Vehicle exhaust system with end cap mixer

A vehicle exhaust system comprising:

• an upstream exhaust component defining a first center axis and including at least a first catalyst surrounded by a first outer housing and having a first outermost dimension;
• a downstream exhaust component defining a second center axis and including at least a second catalyst surrounded by a second outer housing and having a second outermost dimension;
• a mixer that connects the upstream and downstream exhaust components, wherein the mixer comprises a first portion associated with an outlet from the first catalyst and a second portion associated with an inlet to the second catalyst, and wherein the first portion comprises a first mixer housing to provide a first end cap for the first outer housing and the second portion comprises a second mixer housing to provide a second end cap for the second outer housing;
• a swirl component positioned at least partially within the first end cap and having a first length;
• an additional component positioned at least partially within the second end cap and having a second length;
• and
• a connection interface between the first and second mixer housings to allow the upstream and downstream exhaust components to be arranged in different positions relative to each other, and wherein the connection interface can comprise a direct connection or can include one or more additional connection components, and wherein a combined length of the first and second lengths is adjusted relative to the first and second outermost dimensions to achieve a desired position of the upstream and downstream exhaust components relative to each other.

A method of assembling a mixer for a vehicle exhaust system comprising:

• providing an upstream exhaust component defining a first center axis and including at least a first catalyst surrounded by a first outer housing and having a first outer dimension;
• providing a downstream exhaust component defining a second center axis and including at least a second catalyst surrounded by a second outer housing and having a second outer dimension;
• connecting the upstream and downstream exhaust components with a mixer, wherein the mixer comprises a first portion associated with an outlet from the first catalyst and a second portion associated with an inlet to the second catalyst, and wherein the first portion comprises a first mixer housing to provide a first end cap for the first outer housing and the second portion comprises a second mixer housing to provide a second end cap for the second outer housing;
• positioning a swirl component having a first length at least partially within the first end cap;
• positioning an additional component having a second length at least partially within the second end cap;
• providing a connection interface between the first and second mixer housings to allow the upstream and downstream exhaust components to be arranged in different positions relative to each other, and wherein the connection interface comprises either a direct connection between the first and second mixer housings or includes one or more additional pipe sections selected from a group of:
• elbow pipe, straight pipe, flexible pipe;
• and
• adjusting a combined length of the first and second lengths relative to the first and second outer dimensions such that the first and second center axes can be arranged to achieve a desired mounting configuration.