Abstract: A vehicle exhaust system includes an exhaust component defining an engine exhaust gas passageway and which includes an opening. A doser defines a doser axis and extends to a doser tip that is configured to spray a reducing agent into the engine exhaust gas passageway through the opening. A cone has a base end positioned adjacent the opening such that an annular gap is formed within the exhaust component around the doser tip. Exhaust gas is directed into the base end of the cone through the annular gap in a direction transverse to the doser axis. This configuration reduces deposit formation while still allowing the reducing agent to be thoroughly mixed with engine exhaust gases prior to introduction of the mixture into a downstream exhaust component.

Abstract: A vehicle exhaust component includes a first exhaust component, a second exhaust component downstream of the first exhaust component, and a mixer that connects an outlet of the first exhaust component to an inlet to the second exhaust component. The mixer includes a first housing portion with a first connection interface and a second housing portion with a second connection interface. The first housing portion is attached to the outlet of the first exhaust component and the second housing portion is attached to the inlet of the second exhaust component. The first and second connection interfaces are connectable to each other in one of a plurality of different connection orientations such that the first and second exhaust components can be positioned at any of a plurality of different mounting orientations relative to each other.

Abstract: A vehicle exhaust component assembly includes an inlet module configured to receive engine exhaust gas, a mixer housing defining an internal cavity that receives engine exhaust gas from the inlet module, and an injection component defining an injection axis and positioned within the internal cavity. The injection component has a fluid inlet and a fluid outlet to direct injected fluid into the internal cavity to mix with the engine exhaust gas. The injection component comprises at least a first curved sheet and a second curved sheet that cooperate with each other to surround the injection axis, wherein the second curved sheet is offset from the first curved sheet by a radial gap to create a swirling gas flow within the injection component to mix with fluid injected via the fluid inlet. An outlet module directs a mixture of engine exhaust gas and fluid to a downstream exhaust component.

Abstract: A vehicle exhaust system includes an exhaust component defining an engine exhaust gas passageway and which includes an opening. A doser defines a doser axis and extends to a doser tip that is configured to spray a reducing agent into the engine exhaust gas passageway through the opening. A cone has a base end positioned adjacent the opening such that an annular gap is formed within the exhaust component around the doser tip. Exhaust gas is directed into the base end of the cone through the annular gap in a direction transverse to the doser axis. This configuration reduces deposit formation while still allowing the reducing agent to be thoroughly mixed with engine exhaust gases prior to introduction of the mixture into a downstream exhaust component.

Abstract: A mixer assembly for a vehicle exhaust system includes a mixer having an upstream end and a downstream end. The mixer defines an internal cavity within which exhaust gases are mixed. A mixer inlet body has an enclosed end and an open end that attaches to the upstream end of the mixer. The mixer inlet body includes an outer peripheral surface extending from the enclosed end to the open end to surround a center axis. The outer peripheral surface includes an inlet port and the enclosed end includes a helically formed portion that initiates a swirling motion to the exhaust gases exiting the inlet port.

Abstract: A vehicle exhaust component assembly includes a first exhaust component, a second exhaust component downstream of the first exhaust component, and an injection system configured to inject a reducing agent into engine exhaust gases upstream of the second exhaust component. A mixer connects an outlet of the first exhaust component to an inlet to the second exhaust component. The mixer includes an outer housing that is configured to direct a mixture of the reducing agent and the engine exhaust gases into the second exhaust component. The mixer also includes at least one insulation feature that is configured to reduce heat lost at the outer housing.

Abstract: A mixer for a vehicle exhaust system includes a mixer housing that defines an interior cavity for engine exhaust gases, and which includes a doser opening formed within a wall of the mixer housing. A cone has a cone inlet opening aligned with the doser opening and a cone outlet into the interior cavity. A cylindrical member surrounds at least a portion of the cone and includes at least one window opening. At least one diverter duct is fixed to the mixer housing and has a first duct end open to the interior cavity and a second duct end at least partially overlapping the at least one window opening such that a portion of the engine exhaust gases in the interior cavity is directed to enter the first duct end, flow through the at least one window and then flow into the cone inlet opening to be mixed with a fluid injected through the doser opening.

Abstract: A vehicle exhaust system component assembly includes a first exhaust component defining a first center axis and a second exhaust component downstream of the first exhaust component and defining a second center axis that is spaced apart from and generally parallel to the first center axis. The first and second exhaust components are spaced apart from each other by an area. A plenum is positioned substantially within the area, and has a first end connected to the first exhaust component and a second end connected to the second exhaust component. The plenum is defined by a non-uniform cross-sectional shape as the plenum extends along a length from the first end to the second end. A doser is mounted to the plenum and is configured to inject a reducing agent to mix with exhaust gases within the plenum.

Abstract: A vehicle exhaust system includes a mixer and a doser that sprays a reducing agent into the mixer to be thoroughly mixed with engine exhaust gases prior to introduction of the mixture into a downstream exhaust component. The mixer includes an upstream baffle with at least one inlet opening and a downstream baffle with at least one outlet opening. An outer peripheral wall surrounds the upstream and downstream baffle and includes a doser opening. A doser is mounted at the doser opening and is configured to spray a reducing agent into an area between the upstream and downstream baffles. A deflector is positioned between the inlet opening and the doser opening to protect spray at the doser opening from direct impact with exhaust gas from the inlet opening, and an impactor is positioned adjacent the deflector and faces the doser opening.

