Venturi Mixer Clamshell Stamping for DEF Distribution
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Solution Overview
Problem
Current vehicle exhaust systems face challenges in effectively mixing diesel exhaust fluid (DEF) with exhaust gases to reduce NOx emissions, as existing mixers may not efficiently distribute the reductant within the exhaust stream, leading to incomplete reduction reactions.
Innovation Solution
A mixer with a venturi section featuring integrally formed mixing vanes and a doser chamber, where the vanes are bent to create inlet and outlet openings, forming a mixing chamber that aligns with the doser mount opening, ensuring thorough mixing of DEF with exhaust gases, and the doser chamber has a variable cross-section to evenly distribute the fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mixing methods are used without integrally formed mixing vanes, then the device complexity is reduced, but the mixing efficiency and uniformity of DEF distribution deteriorate
Solution Approach 1:
The mixing vanes are integrally formed with the venturi section as a single stamped component, merging the mixing function into the existing structural element. This eliminates the need for separate mixing components while achieving effective DEF distribution and mixing efficiency.
Solution Approach 2:
The venturi section serves multiple functions: it provides the mixing chamber structure, contains the mixing vanes for fluid mixing, and forms the doser chamber. This multi-functionality reduces device complexity while maintaining mixing efficiency.
2Manufacturing precision
If the doser chamber has a uniform cross-section, then the manufacturing process is simpler, but the fluid distribution uniformity deteriorates
Solution Approach 1:
The doser chamber features a variable cross-section that changes along its length, with different dimensions at the inlet versus the outlet. This local variation in geometry optimizes fluid distribution uniformity by controlling flow patterns, while still being manufacturable through stamping processes.
3Reliability
If mixing vanes are not integrally formed, then the manufacturing process is simpler, but the structural integrity and mixing performance deteriorate
Solution Approach 1:
The mixing vanes are integrally formed with the venturi section through a single stamping process, creating a unified structure with continuous material flow. This integral construction ensures structural integrity while the stamping process maintains ease of manufacture.
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 mixer enhances the mixing of DEF with exhaust gases, improving the efficiency of NOx reduction reactions by ensuring uniform distribution and effective contact between the reductant and exhaust gases, thereby optimizing the performance of the selective catalytic reduction (SCR) catalyst.
Implementation Method 1
A mixer with a venturi section featuring integrally formed mixing vanes... forming a mixing chamber that aligns with the doser mount opening, ensuring thorough mixing of DEF with exhaust gases
Data Source
AI summary
A mixer for a vehicle exhaust gas system, according to an exemplary aspect of the present disclosure includes, among other things, a mixer housing defining an internal cavity and a venturi section including integrally formed mixing vanes and positioned within the internal cavity. The venturi section comprises a first portion and a second portion that are combined to provide a mixing chamber therebetween. A doser mount opening is formed within the mixer housing that is open to the mixing chamber.