Exhaust gas aftertreatment system

Abstract

An exhaust aftertreatment system includes a first decomposition chamber, a first dosing module, a first conversion catalyst member, a second decomposition chamber, a second dosing module, a second conversion catalyst member, and a third conversion catalyst member. The first decomposition chamber is configured to receive exhaust gas. The first dosing module is coupled to the first decomposition chamber and is configured to provide a first treatment fluid into the first decomposition chamber. The first conversion catalyst member is configured to receive a mixture of the first treatment fluid and the exhaust gas from the first decomposition chamber. The second decomposition chamber is configured to receive the exhaust gas from the first conversion catalyst member. The second dosing module is coupled to the second decomposition chamber and is configured to provide a second treatment fluid into the second decomposition chamber.

Description

[0001] Cross-referencing of related patent applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 152,138, filed February 22, 2021, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This disclosure generally relates to an exhaust aftertreatment system for an internal combustion engine. Background Technology

[0004] background

[0005] For internal combustion engine systems, it may be desirable to treat the exhaust gas produced by the combustion of fuel in order to reduce the emission of unwanted components. This exhaust treatment can be achieved using an aftertreatment system. One method that can be implemented in an aftertreatment system is to pass the exhaust gas through an aftertreatment component.

[0006] To enhance the reduction of emissions of unwanted components, it may be desirable to route exhaust gases through the aftertreatment system simultaneously in two or more flow paths. However, such routing typically increases the space requirements of the aftertreatment system significantly. Therefore, in some applications, routing exhaust gases through the aftertreatment system simultaneously in two or more flow paths may be difficult or impossible. Summary of the Invention

[0007] Overview

[0008] 1) In one embodiment, an exhaust gas aftertreatment system includes a first decomposition chamber, a first dosing module, a first conversion catalyst component, a second decomposition chamber, a second dosing module, a second conversion catalyst component, and a third conversion catalyst component. The first decomposition chamber is configured to receive exhaust gas. The first dosing module is coupled to the first decomposition chamber and configured to supply a first treatment liquid to the first decomposition chamber. The first conversion catalyst component is configured to receive a mixture of the first treatment liquid and exhaust gas from the first decomposition chamber. The second decomposition chamber is configured to receive exhaust gas from the first conversion catalyst component. The second dosing module is coupled to the second decomposition chamber and configured to supply a second treatment liquid to the second decomposition chamber. The second conversion catalyst component is configured to receive a first portion of the mixture of the second treatment liquid and exhaust gas from the second decomposition chamber. The third conversion catalyst component is configured to receive a second portion of the mixture of the second treatment liquid and exhaust gas from the second decomposition chamber.

[0009] 2) The exhaust aftertreatment system according to 1) further includes a mixer configured to receive the first treatment liquid and the exhaust gas from the first decomposition chamber, and to mix the first treatment liquid and the exhaust gas upstream of the first conversion catalyst member.

[0010] 3) The exhaust aftertreatment system according to 2), wherein the mixer further includes at least one of an upstream mixing plate, a downstream mixing plate, and a perforated plate.

[0011] 4) The exhaust aftertreatment system according to 1) further includes a mixer configured to receive the second treatment liquid and the exhaust gas from the second decomposition chamber, and to mix the second treatment liquid and the exhaust gas upstream of the second conversion catalyst member and the third conversion catalyst member.

[0012] 5) The exhaust aftertreatment system according to 1) further includes a fourth conversion catalyst component, the fourth conversion catalyst component being configured to supply the exhaust gas to the first decomposition chamber; wherein the first conversion catalyst component is a selective catalytic reduction (SCR) catalyst component; and wherein the fourth conversion catalyst component is an oxidation catalyst component.

[0013] 6) The exhaust aftertreatment system according to 1) further includes an outlet exhaust duct configured to receive the exhaust from the second conversion catalyst component and the third conversion catalyst component.

[0014] 7) The exhaust aftertreatment system according to 1), wherein at least one of the first dispensing module and the second dispensing module is configured to mix air with at least one of the first treatment liquid and the second treatment liquid.

[0015] 8) The exhaust aftertreatment system according to 7) further includes at least one air filter configured to filter air.

[0016] 9) The exhaust aftertreatment system according to 1) further includes: an inlet exhaust duct configured to provide the exhaust gas to the first decomposition chamber; and a heater located within the inlet exhaust duct and configured to heat the exhaust gas.

[0017] 10) The exhaust aftertreatment system according to 1) further includes at least one treatment fluid filter, the at least one treatment fluid filter being configured to filter at least one of the first treatment fluid and the second treatment fluid.

