Vehicle

Abstract

A vehicle. The vehicle comprises a muffler. The muffler comprises: a muffler housing, a first heat insulation member, and a fixing member, wherein a sound attenuation chamber is defined within the muffler housing. The first heat insulation member is arranged on the muffler housing, and the first heat insulation member is fixed to the muffler housing by means of the fixing member.

Description

vehicle

[0001] This application claims priority to Chinese patent application No. 202520323696.5, filed on February 25, 2025; Chinese patent application No. 202520334764.8, filed on February 27, 2025; and Chinese patent application No. 202520598082.8, filed on March 31, 2025, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates to the field of vehicle technology, and more particularly to a vehicle. Background Technology

[0003] In the relevant solutions, the vehicle's muffler is covered with a heat insulation component to prevent heat from the exhaust gas from dissipating to the outside of the muffler, thereby protecting the components around the muffler. Summary of the Invention

[0004] This disclosure aims to at least address one of the technical problems existing in the related art. To this end, this disclosure proposes a vehicle comprising: an engine and an exhaust system connected to the engine, wherein the exhaust system includes a catalytic converter and a muffler connected to each other.

[0005] In some embodiments, the muffler includes: a muffler housing, a first heat insulation member, and a fixing member, wherein a silencing cavity is defined within the muffler housing; the first heat insulation member is disposed in the muffler housing; and the first heat insulation member is fixed to the muffler housing by the fixing member.

[0006] In this way, by setting the fastener, the heat insulation component can be fixed, thereby preventing heat from dissipating from the location where the heat insulation component has fallen off to the outside of the muffler, and thus effectively protecting the components around the muffler.

[0007] In some embodiments, the vehicle includes an exhaust system comprising: a muffler, a catalytic converter, and at least one exhaust sensor, wherein the catalytic converter is connected to the muffler, and the projection of the catalytic converter along a first direction at least partially overlaps with the projection of the muffler along the first direction; the exhaust sensor is mounted on the outer wall of the catalytic converter, and at least a portion of the exhaust sensor is located outside the muffler.

[0008] Thus, by using a muffler and catalytic converter, the exhaust gas of the engine can be reduced in noise and purified by catalytic converter. By making the projection of the catalytic converter along the first direction at least partially overlap with the projection of the muffler along the first direction, the overall structure of the exhaust device can be made compact, reducing the space occupied. Furthermore, by placing at least part of the exhaust sensor outside the muffler, the installation and maintenance of the exhaust sensor can be facilitated.

[0009] In some embodiments, the vehicle includes a powertrain for the vehicle and includes an engine, a drive assembly, and an exhaust system, wherein the engine and the drive assembly are connected. The exhaust system is housed in the same compartment as the engine.

[0010] In this way, the engine and drive components are set up and fixed together along the height of the vehicle, resulting in a high degree of integration and better space utilization. Attached Figure Description

[0011] Figure 1 is a schematic diagram of a vehicle according to some embodiments;

[0012] Figure 2 is a schematic diagram of the exhaust device shown in Figure 1 from the first angle;

[0013] Figure 3 is a schematic diagram of the exhaust device shown in Figure 1 from a second angle;

[0014] Figure 4 is a magnified view of part A in Figure 3;

[0015] Figure 5 is a schematic diagram of the exhaust device shown in Figure 3 from the third angle;

[0016] Figure 6 is a schematic diagram of the exhaust device shown in Figure 3 from the fourth angle;

[0017] Figure 7 is a schematic diagram of the exhaust device shown in Figure 3 from the fifth angle;

[0018] Figure 8 is a schematic diagram of the sixth angle of the exhaust device shown in Figure 3;

[0019] Figure 9 is an exploded view of one embodiment of the muffler shown in Figure 3;

[0020] Figure 10 is a schematic diagram of the thickness of the aerogel layer and the glass fiber layer of the rear insulation section shown in Figure 9.

[0021] Figure 11 is an exploded view of another embodiment of the silencer shown in Figure 3;

[0022] Figure 12 is a perspective view of an engine assembly according to some embodiments;

[0023] Figure 13 is a front view of the engine assembly in Figure 12;

[0024] Figure 14 is a perspective view of the exhaust device in Figure 12;

[0025] Figure 15 is a front view of the exhaust device in Figure 14;

[0026] Figure 16 is a side view of the exhaust device in Figure 14;

[0027] Figure 17 is a perspective view of another engine assembly according to some embodiments;

[0028] Figure 18 is a front view of the engine assembly in Figure 17;

[0029] Figure 19 is a perspective view of the exhaust device in Figure 17;

[0030] Figure 20 is a front view of the exhaust device in Figure 19;

[0031] Figure 21 is a side view of the exhaust device in Figure 19;

[0032] Figure 22 is a perspective view of yet another engine assembly according to some embodiments;

[0033] Figure 23 is a front view of the engine assembly in Figure 22;

[0034] Figure 24 is a perspective view of the exhaust device in Figure 22;

[0035] Figure 25 is a front view of the exhaust device in Figure 24;

[0036] Figure 26 is a side view of the exhaust device in Figure 24;

[0037] Figure 27 is a schematic diagram of the internal structure of the muffler in Figure 24;

[0038] Figure 28 is a perspective view of yet another engine assembly according to some embodiments;

[0039] Figure 29 is a front view of the engine assembly in Figure 28;

[0040] Figure 30 is a perspective view of the exhaust device in Figure 28;

[0041] Figure 31 is a front view of the exhaust device in Figure 30;

[0042] Figure 32 is a side view of the exhaust device in Figure 30;

[0043] Figure 33 is a cross-sectional view along line AA in Figure 32;

[0044] Figure 34 is a structural diagram of a vehicle according to some embodiments;

[0045] Figure 35 is a structural diagram of a powertrain according to some embodiments;

[0046] Figure 36 is a structural diagram of an intake system according to some embodiments;

[0047] Figure 37 is a structural diagram of an exhaust device according to some embodiments.

[0048] Reference numerals: 10, muffler; 11, muffler housing; 1100, first groove; 101, front housing; 102, rear housing; 200, first heat insulation element; 2100, first through hole; 2200, aerogel layer; 2300, glass fiber layer; 201, front heat insulation part; 202, rear heat insulation part; 203, lower heat insulation part; 300, fixing element; 3100, first fixing part; 3200, second fixing part; 400, second heat insulation element; 4100, second through hole; 4200, second groove; 401, front cover; 402, rear cover; 403, bottom cover; 3000, EGR; 1000, engine assembly; 100, exhaust device; 110, muffler cavity; 111, muffler outlet; 112, tailpipe; 113, clearance space; 114. Clearance hole; 20. Silencing structure; 210. Partition plate; 21. Silencing chamber; 211. First silencing chamber; 212. Second silencing chamber; 213. Third silencing chamber; 214. Fourth silencing chamber; 215. Fifth silencing chamber; 22. Silencing pipe; 221. First silencing pipe; 222. Second silencing pipe; 223. Third silencing pipe; 224. Fourth silencing pipe; 225. Fifth silencing pipe; 226. Sixth silencing pipe; 23. Connecting pipe; 30. Catalyst; 31. Catalyst housing; 310. Catalyst chamber; 311. Catalyst inlet; 32. First connecting flange; 33. Catalyst outlet; 34. Mounting boss; 341. Connecting channel; 35. First catalyst carrier; 36. Second catalyst carrier; 40. Exhaust sensor; 41. First pressure sensor; 42. Second pressure sensor; 43. Oxygen sensor; 50. Mounting bracket; 2010. Exhaust port; 2020. Second connecting flange; 10000, Powertrain; 1. Horizontally opposed engine; 2. Intake system; 3. Generator; 4. Generator controller; 5. Drive shaft beam; 7. Drive motor; 9. Air filter; 91. Air filter outlet pipe; 92. Air filter intake manifold; 12. Intake manifold mounting flange; 13. Three-way catalytic converter; 14. Exhaust manifold mounting flange; 15. First exhaust muffler; 16. Second exhaust muffler; 17. Flexible pipe; 18. Exhaust piping; 19. Third exhaust muffler; 2000, Engine; 2001, Drive assembly; 600, Vehicle. Detailed Implementation

[0049] Embodiments of this disclosure are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this disclosure, and should not be construed as limiting this disclosure.

[0050] In the embodiments of this disclosure, the terms "first," "second," "third," "fourth," "fifth," and "sixth" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," "third," "fourth," "fifth," and "sixth" may explicitly or implicitly include one or more of that feature.

[0051] In embodiments of this disclosure, the terms "comprising," "including," or any other variations thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0052] "A and / or B" includes the following three combinations: A only, B only, and a combination of A and B.

[0053] In embodiments of this disclosure, "parallel," "perpendicular," and "equal" include the described situation and situations that are similar to the described situation, within an acceptable deviation range, which is determined by those skilled in the art taking into account the measurement under discussion and the error associated with the measurement of a particular quantity (i.e., the limitations of the measurement system). For example, "parallel" includes absolute parallelism and approximate parallelism, where an acceptable deviation range for approximate parallelism may be, for example, within 5°; "perpendicular" includes absolute perpendicularity and approximate perpendicularity, where an acceptable deviation range for approximate perpendicularity may also be, for example, within 5°; "equal" includes absolute equality and approximate equality, where an acceptable deviation range for approximate equality may be, for example, a difference between the two equalities less than or equal to 5% of either one.

[0054] In the relevant solution, the muffler is designed to insulate the heat in the exhaust gas. The heat insulation component covers the muffler shell to prevent the heat in the exhaust gas from dissipating to the outside of the muffler, thereby protecting the components around the muffler. However, during vehicle operation, the connection between the heat insulation component and the muffler shell is unstable, which can easily cause the heat insulation component to deform and fall off the muffler shell, resulting in heat dissipating to the outside of the muffler.

[0055] The muffler 10 according to an embodiment of the present disclosure is described below with reference to the accompanying drawings.

[0056] Referring to Figures 1, 3, 4, and 9, a muffler 10 according to some embodiments of this disclosure is applied to a vehicle 600. The muffler 10 is an important component of the exhaust system of the vehicle 600, and its main function is to reduce the noise generated when the engine 2000 exhausts. It also affects the performance and emission efficiency of the vehicle 600. The muffler 10 includes a muffler housing 11, a first heat insulation member 200, and a fixing member 300. For example, a sound-absorbing cavity is defined within the muffler housing 11; the first heat insulation member 200 is disposed within the muffler housing 11; and the first heat insulation member 200 is fixed to the muffler housing 11 by the fixing member 300.

[0057] For example, as shown in Figures 1, 3, 4 and 9, the muffler housing 11 has a silencing unit inside, which is used to reduce the noise of the engine 2000. The heat insulation component can be located inside the muffler housing 11, or it can be covered on the outer surface of the muffler housing 11.

[0058] When the vehicle 600 is running, the engine 2000 runs and produces exhaust gas. The exhaust gas enters the muffler 10 for noise reduction. Since the exhaust gas is a high-temperature gas, the first heat insulation component 200 absorbs the heat of the exhaust gas, thereby effectively preventing heat from dissipating to the devices around the muffler 10.

[0059] In some embodiments of this disclosure, the muffler 10 is provided with a fixing member 300, which can fix the first heat insulation member 200. Compared with the related technology, which does not fix the first heat insulation member 200, resulting in the first heat insulation member 200 deforming and falling off, the muffler 10 in some embodiments of this disclosure can stably fix the first heat insulation member 200 in the required position, preventing the first heat insulation member 200 from accumulating downward due to vibration. This can prevent heat from dissipating from the position where the first heat insulation member 200 falls off to the outside of the muffler 10, thereby preventing electrical components around the muffler 10 from suffering heat damage and effectively protecting the surrounding devices. At the same time, the first heat insulation member 200 can slow down the material aging and corrosion rate of the muffler 10 caused by high temperature, thereby extending the service life of the muffler 10.

