Outlet arrangement with multi-position universal water separator

Abstract

Exhaust arrangement (20) comprising a housing (22) with an exhaust gas receiving inlet (24), an exhaust gas discharging outlet (28), an inner chamber (32) through which the exhaust gas flows from upstream to downstream from the inlet (24) along a downstream direction to the outlet (28), an exhaust pipe (36) extending from the outlet (28) that directs the exhaust gas to the atmosphere, wherein the housing (22) extends axially along an axis (40) with at least one horizontally extending partial vector component, a water separator (70) in the housing (22) downstream of the inner chamber (32) and upstream of the outlet (28) which prevents water that can enter the exhaust pipe (36) from flowing into the inner chamber (32) along an upstream direction, wherein the water separator (70) prevents upstream water flow in several angular positions around the axis (40). preventedwherein the housing (22) has several water outlets (72, 74, 76) extending through a cylindrical side wall (78) in several angular positions around the axis (40), the water outlets being spaced apart from each other in an arc around the axis (40).

Description

BACKGROUND AND SUMMARY The invention relates to outlet arrangements with a water separator. Exhaust systems typically include a housing with an exhaust gas receiving inlet, an exhaust gas discharging outlet, an inner chamber through which the exhaust gas flows upstream from the inlet to the outlet, and an exhaust pipe extending from the outlet to the atmosphere. A water separator may be provided in the housing downstream of the inner chamber and upstream of the outlet to prevent water entering the exhaust pipe from flowing upstream into the inner chamber. This is desirable if the inner chamber contains one or more components that could be damaged by water ingress, such as exhaust aftertreatment elements like catalysts, filters, etc. From WO 2007 / 078 411 A2 a combination of exhaust silencer, aftertreatment element and water separator is known, wherein the aftertreatment element is surrounded by an annular water collection chamber which receives water which is discharged from an upper dome cap above the aftertreatment element and below the upper outlet. The present invention arose during ongoing development efforts relating to the above-mentioned outlet arrangements. Outlet arrangements according to the present invention are specified in claim 1 and claim 16. Further preferred embodiments are described in the dependent claims. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a partially cropped perspective view of a portion of an outlet arrangement known in the prior art. Fig. 2 is an enlarged sectional view along line 2-2 of Fig. 1. Fig. 3 is like Fig. 2 and shows another embodiment known in the prior art. Fig. 4 is a perspective view of a portion of an outlet arrangement according to the present invention. Fig. 5 is an enlarged sectional view along line 5-5 of Fig. 4. Fig. 6 is an enlarged view of a portion of Fig. 5 along line 6-6. Fig. 7 is like Fig. 4 and shows another embodiment. Fig. 8 is a stretched perspective view of an outlet arrangement according to the invention. Fig. 9 is a sectional view along line 9-9 of Fig. 8. Fig. 10 is an enlarged sectional view along line 10-10 of Fig. 7. Fig. 11 is an enlarged view of part of Fig. 10 along line 11-11. Fig. 12 is like Fig.6 and shows another embodiment. DETAILED DESCRIPTION State of the art Fig. 1 shows an exhaust arrangement 20 comprising a housing 22 with an inlet 24 that receives exhaust gas, as shown by arrow 26, an outlet 28 that discharges the exhaust gas, as shown by arrow 30, and an inner chamber 32 through which the exhaust gas flows from upstream to downstream (from left to right in Fig. 1) from the inlet 24 along a downstream direction (to the right in Fig. 1) to the outlet 28. The inner chamber 32 may contain an exhaust aftertreatment element, such as a catalytic element, a filter, etc., as shown in dashed lines at 34. An exhaust pipe 36 extends from the outlet 28 and directs the exhaust gas to the atmosphere, as shown by arrow 38. The housing 22 extends axially along an axis 40 with at least one horizontally oriented partial vector component.A water separator dam 42 is provided downstream of the inner chamber 32 and upstream of the outlet 28 in the housing and prevents water that can enter the exhaust pipe 36 from flowing into the inner chamber 32 in an upstream direction (to the left in Fig. 1). This protects the aftertreatment element 34 from damage caused by ingress of water. In a known embodiment, Fig. 2, the housing side wall 44 has a water drain hole 46 through which water is carried away, as shown by arrow 48. In another embodiment, which is known in the prior