Crescent Mixing Plate Layout for Low-Backpressure Exhaust Mixing

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Solution Overview

Problem

Existing mixers in exhaust aftertreatment systems for internal combustion engines increase backpressure, which decreases engine power and efficiency, and are prone to deposit formation due to turbulent flow, reducing mixing efficiency.

Innovation Solution

The use of crescent-shaped mixing plates in the mixer, positioned obliquely within the tubular conduit, induces turbulent, spiraling flow to enhance mixing while minimizing deposit formation and backpressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional mixers are used to mix treatment fluid and exhaust, then mixing efficiency is improved, but backpressure increases and engine power decreases

Engineering Contradiction:
Improvemixing efficiencyVSAvoidbackpressure
Core Design Contradiction:
ProductivityVSLoss of energy

Solution Approach 1:

The mixing plates are designed with crescent shapes featuring convex and concave edges instead of flat or straight configurations. This curvature creates more effective flow disruption and mixing while maintaining lower resistance to exhaust flow, thereby reducing backpressure while preserving mixing efficiency.

Inventive Principle:
Principle #14Spheroidality (Curvature)

Solution Approach 2:

The mixing plates employ asymmetric crescent shapes with distinct convex and concave edges positioned at specific orientations. This asymmetric design creates optimized flow patterns that enhance mixing effectiveness while minimizing the resistance imposed on exhaust flow, addressing the backpressure issue.

Inventive Principle:
Principle #4Asymmetry

2Productivity

If conventional mixers are used to mix treatment fluid and exhaust, then mixing efficiency is improved, but deposit formation increases

Engineering Contradiction:
Improvemixing efficiencyVSAvoiddeposit formation
Core Design Contradiction:
ProductivityVSObject-generated harmful factors

Solution Approach 1:

The crescent-shaped mixing plates with curved convex and concave edges create flow patterns that reduce stagnant zones where deposits typically form. The curvature promotes continuous fluid motion and prevents the accumulation of treatment fluid residues that would otherwise solidify into deposits.

Inventive Principle:
Principle #14Spheroidality (Curvature)

Solution Approach 2:

The specific geometric parameters of the crescent-shaped plates, including the curvature radius and edge orientation, are optimized to create flow conditions that minimize deposit formation while maintaining effective mixing. The design alters flow velocity distribution and pressure patterns to prevent deposit accumulation.

Inventive Principle:
Principle #35Parameter changes

3Productivity

If mixing plates are positioned to maximize mixing, then mixing efficiency is improved, but device complexity increases

Engineering Contradiction:
Improvemixing efficiencyVSAvoidmixer structure
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The mixer is divided into multiple discrete crescent-shaped mixing plates positioned at different locations and orientations within the conduit. Each plate performs a specific mixing function, and the segmented design allows for optimized placement that achieves thorough mixing without requiring a single complex structure.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The crescent-shaped mixing plates serve multiple functions simultaneously: they disrupt flow to enhance mixing, guide exhaust flow through the conduit, and minimize backpressure through their curved geometry. This multi-functionality reduces the need for additional components, simplifying the overall device structure.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The crescent-shaped mixing plates facilitate efficient mixing of exhaust and treatment fluid, preventing deposit formation and minimizing backpressure, thereby improving engine performance and efficiency.

Implementation Method 1

The use of crescent-shaped mixing plates in the mixer, positioned obliquely within the tubular conduit, induces turbulent, spiraling flow to enhance mixing

Methodology Applied
Scientific EffectTurbulence: Turbulence

Data Source

PatentUS20250339824A1Exhaust aftertreatment assembly with a mixer having a mixing plate that is crescent shaped
Publication Date: 2025.11.06 CUMMINS EMISSION SOLUTIONS INC
  • US20250339824A1 patent drawing
  • US20250339824A1 patent drawing
  • US20250339824A1 patent drawing

AI summary

An exhaust aftertreatment assembly includes a tubular conduit and a mixer disposed in the tubular conduit. The tubular conduit includes a central axis. The mixer includes a first mixing plate and a second mixing plate. The first mixing plate is crescent shaped and includes a first plate convex edge coupled to the tubular conduit, and a first plate concave edge. The second mixing plate is crescent shaped and includes a second plate convex edge coupled to the tubular conduit, and a second plate concave edge. The first mixing plate and the second mixing plate are positioned relative to the tubular conduit such that the central axis extends between the first plate concave edge and the second plate concave edge. A first plane in which the first mixing plate extends and a second plane in which the second mixing plate extends are oblique to the central axis of the tubular conduit.