BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more readily understood, reference will now be made, by way of example, to the accompanying drawings in which:
FIG. 1 is a schematic representation of a known exhaust system comprising a selective catalytic reduction (SCR) device;
FIG. 2 is an enlarged view of the SCR device shown in FIG. 1;
FIG. 3 shows a known fluid dosing device for introducing a reducing agent into an exhaust flow;
FIG. 4 shows the fluid dosing device of FIG. 3 at an increased exhaust flow velocity;
FIG. 5 shows a further fluid dosing device for introducing a reducing agent into an exhaust flow;
FIG. 6 shows the fluid dosing device of FIG. 5 at an increased exhaust flow velocity;
FIG. 7 shows a fluid dosing device in accordance with an embodiment of the present invention;
FIG. 8 shows a valve member of the nozzle region of the fluid dosing device of FIG. 7 in a first position;
FIG. 9 shows the valve member of the nozzle region of the fluid dosing device of FIG. 7 in a second position;
FIG. 10 shows the fluid dosing device of FIG. 7 at an increased exhaust flow velocity;
FIG. 11 shows a further fluid dosing device in accordance with an embodiment of the present invention;
FIG. 12 shows the fluid dosing device of FIG. 11 at an increased exhaust flow velocity;
FIG. 13 shows an exhaust pipe including a further fluid dosing device in accordance with an embodiment of the present invention and an additional air supply passage;
FIG. 14 shows a further fluid dosing device incorporating an air supply means in accordance with an embodiment of the present invention; and
FIG. 15 shows a C-shaped fluid dosing device incorporating an air supply means in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 3 shows a known spray arrangement for introducing a reducing agent into an exhaust flow. In FIG. 3, a section through an exhaust pipe 30 is shown. A fluid dosing device, which shall be referred to with reference to the drawings as an injection device (generally indicated as 31), for injecting the reducing agent is provided. The injection device 31 comprises a nozzle body 32 which is shown passing through the lower wall of the pipe 30 and is of a generally C shaped construction. A spray 34 of reducing agent is shown entering the interior of the exhaust pipe 30 from a nozzle 36 of the injection device 31. The nozzle 36 is generally in the centre of the pipe 30.
The direction of the exhaust flow is indicated by the arrow 38. It is noted that the injection device 31 introduces the reducing agent in the same direction as the exhaust gas flow 38.
In FIG. 3 the velocity of the exhaust flow is relatively low and it can be seen that the spray 34 is optimised to achieve full mixing of the spray with the exhaust gases, as indicated by the fact that the spray 34 extends across the diameter 40 of the pipe 32.
FIG. 4 shows the same spray arrangement as FIG. 3 and like numerals have been used to denote like features. In FIG. 4, the direction of the exhaust flow is the same as in FIG. 3. However, the velocity of the exhaust flow is greater than in FIG. 3, as indicated by the larger arrow 42. This results in a problem since the diameter 44 of the spray 34 at the point that it evaporates is now less than the diameter 40 of the pipe 30. There is therefore incomplete mixing of the reducing agent within the increased velocity exhaust flow in the conventional spray arrangement of FIGS. 3 and 4. Further it is noted that in its gaseous form, the reducing agent now requires a long distance of exhaust pipe to fully mix with the exhaust gases. In restricted space environments, for example the underside of a car, it is often not possible to provide enough pipe length between catalyst devices to achieve full mixing.
FIG. 5 shows a further known arrangement for introducing a reducing agent into an exhaust flow. In FIG. 5, a generally C shaped injection device 31 once again passes through the wall of the exhaust pipe 30 such that the nozzle 36 is generally in the centre of the pipe 30. The direction of the exhaust gas flow rate is once again indicated by arrow 38. The velocity of the exhaust gas flow is relatively low (as indicated by the size of the arrow 38).
In FIG. 5 however the nozzle is arranged to introduce the reducing agent in two or more separate sprays 46, 48. The reducing agent in this case is introduced perpendicular to the direction of the exhaust gas flow. Such an arrangement is shown in DE10060808.
It can be seen in FIG. 5 that the injection device 31 is optimised to introduce the reducing agent at this low flow velocity since the sprays 46, 48 extend to the walls of the pipe 30.
FIG. 6 shows the same arrangement as FIG. 5. In FIG. 6 however the velocity of the exhaust gas flow has increased as indicated by the larger arrow 42. The reducing agent sprays 46, 48 are deflected in this higher velocity exhaust gas flow such that there is no longer complete mixing of the spray with the exhaust gases before the spray evaporates.
