a first outer channel wall 174, which can be arranged to be substantially parallel to the second outer channel wall 176. The two opposing channel walls form two sides of the outer channel 162. In one aspect, the first outer channel wall 174 and the second outer channel wall 176 are arranged at a second predetermined angle 178 relative to the longitudinal axis of the impact pin 134 (e.g., the second longitudinal axis 150). In one aspect, the second predetermined angle can be approximately 30°. In another aspect, the first predetermined angle can be another angle, such as 25° or 35°; or greater than or less than 25° or 35°. It is worth noting that the channel direction 164 ( Figure 5 ) may be opposite to the channel direction 166 showing the fluid trajectory of the fluid through the plurality of outer channels 156.

[0043] Figure 7 1 is a schematic diagram of an exhaust system 180 for an engine 188 including the nozzle 100 according to an embodiment of the present invention. The exhaust system 180 may further include an air compressor or other compressed air source 182 configured to supply compressed air 116 via a compressed air supply line 190, and one or more reservoirs and pumps configured as a reductant source 184. The reductant source 184 may be, for example, a DEF tank configured to supply the reductant solution 114 via a reductant solution supply line 186. The reductant solution supply line 186 may be connected to the first inlet 108 ( Figure 1 ) fluid connection.

[0044] In some embodiments, the amount of compressed air 116 and / or the amount of reductant solution 114 supplied to the system may be related to the flow rate of the exhaust gas stream 102, the operating state of the engine 188 (e.g., rpm), the temperature of the exhaust gas stream 102, the concentration of a particular gas in the exhaust gas stream 102, and / or one or more other operating conditions of the exhaust system 180. For example, as the flow rate of the exhaust gas stream 102 decreases, a controller or other control component (not shown) operably connected to the air compressor and / or the reductant pump may control the pump to correspondingly decrease the amount of reductant solution 114 and / or compressed air 116 supplied to the nozzle 100 (and thereby introduced into the exhaust gas stream 102). Alternatively, as the flow rate of the exhaust gas stream 102 increases, the controller or other control component (not shown) may increase and / or decrease the amount of reductant solution 114 and / or compressed air 116 supplied to the nozzle 100. Thus, the amount of reductant / air solution 120 introduced into the exhaust gas stream 102 may be controlled by the controller.

[0045] In some embodiments, the nozzle 100 may be located downstream of a selective catalytic reduction system, or may be operated as part of a selective catalytic reduction system within an exhaust pipe 192 and / or other treatment system. The exhaust system 180 may also include one or more oxidation catalysts, mixing features, a particulate filter (e.g., a diesel particulate filter (DPF)), a selective catalytic reduction substrate, an ammonia reduction catalyst, and other devices configured to further enhance the efficiency of reducing NOx (devices not shown). In addition, although only one nozzle 100 is shown, in some embodiments, the exhaust system 180 may include more than one nozzle 100. In addition, the exhaust system 180 may include any number of exhaust pipes 192 in which one or more nozzles 100 are positioned.

[0046] Industrial Applicability

[0047] The nozzle 100, impingement device 130, and exhaust system 180 can increase exhaust system efficiency and operability by reducing and / or eliminating crystallization of urea compounds or other reactants due to adverse response to exhaust system heat. The embodiments described herein can increase turbulence and mixing within the nozzle 100 so that the reductant solution 114 can be maintained at an operable temperature when treating the exhaust flow 102 in the exhaust system of an internal combustion engine.

[0048] Although various aspects of the present invention have been specifically shown and described with reference to the above embodiments, it will be appreciated by those skilled in the art that various additional embodiments may be envisioned by modifying the disclosed machines, systems, and methods without departing from the spirit and scope of the present invention. These embodiments should be understood to fall within the scope of the present invention as determined by the claims and any equivalents thereof.

Claims

1. A nozzle, include: A nozzle body comprising: a proximal end, the proximal end comprising a first inlet and a second inlet disposed in the direction of a longitudinal axis of the nozzle, the second inlet comprising a first air inlet passage disposed at an angle perpendicular to the longitudinal axis of the nozzle; a distal end disposed opposite the proximal end along the longitudinal axis of the nozzle, the distal end comprising a plurality of spray channel outlets; and An interior portion, the interior portion being disposed between the proximal end and the distal end, the interior portion comprising: a fluid impingement chamber fluidly connected to the first inlet and the second inlet, and a mixing chamber fluidly connected at the distal end to the plurality of spray channel outlets; and An impact device, the impact device fluidly connects the fluid impact chamber and the mixing chamber, the impact device comprising: an impact pin comprising a pin body and a convex surface disposed at an end of the impact pin, wherein the convex surface is concentric with the longitudinal axis of the nozzle; and an impact device body coaxial with the longitudinal axis of the impact pin and disposed to the impact pin at a distal end of the impact device, the impact device body having a plurality of apertures disposed therein and through which a fluid impact chamber and the mixing chamber are fluidly connected; The plurality of spray channel outlets are fluidly connected to the plurality of orifices of the impact device body via the mixing chamber.

2. The nozzle according to claim 1, in, The first inlet is a reductant fluid inlet and the second inlet is a compressed air inlet.

3. The nozzle of claim 1, wherein the convex surface is substantially hemispherical and disposed at the end of the impact pin, wherein the convex surface is configured to impact a fluid flow of fluid passing through the first inlet.

4. The nozzle of claim 1 , wherein the impact device body has a first surface and a second surface, wherein one or more of the first surface and the second surface are configured to create a connection that mates with a surface of the interior such that the connection fluidly seals the fluid impact chamber and the mixing chamber, wherein fluid can pass through the impact device body through the plurality of apertures disposed in the impact device body.

