Flow Redirection Conduit Protrusions for Uniform Exhaust Gas Distribution

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Solution Overview

Problem

Aftertreatment systems for internal combustion engines face inefficiencies due to non-uniform exhaust gas distribution over aftertreatment components, leading to increased backpressure and reduced fuel economy, especially when inlet conduits are oriented perpendicular to the housing's longitudinal axis.

Innovation Solution

Inlet assemblies with a flow redirection conduit featuring protrusions or a flow distribution plate are used to redirect and distribute exhaust gas uniformly over the aftertreatment component's inlet face, reducing pressure drop and improving fuel economy by ensuring even gas distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If exhaust gas is redirected at high pressure towards the aftertreatment component, then the exhaust gas can be delivered to the component, but the exhaust gas becomes non-uniformly distributed over the inlet surface resulting in inefficient utilization

Engineering Contradiction:

Improveutilization efficiency of aftertreatment componentVSAvoiduniformity of exhaust gas distribution

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent introduces a flow distribution plate with multiple openings arranged in a specific pattern. Each opening creates a localized flow path that directs exhaust gas to different regions of the inlet surface. This localizes the flow distribution function to achieve uniform overall distribution, resolving the contradiction between delivering high-pressure exhaust gas and achieving uniform distribution.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The flow distribution plate segments the exhaust gas flow into multiple streams through its openings. Instead of a single undistributed flow, the plate divides the flow into numerous smaller streams that collectively cover the entire inlet surface uniformly. This segmentation resolves the contradiction by transforming a non-uniform single flow into multiple uniform flows.

Inventive Principle:

Principle #1Segmentation

2Productivity

If exhaust gas is redirected at high pressure, then exhaust gas can reach the aftertreatment component, but a large reduction in exhaust gas pressure occurs which exerts back pressure on the engine

Engineering Contradiction:

Improveexhaust gas delivery to aftertreatment componentVSAvoidback pressure on engine exhaust gas

Core Design Contradiction:

ProductivityVSStress or pressure

Solution Approach 1:

The flow distribution plate redirects exhaust gas flow from a primarily axial direction to include significant radial components. By utilizing the radial dimension for flow distribution, the plate reduces flow resistance in the axial direction, thereby reducing back pressure on the engine while still delivering exhaust gas effectively to the aftertreatment component.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The flow distribution plate acts as an intermediary between the exhaust gas inlet and the aftertreatment component. It mediates the pressure and flow characteristics, transforming high-pressure concentrated flow into lower-pressure distributed flow, thereby reducing back pressure on the engine while maintaining effective exhaust gas delivery.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution achieves a 9-18% lower pressure drop and a flow distribution index of 0.94-0.96, enhancing the efficiency and utilization of aftertreatment components while minimizing the impact on fuel economy.

Implementation Method 1

the sidewall comprises a plurality of protrusions projecting in a direction substantially parallel to the longitudinal axis of the housing, the plurality of protrusions being configured to distribute exhaust gas flow towards the inlet face of the aftertreatment component as the exhaust gas flows between the plurality of protrusions

Methodology Applied

Scientific EffectFlow distribution through geometric structures:

Implementation Method 2

a flow redirection conduit disposed downstream of the inlet conduit and coupled thereto, the flow redirection conduit configured to be coupled to the housing and redirect exhaust gas received from the inlet conduit towards an inlet face of the aftertreatment component

Methodology Applied

Scientific EffectPressure gradient driven flow: Pressure Gradient

Data Source

PatentUS12012887B2Systems and methods for providing uniform exhaust gas flow to an aftertreatment component

Publication Date: 2024.06.18 CUMMINS EMISSION SOLUTIONS INC

AI summary

An inlet assembly for a housing containing an aftertreatment component of an aftertreatment system comprises an inlet conduit configured to be disposed substantially perpendicular to a longitudinal axis of the housing. A flow redirection conduit is disposed downstream of the inlet conduit and is coupled to the end of the housing. A plurality of protrusions project from a sidewall of the flow redirection conduit towards an inlet face of the aftertreatment component and are configured to provide a uniform exhaust gas flow to the inlet face. Alternatively, a flow distribution plate having a plurality of slots defined substantially perpendicular to the longitudinal axis is disposed in the flow redirection conduit, the plate being inclined with respect to the longitudinal axis. The slots are configured to provide a uniform exhaust gas flow to the inlet face.