Exhaust mixer assembly

Abstract

An exhaust mixer assembly includes a mixer housing, an inlet opening, an inlet plate, a support plate, a support plate opening, a transport tube, an outlet plate, and an outlet plate opening. A mixer housing is coupled to the upstream housing. The inlet plate and the support plate define a first mixing chamber. The inlet opening is configured to receive exhaust gas from the upstream housing and to deliver the exhaust gas to the first mixing chamber. The support plate and the outlet plate define a second mixing chamber. A transport tube is positioned in the second mixing chamber. The support plate opening is configured to receive treated exhaust gas from the first mixing chamber and to deliver the treated exhaust gas to the second mixing chamber. The treated exhaust gas flows circumferentially through the second mixing chamber and through the transport tube. The delivery tube delivers the reductant to the outlet plate opening.

Description

Technical Field

[0001] The present application generally relates to an exhaust mixer assembly for an internal combustion engine. Background Art

[0002] Nitrogen oxides (NO x ) compounds are contained in the exhaust gas of internal combustion engines (such as diesel engines). It is desirable to reduce NO x emissions, for example, to comply with environmental regulations. x emissions, the reductant can be injected into the exhaust gas through a reductant delivery system connected to the dosing system and within the vehicle system. The reductant helps convert a portion of the exhaust gas into non-NO x emissions, such as nitrogen (N2), carbon dioxide (CO2), and water (H2O), thereby reducing NO x The exhaust gas flow through the aftertreatment system must be swirled or otherwise agitated to promote mixing of the exhaust gas with the reductant to reduce NO x However, without proper flow through the aftertreatment system, deposits of exhaust gas may accumulate in the system. Not allowing exhaust gas to flow at a desired rate may reduce the efficiency of the vehicle system. Summary of the invention

[0003] In one embodiment, an exhaust mixer assembly includes a mixer housing, an inlet plate coupled to the mixer housing and including a first inlet opening, and a support plate coupled to the mixer housing downstream of the inlet plate. The support plate includes a support plate opening. The exhaust mixer assembly also includes a first inlet pipe having an upstream end and a downstream end, the upstream end being coupled to the inlet plate and configured to receive exhaust gas from the inlet opening, and the downstream end being closed by a first portion of the support plate. The first inlet pipe includes a first inlet tube lateral opening extending through a circumferential wall of the first inlet pipe. The first inlet pipe deviates from the support plate opening. The exhaust mixer assembly also includes an outlet plate coupled to the mixer housing downstream of the support plate. The outlet plate includes an outlet opening. The exhaust mixer assembly also includes a conveying tube coupled to the support plate and the outlet plate. The conveying tube includes a conveying tube lateral opening extending through the circumferential wall of the conveying tube. The conveying tube is configured to provide exhaust gas to the outlet opening.

[0004] In some embodiments, when viewed along the longitudinal direction of the mixer housing, the first inlet pipe lateral opening is located in the upper half of the first inlet pipe, the support plate opening is located in the lower half of the support plate, and the transport pipe lateral opening is located in the upper half of the transport pipe.

[0005] In some embodiments, the exhaust mixer assembly further comprises a perforated plate coupled to the mixer housing and positioned downstream of the outlet plate, wherein the perforated plate only partially overlaps the outlet opening when viewed in a longitudinal direction of the mixer housing.

[0006] In some embodiments, the perforated plate overlaps 30% to 70% of the outlet opening when viewed in the longitudinal direction of the mixer housing.

[0007] In some embodiments, the delivery tube lateral opening is located in the upper half of the delivery tube when viewed in the longitudinal direction of the mixer housing, and at least 80% of the cross-sectional area of ​​the perforated plate is located in the lower half of the cross-sectional area of ​​the mixer housing.

[0008] In some embodiments, the inlet plate further includes a second inlet opening, and the exhaust mixer assembly includes a second inlet pipe having an upstream end and a downstream end, the upstream end of the second inlet pipe being coupled to the inlet plate and configured to receive exhaust gas from the second inlet opening, the downstream end of the second inlet pipe being closed by a second portion of the support plate, wherein the second inlet pipe includes a second inlet pipe lateral opening extending through a circumferential wall of the second inlet pipe, and wherein the second inlet pipe is offset from the support plate opening.

[0009] In some embodiments, the inlet plate further comprises an auxiliary opening which is located in a lower half of the inlet plate when viewed in a longitudinal direction of the mixer housing, wherein the first inlet opening is positioned in an upper half of the inlet plate when viewed in the longitudinal direction of the mixer housing.

[0010] In some embodiments, the exhaust mixer assembly includes a first baffle extending from an edge of the auxiliary opening.

[0011] In some embodiments, the outlet plate includes at least one peripheral opening, the at least one peripheral opening being positioned outboard of the outlet opening.

[0012] In some embodiments, the mixer housing includes a reductant injection opening at a location between the inlet plate and the support plate.

[0013] In some embodiments, the mixer housing includes a reductant injection opening at a position between the inlet plate and the support plate, wherein the reductant injection opening is located in an upper half of the mixer housing when viewed along a longitudinal direction of the mixer housing.

[0014] In some embodiments, the mixer housing includes a reductant injection opening at a location between the inlet plate and the support plate, and a central axis of the reductant injection opening extends between the first inlet pipe and the second inlet pipe.

[0015] In some embodiments, the first inlet tube includes a first flat surface on a side facing the second inlet tube; and the second inlet tube includes a second flat surface on a side facing the first inlet tube.

[0016] In some embodiments, a distance between the first flat surface and the second flat surface increases in a direction from an upper side to a lower side of the first inlet tube and the second inlet tube.

[0017] In some embodiments, the inlet plate further comprises a flow assist opening positioned adjacent to the first inlet opening.

[0018] In some embodiments, the exhaust mixer assembly includes a second baffle extending from an edge of the flow assist opening.

[0019] In another embodiment, an exhaust mixer assembly includes a mixer housing. The exhaust mixer assembly also includes an inlet plate coupled to the mixer housing. The inlet plate includes a first inlet opening positioned on a first side of the inlet plate and a second inlet opening positioned on a second side of the inlet plate opposite to the first inlet opening. The exhaust mixer assembly also includes a support plate coupled to the mixer housing downstream of the inlet plate. The support plate includes a support plate opening. The exhaust mixer assembly also includes a first wall and a second wall extending from the inlet plate to the support plate. The exhaust mixer assembly also includes a first chamber on the inner side of the first wall and the second wall. The upper edge of the first wall and the upper edge of the second wall define an opening to the first chamber, and the lower edge of the first wall and the lower edge of the second wall extend to the mixer housing. The exhaust mixer assembly also includes a second chamber on the outer side of the first wall and the second wall. The exhaust mixer assembly also includes an outlet plate coupled to the mixer housing downstream of the support plate. The outlet plate includes an outlet opening. The exhaust mixer assembly also includes a delivery pipe coupled to the support plate and the outlet plate. The delivery pipe includes a delivery pipe lateral opening extending through the circumferential wall of the delivery pipe. The transport tube is configured to provide exhaust gas to the outlet opening.

[0020] In some embodiments, when viewed in the longitudinal direction of the mixer housing, the opening to the first chamber is located in the upper half of the inlet plate and the support plate, the support plate opening is located in the lower half of the support plate, and the transport tube lateral opening is located in the upper half of the transport tube.

[0021] In some embodiments, the inlet plate further comprises an auxiliary opening, which is located in a lower half of the inlet plate when viewed in the longitudinal direction of the mixer housing.

[0022] In some embodiments, the exhaust mixer assembly further comprises a perforated plate coupled to the mixer housing and positioned downstream of the outlet plate, wherein the perforated plate only partially overlaps the outlet opening when viewed in a longitudinal direction of the mixer housing.

[0023] In some embodiments, the perforated plate overlaps 30% to 70% of the outlet opening when viewed in the longitudinal direction of the mixer housing.

[0024] In some embodiments, the delivery tube lateral opening is located in the upper half of the delivery tube when viewed in the longitudinal direction of the mixer housing, and at least 80% of the cross-sectional area of ​​the perforated plate is located in the lower half of the cross-sectional area of ​​the mixer housing.

[0025] In some embodiments, the outlet plate includes at least one peripheral opening positioned outside of the outlet opening.

[0026] In some embodiments, the first wall includes a first cylindrical surface and a first planar surface, and the second wall includes a second cylindrical surface and a second planar surface.

[0027] In some embodiments, a distance between the first planar surface and the second planar surface increases in a direction from an upper side to a lower side of the first planar surface and the second planar surface.

[0028] In some embodiments, the exhaust mixer assembly further includes a perforated plate coupled to the mixer housing and positioned downstream of the outlet plate, wherein the perforated plate overlaps the entire outlet opening when viewed in a longitudinal direction of the mixer housing.

[0029] In some embodiments, the mixer housing includes a reductant injection opening at a location between the inlet plate and the support plate, and a central axis of the reductant injection opening extends between the first wall and the second wall.

[0030] In some embodiments, the exhaust mixer assembly also includes an impact plate, which is positioned between the first wall and the second wall, and the impact plate includes: an edge extending along an axis parallel to the longitudinal axis of the mixer housing, the edge being separated from the first wall and separated from the second wall; a first wing, the first wing being separated from the first wall and extending from the edge in a first direction away from the reductant injection opening; and a second wing, the second wing being separated from the second wall and extending from the edge in a second direction away from the reductant injection opening, the second wing being separated from the first wing.

[0031] In some embodiments, the axis coincides with the longitudinal axis.

[0032] In some embodiments, the edge is separated from the first wall by a first distance less than or equal to 10% of the diameter of the mixer housing; and the edge is separated from the second wall by a second distance less than or equal to 10% of the diameter of the mixer housing.

[0033] In some embodiments, the exhaust mixer assembly further includes: a first fin coupled to the inlet plate and the support plate, the first fin being positioned between the first wall and the first wing; and a second fin coupled to the inlet plate and the support plate, the second fin being positioned between the second wall and the second wing.

[0034] In some embodiments, the first wall includes a first wall opening and the second wall includes a second wall opening opposite the first wall opening.

[0035] In some embodiments, the exhaust mixer assembly also includes an impact plate, which is positioned between the first wall and the second wall, and the impact plate includes: an edge extending along an axis parallel to the longitudinal axis of the mixer housing, the edge being separated from the first wall and separated from the second wall; a first wing, the first wing being separated from the first wall and extending from the edge in a first direction away from the reductant injection opening; and a second wing, the second wing being separated from the second wall and extending from the edge in a second direction away from the reductant injection opening, the second wing being separated from the first wing; wherein each of the first wall opening and the second wall opening is positioned between the edge and the reductant injection opening. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The present disclosure will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like elements unless otherwise indicated, and wherein:

[0037] Figure 1 is a schematic block diagram of a portion of an example exhaust aftertreatment system;

[0038] Figure 2 is a perspective view of a portion of an exhaust mixer assembly according to one embodiment;

[0039] Figure 3 yes Figure 2 An exploded view of an exhaust mixer assembly;

[0040] Figure 4 yes Figure 2 A perspective view of a portion of an exhaust mixer assembly;

[0041] Figure 5 yes Figure 2 Another perspective view of a portion of an exhaust mixer assembly;

[0042] Figure 6 yes Figure 2 A perspective view of an exhaust mixer assembly of , wherein a portion of the exhaust mixer assembly is shown in a partially transparent manner;

[0043] Figure 7 It is taken along plane AA Figure 6 A longitudinal view of an exhaust mixer assembly;

[0044] Figure 8 yes Figure 2 Another perspective view of an exhaust mixer assembly of , wherein a portion of the exhaust mixer assembly is shown in a partially transparent manner;

[0045] Fig. 9 It is taken along plane BB Figure 8 A longitudinal view of an exhaust mixer assembly;

[0046] Fig.10 It is taken along plane CC Figure 8 A cross-sectional view of an exhaust mixer assembly;

[0047] Fig.11 is a perspective view of an exhaust mixer assembly according to another embodiment, wherein a portion of the exhaust mixer assembly is shown in a partially transparent manner;

[0048] Fig.12 is based on Fig.11 A perspective view of a portion of an exhaust mixer assembly;

[0049] Fig.13 yes Fig.11 An exploded view of an exhaust mixer assembly;

[0050] Fig.14 yes Fig.11Another exploded view of the exhaust mixer assembly;

[0051] Fig.15 yes Fig.11 Another perspective view of the exhaust mixer assembly;

[0052] Fig.16 yes Fig.11 Another perspective view of the exhaust mixer assembly;

[0053] Fig.17 It is taken along plane 17-17 Fig.16 A longitudinal view of an exhaust mixer assembly;

[0054] Fig.18 It is taken along plane 18-18 Fig.16 A longitudinal view of an exhaust mixer assembly;

[0055] Fig.19 It is taken along plane 19-19 Fig.16 A longitudinal view of an exhaust mixer assembly;

[0056] Fig. 20 It is taken along plane 20-20 Fig.16 A longitudinal view of an exhaust mixer assembly;

[0057] Fig.21 is a perspective view of an exhaust mixer assembly according to another embodiment, wherein a portion of the exhaust mixer assembly is shown in a partially transparent manner;

[0058] Fig. 22 yes Fig.21 An exploded view of an exhaust mixer assembly;

[0059] Fig.23 yes Fig.21 Another perspective view of an exhaust mixer assembly of , wherein a portion of the exhaust mixer assembly is shown in a partially transparent manner;

[0060] Fig.24 It is taken along plane EE Fig.21 A cross-sectional view of an exhaust mixer assembly;

[0061] Fig.25 It is taken along plane FF Fig.24 A longitudinal view of an exhaust mixer assembly;

[0062] Fig.26 yes Fig.21 A perspective view of a portion of an exhaust mixer assembly of , wherein a portion of the exhaust mixer assembly is shown in a partially transparent manner;

[0063] Fig. 27 It is taken along plane GG Fig.24 A longitudinal view of an exhaust mixer assembly;

[0064] Fig.28 yes Fig.21 A perspective view of a portion of an exhaust mixer assembly of , wherein a portion of the exhaust mixer assembly is shown in a partially transparent manner;

[0065] Fig.29 It is taken along plane HH Fig.24 Another longitudinal view of the exhaust mixer assembly;

[0066] Fig.30 It is taken along plane HH Fig.24 A longitudinal view of an exhaust mixer assembly;

[0067] Fig.31 yes Fig.21 Another perspective view of a portion of an exhaust mixer assembly of , wherein a portion of the exhaust mixer assembly is shown in a partially transparent manner;

[0068] Fig.32 It is taken along plane II Fig.24 a longitudinal view of an exhaust mixer assembly; and

[0069] Fig.33 It is taken along plane EE Fig.21 Another cross-sectional view of an exhaust mixer assembly.