[0060] According to some embodiments of the present disclosure, the muffler 10 is provided with a fixing member 300, which can fix the first heat insulation member 200, thereby preventing heat from dissipating from the location where the first heat insulation member 200 falls off to the outside of the muffler 10, and thus effectively protecting the devices around the muffler 10.

[0061] According to some embodiments of this disclosure, referring to Figures 3, 4, and 9, the fixing member 300 includes a first fixing part 3100 and a second fixing part 3200. The first fixing part 3100 is disposed on the muffler housing 11. The first fixing part 3100 and the second fixing part 3200 cooperate to fix the first heat insulation member 200 to the muffler housing 11. This ensures the strength of the fixation between the first heat insulation member 200 and the muffler housing 11, effectively preventing the first heat insulation member 200 from separating from the muffler housing 11, thereby avoiding heat damage to components around the muffler 10. Simultaneously, the cooperation between the first fixing part 3100 and the second fixing part 3200 facilitates the installation of the fixing member 300 and the first heat insulation member 200, thereby improving the assembly efficiency of the muffler 10.

[0062] According to some embodiments of this disclosure, referring to Figures 3, 4, and 9, the first heat insulation member 200 is provided with a first through hole 2100, and the second fixing part 3200 passes through the first through hole 2100 and engages with the first fixing part 3100. Therefore, by providing the first through hole 2100, it is convenient for the second fixing part 3200 to pass through the first through hole 2100 and engage with the first fixing part 3100. This avoids the second fixing part 3200 from piercing the first heat insulation member 200 before engaging with the first fixing part 3100. This facilitates the fixing of the fixing member 300 and the first heat insulation member 200 and also improves the assembly efficiency of the fixing member 300 and the first heat insulation member 200.

[0063] For example, as shown in Figures 3, 4, and 9, the first fixing part 3100 is a threaded hole, and the second fixing part 3200 is a stud. The stud passes through the first through hole 2100 and is screwed into the threaded hole. In some embodiments, the first fixing part 3100 can be a stud, and the second fixing part 3200 can be a threaded hole. The stud passes through the first through hole 2100 and is screwed into the threaded hole.

[0064] According to some embodiments of this disclosure, referring to Figures 3, 4, and 9, a portion of the shell wall of the muffler housing 11 is recessed along the thickness direction of the shell wall (the front-rear direction as shown in Figure 3) to form a first groove 1100, and a first fixing part 3100 is disposed within the first groove 1100. Thus, by providing the first groove 1100, a fixed position can be provided for the first fixing part 3100, thereby facilitating its placement. Simultaneously, the second fixing part 3200 can extend deeper relative to the surface of the muffler 10, thereby reducing the space occupied by the fixing member 300, thus reducing the volume of the muffler 10 and facilitating its installation in the front compartment of the vehicle 600.

[0065] For example, as shown in Figure 4, a portion of the shell wall of the muffler housing 11 can be recessed forward in the front-to-back direction to form a first groove 1100, and a portion of the shell wall of the muffler housing 11 can also be recessed backward in the front-to-back direction to form a first groove 1100. As shown in Figure 4, the muffler housing 11 is provided with a forward-recessed first groove 1100, a first fixing part 3100 is provided on the bottom wall of the first groove 1100, and the front end of the second fixing part 3200 extends into the first groove 1100 and connects with the first fixing part 3100.

[0066] In some embodiments, the first fixing part 3100 can be an external threaded boss, which fixes the first heat insulation component 200 in the form of an external threaded boss and a washer. Alternatively, the first fixing part 3100 can be an internal threaded boss, which fixes the first heat insulation component 200 in the form of an internal threaded boss and a washer. The first fixing part 3100 can be selected in a reasonable form according to actual needs, thereby reducing the manufacturing difficulty of the fixing part and facilitating the installation of the fixing component 300 and the first heat insulation component 200.

[0067] In some embodiments, the first fixing part 3100 can be welded to the bottom wall of the first groove 1100. This connection can ensure the fixing strength between the first fixing part 3100 and the muffler shell 11, effectively prevent the first fixing part 3100 from separating from the muffler shell 11, and thus ensure the stability of the fixing member 300 fixing the heat insulation member.

[0068] According to some embodiments of this disclosure, referring to Figures 3 and 4, the first fixing part 3100 and the second fixing part 3200 are threadedly connected. Therefore, the threaded connection structure is simple and easy to assemble, thereby improving the assembly efficiency of the fixing member 300 and the first heat insulation member 200.

[0069] According to some embodiments of this disclosure, referring to Figures 3, 4, and 9, the number of first fixing parts 3100 is multiple, that is, the number of first fixing parts 3100 can be two, three, four, or more, and they are distributed at intervals on the muffler housing 11. Second fixing parts 3200 correspond one-to-one with the first fixing parts 3100. Thus, multiple fixing parts 300 can divide the heat insulation component into smaller parts, thereby allowing the fixing parts 300 to withstand less shaking of the heat insulation cotton, and thus ensuring the stability of the fixing parts 300 in fixing the heat insulation cotton. For example, as shown in Figures 3, 4, and 9, the number of fixing parts 300 is seven, and the seven fixing parts 300 are arranged at intervals along the vertical direction on the muffler housing 11.

[0070] According to some embodiments of this disclosure, referring to Figures 3, 4, and 9, a first adhesive member is provided between the first heat insulation member 200 and the muffler housing 11, and the two are bonded together by the first adhesive member. Therefore, the first adhesive member can increase the connection strength between the first heat insulation member 200 and the muffler housing 11, thereby effectively preventing the heat insulation member from deforming and falling off.

[0071] In some embodiments, the first adhesive is a high-temperature resistant inorganic adhesive, which can prevent the first adhesive from failing due to heat. At the same time, inorganic adhesives are easy to obtain, so they can be used in batches.

[0072] In some embodiments, as shown in Figures 9 and 11, the insulation component can be a single layer or multiple layers, thereby allowing for the selection of a reasonable number of layers according to actual needs, and thus ensuring the versatility of the insulation component.

[0073] According to some embodiments of this disclosure, referring to Figures 3, 4 and 9, the first heat insulation member 200 is disposed on the inner side and / or outer side of the muffler housing 11. That is, the first heat insulation member 200 can be disposed on the inner side of the muffler housing 11, the first heat insulation member 200 can also be disposed on the outer side of the muffler housing 11, and the first heat insulation member 200 can also be disposed on both the inner and outer sides of the muffler housing 11. Therefore, the first heat insulation component 200 can be placed in a reasonable position according to actual needs, thereby ensuring the heat insulation effect of the muffler 10. For example, if the first heat insulation component 200 is placed inside the muffler shell 11, it can directly absorb the heat in the muffler cavity, thereby protecting the muffler shell 11 and extending its service life. If the first heat insulation component 200 is placed outside the muffler shell 11, it can be maintained and replaced without disassembling the muffler shell 11, thus facilitating after-sales maintenance. If the first heat insulation component 200 is placed inside and outside the muffler shell 11, it can effectively ensure the heat insulation effect of the muffler 10.

[0074] According to some embodiments of this disclosure, referring to Figures 9 and 10, the first heat insulation member 200 includes an aerogel layer 2200 and a glass fiber layer 2300, which are stacked along the thickness direction of the heat insulation member. Thus, the aerogel layer 2200 has a good heat absorption effect, thereby preventing heat from the exhaust gas from dissipating to the outside of the muffler 10. The glass fiber layer 2300 also has a good heat absorption effect and is inexpensive, thereby reducing the manufacturing cost of the muffler 10. Furthermore, the aerogel layer 2200 and the glass fiber layer 2300 work together to absorb heat from the exhaust gas to the maximum extent, thereby effectively protecting the structure surrounding the muffler 10 from heat damage.

[0075] For example, as shown in Figures 9 and 10, the aerogel layer 2200 is disposed on the outside of the glass fiber layer 2300. The substrate of the aerogel layer 2200 is a felt made by needle punching. The aerogel layer 2200 is made by attaching aerogel powder to the substrate through a process with high silica as the substrate. The working temperature can reach above 1050℃. The glass fiber layer 2300 does not have aerogel powder attached and the working temperature is above 650℃.

[0076] Experimental results show that the thermal conductivity of both aerogel layer 2200 and glass fiber layer 2300 increases with increasing temperature. Below 600℃, the thermal insulation effect of aerogel layer 2200 is significantly better than that of glass fiber layer 2300. Above 600℃, the thermal insulation effect of aerogel layer 2200 is similar to that of glass fiber layer 2300. Under idling conditions, comparing the heat dissipation of glass fiber layer 2300 and aerogel layer 2200, both with a single-layer material thickness of 15mm, the heat dissipation of single-layer glass fiber layer 2300 is approximately 14% higher than that of single-layer aerogel layer 2200. This indicates that, at the same thickness, aerogel layer 2200 has better thermal insulation performance than glass fiber layer 2300. Maintaining the same thermal insulation performance, the thermal insulation effects of 15mm single-layer glass fiber layer 2300 and 10mm single-layer aerogel layer 2200 are similar.

[0077] Furthermore, by comparing the heat dissipation performance of double-layer materials with different thickness ratios, using the heat dissipation of a 15mm single-layer aerogel layer 2200 as a benchmark, it was found that the heat dissipation of 10mm glass fiber layer 2300 and 9mm aerogel layer 2200, 16mm glass fiber layer 2300 and 6mm aerogel layer 2200, 22mm glass fiber layer 2300 and 3mm aerogel layer 2200, and 27mm glass fiber layer 2300 is similar to that of a 3mm single-layer aerogel. The operating temperature of the muffler 10 in some embodiments of this disclosure is approximately 800°C. Using a single-layer glass fiber layer 2300 insulation component requires a relatively thick design to meet the insulation requirements. The production cost of using a single-layer aerogel layer 2200 insulation component is high. Considering the overall assembly space, production cost, and insulation performance requirements, a double-layer stacked insulation component is adopted as the insulation solution for the muffler 10.

[0078] According to some embodiments of this disclosure, referring to Figures 9 and 10, the thickness of the glass fiber layer 2300 is greater than the thickness of the aerogel layer 2200. Since the aerogel layer 2200 is expensive, maximizing the thickness of the glass fiber layer 2300 minimizes the thickness of the aerogel layer 2200, thereby minimizing the manufacturing cost of the muffler 10 while ensuring thermal insulation performance.

[0079] For example, as shown in Figure 10, d1 represents the thickness of the glass fiber layer 2300 and d2 represents the thickness of the aerogel layer 2200. It can be seen from the figure that the thickness of the glass fiber layer 2300 is greater than the thickness of the aerogel layer 2200.

[0080] According to some embodiments of this disclosure, referring to Figures 9 and 10, the ratio of the thickness of the glass fiber layer 2300 to the thickness of the aerogel layer 2200 is greater than 1 and less than or equal to 3. Therefore, the manufacturing cost of the muffler 10 can be minimized while ensuring thermal insulation performance.

[0081] For example, as shown in Figures 9 and 10, the thickness ratio of the glass fiber layer 2300 to the aerogel layer 2200 can be 3:1, 3:2, or 3:3. In some embodiments, the thickness ratio of the glass fiber layer 2300 to the aerogel layer 2200 is 3:2.

[0082] According to some embodiments of this disclosure, referring to Figures 3, 9, and 10, the thickness of the first heat insulation member 200 is greater than or equal to 12 mm and less than or equal to 15 mm. This effectively ensures the heat absorption effect of the first heat insulation member 200, thereby protecting the structure surrounding the muffler 10. For example, the thickness of the first heat insulation member 200 can be 12 mm, 13 mm, 14 mm, or 15 mm.

