US20150076811A1 - Thin Foil Encapsulated Assemblies - Google Patents
Thin Foil Encapsulated Assemblies Download PDFInfo
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- US20150076811A1 US20150076811A1 US14/467,907 US201414467907A US2015076811A1 US 20150076811 A1 US20150076811 A1 US 20150076811A1 US 201414467907 A US201414467907 A US 201414467907A US 2015076811 A1 US2015076811 A1 US 2015076811A1
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- Prior art keywords
- tube
- injector
- insulation
- housing
- junction
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/14—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having thermal insulation
- F01N13/141—Double-walled exhaust pipes or housings
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/18—Construction facilitating manufacture, assembly, or disassembly
- F01N13/1838—Construction facilitating manufacture, assembly, or disassembly characterised by the type of connection between parts of exhaust or silencing apparatus, e.g. between housing and tubes, between tubes and baffles
- F01N13/1844—Mechanical joints
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2610/00—Adding substances to exhaust gases
- F01N2610/02—Adding substances to exhaust gases the substance being ammonia or urea
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2610/00—Adding substances to exhaust gases
- F01N2610/14—Arrangements for the supply of substances, e.g. conduits
- F01N2610/1453—Sprayers or atomisers; Arrangement thereof in the exhaust apparatus
Definitions
- This application discloses an invention which is related, generally and in various embodiments, to thin foil encapsulated insulation assemblies.
- Typical exhaust after-treatment systems are configured to reduce the level of undesirable exhaust byproducts such as nitrogen oxides.
- conventional exhaust after-treatment systems include a decomposition tube and fitting for an injector designed to inject a urea based diesel exhaust fluid or reductant, which is capable of decomposing into gaseous ammonia and carbon dioxide in the presence of exhaust gas within the tube under certain conditions.
- exhaust gas flows through a selective catalytic reduction (SCR) system where the ammonia reacts with nitrogen oxides to produce nitrogen and water.
- SCR selective catalytic reduction
- Insulating both the decomposition tube and the junction with injector module is possible using double walled tubes with insulation disposed in the annular space between an inner tube and an outer tube.
- Such a junction typically includes the decomposition tube with an integral injector tube to which an injection flange is joined for mounting the injector module.
- Insulating the junction between the decomposition tube and the injector tube is possible using relatively thick outer tubes and insulation housings that can be welded together at the junction to provide the necessary support and structural rigidity required to transfer loads between the decomposition tube and the injector tube. Nonetheless, double-walled tubes are expensive and add weight to the overall system.
- foil is used to surround the tube insulation on both the decomposition tube and the injector tube, but little or no insulation is used at the junction between the decomposition tube and the injector tube because there is no outer tube on which to support an insulated junction housing.
- the present invention overcomes the deficiencies of prior tube junctions by providing a tube junction housing having; a receptacle portion defining an insulation space; a receptacle portion lip joined to the injector housing and defining an injector flange opening; and a base flange joined to the a receptacle portion and including a thin-walled connection surface.
- the receptacle housing portion can define an injector tube axis through the injector flange opening and the base flange is substantially arcuate to define a receiver tube axis spaced apart from the base flange, and the injector tube axis and the receiver tube axis are disposed to define an angle of less than 90°.
- the receptacle portion lip can define connector openings to allow for screws or bolts to connect an injector tube to a receiver tube. Also, the base flange can extend outwardly from the receptacle portion.
- the tube junction housing can further include an injector flange disposed in the tube junction housing adjacent to and substantially co-planar with the injector flange opening.
- the tube junction housing can also include insulation disposed in the insulation space.
- an injector tube assembly in another aspect of the invention, includes: a receiver tube defining a longitudinal axis; tube insulation substantially surrounding the receiver tube; and a thin foil spaced apart from the receiver tube and substantially surrounding the tube insulation; an injector tube joined to the receiver tube at a tube junction and defining an injection tube axis; and a tube junction housing at least partially surrounding the tube junction and having; a receptacle portion defining an insulation space, and a receptacle portion lip joined to the receptacle portion and defining an injector flange opening, and a base flange joined to the receptacle portion and including a thin foil connection surface joined to the thin foil and the base flange rests on the tube insulation and is spaced apart from the receiver tube.
- Junction insulation is preferably disposed in the insulation space and an injection flange can be disposed in the tube junction housing adjacent to the injector flange opening.
