Mixer for an exhaust system

Abstract

A mixer for an exhaust system of an internal combustion engine, for mixing a reactant with an exhaust gas flow, includes guide blade portions, fold webs and spacer webs. The guide blade portions are provided as guide blade pairs including a first blade portion connected to a second guide blade portion by at least one of the fold webs and folded at the at least one of the fold webs such that the first blade portion is disposed extending adjacent to and spaced from the second guide blade portion. Each of the guide blade pairs is connected to at least one adjacent guide blade pair by at least one of the spacer webs. The fold webs are disposed centrally and located adjacent to each other in an annular pattern of adjacent fold webs and the spacer webs are disposed peripherally spaced apart from each other about a circumference of the mixer.

Claims

1. A mixer for an exhaust system of an internal combustion engine for mixing a reactant with an exhaust gas flow, the mixer comprising: a plurality of guide blade portions; fold webs, the guide blade portions being provided as guide blade pairs comprising a first blade portion connected to a second guide blade portion by at least one of the fold webs and folded at the at least one of the fold webs such that the first blade portion is disposed extending adjacent to and spaced from the second guide blade portion; and spacer webs, each of the guide blade pairs being connected to at least one adjacent guide blade pair by at least one of the spacer webs, wherein the fold webs are disposed centrally and located adjacent to each other in an annular pattern of adjacent fold webs and the spacer webs are disposed peripherally spaced apart from each other about a circumference of the mixer, wherein: the guide blade portions, the fold webs and the spacer webs are formed from a single integral flat blank; the guide blade pairs, comprising the first blade portion connected to the second guide blade portion by the at least one of the fold webs, are separated from adjacent guide blade pairs by one of the spacer webs; each of the guide blade portions has a trailing edge axially spaced from a leading edge wherein the trailing edge is adjacent to a trailing surface extending at a pitch angle relative to a leading surface adjacent to the leading edge; and the spacer webs are connected to one of the first blade portions of one guide blade pair adjacent to the leading edge thereof and are connected to one of the second blade portions of another guide blade pair adjacent to the leading edge thereof.

2. A mixer in accordance with claim 1, wherein the guide blade pairs of the integral flat blank are acted on with a forming process or stamping process to bend guide blade pairs to curve each trailing surface of the guide blade pairs to provide the pitch angle and the guide blade pairs are subsequently folded at the at least one of the fold webs such that the first blade portion is disposed extending adjacent to the second guide blade portion and the curve of the trailing surface of the first blade portion follows the curve of the trailing surface of the second guide blade portion.

3. A mixer in accordance with claim 2, wherein subsequently to folding the guide blade pairs, the folded guide blade pairs are rolled to form the annular pattern of adjacent fold webs wherein the fold webs each abut an adjacent fold web at one side and abut an adjacent fold web at another side to form the annular pattern as a pattern of abutting fold webs.

4. A mixer in accordance with claim 2, wherein: the pitch angle of the trailing surface relative to the leading surface of the first blade portion of the guide blade pairs is the same as the angle of the trailing surface relative to the leading surface of the second blade portion of the guide blade pairs; and each trailing edge is axially spaced from each leading edge to define a blade portion axial length and the axial length of the first blade portion of the guide blade pairs is the same as the axial length of the second blade portion of the guide blade pairs.

5. A mixer in accordance with claim 1, wherein: the spacer webs form an outer peripheral pipe contact surface for engaging an inner surface of an exhaust pipe.

6. A mixer for an exhaust system of an internal combustion engine for mixing a reactant with an exhaust gas flow, the mixer comprising: a plurality of guide blade portions; fold webs, the guide blade portions being provided as guide blade pairs comprising a first blade portion connected to a second guide blade portion by at least one of the fold webs and folded at the at least one of the fold webs such that the first blade portion is disposed extending adjacent to and spaced from the second guide blade portion; and spacer webs, each of the guide blade pairs being connected to at least one adjacent guide blade pair by at least one of the spacer webs, wherein the fold webs are disposed centrally and located adjacent to each other in an annular pattern of adjacent fold webs and the spacer webs are disposed peripherally spaced apart from each other about a circumference of the mixer, wherein: the guide blade portions, the fold webs and the spacer webs are formed from a single integral flat blank; the guide blade pairs, comprising the first blade portion connected to the second guide blade portion by the at least one of the fold webs, are separated from adjacent guide blade pairs by one of the spacer webs; each of the guide blade portions has a trailing edge axially spaced from a leading edge; and each of the guide blade portions is connected to another of the guide blade portions of a guide blade pair by two fold webs with a leading fold web adjacent to the leading edge and a trailing fold web adjacent to the trailing edge.

