CN112282900A

CN112282900A - Exhaust gas aftertreatment system

Info

Publication number: CN112282900A
Application number: CN202010693148.3A
Authority: CN
Inventors: 阿贾伊·钱德拉·梅塔; 阿尔文德·V·哈利纳斯; 基肖尔·德希穆克; 瑞安·彼得森; 普拉蒂克·瓦依希; 戈帕尔·库马尔; 迪佩什·卡达姆; 穆凯什·S·库马尔; 瓦尔加凡·胡什鲁·达斯托尔; 萨钦·夏尔马
Original assignee: Cummins Emission Solutions Inc
Current assignee: Cummins Emission Solutions Inc
Priority date: 2019-07-25
Filing date: 2020-07-17
Publication date: 2021-01-29

Abstract

The present application relates to exhaust aftertreatment systems. A decomposition chamber for a reductant delivery system having a dosing module includes a decomposition chamber inlet, a bend, a decomposition chamber body, a decomposition chamber outlet, and a mounting panel. The decomposition chamber inlet is configured to receive the exhaust gas. The bend is fluidly coupled to the decomposition chamber inlet and configured to receive exhaust gas from the decomposition chamber inlet. The decomposition chamber body is fluidly coupled to the bend and configured to receive exhaust gas from the bend. The decomposition chamber outlet is fluidly coupled to the decomposition chamber body and configured to receive the exhaust gas from the decomposition chamber body and provide the exhaust gas out of the decomposition chamber. The mounting panel has an injector aperture configured to receive a reducing agent. The mounting panel is configured to be coupled to a dosing module.

Description

Exhaust gas aftertreatment system

Technical Field

The present application relates generally to exhaust aftertreatment systems for internal combustion engines.

Background

For internal combustion engines (e.g., diesel engines), Nitrogen Oxides (NO)_x) Compounds may be emitted in the exhaust gas. For example, it may be desirable to reduce NO_xEmissions to comply with environmental regulations. To reduce NO_xEmissions, the reductant may be dosed into the exhaust gas by a dosing system within the exhaust aftertreatment system. The reductant helps to convert a portion of the exhaust gas to non-NO_xEffluents, e.g. nitrogen (N)₂) Carbon dioxide (CO)₂) And water (H)₂O) to reduce NO_xAnd (4) discharging.

Disclosure of Invention

In one embodiment, a decomposition chamber (decomposition chamber) for a reductant delivery system having a dosing module includes a decomposition chamber inlet, a bend, a decomposition chamber body, a decomposition chamber outlet, and a mounting panel. The decomposition chamber inlet is configured to receive the exhaust gas. The bend is fluidly coupled to the decomposition chamber inlet and configured to receive exhaust gas from the decomposition chamber inlet. The decomposition chamber body is fluidly coupled to the bend and configured to receive exhaust gas from the bend. The decomposition chamber outlet is fluidly coupled to the decomposition chamber body and configured to receive the exhaust gas from the decomposition chamber body and provide the exhaust gas out of the decomposition chamber. The mounting panel has an injector aperture (injector aperture) configured to receive a reducing agent. The mounting panel is configured to be coupled to a dosing module. An outer cavity (outer cavity) is concave in curvature. An outer cavity is defined by at least the mounting panel.

In some embodiments, the decomposition chamber inlet is centered on a decomposition chamber inlet axis; the outlet of the decomposition chamber takes the axis of the outlet of the decomposition chamber as the center; and the decomposition chamber inlet axis and the decomposition chamber outlet axis extend through the mounting panel.

In some embodiments, the decomposition chamber outlet axis is orthogonal to the decomposition chamber inlet axis.

In some embodiments, the decomposition chamber outlet axis intersects the decomposition chamber inlet axis.

In some embodiments, the injector bore is centered on an injector axis; the injector axis is separated from the decomposition chamber outlet axis by a first injector angle; and the injector axis is separated from the decomposition chamber inlet axis by a second injector angle different from the first injector angle.

In some embodiments, the second injector angle is greater than twice the first injector angle.

In some embodiments, the decomposition chamber further comprises a flow divider located within and coupled to the curved portion, the flow divider comprising:

a shunt body;

a diverter body inlet configured to receive exhaust gas from the bend;

a splitter body outlet configured to receive exhaust gas from the splitter body inlet and provide the exhaust gas to the decomposition chamber body; and

a diverter bore located between the diverter body inlet and the diverter body outlet and configured to receive reductant from the injector bore.

In some embodiments, the injector bore is centered on an injector axis; and the injector axis extends through the diverter aperture.

In some embodiments, the decomposition chamber further comprises:

an inner tube coupler coupled to the decomposition chamber body; and

an inner tube contained within the decomposition chamber body, the inner tube coupled to the inner tube coupler, separated from the decomposition chamber body by the inner tube coupler, the inner tube coupled to the flow divider, the inner tube fluidly coupled to the flow divider and configured to receive the exhaust gas and the reductant from the flow divider, and fluidly coupled to the decomposition chamber outlet and configured to provide the exhaust gas to the decomposition chamber outlet.

In some embodiments, the inner tube is fluidly coupled to the bend and configured to receive exhaust gas from the bend.

In some embodiments, the decomposition chamber further comprises a mixer contained within the inner tube, the mixer comprising:

a mixer wall coupled to the inner tube;

a plurality of blades, each of the plurality of blades coupled to the mixer wall; and

a hub coupled to each of the plurality of blades;

wherein the decomposition chamber outlet is centered on a decomposition chamber outlet axis; and is

Wherein the hub is centered about the decomposition chamber outlet axis.

In some embodiments, the diverter further includes a first coupling wall coupled to the diverter body near the diverter body outlet, the first coupling wall blocking exhaust gas from flowing along the first coupling wall between the diverter body and the bend.

In another embodiment, a decomposition chamber for a reductant delivery system having a dosing module includes a decomposition chamber inlet, a bend, a decomposition chamber body, a decomposition chamber outlet, a mounting panel, and a flow splitter. The decomposition chamber inlet is configured to receive the exhaust gas. The bend is fluidly coupled to the decomposition chamber inlet and configured to receive exhaust gas from the decomposition chamber inlet. The decomposition chamber body is fluidly coupled to the bend and configured to receive exhaust gas from the bend. The decomposition chamber outlet is fluidly coupled to the decomposition chamber body and configured to receive the exhaust gas from the decomposition chamber body and provide the exhaust gas out of the decomposition chamber. The mounting panel has an injector orifice configured to receive a reductant and is configured to be coupled to a dosing module. A diverter is located within and coupled to the bend. The diverter includes a diverter body inlet, a diverter body outlet, and a diverter bore. The diverter body inlet is configured to receive exhaust gas from the bend. The splitter body outlet is configured to receive the exhaust gas from the splitter body inlet and provide the exhaust gas to the decomposition chamber body. The diverter bore is configured to receive reductant from the injector bore.

In some embodiments, the decomposition chamber further comprises:

an inner tube coupler coupled to the decomposition chamber body; and

an inner tube contained within the decomposition chamber body, the inner tube coupled to the inner tube coupler, separated from the decomposition chamber body by the inner tube coupler, the inner tube coupled to the flow divider, the inner tube fluidly coupled to the flow divider and configured to receive exhaust gas and reductant from the flow divider, the inner tube fluidly coupled to the decomposition chamber outlet and configured to provide exhaust gas to the decomposition chamber outlet, and fluidly coupled to the bend and configured to receive exhaust gas from the bend.

a mixer wall coupled to the inner tube;

a hub coupled to each of the plurality of blades;

Wherein the hub is centered about the decomposition chamber outlet axis.

In some embodiments, the diverter further includes a first coupling wall coupled to the diverter near the diverter body outlet, the first coupling wall preventing exhaust gas from flowing along the first coupling wall between the diverter and the bend; and the first coupling wall is arranged along a plane orthogonal to the outlet axis of the decomposition chamber.

In yet another embodiment, a decomposition chamber for a reductant delivery system having a dosing module includes a decomposition chamber inlet, a bend, a decomposition chamber body, a decomposition chamber outlet, and a mounting panel. The decomposition chamber inlet is configured to receive the exhaust gas, and the decomposition chamber inlet is centered on a decomposition chamber inlet axis. The bend is fluidly coupled to the decomposition chamber inlet and configured to receive exhaust gas from the decomposition chamber inlet. The decomposition chamber body is fluidly coupled to the bend and configured to receive exhaust gas from the bend. The decomposition chamber outlet is fluidly coupled to the decomposition chamber body, configured to receive the exhaust gas from the decomposition chamber body and provide the exhaust gas out of the decomposition chamber, and is centered about a decomposition chamber outlet axis. The mounting panel is configured to be coupled to the dosing module and has an injector hole configured to receive a reducing agent, and the injector hole is centered on an injector axis. The injector axis is separated from the decomposition chamber outlet axis by a first injector angle; the injector axis is separated from the decomposition chamber inlet axis by a second injector angle different from the first injector angle. The decomposition chamber outlet axis intersects the decomposition chamber inlet axis and is orthogonal to the decomposition chamber inlet axis.