- the tube junction housing base flange can be substantially arcuate and spaced apart from the receiver tube axis.
- the tube junction assembly receptacle portion lip preferably defines connector openings for access by screws, bolts or other connectors to secure an injector module to the injection flange.
- the base flange can extend outwardly from the receptacle portion to a distance that minimizes bearing pressure on the tube insulation.
- the assembly can also include an injector flange disposed in the receptacle portion adjacent to and substantially co-planar with the injector flange opening.
- the tube junction assembly also includes insulation disposed in the insulation space.
- FIG. 1 shows a side view of a decomposition tube and injector module assembly with a tube juntion housing in accordance with the present invention
- FIG. 2 shows a perspective view of the embodiment of FIG. 1 ;
- FIG. 3 shows a cross-sectional view of the embodiment of FIG. 1 ;
- FIG. 4 shows a partial cross-sectional perspective view of the embodiment of FIG. 1 ;
- FIG. 5 shows a partial cross-sectional view of an embodiment of a curved decomposition tube assembly
- FIG. 6 shows a perspective view of a tube junction housing of the embodiment of FIG. 1 ;
- FIG. 7 shows a cross-sectional view of the tube junction housing of FIG. 6 ;
- FIG. 8 shows a perspective view of hydroformed tube junction housing used for affixing thin foil around an injector port in a different configuration according to an alternative embodiment of the invention
- FIG. 9 shows a perspective cross-sectional view of an insulated aspirator tube assembly with thin foil encapsulation according to an alternative embodiment
- FIG. 10 shows a perspective view showing the assembly of FIG. 9 with a tube junction housing around the aspirator tube for affixing thin foil;
- FIG. 11 is a partial perspective view of an embossed thin foil used in conjunction with the present invention.
- FIGS. 1 through 4 there is illustrated a partial embodiment of an exhaust after-treatment system 10 , which is coupled to an internal combustion engine (not shown).
- an after-treatment system 10 part of an after-treatment system 10 is illustrated, which is capable of receiving and treating exhaust gas generated by the engine as indicated by directional arrow 12 .
- exhaust gas flows out of the opposite end 15 of the after-treatment system 10 and through an SCR assembly (not-illustrated).
- SCR assembly not-illustrated
- the after-treatment system 10 includes a receiver tube 14 , in this case a decomposition tube, an injector tube 15 , and a tube junction housing that in the illustrated embodiment is a reductant injector housing 16 .
- a reductant injector module 13 (seen in FIG. 1 , but only the injector flange 18 is shown in FIGS. 2 through 4 for clarity) is coupled to a reductant supply source (not shown) and injects reductant past the injector flange 18 , through the injector tube 15 , and into the decomposition tube 14 .
- the injector flange 18 is either welded directly to the injector tube 15 or is integral with and cast from the same material as the injector tube 15 and the decomposition tube 14 .
- the decomposition tube 14 is substantially cylindrically shaped with an elbow at the outlet end 15 , but other shapes, particularly different cross-sectional shapes are possible.
- the decomposition tube 14 includes an inlet 20 to the tube, an inlet tube 22 and an outlet tube 23 .
- the injector tube 15 defines an injector tube axis 25 ( FIGS. 2 and 3 ) that extends outwardly at an angle relative to a receiver tube axis 27 .
- an angle a between the two axes 25 and 27 is less than 90°, but other angles can be used, as seen in FIGS. 9 and 10 , for example.
- the reductant injector housing 16 includes a base flange 24 and receptacle portion 26 extending outwardly at an angle from the base flange 24 .
- the receptacle portion 26 at least partially surrounds the junction 17 and includes a though-hole portion 28 sized and shaped to expose the injector flange 18 to allow connection of the injector module 13 .
- a receptacle portion lip 29 lays over, but is not connected to the injector flange 18 . Cut-outs 31 allow access for bolt holes 29 in the injector flange 18 to be exposed for connecting. While the illustrated embodiment depicts a three bolt hole arrangement, any suitable number of bolt holes can be used, and other suitable connectors and arrangements are possible.
- the decomposition tube 14 is surrounded by a layer of tube insulation 30 which is then encapsulated by a layer of thin foil 32 .
- Junction insulation 34 is preferably provided between the reductant injector housing 16 and the receiver tube 14 .
- the injector housing 16 is held against the junction insulation 34 by the layer of thin foil 32 .