7. A reactant feeding device for an exhaust system of an internal combustion engine, the reactant feeding device comprising: a pipe arrangement for guiding an exhaust gas flow; an injector arranged at the pipe arrangement for generating a spray jet from reactant for introduction of the reactant into the exhaust gas flow; and a mixer arranged in the pipe arrangement downstream of the injector in relation of the exhaust gas flow, the mixer comprising: a plurality of guide blade portions; fold webs, the guide blade portions being provided as guide blade pairs comprising a first blade portion connected to a second guide blade portion by at least one of the fold webs and folded at the at least one of the fold webs such that the first blade portion is disposed extending adjacent to the second guide blade portion; and spacer webs, each of the guide blade pairs being connected to at least one adjacent guide blade pair by at least one of the spacer webs, wherein the fold webs are disposed centrally and located adjacent to each other in an annular pattern of adjacent fold webs and the spacer webs are disposed peripherally spaced apart from each other about a circumference of the mixer, wherein: the guide blade portions, the fold webs and the spacer webs are formed from a single integral flat blank; and the guide blade pairs, comprising the first blade portion connected to the second guide blade portion by the at least one of the fold webs, are separated from adjacent guide blade pairs by one of the spacer webs; the spacer webs are connected to one of the first blade portions of one guide blade pair adjacent to the leading edge thereof and are connected to one of the second blade portions of another guide blade pair adjacent to the leading edge thereof; and the spacer webs form an outer peripheral pipe contact surface for engaging an inner surface of an exhaust pipe.

8. A device in accordance with claim 7, wherein: each of the guide blade portions has a trailing edge axially spaced from a leading edge wherein the trailing edge is adjacent to a trailing surface extending at a pitch angle relative to a leading surface adjacent to the leading edge.

9. A device in accordance with claim 7, wherein the fold webs each abut an adjacent fold web at one side and abut an adjacent fold web at another side to form the annular pattern as a pattern of abutting fold webs.

10. A device in accordance with claim 7, wherein: each of the guide blade portions has a trailing edge axially spaced from a leading edge wherein the trailing edge is adjacent to a trailing surface extending at a pitch angle relative to a leading surface adjacent to the leading edge; the guide blade pairs of the integral flat blank are acted on with a forming process to bend guide blade pairs to curve each trailing surface of the guide blade pairs to provide a pitch angle of a trailing edge relative to a leading edge of each guide blade portion; the guide blade pairs are folded at the at least one of the fold webs subsequent to forming such that the first blade portion is disposed adjacent to the second guide blade portion and the curve of the trailing surface of the first blade portion follows the curve of the trailing surface of the second guide blade portion; and subsequently to folding the guide blade pairs, the folded guide blade pairs are rolled to form the annular pattern of adjacent fold webs wherein the fold webs each abut an adjacent fold web at one side and abut an adjacent fold web at another side to form the annular pattern as a pattern of abutting fold webs.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a highly simplified, circuit schematic diagram of an exhaust system with a reactant injection device which has a mixer according to the invention;

(2) FIG. 2 is a schematic view of an exhaust system as shown in FIG. 1, but in another embodiment with a mixer according to the invention;

(3) FIG. 3 is side plan view of a sheet metal blank;

(4) FIG. 4 is a side plan view of a formed strip;

(5) FIG. 5 is a perspective view of the formed strip of FIG. 4;

(6) FIG. 6 is a top slightly perspective view of a folded guide blade pairs strip;

(7) FIG. 7 is a perspective view of the folded guide blade pairs strip of FIG. 6;