[0070] It should be appreciated that these drawings are schematic representations for illustrative purposes. The drawings are provided for the purpose of illustrating one or more embodiments, with the express understanding that they are not intended to limit the scope or meaning of the claims. DETAILED DESCRIPTION

[0071] The following is a more detailed description of various concepts and implementations thereof related to methods, apparatuses, and methods for providing a mixer assembly for an exhaust aftertreatment system. The various concepts introduced above and discussed in more detail below can be implemented in any of a variety of ways, as the concepts described are not limited to any particular implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.

[0072] I. Overview

[0073] Internal combustion engines (e.g., diesel internal combustion engines, etc.) produce NO x In some applications, an exhaust aftertreatment system is used to add a reductant to the exhaust gas to reduce the NO in the exhaust gas. xEmissions. In order to reduce emissions from an internal combustion engine, it may be desirable to treat the exhaust by injecting a reductant into the exhaust. However, it is difficult to treat the exhaust with the reductant in a desired manner if the exhaust and the reductant are not mixed in a desired manner. In some applications, such as those with physical space and size constraints, it may be challenging to ensure that the desired mixing occurs.

[0074] Embodiments of the present invention relate to an exhaust aftertreatment system including an exhaust mixer assembly. The exhaust mixer assembly disrupts the flow of exhaust gas through the aftertreatment system. The exhaust mixer assembly includes a mixer housing surrounding various components of the exhaust mixer assembly. The exhaust mixer assembly includes an inlet plate, a support plate, and an outlet plate, each of which is connected to the mixer housing. The inlet plate and the support plate define a first mixing chamber in which a reductant is released into the aftertreatment system. In the first mixing chamber, the exhaust gas is directed toward the center of the first mixing chamber so that the exhaust gas is mixed with the reductant. The support plate and the outlet plate define a second mixing chamber. The second mixing chamber receives the exhaust-reductant mixture from the first mixing chamber. The second mixing chamber causes the exhaust-reductant mixture to form a vortex circumferentially upward to further mix the exhaust-reductant mixture, and then guides the exhaust-reductant mixture through a transport pipe and leaves the exhaust mixer assembly and enters a catalyst component housing.

[0075] II. Overview of exhaust aftertreatment systems

[0076] Figure 1 An exhaust aftertreatment system 100 (e.g., a treatment system, etc.) for treating exhaust gas generated by an internal combustion engine (e.g., a diesel internal combustion engine, a gasoline internal combustion engine, a hybrid internal combustion engine, a propane internal combustion engine, a dual-fuel internal combustion engine, etc.) is depicted. The exhaust aftertreatment system 100 includes an upstream exhaust conduit 102 (e.g., a pipeline, a conduit, etc.). The upstream exhaust conduit 102 is configured to receive exhaust gas from an upstream component (e.g., a header, an exhaust manifold, a turbocharger, a diesel oxidation catalyst, etc.). In some embodiments, the upstream exhaust conduit 102 is coupled to (e.g., attached to, fixed to, welded to, fastened to, riveted to, etc.) the internal combustion engine (e.g., the upstream exhaust conduit 102 is coupled to an outlet of the internal combustion engine, etc.). In other embodiments, the upstream exhaust conduit 102 is formed integrally with the internal combustion engine. As utilized herein, two or more elements are “integrally formed” with one another when they are formed and joined together as part of a single manufacturing step to produce a one-piece or unitary structure that cannot be disassembled without at least partial destruction of the entire portion.

[0077] The exhaust aftertreatment system includes a housing assembly 104. The housing assembly 104 includes an intake body 106 (e.g., a chamber, etc.). The intake body 106 is configured to receive exhaust gas from the upstream exhaust conduit 102. The housing assembly 104 also includes an upstream housing 108 (e.g., a chamber, a body, etc.). The upstream housing 108 is configured to receive exhaust gas from the intake body 106. In various embodiments, the upstream housing 108 is coupled to the intake body 106. For example, the upstream housing 108 can be fastened (e.g., using a band, using bolts, etc.), welded, riveted, or otherwise attached to the intake body 106. In other embodiments, the upstream housing 108 is integrally formed with the intake body 106 (e.g., integrally formed, formed in a single-piece structure, inseparable, etc.).

[0078] The upstream housing 108 is centered on a housing axis λ (e.g., longitudinal axis λ). In other words, a center point of a cross-section of the upstream housing 108 is disposed on the longitudinal axis λ along the length of the upstream housing 108. Exhaust gas may be provided (e.g., output, etc.) through the upstream housing 108 in a direction parallel to or coincident with the longitudinal axis λ.

[0079] The housing assembly 104 may include a heater (e.g., an electric heater, a resistive heater, a fluid heat exchanger, etc.) configured to heat the exhaust within the intake body 106 and / or the upstream housing 108. For example, the housing assembly 104 may include a heater that extends within the intake body 106 and is configured to heat the exhaust within the intake body 106. By heating the exhaust, the catalytic reaction performed by the catalyst component may be increased and become more ideal. In addition, the heated exhaust may facilitate regeneration of various components of the exhaust aftertreatment system 100 (e.g., combustion of particulate matter, etc.).

[0080] In various embodiments, the exhaust aftertreatment system 100 further includes an oxidation catalyst 110 (e.g., a diesel oxidation catalyst (DOC), etc.). At least a portion of the oxidation catalyst 110 is positioned within the upstream housing 108 (e.g., contained within the upstream housing 108, contained within the upstream housing 108, located within the upstream housing 108, etc.). In various embodiments, the oxidation catalyst 110 is positioned within the upstream housing 108 and the intake body 106. In other embodiments, the oxidation catalyst 110 is positioned within the upstream housing 108, but not within the intake body 106. In still other embodiments, the oxidation catalyst 110 is positioned within the intake body 106, but not within the upstream housing 108.

[0081] The exhaust gas is provided to the oxidation catalyst 110 by the intake body 106. The oxidation catalyst 110 may be configured to oxidize hydrocarbons and / or carbon monoxide in the exhaust gas. In this way, the oxidation catalyst 110 may remove hydrocarbons and / or carbon monoxide from the exhaust gas before providing the exhaust gas to the downstream components of the exhaust aftertreatment system 100. The oxidation catalyst 110 may be positioned within the intake body 106 and / or the upstream housing 108 (e.g., using a gasket, using a shim, using a seal, etc.), thereby substantially preventing the exhaust gas from flowing between the oxidation catalyst and the intake body 106 and / or between the oxidation catalyst 110 and the upstream housing 108 (e.g., reduced (mitigated), less than 1% of the exhaust gas flow received by the intake body 106 flows between the oxidation catalyst 110 and the intake body 106, less than 1% of the exhaust gas flow received by the intake body 106 flows between the oxidation catalyst 110 and the upstream housing 108, etc.).

[0082] The oxidation catalyst 110 may also be centered on the longitudinal axis λ. For example, where the diameter of the oxidation catalyst 110 is approximately (e.g., within 5%, etc.) equal to the diameter of the upstream housing 108, the center point of the cross-section of the oxidation catalyst 110 may be disposed on the longitudinal axis λ along the length of the oxidation catalyst 110. Exhaust gas may be provided through the oxidation catalyst 110 in a direction parallel to or coincident with the longitudinal axis λ. As used herein, the term "diameter" means the length of a chord passing through the center point of a shape (e.g., square, rectangular, hexagonal, circular, elliptical, pentagonal, triangular, etc.).

[0083] In various embodiments, the exhaust aftertreatment system 100 further includes an exhaust filter device 112 (e.g., a diesel particulate filter (DPF), etc.). The exhaust filter device 112 is positioned within the upstream housing 108. For example, the exhaust filter device 112 may be positioned downstream of the oxidation catalyst 110 within the upstream housing 108. Exhaust gas is provided by the oxidation catalyst 110 into the upstream housing 108 (e.g., between the oxidation catalyst 110, the upstream housing 108, and the exhaust filter device 112, etc.) and then enters the exhaust filter device 112 (e.g., after hydrocarbons in the exhaust gas have been oxidized by the oxidation catalyst 110, after carbon monoxide in the exhaust gas has been oxidized by the oxidation catalyst 110, etc.).

[0084] The exhaust filter device 112 may remove particulate matter (e.g., soot, etc.) from the exhaust gas before the exhaust gas is provided to downstream components of the exhaust aftertreatment system 100. The exhaust filter device 112 may be positioned within the upstream housing 108 (e.g., using a gasket, using a spacer, using a seal, etc.) such that exhaust gas is substantially prevented from flowing between the exhaust filter device 112 and the upstream housing 108 (e.g., less than 1% of the exhaust gas flow received by the intake body 106 flows between the exhaust filter device 112 and the upstream housing 108, etc.).

[0085] Exhaust filter device 112 may be centered about longitudinal axis λ. For example, where the diameter of exhaust filter device 112 is substantially equal to the diameter of upstream housing 108, a center point of a cross-section of exhaust filter device 112 may be disposed on longitudinal axis λ along the length of exhaust filter device 112. Exhaust gas may be provided through exhaust filter device 112 in a direction parallel to or coincident with longitudinal axis λ.

[0086] The housing assembly 104 includes an exhaust mixer assembly 114. The exhaust mixer assembly 114 is positioned downstream of the upstream housing 108. The exhaust mixer assembly 114 is configured to mix the exhaust gas with the reductant. The exhaust gas may be provided to the exhaust mixer assembly from the upstream housing in a direction parallel to or coincident with the longitudinal axis λ.

[0087] The exhaust mixer assembly 114 includes a mixer housing 116. The mixer housing 116 can be coupled to the upstream housing 108 within the housing assembly 104. The mixer housing 116 is configured to house (e.g., surround, store, etc.) various components that facilitate mixing of exhaust gas and reductant. For example, the mixer housing 116 can be coupled to various components that facilitate mixing of exhaust gas and reductant in an aftertreatment system.

[0088] The exhaust mixer assembly 114 includes an inlet plate 118. The inlet plate 118 is coupled to the mixer housing 116 toward the upstream end of the exhaust mixer assembly 114. The inlet plate 118 is configured to direct exhaust gas provided by the upstream housing 108 into the mixer housing 116.

[0089] The inlet plate 118 includes an inlet plate body 119. The inlet plate body 119 is a flat and solid portion of the inlet plate 118. The inlet plate body 119 is configured to disrupt the flow of exhaust gas through the exhaust mixer assembly 114. For example, the inlet plate 118 may disrupt the flow of exhaust gas provided in a direction parallel to or coincident with the longitudinal axis λ (e.g., direct it elsewhere, force it to flow elsewhere).

[0090] The inlet plate 118 includes an inlet opening 120. The inlet opening 120 is positioned in the top half of the inlet plate 118 when viewed along the longitudinal axis λ of the mixer housing 116. For example, the inlet opening 120 is positioned in a half of the inlet plate 118 that is adjacent to (e.g., closest to, next to, etc.) a side of the mixer housing 116 where the reductant is dispensed into the aftertreatment system 100. The inlet opening 120 receives gas provided by the upstream housing 108. For example, the inlet opening 120 facilitates passage of exhaust gas through the inlet plate 118.

[0091] The exhaust mixer assembly 114 also includes a support plate 122. The support plate 122 is also coupled to the mixer housing 116. The support plate 122 is coupled to the mixer housing 116 and is positioned downstream of the inlet plate 118. The support plate 122 is configured to direct the flow of the exhaust gas and air mixture through the mixer housing 116 by obstructing (e.g., blocking, reducing, etc.) flow in a direction parallel to or coincident with the longitudinal axis λ.

[0092] The exhaust mixer assembly 114 also includes a reductant delivery system 124. The reductant delivery system 124 is positioned on an exterior surface of the mixer housing 116. The reductant delivery system 124 is configured to facilitate the introduction of reductant into the exhaust gas.

[0093] The reductant delivery system includes a dosing module 128 (e.g., a dosing device, etc.). The dosing module 128 is configured to facilitate the passage of the reductant through and into the mixer housing 116. As explained in greater detail herein, the dosing module 128 is configured to receive the reductant, and in some embodiments, to receive air and the reductant, and to provide the reductant and / or the air-reductant mixture into the mixer housing 116 to facilitate the treatment of the exhaust gas. The dosing module 128 may include an insulator inserted between a portion of the dosing module 128 and a portion of the mixer housing 116 on which the dosing module 128 is mounted.

[0094] The reductant delivery system 124 also includes a reductant source 126 (e.g., a reductant tank, etc.). The reductant source 126 is configured to contain (e.g., store, etc.) a reductant. The reductant source 126 is configured to provide the reductant to the dosing module 128. The reductant source 126 may include a plurality of reductant sources 126 (e.g., a plurality of tanks connected in series or in parallel, etc.). The reductant source 126 may be, for example, a reductant source 126 comprising Diesel Exhaust Fluid Tank.

[0095] The reductant delivery system 124 also includes a reductant pump 130 (e.g., a supply unit, etc.). The reductant pump 130 is configured to receive the reductant from the reductant source 126 and to provide the reductant to the dosing module 128. The reductant pump 130 is used to pressurize the reductant from the reductant source 126 to deliver it to the dosing module 128. In some embodiments, the reductant pump 130 is pressure controlled. In some embodiments, the reductant pump 130 is coupled to the chassis of a vehicle associated with the exhaust aftertreatment system 100.

[0096] In some embodiments, the reductant delivery system 124 also includes a reductant filter 132. The reductant filter 132 is configured to receive the reductant from the reductant source 126 and provide the reductant to the reductant pump 130. The reductant filter 132 filters the reductant before providing the reductant to the internal components of the reductant pump 130. For example, the reductant filter 132 can inhibit, prevent, or reduce the transmission of solids to the internal components of the reductant pump 130. In this way, the reductant filter 132 can facilitate extending the desired operating time of the reductant pump 130.

[0097] The dosing module 128 includes an injector 134 (e.g., an injection device, a sprayer, etc.). The injector 134 is configured to receive a reductant from the reductant pump 130. The injector 134 is configured to dispense (e.g., spray, inject, spray, etc.) the reductant received by the dosing module 128 into the exhaust gas within the mixer housing 116 along an injector axis α. For example, the injector 134 can be positioned between the inlet plate 118 and the support plate 122. In various embodiments, the injector axis α is positioned at a non-zero angle relative to the longitudinal axis λ. For example, the injector axis α can be perpendicular to the longitudinal axis λ.

[0098] In some embodiments, the reductant delivery system 124 also includes an air pump 136 and an air source 138 (e.g., an air intake, etc.). The air pump 136 is configured to receive air from the air source 138. The air pump 136 is configured to provide air to the dosing module 128. The dosing module 128 is configured to mix the air and the reductant into an air-reductant mixture and provide the air-reductant mixture to the injector 134 (e.g., for dosing to the exhaust gas in the mixer housing 116, etc.). The injector 134 is configured to receive air from the air pump 136. The injector 134 is configured to dispense the air-reductant mixture into the exhaust gas in the mixer housing 116.

[0099] In some of these embodiments, the reductant delivery system 124 further includes an air filter 140. The air filter 140 is configured to receive air from the air source 138 and provide the air to the air pump 136. The air filter 140 is configured to filter the air before the air is provided to the air pump 136. In other embodiments, the reductant delivery system 124 does not include the air pump 136 and / or the reductant delivery system 124 does not include the air source 138. In such embodiments, the dosing module 128 is not configured to mix the reductant with the air.