- the reductant injector housing 16 is preferably hydroformed or stamped, and is thicker than the thin foil layer 32 that is welded, adhered to, or otherwise joined to the upper connection surface 33 of the base flange 24 .
- the reductant injector housing 16 is preferably between about 0.8 mm thick and about 2.7 mm thick, and preferably 1.2 mm thick and made of stainless steel, which is relatively thick and rigid compared to the thin foil 32 , as used in this invention.
- the thin foil 32 is less than about 0.8 mm [0.031′′], and preferably between about 0.17 mm [0.006′′] and about 0.20 mm [0.008′′] thick and made of stainless steel, or other formable metal. Embossment and other manufacturing processes can reduce or increase the foil thickness, particularly in localized areas, so the term “about” in reference to thin foil thickness, as used herein, refers to the dimensions of the foil 32 , but subject to changes from manufacturing processes. For example, embossment of thin foil 32 as seen in FIG. 11 , can thicken the foil to about 0.35 mm [0.014′′] to about 0.41 mm [0.016′′] at the embossments.
- the base flange 24 of the reductant injector housing 16 is not directly connected to the decomposition tube 14 , the injector tube 15 , or the junction 17 . Instead, it bears on the tube insulation 30 , and is spaced apart from the receiver tube 14 .
- the base flange 24 is wide enough to distribute loads on the tube insulation 30 and further provides a connection surface 33 (optionally on the upper or lower side of the base flange 24 ) to which the layer of thin foil 32 can be welded, preferably by resistance welding.
- this connection between the base flange 24 and the thin foil 32 could be done with other types of welds utilizing filler materials, brazing, or adhesives.
- the reductant injector housing 16 provides rigidity to prevent denting during service and installation of the reductant injector 13 , for example.
- the injector housing 16 also includes a receptacle portion 26 that defines an insulation space 35 into which junction insulation 34 can be packed to insulate around the injector junction 17 , thus minimizing the temperature drop across the injector tube 15 and the junction 17 with the decomposition tube 14 to improve performance. Additionally, the housing 16 eliminates the need for stamp tooling the thin foil layer 32 to specific contours around the injector, so it can be universally implemented for a specific tube injection configuration.
- a curved decomposition tube assembly 100 is illustrated in FIG. 5 .
- the tube junction housing/reductant injector housing 116 is provided on the outer bend of a receiver tube/decomposition tube 114 where the injector tube 115 joins the receiver tube 114 at a junction 117 .
- the assembly 100 includes a layer of tube insulation 130 around receiver tube 122 and additional junction insulation 134 is provided between the reductant injector housing 116 and the receiver tube 122 .
- the reductant injector flange 118 is either welded directly to the injection tube 115 or is integral with and cast from the same material as the injection tube 115 and the decomposition tube 114 .
- FIGS. 1 the tube junction housing/reductant injector housing 116 is provided on the outer bend of a receiver tube/decomposition tube 114 where the injector tube 115 joins the receiver tube 114 at a junction 117 .
- the assembly 100 includes a layer of tube insulation 130 around receiver tube 122 and additional junction insulation 134 is provided between the reductant inject
- the curved decomposition tube assembly 100 also includes a layer of thin foil 132 substantially surrounding the tube insulation 130 .
- the injector housing 116 is not connected directly to the decomposition tube 114 , the junction 117 , or the injector tube 115 , and instead bears on the tube insulation 130 and/or the thin foil 132 , and is joined to the thin foil 132 .
- the injector housing 16 , 116 connection surface 33 / 133 can be on the top or the bottom of the base flange 24 / 124 , so that the base flange 24 / 124 can be placed above the thin foil 32 / 132 rather than below the thin foil 32 / 132 .
- the injection housing 16 / 116 can also be used in conjunction with other insulation enclosures, such as foil tapes, elastic wraps, or woven/knitted materials for encapsulating insulation.
- FIGS. 1 through 5 are related to exhaust after-treatment systems, but the present invention is not limited to this field.
- the present invention of a stamped pad/housing could be used in conjunction with thin foil to insulate around any complex geometry.
- the present invention can be implemented with sensor couplings, hydrocarbon injectors, bracketed tubes, aspirator tubes or other complex shapes into which thin foil cannot be stamped, or attached.
- FIGS. 8 through 10 Examples of additional alternative embodiments are illustrated in FIGS. 8 through 10 .
