Hemispherical Exhaust Collector and Catalyst Assembly
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Solution Overview
Problem
Existing exhaust gas purification systems for internal combustion engines are costly to manufacture and have large dimensions, making them unsuitable for small engines due to their complex molding processes and volume requirements.
Innovation Solution
A compact gas purification system comprising a collector and catalyst assembled from stamped and welded half-shells, where the collector is composed of two half-shells with a hemispherical outlet and the catalyst is formed from symmetrical half-shells, allowing for a single-piece, cost-effective, and reduced-size assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If molding process is used to manufacture the collector, then the gas uniformization function is achieved, but the manufacturing cost increases
Solution Approach 1:
The collector is divided into two separate half-shells that are manufactured independently and then assembled together. This segmentation allows each half-shell to be manufactured using simpler stamping processes rather than complex molding, reducing manufacturing cost while maintaining the gas uniformization function through the hemispherical outlet geometry.
Solution Approach 2:
The collector half-shells are manufactured using stamping processes that create thin-walled flexible shell structures. These shells are then assembled and welded to form the complete collector, providing a cost-effective alternative to rigid molded structures while maintaining the necessary geometric properties for gas uniformization.
2Volume of stationary object
If large volume chamber is used in the collector, then the gas mixing function is improved, but the system dimensions increase
Solution Approach 1:
The collector incorporates a hemispherical outlet section formed by the assembly of two half-shells. This spherical curvature provides efficient gas mixing and uniformization in a compact volume, as spherical geometry naturally promotes homogeneous flow distribution with minimal space requirement compared to conventional cylindrical or rectangular chambers.
Solution Approach 2:
The catalyst is positioned directly at the outlet of the collector with minimal spacing, creating a nested arrangement where the catalyst housing is integrated within or immediately adjacent to the collector structure. This nesting eliminates the need for separate large-volume chambers and reduces the overall system volume while maintaining effective gas-catalyst contact.
3Ease of manufacture
If multiple parts are assembled to form the collector and catalyst, then the manufacturing cost decreases, but the assembly complexity increases
Solution Approach 1:
Both the collector and catalyst are segmented into two half-shells each, allowing manufacture by stamping and welding. The collector half-shells are assembled with the catalyst half-shells in a coordinated manner, creating a modular assembly process that reduces manufacturing cost while keeping assembly complexity manageable through standardized joining procedures.
Solution Approach 2:
The collector and catalyst are combined into a single integrated assembly where the collector outlet directly interfaces with the catalyst inlet. This merging of functions into a single assembled unit eliminates the need for separate mounting procedures and reduces overall assembly complexity despite using multiple stamped and welded components.
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 enables the production of a low-cost, reduced-size exhaust gas collection and purification system that is easy to manufacture and adaptable to different engine layouts, while maintaining effective gas mixing and chemical reactions.
Implementation Method 1
the two half-shells of the collector are assembled to each other by an edge-to-edge weld along the connecting edge
Implementation Method 2
the hemispherical outlet of the collector is pressed into the inlet hemispherical of the catalyst
Implementation Method 3
the two half-shells of the catalyst are assembled to each other by a weld according to the connecting sidewalk
Implementation Method 4
the two parts are fixed to each other by a weld bead at the end of the hemispherical inlet of the catalyst
Data Source
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Figure 5
AI summary
The invention concerns a system (10) for collecting and purifying exhaust gas, comprising; - an exhaust manifold (11) mounted downstream of an internal combustion engine; and - a catalytic converter (12); characterized in that the manifold comprises a substantially hemispherical gas outlet (15) on the periphery of a circular opening, and in that the catalytic converter (12) comprises a substantially hemispherical inlet (26) adapted to the hemispherical outlet of the manifold (11), the manifold and the catalytic converter being produced by the assembly of half-shells obtained by swaging.