In some embodiments, the decomposition chamber further comprises a flow splitter located within and coupled to the bend, the flow splitter comprising:

a shunt body;

a diverter body inlet configured to receive exhaust gas from the bend;

a diverter bore located between the diverter body inlet and the diverter body outlet and configured to receive reductant from the injector bore;

wherein the splitter aperture is aligned with the injector aperture.

In some embodiments, the decomposition chamber further comprises:

an inner tube coupler coupled to the decomposition chamber body; and

In some embodiments, the second injector angle is greater than the first injector angle.

Drawings

The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the disclosure will become apparent from the description, the drawings, and the claims, wherein:

FIG. 1 is a block schematic diagram of an example exhaust aftertreatment system;

FIG. 2 is a perspective view of an example reductant delivery system for an exhaust aftertreatment system;

FIG. 3 is a cross-sectional view of the reductant delivery system shown in FIG. 2 taken along plane A-A;

FIG. 4 is a cross-sectional view of the reductant delivery system shown in FIG. 2 taken along plane B-B;

FIG. 5 is a cross-sectional view of an example reductant delivery system for an exhaust aftertreatment system;

FIG. 6 is a perspective view of a flexure for the example reductant delivery system shown in FIG. 5;

FIG. 7 is a cross-sectional view of an example reductant delivery system for an exhaust aftertreatment system;

FIG. 8 is a perspective view of a flexure for the example reductant delivery system shown in FIG. 7;

FIG. 9 is a cross-sectional view of an example reductant delivery system for an exhaust aftertreatment system;

FIG. 10 is a cross-sectional view of the reductant delivery system shown in FIG. 9 taken along plane C-C;

FIG. 11 is a cross-sectional view of the reductant delivery system shown in FIG. 9 taken along plane D-D;

FIG. 12 is a cross-sectional view of an example reductant delivery system for an exhaust aftertreatment system;

FIG. 13 is a cross-sectional view of the reductant delivery system shown in FIG. 12 taken along plane E-E;

FIG. 14 is a cross-sectional view of the reductant delivery system shown in FIG. 12 taken along plane F-F;

FIG. 15 is a cross-sectional view of an example reductant delivery system for an exhaust aftertreatment system;

FIG. 16 is a cross-sectional view of the reductant delivery system shown in FIG. 15, taken along plane G-G;

FIG. 17 is a cross-sectional view of the reductant delivery system shown in FIG. 15 taken along plane H-H;

FIG. 18 is a cross-sectional view of a bend of the example reductant delivery system of FIG. 15 taken along plane J-J;

FIG. 19 is a cross-sectional view of an example reductant delivery system for an exhaust aftertreatment system;

FIG. 20 is a cross-sectional view of the reductant delivery system shown in FIG. 19 taken along plane K-K;

FIG. 21 is a cross-sectional view of the reductant delivery system shown in FIG. 19 taken along the plane L-L;

FIG. 22 is a cross-sectional view of a bend of the example reductant delivery system of FIG. 19 taken along plane M-M;

FIG. 23 is a cross-sectional view of an example reductant delivery system for an exhaust aftertreatment system;

FIG. 24 is a cross-sectional view of the reductant delivery system shown in FIG. 23 taken along plane N-N;

FIG. 25 is a cross-sectional view of the reductant delivery system shown in FIG. 23 taken along plane P-P;

FIG. 26 is a cross-sectional view of an example reductant delivery system for an exhaust aftertreatment system;

FIG. 27 is a cross-sectional view of the reductant delivery system shown in FIG. 26 taken along plane Q-Q;

FIG. 28 is a perspective view of a mounting frame for an exhaust aftertreatment system;

FIG. 29 is a perspective view of a portion of the mounting frame shown in FIG. 28; and

fig. 30 is a perspective view of a portion of the mounting frame shown in fig. 28.

It will be appreciated that some or all of the figures are schematic representations for purposes of illustration. The drawings are provided to illustrate one or more embodiments, and it is to be expressly understood that they are not intended to limit the scope or meaning of the claims.

Detailed Description

The following is a more detailed description of embodiments relating to various concepts of and methods, apparatus for treating exhaust gas of an internal combustion engine. The various concepts introduced above and discussed in greater detail below may be implemented in any of numerous ways, as the described concepts are not limited to any particular implementation. Examples of specific embodiments and applications are provided primarily for illustrative purposes.

I. Overview

Internal combustion engines (e.g. diesel internal combustion engines, etc.) produce a fuel containing a gaseous fuel such as NO_x、N₂、CO₂And/or H₂An exhaust gas of O component. In some applications, exhaust aftertreatment systems are used to dose exhaust gases with a reductant to reduce NO in the exhaust gases_xAnd (5) discharging. These exhaust aftertreatment systems may include a decomposition chamber in which a reductant is provided and mixed with the exhaust gas.

Exhaust aftertreatment systems are defined by space requirements (space close). The space requirements are the amount of physical space occupied by the exhaust aftertreatment system when installed (e.g., mounted on a vehicle, etc.), and the location of the physical space occupied by the exhaust aftertreatment system when installed (e.g., coordinates relative to a vehicle coordinate system, etc.). In some applications, the physical space available for the exhaust aftertreatment system is limited due to location of surrounding components, wiring or plumbing requirements, or other similar limitations. Therefore, it is often difficult to modify the exhaust aftertreatment system, as such modifications typically increase the space requirements of the exhaust aftertreatment system. Such modifications may be required when it is desired to use various components (e.g., different types of dosing modules) in an exhaust aftertreatment system.

Embodiments described herein relate to an exhaust aftertreatment system including a decomposition chamber having a bend forming a cavity to partially receive a dosing module. By partially receiving the dosing module within the cavity formed by the bend, different types of dosing modules may be utilized by the exhaust aftertreatment systems described herein without significantly increasing or changing the space requirements of the exhaust aftertreatment systems. Thus, the exhaust aftertreatment system described herein is able to utilize a dosing module in space requirements where the same dosing module was previously unavailable.

The flexures described herein include a mounting panel that defines a cavity. The mounting panel is configured to be coupled to a dosing module. The mounting panel may be angled relative to the decomposition chamber inlet and the decomposition chamber outlet such that the dosing module is offset relative to a central axis of the decomposition chamber. In this way, heat transfer from the exhaust gas to the dosing module may be minimized.

The decomposition chamber described herein may also include a flow diverter. The flow diverter may cooperate with the bend to desirably mix the exhaust gas and the reductant within the decomposition chamber while delivering relatively hot and high velocity exhaust gas to different locations to reduce backpressure of the decomposition chamber and mitigate impingement (impingement) of the reductant within the decomposition chamber.

Example exhaust aftertreatment System

FIG. 1 depicts an exhaust aftertreatment system 100 having an example reductant delivery system 102 for an exhaust gas conduit system 104. The exhaust aftertreatment system 100 also includes a particulate filter (e.g., a Diesel Particulate Filter (DPF))106 and a Selective Catalytic Reduction (SCR) catalyst member 108.

The particulate filter 106 is configured to remove particulate matter (e.g., soot) from the exhaust gas flowing in the exhaust gas conduit system 104. The particulate filter 106 includes an inlet at which the exhaust gas is received and an outlet at which the exhaust gas exits after the particulate matter has substantially been filtered from the exhaust gas and/or converted to carbon dioxide. In some embodiments, the particulate filter 106 may be omitted.

The reductant delivery system 102 includes a decomposition chamber 110 (e.g., a decomposition reactor, a reactor pipe, a decomposition tube, a reactor tube, etc.). Decomposition chamber 110 is configured to convert the reductant to ammonia. The reducing agent may be, for example, urea, Diesel Exhaust Fluid (DEF),

An aqueous urea solution (UWS), an aqueous urea solution (e.g., AUS32, etc.), andother similar fluids. Decomposition chamber 110 includes an inlet fluidly coupled to particulate filter 106 (e.g., configured to be in fluid communication with particulate filter 106, etc.) to receive the NO-containing gas and an outlet_xExhaust gas of the emissions, the outlet being for the exhaust gas, NO_xThe emissions, ammonia, and/or reductants flow to the SCR catalyst member 108.

Reductant delivery system 102 also includes a dosing module 112 (e.g., a doser, etc.), dosing module 112 configured to dose reductant into decomposition chamber 110. The dosing module 112 may include a spacer disposed between a portion of the dosing module 112 and a portion of the decomposition chamber 110 on which the dosing module 112 is mounted.