- FIG. 8 shows a perspective view of hydroformed pad system 300 having a hydroformed housing 316 used for affixing thin foil 332 around an injector port 319 in the injector flange 318 , and a different configuration that does not completely cover or insulate the junction 317 between the merging tubes 314 and 315 , but provides a base to which the thin foil 332 can be joined. Also, illustrated in FIG. 8 are: a base flange 324 on the housing 316 and an injector axis 325 defined by the injector tube 315 .
- FIG. 9 shows a cross-sectional view of an insulated aspirator tube system 200 having an aspirator tube 215 joined to a receiver tube 214 at a junction 217 .
- Thin foil 232 encapsulation is provided around the receiver tube 214 .
- FIG. 10 shows the assembly 200 from FIG. 9 prior to insulation to illustrate the use of pad/housing 216 around the aspirator tube 215 to aid in affixing thin foil 232 around the tube insulation 230 .
- the housing 216 is not directly affixed to the receiver tube 214 , aspirator tube 215 , or the junction 217 , but instead is able to slide (“float”) relative to the aspirator tube 217 while bearing on the tube insulation 230 .
- Such an arrangement permits the housing 216 to be secured to the thin-foil 232 and bear on the tube insulation 230 to improve the insulation properties around the junction 217 .
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
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- General Engineering & Computer Science (AREA)
- Exhaust Gas After Treatment (AREA)
Abstract
Description
- This application claims the benefit of U.S. Provisional Application No. 61/869,841, filed Aug. 26, 2013.
- This application discloses an invention which is related, generally and in various embodiments, to thin foil encapsulated insulation assemblies.
- In various technologies, effective insulation for providing heat retention is an important design component. One example of a technology in which effective insulation is desired is the field of exhaust after-treatment systems for treatment of harmful exhaust emissions from internal combustion engines. Typical exhaust after-treatment systems are configured to reduce the level of undesirable exhaust byproducts such as nitrogen oxides. Accordingly, conventional exhaust after-treatment systems include a decomposition tube and fitting for an injector designed to inject a urea based diesel exhaust fluid or reductant, which is capable of decomposing into gaseous ammonia and carbon dioxide in the presence of exhaust gas within the tube under certain conditions. After exiting the decomposition tube, exhaust gas flows through a selective catalytic reduction (SCR) system where the ammonia reacts with nitrogen oxides to produce nitrogen and water. The catalytic conversion of nitrogen oxides is highly dependent on temperature, making heat retention through effective insulation a critical design requirement for decomposition tubes.
- Insulating both the decomposition tube and the junction with injector module is possible using double walled tubes with insulation disposed in the annular space between an inner tube and an outer tube. Such a junction typically includes the decomposition tube with an integral injector tube to which an injection flange is joined for mounting the injector module. Insulating the junction between the decomposition tube and the injector tube is possible using relatively thick outer tubes and insulation housings that can be welded together at the junction to provide the necessary support and structural rigidity required to transfer loads between the decomposition tube and the injector tube. Nonetheless, double-walled tubes are expensive and add weight to the overall system. To avoid using double-walled systems, foil is used to surround the tube insulation on both the decomposition tube and the injector tube, but little or no insulation is used at the junction between the decomposition tube and the injector tube because there is no outer tube on which to support an insulated junction housing.
- Thus, there is a need for a tube junction that can be insulated at relatively low cost and maintain light weight of the assembly.
- The present invention overcomes the deficiencies of prior tube junctions by providing a tube junction housing having; a receptacle portion defining an insulation space; a receptacle portion lip joined to the injector housing and defining an injector flange opening; and a base flange joined to the a receptacle portion and including a thin-walled connection surface.
- The receptacle housing portion can define an injector tube axis through the injector flange opening and the base flange is substantially arcuate to define a receiver tube axis spaced apart from the base flange, and the injector tube axis and the receiver tube axis are disposed to define an angle of less than 90°.
- The receptacle portion lip can define connector openings to allow for screws or bolts to connect an injector tube to a receiver tube. Also, the base flange can extend outwardly from the receptacle portion.
- The tube junction housing can further include an injector flange disposed in the tube junction housing adjacent to and substantially co-planar with the injector flange opening.
- The tube junction housing can also include insulation disposed in the insulation space.