[0083] In some embodiments, as shown in Figures 3, 9, and 10, the design thickness of the first thermal insulation component 200 is required to be 15 mm. According to experimental measurements, maintaining a total thickness of 15 mm for the first thermal insulation component 200, when the glass fiber layer 2300 replaces the aerogel layer 2200 with a thickness of 5 mm or less, the increase in heat dissipation in the front compartment of the vehicle 600 is less than 3%; when the glass fiber layer 2300 replaces the aerogel layer 2200 with a thickness of 2.5 mm or less, the increase in heat dissipation in the front compartment of the vehicle 600 is less than 1%. Therefore, to reduce costs while ensuring the thermal insulation performance requirements are met, the thickness ratio of the two materials in the double-layer thermal insulation component is 9 mm for glass fiber and 9 mm for aerogel, with a thickness ratio of 3:2. At this thickness ratio, the thermal insulation performance of the 15 mm double-layer first thermal insulation component 200 is similar to that of a 12 mm single-layer aerogel, but the production cost is significantly reduced. The exhaust gas temperature of engine 2000 is usually above 600℃. Based on the material properties of aerogel layer 2200 and glass fiber layer 2300, as shown in Figure 10, glass fiber layer 2300 is arranged on the side close to muffler housing 11, and aerogel is arranged on the side of second heat insulation component 400. This arrangement can give full play to the heat insulation performance of the two materials at different temperatures, which is beneficial to reducing the surface temperature of muffler 10.

[0084] According to some embodiments of this disclosure, referring to Figures 3 and 9, the muffler 10 further includes: a second heat insulation member 400, which defines a cavity. The muffler housing 11 and the first heat insulation member 200 are both disposed in the cavity. The second heat insulation member 400 is fixed to at least one of the muffler housing 11 and the first heat insulation member 200. That is, the second heat insulation member 400 can be fixed to the muffler housing 11, or it can be fixed to the first heat insulation member 200, or it can be fixed to both the muffler housing 11 and the first heat insulation member 200.

[0085] In this way, the second heat insulation component 400 can protect the first heat insulation component 200 and the muffler shell 11 within the cavity, thereby preventing the first heat insulation component 200 and the muffler shell 11 from contacting other structures and being damaged. At the same time, the second heat insulation component 400 can absorb the residual heat that the first heat insulation component 200 has not fully absorbed, thereby ensuring the heat absorption effect of the muffler 10 and effectively protecting the components around the muffler 10.

[0086] For example, as shown in Figures 3 and 9, the second heat insulation member 400 defines a cavity inside. When the first heat insulation member 200 is located inside the muffler housing 11, the second heat insulation member 400 is fixed to the muffler housing 11. When the first heat insulation member 200 covers the outer surface of the muffler housing 11, the second heat insulation member 400 can be fixed separately to the first heat insulation member 200, or it can be fixed to both the first heat insulation member 200 and the muffler housing 11. In some embodiments, the second heat insulation member 400 is a metal part. Metal materials have excellent high-temperature resistance and can withstand the high temperatures generated by the engine 2000 and the exhaust system. Therefore, the second heat insulation member 400 can effectively prevent heat from being transferred to other critical components, such as wires and plastic parts.

[0087] According to some embodiments of this disclosure, referring to Figures 3 and 9, the first heat insulation member 200 is disposed between the muffler housing 11 and the second heat insulation member 400. Therefore, the first heat insulation member 200 is positioned appropriately, ensuring that the muffler housing 11 can effectively reduce noise from the exhaust gas emitted by the engine 2000, while also preventing contact with the outside environment, thus ensuring the service life of the second heat insulation member 400.

[0088] In some embodiments, as shown in Figures 3 and 9, an inorganic adhesive is provided between the first heat insulation member 200 and the second heat insulation member 400, and the first heat insulation member 200 is bonded to the inner surface of the second heat insulation member 400 by the inorganic adhesive.

[0089] According to some embodiments of this disclosure, referring to Figures 3, 4, and 9, the first heat insulation member 200 is provided with a first through hole 2100, and the second heat insulation member 400 is provided with a second through hole 4100; the fixing member 300 includes a first fixing part 3100 and a second fixing part 3200. The first fixing part 3100 is fixed to the muffler housing 11, and the second fixing part 3200 passes through the first through hole 2100 and the second through hole 4100 and is fixed to the first fixing part 3100. Thus, the fixing member 300 can pass through the first through hole 2100 and the second through hole 4100 sequentially from the outside to the inside to fix the first heat insulation member 200 in the cavity. This installation method is simple and convenient to operate, thereby improving the assembly efficiency of the muffler 10.

[0090] For example, as shown in Figures 3, 4 and 9, the second through hole 4100 corresponds to the first through hole 2100 in the front-back direction. The second through hole 4100 passes through the second heat insulation member 400 in the front-back direction. The second fixing part 3200 passes through the second through hole 4100 and the first through hole 2100 in sequence and is screwed to the first fixing part 3100.

[0091] According to some embodiments of this disclosure, referring to Figures 3, 4 to 6 and 9, a second groove 4200 is formed on the side of the second heat insulation member 400 opposite to the muffler housing 11, and a second through hole 4100 penetrates the bottom wall of the second groove 4200. Thus, the second groove 4200 provides a location for the second through hole 4100, facilitating its arrangement. Simultaneously, the second groove 4200 can limit the heat insulation member in the vertical direction, preventing deformation and detachment.

[0092] For example, as shown in Figures 3, 4 and 9, the second heat insulation component 400 is provided with a second groove 4200, which is recessed toward the muffler housing 11. The second through hole 4100 penetrates the second recess in the front-back direction, and the second recess corresponds to the first recess in the front-back direction.

[0093] According to some embodiments of this disclosure, referring to Figures 3, 4, and 9, one of the second heat insulation member 400 and the muffler housing 11 is provided with a snap fastener, and the other is provided with a snap hole. That is, the second heat insulation member 400 can have a snap fastener and the muffler housing 11 can have a snap hole, or the muffler housing 11 can have a snap fastener and the second heat insulation member 400 can have a snap hole, with the snap fastener and snap hole engaging. Therefore, this connection method is simple and convenient to operate, thereby effectively improving the assembly efficiency of the muffler 10.

[0094] According to some embodiments of this disclosure, referring to Figures 3 and 9, the first heat insulation member 200 includes a front heat insulation portion 201, a rear heat insulation portion 202, and a lower heat insulation portion 203. The front heat insulation portion 201 covers the front side of the muffler housing 11 (as shown in Figure 9), the rear heat insulation portion 202 covers the rear side of the muffler housing 11 (as shown in Figure 9), and the lower heat insulation portion 203 covers the bottom of the muffler housing 11 (as shown in Figure 9). The front heat insulation portion 201, the rear heat insulation portion 202, and the lower heat insulation portion 203 are spliced ​​together. At least one of the front heat insulation portion 201 and the rear heat insulation portion 202 is fixed to the muffler housing 11 or the second heat insulation member 400 by a fastener 300.

[0095] In this way, the front heat insulation part 201, the rear heat insulation part 202 and the lower heat insulation part 203 are spliced ​​together to form the first heat insulation component 200, which can not only cover the muffler shell 11 as a whole, but also facilitate the installation of the heat insulation component on the muffler shell 11, reduce the installation difficulty, and thus effectively improve the manufacturing efficiency of the muffler 10.

[0096] For example, as shown in Figures 3 and 9, the front heat insulation part 201 covers the front side of the muffler housing 11, the rear heat insulation part 202 covers the rear side of the muffler housing 11, and the lower heat insulation part 203 covers the bottom of the muffler housing 11. The front heat insulation part 201, the rear heat insulation part 202 and the lower heat insulation part 203 are spliced ​​together. The front heat insulation part and the rear heat insulation part are both fixed to the muffler housing 11 and the second heat insulation part 400 by the fastener 300.

[0097] According to some embodiments of the present disclosure, referring to Figures 3, 7 to 9, the second heat insulation member 400 includes a front cover 401, a rear cover 402 and a bottom cover 403. The front cover 401 and the rear cover 402 are joined in the front-rear direction (as shown in the front-rear direction in Figure 9) and cooperate to define a cavity with an open bottom. The bottom cover 403 covers the open bottom side of the cavity.

[0098] In this way, the front cover 401, the rear cover 402 and the bottom cover 403 are spliced ​​together to form the second heat insulation component 400, which can not only cover the first heat insulation component 200 one by one, but also facilitate the installation of the second heat insulation component 400 on the muffler shell 11, reduce the installation difficulty, and thus effectively improve the assembly efficiency of the muffler 10.

[0099] For example, as shown in Figures 3 and 9, the front cover 401 is located on the front side of the front heat insulation part 201, the rear cover 402 is located on the rear side of the rear heat insulation part 202, and the bottom cover 403 is located on the lower side of the lower heat insulation part 203. The front cover 401 and the rear cover 402 are joined in the front-rear direction and cooperate to define a cavity with an open bottom. The bottom cover 403 covers the open bottom side of the cavity, and the heat insulation element is located inside the cavity. In some embodiments, the front cover 401, the rear cover 402, and the bottom cover 403 are all formed by stamping from a stainless steel plate with a thickness of 0.3 mm, thereby ensuring the strength of the second heat insulation element 400.

[0100] According to some embodiments of this disclosure, referring to Figures 3 and 9, the muffler housing 11 includes a front housing portion 101 and a rear housing portion 102. The front housing portion 101 and the rear housing portion 102 are joined in the front-rear direction (as shown in Figure 9) and cooperate to define a silencing cavity. This facilitates the assembly of the muffler housing 11. In some embodiments, both the front housing portion 101 and the rear housing portion 102 are formed by stamping from a 1.2mm thick stainless steel plate, thereby ensuring the structural strength of the muffler housing 11.

[0101] In some embodiments, as shown in FIG2, the front surface of the front cover 401 is a plane, which can reduce the space occupied by the muffler 10 in the front compartment of the vehicle 600, thereby facilitating the installation of the muffler 10 in conjunction with the structure of the front compartment.

[0102] In some embodiments, as shown in Figure 2, the muffler 10 is larger than other traditional mufflers, with a length of about 500 mm, a width of about 390 mm, and an internal volume of about 30 L. Above the muffler 10 is an exhaust gas recirculation (EGR) 3000. The entire pipeline is less affected by heat damage, but the motor of the nearby EGR 3000 is more severely affected by heat. Therefore, double-layer insulation is used to ensure the insulation effect of the muffler 10.

[0103] Some embodiments of this disclosure also provide an exhaust device 100. Referring to Figures 1, 2 and 3, the exhaust device 100 includes a catalyst 30 and the above-described muffler 10, with the muffler 10 connected to the catalyst 30.

[0104] For example, as shown in Figures 1, 2 and 3, the muffler 10 has an air inlet, and the catalyst 30 is located on the upper right side of the muffler 10. The catalyst 30 is connected to the air inlet of the muffler 10, so that the exhaust gas of the engine 2000 will enter the muffler 10 after passing through the catalytic action of the catalyst 30, thereby ensuring that the exhaust gas can meet the emission standards. The thickness of the glass fiber layer 2300 is 9mm, and the thickness of the aerogel layer 2200 is 6mm. Therefore, the total thickness of the first heat insulation component 200 is 15mm.

[0105] In some embodiments, as shown in FIG1, the exhaust device 100 is developed and designed based on a 2.0T engine 2000 assembly, with an exhaust temperature of approximately 800°C. For other displacement engines 2000, the exhaust temperature of the 2.0T engine 2000 is slightly higher, but still meets the operating temperature range of the heat insulation component composed of the aerogel layer 2200 and the glass fiber layer 2300. The exhaust temperature of the 1.5L engine 2000 is relatively lower, but also meets the operating temperature range of the heat insulation component. Therefore, the heat insulation structure of the exhaust device 100 can adapt to the heat insulation performance requirements of various engine 2000 assemblies.