FIG. 7 shows an arrangement for introducing a reducing agent into an exhaust flow in accordance with the first aspect of the present invention. FIG. 7 shows a section through an exhaust pipe 50. Upper 52 and lower 54 pipe walls are visible.
Exhaust gases flow through the pipe 50 in a generally right to left direction as indicated by the arrow 56.
An injection device 57 in accordance with an embodiment of the present invention comprises a generally tubular nozzle body 58 and is shown entering the pipe 50 through the lower wall 54 of the pipe 50 in the orientation shown. A sealing arrangement 60 clamps the injection device 57 in place and ensures that no exhaust gases can escape at the point where the injection device 57 enters the pipe 50.
The injection device 57 comprises a nozzle 62 which injects reducing agent 64 into the centre of the pipe 50 in a direction that opposes the direction 56 of exhaust gas flow within the pipe 50. The injection device 57 is shaped so as to form substantially a C-shape along its length. End 66 of the injection device 57 is in fluid communication with a source (not shown) of reducing agent, e.g. the urea tank 13 of FIG. 1. A bore (not shown in FIG. 7) runs through the nozzle body 58 such that a fluid communication path exists between the fluid source/end 66 and the nozzle 62.
The spray 64 introduced into the pipe 50 by the injection arrangement (58, 62) is optimised to substantially reach the full cross section of the exhaust pipe 50.
The nozzle 62 of the injection device shown in FIG. 7 comprises a valve arrangement. For ease of reference and the clarity of the drawings the valve arrangement is not shown in FIG. 7 but is depicted in FIGS. 8 and 9.
Turning to FIG. 8, a cross section through the injection device 57 is shown in the region of the nozzle 62. The nozzle body 58/nozzle 62 comprises a nozzle bore 130 within which a nozzle valve element (indicated generally as 132) is located.
The nozzle valve element 132 comprises a piston 134 located towards the end of the nozzle bore 130 and a shaft 136 located on the other side of the piston 134 than the tip of the nozzle 62. The piston 134 is generally a close clearance fit in the nozzle bore 130 such that the nozzle valve element 132 may slide within the nozzle bore. An annular grove 138 is provided in a downstream portion of the piston 134 and the nozzle bore 130. An end of the piston 134 adjacent the tip of the nozzle 62 is flared outwards to define a valve surface 140 of the piston having a diameter greater than the nozzle bore 130. The nozzle bore 130 adjacent the tip of the nozzle is flared to define a sealing surface 142 complementary to the shape of the valve surface 140 of the piston. A nozzle chamber 144 is defined by the annular grove 138 and the bore 130 of the nozzle.
The end of the piston 134 distant from the tip of the nozzle is attached to the shaft 136 of the valve nozzle element 132. A bush 146 is provided within the nozzle bore 130, and the shaft 136 is a clearance fit within the bush 146. The shaft extends into the bore of the injection device. A retaining collar 148 is carried on and fixed to the shaft 136 close to the end of the shaft distant from the piston 134. A nozzle spring 150, comprising a compression spring, is disposed between the retaining collar 148 and the bush 148 so as to bias the valve surface 140 of the piston against the sealing surface 142 of the nozzle.
Helical grooves 152 are provided on an upstream portion of the piston to define helical passages between the piston 134 and the nozzle bore 130. The source of reducing agent is therefore in communication with the tip of the nozzle by way of the helical passages 152 and a clearance 154 between the shaft and the bush.
Referring to FIGS. 8 and 9, as reducing agent is pumped from the source of reducing agent through the bore 130 of the injection device 57, an increase in pressure of the reducing agent is experienced in the nozzle chamber 144 of the nozzle 62. The pressure of the reducing agent within the nozzle chamber 144 acts upon the valve surface 140 of the piston so as to impart a force on the valve nozzle element 132 opposed to the biasing force of the nozzle spring 150. When the pressure of reagent exceeds a threshold value, the force acting on the valve nozzle element 132 due to the reducing agent pressure is sufficient to overcome the biasing force of the nozzle spring 150 and to create a clearance 156 between the valve surface 140 of the piston and the sealing surface 142 of the nozzle (FIG. 9).
When the valve nozzle element is in an open position (the position described above in relation to FIG. 9), reducing agent is expelled from the nozzle 62 by way of the clearance 156. The size of the clearance and the shape of the sealing surface 142 and valve surface 140 are adapted so that, upon expulsion of the reducing agent, the reducing agent forms a hollow conical spray to aid dispersion and mixing of the reducing agent within the exhaust gas stream.