- In another aspect of the invention, an injector tube assembly is provided that includes: a receiver tube defining a longitudinal axis; tube insulation substantially surrounding the receiver tube; and a thin foil spaced apart from the receiver tube and substantially surrounding the tube insulation; an injector tube joined to the receiver tube at a tube junction and defining an injection tube axis; and a tube junction housing at least partially surrounding the tube junction and having; a receptacle portion defining an insulation space, and a receptacle portion lip joined to the receptacle portion and defining an injector flange opening, and a base flange joined to the receptacle portion and including a thin foil connection surface joined to the thin foil and the base flange rests on the tube insulation and is spaced apart from the receiver tube. Junction insulation is preferably disposed in the insulation space and an injection flange can be disposed in the tube junction housing adjacent to the injector flange opening.
- The tube junction housing base flange can be substantially arcuate and spaced apart from the receiver tube axis.
- The tube junction assembly receptacle portion lip preferably defines connector openings for access by screws, bolts or other connectors to secure an injector module to the injection flange. The base flange can extend outwardly from the receptacle portion to a distance that minimizes bearing pressure on the tube insulation. The assembly can also include an injector flange disposed in the receptacle portion adjacent to and substantially co-planar with the injector flange opening. Preferably, the tube junction assembly also includes insulation disposed in the insulation space.
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FIG. 1 shows a side view of a decomposition tube and injector module assembly with a tube juntion housing in accordance with the present invention; -
FIG. 2 shows a perspective view of the embodiment ofFIG. 1 ; -
FIG. 3 shows a cross-sectional view of the embodiment ofFIG. 1 ; -
FIG. 4 shows a partial cross-sectional perspective view of the embodiment ofFIG. 1 ; -
FIG. 5 shows a partial cross-sectional view of an embodiment of a curved decomposition tube assembly; -
FIG. 6 shows a perspective view of a tube junction housing of the embodiment ofFIG. 1 ; -
FIG. 7 shows a cross-sectional view of the tube junction housing ofFIG. 6 ; -
FIG. 8 shows a perspective view of hydroformed tube junction housing used for affixing thin foil around an injector port in a different configuration according to an alternative embodiment of the invention; -
FIG. 9 shows a perspective cross-sectional view of an insulated aspirator tube assembly with thin foil encapsulation according to an alternative embodiment; -
FIG. 10 shows a perspective view showing the assembly ofFIG. 9 with a tube junction housing around the aspirator tube for affixing thin foil; and -
FIG. 11 is a partial perspective view of an embossed thin foil used in conjunction with the present invention. - It is to be understood that at least some of the figures and descriptions of the invention have been simplified to illustrate elements that are relevant for a clear understanding of the invention, while eliminating, for purposes of clarity, other elements that those of ordinary skill in the art will understand without illustrations.
- In particular, and by reference to
FIGS. 1 through 4 , there is illustrated a partial embodiment of an exhaust after-treatment system 10, which is coupled to an internal combustion engine (not shown). Referring toFIG. 1 , part of an after-treatment system 10 is illustrated, which is capable of receiving and treating exhaust gas generated by the engine as indicated bydirectional arrow 12. After being treated by the after-treatment system 10, exhaust gas flows out of theopposite end 15 of the after-treatment system 10 and through an SCR assembly (not-illustrated). The embodiments described herein are used in conjunction with an exhaust-after-treatment system, but the present invention is useful in any heat-sensitive system having areceiver tube 14 and aninjector tube 15 joined at a junction 17 (FIGS. 3 and 4 ) to merge or separate two fluid flows. - The after-
treatment system 10 includes areceiver tube 14, in this case a decomposition tube, aninjector tube 15, and a tube junction housing that in the illustrated embodiment is areductant injector housing 16. A reductant injector module 13 (seen inFIG. 1 , but only theinjector flange 18 is shown inFIGS. 2 through 4 for clarity) is coupled to a reductant supply source (not shown) and injects reductant past theinjector flange 18, through theinjector tube 15, and into thedecomposition tube 14. Theinjector flange 18 is either welded directly to theinjector tube 15 or is integral with and cast from the same material as theinjector tube 15 and thedecomposition tube 14. In thestraight decomposition tube 14 embodiment shown inFIGS. 1 through 4 , thedecomposition tube 14 is substantially cylindrically shaped with an elbow at theoutlet end 15, but other shapes, particularly different cross-sectional shapes are possible. Referring toFIG. 2 , thedecomposition tube 14 includes an inlet 20 to the tube, an inlet tube 22 and an outlet tube 23. Theinjector tube 15 defines an injector tube axis 25 (FIGS. 2 and 3 ) that extends outwardly at an angle relative to areceiver tube axis 27. Preferably, an angle a between the twoaxes FIGS. 9 and 10 , for example. - As shown in