The dosing module 112 is fluidly coupled to a reductant source 114. The reductant source 114 may include a plurality of reductant sources 114. The reductant source 114 may be, for example, a source containing

The diesel exhaust treatment fluid tank of (1). A reductant pump 116 (e.g., a supply unit, etc.) is used to pressurize reductant from the reductant source 114 for delivery to the dosing module 112. In some embodiments, reductant pump 116 is pressure controlled (e.g., controlled to achieve a target pressure, etc.). The reductant pump 116 includes a reductant filter 118. The reductant filter 118 filters (e.g., strainers, etc.) the reductant before it is provided to internal components (e.g., pistons, vanes, etc.) of the reductant pump 116. For example, the reductant filter 118 may inhibit or prevent the transport of solids (e.g., solidified reductant, contaminants, etc.) to internal components of the reductant pump 116. In this manner, the reductant filter 118 may facilitate long-term desired operation of the reductant pump 116. In some embodiments, the reductant pump 116 is coupled to (e.g., attached to, fixed to, welded to, integrated into, etc.) a vehicle chassis associated with the exhaust aftertreatment system 100.

The dosing module 112 includes at least one injector 120. Each injector 120 is configured to dose a reducing agent into the exhaust gas (e.g., within decomposition chamber 110, etc.). In some embodiments, reductant delivery system 102 also includes an air pump 122. In these embodiments, the air pump 122 draws air from an air source 124 (e.g., air inlet, etc.) and through an air filter 126 disposed upstream of the air pump 122. In addition, the air pump 122 provides air to the dosing module 112 via a conduit. In these embodiments, the dosing module 112 is configured to mix air and reductant into an air-reductant mixture and provide the air-reductant mixture into the decomposition chamber 110. In other embodiments, the reductant delivery system 102 does not include the air pump 122 or the air source 124. In such embodiments, the dosing module 112 is not configured to mix the reductant with air.

The dosing module 112 and the reductant pump 116 are also electrically coupled or communicatively coupled to a reductant delivery system controller 128. The reductant delivery system controller 128 is configured to control the dosing module 112 to dose reductant into the decomposition chamber 110. The reductant delivery system controller 128 may also be configured to control the reductant pump 116.

The reductant delivery system controller 128 includes a processing circuit 130. Processing circuitry 130 includes a processor 132 and a memory 134. The processor 132 may include a microprocessor, an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA), the like, or combinations thereof. The memory 134 may include, but is not limited to, an electronic, optical, magnetic, or any other storage or transmission device capable of providing program instructions to a processor, ASIC, FPGA, or the like. The memory 134 may include a memory chip, an electrically erasable programmable read-only memory (EEPROM), an erasable programmable read-only memory (EPROM), flash memory, or any other suitable memory from which the reductant delivery system controller 128 may read instructions. The instructions may include code from any suitable programming language. Memory 134 may include various modules including instructions configured to be implemented by processor 132.

In various embodiments, the reductant delivery system controller 128 is configured to communicate with a central controller 136 (e.g., an Engine Control Unit (ECU), an Engine Control Module (ECM), etc.) of an internal combustion engine having the exhaust aftertreatment system 100. In some embodiments, the central controller 136 and the reductant delivery system controller 128 are integrated into a single controller.

In some embodiments, the central controller 136 may communicate with a display device (e.g., a screen, a monitor, a touch screen, a heads-up display (HUD), an indicator light, etc.). The display device may be configured to change state in response to receiving information from the central controller 136. For example, the display device may be configured to change between a static state (e.g., displaying a green light, displaying a "SYSTEM OK" message, etc.) and an alarm state (e.g., displaying a flashing red light, displaying a "repair needed (SERVICE NEEDED)" message, etc.) based on communications from the central controller 136. By changing the state, the display device may provide an indication to a user (e.g., an operator, etc.) of the state of the reductant delivery system 102 (e.g., in operation, in need of maintenance, etc.).

Decomposition chamber 110 is located upstream of SCR catalyst member 108. As a result, the reductant is injected by the injector 120 upstream of the SCR catalyst component 108 such that the SCR catalyst component 108 receives a mixture of the reductant and the exhaust gas. The reductant droplets undergo evaporation, pyrolysis, and hydrolysis processes in decomposition chamber 110, SCR catalyst member 108, and/or exhaust gas conduit system 104 to form non-NO_xEmissions (e.g., gaseous ammonia, etc.).

The SCR catalyst member 108 is configured to accelerate NO of the reductant and exhaust gas_xNO between_xReduction into diatomic nitrogen, water and/or carbon dioxide to help reduce NO_xAnd (4) discharging. SCR catalyst component 108 includes an inlet fluidly coupled to decomposition chamber 110, from which exhaust gas and reductant are received, and an outlet fluidly coupled to an end of exhaust gas conduit system 104.

The exhaust aftertreatment system 100 may also include an oxidation catalyst (e.g., a Diesel Oxidation Catalyst (DOC)) fluidly coupled to the exhaust conduit system 104 (e.g., downstream of the SCR catalyst component 108 or upstream of the particulate filter 106) to oxidize hydrocarbons and carbon monoxide in the exhaust gas.

In some embodiments, particulate filter 106 may be positioned downstream of decomposition chamber 110. For example, the particulate filter 106 and the SCR catalyst component 108 may be combined into a single unit. In some embodiments, the dosing module 112 may alternatively be positioned downstream of a turbocharger or upstream of a turbocharger.

While the exhaust aftertreatment system 100 has been shown and described in the context of use with a diesel internal combustion engine, it should be understood that the exhaust aftertreatment system 100 may be used with other internal combustion engines (e.g., gasoline, hybrid, propane, and other similar internal combustion engines).

Example reductant delivery System

2-4 illustrate a reductant delivery system 102 according to an example embodiment. Decomposition chamber 110 includes a decomposition chamber inlet 200 (e.g., inlet fitting, etc.). Decomposition chamber inlet 200 is configured to be coupled to an exhaust conduit of exhaust conduit system 104 upstream of decomposition chamber 110. For example, decomposition chamber inlet 200 may be coupled to an exhaust conduit of exhaust conduit system 104 using a band clamp. Decomposition chamber 110 also includes a decomposition chamber outlet 202 (e.g., outlet fitting, etc.). Decomposition chamber outlet 202 is configured to be coupled to an exhaust gas conduit of exhaust gas conduit system 104 downstream of decomposition chamber 110. For example, decomposition chamber outlet 202 may be coupled to an exhaust conduit of exhaust conduit system 104 using a band clamp.

Decomposition chamber 110 also includes a decomposition chamber body 204 (e.g., a member, etc.). Decomposition chamber body 204 extends from decomposition chamber inlet 200 to decomposition chamber outlet 202 (e.g., decomposition chamber body 204 is connected to decomposition chamber inlet 200 and decomposition chamber outlet 202, etc.). In various embodiments, decomposition chamber inlet 200 and decomposition chamber outlet 202 are structurally integrated with decomposition chamber body 204 (e.g., with decomposition chamber inlet 200, decomposition chamber outlet 202, and decomposition chamber body 204 being of a single piece construction, etc.).

The decomposition chamber inlet 200 is centered on a decomposition chamber inlet axis 206 (e.g., central axis, etc.) (e.g., a center point of the decomposition chamber inlet 200 is on the axis, etc.). Similarly, the decomposition chamber outlet 202 is centered on a decomposition chamber outlet axis 208 (e.g., central axis, etc.). The decomposition chamber inlet axis 206 intersects the decomposition chamber outlet axis 208 and is separated from the decomposition chamber outlet axis 208 by an axis angle a, as measured along a plane bisecting the decomposition chamber inlet 200 and the decomposition chamber outlet 202 along which the decomposition chamber inlet axis 206 and the decomposition chamber outlet axis 208 lie. α may be approximately equal (e.g., within 5%, etc.): 80 °, 85 °, 90 °, 95 °, 100 °, or other similar values.

Decomposition chamber body 204 includes a bend 210 (e.g., elbow, etc.). Bend 210 facilitates a transition of decomposition chamber body 204 from a first portion connected to decomposition chamber inlet 200 to a second portion connected to decomposition chamber outlet 202. Because of α, bend 210 is generally curved (e.g., L-shaped, right-angled, etc.). In various embodiments, decomposition chamber inlet axis 206 and decomposition chamber outlet axis 208 both extend through bend 210.

The flexure 210 includes a mounting panel 212 (e.g., a face, plate, etc.). The mounting panel 212 is configured to be coupled to the dosing module 112 such that the reducing agent from the injector 120 may be provided into the bend 210 and subsequently into the decomposition chamber body 204.

A portion of the mounting panel 212 protrudes (e.g., projects, etc.) into an interior decomposition chamber body cavity 214 (e.g., void, etc.) of the decomposition chamber body 204, into the bend 210. As a result, dosing module 112 is embedded (e.g., partially contained within, etc.) an outer decomposition chamber cavity 216 (e.g., a void, etc.) of flexure 210. The outer decomposition chamber cavity 216 creates an interruption (e.g., a decrease in cross-sectional area, etc.) in the exhaust flow through the bend 210.

