Two-Part Two-Stage Exhaust Mixer Assembly
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Solution Overview
Problem
Existing exhaust gas mixers for internal combustion engines are costly to manufacture, and there is a need to reduce these costs while maintaining effective mixing of reductants with exhaust gases for treatment systems like selective catalytic reduction.
Innovation Solution
A mixer design comprising multiple interlocking mixing elements with deflection and correction fins, formed from metal sheets and welded together to create a one-piece assembly that can be easily assembled and positioned within an exhaust conduit, reducing manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional mixer designs are used, then effective mixing of exhaust gases is achieved, but manufacturing costs are high
Solution Approach 1:
The mixer is divided into multiple separate mixing elements (first mixing element, second mixing element, third mixing element, fourth mixing element) that can be manufactured independently and then assembled together. Each element contains specific fins (deflection fins, correction fins, mixing fins) that perform specific mixing functions, allowing for modular manufacturing and assembly while maintaining effective exhaust gas mixing.
2Ease of manufacture
If multiple separate mixing elements are used, then manufacturing cost is reduced, but assembly complexity increases
Solution Approach 1:
The multiple mixing elements are merged together through welding to form an integrated assembly. The first mixing element is welded to the second mixing element, and the third mixing element is welded to the fourth mixing element, creating a unified structure that functions as a single mixer unit. This merging process reduces assembly complexity while maintaining the manufacturing cost benefits of separate element production.
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 design reduces manufacturing costs by simplifying assembly and fabrication while maintaining effective mixing of exhaust gases, ensuring efficient interaction with reductants and optimal positioning within the exhaust conduit for treatment processes.
Implementation Method 1
The base includes a deflection element extending upstream of the first and second sidewalls and substantially parallel to a direction of the exhaust flow
Implementation Method 2
The second mixing element includes a mixing fin to change a direction of the exhaust flow
Data Source
AI summary
A mixer comprises a first subassembly including a first holder fixed to a first mixing element. The first holder includes a base interconnecting a first sidewall with a spaced apart second sidewall. The first mixing element includes a base interconnecting first and second spaced apart mounting flanges that are fixed to the first and second sidewalls. A second subassembly includes a second holder fixed to a second mixing element. The second holder includes a base interconnecting a third sidewall with a spaced apart fourth sidewall. The second mixing element including a base interconnecting third and fourth spaced apart mounting flanges that are fixed to the third and fourth sidewalls. Distal ends of the first sidewall and the third sidewall are fixed to one another. Distal ends of the second sidewall and the fourth sidewall are fixed to one another.