FIGS. 1 through 7 , thereductant injector housing 16 includes abase flange 24 andreceptacle portion 26 extending outwardly at an angle from thebase flange 24. Thereceptacle portion 26 at least partially surrounds the junction 17 and includes a though-hole portion 28 sized and shaped to expose theinjector flange 18 to allow connection of theinjector module 13. Areceptacle portion lip 29 lays over, but is not connected to theinjector flange 18. Cut-outs 31 allow access forbolt holes 29 in theinjector flange 18 to be exposed for connecting. While the illustrated embodiment depicts a three bolt hole arrangement, any suitable number of bolt holes can be used, and other suitable connectors and arrangements are possible. - Referring to
FIGS. 3 and 4 , thedecomposition tube 14 is surrounded by a layer of tube insulation 30 which is then encapsulated by a layer ofthin foil 32. Junction insulation 34 is preferably provided between thereductant injector housing 16 and thereceiver tube 14. Theinjector housing 16 is held against the junction insulation 34 by the layer ofthin foil 32. Thereductant injector housing 16 is preferably hydroformed or stamped, and is thicker than thethin foil layer 32 that is welded, adhered to, or otherwise joined to theupper connection surface 33 of thebase flange 24. Thereductant injector housing 16 is preferably between about 0.8 mm thick and about 2.7 mm thick, and preferably 1.2 mm thick and made of stainless steel, which is relatively thick and rigid compared to thethin foil 32, as used in this invention. Thethin foil 32, on the other hand, is less than about 0.8 mm [0.031″], and preferably between about 0.17 mm [0.006″] and about 0.20 mm [0.008″] thick and made of stainless steel, or other formable metal. Embossment and other manufacturing processes can reduce or increase the foil thickness, particularly in localized areas, so the term “about” in reference to thin foil thickness, as used herein, refers to the dimensions of thefoil 32, but subject to changes from manufacturing processes. For example, embossment ofthin foil 32 as seen inFIG. 11 , can thicken the foil to about 0.35 mm [0.014″] to about 0.41 mm [0.016″] at the embossments. - The
base flange 24 of thereductant injector housing 16 is not directly connected to thedecomposition tube 14, theinjector tube 15, or the junction 17. Instead, it bears on the tube insulation 30, and is spaced apart from thereceiver tube 14. Thebase flange 24 is wide enough to distribute loads on the tube insulation 30 and further provides a connection surface 33 (optionally on the upper or lower side of the base flange 24) to which the layer ofthin foil 32 can be welded, preferably by resistance welding. Alternatively, this connection between thebase flange 24 and thethin foil 32 could be done with other types of welds utilizing filler materials, brazing, or adhesives. Thereductant injector housing 16 provides rigidity to prevent denting during service and installation of thereductant injector 13, for example. Theinjector housing 16 also includes areceptacle portion 26 that defines aninsulation space 35 into which junction insulation 34 can be packed to insulate around the injector junction 17, thus minimizing the temperature drop across theinjector tube 15 and the junction 17 with thedecomposition tube 14 to improve performance. Additionally, thehousing 16 eliminates the need for stamp tooling thethin foil layer 32 to specific contours around the injector, so it can be universally implemented for a specific tube injection configuration. - A curved
decomposition tube assembly 100 is illustrated inFIG. 5 . In this embodiment, the tube junction housing/reductant injector housing 116 is provided on the outer bend of a receiver tube/decomposition tube 114 where theinjector tube 115 joins thereceiver tube 114 at ajunction 117. Like the embodiment ofFIGS. 1 through 4 , theassembly 100 includes a layer oftube insulation 130 around receiver tube 122 andadditional junction insulation 134 is provided between thereductant injector housing 116 and the receiver tube 122. The reductant injector flange 118 is either welded directly to theinjection tube 115 or is integral with and cast from the same material as theinjection tube 115 and thedecomposition tube 114. Like the embodiment ofFIGS. 1 through 4 , the curveddecomposition tube assembly 100 also includes a layer ofthin foil 132 substantially surrounding thetube insulation 130. Like the previously described embodiments, theinjector housing 116 is not connected directly to thedecomposition tube 114, thejunction 117, or theinjector tube 115, and instead bears on thetube insulation 130 and/or thethin foil 132, and is joined to thethin foil 132. - As stated above, the