Another portion of the mounting panel 212 extends (e.g., protrudes, etc.) from the inner decomposition chamber body cavity 214 of the decomposition chamber body 204. This extension enables the mounting panel 212 to be disposed along a plane such that the dosing module 112 may be angled with respect to the decomposition chamber outlet axis 208 and the decomposition chamber inlet axis 206.

As such, bend 210 facilitates reducing a space requirement (e.g., footprint, external volume, etc.) of reductant delivery system 102 as compared to other systems that do not include a dosing module embedded in the decomposition chamber. The reduction in space requirements may enable the reductant delivery system 102 to utilize a particular dosing module 112, such as a dosing module 112 that does not receive air (e.g., air from the air pump 122 or air source 124, pure liquid dosing module 112, etc.), which other systems cannot readily utilize due to the size of such dosing module 112. As a result, reductant delivery system 102 may utilize some dosing modules 112 (e.g., pure liquid dosing modules 112, etc.) in applications where other systems cannot be used and other types of dosing modules (e.g., air-assisted dosing modules or liquid-air dosing modules) must be used. In some examples, the pure liquid dosing module 112 may be approximately 70% larger (e.g., in height or total volume, width, depth, etc.) than the air-assisted or liquid-to-air dosing module 112.

The mounting panel 212 includes at least one fastener recess 218 (e.g., depression, etc.). The fastener recess 218 is configured to facilitate coupling the dosing module 112 to the mounting panel 212 using a fastener (e.g., a screw, a bolt, a threaded fastener, etc.) without the fastener protruding through the mounting panel 212 (e.g., into the internal relief body cavity 214, etc.).

The mounting panel 212 also includes an injector recess 220 (e.g., a depression, etc.). The injector recess 220 is configured to receive a portion of the injector 120 and/or a portion of the dosing module 112. Injector recess 220 includes an injector hole 222 (e.g., an opening, an orifice, etc.). Injector orifice 222 is configured to facilitate the passage of reductant from injector 120 into internal decomposition chamber body cavity 214.

In various embodiments, fastener recess 218 is shaped and positioned relative to injector bore 222 such that, as exhaust gas flows around fastener recess 218, the exhaust gas flows through injector bore 222 and is directed into inner tube inlet 234. In this manner, fastener recess 218 may mitigate the impact of the reductant near injector orifice 222 (e.g., on injector 120, etc.). By mitigating the impact of the reductant near injector orifice 222, reductant delivery system 102 may be more desirable than other systems that do not include similar mechanisms for mitigating reductant impact (e.g., due to additional cleaning of reductant deposits in these systems, etc.).

Mounting panel 212 is configured such that reductant is provided into internal decomposition chamber body cavity 214 along an injector axis 224 (e.g., a central axis of injector 120, a central axis of injector bore 222, etc.). The injector axis 224 intersects the decomposition chamber outlet axis 208.

The injector axis 224 is separated from the decomposition chamber outlet axis 208 by a first injector angle Φ when measured along a first plane, the injector axis 224, the decomposition chamber outlet axis 208, and the decomposition chamber inlet axis 206 are disposed on the first plane, and the injector axis 224 is separated from the decomposition chamber outlet axis 208 by a second injector angle θ when measured along a second plane orthogonal to the first plane, the injector axis 224 and the decomposition chamber outlet axis 208 are disposed on the second plane, and the second plane is orthogonal to the decomposition chamber inlet axis 206. Φ can be approximately equal to: 11.5 °, 12 °, 12.37 °, 12.5 °, 13 °, or other similar values. θ may be approximately equal to: 30 °, 31 °, 32 °, 32.32 °, 33 °, 34 °, 35 °, or other similar values.

In some embodiments, the injector axis 224 does not intersect the decomposition chamber outlet axis 208 in any plane, but rather the injector axis 224 is parallel to the decomposition chamber outlet axis 208.

In some embodiments, injector axis 224 intersects decomposition chamber outlet axis 208 only along a first plane on which injector axis 224, decomposition chamber outlet axis 208, and decomposition chamber inlet axis 206 are disposed, and does not intersect decomposition chamber outlet axis 208 along a second plane that is orthogonal to the first plane, on which injector axis 224 and decomposition chamber outlet axis 208 are disposed and which is orthogonal to decomposition chamber inlet axis 206. In other embodiments, the injector axis 224 intersects the decomposition chamber outlet axis 208 only along a first plane on which the injector axis 224, the decomposition chamber outlet axis 208, and the decomposition chamber inlet axis 206 are disposed and overlaps the decomposition chamber outlet axis 208 along a second plane that is orthogonal to the first plane, and the injector axis 224 and the decomposition chamber outlet axis 208 are disposed on the second plane and the second plane is orthogonal to the decomposition chamber inlet axis 206.

The mounting panel 212 positions the dosing module 112 and the injector 120 such that the dosing module 112 and the injector 120 may be offset from the decomposition chamber body 204. For example, the mounting panel 212 may be configured such that the decomposition chamber inlet axis 206 does not intersect the dosing module 112 or the injector 120. As a result, heat transfer from the exhaust gas to the dosing module 112 and the injector 120 is reduced. By reducing heat transfer to the dosing module 112 and the injector 120, the temperature of the dosing module 112 and the injector 120 may be maintained at a lower level, thereby increasing the desirability of the dosing module 112 and the injector 120. Further, the offset provided by the mounting panel 212 may facilitate routing of the harness cable and reductant conduit to the dosing module 112.

Decomposition chamber 110 also includes an inner tube 226 (e.g., inner chamber, etc.). The inner tube 226 is at least partially located within the decomposition chamber body 204. In some embodiments, the inner tube 226 is contained within the decomposition chamber body 204 (e.g., the inner tube 226 does not extend into the decomposition chamber outlet 202, etc.).

The inner tube 226 defines an inner tube cavity 228 (e.g., void, etc.) and has an inner tube inlet 230 and an inner tube outlet 232. The inner tube inlet 230 is configured to receive the exhaust gas and the reductant, and the inner tube outlet is configured to provide the exhaust gas and the reductant. A portion of the exhaust gas flowing through the decomposition chamber body 204 may flow between the decomposition chamber body 204 and the inner tube 226 (e.g., such that the portion of the exhaust gas does not flow into the inner tube cavity 228). In various embodiments, the inner tube inlet 230 has a rounded lip 234 (e.g., flange, etc.). The rounded lip 234 is configured to direct exhaust gas into the inner lumen 228.

Decomposition chamber 110 also includes a mixer 236 (e.g., a mixing assembly, etc.), which mixer 236 is contained within inner tube 226. The mixer 236 may include a mixer wall 238. Mixer wall 238 may be coupled to inner tube 226. The mixer 236 also includes a plurality of blades 240 (e.g., blades, etc.) and a hub 242. Each blade 240 is coupled to mixer wall 238 and hub 242. As the exhaust gas flows through the inner lumen 228, the exhaust gas flows between the mixer 236 and the adjacent vanes 240. The exhaust gas is caused to rotate downstream of the mixer 236 by flowing between adjacent vanes 240. This rotation facilitates mixing of the exhaust gas and the reducing agent.

In some embodiments, mixer 236 is positioned outside of inner tube 226. For example, the mixer may be located upstream of the inner tube 226 and downstream of the bend 210. When mixer 236 is located outside inner tube 226, mixer wall 238 may be coupled to decomposition chamber body 204 and/or inner tube 226.

In some embodiments, mixer 236 does not include mixer wall 238. In these embodiments, blades 240 may be coupled directly to inner tube 226.

In various embodiments, the hub 242 is configured to facilitate exhaust gas flow through the hub 242 (e.g., such that a portion of the exhaust gas may flow through the hub 242 without flowing between adjacent blades 240, etc.). In such embodiments, exhaust gas flowing through hub 242 may help to push exhaust gas downstream of mixer 236 toward decomposition chamber outlet 202, thereby reducing backpressure in decomposition chamber 110.

Decomposition chamber 110 also includes an inner tube coupling 244 (e.g., a coupling member, etc.). An inner tube coupler 244 couples the inner tube 226 to the decomposition chamber body 204. The inner pipe coupling 244 facilitates the passage of exhaust gas therethrough so that exhaust gas may pass between the decomposition chamber body 204 and the inner pipe 226 to the decomposition chamber outlet 202. The inner tube coupler 244 may extend partially or completely around the inner tube 226. In some embodiments, decomposition chamber 110 includes a plurality of inner tube couplings 244.

Decomposition chamber 110 also includes a decomposition chamber inner layer 246 (e.g., a wrapping layer, etc.). Decomposition chamber inner layer 246 covers (e.g., overlays, etc.) at least a portion of decomposition chamber body 204. Decomposition chamber inner layer 246 may also cover at least a portion of decomposition chamber inlet 200 and/or decomposition chamber outlet 202.