(8) FIG. 8 is a perspective view showing the rolled blade pairs forming the shape of the final mixer;

(9) FIG. 9 is a side view of the mixer of FIG. 8;

(10) FIG. 10 is an trailing end view showing the trailing end of the mixer of FIG. 8;

(11) FIG. 11 is a leading end view showing the leading end of the mixer of FIG. 8;

(12) FIG. 12 is a side view of a mixer having a smaller axial dimension and larger circumferential dimension, as compared to the mixer of FIG. 8;

(13) FIG. 13 is a side view of a mixer having a smaller axial dimension and smaller circumferential dimension, as compared to the mixer of FIG. 8;

(14) FIG. 14 is a side view of a mixer having a larger axial dimension, as compared to the mixer of FIG. 8;

(15) FIG. 15 is a top view of a metal blank/intermediate form with the left portion being flat (following a blank forming stamping process) and the right portion having guide blade pairs formed, such as by further stamping, to provide a bend or curve to the trailing edge surface;

(16) FIG. 16 is a side view of the metal blank/intermediate form of FIG. 15;

(17) FIG. 17 is a top view of an intermediate form with the left portion having guide blade pairs formed to provide a bend or curve to the trailing edge surface and the right portion having folded guide blade pairs following a forming or roll-forming process; and

(18) FIG. 18 is a side view of the intermediate form of the middle blank of FIG. 17.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(19) Referring to the drawings, corresponding to FIGS. 1 and 2, an exhaust system generally designated 1, shown only partially, is used to remove combustion waste gases in an internal combustion engine. The exhaust system 1 comprises an exhaust line generally designated 2 for guiding an exhaust gas flow indicated by arrows 3. An SCR catalytic converter generally designated 4 is arranged in the exhaust line 2. A reactant feeding device generally designated 5 is arranged in the exhaust line 2 upstream of the SCR catalytic converter 4. A reactant, for example, delivered in the form of a spray jet 6, can be fed into the exhaust gas flow 3 via the reactant feeding device 5. A reducing agent may be used as the reactant in connection with such an SCR catalytic converter 4. Nitrogen oxides can be reduced by means of the reducing agent in the SCR catalytic converter. In the example, the exhaust line 2 comprises, upstream of the reactant feeding device 5, an oxidation catalytic converter 7, which is preferably a diesel oxidation catalytic converter or a diesel particulate filter. Downstream of the reactant feeding device 5, the exhaust line 2 may contain a particle (particulate) filter generally designated 8, which is especially a diesel particle filter. The particle filter 8 may be arranged, downstream of the SCR catalytic converter 4. The SCR catalytic converter 4 and the particle filter 8 form separate components in this case. However, FIGS. 1 and 2 show embodiments, in which the SCR catalytic converter 4 is formed by an SCR catalytic converter coating, with which the particle filter 8 is provided. The particle filter 8 has, for example, a ceramic filter body, which has a plurality of inlet ducts, which are closed on the outlet side, and a plurality of outlet ducts, which are closed on the inlet side, wherein partitions, which separate the inlet ducts from the outlet ducts, are permeable to the exhaust gas flow 3, whereas they are essentially impermeable to the particles being entrained. The inlet ducts and/or the outlet ducts may be provided with said SCR catalytic converter coating 9, as a result of which the function of the SCR catalytic converter 4 is integrated in the particle filter 8.

(20) Corresponding to FIGS. 1 and 2, the reactant feeding device 5 comprises a pipe arrangement 10, which is integrated into the exhaust line 2 and which is correspondingly likewise used to guide the exhaust gas flow 3. Further, the reactant feeding device 5 comprises an injector 11 for generating the spray jet 6 from reactant in order to introduce the reactant into the gas flow 3. The injector 11 is arranged for this on or adjacent to the pipe arrangement 10. The reactant feeding device 5 comprises, moreover, a mixer 12, which is arranged downstream of the injector 11 in the pipe arrangement 10 in relation to the exhaust gas flow 3. The mixer 12 is a separate component in relation to the pipe arrangement 10. The mixer 12 is inserted into the pipe arrangement 10 and the mixer 12 is fastened to the pipe arrangement 10 in a suitable manner.

