Vehicles equipped with internal combustion engines (e.g., diesel engines) typically include exhaust systems that have aftertreatment components such as selective catalytic reduction (SCR) catalyst devices, lean NOx catalyst devices, or lean NOx trap devices to reduce the amount of undesirable gases, such as nitrogen oxides (NOx) in the exhaust. In order for these types of aftertreatment devices to work properly, a doser injects reactants, such as urea, ammonia, or hydrocarbons, into the exhaust gas. As the exhaust gas and reactants flow through the aftertreatment device, the exhaust gas and reactants convert the undesirable gases, such as NOx, into more acceptable gases, such as nitrogen and water. However, the efficiency of the aftertreatment system depends upon how evenly the reactants are mixed with the exhaust gases. Therefore, there is a need for a flow device that provides a uniform mixture of exhaust gases and reactants.
SCR exhaust treatment devices focus on the reduction of nitrogen oxides. In SCR systems, a reductant (e.g., aqueous urea solution) is dosed into the exhaust stream. The reductant reacts with nitrogen oxides while passing through an SCR substrate to reduce the nitrogen oxides to nitrogen and water. When aqueous urea is used as a reductant, the aqueous urea is converted to ammonia which in turn reacts with the nitrogen oxides to covert the nitrogen oxides to nitrogen and water. Dosing, mixing and evaporation of aqueous urea solution can be challenging because the urea and by-products from the reaction of urea to ammonia can form deposits on the surfaces of the aftertreatment devices. Such deposits can accumulate over time and partially block or otherwise disturb effective exhaust flow through the aftertreatment device.
An aspect of the present disclosure relates to a method for dosing and mixing exhaust gas in exhaust aftertreatment. Another aspect of the present disclosure relates to a dosing and mixing unit for use in exhaust aftertreatment. More specifically, the present disclosure relates to a dosing and mixing unit including a mixing tube configured to direct exhaust gas flow to flow around and through the mixing tube to effectively mix and dose exhaust gas within a relatively small area.
In accordance with some aspects, the mixing tube includes a slotted region and a non-slotted region. In examples, the slotted region extends over a majority of a circumference of the mixing tube. In examples, the slotted region extends over a majority of an axial length of the mixing tube. In examples, a circumferential width of the non-slotted region is substantially larger than a circumferential width of a gap between slots of the slotted region.
In accordance with some aspects, the mixing tube includes a louvered region and a non-louvered region. The louvered region extends over a majority of a circumference of the mixing tube. In examples, the louvered region extends over a majority of an axial length of the mixing tube. In examples, a circumferential width of the non-slotted region is substantially larger than a circumferential width of a gap between louvers of the louvered region.
In accordance with some aspects, the mixing tube is offset within a mixing region of a housing. For example, the mixing tube can be located closer to one wall of the housing than to an opposite wall of the housing.
A variety of additional aspects will be set forth in the description that follows. These aspects can relate to individual features and to combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad concepts upon which the embodiments disclosed herein are based.
The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several aspects of the present disclosure. A brief description of the drawings is as follows:
Reference will now be made in detail to the exemplary aspects of the present disclosure that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like structure.
A selective catalytic reduction (SCR) catalyst device is typically used in an exhaust system to remove undesirable gases such as nitrogen oxides (NOx) from the vehicle's emissions. SCR's are capable of converting NOx to nitrogen and oxygen in an oxygen rich environment with the assistance of reactants such as urea or ammonia, which are injected into the exhaust stream upstream of the SCR through a doser. In alternative implementations, other aftertreatment devices such as lean NOx catalyst devices or lean NOx traps could be used in place of the SCR catalyst device, and other reactants (e.g., hydrocarbons) can be dispensed by the doser.
A lean NOx catalyst device is also capable of converting NOx to nitrogen and oxygen. In contrast to SCR's, lean NOx catalysts use hydrocarbons as reducing agents/reactants for conversion of NOx to nitrogen and oxygen. The hydrocarbon is injected into the exhaust stream upstream of the lean NOx catalyst. At the lean NOx catalyst, the NOx reacts with the injected hydrocarbons with the assistance of a catalyst to reduce the NOx to nitrogen and oxygen. While the exhaust treatment systems 200, 220, 240 are described as including an SCR, it will be understood that the scope of the present disclosure is not limited to an SCR as there are various catalyst devices (a lean NOx catalyst substrate, a SCR substrate, a SCRF substrate (i.e., a SCR coating on a particulate filter), and a NOx trap substrate) that can be used in accordance with the principles of the present disclosure.
The lean NOx traps use a material such as barium oxide to absorb NOx during lean burn operating conditions. During fuel rich operations, the NOx is desorbed and converted to nitrogen and oxygen by reaction with hydrocarbons in the presence of catalysts (precious metals) within the traps.