5. The nozzle of claim 1 , wherein the first air inlet passage is disposed opposite the pin body of the impact pin such that a central longitudinal axis of the first air inlet passage is substantially perpendicular to an outer surface of the pin body of the impact pin and substantially perpendicular to the longitudinal axis.

6. The nozzle of claim 5, further comprising a second air inlet passage disposed opposite the pin body of the impact pin such that a central longitudinal axis of the second air inlet passage is substantially perpendicular to an outer surface of the pin body of the impact pin and substantially perpendicular to the longitudinal axis.

7. The nozzle of claim 1, wherein the impact device further comprises a second longitudinal axis coaxial with the longitudinal axis of the nozzle, Wherein the plurality of apertures are circumferentially arranged around the second longitudinal axis.

8. The nozzle of claim 7, wherein the plurality of orifices are substantially equicircumferentially distributed about the longitudinal axis of the nozzle.

9. The nozzle according to claim 8, in, The plurality of apertures includes a first plurality of apertures having a first predetermined angle relative to a first surface of the impact device and a second plurality of apertures having a second angle relative to the first surface of the impact device.

10. An impact device, adapted to be arranged in a nozzle, the impact device include: an impact pin and a device body coaxial with a longitudinal axis of the impact pin and disposed to the impact pin at a distal end of the impact device; The impact pin comprises: a convex surface of the impact pin at a proximal end of the device; and The device body comprises: a first surface; a second surface opposite to the first surface; and a plurality of internal passages connecting the first surface and the second surface, the plurality of internal passages being arranged in a first circular array at a first radial distance from a longitudinal axis of the impact pin; and a plurality of outer channels connecting the first surface and the second surface, the plurality of outer channels being arranged in a second circular array at a second radial distance from the longitudinal axis of the impact device; The distal end of the nozzle body of the nozzle comprises a plurality of spray channel outlets, and the plurality of inner channels and the plurality of outer channels of the device body are fluidically connected to the plurality of spray channel outlets.

11. The impact device of claim 10, further comprising a plurality of slits forming the plurality of inner channels connecting the first surface and the second surface.

12. The impact device according to claim 11, wherein a first inner channel among the plurality of inner channels comprises two opposing inner channel walls, wherein the two opposing inner channel walls include a first inner channel wall, the first inner channel wall being arranged substantially parallel to the second inner channel wall, and The first inner channel wall and the second inner channel wall are arranged at a first predetermined angle relative to the longitudinal axis of the impact pin.

13. The impact device according to claim 11, in, A first outer channel of the plurality of outer channels comprises two opposing outer channel walls, wherein the two opposing outer channel walls include a first outer channel wall, the first outer channel wall being arranged substantially parallel to the second outer channel wall, and Wherein the first outer channel wall and the second outer channel wall are arranged at a second predetermined angle relative to the longitudinal axis of the impact pin.

14. The impact device of claim 11, wherein the convex surface is substantially hemispherical and is disposed at an end of the impact pin, wherein the convex surface is configured to impact a fluid flow of a fluid.

15. Exhaust system, include: an exhaust pipe configured to receive exhaust gas from the engine; Compressed air source; a source of reducing agent; as well as a nozzle fluidly connected to the exhaust pipe, the nozzle being configured to receive compressed air from the compressed air source and reductant from the reductant source, the nozzle having a nozzle body, the nozzle body comprising: a proximal end, the proximal end comprising a first inlet and a second inlet disposed in the direction of the longitudinal axis of the nozzle, the second inlet comprising a first air inlet passage disposed at an angle perpendicular to the longitudinal axis of the nozzle; a distal end, the distal end being disposed opposite the proximal end along the longitudinal axis of the nozzle, the distal end comprising a plurality of spray channel outlets; An interior portion, the interior portion being disposed between the proximal end and the distal end, the interior portion comprising: a fluid impingement chamber fluidly connected to the first inlet and the second inlet, and a mixing chamber fluidly connected at the distal end to the plurality of spray channel outlets; and An impact device, the impact device fluidly connects the fluid impact chamber and the mixing chamber, the impact device comprising: an impact pin comprising a pin body and a convex surface disposed at an end of the impact pin, wherein the convex surface is concentric with the longitudinal axis of the nozzle; and an impact device body coaxial with the longitudinal axis of the impact pin and disposed to the impact pin at a distal end of the impact device, the impact device body having a plurality of apertures disposed therein and through which a fluid impact chamber and the mixing chamber are fluidly connected; The plurality of spray channel outlets are fluidly connected to the plurality of orifices of the impact device body via the mixing chamber.

16. The exhaust system according to claim 15, in, The first inlet is a reductant fluid inlet and the second inlet is a compressed air inlet.

17. The exhaust system of claim 15, wherein the convex surface is substantially hemispherical and disposed at the end of the impingement pin, wherein the convex surface is configured to impinge on a fluid flow of fluid passing through the first inlet.

18. The exhaust system of claim 15, wherein the impact device body has a first surface and a second surface, wherein one or more of the first surface and the second surface are configured to create a connector that cooperates with a surface of the interior so that the connector fluidly seals the fluid impact chamber and the mixing chamber, wherein fluid can pass through the impact device body through the plurality of orifices provided in the impact device body.

19. The exhaust system of claim 15, wherein the first air inlet passage is disposed opposite the pin body such that a central longitudinal axis of the first air inlet passage is substantially perpendicular to an outer surface of the pin body of the impingement pin and substantially perpendicular to the longitudinal axis.

20. The exhaust system of claim 19, further comprising a second air inlet passage disposed opposite the pin body such that a central longitudinal axis of the second air inlet passage is substantially perpendicular to the outer surface of the pin body of the impact pin and substantially perpendicular to the longitudinal axis.

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