(21) Preferred embodiments of the mixer 12 will be described in more detail below on the basis of FIGS. 3 through 18. The mixer 12 comprises a plurality of guide blade portions 22 that are provided in guide blade pairs 28. Each of the guide blade pairs 28 includes a first guide blade portion 22 connected to a second guide blade portion 22 by at least one fold web 24. In the embodiments shown, two fold webs 24 connect one (first) guide blade portion 22 to another (second) guide blade portion 22 for each of the guide blade pairs 28. The guide blade pairs 28 are connected to each other by at least one spacer web 26. In the embodiments shown, one spacer web 26 connects adjacent guide blade pairs 28.

(22) The mixer is advantageously formed from a single integral flat blank (a sheet metal blank generally designated 20FIG. 3). The flat blank 20 is punched from sheet steel or may be laser cut or otherwise provided from sheet metal. The flat blank 20 includes the guide blade portions 22, fold webs 24 and spacer webs 26. Each of the guide blade pairs 28 is connected to at least one adjacent guide blade pair 28 by at least one of the spacer webs 26. In the embodiments shown, eight guide blade pairs 28 are provided with seven spacer webs 26 between respective adjacent guide blade pairs 28. A first end spacer web segment 38 is at a first end of the flat blank 20, adjacent to a first end guide blade pair 40 and a second end spacer web segment 42 is at a second end of the flat blank 20, adjacent to second end guide blade pair 44.

(23) The mixer 12 is formed from the flat blank 20. The method of forming comprises providing the single integral sheet metal blank 20 with the plurality of guide blade portions 22, the fold webs 24 and the spacer webs 26. Preferably, the guide blade portions 22 are shaped in a forming process such that each of the guide blade portions 22 has other than a flat shape. However, some or all of the guide blade portions 22 may have a flat extent from a guide blade leading edge 36 to a guide blade trailing edge 34. Advantageously, the trailing edge 34, which is axially spaced from the leading edge 36, may have a tailing surface that is at an angle relative to the blade surface proximate to the leading edge 36, to provide a pitch angle. This may promote better mixing. This tailing surface may be flat and the pitch angle may be formed simply by bending the trailing surface relative to the flat leading surfacerelative to the blade surface proximate to the leading edge. The tailing surface or the entire blade may also be bent or curved. Further the bend or curve of the blade surfaces of the same blade pair 28 may be the same or different. In particular, the first portion curved or angled trailing surface 46 of the same blade pair 28 may have essentially the same curved surface as the second portion curved or angled trailing surface 48 of that same blade pair 28 (FIGS. 8 and 9).

(24) According to an advantageous embodiment of the invention, the guide blade pairs 28 of the integral flat blank 20 may be acted on with a twisting forming process to bend guide blade pairs 28 to curve each trailing surface 46, 48 of the guide blade pairs 48. The first blade portion 30 and the second guide blade portion 32 of the flat blank 20 are acted on concurrently to twist the first portion trailing surface 46 and the second portion trailing surface 48 with a same directional twist forming operation. This may also be by acting on the first blade portion 30 and the second guide blade portion 32 of the flat blank 20 with a further stamping process. This provides the formed strip 50 as shown in FIGS. 4 and 5.

(25) Each of the guide blade pairs 28 is folded at the at least one of the fold webs 24 to form a folded strip 60 as shown in FIGS. 6 and 7. If the blades 22 are shaped, curved or bent, the folding occurs subsequent to the forming step. Upon folding, each first blade portion 30 is disposed adjacent to the associated second guide blade portion 32 of each guide blade pair 28. With the forming based on the concurrent twisting of the first portion trailing surface 46 and the second portion trailing surface 48 essentially the same curve and pitch angle are provided for each guide blade 22 of each guide blade pair 28. A stamping of the blades 22 of the flat blank 20 may be used to provide the shaped, curved or bent form. The folding step positions the first blade portion 30 adjacent to the second guide blade portion 32. In the embodiment shown (see FIGS. 6 and 7) the curve of the trailing surface of the first blade portion 30 of a blade pair 28 essentially follows the curve of the trailing surface of the second guide blade portion 32. The first portion curved trailing surface 46 is essentially identical to the second portion curved trailing surface 48. Stamping and forming can be used to provide this and other blade shapes.