[0100] The exhaust aftertreatment system 100 also includes a controller 142 (e.g., control circuitry, a driver, etc.). The dosing module 128, the reductant pump 130, and the air pump 136 are also electrically coupled or communicatively coupled to the controller 142. The controller 142 is configured to control the dosing module 128 to dosing the reductant and / or the air-reductant mixture into the mixer housing 116. The controller 142 may also be configured to control the reductant pump 130 and / or the air pump 136 to control the reductant and / or the air-reductant mixture dosing into the mixer housing 116.

[0101] The controller 142 includes a processing circuit 144. The processing circuit 144 includes a processor 146. The processor 146 may include a microprocessor, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), etc., or a combination thereof. The processing circuit 144 may also include a memory 148. The memory 148 may include, but is not limited to, an electronic, optical, magnetic, or any other storage or transmission device capable of providing program instructions to the processor, ASIC, FPGA, etc. The memory 148 may include a memory chip, an electrically erasable programmable read-only memory (EEPROM), an erasable programmable read-only memory (EPROM), a flash memory, or any other suitable memory from which the controller 142 can read instructions. The instructions may include code in any suitable programming language. The memory 148 may include various modules that include instructions configured to be implemented by the processor 146.

[0102] In various embodiments, controller 142 is configured to communicate with a central controller 150 (e.g., an engine control unit (ECU), an engine control module (ECM), etc.) of an internal combustion engine having exhaust aftertreatment system 100. In some embodiments, central controller 150 and controller 142 are integrated into a single controller.

[0103] In some embodiments, the central controller 150 may communicate with a display device (e.g., a screen, a monitor, a touch screen, a heads-up display (HUD), an indicator light, etc.). The display device may be configured to change states in response to receiving information from the central controller 150. For example, the display device may be configured to change between a static state and an alarm state based on communications from the central controller 150. By changing states, the display device may provide an indication of the state of the reductant delivery system 124 to the user.

[0104] The inlet plate 118 and the support plate 122 define a first mixing chamber 152 within the mixer housing 116. The dosing module 128 may be positioned within the first mixing chamber 152. For example, the dosing module 128 may provide the reductant and / or the air-reductant mixture to the first mixing chamber 152. The first mixing chamber 152 defines a first region within the mixer housing 116 for mixing (e.g., forming a vortex, etc.) the exhaust gas with the reductant and / or the air-reductant mixture.

[0105] The exhaust mixer assembly 114 includes an outlet plate 154. The outlet plate 154 is coupled to the mixer housing 116 and is positioned downstream of the support plate 122. The outlet plate 154 directs the exhaust and reductant mixture to flow through the mixer housing 116. For example, the outlet plate 154 may direct the exhaust reductant mixture rearwardly in a direction toward the longitudinal axis λ.

[0106] The support plate 122 and the outlet plate 154 define a second mixing chamber 156. The second mixing chamber 156 is positioned downstream of the support plate 122 and upstream of the outlet plate 154. For example, the second mixing chamber 156 is positioned downstream of the first mixing chamber 152. The second mixing chamber 156 is configured to mix the exhaust gas and the reductant mixture a second time (e.g., form a vortex) within the mixer housing 116.

[0107] The support plate 122 includes a support plate body 157. The support plate body 157 is a flat and solid portion of the support plate 122. The support plate body 157 is configured to disrupt (eg, block, obstruct, direct, etc.) the flow of exhaust gas through the exhaust mixer assembly 114.

[0108] The support plate 122 also includes a support plate opening 158. The support plate opening 158 is positioned on a lower half of the support plate 122 when viewed along the longitudinal axis λ of the mixer housing 116. For example, the support plate opening 158 may be positioned on a half (e.g., portion, etc.) of the support plate 122 that is opposite to a side of the mixer housing 116 where the reductant is provided to the aftertreatment system 100. For example, the support plate may be oriented with respect to the support plate opening axis λ of the mixer housing 116. bThe support plate opening 158 may include two edges perpendicular to the horizontal top edge and a curved bottom edge defined by the mixer housing 116 . The support plate opening 158 is configured to facilitate exhaust gas mixed with the reductant to pass through the support plate 122 into the second mixing chamber 156 .

[0109] The outlet plate 154 includes an outlet plate body 159. The outlet plate body 159 is a flat and solid portion of the outlet plate 154. The outlet plate body 159 is configured to disrupt (eg, block, obstruct, direct, etc.) the flow of exhaust gas through the exhaust mixer assembly 114.

[0110] The outlet plate 154 includes an outlet opening 160. The shape of the outlet opening 160 can be circular. In some embodiments, the outlet opening 160 can be positioned at the center of the outlet plate 154. For example, the outlet opening 160 can be centered along the housing center axis λ. In other embodiments, the outlet opening 160 can be offset from the housing center axis λ. The outlet opening 160 is configured to guide the treated exhaust gas (e.g., exhaust reductant mixture, etc.) through the outlet plate 154. For example, the outlet opening 160 facilitates the passage of the exhaust reductant mixture in a direction parallel to the longitudinal axis λ or coinciding with the longitudinal axis λ.

[0111] The exhaust mixer assembly 114 also includes a delivery tube 162. The delivery tube 162 is coupled to each of the support plate 122 and the outlet plate 154. For example, the upstream end of the delivery tube is coupled to the support plate 122, and the downstream end of the delivery tube 162 is coupled to the outlet plate 154. For example, the downstream end of the delivery tube 162 can be coupled to align with the outlet opening 160. The delivery tube 162 is configured to provide the treated exhaust gas to the outlet opening 160 of the outlet plate 154. For example, the delivery tube can be centered along the longitudinal axis λ to provide the exhaust reductant mixture in a direction parallel to the longitudinal axis λ or coincident with the longitudinal axis λ.

[0112] The exhaust mixer assembly 114 also includes a perforated plate 164. The perforated plate 164 is coupled to the mixer housing 116 and is positioned downstream of the outlet plate 154. According to some embodiments, the perforated plate 164 may partially overlap the outlet opening 160. For example, when viewed along the longitudinal axis λ of the exhaust mixer assembly 114 (e.g., the housing center axis λ), the perforated plate 164 may overlap a portion of the outlet opening 160. For example, when viewed along the housing center axis λ, the perforated plate 164 may overlap 30% to 70% of the outlet opening 160.

[0113] By overlapping the perforated plate 164 with 30%-70% of the outlet opening 160, the flow of the exhaust reductant mixture is disturbed to further mix the exhaust reductant mixture. For example, a first portion of the exhaust reductant mixture may flow through the outlet opening 160 and through the perforated plate 164, while a second portion of the exhaust reductant mixture may flow only through the outlet opening 160. The first portion of the exhaust reductant mixture may be disturbed (e.g., slowing down the flow through the perforated plate 164, redirecting, etc.) before mixing with the unimpeded second portion of the exhaust reductant mixture. In addition, the speed at which the exhaust reductant mixture flows through the outlet opening 160 is relatively high (e.g., moving quickly, etc.). By overlapping the perforated plate 164 with only a portion of the outlet opening 160 (e.g., overlapping 30%-70%), the perforated plate 164 partially blocks a portion of the flow from the outlet opening 160, which improves the flow distribution index (FDI) of the flow out of the aftertreatment system 100. By promoting some flow through the perforated plate 164, the perforations in the perforated plate 164 reduce back pressure. By variously configuring the perforated plate 164 (eg, shape, size, location, number of perforations, size of perforations, location of perforations, etc.), a target FDI for flow exiting the aftertreatment system 100 may be achieved.

[0114] The perforated plate 164 includes a perforated plate body 165. The perforated plate body 165 is a solid portion of the perforated plate 164. The perforated plate body 165 prevents the exhaust-reductant mixture from flowing through the perforated plate 164. The perforated plate body 165 is configured to disrupt the flow and further mix the exhaust-reductant mixture provided by the outlet opening 160.

[0115] The housing assembly 104 also includes a catalyst component housing 166 and a catalyst component 168. The catalyst component housing 166 is located downstream of the perforated plate 164. The catalyst component housing 166 is connected to a catalyst component 168 (e.g., a selective catalytic reduction (SCR) catalyst component, etc.). The catalyst component 168 is configured to receive, process and output exhaust gas output by the exhaust mixer assembly 114. At least a portion of the catalyst component 168 is positioned within the catalyst component housing 166. As explained in more detail herein, the catalyst component 168 is configured to cause exhaust gas components (e.g., through a catalytic reaction, etc.) to decompose using a reductant. Specifically, the reductant that has been provided to the exhaust gas by the injector 134 undergoes a process of evaporation, pyrolysis and hydrolysis to form non-NO in the mixer housing 116, the catalyst component housing 166, the catalyst component 168 and / or the housing assembly 104. x The catalyst component 168 is configured to accelerate the reductant and NO in the exhaust gas. x NO x The reduction process makes the reducing agent and NO in the exhaust gas xinto diatomic nitrogen, water and / or carbon dioxide to help reduce NO x Emissions.

[0116] III. First Example Exhaust Mixer Assembly

[0117] Figure 2-Figure 10 An exhaust mixer assembly 114 is shown in accordance with various embodiments.

[0118] The inlet plate 118 includes a first inlet opening 202. According to this embodiment, the shape of the first inlet opening 202 is circular. However, in other embodiments, other shapes (e.g., oval, elliptical, rectangular, square, hexagonal, etc.) are possible. When the exhaust mixer assembly 114 is viewed along the longitudinal axis λ, the first inlet opening 202 can be positioned in the upper half of the inlet plate 118. In addition, the first inlet opening 202 can be positioned offset from the transverse axis of the exhaust mixer assembly 114.

[0119] First inlet opening 202 is configured to receive exhaust gas from upstream housing 108 (eg, exhaust gas provided by upstream housing 108 , etc.) and direct the exhaust gas through inlet plate 118 .

[0120] The inlet plate 118 may also include a second inlet opening 204. According to this embodiment, the second inlet opening 204 is circular. In other embodiments, other shapes (e.g., oval, elliptical, rectangular, square, hexagonal, etc.) are possible. When the exhaust mixer assembly 114 is viewed along the longitudinal axis λ, the second inlet opening 204 is positioned in the upper half of the inlet plate 118 and adjacent to the first inlet opening 202. The second inlet opening 204 is configured to receive exhaust gas from the upstream housing 108 and guide the exhaust gas through the inlet plate 118.

[0121] The inlet plate 118 also includes an auxiliary opening 206. When viewed along the longitudinal axis λ of the exhaust mixer assembly 114, the auxiliary opening 206 is positioned on the lower half of the inlet plate 118. For example, the auxiliary opening 206 is positioned in a half (e.g., a portion, etc.) of the inlet plate 118 that is opposite to the half in which the first inlet opening 202 and the second inlet opening 204 are positioned. According to this embodiment, the shape of the auxiliary opening 206 can be substantially rectangular (e.g., the sides are perpendicular to the top edge, and the bottom edge is curved and defined by the shell, etc.). In other embodiments, other shapes (e.g., square, oval, circular, etc.) are possible. The auxiliary opening 206 is configured to guide the exhaust gas through the bottom of the inlet plate 118 into the first mixing chamber 152. The auxiliary opening 206 is also configured to help the exhaust gas and air flow through the exhaust mixer assembly 114.

[0122] The inlet plate 118 also defines a transverse axis A T . Transverse axis A T perpendicular to the longitudinal axis λ and parallel to the injector axis α. For example, the transverse axis A T The inlet plate 118 is bisected. T For example, the first inlet opening 202 is positioned on a first side of the inlet plate 118 and the second inlet opening 204 is positioned on a second side of the inlet plate, and the first inlet opening 202 and the second inlet opening 204 are aligned with the transverse axis A. T The symmetry of the inlet plate 118 promotes equal flow through each of the first inlet opening 202 and the second inlet opening 204 .

[0123] The exhaust mixer assembly 114 includes a first inlet pipe 208. The first inlet pipe 208 is coupled to each of the inlet plate 118 and the support plate 122. The upstream end of the first inlet pipe 208 is coupled to the inlet plate 118 and aligned with the first inlet opening 202. The downstream end of the first inlet pipe 208 is coupled to the support plate 122. The downstream end of the first inlet pipe 208 is blocked (e.g., closed, etc.) by a first portion of the support plate 122. For example, the support plate 122 prevents exhaust gas from flowing through the downstream end of the first inlet pipe 208. The first inlet pipe 208 is configured to receive exhaust gas from the first inlet opening 202. The first inlet pipe 208 is also configured to provide exhaust gas to the first mixing chamber 152.

[0124] The first inlet pipe 208 includes a first inlet pipe lateral opening 210. The first inlet pipe lateral opening 210 is positioned on one side of the first inlet pipe 208. For example, the first inlet pipe lateral opening 210 may be positioned on a top side (e.g., a circumferential side) of the first inlet pipe 208 that faces the injector 134. According to this embodiment, the first inlet pipe lateral opening 210 is rectangular. However, in other embodiments, other shapes (e.g., oval, square, etc.) are possible. The first inlet pipe lateral opening 210 is configured to provide exhaust gas to the first mixing chamber 152.

[0125] The first inlet pipe 208 also includes a first flat surface 212. The first flat surface 212 is positioned on a side of the first inlet pipe 208 adjacent to the injector axis α. The first flat surface 212 protrudes into the inner cavity of the first inlet pipe 208. The first flat surface 212 is configured to direct the exhaust gas to flow upward toward the injector axis α through the first inlet pipe lateral opening 210.

[0126] The first portion of the exhaust gas is provided to the first inlet pipe 208 through the first inlet opening 202. The first portion of the exhaust gas flows through the first inlet pipe 208 and flows out of the first inlet pipe lateral opening 210 into the first mixing chamber 152. For example, the first portion of the exhaust gas flows horizontally through the first inlet pipe 208 parallel to the longitudinal axis λ. Then, the first portion of the exhaust gas is directed upward at a non-zero angle relative to the longitudinal axis λ by the first flat surface 212, and exits the first inlet pipe 208 through the first inlet pipe lateral opening 210.

[0127] The exhaust mixer assembly 114 includes a second inlet pipe 214. The upstream end of the second inlet pipe 214 is coupled to the inlet plate 118 and aligned with the second inlet opening. The downstream end of the second inlet pipe 214 is coupled to the support plate 122. The downstream end of the second inlet pipe 214 is blocked by a second portion of the support plate 122. For example, the support plate 122 prevents the exhaust gas from flowing through the downstream end of the second inlet pipe 214. The second inlet pipe 214 can also be positioned adjacent to (e.g., parallel to, etc.) the first inlet pipe 208. For example, the second inlet pipe 214 is adjacent to the first inlet pipe 208 along a horizontal plane. In other embodiments, the second inlet pipe 214 is positioned above or below the first inlet pipe 208. The second inlet pipe 214 is configured to receive exhaust gas from the upstream housing 108 and provide the exhaust gas to the first mixing chamber 152.