[0018] 11) The exhaust aftertreatment system according to 1) further includes an exhaust filter element configured to remove particles from the exhaust gas.

[0019] 12) The exhaust aftertreatment system according to 11), wherein the exhaust filter component is selectively attached to and detached from the exhaust aftertreatment system.

[0020] 13) The exhaust aftertreatment system according to 1) further includes: a first exhaust diversion conduit configured to receive a first portion of the mixture of the exhaust gas and the second treatment liquid from the second decomposition chamber; and a second exhaust diversion conduit configured to receive a second portion of the mixture of the exhaust gas and the second treatment liquid from the second decomposition chamber.

[0021] 14) The exhaust aftertreatment system according to 1), wherein the second dispensing module is connected to and uses the treatment fluid pump connected to the first dispensing module.

[0022] 15) The exhaust aftertreatment system according to 1), wherein at least one of the first conversion catalyst component, the second conversion catalyst component and the third conversion catalyst component further comprises vanadium, platinum, rhodium, palladium, zinc or copper.

[0023] 16) The exhaust aftertreatment system according to 1), wherein at least one of the first conversion catalyst component, the second conversion catalyst component and the third conversion catalyst component is a ceramic conversion catalyst component.

[0024] 17) The exhaust aftertreatment system according to 1) further includes: a first shroud configured to receive a first portion of the mixture of the second treatment liquid from the second conversion catalyst member and the exhaust gas; and a second shroud configured to receive a second portion of the mixture of the second treatment liquid from the third conversion catalyst member and the exhaust gas; wherein the first shroud and the second shroud are parallel to each other.

[0025] 18) The exhaust aftertreatment system according to 1), wherein, when the third conversion catalyst component treats the second portion of the mixture of the second treatment liquid and the exhaust gas, the second conversion catalyst component treats the mixture of the second treatment liquid and the exhaust gas...

[0026] The first part.

[0027] 19) The exhaust aftertreatment system according to 1), wherein the first treatment fluid is different from the second treatment fluid.

[0028] 20) The exhaust aftertreatment system according to 1), wherein the first treatment fluid is the same as the second treatment fluid. Attached Figure Description Brief description of the attached diagram

[0030] This disclosure will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, wherein, unless otherwise indicated, the same reference numerals refer to the same elements in the drawings:

[0031] Figure 1 This is a schematic diagram of an example exhaust aftertreatment system including the housing assembly;

[0032] Figure 2 yes Figure 1 A perspective view of the exhaust aftertreatment system shown.

[0033] Figure 3 yes Figure 1 The side view of the exhaust aftertreatment system shown;

[0034] Figure 4 yes Figure 1 Another side view of the exhaust aftertreatment system shown; and

[0035] Figure 5 yes Figure 1 The diagram shows a front view of the exhaust aftertreatment system.

[0036] It should be recognized that these drawings are schematic representations for illustrative purposes. These drawings are provided to illustrate one or more implementations, and it should be clearly understood that the drawings are not intended to limit the scope or meaning of the claims. Detailed Implementation

[0037] Detailed description

[0038] The following is a more detailed description of various concepts and implementations related to methods and apparatus for providing exhaust aftertreatment systems for internal combustion engines. The various concepts introduced above and discussed in more detail below can be implemented in any of a variety of ways, as the described concepts are not limited to any particular implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.

[0039] I. Overview

[0040] To reduce emissions, it may be desirable to use an aftertreatment system that includes at least one aftertreatment component to treat exhaust gases. However, under certain space constraints, it may be desirable to guide exhaust gases through the aftertreatment system simultaneously in two or more flow paths. In some cases, however, this may not be desirable. For example, such systems are typically relatively large and therefore cannot be used in applications with certain space requirements. These systems are typically relatively large to achieve ideal mixing of urea and exhaust gases.

[0041] Embodiments herein relate to an exhaust aftertreatment system comprising two treatment fluid delivery systems, two decomposition chambers, and multiple aftertreatment component bases (such as conversion catalyst components), which facilitates exhaust treatment in two parallel flow paths. The exhaust aftertreatment system includes a housing assembly with multiple housing panels that facilitate the mounting of various components in this arrangement.

[0042] The exhaust aftertreatment system described herein utilizes an arrangement that not only improves the efficiency of exhaust treatment but also collects heat from the exhaust to heat multiple components of the aftertreatment system. For example, exhaust flowing through the second decomposition chamber heats the bases of multiple aftertreatment components. As a result, the exhaust aftertreatment system can reach the "light-off" temperature (e.g., the temperature at which the exhaust can be ideally treated) in a significantly shorter time than other systems.