Abstract: A vehicle exhaust system includes an exhaust component having an outer surface and an inner surface that defines an internal exhaust component cavity. At least one bleed hole is formed in the exhaust component to reduce a resonance frequency. The bleed hole comprises a discontinuous opening into the exhaust component cavity.

Abstract: An end cap module for a vehicle exhaust system is comprised of an outer skin and inner skin that cooperate to define an internal cavity. The outer skin includes a mount interface configured for attachment to a vehicle structure. A cast internal sub-structure is mounted within the internal cavity. The inner skin positioned within the internal cavity such that the cast internal sub-structure is positioned between the inner skin and the outer skin.

Abstract: An exhaust component assembly includes a first pipe that defines a center axis and has a first end, and a second pipe that has a second end inserted into the first end of the first pipe such that an outer surface of the second end is in contact with an inner surface of the first end. At least one axial weld connects the first and second ends together.

Abstract: An apparatus sizes an exhaust component that includes an outer shell that surrounds first and second substrates. At least one sensor hole is formed in the outer shell at a location between the first and second substrates. A first end of the outer shell is surrounded with a plurality of first fingers to size the first end around the first substrate to a first cross-section. At least one first finger has a protruding portion at a first finger distal end that is longer than first finger distal ends of the other first fingers. A plurality of second fingers surrounds the second shell end to size the outer shell about the second substrate to a second cross-section. At least one second finger has a recess portion at a second finger distal end that receives the protruding portion of the at least one first finger.

Abstract: A mixer for a vehicle exhaust system includes an upstream baffle with at least one inlet opening configured to receive engine exhaust gas, a downstream baffle with at least one outlet opening configured to conduct engine exhaust gases to a downstream exhaust component, and an outer peripheral wall surrounding the upstream and downstream baffles and defining a mixer central axis. An intermediate plate is positioned between the upstream and downstream baffles to block direct flow from the inlet opening to the outlet opening. The intermediate plate initiates a rotational flow path that directs exhaust gases exiting the inlet opening through a rotation of more than 360 degrees about the mixer central axis before exiting the outlet opening.

Abstract: An adaptive valve assembly includes a pipe defining a passageway for conducting engine exhaust gases, a pivot shaft supported by the pipe, and a valve body coupled to the pivot shaft. The valve body is moveable between an open position where exhaust gas flow through the passageway is increased and a closed position where exhaust gas flow through the passageway is reduced. A resilient member biases the valve body toward the closed position. A retainer assembly includes at least one damping feature that engages the resilient member to dampen vibrations.

Abstract: A method and apparatus forms an exhaust component that includes first and second substrates. An outer shell surrounds the first and second substrates. At least one sensor hole is formed in the outer shell at a location between the first and second substrates. A first end of the outer shell is surrounded with a plurality fingers to size the first end around the first substrate to a first diameter. The plurality of fingers includes an extended finger that is longer than the other fingers such that the extended finger at least partially covers the sensor hole during sizing of the first end. A second end of the outer shell is then surrounded by the fingers to size the second end around the second substrate to a second diameter. The extended finger at least partially covers the sensor hole during sizing of the second end.

Abstract: A vehicle exhaust system includes a mixer having an inlet that receives engine exhaust gases and an outlet to direct swirling engine exhaust gas to a downstream exhaust component. The mixer has a plurality of internal surfaces that come into contact with the engine exhaust gases. At least one of the internal surfaces has a coating comprised of a low-coefficient of friction material.

Abstract: A vehicle exhaust system includes a mixer having an inlet that receives engine exhaust gases and an outlet to direct swirling engine exhaust gas to a downstream exhaust component. The mixer has a plurality of internal surfaces that come into contact with the engine exhaust gases. At least one of the internal surfaces has a coating comprised of a low-coefficient of friction material.

Abstract: A mixer for a vehicle exhaust system includes a mixer body defining a mixer central axis and having an inlet configured to receive engine exhaust gas and an outlet. The mixer further includes an upstream baffle positioned within the mixer body and a downstream baffle positioned within the mixer body to be spaced from the upstream baffle in a direction along the mixer central axis. A doser defines a doser axis and is positioned to spray a reducing agent into an area between the upstream baffle and the downstream baffle such that a mixture of reducing agent and exhaust gas exits the outlet. The mixture moves through a rotational flow path that is at least 360 degrees before exiting the outlet.

Abstract: A mixer for a vehicle exhaust system includes an outer housing having an upstream end and a downstream end. An upstream baffle has an inlet opening configured to receive exhaust gas and is mounted at the upstream end of the outer housing. A downstream baffle has an outlet opening configured to conduct exhaust gases to a downstream exhaust component and is mounted at the downstream end of the outer housing. A doser opening is formed within the outer housing at a location between the upstream and downstream baffles. A cone has a narrow end with an inlet opening and a wide end with an outlet opening. A tapered body portion extends from the narrow end to the wide end, with the cone being aligned with the doser opening. An extension portion extends outwardly from the wide end of the cone and provides a wall that surrounds the outlet opening.