(26) The folded pairs 28 are rolled to form rolled blade pairs 62 having the final shape of the mixer 12 as shown in FIGS. 8-11. The shown blade pairs 28 each have first guide blade portion 30 connected to second guide blade portion 32 by two fold webs 24. One of the fold webs 24 is a leading fold web 24, adjacent to, and shown as forming a part of, the leading edge 36 and a trailing fold web 24 is adjacent to and/or forms a part of the trailing edge 34. With the rolled blade pairs 62 configuration of the mixer 12, a leading edge annular pattern of abutting fold webs 64 is provide (FIG. 11) and a trailing edge annular pattern of abutting fold webs 66 is provided (FIG. 10). In this configuration, the fold webs 24 are disposed centrally and located adjacent to each other in an annular pattern of adjacent fold webs 64. The annular pattern 64 may be provided with each of the fold webs 24 abutting two adjacent fold webs 24. The rolling positions the spacer webs 26 such that they are disposed peripherally spaced apart from each other about a circumference of the mixer 12. This provides an outer peripheral pipe contact surface 68. The dimension and shape of the fold webs 24 may be changed to change the annular pattern 64, in particular to increase or decrease or change the shape of a central passage and to change the flow characteristics of the mixer. Also the number and position of the fold webs may be changed. The tailing fold web 24 may be moved axially away from the trailing edge 34 to allow more of the trailing surface to be angled or curved.

(27) After the rolling of the folded pairs, the mixer 12 may be deployed in an exhaust pipe section of a pipe arrangement 10. The spacer webs 26 form an outer peripheral pipe contact surface 68 that may be fixed to an inner surface of an exhaust pipe. The rolled blade pairs 62 may have some resiliency so that the rolled blade pairs 62 expand slightly upon being inserted into the inner surface of an exhaust pipe. The peripheral pipe contact surface 68 or edges and peripheral regions of the webs 26, may be welded or otherwise fixed to the inner surface of an exhaust pipe after insertion of the rolled blade pairs 62. The fixing may include axial stops that prevent the mixer 12 from axially moving relative to the exhaust pipe. In this case the rolled blade pairs 62 may be retained without any welding or bonding. Further, the first end spacer web segment 38 may be welded or bonded to the second end spacer web segment 42 either before or after the mixer 12 is inserted into the exhaust pipe.

(28) The configuration with the rolled blade pairs 62 may be used to provide various different sizes, aspect ratios, blade angles and various other modifications. For example, in FIG. 12 a mixer 12 is shown which has much steeper pitch angles for the blades 22. Further, the mixer 12 has a smaller axial extent (extent in the direction of exhaust gas flow or the direction of the exhaust gas pipe) and has a larger diametercircumference based on a larger spacing between outer edges of the blades 22 and longer spacer webs 26. FIG. 13 shows a mixer 12 with blades 22 which have a less steep pitch angle and with a shorter axial extent and smaller circumference based on a larger spacing between outer edges of the blades 22 and longer spacer webs 26. FIG. 14 shows a mixer 12 with blades 22 which have a less steep pitch angle as compared to the mixer 12 and with a much longer axial extent and with a circumference that is larger than mixer 12 and smaller than mixer 12. The dimension of the spacer webs 26 may be changed and this may be done in conjunction with changes to the shape and size of the fold webs 24. The spacing between the trailing edges of the blade groups and the trailing edges of adjacent blade groups is made uniform in the disclosed embodiment, for uniform mixing. However, the spacing between the trailing edges of the blade groups and the trailing edges of adjacent blade groups as well the spacing between trailing edges of the same group as well as the number of blade groups may be adjusted if needed.