The decomposition chamber 110 also includes a decomposition chamber outer layer 248 (e.g., a wrapping layer, etc.). Decomposition chamber outer layer 248 covers (e.g., overlays, etc.) at least a portion of decomposition chamber inner layer 246.

Fig. 5 and 6 illustrate a reductant delivery system 102 and its elements, according to various embodiments. Fig. 6 shows flexure 210 in isolation. The mounting panel 212 also includes a first mounting surface 600 (e.g., face, etc.) and a second mounting surface 602 (e.g., face, etc.). In various embodiments, the first mounting surface 600 and the second mounting surface 602 are coplanar. The first mounting surface 600 includes a first fastener hole 604 (e.g., an aperture, opening, etc.) configured to receive a fastener for coupling the dosing module 112 to the mounting panel 212. The first fastener hole 604 extends into the fastener recess 218.

The second mounting surface 602 includes a second fastener hole 606 (e.g., an aperture, an opening, etc.) and a third fastener hole 608 (e.g., an aperture, an opening, etc.), the second fastener hole 606 and the third fastener hole 608 configured to receive a fastener for coupling the dosing module 112 to the mounting panel 212. Second fastener hole 606 and third fastener hole 608 extend within mounting panel protrusion 610 (e.g., a boss, rib, etc.). Mounting panel tabs 610 extend from a portion of decomposition chamber body 204 near inner tube inlet 230 and help position dosing module 112 offset from decomposition chamber body 204. The mounting panel 212 also includes an injector receiver 614 (e.g., a hole, aperture, opening, etc.). The injector receiver 614 is configured to receive the injector 120 and/or the dosing module 112. Injector receiver 614 includes injector bore 222.

Fig. 7 and 8 illustrate a reductant delivery system 102 and elements thereof, according to various embodiments. In these embodiments, inner tube 226 is partially located within bend 210. Further, the mounting panel 212 is configured such that θ is smaller than θ in fig. 4. For example, θ may be approximately equal to: 24 °, 24.5 °, 25 °, 25.5 °, 26 °, or other similar values.

The mounting panel 212 also includes a third mounting surface 800 (e.g., face, etc.). The third mounting surface 800 is parallel to the first mounting surface 600 and the second mounting surface 602. In various embodiments, the third mounting surface 800 is offset from the first mounting surface 600 and the second mounting surface 602. The third mounting surface 800 includes a fourth fastener hole 802 (e.g., an aperture, an opening, etc.) and a fifth fastener hole 804 (e.g., an aperture, an opening, etc.), the fourth and fifth fastener holes 802, 804 configured to receive a fastener for coupling the dosing module 112 to the mounting panel 212. Fourth fastener hole 802 and fifth fastener hole 804 extend within mounting panel protrusion 610.

In various embodiments, the second and third fastener holes 606, 608 are configured to facilitate coupling of one type or configuration of dosing module 112 to the mounting panel 212, and the fourth and fifth fastener holes 802, 804 are configured to facilitate coupling of another type or configuration of dosing module 112 to the mounting panel 212. By including second fastener hole 606, third fastener hole 608, fourth fastener hole 802, and fifth fastener hole 804, mounting panel 212 can facilitate use of reductant delivery system 102 in a variety of different applications, such as applications requiring a pure liquid dosing module 112 or applications requiring an air assisted dosing module 112.

9-11 illustrate a reductant delivery system 102 and elements thereof, according to various embodiments. Decomposition chamber 110 also includes a flow diverter 900. The flow splitter 900 is at least partially contained within the decomposition chamber body 204. In various embodiments, flow splitter 900 is contained within bend 210. As explained in more detail herein, the flow splitter 900 is used to split the exhaust gas as it flows through the bend 210 such that a portion of the exhaust gas bypasses the inner tube 226 and another portion of the exhaust gas flows through the inner tube 226. With the use of the shunt 900, θ may be approximately equal to: 24 °, 24.5 °, 25 °, 25.2 °, 26 °, 27 °, or other similar values.

The shunt 900 includes a shunt body 902 (e.g., frame, etc.). The diverter body 902 includes a diverter body inlet 904 and a diverter body outlet 906. Diverter body inlet 904 is located near decomposition chamber inlet 200 and is suspended within bend 210 (e.g., diverter body inlet 904 does not contact bend 210, etc.). The diverter body outlet 906 is aligned with the inner tube inlet 230 and/or disposed about the inner tube inlet 230. In various embodiments, the splitter body outlet 906 is coupled to the inner tube inlet 230. For example, the diverter body outlet 906 may be coupled to the inner tube inlet 230 around the inner tube inlet 230.

The shunt body 902 defines a shunt lumen 908 (e.g., void, etc.). The diverter cavity 908 is configured to receive exhaust gas from the diverter body inlet 904 and provide the exhaust gas to the diverter body outlet 906. The shunt body 902 includes a shunt hole 910 (e.g., an orifice, an opening, etc.). The diverter aperture 910 is configured to receive the reductant provided by the injector 120. Diverter aperture 910 may be disposed above or aligned with injector aperture 222. In various embodiments, the diverter hole 910 has a diameter that is larger than the diameter of the injector hole 222. This increase in diameter may help to collect reductant displaced by exhaust gas flowing between the mounting panel 212 and the diverter body 902 through the diverter aperture 910.

In some embodiments, the injector 120 extends through the diverter aperture 910 such that reductant is not provided to the exhaust gas between the diverter body 902 and the mounting panel 212. In other embodiments, a portion of the reductant is provided through the diverter aperture 910 and a portion of the reductant is provided to the exhaust between the diverter body 902 and the mounting panel 212. In such embodiments, exhaust gas may flow through the diverter hole 910, causing the reductant provided by the injector 120 to be drawn into the diverter 900 along with the exhaust gas.

Flow splitter 900 also includes a first coupling wall 912 (e.g., panel, member, etc.) and a second coupling wall 914 (e.g., panel, member, etc.). A first coupling wall 912 and a second coupling wall 914 are coupled to the shunt body 902 and the bend 210, respectively, near the shunt body exit 906 or are structurally integrated with the shunt body 902 and the bend 210. For example, the first coupling wall 912 and/or the second coupling wall 914 can be coupled to the diverter body outlet 906. FIG. 11 illustrates the reductant delivery system 102 with the inner tube 226 concealed. In various embodiments, first coupling wall 912 and second coupling wall 914 are disposed along a plane orthogonal to decomposition chamber outlet axis 208. In some embodiments, first coupling wall 912 and second coupling wall 914 are disposed along a plane that is orthogonal to decomposition chamber outlet axis 208 and parallel to decomposition chamber inlet axis 206.

The first coupling wall 912 and the second coupling wall 914 are each coupled to the bent portion 210. In various embodiments, both the first coupling wall 912 and the second coupling wall 914 are additionally coupled to the inner tube 226. For example, the first coupling wall 912 and/or the second coupling wall 914 may be coupled to the inner tube 226 near the inner tube inlet 230.

A first diverter channel 916 (e.g., a cavity, etc.) is defined between the first coupling wall 912, the second coupling wall 914, the bend 210, and the diverter body 902. Similarly, a second diverter channel 918 (e.g., a cavity, etc.) is defined between the first coupling wall 912, the second coupling wall 914, the bend 210, and the diverter body 902.

As the exhaust gas flows into elbow 210, a first portion of the exhaust gas flows into diverter body inlet 904 and a second portion of the exhaust gas flows between diverter body 902 and elbow 210. The exhaust gas flowing between the diverter body 902 and the bend 210 is not provided with reductant from the dosing module 112. As a result, the exhaust gas flowing between the diverter body 902 and the bend 210 is relatively hot, thereby heating the diverter body 902. By heating the diverter body 902, the impact of the reductant (e.g., accumulation of reductant deposits, etc.) may be mitigated, thereby increasing the desirability of the reductant delivery system 102. Exhaust gas flowing between the diverter body 902 and the bend 210 flows into the first diverter channel 916, into the second diverter channel 918, against (against) the first coupling wall 912, or against the second coupling wall 914. Exhaust gas flowing against the first or

second coupling wall

912, 914 is redirected toward the first or

second diverter channels

916, 918.

When exhaust gas flows out of the first diverter channel 916 and exhaust gas flows out of the second diverter channel 918, exhaust gas is not provided into the inner tube inlet 230. Instead, exhaust gas exiting the first diverter channel 916 and exhaust gas exiting the second diverter channel 918 flow between the inner tube 226 and the decomposition chamber body 204, through the inner tube coupling 244, and over the inner tube 226 to the decomposition chamber outlet 202. As a result, exhaust gas flowing into the first diverter channel 916 and exhaust gas flowing into the second diverter channel 918 do not flow through the mixer 236, thereby causing exhaust gas flowing around the inner tube 226 and into the decomposition chamber outlet 202 to have a greater velocity than exhaust gas flowing through the inner tube 226 and into the decomposition chamber outlet 202. This causes the exhaust gas flowing around the inner tube 226 and into the decomposition chamber outlet 202 to push the exhaust gas flowing through the inner tube 226 towards the decomposition chamber outlet 202. In addition, since the reducing agent is provided to the exhaust gas flowing through the inner tube 226 and the mixer 236, the exhaust gas flowing out of the first splitter passage 916 and the exhaust gas flowing out of the second splitter passage 918 have a higher temperature than the exhaust gas flowing through the inner tube 226 and the mixer 236. As a result, the exhaust gas flowing out of the first splitter passage 916 and the exhaust gas flowing out of the second splitter passage 918 heat the inner tube 226 and the mixer 236 and mitigate impingement of the reductant on the inner tube 226 and the mixer 236.