injector housing connection surface 33/133 can be on the top or the bottom of thebase flange 24/124, so that thebase flange 24/124 can be placed above thethin foil 32/132 rather than below thethin foil 32/132. Theinjection housing 16/116 can also be used in conjunction with other insulation enclosures, such as foil tapes, elastic wraps, or woven/knitted materials for encapsulating insulation. - As stated above, the embodiments illustrated in
FIGS. 1 through 5 are related to exhaust after-treatment systems, but the present invention is not limited to this field. The present invention of a stamped pad/housing could be used in conjunction with thin foil to insulate around any complex geometry. For example, the present invention can be implemented with sensor couplings, hydrocarbon injectors, bracketed tubes, aspirator tubes or other complex shapes into which thin foil cannot be stamped, or attached. - Examples of additional alternative embodiments are illustrated in
FIGS. 8 through 10 . -
FIG. 8 shows a perspective view ofhydroformed pad system 300 having ahydroformed housing 316 used for affixingthin foil 332 around an injector port 319 in theinjector flange 318, and a different configuration that does not completely cover or insulate thejunction 317 between the mergingtubes thin foil 332 can be joined. Also, illustrated inFIG. 8 are: abase flange 324 on thehousing 316 and aninjector axis 325 defined by theinjector tube 315. -
FIG. 9 shows a cross-sectional view of an insulatedaspirator tube system 200 having anaspirator tube 215 joined to areceiver tube 214 at ajunction 217.Thin foil 232 encapsulation is provided around thereceiver tube 214.FIG. 10 shows theassembly 200 fromFIG. 9 prior to insulation to illustrate the use of pad/housing 216 around theaspirator tube 215 to aid in affixingthin foil 232 around thetube insulation 230. Thehousing 216 is not directly affixed to thereceiver tube 214,aspirator tube 215, or thejunction 217, but instead is able to slide (“float”) relative to theaspirator tube 217 while bearing on thetube insulation 230. Such an arrangement permits thehousing 216 to be secured to the thin-foil 232 and bear on thetube insulation 230 to improve the insulation properties around thejunction 217. - Nothing in the above description is meant to limit the invention to any specific formulation, calculation, or methodology. Many formulation, calculation and methodology substitutions are contemplated within the scope of the invention and will be apparent to those skilled in the art. The embodiments described herein were presented by way of example only and should not be used to limit the scope of the invention.
- Although the invention has been described in terms of particular embodiments in this application, one of ordinary skill in the art, in light of the teachings herein, can generate additional embodiments and modifications without departing from the spirit of, or exceeding the scope of, the described invention. Accordingly, it is understood that the drawings and the descriptions herein are proffered only to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
Claims (14)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US14/467,907 US20150076811A1 (en) | 2013-08-26 | 2014-08-25 | Thin Foil Encapsulated Assemblies |
US15/638,753 US10329991B2 (en) | 2013-08-26 | 2017-06-30 | Thin foil encapsulated assemblies |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US201361869841P | 2013-08-26 | 2013-08-26 | |
US14/467,907 US20150076811A1 (en) | 2013-08-26 | 2014-08-25 | Thin Foil Encapsulated Assemblies |
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US15/638,753 Division US10329991B2 (en) | 2013-08-26 | 2017-06-30 | Thin foil encapsulated assemblies |
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US15/638,753 Active 2034-09-12 US10329991B2 (en) | 2013-08-26 | 2017-06-30 | Thin foil encapsulated assemblies |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20180306081A1 (en) * | 2015-10-30 | 2018-10-25 | Continental Automotive Gmbh | Fluid Injection System |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
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DE102019114999A1 (en) * | 2019-06-04 | 2020-12-10 | Friedrich Boysen Gmbh & Co. Kg | Unit for a structural component, in particular an exhaust system, of a vehicle or for a stationary exhaust system |
US11555437B2 (en) * | 2020-12-07 | 2023-01-17 | Caterpillar Inc. | Exhaust pipe |
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Also Published As
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US10329991B2 (en) | 2019-06-25 |
US20170298804A1 (en) | 2017-10-19 |
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