Modular Exhaust Mixer With Rotatable Interfaces
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Solution Overview
Problem
Existing vehicle exhaust systems face challenges in efficiently arranging components within tight packaging restraints due to varying vehicle configurations, leading to increased costs from different connection orientations required for each configuration.
Innovation Solution
A modular mixer design with first and second housing portions and connectable interfaces that allow multiple mounting orientations, enabling flexible positioning of exhaust components such as diesel particulate filters and selective catalytic reduction catalysts, and incorporating an injector for fluid mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different connection orientations are used for each vehicle configuration, then the exhaust system can be adapted to various packaging envelopes, but the manufacturing cost increases
Solution Approach 1:
The connection interfaces are designed with rotational symmetry to perform multiple functions: they can connect exhaust components in any orientation (0°, 90°, 180°, 270°) while maintaining proper fluid flow and component alignment. This universal interface design eliminates the need for different connection configurations for different vehicle packages, thereby reducing manufacturing costs while preserving adaptability.
2Area of stationary object
If exhaust components are arranged in tight packaging restraints, then the exhaust system fits within vehicle packaging envelopes, but the arrangement becomes difficult and costly
Solution Approach 1:
The connection interfaces are designed to be rotatable relative to each other, allowing the exhaust components to be dynamically repositioned in different orientations (0°, 90°, 180°, 270°) to fit various packaging constraints. This dynamic adjustment capability simplifies the arrangement process and reduces complexity by providing flexibility in component positioning without requiring complex mounting mechanisms.
3Ease of manufacture
If fixed connection orientations are used between exhaust components, then the manufacturing process is simplified, but the system cannot adapt to different vehicle configurations
Solution Approach 1:
The connection interfaces incorporate rotational symmetry that allows them to maintain proper alignment and fluid flow characteristics across multiple orientations (0°, 90°, 180°, 270°). This universal design enables the same component to be manufactured once and then installed in any orientation required by different vehicle configurations, achieving both manufacturing simplicity and configuration adaptability.
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 modular mixer facilitates efficient assembly and adaptation to various vehicle configurations without compromising mixing performance, reducing costs and improving packaging efficiency.
Implementation Method 1
An injector is mounted to one of the first and second housing portions adjacent an outlet of the diesel particulate filter, wherein the injector is configured to inject a fluid into the mixer
Data Source
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Figure 7~8B
AI summary
A vehicle exhaust component includes a first exhaust component, a second exhaust component downstream of the first exhaust component, and a mixer that connects an outlet of the first exhaust component to an inlet to the second exhaust component. The mixer includes a first housing portion with a first connection interface and a second housing portion with a second connection interface. The first housing portion is attached to the outlet of the first exhaust component and the second housing portion is attached to the inlet of the second exhaust component. The first and second connection interfaces are connectable to each other in one of a plurality of different connection orientations such that the first and second exhaust components can be positioned at any of a plurality of different mounting orientations relative to each other.