[0128] The second inlet pipe 214 includes a second inlet pipe lateral opening 216. The second inlet pipe lateral opening 216 is positioned on one side of the second inlet pipe 214. For example, the second inlet pipe lateral opening 216 may be positioned on a top side (e.g., circumferential side, etc.) of the second inlet pipe 214 near the injector 134. According to this embodiment, the shape of the second inlet pipe lateral opening 216 is also rectangular. In other embodiments, other shapes (e.g., square, circular, oval, etc.) are possible. The second inlet pipe lateral opening 216 is configured to provide exhaust gas to the first mixing chamber 152.

[0129] The second inlet pipe 214 also includes a second flat surface 218. The second flat surface 218 is positioned on one side of the second inlet pipe 214. For example, the second flat surface 218 may be positioned on one side of the second inlet pipe 214 adjacent to the injector axis α. The second flat surface 218 protrudes into the inner cavity of the second inlet pipe 214. The second flat surface 218 is configured to direct the exhaust gas upward and out of the second inlet pipe lateral opening 216.

[0130] The second portion of the exhaust gas is provided to the second inlet pipe 214 through the second inlet opening 204. The second portion of the exhaust gas flows through the second inlet pipe 214 and exits from the second inlet pipe lateral opening 216 into the first mixing chamber 152. For example, the second portion of the exhaust gas flows horizontally through the second inlet pipe 214 substantially parallel to the longitudinal axis λ. The second portion of the exhaust gas is then directed upwardly at a non-zero angle relative to the longitudinal axis λ by the second flat surface 218, exiting the second inlet pipe 214 through the second inlet pipe lateral opening 216. The second portion of the exhaust gas exits the second inlet pipe lateral opening 216 and enters the first mixing chamber 152 opposite to the first portion of the exhaust gas. For example, the first portion of the exhaust gas exits from the first inlet pipe lateral opening 210 and is directed toward the injector axis α. The second portion of the exhaust gas exits from the second inlet pipe lateral opening 216 opposite to the first inlet pipe lateral opening 210 and is directed toward the injector axis α, so that the first portion of the exhaust gas and the second portion of the exhaust gas collide (e.g., mix, etc.) along the injector axis α in the first mixing chamber 152.

[0131] In addition, a third portion of the exhaust gas is provided to the auxiliary opening 206. The third portion of the exhaust gas is provided along the support plate opening axis A. b The third portion of the exhaust gas flows horizontally through the auxiliary opening 206 and enters the first mixing chamber 152. The third portion of the exhaust gas flows along the support plate opening axis A with the first portion of the exhaust gas and the second portion of the exhaust gas. b mix.

[0132] The first inlet pipe 208 and the second inlet pipe 214 are configured to provide exhaust gas to the first mixing chamber 152 simultaneously (e.g., at the same time, etc.). For example, exhaust gas flows from the upstream housing 108 into the first inlet pipe 208 through the first inlet opening 202 of the inlet plate 118 along the first inlet axis A1. At the same time, exhaust gas flows from the upstream housing 108 into the second inlet pipe 214 through the second inlet opening 204 of the inlet plate 118 along the second inlet axis A2. The first inlet axis A1 and the second inlet axis A2 are substantially parallel to each other and substantially parallel to the longitudinal axis λ. Then, the exhaust gas flows out of the first inlet pipe 208 through the first inlet pipe lateral opening 210 guided by the first flat surface 212, and flows out of the second inlet pipe 214 through the second inlet pipe lateral opening 216 guided by the second flat surface 218. When the exhaust gas is directed upward through each of the first inlet pipe lateral opening 210 and the second inlet pipe lateral opening 216, the exhaust gas flows at a non-zero angle relative to the first inlet axis A1 and the second inlet axis A2, respectively. For example, exhaust gas may flow along the first inlet axis A1 and the second inlet axis A2 and then be directed out of the first inlet pipe lateral opening 210 and the second inlet pipe lateral opening 216 at an angle substantially perpendicular to the first inlet axis A1 and the second inlet axis A2.

[0133] like Figure 2 As shown, the exhaust mixer assembly 114 includes an injector mounting bracket 220. The injector mounting bracket 220 is coupled to the housing. The injector mounting bracket 220 is positioned within the first mixing chamber 152 and between the first inlet pipe 208 and the second inlet pipe 214. For example, the injector mounting bracket 220 is positioned so that the injector axis α is between the first inlet pipe 208 and the second inlet pipe 214.

[0134] When the exhaust gas flows out of the first inlet pipe lateral opening 210 and the second inlet pipe lateral opening 216, the reductant is injected downwardly along the injector axis α into the first mixing chamber 152. When the reductant is injected downwardly along the injector axis α between the first inlet pipe 208 and the second inlet pipe 214, the exhaust gas is then forced to flow downwardly along the injector axis α within the first mixing chamber 152.

[0135] The support plate 122 includes a support plate body 157. The support plate body 157 is a substantially flat and solid portion of the support plate 122. For example, the support plate body 157 blocks the flow of exhaust gases along the longitudinal axis λ.

[0136] The support plate 122 includes a support plate opening 158. The support plate opening 158 is positioned on a bottom edge of the support plate 122 adjacent a side of the mixer housing 116 opposite the injector 134. For example, the exhaust mixer assembly 114 may define a support plate opening axis A1 that is parallel to the longitudinal axis λ, the first inlet axis A1, and the second inlet axis A2. b The support plate opening 158 can be centered on the support plate opening axis A. b The support plate opening 158 may be defined as having a curved upper edge. The support plate opening 158 is configured to guide the exhaust gas and the reductant from the first mixing chamber 152 through the support plate 122 . For example, the exhaust gas travels from the first mixing chamber 152 through the support plate opening 158 to the second mixing chamber 156 .

[0137] The first portion of the exhaust gas flows from the first inlet opening 202 through the first inlet pipe 208 and out of the first inlet pipe lateral opening 210 into the first mixing chamber 152. The second portion of the exhaust gas flows from the second inlet opening 204 through the second inlet pipe 214 and out of the second inlet pipe lateral opening 216 into the first mixing chamber 152. The third portion of the exhaust gas flows through the auxiliary opening into the first mixing chamber 152. Each of the first portion of the exhaust gas, the second portion of the exhaust gas, and the third portion of the exhaust gas flows out of the first mixing chamber 152 through the support plate opening 158 together with the reductant.

[0138] The exhaust mixer assembly 114 also includes an outlet plate 154. The outlet plate is positioned downstream of the support plate 122. The outlet plate 154 is configured to direct the exhaust flow into the second mixing chamber 156. For example, the outlet plate 154 may prevent the exhaust reductant mixture from flowing along the support plate opening axis A. b flow.

[0139] The outlet plate 154 includes an outlet plate body 159. The outlet plate body 159 is a flat and solid portion of the outlet plate 154. The outlet plate body 159 is configured to disrupt (eg, block, obstruct, direct, etc.) the flow of exhaust gas through the exhaust mixer assembly 114.

[0140] The outlet plate 154 defines an outlet opening 160. The shape of the outlet opening 160 is circular. In other embodiments, other shapes (e.g., square, oval, etc.) are possible. The outlet opening 160 can be defined as being centered on the outlet plate 154 (e.g., centered along the longitudinal axis λ). However, in other embodiments, the outlet opening 160 can be offset from the longitudinal axis λ. The outlet opening 160 is configured to guide the treated exhaust gas (e.g., exhaust reductant mixture, etc.) through the outlet plate 154 and provide the treated exhaust gas downstream of the exhaust mixer assembly 114.

[0141] The exhaust mixer assembly 114 includes a transport tube 162. The transport tube 162 is positioned within the second mixing chamber 156 between the support plate 122 and the outlet plate 154. A first end of the transport tube 162 is coupled to the support plate 122. The first end of the transport tube 162 is closed (e.g., blocked, etc.) by the support plate 122. A second end of the transport tube 162 is coupled to the outlet plate 154 such that the second end of the transport tube 162 is aligned with the outlet opening 160. The transport tube 162 is configured to provide the processed exhaust gas from the second mixing chamber 156 to the outlet opening 160 of the outlet plate 154.

[0142] The transport tube 162 includes a transport tube lateral opening 226. The transport tube lateral opening 226 is positioned on a circumferential side of the transport tube 162. For example, the transport tube lateral opening 226 can be positioned on a circumferential side of the transport tube 162 facing the mixer housing 116 on which the injector 134 is positioned (e.g., the top side of the transport tube 162). According to this embodiment, the shape of the transport tube lateral opening 226 can be rectangular, and the transport tube lateral opening 226 extends around a portion of the circumference of the transport tube 162. In other embodiments, other shapes (e.g., square, oval, etc.) are possible. The transport tube lateral opening 226 is configured to receive treated exhaust gas (e.g., exhaust reductant mixture, etc.) from the second mixing chamber 156 and provide the treated exhaust gas through the outlet opening 160 to the downstream end of the exhaust mixer assembly 114.

[0143] like Figure 2 As shown, the second mixing chamber 156 is positioned between the support plate 122 and the outlet plate 154 and surrounds the delivery tube 162. The exhaust gas flows along the support plate opening axis A. b The exhaust gas passes through the support plate opening 158 and enters the lower end of the second mixing chamber 156. Then, the exhaust gas flows upward around the delivery pipe 162. For example, the exhaust gas flows along the support plate opening axis A. b Enters the second mixing chamber 156 and is then forced around the delivery tube 162 (eg, perpendicular to the support plate opening axis A). b The exhaust gas then travels through the transport tube lateral opening 226 , through the transport tube 162 , and out of the outlet opening 160 of the outlet plate 154 .

[0144] The outlet plate 154 also includes a plurality of peripheral openings 228. A plurality of peripheral openings 228 are positioned around the outlet opening 160. For example, when viewed along the longitudinal axis λ, a plurality of peripheral openings 228 can be positioned around the outlet opening 160 on the upper half of the outlet plate 154. For example, the peripheral openings 228 can be positioned in the half of the outlet plate 154 adjacent to the mixer housing 116 where the reductant is provided on one side. According to this embodiment, the shape of the plurality of peripheral openings 228 is rectangular. In other embodiments, other shapes (e.g., square, circular, etc.) are possible. As shown in this embodiment, the outlet plate 154 includes three peripheral openings 228. However, in other embodiments, the outlet plate 154 may include more (e.g., 4, 5, etc.) or less (e.g., 1 or 2) peripheral openings 228. A plurality of peripheral openings 228 are configured to help the processed exhaust gas and air flow through the upper half of the outlet plate 154 of the exhaust mixer assembly 114.

[0145] like Figure 3 As shown in FIG. 1 , the exhaust mixer assembly 114 further includes a perforated plate 164. The perforated plate 164 is coupled to the mixer housing 116 and is positioned downstream of the outlet plate 154. The perforated plate 164 is disposed along the support plate opening axis A. bPositioned on one side of the mixer housing. For example, the perforated plate 164 is located in the lower half of the cross-sectional area of ​​the mixer housing 116. For example, at least 80% of the cross-sectional area of ​​the perforated plate 164 may be located in the lower half of the cross-sectional area of ​​the mixer housing 116. Since 80% of the cross-sectional area of ​​the perforated plate 164 is positioned in the lower half of the cross-sectional area of ​​the mixer housing 116, the exhaust reductant mixture directed downward (e.g., toward the bottom of the mixer housing 116) is also directed toward the perforated plate 164 to promote further mixing of the exhaust reductant mixture. When viewed in the longitudinal direction of the mixer housing 116 (e.g., along the longitudinal axis λ, etc.), the perforated plate 164 partially overlaps a portion of the outlet opening 160. For example, the perforated plate 164 may overlap 30% to 70% of the outlet opening 160. The perforated plate 164 is configured to interfere with the flow of the treated exhaust gas through the exhaust mixer assembly 114. The perforated plate 164 is also configured to regulate air flow velocity and improve the FDI of flow out of the aftertreatment system 100. In other embodiments, the perforated plate 164 may overlap the entire outlet opening 160 to improve the FDI of flow out of the aftertreatment system 100.

[0146] The perforated plate includes a perforated plate body 165. The perforated plate body 165 prevents the exhaust-reductant mixture from flowing through the perforated plate 164, forcing the exhaust-reductant mixture to further mix.

[0147] The perforated plate 164 defines a plurality of openings 302. The plurality of openings 302 have the same shape and the same cross-sectional area and are spaced an equal distance from adjacent openings 302 throughout the perforated plate 164. However, in other embodiments, the plurality of openings 302 may be defined in only a portion of the perforated plate 164. Figure 3 As shown in , the shape of the plurality of openings 302 may be circular. In other embodiments, other shapes (eg, square, rectangular, etc.) are possible. The plurality of openings 302 are configured to allow the exhaust reductant mixture received through the outlet opening 160 to flow through the perforated plate 164 .

[0148] The mixer housing 116 defines an injector opening 304. The injector opening 304 is located at an axis of the mixer housing 116 that is aligned with the support plate opening axis A. b On the opposite circumferential side (e.g., top side, etc.). The injector opening 304 is configured to receive the injector mounting bracket 220 of the dosing module 128. According to this embodiment, the shape of the injector opening 304 can be circular. In other embodiments, other shapes (e.g., oval, square, etc.) are possible.

[0149] Figure 41 is another perspective view of the exhaust mixer assembly 114. According to this embodiment, the inlet plate 118 also includes a flow assist opening 402. The flow assist opening 402 is positioned adjacent to each of the first inlet pipe 208 and the second inlet pipe 214. For example, the flow assist opening 402 can be centered above each of the first inlet pipe 208 and the second inlet pipe 214. In this embodiment, the shape of the flow assist opening 402 is rectangular. In other embodiments, other shapes (e.g., circular, oval, etc.) are possible. The flow assist opening 402 is configured to receive exhaust gas from an upstream housing. The flow assist opening 402 is also configured to help the exhaust gas flow through the inlet plate 118 of the exhaust mixer assembly 114.

[0150] The flow assist opening 402 may include a flow assist flap 404. The flow assist flap 404 extends from a top edge of the flow assist opening 402. For example, the flow assist flap 404 extends into the first mixing chamber 152 at a non-zero angle (e.g., between 30-80 degrees, etc.). The flow assist flap 404 is configured to disrupt the flow of exhaust gas through the flow assist opening 402. For example, the flow assist flap 404 can direct the exhaust gas to flow downward through the flow assist opening 402 to promote mixing with the reductant within the first mixing chamber 152.