[0043] II. Overview of Example Exhaust Aftertreatment Systems

[0044] Figures 1-5 An exhaust aftertreatment system 100 (e.g., a treatment system, etc.) for treating exhaust gases produced by internal combustion engines (e.g., diesel internal combustion engines, gasoline internal combustion engines, hybrid internal combustion engines, propane internal combustion engines, dual-fuel internal combustion engines, etc.) is described. The exhaust aftertreatment system 100 includes an exhaust duct system 102 (e.g., a pipeline system, a pipe system, etc.). The exhaust duct system 102 is configured to facilitate the guidance of exhaust gases produced by the internal combustion engine through the exhaust aftertreatment system 100 and to the atmosphere (e.g., the surrounding environment, etc.).

[0045] The exhaust aftertreatment system 100 also includes a housing assembly 104 (e.g., a main body assembly, etc.). As explained in more detail herein, the housing assembly 104 is configured to facilitate exhaust treatment. This treatment can facilitate the reduction of unwanted components in the exhaust (e.g., nitrogen oxides (NOx)). x This treatment can also, or alternatively, promote the conversion of various oxidizing components of exhaust gas (e.g., carbon monoxide (CO), hydrocarbons, etc.) into other components (e.g., carbon dioxide (CO2), water vapor, etc.). This treatment can also, or alternatively, promote the removal of particulate matter (e.g., soot, particulate matter, etc.) from exhaust gas.

[0046] Housing assembly 104 includes a first housing panel 106 (e.g., platform, plate, flange, etc.). As explained in more detail herein, the first housing panel 106 is configured to support various components of the exhaust aftertreatment system 100 (e.g., support on the frame of a vehicle having the exhaust aftertreatment system 100, etc.). The first housing panel 106 includes a first housing panel inlet aperture 108 (e.g., orifice, window, opening, etc.). As explained in more detail herein, the first housing panel inlet aperture 108 facilitates exhaust flow through the first housing panel 106.

[0047] The exhaust duct system 102 includes an inlet exhaust duct 110 (e.g., a line, pipe, etc.). The inlet exhaust duct 110 is fluidly coupled to an upstream component (e.g., a header on an internal combustion engine, an exhaust manifold on an internal combustion engine, an internal combustion engine, etc.) and configured to receive exhaust gas from the upstream component. In some embodiments, the inlet exhaust duct 110 is coupled (e.g., attached, fixed, welded, fastened, riveted, adhesively attached, joined, pinned, etc.) to the upstream component. In other embodiments, the inlet exhaust duct 110 is integrally formed with the upstream component.

[0048] An inlet exhaust duct 110 extends through the inlet aperture 108 of the first housing panel. In this way, the first housing panel 106 supports the inlet exhaust duct 110 (e.g., relative to a frame to which the first housing panel 106 is attached), and the inlet exhaust duct 110 facilitates exhaust through the first housing panel 106. In various embodiments, the inlet exhaust duct 110 is coupled to the first housing panel 106 (e.g., at least partially surrounding the inlet aperture 108 of the first housing panel).

[0049] The housing assembly 104 also includes a second housing panel 112 (e.g., platform, plate, flange, etc.). As explained in more detail herein, the second housing panel 112 is configured to support various components of the exhaust aftertreatment system 100 (e.g., support on the frame of a vehicle having the exhaust aftertreatment system 100, etc.). The second housing panel 112 includes a second housing panel inlet (e.g., orifice, window, opening, etc.).

[0050] The inlet exhaust duct 110 also extends through the inlet aperture 114 of the second housing panel. In this way, the second housing panel 112 supports the inlet exhaust duct 110 (e.g., relative to a frame to which the second housing panel 112 is attached), and the inlet exhaust duct 110 facilitates exhaust through the second housing panel 112. In various embodiments, the inlet exhaust duct 110 is coupled to the second housing panel 112 (e.g., at least partially surrounding the second housing panel inlet aperture 114).

[0051] In various embodiments, the exhaust aftertreatment system 100 includes a heater (e.g., an electric heater, a resistance heater, etc.). The heater is positioned within an inlet exhaust duct 110 and configured to heat the exhaust gas flowing through the inlet exhaust duct 110. The heater can be controlled to cause heating of the exhaust gas (e.g., during the preheating of an internal combustion engine having the exhaust aftertreatment system 100, etc.) to facilitate a desirable reduction of unwanted components in the exhaust gas. This may result in an increase in the temperature of the exhaust gas (e.g., thereby promoting the regeneration of components of the exhaust aftertreatment system 100, etc.).