[0106] In some embodiments, as shown in FIG1, the heat insulation component of the exhaust device 100 meets the heat insulation performance requirements of the vehicle under various operating conditions, such as idling, low-speed climbing, high-speed climbing, and high-speed driving. Similarly, this double-layer heat insulation structure is suitable for traditional vehicle exhaust systems with the risk of high-temperature heat damage.

[0107] In some embodiments of this disclosure, the exhaust device 100, by providing the aforementioned muffler 10 and a fixing member 300, can fix the heat insulation member, thereby preventing heat from dissipating from the location where the heat insulation member has detached to the outside of the muffler 10, thus effectively protecting the components around the muffler 10. At the same time, the catalyst 30 is connected to the muffler 10, which can improve the functional integration of the exhaust device 100, thereby reducing the size of the exhaust device 100 and its space occupation.

[0108] Some embodiments of this disclosure also provide a vehicle 600. Referring to Figures 1, 2 and 3, the vehicle 600 includes an engine 2000 and the exhaust device 100 described above. The engine 2000 has an exhaust port. The exhaust device 100 is in communication with the exhaust port, and a muffler 10 is arranged on the front side of the engine 2000 (as shown in Figure 1).

[0109] For example, as shown in Figures 1, 2 and 3, the engine 2000 has an exhaust port, and the catalytic converter 30 is connected to the exhaust port, so that the exhaust gas of the engine 2000 enters the muffler 10 after being catalyzed by the catalytic converter 30.

[0110] According to an embodiment of the present disclosure, a vehicle 600 is provided with an exhaust device 100, a muffler 10 is provided on the exhaust device 100, and a fixing member 300 is provided. The fixing member 300 can fix the heat insulation member, thereby preventing heat from dissipating from the location where the heat insulation member falls off to the outside of the muffler 10, thus effectively protecting the components around the muffler 10. At the same time, the catalyst 30 is connected to the muffler 10, which can improve the functional integration of the exhaust device 100, thereby reducing the size of the exhaust device 100 and reducing the space occupied by the exhaust device 100.

[0111] In related technologies, exhaust systems with mufflers and catalytic converters are typically used to reduce engine exhaust noise and the environmental impact of exhaust gases. However, in these systems, the exhaust sensor mounted on the catalytic converter is poorly positioned, making installation and maintenance inconvenient. Therefore, improvements are needed.

[0112] The exhaust device 100 and engine assembly 1000 according to some embodiments of the present disclosure are described below with reference to the accompanying drawings.

[0113] Referring to Figures 14, 19, 24 and 30, some embodiments of this disclosure provide an exhaust device 100, which includes a muffler 10, a catalytic converter 30 and at least one exhaust sensor 40.

[0114] The muffler 10 includes a muffler housing 11, which has a muffler cavity 110 and a muffler outlet 111 communicating with the muffler cavity 110. Gases exhausted from the engine 2000 enter the muffler cavity 110 of the muffler 10, reducing exhaust noise. The catalytic converter 30 includes a catalytic converter housing 31, which has a catalytic converter cavity 310 communicating with the muffler cavity 110. A catalyst can be placed in the catalytic converter cavity 310, which can catalytically decompose harmful substances in the exhaust gases of the engine 2000, purifying the exhaust gases and reducing environmental pollution.

[0115] For example, the catalyst housing 31 has a catalyst inlet 311 and a catalyst outlet 33, and the catalyst chamber 310 connects the catalyst inlet 311 and the catalyst outlet 33. The catalyst inlet 311 is used to connect to the exhaust port 2010 of the engine 2000. The gas discharged from the engine 2000 can enter the catalyst chamber 310 of the catalyst 30 from the exhaust port 2010 and the catalyst inlet 311.

[0116] For example, the catalytic converter 310 can be connected to the muffler 110 through the catalytic outlet 33. The gas discharged from the engine 2000 can be purified by the catalytic converter 30 and then discharged into the muffler 110 through the catalytic outlet 33. After noise reduction treatment in the muffler 110, it can be discharged through the muffler outlet 111.

[0117] The catalytic converter 30 is connected to the muffler 10. The projection of the catalytic converter 30 along a first direction at least partially coincides with the projection of the muffler 10 along the first direction. The first direction can be the Z-direction of the vehicle, for example, the up-down direction as shown in the attached figures. For example, the projection of the catalytic converter 30 along the first direction partially coincides with the projection of the muffler 10 along the first direction; for example, the projection of the catalytic converter 30 along the first direction completely coincides with the projection of the muffler 10 along the first direction. The partial coincidence of the projection of the catalytic converter 30 along the first direction and the projection of the muffler 10 along the first direction can also include the following situations: for example, the projection of the catalytic converter 30 along the first direction is completely located within the projection of the muffler 10 along the first direction; or, for another example, the projection of the catalytic converter 30 along the first direction is partially located within the projection of the muffler 10 along the first direction, and the projection of the catalytic converter 30 along the first direction is partially located outside the projection of the muffler 10 along the first direction.

[0118] By making the projection of the catalytic converter 30 along the first direction at least partially coincide with the projection of the muffler 10 along the first direction, the catalytic converter 30 and the muffler 10 can be arranged in a compact manner, making the overall structure of the exhaust device 100 compact and helping to reduce the space occupied by the exhaust device 100.

[0119] There is at least one exhaust sensor 40, for example, there can be one exhaust sensor 40 or multiple exhaust sensors 40. The exhaust sensor 40 is installed on the outer wall of the catalytic converter 30. The exhaust sensor 40 is used to detect the gas discharged from the engine 2000. The engine 2000 can be controlled to work better based on the detection results of the exhaust sensor 40, and harmful gaseous substances in the exhaust gas of the engine 2000 can be reduced, thus reducing environmental pollution.

[0120] At least a portion of the exhaust sensor 40 is located outside the muffler 10. For example, the main body of the exhaust sensor 40 may be located outside the muffler 10, or the entire exhaust sensor 40 may be located outside the muffler 10. By placing the exhaust sensor 40 outside the muffler 10, the exhaust sensor 40 does not occupy space inside the muffler 10, and its installation is convenient, avoiding installation limitations imposed by the internal space of the muffler 10. Furthermore, when maintaining the exhaust sensor 40, since it is installed on the outer wall of the catalytic converter 30 and located outside the muffler 10, maintenance of the muffler 10 is convenient. Compared to placing the exhaust sensor 40 inside the muffler 10, it is not necessary to remove the muffler housing 11 before maintaining the exhaust sensor 40.

[0121] According to the exhaust device 100 of the present disclosure, the exhaust of the engine 2000 can be reduced in noise and purified by the provided muffler 10 and catalyst 30. By making the projection of the catalyst 30 along the first direction at least partially coincide with the projection of the muffler 10 along the first direction, the overall structure of the exhaust device 100 can be made compact, reducing the space occupied. Furthermore, by setting at least a part of the exhaust sensor 40 outside the muffler 10, the installation and maintenance of the exhaust sensor 40 are facilitated.

[0122] According to some embodiments of this disclosure, referring to Figures 14-16, 20-21, 25-26, and 31-33, a mounting boss 34 is provided on the outer wall of the catalytic converter 30, and a mounting boss 34 is also provided on the outer wall of the catalytic converter housing 31. An exhaust sensor 40 is connected to the mounting boss 34, and the mounting boss 34 has a communicating channel 341 that communicates with the catalytic converter chamber 310. By providing the mounting boss 34 on the outer wall of the catalytic converter 30, it is convenient for the exhaust sensor 40 to be mounted and fixed to the catalytic converter 30 via the mounting boss 34.

[0123] During the operation of engine 2000, the exhaust gas enters the catalytic chamber 310 of catalytic converter 30. A small amount of gas entering the catalytic chamber 310 can flow into the connecting channel 341 of mounting boss 34. Since exhaust sensor 40 is connected to mounting boss 34, exhaust sensor 40 can contact the gas in connecting channel 341, thereby detecting the gas discharged from engine 2000 into catalytic chamber 310.

[0124] The mounting boss 34 can be integrally formed with the catalyst housing 31; or, the mounting boss 34 can be welded to the catalyst housing 31.

[0125] According to some embodiments of this disclosure, the exhaust sensor 40 is detachably connected to the mounting boss 34. This detachable connection facilitates the maintenance and replacement of the exhaust sensor 40.

[0126] According to some embodiments of this disclosure, the exhaust sensor 40 is threadedly connected to the mounting boss 34. By making the exhaust sensor 40 threadedly connected to the mounting boss 34, the exhaust sensor 40 and the mounting boss 34 can be detachably connected, while also ensuring a stable and reliable connection between the exhaust sensor 40 and the mounting boss 34.

[0127] According to some embodiments of this disclosure, referring to FIG33, the protrusion height h of the mounting boss 34 relative to the outer wall of the catalyst 30 is 10.5mm to 16mm. For example, the protrusion height h of the mounting boss 34 relative to the catalyst 30 can be 10.5mm, 11mm, 11.5mm, 12mm, 12.5mm, 13mm, 13.5mm, 14mm, 14.5mm, 15mm, 15.5mm, 16mm, etc.

[0128] By setting the protrusion height h of the mounting boss 34 relative to the catalytic converter 30 to be no less than 10.5 mm, the connection length between the exhaust sensor 40 and the mounting boss 34 can meet the requirements, thus ensuring the stability and reliability of the connection between the exhaust sensor 40 and the mounting boss 34. By setting the protrusion height h of the mounting boss 34 relative to the catalytic converter 30 to be no more than 16 mm, the problem of inaccurate detection caused by a large distance between the exhaust sensor 40 and the catalytic chamber 310 can be reduced or avoided, thus making the detection results of the exhaust sensor 40 more accurate.

[0129] According to some embodiments of this disclosure, referring to FIG33, the connecting channel 341 extends downwardly in the direction from the end of the mounting boss 34 away from the catalytic chamber 310 to the catalytic chamber 310. By making the connecting channel 341 in the mounting boss 34 extend downwardly in the direction adjacent to the catalytic chamber 310, the condensate formed by the condensation of gas entering the connecting channel 341 flows downward along the connecting channel 341 into the catalytic chamber 310 under its own gravity, reducing or avoiding the retention of condensate in the connecting channel 341 and affecting the accuracy of the detection results of the exhaust sensor 40.

[0130] According to some embodiments of this disclosure, referring to FIG3, the angle α between the central axis of the connecting channel 341 and the horizontal plane is not less than 15°. By making the connecting channel 341 in the mounting boss 34 extend downward in the direction adjacent to the catalytic chamber 310, and at the same time making the angle α between the central axis of the connecting channel 341 and the horizontal plane not less than 15°, the condensate formed in the connecting channel 341 can flow more smoothly into the catalytic chamber 310 under its own gravity, and the condensate in the connecting channel 341 can be better reduced.

[0131] According to some embodiments of this disclosure, referring to Figures 15-16, 20-21, 25-26, and 31-33, there are multiple exhaust sensors 40, including at least one of a pressure sensor, an oxygen sensor 43, and an EGR sensor. The pressure sensor can be used to detect exhaust pressure, which helps the engine 2000 achieve more precise fuel injection and ignition control, thereby improving the engine 2000's performance and fuel economy, and reducing exhaust emissions. The oxygen sensor 43 monitors the oxygen content in the exhaust and sends a feedback signal to the electronic control unit (ECU) to help adjust the fuel injection quantity, ensuring the air-fuel ratio is maintained at an ideal state, thereby optimizing the air-fuel ratio, improving fuel economy, and reducing harmful emissions. The EGR sensor provides the ECU with the position signal of the EGR valve, providing data support for the exhaust gas recirculation amount, ensuring efficient engine operation and reducing emissions.

[0132] By setting multiple exhaust sensors 40, including at least one of a pressure sensor, an oxygen sensor 43, and an EGR sensor, the exhaust of the engine 2000 can be better monitored, thereby improving the performance and fuel economy of the engine 2000 and reducing exhaust emissions.