[0151] The exhaust mixer assembly 114 may also include a second flow auxiliary opening 406. The second flow auxiliary opening 406 is positioned adjacent to the flow auxiliary opening 402 on the edge of the inlet plate 118 near the injector mounting bracket 220. In other embodiments, the second flow auxiliary opening 406 is positioned elsewhere on the inlet plate 118 (e.g., adjacent to each of the first inlet opening 202 and the second inlet opening 204, adjacent to the auxiliary opening 206, etc.). In this embodiment, the shape of the second flow auxiliary opening 406 is also rectangular. However, in other embodiments, other shapes (e.g., circular, square, oval, etc.) are possible. According to this embodiment, the second flow auxiliary opening 406 is smaller than the flow auxiliary opening 402 (e.g., a smaller cross-sectional area, etc.). The second flow auxiliary opening 406 is also configured to help the exhaust gas flow through the inlet plate 118 of the exhaust mixer assembly 114.

[0152] The second flow assist opening 406 may include a second flow assist baffle 408. The second flow assist baffle 408 extends from a top edge of the second flow assist opening 406. For example, the second flow assist baffle 408 extends into the first mixing chamber 152 at a non-zero angle (e.g., between 30-80 degrees, etc.). The second flow assist baffle 408 is configured to interfere with the flow of exhaust gas through the second flow assist opening 406. For example, the second flow assist baffle 408 may direct the exhaust gas to flow downward through the second flow assist opening 406 to promote mixing with the reductant within the first mixing chamber 152.

[0153] Each peripheral opening 228 may also include a peripheral opening baffle 410. Each peripheral opening baffle 410 may extend from any edge of each peripheral opening 228. The peripheral opening baffle 410 is configured to disrupt the flow of the exhaust-reductant mixture (eg, treated exhaust gas) through the outlet plate 154 to further promote mixing.

[0154] Figure 5 is a side view of the exhaust mixer assembly 114. Figure 5 As shown, the first inlet pipe 208 and the second inlet pipe 214 are positioned in the upper half of the first mixing chamber 152 when viewed along the longitudinal axis λ of the mixer housing 116. For example, the first inlet pipe 208 and the second inlet pipe 214 may be positioned in the half of the outlet plate 154 adjacent to the side of the mixer housing 116 where the reductant is provided. In addition, the delivery pipe 162 is centered within the second mixing chamber 156 along the longitudinal axis λ of the mixer housing 116.

[0155] The auxiliary opening 206 also includes an auxiliary opening baffle 502. The auxiliary opening baffle 502 is positioned on the upper edge of the auxiliary opening 206. For example, the auxiliary opening baffle 502 extends from the upper edge of the auxiliary opening 206 at a non-zero angle relative to the inlet plate 118. The auxiliary opening baffle 502 is configured to interfere with the flow of exhaust gas through the auxiliary opening 206 to promote mixing with the reductant. For example, when the exhaust gas flows through the auxiliary opening 206 of the inlet plate 118, the auxiliary opening baffle 502 can guide the exhaust gas flow downward into the first mixing chamber 152. The auxiliary opening baffle 502 can be relative to the support plate opening axis A. b Direct the exhaust gas downward at a non-zero angle.

[0156] Likewise Figure 5 As shown, the injector mounting bracket 220 is positioned above the first mixing chamber 152. The injector mounting bracket 220 may be centered above the first mixing chamber 152, or may be positioned off-center from the first mixing chamber 152.

[0157] Figure 6 Flow of exhaust gas entering the exhaust mixer assembly 114 is shown. Figure 6 As shown, the first inlet axis A1 and the second inlet axis A2 are parallel to the support plate opening axis A of the exhaust mixer assembly 114. b and each of the longitudinal axes λ. In addition, the first inlet axis A1 and the second inlet axis A2 are aligned in a horizontal plane. According to this embodiment, the support plate opening axis A b May be positioned below and between the first inlet axis A1 and the second inlet axis A2.

[0158] Figure 7 is a longitudinal view of the exhaust mixer assembly 114 . Figure 7 The flow of exhaust gas and reductant into and within the first mixing chamber 152 is shown.

[0159] A first portion of the exhaust flows through the inlet plate 118 via the first inlet pipe, a second portion of the exhaust flows through the second inlet pipe 214, and a third portion of the exhaust flows through the auxiliary opening 206. Once the first portion of the exhaust and the second portion of the exhaust are within the first inlet pipe 208 and the second inlet pipe 214, respectively, the first portion of the exhaust and the second portion of the exhaust are directed upward through each of the first inlet pipe lateral opening 210 and the second inlet pipe lateral opening 216, respectively. For example, the first portion of the exhaust and the second portion of the exhaust are directed upward by the first planar surface 212 and the second planar surface 218, respectively, at a non-zero angle relative to each of the first inlet axis A1 and the second inlet axis A2.

[0160] The auxiliary opening 206 is configured to provide the third portion of the exhaust gas to the first mixing chamber 152. The auxiliary opening 206 provides the third portion of the exhaust gas along the support plate opening axis A. b 134. The third portion of the exhaust gas provided through the auxiliary opening 206 provides a high flow rate along the bottom surface of the mixer housing 116 opposite the ejector 134. For example, the high flow rate of the third portion of the exhaust gas provided through the auxiliary opening 206 can reduce the formation of deposits (e.g., pooling of exhaust gas, etc.) by providing a high flow rate of hot exhaust gas along the bottom surface of the mixer housing 116 (opposite the ejector 134).

[0161] like Figure 7 As shown, the first flat surface 212 and the second flat surface 218 are positioned on a side of each of the first inlet tube 208 and the second inlet tube 214 adjacent to the injector axis α. In addition, each of the first flat surface 212 and the second flat surface 218 is positioned at a non-zero angle relative to the injector axis α. For example, the non-zero angle may be between 10 degrees and 60 degrees.

[0162] The first inlet pipe lateral opening 210 can be positioned offset from the first inlet axis A1. For example, in some embodiments, the first inlet pipe lateral opening 210 can be centered above the first inlet axis A1. For example, the central axis of the first inlet pipe lateral opening can be perpendicular to the first inlet axis A1 and intersect with the first inlet axis A1. However, as shown in the present embodiment, the first inlet pipe lateral opening 210 can be positioned above the first inlet axis A1 and offset from the first inlet axis A1. For example, the central axis of the first inlet pipe lateral opening is perpendicular to the first inlet axis A1 and offsets from the first inlet axis A1 by a certain horizontal distance. For example, the first inlet pipe lateral opening 210 can be positioned above the first inlet axis A1 and toward the injector axis α to guide the exhaust flow from the first inlet pipe 208 toward the injector axis α. The positioning of the first inlet pipe lateral opening 210 is configured to guide the exhaust flow toward the injector axis α so that the exhaust gas is mixed with the reductant.

[0163] The second inlet pipe lateral opening 216 can be positioned away from the second inlet axis A2. For example, in some embodiments, the second inlet pipe lateral opening 216 can be centered above the second inlet axis A2. For example, the second inlet pipe lateral opening center axis can be perpendicular to the second inlet axis A2 and intersect with the second inlet axis A2. However, as shown in the present embodiment, the second inlet pipe lateral opening 216 can be positioned above the second inlet axis A2 and away from the second inlet axis A2. For example, the second inlet pipe lateral opening center axis is perpendicular to the second inlet axis A2 and away from the second inlet axis A2 by a certain horizontal distance. For example, the second inlet pipe lateral opening 216 can be positioned above the second inlet axis A2 and toward the injector axis α to guide the exhaust flow from the second inlet pipe 214 toward the injector axis α. The positioning of the second inlet pipe lateral opening 216 is configured to guide the exhaust flow toward the injector axis α so that the exhaust gas is mixed with the reductant.

[0164] Once the exhaust gas is provided to the first mixing chamber 152 (e.g., the exhaust gas has left each of the first inlet pipe 208 and the second inlet pipe 214), the exhaust gas flows upward toward the injector mounting bracket 220. The exhaust gas is then directed downward toward the injector axis α along with the reductant. For example, the exhaust gas can be directed downward by the top surface of the mixer housing 116. A portion of the exhaust gas can also flow outward and around each of the first inlet pipe 208 and the second inlet pipe 214. For example, a first portion 702 of the exhaust gas can be directed upward and toward the injector axis α. For example, the first portion 702 of the exhaust gas can flow out clockwise from the first inlet pipe lateral opening 210 toward the injector axis α, and flow out counterclockwise from the second inlet pipe lateral opening 216. The second portion 704 of the exhaust gas can flow outward between a side of the mixer housing 116 and each of the first inlet pipe 208 and the second inlet pipe 214. For example, the second portion of the exhaust gas can flow out counterclockwise from the first inlet pipe lateral opening 210, and flow out clockwise from the second inlet pipe lateral opening 216.

[0165] The exhaust gas and reductant then travel along the injector axis α (e.g., downward, etc.) toward the support plate opening 158. As the exhaust gas and reductant travel downward along the injector axis α, the reductant mixes with the exhaust gas, thereby treating the exhaust gas. The exhaust gas and reductant mixture then exits the first mixing chamber 152 through the support plate opening 158.

[0166] Figure 8 is a perspective view of the exhaust mixer assembly 114. Figure 8 As shown, the exhaust gas and the reductant mixture flows toward the bottom surface of the mixer housing 116 and flows through the support plate opening 158. The untreated exhaust gas also flows to the first mixing chamber 152 through the auxiliary opening 206 near the bottom surface of the mixer housing 116. The untreated exhaust gas (e.g., the third portion) flowing to the first mixing chamber 152 through the auxiliary opening 206 is mixed with the exhaust gas and the reductant mixture (e.g., the treated exhaust gas, etc.) in the first mixing chamber 152 near the bottom surface of the mixer housing 116 opposite to the injector 134. Then, the untreated exhaust gas is treated with the reductant and also flows out of the first mixing chamber 152 through the support plate opening 158.

[0167] Fig. 9 is based on Figure 2 Another longitudinal view of the exhaust mixer assembly 114 of an embodiment of the present invention. Fig. 9 is a longitudinal view looking from the rear end of the exhaust mixer assembly 114 toward the front end of the exhaust mixer assembly 114 . Fig. 9 The flow of the exhaust gas and reductant mixture within the second mixing chamber 156 is shown.

[0168] The exhaust gas enters the second mixing chamber 156 near the bottom surface of the mixer housing 116. The second mixing chamber 156 receives the exhaust gas and reductant mixture from the support plate opening 158, for example.

[0169] The exhaust-reductant mixture is then directed upward and around the delivery tube 162. For example, the exhaust-reductant mixture flows between the side of the mixer housing 116 and the delivery tube 162. For example, the exhaust-reductant mixture flows along the support plate opening axis A. b The exhaust gas and the reducing agent mixture then flow into the second mixing chamber 156. Then, the exhaust gas and the reducing agent mixture flow along the support plate opening axis A. b The horizontal flow of is disrupted by the outlet plate 154 and is forced to flow upward around the delivery tube 162 toward the top surface of the mixer housing 116.

[0170] The exhaust-reductant mixture is then directed downward through the delivery tube lateral opening 226. Fig. 9 As shown, the delivery duct lateral opening 226 is located in the upper half of the exhaust mixer assembly 114 when the mixer assembly is viewed along the longitudinal axis λ. The delivery duct lateral opening 226 is located at a transverse axis A of the exhaust mixer assembly 114 perpendicular to the longitudinal axis λ. T As the center.

[0171] Fig.10 is based on Figure 2 A side cross-sectional view of an exhaust mixer assembly 114 of an embodiment of FIG. Fig.10 As shown, a first portion of the exhaust reductant mixture 1002 flows out of the second mixing chamber 156 by flowing through the delivery tube lateral opening 226 and out of the outlet opening 160. A second portion of the exhaust reductant mixture 1004 may exit the second mixing chamber 156 by flowing through the peripheral opening 228. For example, the second portion of the exhaust reductant mixture 1004 may bypass the delivery tube 162 and flow through the peripheral opening 228 to exit the second mixing chamber 156.

[0172] When the exhaust reductant mixture exits the delivery tube 162 through the outlet opening 160, the exhaust reductant mixture may exit the delivery tube at a non-zero angle relative to the longitudinal axis λ. For example, the exhaust reductant mixture may flow out of the delivery tube 162 through the outlet opening 160 at a non-zero angle (e.g., between 20 and 60 degrees, 45 degrees, etc.) downward toward the perforated plate 164. However, some of the exhaust reductant mixture may also flow out of the delivery tube 162 through the outlet opening 160 along the longitudinal axis λ (e.g., perpendicular to the direction of flow into the delivery tube 162).

[0173] The exhaust and reductant flow exiting the transport tube 162 at a non-zero angle relative to the longitudinal axis λ is directed toward the perforated plate 164. The exhaust-reductant mixture may flow through the plurality of openings 302 of the perforated plate 164 at a non-zero angle. The plurality of openings 302 facilitates the reductant to pass through a portion of the perforated plate 164. The perforated plate 164 also disrupts the flow of the exhaust-reductant mixture to facilitate further mixing at the downstream end of the exhaust mixer assembly 114.

[0174] IV. Second Example Exhaust Mixer Assembly

[0175] Figure 11-Figure 20 An exhaust mixer assembly 1100 is shown in accordance with various embodiments. The exhaust mixer assembly 1100 is similar to the exhaust mixer assembly 114 described previously, and the foregoing description of the exhaust mixer assembly 114 similarly applies to the exhaust mixer assembly 1100 unless indicated to the contrary below.

[0176] The inlet plate 118 defines a first inlet opening 1102. The first inlet opening 1102 is positioned on a first side 1104 of the inlet plate 118. The first inlet opening 1102 is configured to receive exhaust gas from the upstream housing 108 and facilitate passage of the exhaust gas through the inlet plate 118.

[0177] The inlet plate 118 further defines a second inlet opening 1106. The second inlet opening 1106 is positioned on a second side 1108 of the inlet plate 118. The second inlet opening 1106 is positioned opposite the first inlet opening 1102. The second inlet opening 1106 is configured to receive exhaust gas from the upstream housing 108 and facilitate passage of the exhaust gas through the inlet plate 118.

[0178] The inlet plate 118 also defines a transverse axis A T . Transverse axis A T perpendicular to the longitudinal axis λ and parallel to the injector axis α. For example, the transverse axis A T The inlet plate 118 is divided into two. The inlet plate 118 is about the transverse axis A T For example, the first inlet opening 1102 is positioned on the first side 1104 of the inlet plate 118 and the second inlet opening 1106 is positioned on the second side 1108 of the inlet plate, and the first inlet opening 1102 and the second inlet opening 1106 are symmetrical with respect to the transverse axis A. T The symmetry of the inlet plate 118 promotes equal flow through each of the first inlet opening 1102 and the second inlet opening 1106 .

[0179] In addition, each of the auxiliary opening 206, the flow assist opening 402 and the second flow assist opening 406 is oriented along a transverse axis A. T For example, the horizontal axis A TEach of the assist opening 206 , the flow assist opening 402 , and the second flow assist opening 406 is divided into two.

[0180] The exhaust mixer assembly 1100 also includes a support plate 122 positioned downstream of the inlet plate 118, the support plate 122 including a support plate opening 158. The inlet plate 118 and the support plate 122 define a second chamber 1110.