Fig. 12-14 illustrate a reductant delivery system 102 and elements thereof, according to various embodiments. In these embodiments, flow diverter 900 does not include second coupling wall 914, but only first coupling wall 912. As a result, diverter 900 does not include second diverter channel 918, but only first diverter channel 916.

The first coupling wall 912 may be sized to define (e.g., encircle, extend around, etc.) approximately half of the circumference of the diverter body 902. As a result, the first diverter channel 916 defines about half of the circumference of the diverter body 902.

Exhaust gas flowing between the diverter body 902 and the bend 210 flows into the first diverter channel 916 or against the first coupling wall 912 (e.g., exhaust gas does not flow into the second diverter channel or against the second coupling wall). The exhaust gas flowing against the first coupling wall 912 is redirected towards the first diverter channel 916.

When the exhaust gas flows out of the first diverter channel 916, the exhaust gas is not provided into the inner tube inlet 230. Instead, exhaust gas exiting the first diverter channel 916 flows between the inner tube 226 and the decomposition chamber body 204, through the inner tube coupling 244, and over the inner tube 226 to the decomposition chamber outlet 202. As a result, exhaust gas flowing into the first diverter channel 916 does not flow through the mixer 236, thereby causing exhaust gas flowing around the inner tube 226 and into the decomposition chamber outlet 202 to have a greater velocity than exhaust gas flowing through the inner tube 226 and into the decomposition chamber outlet 202. This causes the exhaust gas flowing around the inner tube 226 and into the decomposition chamber outlet 202 to push the exhaust gas flowing through the inner tube 226 towards the decomposition chamber outlet 202. Additionally, the exhaust gas exiting the first diverter channel 916 has a higher temperature than the exhaust gas flowing through the inner tube 226 and the mixer 236 due to the reductant provided to the exhaust gas flowing through the inner tube 226 and the mixer 236. As a result, the exhaust gas flowing out of the first diverter channel 916 heats the inner tube 226 and the mixer 236 and mitigates impingement of the reductant on the inner tube 226 and the mixer 236.

15-18 illustrate a reductant delivery system 102 and elements thereof, according to various embodiments. In these embodiments, flow diverter 900 does not include second coupling wall 914, but only first coupling wall 912. As a result, decomposition chamber 110 does not include second flow splitter passage 918. Instead, decomposition chamber 110 includes only first diverter channel 916. However, the first diverter channel 916 is not defined between the bend 210, diverter body 902 and two coupling walls, but only between the bend 210, diverter body 902 and first coupling wall 912. Therefore, the exhaust gas flowing through the bent portion 210: (i) flows into the diverter body inlet 904 and out the diverter body outlet 906, or (ii) does not flow into the diverter body inlet 904, but bypasses the diverter 900 by flowing through the first diverter channel 916.

Exhaust gas flowing within the first diverter channel 916 may flow into the diverter body inlet 904 and exhaust gas flowing within the diverter chamber 908 may flow into the first diverter channel 916. Similarly, the reductant provided to the exhaust gas within the diverter chamber 908 may also be provided to the exhaust gas within the first diverter channel 916. Exhaust gas flowing against the first coupling wall 912 may be redirected toward the first diverter channel 916 or may flow into the diverter body inlet 904.

Along a plane orthogonal to the decomposition chamber outlet axis 208 along which the diverter body outlet 906 is disposed, such as plane G-G, the first coupling wall 912 may be generally semi-circular along the plane. Thus, the diverter cavity 908 and the first diverter channel 916 may each be semi-circular. In one embodiment, the first coupling wall 912 extends along approximately half of the circumference of the bend 210 as measured along a plane orthogonal to the decomposition chamber outlet axis 208 along which the splitter body outlet 906 is disposed.

The angular length (angular length) of first coupling wall 912 and/or second coupling wall 914 is related to the amount of exhaust gas flowing into first diverter channel 916, the amount of gas flowing into second diverter channel 918, and the amount of exhaust gas flowing into diverter body inlet 904. As such, the angular length of first coupling wall 912 and/or second coupling wall 914 may be modified to make reductant delivery system 102 suitable for a target application.

The first diverter channel 916 extends through (e.g., bisects, etc.) the inner tube inlet 230. As a result, exhaust gas may be provided from the first diverter channel 916 and enter the inner tube inlet 230 or flow around the inner tube inlet 230 without flowing into the inner tube 226. Thus, some of the exhaust gas flowing through the inner tube 226, i.e., the exhaust gas provided by the first diverter channel 916 into the inner tube inlet 230, may have a greater velocity and a higher temperature than other exhaust gas flowing through the inner tube 226, which is provided into the inner tube inlet 230 by the diverter body outlet 906. As such, the first diverter channel 916 may help to push the exhaust gas through the inner tube 226 and help to heat the inner tube 226 and the mixer 236 to reduce the impact of the reductant on the inner tube 226 and the mixer 236. Similarly, the exhaust gas flowing from the first diverter channel 916 around the inner tube 226 may have a greater velocity and a higher temperature than the exhaust gas flowing from the diverter body outlet 906 into the inner tube inlet 230 due to the reductant provided to the exhaust gas within the diverter 900. The exhaust gas flowing around the inner tube 226 may heat the inner tube 226 and the mixer 236 and mitigate impingement of the reductant on the inner tube 226 and the mixer 236.

19-22 illustrate a reductant delivery system 102 and elements thereof, according to various embodiments. In these embodiments, flow splitter 900 does not include first coupling wall 912 or second coupling wall 914. Rather than being coupled to bend 210 using first coupling wall 912 or second coupling wall 914, flow splitter 900 also includes first divider wall 2000 (e.g., a panel, a member, etc.) and second divider wall 2002 (e.g., a panel, a member, etc.). The first and

second partition walls

2000, 2002 are each coupled to the diverter body 902 and the bend 210 near the diverter body outlet 906 or are structurally integrated with the diverter body 902 and the bend 210. Unlike the first and

second coupling walls

912, 914, the first and

second partition walls

2000, 2002 are relatively thin and do not redirect exhaust gases. Instead, the first and

second partition walls

2000, 2002 serve to couple the flow splitter 900 to the bend 210 and separate the flow splitter cavity 908 from the internal breaking chamber body cavity 214.

Exhaust gas flowing within the first diverter channel 916 may flow into the diverter body inlet 904 and exhaust gas flowing within the diverter chamber 908 may flow into the first diverter channel 916. Similarly, the reductant provided to the exhaust gas within the diverter chamber 908 may also be provided to the exhaust gas within the first diverter channel 916. However, exhaust gas flowing within second diverter channel 918 is separated from diverter body inlet 904.

A first diverter channel 916 is defined between the first divider wall 2000, the second divider wall 2002, the bend 210, and the diverter body 902. Similarly, a second diverter channel 918 is defined between first divider wall 2000, second divider wall 2002, bend 210, and diverter body 902. As a result, the exhaust gas flowing through the bent portion 210: (i) into the diverter body inlet 904 and out of the diverter body outlet 906, (ii) into the first diverter channel 916, or (iii) into the second diverter channel 918.

In some embodiments, the first and

second divider walls

2000, 2002 are each configured such that exhaust gas may flow from the first and

second splitter passages

916, 918 into the inner tube inlet 230 or around the inner tube 226.

In some embodiments, the first and

second divider walls

2000, 2002 are each configured such that exhaust gas exiting the first diverter channel 916 may only flow into the inner tube inlet 230 and may not flow around the inner tube 226. In some of these embodiments, the first divider wall 2000 and the second divider wall 2002 may each be configured such that exhaust gas exiting the second splitter passage 918 may flow into the inner tube inlet 230 and around the inner tube 226. In other of these embodiments, the first divider wall 2000 and the second divider wall 2002 may each be configured such that exhaust gas exiting the second splitter passage 918 may flow only around the inner tube 226 and may not flow into the inner tube inlet 230.

Along a plane orthogonal to the decomposition chamber outlet axis 208 along which the diverter body outlet 906 is disposed, such as plane K-K, the first partition wall 2000 is aligned with the second partition wall 2002 (e.g., the first partition wall 2000 is disposed along an axis and the second partition wall 2002 is also disposed along the axis, etc.). Thus, the diverter cavity 908 and the first diverter channel 916 may each be semicircular in shape along a plane.