art, Fig. 3, the heat insulation layer 50 is spaced apart along the side wall of the housing from the axial end of the housing by a gap 52, which provides a water drainage passage through there into the collection chamber 54 for drainage at the hole 56, as shown by water drainage arrow 58. In Figures 1-3, the outlet 28 is a side outlet that does not extend parallel to the axis 40. In the embodiments shown, the side outlet 28 extends upwards. In other applications, it may be desirable for the side outlet 28 to extend horizontally to the right or horizontally to the left, etc. For these different implementations, a different housing end part at 22a must be selected by the bearing to accommodate the desired orientation; for example, a right-extending side outlet 28 (instead of the upward-extending outlet as shown in Figures 1-3) would require the selection of a housing end part 22a whose outlet 28 extends to the right, and a water separator dam 42 reoriented so that it is located at the bottom of such a housing end part, and a water drain hole 46 or 56 located at the bottom of such a housing end part.This in turn requires that several parts and components be stored in the warehouse, which is considered not cost-effective. US patent application no. 12 / 104,520 (hereinafter referred to as "the '520 application') Figures 4-11 show the present invention and, where appropriate, use the same reference numerals as above for better understanding. In Figures 4 and 5, a water separator 70 is provided in a housing end section 22b downstream of the inner chamber 32 and upstream of the outlet 28. It prevents water that can enter the exhaust pipe 36 from flowing into the inner chamber 32 in an upstream direction (to the left in Figures 4 and 5). The water separator 70 blocks upstream water flow in several angular positions around the axis 40, allowing the outlet 28 to extend upwards, as shown in the solid line in Figure 4, or horizontally to the right, as shown in the dashed line in Figure 28a, or in other orientations, all with the same housing end section 22b and water separator 70, without the need to exchange parts or to store multiple parts with alternative orientations. The housing part 22b, Fig. 4-6, has several water outlets, such as 72, 74, and 76, each at various angular positions around the axis 40. The water outlets are spaced apart from each other in an arc around the axis 40 and ensure water drainage for the respective orientation of the housing end part 22b and outlet 28. For example, if the outlet 28 is oriented upwards, the water outlet 72 is located at the bottom of the housing and provides water drainage. If the housing outlet is oriented to the right, as shown, for example, with the dashed line 28a in Fig. 4, the water outlet 74 is located at the bottom of the housing and provides water drainage. If the outlet is oriented to the left, i.e., opposite to 28a, then the water outlet 76 is located at the bottom of the housing and provides water drainage.The water separator 70 blocks upstream water flow in several angular positions around the axis 40, not just in a single position as in Figs. 1-3. The aforementioned several angular positions preferably include at least two angular positions spaced at least 180° apart for flexibility in the orientation of the outlet 28. Furthermore, if the exhaust pipe 36 is a side outlet exhaust pipe that does not extend parallel to the axis 40, then such a side outlet exhaust pipe is preferably rotatable 360° around the axis 40, and the aforementioned several angular positions lie along an arc of 360° around the axis 40. The water separator 70 is preferably provided by a dam that does not extend parallel to the axis 40 and preferably has a uniform vertical height that is the same in each of the aforementioned angular positions. The housing 22 at the end part 22b includes a cylindrical side wall 78. The dam 70 is preferably a ring with an outer circumference 80 at the side wall 78, extending radially inwards to an inner circumference 82. The vertical span, as shown at 84, Fig. 6, between the inner and outer circumferences 82 and 80 at the lower end of the ring ensures the aforementioned uniform vertical height, which is the same in each of the aforementioned angular positions. In one embodiment, Figs. 4-6, the water separator dam 70 is provided by an L-shaped member 86, which, Figs. 5, 6, has a first leg 88 extending along the side wall 78 and a second leg 90 not extending parallel to the axis 40. In this embodiment, the dam 70 is an L-shaped thermal insulation member containing both the first and second legs 88 and 90, which are thermally insulating to: a) block upstream water flow, particularly by the second leg 90; and b) reduce the outer surface temperature of the side wall 78, particularly by the