[0181] The exhaust mixer assembly 1100 also includes a first wall 1112. The first wall 1112 extends from the inlet plate 118 to the support plate 122. The first wall 1112 is configured to direct the flow of exhaust gas between the inlet plate 118 and the support plate 122.

[0182] The first wall 1112 includes a first cylindrical surface 1114. The first cylindrical surface 1114 is positioned in the second chamber 1110. The first cylindrical surface 1114 extends from the back side of the inlet plate 118 and the first inlet opening 1102 to the support plate 122. The first cylindrical surface 1114 is configured to direct exhaust gas from the first inlet opening 1102 upward within the second chamber 1110 toward the injector mounting bracket 220.

[0183] First wall 1112 also includes first planar surface 1116. First planar surface 1116 is coupled to a bottom edge of first cylindrical surface 1114. First planar surface 1116 is also coupled to a bottom edge of first inlet opening 1102. First planar surface 1116 is configured to direct exhaust gas flow from first inlet opening 1102 upward around first cylindrical surface 1114 toward injector mounting bracket 220. First planar surface 1116 is also configured to prevent exhaust gas from flowing upward from auxiliary opening 206 into second chamber 1110.

[0184] The first planar surface 1116 includes a first lower edge 1118. The first lower edge 1118 is coupled to a side of the mixer housing 116. The first lower edge 1118 is configured to prevent exhaust gas from flowing downwardly away from the injection of reductant.

[0185] The exhaust mixer assembly 1100 further includes a second wall 1120. The second wall 1120 extends from the inlet plate 118 to the support plate 122. The second wall 1120 is positioned opposite the first wall 1112. The second wall 1120 is configured to direct exhaust gas flow between the inlet plate 118 and the support plate 122.

[0186] The second wall 1120 includes a second cylindrical surface 1122. The second cylindrical surface 1122 is positioned in the second chamber 1110 opposite the first cylindrical surface 1114. The second cylindrical surface 1122 extends from the back side of the inlet plate 118 and the second inlet opening 1106 to the support plate 122. The second cylindrical surface 1122 is configured to direct exhaust gas from the second inlet opening 1106 upward within the second chamber 1110 toward the injector mounting bracket 220.

[0187] Second wall 1120 also includes second flat surface 1124. Second flat surface 1124 is coupled to a bottom edge of second cylindrical surface 1122. Second flat surface 1124 is also coupled to a bottom edge of second inlet opening 1106. Second flat surface 1124 is positioned within second chamber 1110 opposite first flat surface 1116. Second flat surface 1124 is configured to direct exhaust gas flow from second inlet opening 1106 upward around second cylindrical surface 1122 toward injector mounting bracket 220. Second flat surface 1124 is also configured to prevent exhaust gas from flowing upward from auxiliary opening 206 into second chamber 1110.

[0188] The second planar surface 1124 includes a second lower edge 1126. The second lower edge 1126 is coupled to a side of the mixer housing 116. The second lower edge 1126 is configured to prevent the exhaust gas from flowing downwardly away from the injection of the reductant.

[0189] The first wall 1112 and the second wall 1120 define a first chamber 1128. The first chamber 1128 is located along the injector axis α. For example, according to this embodiment, the first chamber 1128 is centered along the injector axis α. However, in other embodiments, the first chamber 1128 can be located on the injector axis α and offset from the injector axis α.

[0190] The upper edge of each of the first wall 1112 and the second wall 1120 defines a first opening 1130. For example, the upper edge of each of the first wall 1112 and the second wall 1120 is an edge adjacent to the injector 134. When viewed along the longitudinal axis λ of the exhaust mixer assembly 114, the first opening 1130 is positioned in the upper half of the exhaust mixer assembly 1100. For example, the first opening 1130 can be positioned in the half of the outlet plate 154 adjacent to the side of the mixer housing 116 where the reductant is provided. The first opening 1130 facilitates the passage of exhaust gas and reductant into the first chamber 1128.

[0191] According to this embodiment, the first wall 1112 and the second wall 1120 are separate walls. In other embodiments, the first wall 1112 and the second wall 1120 can be coupled or connected. For example, the upper edge of each of the first wall 1112 and the second wall 1120 can extend toward each other for connection, or can include a connector portion that couples the upper edge of each of the first wall 1112 and the second wall 1120. In another embodiment, the first wall 1112 and the second wall 1120 can be integrally formed as a continuous wall, wherein the upper edge defines the first opening 1130.

[0192] The first inlet opening 1102 is configured to provide a first portion of the exhaust gas to the first chamber 1128. For example, the first portion of the exhaust gas provided by the first inlet opening 1102 flows around the first wall 1112 through the first opening 1130 into the first chamber 1128. The second inlet opening 1106 is configured to provide a second portion of the exhaust gas to the first chamber 1128. For example, the second portion of the exhaust gas provided by the second inlet opening 1106 flows around the second wall 1120 through the first opening 1130 into the first chamber 1128.

[0193] The first lower edge 1118 and the second lower edge 1126 define a second opening 1132. The second opening 1132 is positioned in the lower half of the exhaust mixer assembly 1100 when viewed along the longitudinal axis λ of the exhaust mixer assembly 114. For example, the second opening 1132 is positioned adjacent to a side of the mixer housing 116 opposite the injector 134. The second opening 1132 facilitates passage of the exhaust reductant mixture from the first chamber 1128 and through the support plate opening 158.

[0194] When the exhaust-reductant mixture flows out from the second opening 1132, the third portion of the exhaust gas flows along the support plate opening axis A. b The untreated exhaust gas flows through the auxiliary opening 206 into the bottom of the first chamber 1128 opposite the injector 134. The untreated exhaust gas flowing through the auxiliary opening 206 mixes with the exhaust reductant mixture (eg, treated exhaust gas) at the bottom of the first chamber 1128 opposite the injector 134 and enters the second mixing chamber 156.

[0195] The third portion of the exhaust gas provided through the auxiliary openings 206 provides a high flow rate along the bottom surface of the mixer housing 116 opposite the ejector 134. For example, the high velocity of the flow of the third portion of the exhaust gas provided through the auxiliary openings 206 may reduce the formation of deposits (e.g., pooling of exhaust gas, etc.) by providing a high flow rate of hot flow of the exhaust gas along the bottom surface of the mixer housing 116 opposite the ejector 134.

[0196] Once in the second mixing chamber 156, the exhaust-reductant mixture is then directed upward toward the side of the mixer housing 116 where the injector 134 is positioned around the delivery tube 162. For example, in the second mixing chamber 156, the exhaust-reductant mixture is directed upward toward the side of the mixer housing 116 where the injector 134 is positioned around the delivery tube 162. b The flow enters the second mixing chamber 156 and is directed upward circumferentially around the delivery tube 162 .

[0197] At the top of the second mixing chamber 156 (eg, adjacent to the side of the housing where the injector 134 is positioned, etc.), the first portion of the exhaust reductant mixture passes through the delivery tube lateral opening 226 toward the support plate opening axis A opposite to the injector 134. b For example, the first portion of the exhaust-gas reductant mixture may be directed downwardly through the delivery tube lateral opening 226 substantially parallel to the injector axis α.

[0198] The first portion of the exhaust reductant mixture then flows through the delivery tube 162 and out of the outlet opening 160. The first portion of the exhaust reductant mixture may flow out of the outlet opening 160 at a non-zero angle relative to the longitudinal axis λ of the exhaust mixer assembly 114, such that the first portion of the exhaust reductant mixture is directed toward the perforated plate 164. As the first portion of the exhaust reductant mixture flows through the perforated plate 164, it is further mixed (e.g., the flow is disturbed, vortexed, etc.) before it flows to the catalyst component 168.

[0199] Additionally, at the top of the second mixing chamber 156 adjacent to the side of the housing where the injector 134 is positioned, the second portion of the exhaust reductant mixture flows horizontally (e.g., substantially parallel to the longitudinal axis λ) through the plurality of peripheral openings 228. For example, the second portion of the exhaust reductant mixture may flow horizontally through the plurality of peripheral openings 228 such that the second portion of the exhaust reductant mixture bypasses the perforated plate 164 when flowing through the end of the exhaust mixer assembly 1100. The second portion of the exhaust reductant mixture flowing through the plurality of peripheral openings 228 is disrupted (e.g., redirected, mixed, etc.) by the plurality of peripheral opening baffles 410.

[0200] V. Third Example Exhaust Mixer Assembly

[0201] Figure 21-Figure 33 An exhaust mixer assembly 2100 is shown according to various embodiments. The exhaust mixer assembly 2100 is similar to the exhaust mixer assembly 114 and the exhaust mixer assembly 1100 described previously, and the descriptions of the exhaust mixer assembly 114 and the exhaust mixer assembly 1100 apply similarly to the exhaust mixer assembly 2100 unless indicated to the contrary below.

[0202] The inlet plate 118 defines a first inlet opening 2102. The first inlet opening 2102 is positioned on a first side 2104 of the inlet plate 118. The first inlet opening 2102 is also positioned in a lower half of the inlet plate 118 when viewed along the longitudinal axis λ of the mixer housing 116. For example, the first inlet opening 2102 may be positioned in a half of the outlet plate 154 opposite a side of the mixer housing 116 where the injector mounting bracket 220 is positioned. The first inlet opening 2102 is configured to receive exhaust gas from the upstream housing 108 and facilitate passage of the exhaust gas through the inlet plate 118.

[0203] The inlet plate 118 defines a second inlet opening 2106. The second inlet opening 2106 is positioned on a second side 2108 of the inlet plate 118 and is also located in a lower half of the inlet plate 118 when viewed along the longitudinal axis λ of the mixer housing 116. For example, the second inlet opening 2106 is positioned in the same half of the inlet plate 118 as the positioning auxiliary opening 206. The second inlet opening 2106 is positioned opposite the first inlet opening 2102. The second inlet opening 2106 is configured to receive exhaust gas from the upstream housing 108 and facilitate passage of the exhaust gas through the inlet plate 118.

[0204] The inlet plate 118 also defines a transverse axis A T . Transverse axis A T perpendicular to the longitudinal axis λ and parallel to the injector axis α. For example, the transverse axis A T The inlet plate 118 is divided into two. The inlet plate 118 is about the transverse axis A T For example, the first inlet opening 2102 is positioned on the first side 2104 of the inlet plate 118, and the second inlet opening 2106 is positioned on the second side 2108 of the inlet plate, and the first inlet opening 2102 and the second inlet opening 2106 are aligned with the transverse axis A. T The symmetry of the inlet plate 118 promotes equal flow through each of the first inlet opening 2102 and the second inlet opening 2106 .

[0205] In addition, each of the auxiliary opening 206, the flow assist opening 402 and the second flow assist opening 406 is oriented along a transverse axis A. T For example, the horizontal axis A T Each of the assist opening 206 , the flow assist opening 402 , and the second flow assist opening 406 is divided into two.

[0206] The exhaust mixer assembly 2100 further includes a support plate 122 positioned downstream of the inlet plate 118, the support plate 122 including a support plate opening 158. The inlet plate 118 and the support plate 122 define a second chamber 1110. The support plate opening 158 is disposed along a support plate opening axis A. b Positioning. The auxiliary opening 206 is also along the support plate opening axis A b Positioning. The auxiliary opening 206 and the support plate opening 158 are located along the support plate opening axis A b The alignment promotes continuous (eg, unimpeded, etc.) flow between the inlet plate 118 and the support plate 122 , thereby reducing the formation of deposits within the exhaust mixer assembly 2100 .

[0207] The exhaust mixer assembly 2100 further includes an outlet plate 154 including an outlet plate body 159 and an outlet opening 160. The support plate 122 and the outlet plate 154 define a second mixing chamber 156.

[0208] The exhaust mixer assembly 1100 further includes a first wall 2110. The first wall 2110 extends from the inlet plate 118 to the support plate 122. The shape of the first wall 2110 is curved (e.g., arched, arc-shaped, cylindrical, etc.). The first wall 2110 is configured to guide the flow of exhaust gas between the inlet plate 118 and the support plate 122.

[0209] The first wall 2110 includes a first lower edge 2112. The first lower edge 2112 contacts the mixer housing 116. By positioning the first lower edge 2112 of the first wall 2110 in contact with the mixer housing 116, the exhaust gas flow entering the second chamber 1110 via the first inlet opening 2102 is forced to flow upward toward the injector mounting bracket 220.

[0210] The first wall 2110 includes a first tab 2114. The first tab 2114 is positioned on a first lateral edge 2115 of the first wall 1112 adjacent to the inlet plate 118. The first tab 2114 protrudes outwardly from the first inlet opening 2102 toward the upstream housing 108. The first tab 2114 is configured to engage with the first inlet opening 2102 and prevent a portion of the exhaust gas from flowing through the first inlet opening 2102 such that the portion of the exhaust gas contacts the inlet plate body 119.

[0211] The exhaust mixer assembly 1100 also includes a second wall 2116. The second wall 2116 extends from the inlet plate 118 to the support plate 122. The shape of the second wall 2116 is curved (e.g., a small arc, an arch, a cylinder, etc.). The second wall 2116 is positioned opposite the first wall 2110. The second wall 2116 is configured to guide the exhaust gas to flow between the inlet plate 118 and the support plate 122 (e.g., into the second chamber 1110).

[0212] The first wall 2110 and the second wall 2116 define a first chamber 1128. The first chamber 1128 is positioned along the injector axis α. For example, according to this embodiment, the first chamber 1128 is centered along the injector axis α. However, in other embodiments, the first chamber 1128 can be positioned on the injector axis α and offset from the injector axis α.

[0213] According to this embodiment, the first chamber 1128 is a converging mixing chamber. For example, the arc shape of each of the first wall 2110 and the second wall 2116 reduces the volume of the first chamber 1128. The reduced volume of the first chamber 1128 improves the energy utilization of the exhaust gas. For example, the reduced volume forces the reductant and the exhaust gas to converge toward the center of the first mixing chamber, which accelerates the mixing of the reductant and the exhaust gas.

[0214] The second wall 2116 includes a second lower edge 2118. The second lower edge 2118 contacts the mixer housing 116. By positioning the second lower edge 2118 of the second wall 2116 in contact with the mixer housing 116, the exhaust gas flow entering the second chamber 1110 via the second inlet opening 2106 is forced to flow upward toward the injector mounting bracket 220. For example, each of the first lower edge 2112 and the second lower edge 2118 prevents the exhaust gas from bypassing the first chamber 1128 and flowing downward away from the injector mounting bracket 220.

[0215] The second wall 2116 includes a second tab 2120. The second tab 2120 is positioned on a second lateral edge 2117 of the second wall 2116 adjacent to the inlet plate 118. The second tab 2120 protrudes outwardly from the second inlet opening 2106 toward the upstream housing. The second tab 2120 is configured to engage with the second inlet opening 2106 and prevent a portion of the exhaust gas from flowing through the second inlet opening 2106 such that the portion of the exhaust gas contacts the inlet plate body 119.