(29) For each of the embodiments, the first blade portions 30 and the second guide blade portions 32 of each guide blade pair 28 may, based on plural pairs 28, be treated as a first guide blade group and a second guide blade group. The first guide blade group may have the same pitch angle as the guide blades of the second guide blade group as per the shown embodiments. The axial length of each first blade portion of the guide blade pairs may be essentially the same as the axial length of the second blade portion of the guide blade pairs. However, the pitch angles and other blade attributes may be made different so that the pitch angle or length alternates between the first guide blade group and the second guide blade group. Also the nature of the curved or angled trailing surfaces 46 of the first guide blade group and the second guide blade group may be different. For example, the forming step may twist the first blade portion is 30 more than the second blade portion is 32 or may only act on one of the blade portions 30 or 32, leaving the other without a curved or angled trailing surface 46. One of the guide blade groups may have a flat blade surface. All or some of the guide blades may have a simple flat trailing surface that is bent (angled) relative to the leading blade surface. The curves may each be different or groups of curves/angle bends may be different or the lengths of each blade, or of groups of blades may be different such that the degree of mixing and the action imparted to the exhaust gas is selectively different at different portions of the mixer. This may be used in conjunction with physical attributes of the exhaust system such as bends of exhaust pipes and angles and mounting positions of the of the spray jet 6.

(30) FIGS. 15-18 show possibilities with regard to providing multiple processes (method steps) in combination,combination steps. The configuration and design of the mixer 12, according to the invention, is such that there are several processing options for manufacture. According to one manufacture method embodiment, the sheet metal is blanked to form the blank 20 as shown in FIG. 3 and formed (FIGS. 4 and 5) from a stamping press to form the formed strip 50. The stamping press used to form the formed strip 50 may the same or a different stamping press from the stamping press used to form the blank 20. The formed strip 50 is then placed or fed again in a different stamping press for a different stamping operation to set a form radii and provide the folded strip 60 (FIGS. 6 and 7). The folded strip 60 is then rolled up to produce the rolled blade pair form 62 of the mixer 12. For example, FIG. 15 shows the progression of the method with the intermediate form 80 having a left portion that is flat (following stamping to form the blank 20) and has a right portion that has guide blade pairs formed to provide a bend or curve to the trailing edge surface. This depicts the blanking and forming progression of the intermediate form 80 with a stamping press. This same intermediate form 80 is shown in FIG. 16 (the intermediate form 80 of FIG. 15 is shown in FIG. 16, viewed from the top with reference to FIG. 15). The output of this stamping press operation is the formed strips 50.

(31) The mixer 12 may also be produced by a form rolling operation by feeding this form rolling operation with formed strips 50. FIG. 17 shows the progression of the intermediate form 90 with a left portion having the configuration of the formed strips 50 and the right portion having passed through the form rolling operation. This intermediate form 90 is shown in FIG. 18 (the intermediate form 90 of FIG. 17 is shown in FIG. 18, viewed from the top with reference to FIG. 17). FIGS. 17 and 18 show a formed strips 50 as the formed strips 50 passes through such a form rolling operation. The advantage to this is that the tooling for such an operation might be much less costly than the tooling for a stamping operation to make the same shape in a press. The configuration and design of the mixer 12, according to the invention, enables either process; typical mixer designs do not.

(32) While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.

(33) TABLE-US-00001 LIST OF REFERENCE CHARACTERS 1 exhaust system 36 guide blade leading edge 2 exhaust line 38 first end spacer web segment 3 exhaust gas flow 40 first end guide blade pair 4 SCR catalytic converter 42 second end spacer web segment 5 reactant feeding device 44 second end guide blade pair 6 spray jet 46 1st portion curved or angled 7 oxidation catalytic converter trailing surface 8 particle filter 48 2nd portion curved or angled 9 SCR catalytic converter coating trailing surface 10 pipe arrangement 50 formed blank 11 injector 60 folded blank 12 mixer 62 rolled blade pairs 20 sheet metal blank 64 leading edge annular pattern 22 guide blade portions of abutting fold webs 24 fold webs 66 trailing edge annular pattern 26 spacer webs of abutting fold webs 28 guide blade pairs 68 outer peripheral pipe contact 30 first blade portion surface 32 second guide blade portion 80 intermediate form 34 guide blade trailing edge 90 intermediate form