first leg 88. If the insulation is susceptible to water damage, it is preferred that the insulation be encased in a waterproof covering, for example, a metal foil 92.Furthermore, a liner or receptacle 94 can be provided between the insulation and the side wall 78 to further support the insulation and to form a gap 96 between the end of the insulation and the axial end of the housing and to provide a flow channel or passage 98 for the water drain 72, so that water drains through the gap 96 and the channel 98 to the water drain hole 72. Figures 7-11 show a further embodiment and, where appropriate, use the same reference numerals as above for clarity. The water separator dam 70 mentioned in Figures 4-6 is provided in Figures 7-11 as an L-shaped flange 102, Figure 10, the outer surface 104 of which, Figure 11, is attached to the first leg 106 on the side wall 78 of the housing. In such an embodiment, the side wall 78 has an inner surface with thermal insulation 108 extending along it, which may contain a liner or a receptacle 94, and the outer surface 104 of the L-shaped flange 102 on the first leg 106 is welded to the thermal insulation on the side wall. The second leg 110 of the L-shaped member 102 does not extend parallel to the axis 40. The water separator dam 102 is a ring with an outer circumference at 104 on the side wall 78, extending radially inwards to an inner circumference at 112.The vertical span 114 between the inner and outer circumferences 112 and 104 at the lower end of the ring ensures the aforementioned uniform vertical height, which is the same for each of the aforementioned angular positions, which in turn ensures the aforementioned alignment flexibility of the outlet 28 and the exhaust pipe 36 and universal application and implementation of the present system without stocking several alternative alignment parts. Several diffusers, for example 122, 124, 126, Fig. 8, are each radially spaced outwards from a respective water outlet 72, 74, 76 with respect to the axis 40. The diffusers disperse exhaust gas from the respective water outlet when it is not draining water, thereby aiding the cooling of the exhaust gas. The housing side wall 78 has an outer surface that engages with one or more mounting clips, as shown, for example, in dashed lines at 128 in Fig. 11. Installation or repair personnel may use mounting clips to install the outlet assembly in various implementations, including different engine compartments, etc. The use and positioning of such clips may be unpredictable and / or may not conform to recommended manufacturer specifications. Accordingly, improper positioning of a mounting clip in Fig.1-3 cover and block a water drain hole, such as 46 or 56. The diffusers 122, 124, 126 provide covers that are radially spaced outwards from the respective water holes 72, 74, 76, and ensure that the holes are not blocked by one or more mounting clips. The housing includes the aforementioned side wall 78, which is preferably arcuate and further preferably cylindrical. The water drains are provided through the aforementioned holes 72, 74, 76, etc., through the side wall. The diffusers 122, 124, 126, provided by the aforementioned covers, deflect the exhaust gas so that it flows tangentially with respect to the arcuate side wall. Fig. 12 shows another embodiment and, where appropriate, uses the same reference numerals as above for clarity. In the embodiments above, the water outlets, such as 72, 74, 76, extend radially with respect to the axis 40. In Fig. 12, and also as shown in dashed lines in Fig. 10, the water outlets, such as 130, 132, etc., extend axially through the housing end wall 134, which is spaced axially downstream of the water separator 70. The outlet holes 130, 132, etc., can be used in addition to or instead of the outlet holes 72, 74, 76. Unused outlet holes, such as 132, can be closed in the orientation shown in Fig. 10 and Fig. 12, for example, by a screw plug. The drain hole used for water drainage, for example drain hole 130 in the orientation of Fig. 10, Fig.12 , can be left open or may have an optional connection for a drain hose to direct drainage water to a suitable location on the vehicle for drainage. For the sake of brevity, clarity, and understanding, certain terms have been used in the preceding description. No unnecessary restrictions beyond those required by the prior art should be derived from these terms, as they are used for illustrative purposes and are intended to be interpreted generally. The various configurations, systems, and process steps described herein can be used alone or in combination with other configurations, systems, and process steps. It is to be expected that various equivalents, alternatives, and modifications within the scope of the attached claims are possible.