[0216] The first wall 2110 also includes a first wall opening 2122. In various embodiments, the first wall opening 2122 is positioned in an upper half of the first wall 2110 closest to the injector mounting bracket 220 when viewed along the longitudinal axis λ of the mixer housing 116. For example, the first wall opening 2122 is positioned in a half of the first wall 2110 adjacent to (e.g., closest to, etc.) the injector mounting bracket 220. In various embodiments, the shape of the first wall opening 2122 may be rectangular. In other embodiments, other shapes (e.g., circular, oval, etc.) are possible. The first wall opening 2122 is configured to allow a first portion of the exhaust gas in the second chamber 1110 to flow through the first wall opening 2122 and into the first chamber 1128. For example, a portion of the exhaust gas may flow into the second chamber 1110 horizontally (e.g., parallel to the longitudinal axis λ of the mixer housing 116) via the first inlet opening 2102. Upon entering second chamber 1110 , a first portion of the exhaust gas flows through first wall opening 2122 , while the remaining portion of the exhaust gas that enters second chamber 1110 via first inlet opening 2102 is directed upward toward injector mounting bracket 220 .

[0217] The second wall 2116 also includes a second wall opening 2124. In various embodiments, when viewed along the longitudinal axis λ of the mixer housing 116, the second wall opening 2124 is positioned in the upper half of the second wall 2116 closest to the injector mounting bracket 220. The second wall opening 2124 is positioned opposite the first wall opening 2122. In various embodiments, the shape of the second wall opening 2124 is rectangular. In other embodiments, other shapes (e.g., circular, oval, etc.) are possible. The second wall opening 2124 is configured to allow a second portion of the exhaust gas entering the second chamber 1110 to flow through the second wall opening 2124 and enter the first chamber 1128. For example, a portion of the exhaust gas can flow into the second chamber 1110 horizontally (e.g., parallel to the longitudinal axis λ of the housing) via the second inlet opening 2106. Once in second chamber 1110 , a second portion of the exhaust gas flows through second wall opening 2124 , while the remaining portion of the exhaust gas that enters second chamber 1110 via second inlet opening 2106 is directed upward toward injector mounting bracket 220 .

[0218] The upper edge of each of the first wall 2110 and the second wall 2116 defines a first opening 1130. For example, the upper edge of each of the first wall 2110 and the second wall 2116 is an edge adjacent to the injector 134. When viewed along the longitudinal axis λ of the exhaust mixer assembly 114, the first opening 1130 is positioned in the upper half of the exhaust mixer assembly 2100. For example, the first opening 1130 is positioned adjacent to the injector mounting bracket 220 where the reductant is provided to the exhaust aftertreatment system 100. The first opening 1130 allows a portion of the exhaust gas and the reductant to flow into the first chamber 1128. For example, a portion of the exhaust received by the first inlet opening 2102 and forced upward toward the injector mounting bracket 220 (e.g., the remaining portion of the exhaust that does not flow through the first wall opening 2122, etc.) and another portion of the exhaust received by the second inlet opening 2106 and forced upward toward the injector mounting bracket 220 (e.g., the remaining portion of the exhaust that does not flow through the second wall opening 2124, etc.) enter the first chamber 1128 via the first opening 1130.

[0219] The first lower edge 2112 of the first wall 2110 and the second lower edge 2118 of the second wall 2116 define a second opening 1132. The second opening 1132 is positioned in the lower half of the exhaust mixer assembly 2100 when viewed along the longitudinal axis λ of the exhaust mixer assembly 114. For example, the second opening 1132 is positioned adjacent to a side of the mixer housing 116 opposite the injector 134. The second opening 1132 allows the exhaust reductant mixture to exit the first chamber 1128 and flow through the support plate opening 158.

[0220] like Figure 21-23 As shown, the exhaust mixer assembly 2100 also includes an impingement plate 2126. The impingement plate 2126 is positioned between the first wall 2110 and the second wall 2116 along the longitudinal axis λ. The impingement plate 2126 is also positioned in the first chamber 1128 in the half of the mixer housing 116 opposite to the side of the mixer housing 116 where the injector mounting bracket 220 is positioned. According to this embodiment, the impingement plate 2126 is V-shaped. In other embodiments, other shapes (e.g., U-shaped, vertical plates, horizontal plates, etc.) are possible. The impingement plate 2126 is configured to block (e.g., hinder, guide, etc.) the flow of exhaust gas and reductant in the first chamber 1128 to promote further mixing.

[0221] According to this embodiment, the impingement plate includes an edge 2127 (e.g., a V-shaped point of the impingement plate 2126, etc.). The edge 2127 is positioned parallel to the longitudinal axis λ. In some embodiments, the edge 2127 is positioned directly along the longitudinal axis λ. The edge 2127 is configured to guide a portion of the exhaust gas and reductant mixture within the first chamber 1128.

[0222] According to this embodiment, the impact plate 2126 also includes a first wing 2128 and a second wing 2130. The first wing 2128 and the second wing 2130 extend from the edge 2127 of the impact plate 2126 at a non-zero angle. For example, the non-zero angle is positioned between the first wing 2128 and the second wing 2130. The non-zero angle may be in a range between 15 degrees and 60 degrees. The first wing 2128 and the second wing 2130 direct the flow of the exhaust gas and the reductant away from the injector axis α and toward each of the first wall 2110 and the second wall 2116, respectively.

[0223] The edge 2127 of the impact plate 2126 is separated from the first wall 2110 by a first distance and from the second wall 2116 by a second distance, defining a first channel 2131 and a second channel 2132, respectively. According to this embodiment, the first distance and the second distance are equal. For example, the edge 2127 can be equidistant from each of the first wall 2110 and the second wall 2116. In other embodiments, the first distance between the edge 2127 and the first wall 2110 can be different from (e.g., unequal, etc.) the second distance between the edge 2127 and the second wall 2116. When viewed in cross section, the first distance between the edge 2127 and the first wall 2110 and the second distance between the edge 2127 and the second wall 2116 are less than or equal to 10% of the diameter of the mixer housing 116.

[0224] In addition, each of the first passage 2131 and the second passage 2132 receives a portion of the exhaust gas from the first opening 1130. The first passage 2131 and the second passage 2132 are configured to further mix the exhaust gas and the reductant in the first chamber 1128.

[0225] The first wing 2128 and the second wing 2130 include a first wing edge 2134 and a second wing edge 2136, respectively. The first wing edge 2134 is positioned at a third distance away from the first wall 2110, and the second wing edge 2136 is positioned at a fourth distance away from the second wall 2116. The third distance and the fourth distance are measured along a plane perpendicular to the ejector axis α (e.g., when viewed along a cross section, when perpendicular to the ejector axis α, a horizontal axis, etc.). According to this embodiment, the third distance is equal to the fourth distance. In addition, the third distance is less than the first distance, and the fourth distance is less than the second distance. For example, each of the first channel 2131 and the second channel 2132 decreases in size (e.g., decreases in width, etc.) from the edge 2127 of the impact plate 2126 to each of the first wing edge 2134 and the second wing edge 2136. In other embodiments, the third distance may be greater than or less than the fourth distance.

[0226] When the reductant is dispensed into the aftertreatment system 100, the reductant may fall (e.g., settle, drop, etc.) onto the impingement plate 2126. The impingement plate 2126 is heated by the exhaust gas in the first chamber 1128, thereby reducing the formation of deposits. For example, the impingement plate 2126 may reduce the formation of deposits on the mixer housing 116.

[0227] In addition, the impact plate 2126 increases the evaporation area of ​​the reducing agent. For example, the reducing agent droplets slide down along each of the first wing 2128 and the second wing 2130 and evaporate continuously, which reduces the formation of deposits. The positioning of the impact plate 2126 in the center of the first chamber 1128 and the distance away from the first opening 1130 and the injector 134 allow heat to accumulate near the impact plate 2126. The heat accumulation around the impact plate 2126 contributes to the evaporation of the reducing agent and reduces the formation of deposits. For example, the hot exhaust gas passes around each of the first wing 2128 and the second wing 2130 of the impact plate 2126. The hot exhaust gas heats the impact plate 2126 (e.g., increases the temperature of the impact plate 2126, etc.), causing the reducing agent to evaporate from the surface of each of the first wing 2128 and the second wing 2130.

[0228] The exhaust mixer assembly 2100 also includes a first fin 2137. The first fin 2137 is positioned in the first channel 2131 between the first wall 2110 and the first wing 2128 of the impact plate 2126. The first fin 2137 is positioned at a non-zero angle relative to the first wing 2128. For example, the first fin 2137 can be positioned at an angle between 30 degrees and 80 degrees relative to the first wing 2128. The first fin 2137 is configured to interact with the flow of the exhaust reductant mixture passing through the first channel 2131 to promote additional mixing. For example, the first fin 2137 can be configured to direct the flow toward the first wing 2128.

[0229] The exhaust mixer assembly 2100 also includes a second fin 2138. The second fin 2138 is positioned in the second passage 2132 between the second wall 2116 and the second wing 2130 of the impact plate 2126. The second fin 2138 is also positioned opposite to the first fin 2137. The second fin 2138 is positioned at a non-zero angle relative to the second wing 2130. For example, the second fin 2138 can be positioned at an angle between 30 degrees and 80 degrees relative to the second wing 2130. The second fin 2138 is configured to interact with the flow of the exhaust reductant mixture passing through the second passage 2132 to promote additional mixing. For example, the second fin 2138 is configured to direct the flow toward the second wing 2130 to promote further mixing.

[0230] The first fin 2137 and the second fin 2138 provide additional surface area for the impingement plate 2126. Thus, the first fin 2137 and the second fin 2138 are additional surface areas that are heated by the exhaust gas to cause the reductant droplets to evaporate. For example, the first fin 2137 and the second fin 2138 can be positioned at a non-zero angle relative to each of the first wing 2128 and the second wing 2130 so that they can provide a flatter surface to capture the reductant droplets and further promote evaporation.

[0231] After each portion of the exhaust gas flows through at least one of the first passage 2131 or the second passage 2132, the exhaust gas flows through the second opening 1132, out of the first chamber 1128. The exhaust gas is then directed to the second mixing chamber 156 through the support plate opening 158.

[0232] Once in the second mixing chamber 156, the exhaust reductant mixture may contact the outlet plate 154 and be directed around the delivery tube 162 upward toward the side of the mixer housing 116 where the injector 134 is located. For example, in the second mixing chamber 156, the exhaust reductant mixture is directed along the support plate opening axis A b The flow enters the second mixing chamber 156 and is directed upwardly around the circumference of the delivery tube 162 .

[0233] At the top of the second mixing chamber 156 (eg, adjacent to the side of the housing where the injector 134 is located, etc.), the first portion of the exhaust reductant mixture passes through the delivery tube lateral opening 226 downwardly toward the support plate opening axis A opposite the injector 134. b For example, a first portion of the exhaust-gas reductant mixture may be directed downwardly through the delivery tube lateral opening 226 substantially parallel to the injector axis α.

[0234] Also at the top of the second mixing chamber 156, a second portion of the exhaust gas is directed out of the second mixing chamber 156 through each of the plurality of peripheral openings 228. The exhaust gas mixer assembly 2100 includes three peripheral openings, but any number of peripheral openings 228 is possible.

[0235] like Fig.25 As shown, the exhaust mixer assembly 2100 also includes a perforated plate 2140. The perforated plate 2140 is coupled to the mixer housing 116 and is positioned downstream of the outlet plate 154. According to this embodiment, the perforated plate 2140 overlaps the entire outlet opening 160. For example, exhaust gas directed through the outlet opening 160 and each of the plurality of peripheral openings 228 flows through the perforated plate 2140 and out of the exhaust mixer assembly 2100.

[0236] The perforated plate 2140 includes a plurality of openings 2142. The plurality of openings 2142 may be uniformly defined by the perforated plate 2140. The plurality of openings 2142 are configured to further mix the exhaust reductant mixture as it exits the exhaust mixer assembly 2100.

[0237] like Figure 26-Figure 28 As shown, a first portion 2602 of the exhaust gas is received by the first inlet opening 2102 and directed into the second chamber 1110. A second portion 2604 of the exhaust gas is received by the second inlet opening 2106 and is also directed into the second chamber 1110. A third portion 2606 of the exhaust gas is received by the auxiliary opening 206 and directed toward the support plate opening 158 below the second opening 1132. In addition, a fourth portion 2608 of the exhaust gas may flow through each of the flow assist opening 402 and the second flow assist opening 406 into an upper portion of the second chamber 1110 proximate the first opening 1130 and the injector mounting bracket 220.

[0238] like Figure 29-Figure 30 Shown are the second chamber 1110 and the first chamber 1128 of the exhaust mixer assembly 2100. After the first and second portions 2602, 2604 of the exhaust gas enter the second chamber 1110 via each of the first and second inlet openings 2102, 2106, respectively, the first and second portions 2602, 2604 of the exhaust gas are forced to flow upward toward the injector mounting bracket 220.

[0239] Towards center line A M (e.g., a transverse plane perpendicular to the longitudinal axis λ of the mixer housing 116), the first amount 3002 of the first portion 2602 of the exhaust gas is directed through the first wall opening 2122 to the first chamber 1128. For example, the first amount 3002 of the first portion 2602 of the exhaust gas is directed through the first wall opening 2122 perpendicular to the longitudinal axis λ and parallel to the centerline A M Additionally, the second amount 3004 of the first portion 2602 of the exhaust gas is additionally directed upward toward the injector mounting bracket 220 and the first opening 1130. Once reaching the top of the mixer housing 116, the second amount 3004 of the first portion 2602 of the exhaust gas is directed downward toward the impingement plate 2126 to enter the first chamber 1128 along with the reductant injected by the injector 134.

[0240] The first amount 3002 and the second amount 3004 of the first portion 2602 of the exhaust gas are then directed to at least one of the first channel 2131 or the second channel 2132. Once in the first channel 2131 or the second channel 2132, the first amount 3002 and the second amount 3004 contact at least one of the first fin 2137 or the second fin 2138 while moving downward toward the support plate opening axis A. bmove.

[0241] Towards center line A M , the first amount 3006 of the second portion 2604 of the exhaust gas is directed through the second wall opening 2124 to the first chamber 1128. For example, the first amount 3006 of the second portion 2604 of the exhaust gas is directed through the second wall opening 2124 perpendicular to the longitudinal axis λ and parallel to the centerline A M Additionally, the second amount 3008 of the second portion 2604 of the exhaust gas is additionally directed upward toward the injector mounting bracket 220 and the first opening 1130. Once reaching the top of the mixer housing 116, the second amount 3008 of the second portion 2604 of the exhaust gas is directed downward toward the impingement plate 2126, entering the first chamber 1128 along with the reductant injected by the injector 134.

[0242] The first amount 3006 and the second amount 3008 of the second portion 2604 of the exhaust gas are then directed to at least one of the first channel 2131 or the second channel 2132. Once in the first channel 2131 or the second channel 2132, the first amount 3006 and the second amount 3008 of the second portion 2604 contact at least one of the first fin 2137 or the second fin 2138 while moving downward toward the support plate opening axis A. b move.