[0133] According to some embodiments of this disclosure, referring to Figures 15-16, 20-21, 25-26, and 31-33, multiple exhaust sensors 40 include pressure sensors and oxygen sensors 43. There are two pressure sensors: a first pressure sensor 41 and a second pressure sensor 42. The catalytic converter 30 includes a first catalytic carrier 35 and a second catalytic carrier 36 connected sequentially along the airflow direction. The first pressure sensor 41 and the oxygen sensor 43 are both mounted on the first catalytic carrier 35, and the second pressure sensor 42 is mounted on the second catalytic carrier 36. Gas emitted from the engine 2000 enters the catalytic chamber 310 through the catalytic inlet 311 of the catalytic converter 30, first flowing through the first catalytic carrier 35 and then through the second catalytic carrier 36. During the flow of gas through both the first and second catalytic carriers, catalytic decomposition occurs, purifying the gas and reducing harmful substances in the exhaust gas.

[0134] By setting the catalyst 30 as a first catalyst carrier 35 and a second catalyst carrier 36 arranged sequentially along the airflow direction, and installing the first pressure sensor 41 and the oxygen sensor 43 on the first catalyst carrier 35, the exhaust pressure of the engine 2000 and the oxygen content in the exhaust can be monitored; and by setting the second pressure sensor 42 on the second catalyst carrier 36 located downstream, the pressure at that location can be detected to determine whether the exhaust flows smoothly in the catalytic chamber 310, for example, to determine whether there is a blockage problem caused by excessive carbon deposits.

[0135] According to some embodiments of this disclosure, the catalyst 30 is welded to the muffler 10, for example, the catalyst housing 31 is welded to the muffler housing 11. By welding the catalyst 30 to the muffler 10, it is convenient to install the catalyst 30 onto the muffler 10, and the installation is stable and reliable.

[0136] According to some embodiments of this disclosure, referring to Figures 13-15, 18-19, 23-25, and 29-31, the exhaust device 100 includes a fixing bracket 50. The fixing bracket 50 is disposed on the muffler and located outside the catalytic converter 30. For example, the fixing bracket 50 is disposed on the muffler housing 11, and the fixing bracket 50 is used to support and fix the catalytic converter 30. By providing the fixing bracket 50 on the muffler 10 to support and fix the catalytic converter 30, the stability of the catalytic converter 30 installation can be improved.

[0137] According to some embodiments of the present disclosure, referring to Figures 27 and 33, the silencer 10 includes a silencer structure 20 disposed in a silencer cavity 110. The silencer structure 20 includes a plurality of partitions 210 and a plurality of silencer pipes 22. The plurality of partitions 210 are disposed in the silencer cavity 110 to divide the silencer cavity 110 into a plurality of silencer chambers 21. The plurality of silencer pipes 22 are used to connect different silencer chambers 21. By setting the silencing structure 20 inside the silencing cavity 110 to include multiple baffles 210 and multiple silencing pipes 22, the silencing cavity 110 is divided into multiple silencing chambers 21 by the multiple baffles 210 and the multiple silencing pipes 22 are used to connect different silencing chambers 21. After the gas is catalyzed and decomposed by the catalyst 30, it enters the silencing cavity 110 and flows through multiple silencing chambers 21 and multiple silencing pipes 22. Since the flow area of ​​the silencing chamber 21 is much larger than that of the silencing pipe 22, the flow area changes multiple times during the flow of the air in the silencing cavity 110, realizing multiple expansion of the airflow, which can achieve a good noise reduction effect.

[0138] For example, multiple partitions 210 installed inside the anechoic cavity 110 can be arranged sequentially and spaced apart in the vertical direction, thereby dividing the anechoic cavity 110 into multiple anechoic chambers 21 in the vertical direction.

[0139] According to some embodiments of this disclosure, referring to FIG33, a plurality of anechoic chambers 21 include a first anechoic chamber 211, a second anechoic chamber 212, a third anechoic chamber 213, and a fourth anechoic chamber 214, which can be arranged sequentially from top to bottom. A plurality of anechoic pipes 22 include a first anechoic pipe 221, a second anechoic pipe 222, a third anechoic pipe 223, a fourth anechoic pipe 224, and a fifth anechoic pipe 225. The first anechoic pipe 221 has a first anechoic channel and is connected to the catalytic outlet 33. For example, the first anechoic pipe 221 and the catalytic outlet 33 can be connected by a connecting pipe 23, which can be U-shaped. Catalytic outlet 33 connects catalytic chamber 310 and the first silencing channel. The first silencing channel connects the second silencing chamber 212 and catalytic outlet 33, and also connects the fourth silencing chamber 214 and catalytic outlet 33. The second silencing pipe 222 has a second silencing channel, which connects the second silencing chamber 212 and the first silencing chamber 211. The third silencing pipe 223 has a third silencing channel, which connects the fourth silencing chamber 214 and the first silencing chamber 211. The fourth silencing pipe 224 has a fourth silencing channel, which connects the first silencing chamber 211 and the third silencing chamber 213. The fifth silencing pipe 225 has a fifth silencing channel, which connects the third silencing chamber 213 and the silencing outlet 111.

[0140] During the process of the gas entering the silencing chamber 110 after being catalytically decomposed by the catalyst 30, the gas first flows into the larger second silencing chamber 212 and the fourth silencing chamber 214 through the first silencing channel. The gas flowing into the second silencing chamber 212 flows into the first silencing chamber 211 through the second silencing channel. The gas flowing into the fourth silencing chamber 214 flows into the first silencing chamber 211 through the third silencing channel. The gas flowing into the first silencing chamber 211 flows into the third silencing chamber 213 through the fourth silencing channel. The gas flowing into the third silencing chamber 213 is discharged through the fifth silencing channel and the silencing outlet 111, thus achieving noise reduction of the airflow.

[0141] For example, a tailpipe 112 can be connected to the silencer outlet 111, and the airflow after being reduced by the silencer 10 can be discharged through the tailpipe 112.

[0142] The first silencer 221, the second silencer 222, the third silencer 223, and the fourth silencer 224 can all be straight pipes, which can extend vertically. The fifth silencer 225 can be composed of a U-shaped pipe and a straight pipe.

[0143] According to some embodiments of this disclosure, referring to FIG33, the plurality of anechoic chambers 21 further includes a fifth anechoic chamber 215. For example, the first anechoic chamber 211, the second anechoic chamber 212, the third anechoic chamber 213, the fourth anechoic chamber 214, and the fifth anechoic chamber 215 can be arranged sequentially from top to bottom. The plurality of mufflers 22 further includes a sixth muffler 226, which has a sixth muffler channel connecting the third anechoic chamber 213 and the fifth anechoic chamber 215. A portion of the gas flowing into the third anechoic chamber 213 can flow into the fifth anechoic chamber 215 through the sixth muffler channel. The noise-reduced airflow flowing into the fifth anechoic chamber 215 then flows back to the third anechoic chamber 213 through the sixth muffler channel. The fifth anechoic chamber 215, as a broadband anechoic chamber 21, can reduce the high-frequency noise generated by the rapid vibration of the engine 2000.

[0144] The sixth silencer 226 can be a straight pipe that can extend vertically.

[0145] According to some embodiments of this disclosure, referring to Figures 12-21, the catalyst 30 is entirely located outside the muffler 10, for example, the catalyst 30 is entirely located outside the muffler housing 11. By placing the catalyst 30 entirely outside the muffler 10, the installation of the exhaust sensor 40 can be made more convenient. For example, the exhaust sensor 40 does not need to pass through the muffler 10, and there is no need to provide a clearance hole 114 on the muffler 10 to avoid the exhaust sensor 40.

[0146] For example, when the exhaust device 100 includes the aforementioned fixed bracket 50, the fixed bracket 50 is disposed outside the muffler 10 and connected to the muffler 10. For example, the fixed bracket 50 is disposed outside the muffler housing 11 and connected to the muffler housing 11.

[0147] According to some embodiments of this disclosure, referring to Figures 12-21, a clearance space 113 is formed on the exterior of the muffler 10. For example, a clearance space 113 is formed on the exterior of the muffler housing 11, and at least a portion of the catalytic converter 30 is accommodated within the clearance space 113. By forming a clearance space 113 on the exterior of the muffler 10 and accommodating at least a portion of the catalytic converter within the clearance space 113, the overall structure of the exhaust device 100 can be made compact, reducing space occupation.

[0148] According to some embodiments of this disclosure, referring to Figures 12-16, at least a portion of the catalyst 30 is positioned laterally. By positioning at least a portion of the catalyst 30 laterally, the upper space of the muffler 10 can be utilized, resulting in a compact structure.

[0149] According to some embodiments of this disclosure, referring to Figures 12-16, the catalyst 30 includes a first catalyst support 35 and a second catalyst support 36 connected sequentially along the flow direction of the gas flow. The first catalyst support 35 and the second catalyst support 36 are arranged vertically, and both are placed horizontally. By arranging the first catalyst support 35 and the second catalyst support 36 of the catalyst 30 vertically and placing both horizontally, the upper space of the muffler 10 can be fully utilized, resulting in a compact structure.

[0150] According to some embodiments of this disclosure, referring to Figures 17-21, at least a portion of the catalyst 30 is positioned vertically. By positioning at least a portion of the catalyst 30 vertically, the side space of the muffler 10 can be utilized, resulting in a compact structure.

[0151] According to some embodiments of this disclosure, referring to Figures 22-27, a portion of the catalyst 30 is located inside the muffler 10, and a portion of the catalyst 30 is located outside the muffler 10. For example, a portion of the catalyst 30 is located inside the muffler housing 11, and a portion of the catalyst 30 is located outside the muffler housing 11. By placing a portion of the catalyst 30 inside the muffler 10, the space inside the muffler 10 can be utilized, and by placing a portion of the catalyst 30 outside the muffler 10, the space outside the muffler 10 can be utilized, resulting in a compact overall structure.

[0152] According to some embodiments of this disclosure, referring to Figures 22-27, the catalyst 30 includes a first catalyst carrier 35 and a second catalyst carrier 36 connected sequentially along the flow direction of the gas flow. The first catalyst carrier 35 is located outside the muffler 10, for example, outside the muffler housing 11, and the second catalyst carrier 36 is located inside the muffler 10, for example, inside the muffler housing 11. A plurality of exhaust sensors include a first portion and a second portion. The first portion of the plurality of exhaust sensors 40 is mounted on the first catalyst carrier 35, and a portion of the plurality of exhaust sensors 40 is mounted on the second catalyst carrier 36. The muffler 10 is provided with a clearance hole 114 for avoiding the exhaust sensors 40, for example, the muffler housing 11 is provided with a clearance hole 114 for avoiding the exhaust sensors 40. Since the first catalytic carrier 35 is located outside the muffler 10, the exhaust sensor 40 installed on the first catalytic carrier 35 is convenient and does not require a corresponding clearance hole 114 on the muffler 10; since the second catalytic carrier 36 is located inside the muffler 10, the exhaust sensor 40 installed on the second catalytic carrier 36 needs a corresponding clearance hole 114 on the muffler 10 to facilitate the installation of the exhaust sensor 40 installed on the second catalytic carrier 36.

[0153] For example, when the exhaust device 100 includes the aforementioned fixed bracket 50, the fixed bracket 50 can be disposed inside the muffler housing 11 and connected to the muffler housing 11.

[0154] According to some embodiments of this disclosure, referring to Figures 28-33, the catalyst 30 is entirely located within the muffler 10, and the muffler 10 is provided with a clearance hole 114 for avoiding the exhaust sensor 40. For example, the catalyst 30 is entirely located within the muffler housing 11, and the muffler housing 11 is provided with a clearance hole 114 for avoiding the exhaust sensor 40. The fact that the catalyst 30 is entirely located within the muffler 10 allows for a compact overall structure, and the clearance hole 114 on the muffler 10 facilitates the installation of the exhaust sensor 40.