Claims

Exhaust arrangement (20) comprising a housing (22) with an exhaust gas receiving inlet (24), an exhaust gas discharging outlet (28), an inner chamber (32) through which the exhaust gas flows from upstream to downstream from the inlet (24) along a downstream direction to the outlet (28), an exhaust pipe (36) extending from the outlet (28) that directs the exhaust gas to the atmosphere, wherein the housing (22) extends axially along an axis (40) with at least one horizontally extending partial vector component, a water separator (70) in the housing (22) downstream of the inner chamber (32) and upstream of the outlet (28) which prevents water that can enter the exhaust pipe (36) from flowing into the inner chamber (32) along an upstream direction, wherein the water separator (70) prevents upstream water flow in several angular positions around the axis (40). preventedwherein the housing (22) has several water outlets (72, 74, 76) extending through a cylindrical side wall (78) in several angular positions around the axis (40), the water outlets being spaced apart from each other in an arc around the axis (40). Outlet arrangement according to claim 1, wherein the multiple angular positions comprise at least two angular positions spaced apart by at least 180°. Exhaust arrangement according to claim 1, wherein the exhaust pipe (36) is a side exhaust pipe which does not extend parallel to the axis (40), and wherein the side exhaust pipe is rotatable by 360° about the axis (40) and the multiple angular positions are located along a 360° arc about the axis (40). Outlet arrangement according to claim 1, wherein the water separator (70) comprises a dam (42) which does not extend parallel to the axis (40) and has a uniform vertical height which is the same in each of the angular positions. Outlet arrangement according to claim 4, wherein the housing (22) has a cylindrical side wall (78) and the dam (42) is a ring with an outer circumference (80) on the side wall (78) extending radially inwards to an inner circumference (82), wherein the vertical span between the inner circumference (82) and the outer circumference (80) at the lower end of the ring ensures the uniform vertical height which is the same in each of the angular positions. Outlet arrangement according to claim 1, wherein the housing (22) has a side wall (78) and the water separator (70) comprises a dam (42) which includes an L-shaped member (102) in cross-section, comprising a first leg (106) extending along the side wall (78) and a second leg (110) extending not parallel to the axis (40). Outlet arrangement according to claim 6, wherein the dam (42) comprises an L-shaped thermal insulation element (102) which includes both the first leg (106) and the second leg (110) which are thermally insulating in order to: a) block upstream water flow, in particular by the second leg (110); and b) reduce the outer skin temperature of the side wall (78), in particular by the first leg (106). Outlet arrangement according to claim 6, wherein the dam (42) comprises an L-shaped flange (102) having an outer surface (104) on the first leg (106) which is attached to the side wall (78) of the housing (22). Outlet arrangement according to claim 8, wherein the side wall (78) has an inner surface with thermal insulation (108) extending along it and the outer surface (104) of the L-shaped flange (102) is welded to the thermal insulation (108) on the side wall (78) at the first leg (106). Outlet arrangement according to claim 1, comprising several diffusers (122, 124, 126) each being radially spaced outwards from a respective water outlet with respect to the axis (40), wherein the diffusers (122, 124, 126) disperse the exhaust gas from the respective water outlet when it is not draining water, thereby assisting in the cooling of the exhaust gas. Outlet arrangement according to claim 10, wherein the housing (22) has a side wall (78) with an outer surface which engages with one or more fastening clamps (128), and wherein the water drains comprise holes (72, 74, 76) through the side wall (78) and the diffusers (122, 124, 126) comprise covers which are spaced radially outwards from the holes (72, 74, 76) and ensure that the holes (72, 74, 76) are not blocked by the fastening clamps (128). Outlet arrangement according to claim 10, wherein the housing (22) has an arc-shaped side wall (78), the water drains comprise holes (72, 74, 76) through the side wall (78), and the diffusers (122, 124, 126) comprise covers that deflect the exhaust gas so that it flows tangentially with respect to the arc-shaped side wall (78). Outlet arrangement according to claim 1, wherein the water outlets extend radially with respect to the axis (40). Outlet arrangement according to claim 1, wherein the water outlets extend axially. Outlet arrangement according to claim 1, wherein the housing (22) has an end wall (134) which is axially spaced downstream of the water separator (70), and the water outlets extend through the end wall (134). Exhaust arrangement comprising a housing (22) with an exhaust gas receiving inlet (24), an exhaust gas discharging outlet (28), an inner chamber (32) through which the exhaust gas flows from upstream to downstream from the inlet (24) along a downstream direction to the outlet (28), an exhaust pipe (36) extending from the outlet (28) that directs the exhaust gas to the atmosphere, wherein the housing (22) extends axially along an axis (40) with at least one horizontally extending partial vector component, a water separator (70) in the housing (22) downstream of the inner chamber (32) and upstream of the outlet (28) that prevents water that can enter the exhaust pipe (36) from flowing into the inner chamber (32) along an upstream direction, wherein the housing (22) has at least one water drain, at least one diffuser (122, 124, 126),which is radially spaced outwards from the water outlet with respect to the axis (40) and disperses the exhaust gas from the water outlet when it is not draining water, thereby supporting the cooling of the exhaust gas. Outlet arrangement according to claim 16, wherein the housing (22) has a side wall (78) with an outer surface (104) which engages with a fastening clamp (128), and wherein the water outlet comprises a hole (72, 74, 76) through the side wall (78) and the diffuser (122, 124, 126) comprises a cover which is spaced radially outwards from the hole (72, 74, 76) and ensures that the hole (72, 74, 76) is not blocked by the fastening clamp (128). Outlet arrangement according to claim 16, wherein the housing (22) has an arc-shaped side wall (78), the water outlet comprises a hole (72, 74, 76) through the side wall (78) and the diffuser (122, 124, 126) comprises a cladding that deflects the exhaust gas so that it flows tangentially with respect to the arc-shaped side wall (78).

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