[0243] The first amount 3002 of the first portion 2602 and the first amount 3006 of the second portion 2604 of the exhaust are along the same plane (eg, the centerline A). M ) into the first chamber 1128. The relative flows through the first wall opening 2122 and the second wall opening 2124 further disrupt the downward flow of each of the second amount 3004 of the first portion 2602 and the second amount 3008 of the second portion 2604 of the exhaust within the first chamber 1128, further mixing the exhaust with the reductant.

[0244] like Fig.31 As shown, each of the first amount 3002 and the second amount 3004 of the first portion 2602 of the exhaust gas and the first amount 3006 and the second amount 3008 of the second portion 2604 flow into the second mixing chamber 156 via the support plate opening 158. At the same time, the exhaust gas flows along the support plate opening axis A. b The flow passes through the auxiliary opening 206 , mixing with each of the first amount 3002 and the second amount 3004 of the first portion 2602 and the first amount 3006 and the second amount 3008 of the second portion 2604 of the exhaust gas below the second opening 1132 .

[0245] like Fig.32As shown, once entering the second mixing chamber 156, the first portion 3202 and the second portion 3204 of the exhaust gas are directed upward toward the side of the mixer housing 116 where the injector mounting bracket 220 is located. The first portion 3202 and the second portion 3204 of the exhaust gas nearly converge and mix each of the first amount 3002 and the second amount 3004 of the first portion 2602 of the exhaust gas and the first amount 3006 and the second amount 3008 of the second portion 2604, and then pass through the transfer tube lateral opening 226 downward toward the support plate opening axis A. b guide.

[0246] like Fig.33 As shown, once entering the delivery tube 162, a portion of the exhaust gas is directed along the longitudinal axis λ of the mixer housing 116 and out of the outlet opening 160. A second portion of the exhaust gas bypasses the delivery tube 162 and exits the second mixing chamber through the plurality of peripheral openings 228. After exiting the outlet opening 160 or one of the plurality of peripheral openings 228, the exhaust gas is then directed through the plurality of openings 2142 of the perforated plate 2140.

[0247] VI. Configuration of Example Embodiments

[0248] As utilized herein, area is measured along a plane (e.g., a two-dimensional plane, etc.), unless otherwise specified. The area may vary in directions not disposed along the plane (e.g., along a direction orthogonal to the plane, etc.), unless otherwise specified.

[0249] Although this specification contains many specific implementation details, these should not be interpreted as limitations on the scope of the content that may be claimed, but rather as descriptions of features specific to a particular embodiment. Certain features described in the context of a separate embodiment in this specification may also be implemented in combination in a single embodiment. On the contrary, the various features described in the context of a single embodiment may also be implemented individually or in any suitable sub-combination in multiple embodiments. In addition, although features may be described as working in certain combinations, and even initially claimed as such, in some cases, one or more features from the claimed combination may be deleted from the combination, and the claimed combination may refer to a variant of a sub-combination or a sub-combination.

[0250] As used herein, the terms "substantially," "approximately," "about," and similar terms are intended to have a broad meaning consistent with common and acceptable usage by those of ordinary skill in the art to which the subject matter of the present disclosure relates. Those skilled in the art who review the present disclosure should understand that these terms are intended to allow description of certain features described and claimed without limiting the scope of these features to the precise numerical ranges provided. Therefore, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations to the subject matter described and claimed are considered to be within the scope of the appended claims.

[0251] As used herein, the terms "coupled" and the like refer to the joining of two components directly or indirectly to one another. Such joining may be fixed (e.g., permanent) or movable (e.g., removable or releasable). Such joining may be achieved by the two components or the two components and any additional intermediate components being integrally formed as a single unitary body with one another, or by the two components or the two components and any additional intermediate components being attached to one another.

[0252] As used herein, the terms "configured to receive exhaust gas from", "configured to receive air from", "configured to receive reductant from", etc. refer to two components or objects having a passage formed between the two components or objects, with or without an intermediate component or object, in which a fluid, such as air, reductant, air-reductant mixture, etc., can flow. Examples of fluid couplings or configurations for achieving fluid communication may include pipes, channels, or any other suitable components for achieving fluid flow from one component or object to another component or object.

[0253] It is important to note that the construction and arrangement of the various systems shown in the various example embodiments are merely illustrative and not restrictive in nature. All changes and modifications within the spirit and / or scope of the described embodiments are intended to be protected. It should be understood that some features may not be required, and embodiments lacking various features may be considered to be within the scope of the present disclosure, the scope of which is defined by the appended claims. When the language "a portion" is used, an item may include a portion and / or the entire item unless otherwise specifically stated to the contrary.

[0254] Additionally, in the context of a list of elements, the term "or" is used in its inclusive sense (rather than its exclusive sense), so that when used to connect a series of elements, the term "or" refers to one, some, or all of the elements in the list. Unless otherwise specifically stated, conjunction language such as the phrase "at least one of X, Y, and Z" is understood with the context in which it is commonly used to express an item, term, or the like, which can be X; Y; Z; X and Y; X and Z; Y and Z; or X, Y, and Z (i.e., any combination of X, Y, and Z). Therefore, unless otherwise indicated, such conjunction language is generally not intended to imply that certain embodiments require that at least one of X, at least one of Y, and at least one of Z each be present.

[0255] In addition, unless otherwise indicated, the value ranges used herein (e.g., W1 to W2, etc.) include their maximum and minimum values ​​(e.g., W1 to W2 includes W1 and includes W2, etc.). In addition, unless otherwise indicated, the value ranges (e.g., W1 to W2, etc.) are not necessarily required to include intermediate values ​​in the value range (e.g., W1 to W2 may only include W1 and W2, etc.).

Claims

1. An exhaust mixer assembly, comprising: Mixer housing; an inlet plate coupled to the mixer housing and including a first inlet opening; a support plate coupled to the mixer housing downstream of the inlet plate, the support plate including a support plate opening; a first inlet pipe having an upstream end and a downstream end, the upstream end being coupled to the inlet plate and configured to receive exhaust gas from the first inlet opening, the downstream end being closed by a first portion of the support plate, wherein the first inlet pipe includes a first inlet pipe lateral opening extending through a circumferential wall of the first inlet pipe, and wherein the first inlet pipe is offset from the support plate opening; an outlet plate coupled to the mixer housing downstream of the support plate, the outlet plate including an outlet opening; and A delivery tube is coupled to the support plate and the outlet plate, the delivery tube including a delivery tube lateral opening extending through a circumferential wall of the delivery tube, wherein the delivery tube is configured to provide exhaust gas to the outlet opening.

2. The exhaust mixer assembly according to claim 1, wherein: When viewed in the longitudinal direction of the mixer housing, the first inlet pipe lateral opening is located in an upper half of the first inlet pipe, the support plate opening is located in a lower half of the support plate, and the transport pipe lateral opening is located in an upper half of the transport pipe.

3. The exhaust mixer assembly of claim 1 further comprising a perforated plate coupled to the mixer housing and positioned downstream of the outlet plate, wherein When viewed in the longitudinal direction of the mixer housing, the perforated plate only partially overlaps the outlet opening.

4. The exhaust mixer assembly according to claim 3, wherein: When viewed in the longitudinal direction of the mixer housing, the perforated plate overlaps 30% to 70% of the outlet opening.

5. The exhaust mixer assembly according to claim 3, wherein: When viewed in the longitudinal direction of the mixer housing, the conveyor pipe lateral opening is located in the upper half of the conveyor pipe and at least 80% of the cross-sectional area of ​​the perforated plate is located in the lower half of the cross-sectional area of ​​the mixer housing.

6. The exhaust mixer assembly of claim 1, wherein: The inlet plate further includes a second inlet opening, and The exhaust gas mixer assembly includes a second inlet pipe having an upstream end and a downstream end, the upstream end of the second inlet pipe being coupled to the inlet plate and configured to receive exhaust gas from the second inlet opening, the downstream end of the second inlet pipe being closed by a second portion of the support plate, wherein the second inlet pipe includes a second inlet pipe lateral opening extending through a circumferential wall of the second inlet pipe, and wherein the second inlet pipe is offset from the support plate opening.

7. The exhaust mixer assembly according to claim 1, wherein: The inlet plate further comprises an auxiliary opening which is located in a lower half of the inlet plate when viewed in a longitudinal direction of the mixer housing, wherein the first inlet opening is positioned in an upper half of the inlet plate when viewed in the longitudinal direction of the mixer housing.

8. The exhaust mixer assembly of claim 7, comprising a first baffle extending from an edge of the auxiliary opening.

9. The exhaust mixer assembly according to claim 1, wherein: The outlet plate includes at least one peripheral opening positioned outboard of the outlet opening.

10. The exhaust mixer assembly according to claim 1, wherein: The mixer housing includes a reductant injection opening at a location between the inlet plate and the support plate.

11. The exhaust mixer assembly according to claim 2, wherein: The mixer housing includes a reducing agent injection opening at a position between the inlet plate and the support plate, wherein the reducing agent injection opening is located in an upper half of the mixer housing when viewed in a longitudinal direction of the mixer housing.

12. The exhaust mixer assembly according to claim 6, wherein: The mixer housing includes a reductant injection opening at a position between the inlet plate and the support plate, and a central axis of the reductant injection opening extends between the first inlet pipe and the second inlet pipe.

13. The exhaust mixer assembly of claim 6, wherein: The first inlet pipe includes a first flat surface on a side facing the second inlet pipe; and The second inlet pipe includes a second flat surface on a side facing the first inlet pipe.

14. The exhaust mixer assembly according to claim 13, wherein: A distance between the first flat surface and the second flat surface increases in a direction from an upper side to a lower side of the first inlet pipe and the second inlet pipe.

15. The exhaust mixer assembly according to claim 1, wherein: The inlet plate also includes a flow assist opening positioned adjacent the first inlet opening.

16. The exhaust mixer assembly of claim 15, comprising a second baffle extending from an edge of the flow assist opening.

17. An exhaust mixer assembly comprising: Mixer housing; an inlet plate coupled to the mixer housing, the inlet plate comprising: a first inlet opening positioned on a first side of the inlet plate, and a second inlet opening positioned on a second side of the inlet plate opposite the first inlet opening; a support plate coupled to the mixer housing downstream of the inlet plate, the support plate including a support plate opening; a first wall and a second wall extending from the inlet plate to the support plate; a first chamber located inboard of the first wall and the second wall, an upper edge of the first wall and an upper edge of the second wall defining an opening to the first chamber, and a lower edge of the first wall and a lower edge of the second wall extending to the mixer housing; a second chamber, the second chamber being outside the first wall and the second wall; an outlet plate coupled to the mixer housing downstream of the support plate, the outlet plate including an outlet opening; and A delivery tube is coupled to the support plate and the outlet plate, the delivery tube including a delivery tube lateral opening extending through a circumferential wall of the delivery tube, wherein the delivery tube is configured to provide exhaust gas to the outlet opening.

18. The exhaust mixer assembly according to claim 17, wherein: When viewed in the longitudinal direction of the mixer housing, the opening to the first chamber is located in the upper half of the inlet plate and the support plate, the support plate opening is located in the lower half of the support plate, and the transport pipe lateral opening is located in the upper half of the transport pipe.

19. The exhaust mixer assembly according to claim 17, wherein: The inlet plate further comprises an auxiliary opening which is located in a lower half of the inlet plate when viewed in the longitudinal direction of the mixer housing.

20. The exhaust mixer assembly of claim 17, further comprising a perforated plate coupled to the mixer housing and positioned downstream of the outlet plate, wherein When viewed in the longitudinal direction of the mixer housing, the perforated plate only partially overlaps the outlet opening.

21. The exhaust mixer assembly according to claim 20, wherein: When viewed in the longitudinal direction of the mixer housing, the perforated plate overlaps 30% to 70% of the outlet opening.

22. The exhaust mixer assembly of claim 20, wherein: When viewed in the longitudinal direction of the mixer housing, the conveyor pipe lateral opening is located in the upper half of the conveyor pipe and at least 80% of the cross-sectional area of ​​the perforated plate is located in the lower half of the cross-sectional area of ​​the mixer housing.

23. The exhaust mixer assembly of claim 17, wherein: The outlet plate includes at least one peripheral opening positioned outboard of the outlet opening.

24. The exhaust mixer assembly of claim 17, wherein: The first wall includes a first cylindrical surface and a first planar surface, and the second wall includes a second cylindrical surface and a second planar surface.

25. The exhaust mixer assembly of claim 24, wherein: A distance between the first flat surface and the second flat surface increases in a direction from an upper side to a lower side of the first flat surface and the second flat surface.

26. The exhaust mixer assembly of claim 17, further comprising a perforated plate coupled to the mixer housing and positioned downstream of the outlet plate, wherein When viewed in the longitudinal direction of the mixer housing, the perforated plate overlaps the entire outlet opening.

27. The exhaust mixer assembly of claim 17, wherein: The mixer housing includes a reductant injection opening at a position between the inlet plate and the support plate, and a central axis of the reductant injection opening extends between the first wall and the second wall.

28. The exhaust mixer assembly of claim 27, further comprising: an impact plate positioned between the first wall and the second wall, the impact plate comprising: an edge extending along an axis parallel to the longitudinal axis of the mixer housing, the edge being separated from the first wall and from the second wall, a first wing spaced apart from the first wall and extending from the edge in a first direction away from the reductant injection opening, and A second wing is spaced apart from the second wall and extends from the edge in a second direction away from the reductant injection opening, the second wing being spaced apart from the first wing.

29. An exhaust mixer assembly according to claim 28, wherein: The axis coincides with the longitudinal axis.

30. The exhaust mixer assembly of claim 29, wherein: The edge is separated from the first wall by a first distance, the first distance being less than or equal to 10% of a diameter of the mixer housing; and The edge is separated from the second wall by a second distance, the second distance being less than or equal to 10% of a diameter of the mixer housing.

31. The exhaust mixer assembly of claim 28, further comprising: a first fin coupled to the inlet plate and the support plate, the first fin being positioned between the first wall and the first wing; and A second fin is coupled to the inlet plate and the support plate, the second fin being positioned between the second wall and the second wing.

32. The exhaust mixer assembly of claim 27, wherein: The first wall includes a first wall opening, and the second wall includes a second wall opening opposite the first wall opening.

33. The exhaust mixer assembly of claim 32, further comprising: an impact plate positioned between the first wall and the second wall, the impact plate comprising: an edge extending along an axis parallel to the longitudinal axis of the mixer housing, the edge being separated from the first wall and from the second wall, a first wing spaced apart from the first wall and extending from the edge in a first direction away from the reductant injection opening, and a second wing, the second wing being spaced apart from the second wall and extending from the edge in a second direction away from the reductant injection opening, the second wing being spaced apart from the first wing; Wherein, each of the first wall opening and the second wall opening is positioned between the edge and the reductant injection opening.

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