[0155] For example, when the exhaust device 100 includes the aforementioned fixed bracket 50, the fixed bracket 50 can be disposed inside the muffler housing 11 and connected to the muffler housing 11.

[0156] Referring to Figures 12-14, 17-19, 22-24, and 28-30, some embodiments of this disclosure also provide an engine assembly 1000, which includes an engine 2000 and the aforementioned exhaust device 100 for the engine 2000. The exhaust device 100 is integrated on the engine 2000, and the catalytic inlet 311 of the catalytic converter 30 is connected to the exhaust port 2010 of the engine 2000.

[0157] For example, the engine 2000 is located in the front engine compartment of the vehicle body. By integrating the exhaust system 100 into the engine 2000, the space in the front engine compartment can be fully utilized.

[0158] In some embodiments of this disclosure, the engine assembly 1000, by providing the aforementioned exhaust device 100, can perform noise reduction and catalytic purification treatment on the exhaust of the engine 2000, and makes the installation and maintenance of the exhaust sensor 40 more convenient. In addition, by integrating the exhaust device 100, which has a muffler 10 and a catalytic converter 30, onto the engine 2000, it is convenient to install the engine 2000 and the exhaust device 100 as a whole onto the vehicle body. This facilitates installation, makes the structure compact, reduces the space occupied by the vehicle body, and is beneficial to the layout of other components inside the vehicle body.

[0159] In some embodiments of this disclosure, referring to Figures 12-14, 17-19, 22-24, and 28-30, a first connecting flange 32 is provided at the catalytic inlet 311, and a second connecting flange 2020 is provided at the exhaust port 2010. The first connecting flange 32 and the second connecting flange 2020 are connected, for example, by fasteners. By providing the first connecting flange 32 at the catalytic inlet 311 of the catalytic converter 30 and the second connecting flange 2020 at the exhaust port 2010 of the engine 2000, it is convenient to connect the exhaust port 2010 of the engine 2000 to the catalytic inlet 311.

[0160] Referring to Figures 12-13, 17-18, 22-23, and 28-29, in some embodiments of this disclosure, the exhaust device 100 is installed on the front side of the engine 2000. By arranging the exhaust device 100 on the front side of the engine 2000, the space on the front side of the engine 2000 can be fully utilized, thereby improving the space utilization rate within the vehicle body.

[0161] Some embodiments of this disclosure also provide a vehicle, the vehicle including: an engine assembly, which may be the engine assembly 1000 described above.

[0162] In some embodiments of the present disclosure, the vehicle, by setting the engine assembly 1000 described above, can perform noise reduction and catalytic purification treatment on the exhaust of the engine 2000, and makes the installation and maintenance of the exhaust sensor 40 more convenient. In addition, by integrating the exhaust device 100 with the muffler 10 and the catalytic converter 30 onto the engine 2000, it is convenient to install the engine 2000 and the exhaust device 100 as a whole onto the vehicle body. This makes installation convenient, the structure compact, and helps to reduce the space occupied by the vehicle body, which is beneficial to the layout of other components in the vehicle body.

[0163] In related technologies, the engine and drive motor of a range-extended powertrain are generally arranged front-to-rear or separately, resulting in low integration and a large space occupation, leading to low space utilization in the front compartment. For vehicles with limited front compartment space, the entire powertrain layout becomes difficult. Therefore, the low integration and unreasonable powertrain layout of range-extended powertrains in related technologies result in insufficient utilization of front compartment space.

[0164] Please refer to Figures 34 to 37. Some embodiments of this disclosure provide a powertrain 10000 for a vehicle 600. The powertrain 10000 includes an engine 2000, a drive assembly 2001, and an exhaust system 100. The engine 2000 and the drive assembly 2001 are connected, and the exhaust system 100 and the engine 2000 are housed in the same compartment.

[0165] In this embodiment, the powertrain 10000 is used in the vehicle 600. The powertrain 10000 includes an engine 2000, a drive assembly 2001, and an exhaust system 100. The engine 2000 and the drive assembly 2001 are connected, and the exhaust system 100 and the engine 2000 are housed in the same compartment. Thus, the engine 2000 and the drive assembly 2001 are arranged and fixedly connected together along the height direction of the vehicle 600, resulting in high integration and better space utilization.

[0166] This disclosure provides a powertrain 10000 for use in a vehicle 600. The powertrain 10000 includes an engine 2000 and a drive assembly 2001. The drive assembly 2001 is fixedly connected to the engine 2000. The engine 2000 and the drive assembly 2001 are distributed along the height direction of the vehicle 600. The projection of the engine 2000 in the height direction of the vehicle 600 is located inside the projection of the drive assembly 2001 in the height direction of the vehicle 600.

[0167] In this embodiment, the powertrain 10000 is used in a vehicle 600. The powertrain 10000 includes an engine 2000 and a drive assembly 2001. The drive assembly 2001 is fixedly connected to the engine 2000. The engine 2000 and the drive assembly 2001 are distributed along the height direction of the vehicle 600, and the projection of the engine 2000 in the height direction of the vehicle 600 is located inside the projection of the drive assembly 2001 in the height direction of the vehicle 600. Thus, the engine 2000 and the drive assembly 2001 are arranged and fixedly connected together along the height direction of the vehicle 600, resulting in high integration and better space utilization.

[0168] This disclosure also provides a vehicle 600, which includes a powertrain that can be a powertrain 10000 in some embodiments of this disclosure.

[0169] This disclosure does not limit the form of vehicle 600 to meet different needs. For example, vehicle 600 can be a pure electric vehicle, a hybrid electric vehicle, a plug-in hybrid electric vehicle, a range-extended electric vehicle, etc. Vehicle 600 can also be a sedan, truck, bus, lorry, trailer, etc. Powertrain 10000 can be applied to hybrid electric vehicles, range-extended electric vehicles, or pure electric vehicles. By adjusting the configuration of engine 2000 and drive assembly 2001, the power requirements of different vehicle types can be met. For example, in a range-extended electric vehicle, engine 2000 can be a horizontally opposed engine 1, and drive assembly 2001 can be a generator 3, both arranged along the height direction to form a highly efficient range-extending system. In this embodiment, vehicle 600 is described as a range-extended vehicle.

[0170] For example, the powertrain 10000 includes an engine 2000 and a drive assembly 2001, which are tightly connected to the engine 2000 by a fixed connection method (such as bolting, welding, or integral casting). The engine 2000 and the drive assembly 2001 are distributed along the height direction (i.e., the vertical direction) of the vehicle 600, and the projection of the engine 2000 in the height direction of the vehicle 600 is completely located within the projection of the drive assembly 2001 in the height direction of the vehicle 600. This arrangement allows the two drive assemblies to overlap in the vertical direction, thereby minimizing the space occupied by the powertrain 10000 in the longitudinal and lateral directions of the vehicle 600.

[0171] In some embodiments, the engine 2000 and drive assembly 2001 are distributed and fixedly connected along the height direction to form a compact integral structure. This not only reduces the number of parts but also lowers assembly complexity and improves the overall reliability of the powertrain 10000. By overlapping the projections of the two drive assemblies, the volume of the powertrain 10000 is optimized, making it particularly suitable for space-constrained front or rear compartment layouts in vehicles 600.

[0172] In some embodiments, since the engine 2000 and drive assembly 2001 are fixedly connected and distributed along the height direction, their vibrations and noises can cancel each other out, thereby improving the noise, vibration, and harshness (NVH) performance of the vehicle 600.

[0173] In some embodiments, the projection of the engine 2000 in the height direction of the vehicle 600 is located inside the projection of the drive assembly 2001 in the height direction of the vehicle 600.

[0174] In some embodiments, the drive assembly 2001 includes a drive motor 7, which is disposed on the side of the engine 2000 closer to the chassis of the vehicle 600.

[0175] In some embodiments, the powertrain 10000 further includes a generator 3, which is connected to the engine 2000 and positioned at the same horizontal level.

[0176] In some embodiments, the powertrain 10000 further includes a generator controller 4, which is connected to the generator 3 and positioned at the same horizontal level.

[0177] In some embodiments, the generator controller 4 is integrated inside the generator 3 or within the motor controller of the drive motor 7.

[0178] In some embodiments, the exhaust device 100 is connected to the engine 2000.

[0179] In some embodiments, the exhaust system 100 includes a three-way catalytic converter 13 and a muffler, the three-way catalytic converter 13 being disposed on the side of the engine 2000 away from the drive assembly 2001.

[0180] In some embodiments, the three-way catalytic converter 13 is disposed on the upper side of the engine 2000, and the muffler is disposed on the front or lower side of the engine 2000.

[0181] In some embodiments, the muffler further includes a first exhaust muffler 15 and a second exhaust muffler 16, which are disposed on the side of the engine 2000 away from the generator 3.

[0182] In some embodiments, the first exhaust muffler 15 occupies less space in the horizontal direction of the vehicle 600 than the second exhaust muffler 16 occupies less space in the horizontal direction of the vehicle 600.

[0183] In some embodiments, the muffler further includes a third exhaust muffler 19, which is disposed on the side of the drive assembly 2001 away from the second exhaust muffler 16.

[0184] In some embodiments, the third exhaust muffler 19 is fixed to the front body or front subframe of the vehicle 600.

[0185] In some embodiments, the exhaust gas discharged from the engine 2000 passes sequentially through the first exhaust muffler 15, the second exhaust muffler 16, and the third exhaust muffler 19.

[0186] In some embodiments, the exhaust device 100 further includes an exhaust pipe 18, which is integrated on the side of the drive motor 7 away from the engine 2000.

[0187] In some embodiments, the exhaust pipe 18 connects the second exhaust muffler 16 and the third exhaust muffler 19.

[0188] In some embodiments, the exhaust device 100 further includes a flexible pipe 17 integrated on the side of the drive motor 7 away from the engine 2000.

[0189] In some embodiments, the exhaust pipe 18 is connected to the second exhaust muffler 16 via a flexible pipe 17.

[0190] In some embodiments, there are two exhaust pipes 18, which are located on both sides of the drive assembly 2001.

[0191] In some embodiments, the exhaust system 100 further includes an air filter 9, which is integrated into the engine 2000.

[0192] In some embodiments, engine 2000 is horizontally opposed engine 1.

[0193] Thus, the cylinders of the horizontally opposed engine 1 are arranged horizontally opposite each other, and the pistons move in the horizontal direction. This results in a lower overall height for the engine 2000, with the cylinders on the left and right sides arranged symmetrically and the pistons moving in opposite directions. The engine 2000 is flat, low in height, and wide, providing sufficient space for the drive assembly 2001 and reducing the overall height of the powertrain 10000.

[0194] In related technologies, the engine and motor are arranged front and rear. However, due to limited space in the front compartment, this type of powertrain cannot be installed. This restricts the space in the entire front compartment, severely compressing the space for other components. The low integration of the powertrain and the unreasonable arrangement of the powertrain result in insufficient utilization of the front compartment space.

[0195] In this embodiment, the horizontally opposed engine 1 and drive motor 7 are integrated vertically, taking full advantage of the low height of the horizontally opposed engine 1, making it suitable for vehicles with limited front compartment space. Furthermore, the flat structure of the horizontally opposed engine 1 allows it to be mounted at a lower position on the vehicle 600, lowering the center of gravity of the vehicle 600 in conjunction with the drive assembly 2001. This significantly improves the handling stability and cornering performance of the vehicle 600, and reduces body roll during high-speed driving or sharp turns.

[0196] In some embodiments, the powertrain 10000 is arranged in the front compartment of the vehicle 600.

[0197] In some embodiments, the powertrain 10000 is mounted on the longitudinal or transverse beams of the vehicle 600.