As shown in
In an example, the longitudinal axis L defines a flow axis for the outlet 109. In certain implementations, the second end 106 is closed. In certain implementations, the second end 106 is curved to define a contoured interior surface 122. In an example, the second end 106 defines half of a cylindrical shape. In certain implementations, the third end 107 defines a port 140 at which a doser can be coupled (see
As shown in
As shown in
A doser (or doser port) is disposed at one end of the mixing tube arrangement 110 (see
In other implementations, the dosing and mixing unit 100 can be used to mix hydrocarbons with the exhaust to reactivate a diesel particulate filter (DPF). In such implementations, the reactant doser injects hydrocarbons into the gas flow within the mixing tube arrangement 110. The mixed gas leaves the mixing tube arrangement 110 and is directed to a downstream diesel oxidation catalyst (DOC) at which the hydrocarbons ignite to heat the exhaust gas. The heated gas is then directed to the DPF to burn particulate clogging the filter.
In some implementations, the mixing tube arrangement 110 is offset within the mixing region 121. For example, the mixing tube arrangement 110 can be disposed so that a cross-sectional area of the annulus is decreasing as the flow travels along a perimeter of the mixing tube arrangement 110. In the example shown, the mixing tube arrangement is located closer to the second side 124 than to the first side 123. In other implementations, however, the mixing tube arrangement 110 can be located closer to the first side 123. In some implementations, offsetting the mixing tube arrangement 110 guides the exhaust flow in the first circumferential direction D1. In some implementations, offsetting the mixing tube arrangement 110 inhibits exhaust gases G from flowing in an opposite circumferential direction.
For example, offsetting the mixing tube arrangement may create a high pressure zone 125 and a flow zone 126. The high pressure zone 125 is defined where the mixing tube arrangement 110 approaches the closest side (e.g., the second side 124). As the exterior surface of the mixing tube arrangement 110 approaches the housing side 124, less flow can pass between the mixing tube arrangement 110 and the side 124. Accordingly, the flow pressure builds and directs the exhaust gases away from the high pressure zone 125. The flow zone 126 is defined along the portions of the mixing tube 110 that are spaced farther from the wall (e.g., side wall 123, interior surface 122), thereby enabling flow between the mixing tube arrangement 110 and the wall.
In certain implementations, a portion of the mixing tube arrangement 110 contacts the closest side wall (e.g., side wall 124). For example, a distal end of a louver 114 (see
In some implementations, the slotted region 115 defines multiple slots 113. In certain implementations, the slotted region 115 defines between five slots 113 and twenty-five slots 113. In certain implementations, the slotted region 115 defines between ten slots 113 and twenty slots 113. In an example, the slotted region 115 defines about fifteen slots 113. In an example, the slotted region 115 defines about fourteen slots 113. In an example, the slotted region 115 defines about sixteen slots 113. In an example, the slotted region 115 defines about twelve slots 113. In other implementations, the slotted region 115 can define any desired number of slots 113.
As shown in
In some implementations, a ratio of the length L2 of the slotted region 115 to a tube diameter D (
As shown in
In some implementations, the circumferential width S2 of the non-slotted region 116 is significantly larger than a circumferential width of any portion of the tube body 111 extending between two adjacent slots 113 at the slotted region 115. For example, in certain examples, the circumferential width S2 of the non-slotted region 116 is at least double the circumferential width of any portion of the tube body 111 extending between two adjacent slots 113 at the slotted region 115. In certain examples, the circumferential width S2 of the non-slotted region 116 is at least triple the circumferential width of any portion of the tube body 111 extending between two adjacent slots 113 at the slotted region 115. In certain examples, the circumferential width S2 of the non-slotted region 116 is at least four times the circumferential width of any portion of the tube body 111 extending between two adjacent slots 113 at the slotted region 115. In certain examples, the circumferential width S2 of the non-slotted region 116 is at least five times the circumferential width of any portion of the tube body 111 extending between two adjacent slots 113 at the slotted region 115.
In some implementations, the circumferential width S1 of the slotted region 115 is substantially larger than the circumferential width S2 of the non-slotted region 116. In certain implementations, the circumferential width S1 of the slotted region 115 is at least twice the circumferential width S2 of the non-slotted region 116. In certain implementations, the circumferential width S1 of the slotted region 115 is about triple the circumferential width S2 of the non-slotted region 116.
In some examples, the slotted region 115 extends about 200° to about 350° around the tube body 111 and the non-slotted region 116 extends about 10° to about 160° around the tube body 111. In certain examples, the slotted region 115 extends about 210° to about 330° around the tube body 111 and the non-slotted region 116 extends about 30° to about 150° around the tube body 111. In an example, the slotted region 115 extends about 270° around the tube body 111 and the non-slotted region 116 extends about 90° around the tube body 111. In an example, the slotted region 115 extends about 300° around the tube body 111 and the non-slotted region 116 extends about 60° around the tube body 111. In an example, the slotted region 115 extends about 240° around the tube body 111 and the non-slotted region 116 extends about 120° around the tube body 111.
