Integrated Exhaust Mixer Assembly for Gas-Tight Flange Coupling
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Solution Overview
Problem
Existing mixer assembly units for exhaust systems of internal combustion engines require complex assembly processes and multiple components, making integration into the exhaust system cumbersome and time-consuming.
Innovation Solution
A mixer assembly unit with a mixer body and a carrier area integrated as a single component, featuring a ring-like configuration with exhaust gas guide element connections and a flange-like coupling section for a gas-tight and stable connection to other exhaust gas guide elements, reducing the number of components and assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a mixer assembly unit with integrated carrier area is used, then the number of components and assembly steps is reduced, but the connection stability and gas-tightness must be maintained
Solution Approach 1:
The mixer body and carrier area are merged into a single integrated component. The carrier area is formed as an integral part of the mixer body, eliminating the need for separate carrier elements and reducing the number of assembly steps while maintaining connection reliability through the integrated design
Solution Approach 2:
The mixer assembly unit serves multiple functions: it mixes exhaust gas with reactants through the mixer body, provides structural support and positioning through the integrated carrier area, and enables gas-tight connections through the flange-like coupling section. This multi-functionality reduces the overall number of components needed in the exhaust system
2Ease of operation
If multiple separate components are used for mixer and carrier, then assembly flexibility is improved, but assembly time and complexity increase
Solution Approach 1:
The mixer body and carrier area are combined into a single pre-assembled unit, reducing the number of separate assembly operations required. This integration maintains flexibility because the entire mixer assembly unit can be installed as one module in the exhaust system
Solution Approach 2:
The carrier area is pre-integrated with the mixer body during manufacturing, creating a pre-assembled unit that requires fewer on-site assembly steps. This preliminary integration reduces assembly time while maintaining the flexibility to position the complete mixer assembly unit at the desired location in the exhaust system
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
Facilitates a simple and efficient integration into the exhaust system with a reduced number of components and assembly steps, ensuring a stable and gas-tight connection, thereby enhancing the mixing efficiency of exhaust gas and reactants.
Implementation Method 1
a mixer, which brings about swirling of the exhaust gas flowing in the exhaust system and hence mixing with the injected reactant
Data Source
AI summary
A mixer assembly unit, especially for an exhaust system of an internal combustion engine of a vehicle, includes a mixer body (48a) with an incoming flow side (58a) and with an outflow side (60a) and with a plurality of flow deflection elements (62b). A carrier area (24a) is provided radially outwards in relation to a mixer longitudinal axis (L) at the mixer body (48a). The carrier area (24a) has an exhaust gas guide element connection area (72a) for permanent connection to a preferably tubular exhaust gas guide element (16a). Radially outside of the exhaust gas guide element connection area (72a), a flange coupling section (88a) couples with a flange coupling section (98a) of another exhaust gas guide element (14a).