[0198] Thus, the generator controller 4, generator 3, and engine 2000 are positioned at the same horizontal level, all above the drive motor 7, allowing for effective integration and improved space utilization.

[0199] For example, the drive assembly 2001 may include a drive motor 7, which is positioned on the side of the engine 2000 closer to the chassis of the vehicle 600. This arrangement makes full use of the space under the vehicle 600 while leaving more space above for other components (such as the battery pack or electronic control system). The close proximity of the drive motor 7 to the chassis also helps to lower the center of gravity of the vehicle 600, thereby improving the handling stability and driving safety of the vehicle 600. The engine 2000 and the drive motor 7 are tightly integrated through a fixed connection (such as a bolted connection or an integrated design) to form a highly integrated powertrain 10000. This design reduces the number of parts, lowers assembly complexity, and improves the reliability and efficiency of the powertrain 10000.

[0200] Furthermore, in the embodiments disclosed herein, generator 3 is connected to engine 2000 and positioned at the same horizontal level, and generator controller 4 is connected to generator 3 and positioned at the same horizontal level. This design allows for a high degree of integration of generator 3, generator controller 4, and engine 2000 at the same horizontal level, improving space utilization and the overall efficiency of the powertrain 10000.

[0201] This disclosure does not limit the form of the flexible tube 17. The flexible tube 17 can be a corrugated tube or a flexible tube to meet different needs.

[0202] In related technologies, the engine and drive motor of a range-extended electric vehicle powertrain are generally arranged front-to-rear or separately, resulting in low integration and a large space occupation, leading to low utilization of the front compartment space. Furthermore, the drive system, exhaust system, and intake system of the range-extended electric vehicle powertrain are generally arranged independently of the range extender, resulting in low integration and requiring significant front compartment space. For vehicles with limited front compartment space, the entire powertrain layout becomes difficult. The low integration and unreasonable powertrain layout of the range-extended electric vehicle powertrain in these technologies lead to insufficient utilization of the front compartment space.

[0203] In this embodiment, the powertrain 10000 includes: an engine 2000 (in some embodiments of this disclosure, the engine refers to a horizontally opposed engine 1), a generator 3, a drive motor 7, an intake system 2, and an exhaust system 100. Unlike inline engines and V-type engines, which are limited by the relatively high height of the engine 2000 and are generally integrated with the drive motor 7 in a left-right or front-back orientation, this range-extended powertrain 10000 integrated arrangement structure arranges the horizontally opposed engine 1 and the drive motor 7 in a vertically integrated manner. This fully utilizes the advantage of the low height of the horizontally opposed engine 1 and is more suitable for vehicles with relatively short front compartment space.

[0204] In some embodiments of this disclosure, the exhaust system 100 components of the vehicle range-extended powertrain 100, such as the three-way catalytic converter 13, the first exhaust muffler 15, and the second exhaust muffler 16, are all integrated on the horizontally opposed engine 1 and located in the front compartment. The third exhaust muffler 19 can be integrated and installed under the front subframe or the front compartment of the vehicle body. The exhaust pipe 18 and exhaust port are also located in the front compartment. Compared to traditional vehicles where the exhaust pipe 18 needs to pass under the entire floor of the vehicle, the exhaust system 100 of the range-extended powertrain 100 of this disclosure no longer passes under the floor. This arrangement increases the space for the battery pack of the range-extended vehicle, which has a positive effect on improving the pure electric range of the range-extended vehicle and the battery, as well as realizing the integrated design of the vehicle body and chassis.

[0205] The main components of the intake system 2 of the horizontally opposed range extender in some embodiments of this disclosure, such as the air filter 9, intake piping, and intake manifold, are integrated onto the horizontally opposed engine 1 and the drive motor 7. In conventional vehicles, the intake system 2 is typically arranged separately from the engine 2000, with the air filter 9, intake piping, and intake manifold occupying a significant amount of front compartment space and exhibiting low integration. In contrast, the intake system 2 of the range extender powertrain 10000 in some embodiments of this disclosure has high integration, occupies less front compartment space, and achieves higher utilization of front compartment space.

[0206] In summary, the powertrain 10000 of this embodiment can be a range-extended powertrain 10000 integrated layout structure, which mainly consists of a horizontally opposed engine 1, an intake system 2, a generator 3, a generator controller 4, a drive shaft, an exhaust system 100, and a drive motor 7. The horizontally opposed engine 1 is arranged above the drive motor 7, i.e., in an up-down arrangement. The horizontally opposed engine 1 and the drive motor 7 are coupled together by bolts, and after coupling, they are installed on the longitudinal or transverse beams of the vehicle body through suspension bushings. The generator 3 is bolted to the output shaft of the horizontally opposed engine 1 to generate electricity while the engine 2000 is running. The generator controller 4 is located next to the generator 3 and installed above the drive motor 7.

[0207] In some embodiments of this disclosure, the generator controller 4 may also be integrated inside the generator 3 or within the motor controller of the drive motor 7. The intake system 2 is mainly arranged on the horizontally opposed engine 1 and the drive motor 7. The air filter 9 of the intake system 2 is bolted to the top of the drive motor 7, and the intake manifold of the intake system 2 is mounted on both sides of the horizontally opposed engine 1 via mounting flanges. The exhaust system 100 is arranged on the horizontally opposed engine 1 and the drive motor 7. The three-way catalytic converter 13 of the exhaust system 100 is mounted above the horizontally opposed engine 1. A portion of the muffler is mounted on the side of the horizontally opposed engine 1 and the drive motor 7, and another portion of the muffler, along with the exhaust pipe 18, is fixed to the front compartment body or the front subframe via lifting lugs.

[0208] Traditional inline and V-type engines, limited by their relatively high engine height, are typically integrated with the drive motor 7 in a left-right orientation. However, this range-extended powertrain 10000 integrates the horizontally opposed engine 1 and drive motor 7 vertically, fully utilizing the low height of the horizontally opposed engine 1. This allows for better adaptation to vehicle models with limited front compartment length for the placement of the powertrain 10000 and its accessories. The powertrain 10000 can also be secured via the drive shaft beam 5, ensuring stable installation.

[0209] Additionally, the intake system 2 includes an air filter 9, an air filter outlet pipe 91, an air filter intake manifold 92, and an intake manifold mounting flange 12. The air filter 9 is fixed to the drive motor 7 and connected to the air filter intake manifold 92 below the horizontally opposed engine 1 via the air filter outlet pipe 91. The intake manifold mounting flange 12 is bolted to the left and right engine air intakes below the horizontally opposed engine 1. The structure of this range-extended powertrain 10000 intake system 2 differs from that of traditional vehicle intake systems 2, which are located on the vehicle body. Its innovation lies in the fact that the air filter 9 is positioned above the range extender, resulting in a compact structure and higher integration, fully utilizing the limited space in the front compartment and increasing the utilization rate of the front compartment space.

[0210] Furthermore, the exhaust system 100 mainly consists of a three-way catalytic converter 13, an exhaust manifold mounting flange 14, a first exhaust muffler 15, a second exhaust muffler 16, a flexible pipe 17, an exhaust pipe 18, and a third exhaust muffler 19. The three-way catalytic converter 13 is fixed above the horizontally opposed engine 1 via two exhaust manifold mounting flanges 14 on each side. The first exhaust muffler 15 and the second exhaust muffler 16 are located on the sides of the horizontally opposed engine 1. Because the horizontally opposed engine 1 will cause the first exhaust muffler 15 and the second exhaust muffler 16 to vibrate, and the exhaust pipe 18, which is fixed to the vehicle body, will also transmit vibrations from the vehicle body, the flexible pipe 17 connects the second exhaust muffler 16 and the exhaust pipe 18 to absorb the vibrations from both. The third exhaust muffler 19 is mounted on the front subframe.

[0211] The exhaust device 100 arrangement structure of the powertrain 1000 of this disclosure innovatively integrates the exhaust device 100 around the entire range-extended powertrain 10000 and is located in the front compartment. All exhaust pipes 18 and exhaust mufflers do not pass under the floor, resulting in a high degree of integration and not occupying the battery space under the floor, which is conducive to maximizing the battery pack space of the range-extended vehicle.

[0212] In the description of the embodiments disclosed herein, specific features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments or examples.

[0213] In the description of this disclosure, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this disclosure and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this disclosure.

[0214] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this disclosure, "a plurality of" means two or more, unless otherwise expressly specified.

[0215] In this disclosure, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances.

[0216] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this disclosure. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0217] In the description of this disclosure, the first feature being "above" or "below" the second feature may include the first and second features being in direct contact, or it may include the first and second features not being in direct contact but being in contact through another feature between them.

[0218] In the description of this disclosure, the terms "above," "over," and "on top" for the first feature and the second feature include the first feature being directly above or diagonally above the second feature, or simply indicating that the first feature is at a higher horizontal level than the second feature.

[0219] The above are merely specific embodiments of this disclosure, but the scope of protection of this disclosure is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this disclosure should be included within the scope of protection of this disclosure. Therefore, the scope of protection of this disclosure should be determined by the scope of the claims and their equivalents.

Claims

1. A vehicle (600), comprising: Engine (2000); as well as An exhaust device (100) is connected to the engine (2000), and the exhaust device (100) includes a catalytic converter (30) and a muffler (10), the catalytic converter (30) and the muffler (10) being connected.

2. The vehicle (600) according to claim 1, wherein, The exhaust device (100) is integrated on the engine (2000), and the catalytic inlet (311) of the catalytic converter (30) is connected to the exhaust port (2010) of the engine (2000).

3. The vehicle (600) according to claim 2, wherein, The projection of the catalyst (30) along the first direction at least partially overlaps with the projection of the muffler (10) along the first direction; The exhaust device (100) further includes: At least one exhaust sensor (40) is mounted on the outer wall of the catalyst (30), and at least a portion of the exhaust sensor (40) is located outside the muffler (10).

4. The vehicle (600) according to claim 3, wherein, The catalyst (30) has a mounting boss (34) on its outer wall. The exhaust sensor (40) is connected to the mounting boss (34). The mounting boss (34) has a communication channel (341) that communicates with the catalytic chamber (310) of the catalyst (30).

5. The vehicle (600) according to claim 4, wherein, The exhaust sensor (40) is detachably connected to the mounting boss (34).

6. The vehicle (600) according to claim 5, wherein, The exhaust sensor (40) is threadedly connected to the mounting boss (34).

7. The vehicle (600) according to any one of claims 4-6, wherein, The protrusion height of the mounting boss (34) relative to the outer wall of the catalyst (30) is 10.5 mm to 16 mm.

8. The vehicle (600) according to any one of claims 4-7, wherein, The connecting channel (341) extends downward in a direction from the end of the mounting boss (34) away from the catalytic cavity (310) to the catalytic cavity (310).

9. The vehicle (600) according to claim 8, wherein, The angle between the central axis of the connecting channel (341) and the horizontal plane is not less than 15°.

10. The vehicle (600) according to any one of claims 3-9, wherein, The at least one exhaust sensor (40) includes a plurality of exhaust sensors (40), the plurality of exhaust sensors (40) including at least one of a pressure sensor, an oxygen sensor (43) and an exhaust gas recirculation (EGR) sensor.

11. The vehicle (600) according to claim 10, wherein, The plurality of exhaust sensors (40) include an oxygen sensor (43) and two pressure sensors, the two pressure sensors including a first pressure sensor (41) and a second pressure sensor (42), and the catalyst (30) includes a first catalyst support (35) and a second catalyst support (36) connected in sequence along the flow direction of the gas flow. The first pressure sensor (41) and the oxygen sensor (43) are both mounted on the first catalyst carrier (35), and the second pressure sensor (42) is mounted on the second catalyst carrier (36).