In some implementations, each slot 113 has a common width S3 (defined along the circumference of the tube body 111. In some implementations, the width S3 of each slot 113 is less than the circumferential width S2 of the non-slotted region 116. In certain implementations, the width S3 of each slot 113 is substantially less than the width S2 of the non-slotted region 116. In certain implementations, the width S3 of each slot 113 is less than half the width S2 of the non-slotted region 116. In certain implementations, the width S3 of each slot 113 is less than a third of the width S2 of the non-slotted region 116. In certain implementations, the width S3 of each slot 113 is less than a quarter of the width S2 of the non-slotted region 116. In certain implementations, the width S3 of each slot 113 is less than 20% the width S2 of the non-slotted region 116. In certain implementations, the width S3 of each slot 113 is less than 10% the width S2 of the non-slotted region 116.
In some implementations, the tube body 111 has a ratio of slot width S3 to tube diameter D (
In some implementations, the slots 113 are spaced evenly around the circumferential width S1 of the slotted region 115. In such implementations, gaps between adjacent slots 113 within the slotted region 115 have a circumferential width S4. In certain implementations, the circumferential width S4 of the gaps is larger than the circumferential width S3 of the slots 113. In certain implementations, the circumferential width S3 of the slots 113 is at least half of the circumferential width S4 of the gaps. In certain implementations, the circumferential width S3 of the slots 113 is at least 60% of the circumferential width S4 of the gaps. In certain implementations, the circumferential width S3 of the slots 113 is at least 75% of the circumferential width S4 of the gaps. In certain implementations, the circumferential width S3 of the slots 113 is at least 85% of the circumferential width S4 of the gaps. In other implementations, however, the gaps between the slots 113 can have different widths.
In some implementations, the width S4 of each gap is less than the circumferential width S2 of the non-slotted region 116. In certain implementations, the width S4 of each gap is substantially less than the width S2 of the non-slotted region 116. In certain implementations, the width S4 of each gap is less than half the width S2 of the non-slotted region 116. In certain implementations, the width S4 of each gap is less than a third of the width S2 of the non-slotted region 116. In certain implementations, the width S4 of each gap is less than a quarter of the width S2 of the non-slotted region 116. In certain implementations, the width S4 of each gap is less than 20% the width S2 of the non-slotted region 116. In certain implementations, the width S4 of each gap is less than 10% the width S2 of the non-slotted region 116.
In certain implementations, the slots 113 occupy about 25% to about 60% of the area of the slotted region 115. In certain implementations, the slots 113 occupy about 35% to about 55% of the area of the slotted region 115. In certain implementations, the slots 113 occupy less than about 50% of the area of the slotted region 115. In certain implementations, the slots 113 occupy about 45% of the area of the slotted region 115. In other words, the percentage of open area to closed area at the slotted region 115 is about 45%.
In some implementations, louvers 114 are disposed at the slotted region 115. In some implementations, each slot 113 has a corresponding louver 114. In other implementations, however, only a portion of the slots 113 have a corresponding louver 114. In some implementations, each louver 114 extends the length of the corresponding slot 113. In other implementations, a louver 114 can be longer or shorter than the corresponding slot 113.
As shown in
In some implementations, each louver 114 extends straight from the slot 113 to define a plane. In certain implementations, the louvers 114 extend from the slot 113 at an angle θ relative to the tube body 111. In certain implementations, the angle θ is about 20° to about 70°. In an example, the angle θ is about 45°. In an example, the angle θ is about 40°. In an example, the angle θ is about 50°. In an example, the angle θ is about 35°. In certain implementations, the angle θ is about 30° to about 55°. In other implementations, each louver 114 defines a concave curve as the louver 114 extends away from the slot 113.
In some implementations, the tube body 111 has a louvered region over which the louvers 114 extend and a non-louvered region over which no louver extends. In some such implementations, the louvered region extends about 200° to about 350° around the tube body 111 and the non-louvered region extends about 10° to about 160° around the tube body 111. In certain examples, the louvered region extends about 210° to about 330° around the tube body 111 and the non-louvered region extends about 30° to about 150° around the tube body 111. In an example, the louvered region extends about 270° around the tube body 111 and the non-louvered region extends about 90° around the tube body 111. In certain examples, the louvered region largely corresponds with the slotted region 115. In an example, the louvered region overlaps the slotted region 115.
Various modifications and alterations of this disclosure will become apparent to those skilled in the art without departing from the scope and spirit of this disclosure, and it should be understood that the scope of this disclosure is not to be unduly limited to the illustrative embodiments set forth herein.
This application is a continuation of U.S. patent application Ser. No. 15/021,567, filed on Mar. 11, 2016, now U.S. Pat. No. 10,369,533, which is a U.S. National Stage Application under 35 U.S.C. § 371 of International Patent Application No. PCT/US2014/055404, filed on Sep. 12, 2014, which claims priority to U.S. Patent Application No. 61/877,749, filed on Sep. 13, 2013, the disclosures of all of which are hereby incorporated by reference in their entireties.
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Number | Date | Country | |
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Parent | 15021567 | US | |
Child | 16531359 | US |