The first diverter channel 916 extends through (e.g., bisects, etc.) the inner tube inlet 230. As a result, exhaust gas may be provided from the first diverter channel 916 and enter the inner tube inlet 230 or surround the inner tube inlet 230 without flowing into the inner tube 226. Thus, some of the exhaust gas flowing through the inner tube 226, i.e., the exhaust gas provided by the first diverter channel 916 into the inner tube inlet 230, may have a greater velocity and a higher temperature than other exhaust gas flowing through the inner tube 226, which is provided into the inner tube inlet 230 by the diverter body outlet 906. As such, the first diverter channel 916 may help to push the exhaust gas through the inner tube 226 and help to heat the inner tube 226 and the mixer 236 to reduce the impact of the reductant on the inner tube 226 and the mixer 236. Similarly, the exhaust gas flowing from the first diverter channel 916 around the inner tube 226 may have a greater velocity and a higher temperature than the exhaust gas flowing from the diverter body outlet 906 into the inner tube inlet 230 due to the reductant provided to the exhaust gas within the diverter 900. The exhaust gas flowing around the inner tube 226 may heat the inner tube 226 and the mixer 236 and mitigate impingement of the reductant on the inner tube 226 and the mixer 236.

The flow diverter 900 also includes a flow diverter 2200. The flow guide 2200 is coupled to the diverter body 902 about a diverter aperture 910 and to the mounting panel 212 about the injector aperture 222. The flow guide 2200 may separate the reducing agent provided from the injector 120 from the exhaust flowing within the second flow splitter passage 918. The injector 120 may be coupled to the mounting panel 212 rather than extending through the mounting panel 212.

23-25 illustrate a reductant delivery system 102 and elements thereof, according to various embodiments. In these embodiments, flow splitter 900 does not include first coupling wall 912, second coupling wall 914, first divider wall 2000, or second divider wall 2002. Rather than being coupled to flexure 210 using first coupling wall 912, second coupling wall 914, first divider wall 2000, or second divider wall 2002, flow splitter 900 is coupled to mounting panel 212 about injector hole 222. The flow splitter 900 separates the reductant provided from the injector 120 from the portion of the exhaust gas flowing within the second splitter passage 918.

The diverter body inlet 904 extends annularly along the diverter body 902, extending annularly around the diverter aperture 910, and thus extending annularly around the reductant provided by the injector 120. The diverter body inlet 904 is disposed at an upstream portion of the diverter body 902 such that exhaust gas may enter the diverter body cavity 908 via the diverter body inlet 904 without first flowing around the diverter body 902.

In various embodiments, the diverter 900 is configured such that exhaust gas flowing out of the diverter outlet 906 may flow into the inner tube inlet 230 or around the inner tube 226. For example, the splitter outlet 906 may be disposed upstream of the inner tube inlet 230 and separate from the inner tube inlet 230. In other embodiments, the diverter 900 is configured such that exhaust gas flowing out of the diverter outlet 906 may only flow into the inner tube inlet 230 and may not flow around the inner tube 226. For example, the diverter outlet 906 may be disposed within the inner tube 226.

The flow directing body 902 may be generally conical (e.g., frustoconical, etc.) and have a smaller diameter or apex near the injector orifice 222 and a largest diameter at the flow directing outlet 906. In addition to surrounding the injector holes 222, the flow directing body 902 may be separated from the bend 210 so that exhaust may flow completely around the flow directing body 902.

Diverter body inlet 904 is positioned such that exhaust gas is caused to flow through injector orifice 222, thereby mitigating the impact of the reductant near injector orifice 222 (e.g., on injector 120, etc.). By mitigating the impact of the reductant near injector orifice 222, reductant delivery system 102 may be more desirable than other systems that do not include similar mechanisms for mitigating the impact of the reductant (e.g., due to additional cleaning of reductant deposits in these systems, etc.).

In various embodiments, inner tube 226 extends into decomposition chamber outlet 202 (e.g., instead of being contained in decomposition chamber body 204, etc.). Thus, the inner tube 226 contains the reductant for a longer period of time than if the inner tube 226 did not extend to the decomposition chamber outlet 202. Because the inner tube 226 is submerged in the exhaust gas and is not proximate to ambient air, the inner tube 226 may have a higher temperature than the decomposition chamber outlet 202 and/or a higher temperature than the decomposition chamber body 204. By extending the inner tube 226 into the decomposition chamber outlet 202, the reductant may be exposed to the relatively higher temperature of the inner tube 226 for a longer period of time. Further, the reductant may be directed to a location within decomposition chamber outlet 202, rather than upstream of decomposition chamber outlet 202. In these ways, the impact of the reductant on the decomposition chamber outlet 202 and the decomposition chamber body 204 may be reduced.

The Φ of the reductant delivery system 102 shown in fig. 23 is greater than the Φ of the reductant delivery system 102 shown in fig. 3. For example, Φ of the reductant delivery system 102 shown in FIG. 23 may be approximately equal to 7.59, while Φ of the reductant delivery system 102 shown in FIG. 3 may be approximately equal to 4.78. In some embodiments, θ of the reductant delivery system 102 shown in FIG. 23 is greater than θ of the reductant delivery system 102 shown in FIG. 3. For example, θ for the reductant delivery system 102 shown in FIG. 23 may be approximately equal to 37.5, while θ for the reductant delivery system 102 shown in FIG. 3 may be approximately equal to 25.5.

In various embodiments, the diverter body inlet 904 is connected to the diverter aperture 910.

FIG. 26 illustrates a reductant delivery system 102 and elements thereof, according to various embodiments. In these embodiments, inner tube 226 extends into bend 210. Inner tube 226 may also extend into decomposition chamber outlet 202. Additionally, the reductant delivery system 102 does not include the flow splitter 900.

The mounting panel 212 is not contained within the bend 210, but rather extends toward the decomposition chamber body outlet 202. Further, Φ of the reductant delivery system 102 shown in FIG. 26 is greater than Φ of the reductant delivery system 102 shown in FIG. 3. In some embodiments, θ of the reductant delivery system 102 shown in FIG. 26 is less than θ of the reductant delivery system 102 shown in FIG. 3.

The inner tube 226 includes an inner tube bore 2600 (e.g., openings, orifices, etc.). The inner pipe hole 2600 is disposed adjacent to the mounting panel 212. Inner tube bore 2600 is partially contained within bend 210 and extends toward decomposition chamber outlet 202.

In operation, exhaust gas flows from decomposition chamber inlet 200 into inner tube inlet 230 or around inner tube 226. Exhaust gas flowing through the inner tube inlet 230 may exit the inner tube 226 via the inner tube apertures 2600 or may continue to flow within the inner tube 226 toward the inner tube outlet 232. Injector axis 224 extends through inner tube bore 2600 and reductant provided by injector 120 is provided into inner tube 226 via inner tube bore 2600. Accordingly, exhaust gas flowing within the inner tube 226 downstream of the inner tube apertures 2600 may be mixed with the reductant (e.g., via the mixer 236, etc.). Exhaust gas flowing around the inner tube 226 may flow into the inner tube 226 via the inner tube apertures 2600. This may result in reductant provided by injector 220 being pushed into inner tube 226 via inner tube apertures 2600.

28-30 illustrate portions of the exhaust aftertreatment system 100 and elements thereof according to various embodiments.

Fig. 28 illustrates a mounting frame 2800 (e.g., body, housing, etc.) in which portions of the exhaust aftertreatment system 100, such as portions of the reductant delivery system 102, are located 2800. Mounting frame 2800 includes removable panels 2802 (e.g., sidewalls, etc.) and a rail system 2804 (e.g., support structure, etc.). A removable panel 2802 is selectively coupled to the rail system 2804 and is configured to be removed from the rail system 2804 to access portions of the exhaust aftertreatment system 100 located within the mounting frame 2800.

As shown in fig. 29, the decomposition chamber 110 is configured to be positioned adjacent to the removable panel 2802 and such that the dosing module 112 is accessible through the track system 2804 after the removable panel 2802 has been removed from the track system 2804. In this manner, a user may access the dosing module 112 (e.g., replace the dosing module 112, repair the dosing module 112, etc.) by removing only the removable panel 2802 without removing additional components of the mounting frame 2800. When the removable panel 2802 is coupled to the track system 2804, the dosing module 112 does not interfere with the removable panel 2802 because the external decomposition chamber cavity 216 provides additional space.