12. The vehicle (600) according to any one of claims 3-11, wherein, The catalyst (30) is welded to the muffler (10).

13. The vehicle (600) according to any one of claims 3-12, further comprising: A fixing bracket (50) is provided on the muffler (10) and located outside the catalyst (30). The fixing bracket (50) is used to support and fix the catalyst (30).

14. The vehicle (600) according to any one of claims 3-13, wherein, The catalyst (30) is located entirely outside the muffler (10).

15. The vehicle (600) according to claim 14, wherein, The muffler (10) has an external clearance space (113) formed therein, and at least a portion of the catalyst (30) is accommodated within the clearance space (113).

16. The vehicle (600) according to claim 14 or 15, wherein, At least a portion of the catalyst (30) is positioned laterally.

17. The vehicle (600) according to claim 16, wherein, The catalyst (30) includes a first catalyst support (35) and a second catalyst support (36) connected sequentially along the flow direction of the gas flow. The first catalyst support (35) and the second catalyst support (36) are arranged in the vertical direction and are placed horizontally.

18. The vehicle (600) according to any one of claims 14-17, wherein, At least a portion of the catalyst (30) is placed vertically.

19. The vehicle (600) according to any one of claims 3-18, wherein, Part of the catalyst (30) is located inside the muffler (10), and part of the catalyst (30) is located outside the muffler (10).

20. The vehicle (600) according to claim 19, wherein, The catalyst (30) includes a first catalyst carrier (35) and a second catalyst carrier (36) connected sequentially along the flow direction of the airflow. The first catalyst carrier (35) is located outside the muffler (10), and the second catalyst carrier (36) is located inside the muffler (10). The at least one exhaust sensor (40) includes a plurality of exhaust sensors (40). A first part of the plurality of exhaust sensors (40) is installed on the first catalyst carrier (35), and a second part of the plurality of exhaust sensors (40) is installed on the second catalyst carrier (36). The muffler (10) is provided with a clearance hole (114) for avoiding the exhaust sensors (40).

21. The vehicle (600) according to any one of claims 3-20, wherein, The catalyst (30) is located entirely within the muffler (10), and the muffler (10) is provided with a clearance hole (114) for avoiding the exhaust sensor (40).

22. The vehicle (600) according to any one of claims 2-21, wherein, A first connecting flange (32) is provided at the catalytic inlet (311), and a second connecting flange (2020) is provided at the exhaust port (2010). The first connecting flange (32) is connected to the second connecting flange (2020).

23. The vehicle (600) according to any one of claims 2-22, wherein, The exhaust device (100) is installed on the front side of the engine (2000).

24. The vehicle (600) according to claim 1, further comprising a powertrain (10000), the powertrain (10000) comprising: The engine (2000); A drive assembly (2001) is connected to the engine (2000); The exhaust device (100) is located in the same compartment as the engine (2000).

25. The vehicle (600) according to claim 24, wherein, The projection of the engine (2000) in the height direction of the vehicle (600) is located inside the projection of the drive assembly (2001) in the height direction of the vehicle (600).

26. The vehicle (600) according to claim 25, wherein, The drive assembly (2001) includes a drive motor (7) which is located on the side of the engine (2000) closer to the chassis of the vehicle (600).

27. The vehicle (600) according to claim 26, wherein, The powertrain (10000) also includes a generator (3), which is connected to the engine (2000) and positioned at the same horizontal level.

28. The vehicle (600) according to claim 27, wherein, The powertrain (10000) also includes a generator controller (4), which is connected to the generator (3) and positioned at the same horizontal level.

29. The vehicle (600) according to claim 28, wherein, The generator controller (4) is integrated inside the generator (3) or integrated into the motor controller of the drive motor (7).

30. The vehicle (600) according to any one of claims 27-29, wherein, The exhaust device (100) is connected to the engine (2000).

31. The vehicle (600) according to claim 30, wherein, The exhaust system (100) includes a three-way catalytic converter (13) and a muffler, the three-way catalytic converter (13) being disposed on the side of the engine (2000) away from the drive assembly (2001).

32. The vehicle (600) according to claim 31, wherein, The three-way catalytic converter (13) is located on the upper side of the engine (2000), and the muffler is located on the front or lower side of the engine (2000).

33. The vehicle (600) according to claim 32, wherein, The muffler also includes a first exhaust muffler (15) and a second exhaust muffler (16), which are located on the side of the engine (2000) away from the generator (3).

34. The vehicle (600) according to claim 33, wherein, The first exhaust muffler (15) occupies less space in the horizontal direction of the vehicle (600) than the second exhaust muffler (16) occupies less space in the horizontal direction of the vehicle (600).

35. The vehicle (600) according to claim 33 or 34, wherein, The muffler also includes a third exhaust muffler (19), which is disposed on the side of the drive assembly (2001) away from the second exhaust muffler (16).

36. The vehicle (600) according to claim 35, wherein, The exhaust third muffler (19) is installed on the front body or front subframe of the vehicle (600).

37. The vehicle (600) according to claim 35 or 36, wherein, The exhaust gas discharged from the engine (2000) passes sequentially through the first exhaust muffler (15), the second exhaust muffler (16), and the third exhaust muffler (19).

38. The vehicle (600) according to any one of claims 35-37, wherein, The exhaust device (100) further includes at least one exhaust pipe (18) integrated on the side of the drive motor (7) away from the engine (2000).

39. The vehicle (600) according to claim 38, wherein, The exhaust pipe (18) connects the second exhaust muffler (16) and the third exhaust muffler (19).

40. The vehicle (600) according to claim 39, wherein, The exhaust device (100) also includes a flexible pipe (17) integrated on the side of the drive motor (7) away from the engine (2000).

41. The vehicle (600) according to claim 40, wherein, The exhaust pipe (18) is connected to the second exhaust muffler (16) through the flexible pipe (17).

42. The vehicle (600) according to any one of claims 39-41, wherein, The at least one exhaust pipe (18) includes two exhaust pipes (18), which are located on both sides of the drive assembly (2001).

43. The vehicle (600) according to any one of claims 31-42, wherein, The exhaust system (100) also includes an air filter (9) which is integrated into the engine (2000).

44. The vehicle (600) according to any one of claims 25-43, wherein, The engine (2000) is a horizontally opposed engine (1).

45. The vehicle (600) according to any one of claims 24-44, wherein, The powertrain (10000) is located in the front compartment of the vehicle (600).

46. ​​The vehicle (600) according to claim 45, wherein, The powertrain (10000) is mounted on the longitudinal or transverse beams of the vehicle (600).

47. The vehicle (600) according to claim 1, wherein, The silencer (10) includes: A muffler housing (10), wherein a silencing cavity is defined within the muffler housing (11); A first heat insulation element (200) is disposed on the muffler housing (11); and The first heat insulation member (200) is connected to the muffler housing (11) via the fastener (300).

48. The vehicle (600) according to claim 47, wherein, The fastener (300) includes at least one first fastening part (3100) and at least one second fastening part (3200). The first fastening part (3100) is disposed on the muffler housing (11). The first fastening part (3100) and the second fastening part (3200) cooperate to fix the first heat insulation member (200) to the muffler housing (11).

49. The vehicle (600) according to claim 48, wherein, The first heat insulation component (200) is provided with a first through hole (2100), and the second fixing part (3200) passes through the first through hole (2100) and is connected to the first fixing part (3100).

50. The vehicle (600) according to claim 48 or 49, wherein, A portion of the shell wall of the muffler housing (11) is recessed along the thickness direction of the shell wall to form a first groove (1100), and the first fixing part (3100) is disposed in the first groove (1100).

51. The vehicle (600) according to any one of claims 48-50, wherein, The first fixing part (3100) is threadedly connected to the second fixing part (3200).

52. The vehicle (600) according to any one of claims 48-51, wherein, The at least one first fixing part (3100) includes a plurality of first fixing parts (3100) and is spaced apart on the muffler housing (11); the at least one second fixing part (3200) includes a plurality of second fixing parts (3200), and the plurality of second fixing parts (3200) correspond to the plurality of first fixing parts (3100) respectively.

53. The vehicle (600) according to any one of claims 47-52, wherein, A first adhesive is provided between the first heat insulation component (200) and the muffler housing (11), and they are connected by the first adhesive.

54. The vehicle (600) according to any one of claims 47-53, wherein, The first heat insulation element (200) is disposed at least at one of the inner and outer sides of the muffler housing (11).

55. The vehicle (600) according to any one of claims 47-54, wherein, The first thermal insulation component (200) includes an aerogel layer (2200) and a glass fiber layer (2300), wherein the aerogel layer (2200) and the glass fiber layer (2300) are stacked along the thickness direction of the thermal insulation component.

56. The vehicle (600) according to claim 55, wherein, The thickness of the glass fiber layer (2300) is greater than or equal to the thickness of the aerogel layer (2200).

57. The vehicle (600) according to claim 55 or 56, wherein, The ratio of the thickness of the glass fiber layer (2300) to the thickness of the aerogel layer (2200) is greater than 1 and less than or equal to 3.

58. The vehicle (600) according to any one of claims 55-57, wherein, The thickness of the first heat insulation element (200) is greater than or equal to 12 mm and less than or equal to 15 mm.

59. The vehicle (600) according to any one of claims 47-58, further comprising: The second heat insulation element (400) defines a cavity, and the muffler housing (11) and the first heat insulation element (200) are both disposed in the cavity. The second heat insulation element (400) is fixed to at least one of the muffler housing (11) and the first heat insulation element (200).

60. The vehicle (600) according to claim 59, wherein, The first heat insulation element (200) is disposed between the muffler housing (11) and the second heat insulation element (400).

61. The vehicle (600) according to claim 60, wherein, The first heat insulation component (200) is provided with a first through hole (2100), and the second heat insulation component (400) is provided with a second through hole (4100); The fastener (300) includes a first fixing part (3100) and a second fixing part (3200). The first fixing part (3100) is fixed to the muffler housing (11), and the second fixing part (3200) passes through the first through hole (2100) and the second through hole (4100) and is fixed to the first fixing part (3100).

62. The vehicle (600) according to claim 61, wherein, The second heat insulation member (400) has a second groove (4200) formed on the side opposite to the muffler housing (11), and the second through hole (4100) penetrates the bottom wall of the second groove (4200).

63. The vehicle (600) according to any one of claims 59-62, wherein, The second heat insulation component (400) and the muffler housing (11) are provided with a buckle and the other is provided with a locking hole, and the buckle engages with the locking hole.

64. The vehicle (600) according to any one of claims 59-63, wherein, The second heat insulation member (400) includes a front cover (401), a rear cover (402) and a bottom cover (403), the front cover (401) and the rear cover (402) are joined in the front-rear direction and cooperate to define the cavity with an open bottom, and the bottom cover (403) covers the open bottom side of the cavity.

65. The vehicle (600) according to any one of claims 47-64, wherein, The first heat insulation component (200) includes a front heat insulation part (201), a rear heat insulation part (202), and a lower heat insulation part (203). The front heat insulation part (201) covers the front side of the muffler housing (11), the rear heat insulation part (202) covers the rear side of the muffler housing (11), and the lower heat insulation part (203) covers the bottom of the muffler housing (11). The front heat insulation part (201), the rear heat insulation part (202), and the lower heat insulation part (203) are spliced ​​together. At least one of the front heat insulation part (201) and the rear heat insulation part (202) is fixed to the muffler housing (11) by the fastener (300).

66. The vehicle (600) according to any one of claims 47-65, wherein, The muffler housing (11) includes a front housing portion (101) and a rear housing portion (102), which are joined together in the front-rear direction and cooperate to define the muffler cavity.

67. The vehicle (600) according to any one of claims 47-66, wherein, The engine (2000) has an exhaust port; The exhaust device (100) is connected to the exhaust port, and the muffler (10) is arranged on the front side of the engine (2000).

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