The nozzle valve element 132 described above has the advantage that no reducing agent is exposed to the exhaust gases when the nozzle is not injecting. This reduces the chance of the reducing agent decomposing and blocking the nozzle 62 (or any exhaust contaminants blocking it). It is noted that the movement of the nozzle as it opens tends to be self-cleaning. The hollow conical spray produced is also likely to mix better than the individual sprays in the prior art.
It is noted that the nozzle valve element 132 described in relation to FIGS. 8 and 9 is located in the nozzle 62 of each of the arrangements shown in FIGS. 7 & 10-12. It may also additionally be located in the arrangements depicted FIGS. 13 to 15 relating to the second aspect of the present invention.
FIG. 10 shows the same injection arrangement (58, 62) of FIG. 7. In this Figure however the exhaust gas flow has a greater velocity than in FIG. 7. This greater velocity flow is indicated by arrow 68. It is noted that the direction of the exhaust flow remains from right to left in the Figure.
In the higher velocity flow of FIG. 10 the spray 64 of reducing agent that is introduced from the nozzle 62 of the injection device 57 is deflected backwards (relative to the direction in which it is injected) such that the direction of the spray 64 begins to approximate the direction of the exhaust flow (the changed direction of the spray 64 being indicated by the arrows 70).
It is noted however that, as the distance the spray 64 travels before reaching the walls 52, 54 of the pipe 50 is not substantially altered, the spray 64 still substantially fills the full pipe cross section.
There is a high differential velocity between the spray 64 and the exhaust gas flow 68 at the centre of the pipe in the arrangement of FIG. 10. Close to the pipe walls however there is a low differential velocity between the spray 64 and the exhaust gas flow 68. This varying velocity differential across the pipe 50 results in the formation of vortices 72 downstream from the nozzle 62 of the injection device 57. These vortices 72 act to provide further mixing of the reducing agent 64 with the exhaust gases. It is noted that since these vortices are only generated while the injection device is spraying reducing agent much less energy is required to create them than is the case if the turbulence is generated by deflecting the exhaust gases directly (by for example using an arrangement similar to that shown in DE10060808).
To achieve the most even mixing it is advantageous to inject reducing agent into the centre of the exhaust pipe as shown in Figures. 7 and 10. However, this may be undesirable for reasons of heat management and it is noted that heating of the nozzle of the injection device by the exhaust gases can result in the urea solution exceeding the temperature (around 70° C.) at which crystals precipitate out of it.
To reduce heating of the nozzle and injection device it is known to inject reducing agent from close to the wall of the pipe. An example of this arrangement is shown in DE19856366.
An embodiment of the present invention in which reducing agent is introduced from close to one of the walls of the exhaust pipe is shown in FIGS. 11 and 12.
In FIG. 11 and 12, reducing agent is introduced into the pipe 50 from a linearly shaped injection device 74. The nozzle 76 of this device 74 is shown to be closer to the lower wall 54 of the pipe 50 than the centre of the pipe. The axis of the injection device 74 is orientated such that the spray 78 of reducing agent from the nozzle 76 has an injection direction 80 with a substantial component that opposes the direction 56 of the exhaust gas flow. The angle between the axis of the injection device 74 and the axis of the pipe 50 may generally be in the range 15-45 degrees to ensure good mixing of the reducing agent with the exhaust gases.
The injection device 74 is mounted and received in a complementary shaped port 75 formed by the lower wall 54 of the pipe 50.
FIG. 11 shows a pipe 50 in which the exhaust gases have a relatively low velocity. It can be seen from this Figure that the injection arrangement (74, 76) is optimised to produce a spray 78 that substantially fills the entire cross section of the pipe.
FIG. 12 shows the same arrangement as in FIG. 11 except that the velocity of the exhaust gas flow is relatively higher (as indicated by the larger arrow 68).
The initial injection direction 80 is the same as in FIG. 11 but the increased exhaust gas flow velocity causes the spray 78 to curl backwards until the spray direction changes (as indicated by arrow 82) such that it has a component that is travelling substantially in the same direction as the exhaust gas flow.
It is noted however that the fact that the initial injection occurs substantially against the flow of exhaust gas means that the spray 78 still substantially fills the cross section of the pipe 50. The relatively high velocity differential between the spray 78 and the exhaust gases at the bottom of the pipe 50 (as shown in the orientation illustrated in FIGS. 11 and 12) and the relatively low differential velocity between the spray and exhaust gases at the top of the pipe (as shown in the orientation shown in FIGS. 11 and 12) generates a vortex 84 which further aids mixing of the spray and the exhaust gas.