As shown in fig. 30The exhaust aftertreatment system 100 may further include NO_xThe sensor module 3000. NO_x Sensor module 3000 is configured to determine NO in exhaust gases_xAmount of the compound (A). NO_x Sensor module 3000 is electrically or communicatively coupled to reductant delivery system controller 128 and is configured to provide NO to reductant delivery system controller 128_xThe amount of (c). Because the dosing module 112 is coupled to the decomposition chamber 102 using the mounting panel 212, the NO is_xThe sensor module 3000 may be located within the track system 2804 and cause the NO to be removed after the removable panel 2802 has been removed from the track system 2804_xThe sensor module 3000 is accessible via the rail system 2804. In this manner, a user may access the NO by removing only the removable panel 2802_xSensor module 3000 (e.g., replace NO)_x Sensor module 3000, maintenance NO_xSensor module 3000, etc.) without removing additional components of mounting frame 2800. NO_xThe sensor module 3000 may be thermally isolated from high temperature regions of the exhaust aftertreatment system 100. May be routed through the rail system 2804 (e.g., for NO)_xWiring for sensor module 3000, wiring for dosing module 112, etc.).

Construction of the example embodiment

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features specific to particular implementations. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Furthermore, although features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

As utilized herein, the terms "substantially," "approximately," "about," and similar terms are intended to have a broad meaning consistent with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Those skilled in the art who review this disclosure will appreciate that these terms are intended to allow for the description of certain features described and claimed without limiting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or variations of the described and claimed subject matter are considered within the scope of the invention as recited in the appended claims.

The term "coupled" and similar terms as used herein mean that two components are joined to one another either directly or indirectly. Such joining may be fixed (e.g., permanent) or movable (e.g., removable or releasable). Such joining may be achieved by the two components or the two components and any additional intermediate components being integrally formed as a single unitary body with one another, by the two components or the two components and any additional intermediate components being attached to one another.

The term "fluidly coupled" and similar terms as used herein mean that two components or objects have a passageway formed therebetween through which a fluid (e.g., air, exhaust gas, liquid reductant, gaseous reductant, aqueous reductant, gaseous ammonia, etc.) may flow with or without an intervening component or object. Examples of fluid couplings or configurations for achieving fluid communication may include pipes, channels, or any other suitable components for achieving a flow of fluid from one component or object to another component or object.

It is important to note that the construction and arrangement of the various systems shown in the various exemplary embodiments are illustrative only and not limiting in nature. All changes and modifications that come within the spirit and/or scope of the described embodiments are desired to be protected. It should be understood that some features may not be necessary and embodiments lacking the same may be contemplated as within the scope of the disclosure, the scope being defined by the claims that follow. When the language "a portion" is used, the item can include a portion and/or the entire item unless specifically stated to the contrary.

Furthermore, the term "or" is used in the context of a list of elements in its inclusive sense (and not in its exclusive sense) such that when used in conjunction with a list of elements, the term "or" means one, some, or all of the elements in the list. Unless expressly stated otherwise, a conjunctive such as the phrase "X, Y or at least one of Z" is understood in this context to be commonly used to express that an item, term, or the like may be: x; y; z; x and Y; x and Z; y and Z; or X, Y and Z (i.e., any combination of X, Y and Z). Thus, such conjunctions are generally not intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to be present individually, unless otherwise indicated.

In addition, unless otherwise indicated, the use of value ranges herein (e.g., W1-W2, etc.) include their maximum and minimum values (e.g., W1-W2 include W1 and include W2, etc.). Further, unless otherwise indicated, a range of values (e.g., W1-W2, etc.) does not necessarily require the inclusion of intermediate values within the range of values (e.g., W1-W2 may include only W1 and W2, etc.).

Claims

1. A decomposition chamber for a reductant delivery system having a dosing module, the decomposition chamber comprising:

a decomposition chamber inlet configured to receive an exhaust gas;

a bend fluidly coupled to the decomposition chamber inlet and configured to receive exhaust gas from the decomposition chamber inlet;

a decomposition chamber body fluidly coupled to the bend and configured to receive exhaust gas from the bend;

a decomposition chamber outlet fluidly coupled to the decomposition chamber body and configured to receive exhaust gas from the decomposition chamber body and provide the exhaust gas out of the decomposition chamber; and

a mounting panel having an injector aperture configured to receive a reducing agent, the mounting panel configured to be coupled to the dosing module;

wherein an outer cavity is recessed into the curved portion, the outer cavity being defined by at least the mounting panel.

2. The decomposition chamber of claim 1, wherein:

the decomposition chamber inlet is centered on a decomposition chamber inlet axis;

the outlet of the decomposition chamber takes the axis of the outlet of the decomposition chamber as the center; and is

The decomposition chamber inlet axis and the decomposition chamber outlet axis extend through the mounting panel.

3. The decomposition chamber according to claim 2, wherein the decomposition chamber outlet axis is orthogonal to the decomposition chamber inlet axis.

4. The decomposition chamber of claim 3, wherein the decomposition chamber outlet axis intersects the decomposition chamber inlet axis.

5. The decomposition chamber of claim 2, wherein:

the injector bore is centered on an injector axis;

the injector axis is separated from the decomposition chamber outlet axis by a first injector angle; and is

The injector axis is separated from the decomposition chamber inlet axis by a second injector angle different from the first injector angle.

6. The decomposition chamber of claim 5, wherein the second injector angle is greater than twice the first injector angle.

7. The decomposition chamber of claim 1, further comprising a flow diverter positioned within and coupled to the bend, the flow diverter comprising:

a shunt body;

a diverter body inlet configured to receive exhaust gas from the bend;

8. The decomposition chamber of claim 7, wherein:

the injector bore is centered on an injector axis; and is

The injector axis extends through the diverter bore.

9. The decomposition chamber of claim 7, further comprising:

an inner tube coupler coupled to the decomposition chamber body; and

10. The decomposition chamber of claim 9, wherein the inner tube is fluidly coupled to the bend and configured to receive exhaust gas from the bend.

11. The decomposition chamber of claim 9, further comprising a mixer contained within the inner tube, the mixer comprising:

a mixer wall coupled to the inner tube;

a hub coupled to each of the plurality of blades;

Wherein the hub is centered about the decomposition chamber outlet axis.

12. The decomposition chamber of claim 7, wherein the diverter further comprises a first coupling wall coupled to the diverter body near the diverter body outlet, the first coupling wall preventing exhaust gas from flowing along the first coupling wall between the diverter body and the bend.

13. A decomposition chamber for a reductant delivery system having a dosing module, the decomposition chamber comprising:

a decomposition chamber inlet configured to receive an exhaust gas;

a decomposition chamber outlet fluidly coupled to the decomposition chamber body and configured to receive exhaust gas from the decomposition chamber body and provide the exhaust gas out of the decomposition chamber;

a mounting panel having an injector orifice configured to receive a reducing agent and configured to be coupled to the dosing module; and

a shunt located within and coupled to the bend, the shunt comprising:

a diverter body inlet configured to receive exhaust gas from the bend; and

a diverter bore configured to receive reductant from the injector bore.

14. The decomposition chamber of claim 13, further comprising:

an inner tube coupler coupled to the decomposition chamber body; and

15. The decomposition chamber of claim 14, further comprising a mixer contained within the inner tube, the mixer comprising:

a mixer wall coupled to the inner tube;

a hub coupled to each of the plurality of blades;

Wherein the hub is centered about the decomposition chamber outlet axis.

16. The decomposition chamber of claim 15, wherein:

the diverter also includes a first coupling wall coupled to the diverter near the diverter body outlet, the first coupling wall preventing exhaust gas from flowing along the first coupling wall between the diverter and the bend; and is

The first coupling wall is disposed along a plane orthogonal to the decomposition chamber outlet axis.

17. A decomposition chamber for a reductant delivery system having a dosing module, the decomposition chamber comprising:

a decomposition chamber inlet configured to receive the exhaust gas and centered about a decomposition chamber inlet axis;

a decomposition chamber outlet fluidly coupled to the decomposition chamber body, configured to receive exhaust gas from the decomposition chamber body and provide the exhaust gas out of the decomposition chamber, and centered about a decomposition chamber outlet axis; and

a mounting panel configured to be coupled to a dosing module and having an injector bore configured to receive a reducing agent and centered about an injector axis;

wherein the injector axis is separated from the decomposition chamber outlet axis by a first injector angle;

wherein the injector axis is separated from the decomposition chamber inlet axis by a second injector angle different from the first injector angle; and is

Wherein the decomposition chamber outlet axis intersects the decomposition chamber inlet axis and is orthogonal to the decomposition chamber inlet axis.

18. The decomposition chamber of claim 17, further comprising a flow diverter positioned within and coupled to the bend, the flow diverter comprising:

a shunt body;

a diverter body inlet configured to receive exhaust gas from the bend;

wherein the splitter aperture is aligned with the injector aperture.

19. The decomposition chamber of claim 18, wherein the diverter further comprises a first coupling wall coupled to the diverter body near the diverter body outlet, the first coupling wall preventing exhaust gas from flowing along the first coupling wall between the diverter body and the bend.

20. The decomposition chamber of claim 18, further comprising:

an inner tube coupler coupled to the decomposition chamber body; and

21. The decomposition chamber of claim 17, wherein the second injector angle is greater than the first injector angle.