As noted above, the exhaust flow from an engine may contain contaminants. Furthermore, it is possible for material to deposit out of the reducing agent once it has been injected into the exhaust pipe. Such contaminants and materials may deposit onto the nozzle of an injection device thereby having an adverse affect on the ability of the injection device to form a spray of reducing agent. Such a problem is particularly relevant in the case of the present invention where reducing agent is injected counter to the exhaust flow direction.
FIGS. 13 to 15 show various injection device arrangements designed to reduce the chance of material depositing onto the nozzle of the injection device in accordance with the second aspect of the present invention. It is noted that the arrangements shown in FIGS. 13-15 may also include the valve arrangement described above in relation to FIGS. 8 and 9.
FIG. 13 shows a first arrangement which is generally similar to that depicted in FIG. 12 (it is noted that like numerals have been used to denote like features between FIGS. 12 and 13). In FIG. 13 however the lower pipe wall 54 defines a further injection means 86 located upstream from the injection device 74.
Injection means 86 (air inlet 86) is arranged to introduce a flow of air 88 into the exhaust pipe 50 in substantially the direction of the exhaust flow 68. This air flow 88 forms a pocket 90 of clean air around the nozzle 76 of the injection device 74 thereby reducing the risk of material deposits forming on the nozzle 76 opening.
FIG. 14 shows an alternative design for the injection device 74 shown in FIG. 13. FIG. 14 therefore shows an injection arrangement 92 in which an injection device 94 is mounted and received in a substantially complementary shaped port 96 formed by the lower wall 54 of the pipe 50. The injection device comprises a nozzle 98 within the pipe 50 and serves to convey reducing agent from a source of reducing agent (not shown) to the pipe 50 (the direction of reducing agent being generally indicated by the arrow 100).
An annular clearance 102 surrounds the injection device 94 as defined by the outer surface of the injection device 94 and the inner surface of the socket 96.
The port 96 further comprises an air inlet 104 having an air supply bore 106 that connects the annular clearance 102 to a source of air (indicated by the air flow arrow 108).
The air inlet 104, clearance 102 and source of air together form an air supply means that, in use allows air to flow through the air supply passage 106 and the annular passage 102 to the nozzle opening 98. This flow of air once again forms a pocket 110 of relatively clean air around the injection device 94 and the nozzle 98 thereby reducing the risk that deposits will form on the nozzle 98 and impair injection performance.
FIG. 15 shows a variation of the injection device arrangement of FIGS. 5 and 6 (it is noted that like numerals have been used to denote like features between FIGS. 5, 6 and 15).
In FIG. 15, the injection device 58 is surrounded by a sleeve 112. The sleeve is clamped in position by the sealing arrangement 60. The sleeve 112 is designed such that a gap 114 is defined between the inner surface of the sleeve 112 and the outer surface of the injection device 58.
An air inlet 116, comprising an air supply bore 118, is defined by the sleeve member 112 which serves to connect the gap 114 to a source of air (not shown in FIG. 15).
The source of air and gap 114 together form an air supply means and, in use, a flow of air 120 is passed through the air supply bore 118 and gap 114 to the region of the nozzle 62 of the injection device 58. In this manner a pocket 122 of relatively clean air is formed around the nozzle region of the injection device 58.
It is noted that as a relatively low pressure of air is needed to form the air pockets of FIGS. 13-15, it may conveniently be bled from anywhere in the inlet passages of the engine downstream of the turbocharger's compressor wheel.
It is also noted in the embodiments of FIGS. 13-15 that the air serves to reduce the temperature of the nozzle (76, 98, 62) which further minimises the tendency for crystals to from in the reducing agent solution within the nozzle.
The embodiments of the present invention described above are illustrated injecting into straight, parallel sided sections of the exhaust. However, it will be appreciated by the skilled person that the same principles can be applied for injection into a bend of the exhaust pipe and/or into a pipe of varying cross section. If required, the pipe cross-section can be deliberately varied near the point of injection of the reducing agent in order to optimise the exhaust velocity to achieve the best spray mixing. For instance, the spray could be introduced into the throat region of a venturi in order to inject into a high velocity exhaust flow without generating excessive back pressure.
It will be understood that the embodiments described above are given by way of example only and are not intended to limit the invention, the scope of which is defined in the appended claims. It will also be understood that the embodiments described may be used individually or in combination with the other embodiments described herein.
Patent Application
20080011777