[0052] In various embodiments, the exhaust aftertreatment system 100 includes a hydrocarbon dispensing system configured to dispense hydrocarbons (e.g., fuel, oil, additives, etc.) into exhaust gas flowing within the inlet exhaust duct 110. This may result in an increase in exhaust gas temperature (e.g., to promote regeneration of components of the exhaust aftertreatment system 100). For example, the exhaust gas temperature can be increased by burning hydrocarbons in the exhaust gas (e.g., using spark plugs, etc.).

[0053] The housing assembly 104 also includes an inlet housing 116 (e.g., a decomposition housing, a hydrocarbon inlet housing, etc.). The inlet housing 116 is fluidly coupled to the inlet exhaust duct 110 and configured to receive exhaust gas from the inlet exhaust duct 110. In various embodiments, the inlet housing 116 is coupled to the inlet exhaust duct 110. For example, the inlet housing 116 may be fastened (e.g., using a strap, using bolts, using twist-lock fasteners, threads, etc.), welded, riveted, or otherwise attached to the inlet exhaust duct 110. In other embodiments, the inlet housing 116 is integrally formed with the inlet exhaust duct 110. As used herein, the terms “fastened,” “fastening,” etc., describe two structures attached (e.g., connected, etc.) in such a way that disassembly (e.g., separation, etc.) of the two structures is still possible during or after “fastening” without damaging or destroying one or both of the structures.

[0054] As explained in more detail herein, the housing 116 is configured to facilitate the delivery of treatment fluids (such as reducing agents (e.g., diesel exhaust fluid (DEF)). Urea-water solution (UWS), aqueous urea solution, AUS32, etc.) or hydrocarbons are introduced into the exhaust gas. When a reducing agent is introduced into the exhaust gas, it can promote the reduction of unwanted components in the exhaust gas (such as nitrogen oxides (NOx)). xEmissions such as hydrocarbons. When hydrocarbons are introduced into the exhaust gas, the temperature of the exhaust gas can be increased (e.g., to promote the regeneration of components of the exhaust aftertreatment system 100). For example, the temperature of the exhaust gas can be increased by burning hydrocarbons in the exhaust gas (e.g., using spark plugs).

[0055] The inlet housing 116 also includes a first aftertreatment component 118 (e.g., an exhaust aftertreatment component, an aftertreatment module, etc.). The first aftertreatment component 118 includes a first casing 120 (e.g., a housing, an outer shell, a body, etc.). The first casing 120 is positioned within the inlet housing 116 (e.g., using a gasket, a shim, a seal, etc.) such that exhaust gas flows from the inlet exhaust duct 110 to the first aftertreatment component 118.

[0056] The first aftertreatment component 118 also includes a first aftertreatment component base 122 (e.g., a working member, etc.). The first aftertreatment component base 122 is positioned within the first shroud 120. For example, the first aftertreatment component base 122 may be coupled to the first shroud 120. The first aftertreatment component base 122 receives exhaust gas from the first shroud 120 (e.g., from the inlet of the first shroud 120, etc.) and provides a first portion of the exhaust gas to the first shroud 120 (e.g., to the outlet of the first shroud 120, etc.). The first aftertreatment component base 122 is configured to facilitate treatment of the exhaust gas. This treatment may facilitate the reduction of emissions of undesirable components in the exhaust gas. This treatment may also, or alternatively, facilitate the conversion of various oxidizing components of the exhaust gas into other components. This treatment may also, or alternatively, facilitate the removal of particulate matter from the exhaust gas.

[0057] In various embodiments, the first aftertreatment component base 122 includes an oxidation catalyst member (e.g., a diesel oxidation catalyst (DOC), etc.). In these embodiments, the first aftertreatment component base 122 is configured to oxidize hydrocarbons and / or carbon monoxide in a first portion of the exhaust gas. In this way, the first aftertreatment component base 122 can oxidize hydrocarbons and / or carbon monoxide from the first portion of the exhaust gas before exhaust gas is supplied from the first shroud 120. For example, the first aftertreatment component base 122 may be an oxidation catalyst member configured to facilitate the conversion of carbon monoxide in the first portion of the exhaust gas into carbon dioxide. In this example, the first shroud 120 may receive carbon monoxide and supply carbon dioxide.

[0058] The oxidation catalyst component included in the first aftertreatment component base 122 can be directional (meaning that exhaust gas is expected to flow through the first aftertreatment component base 122 in a single direction) or non-directional (meaning that exhaust gas is expected to flow through the first aftertreatment component base 122 in any direction). In applications where the oxidation catalyst component included in the first aftertreatment component base 122 is directional, the first shroud 120 may include structures or features that facilitate (e.g., in a poka-yoke manner) fastening the first shroud 120 to the first housing panel 106 in only one orientation relative to the first housing panel 106.

[0059] The exhaust aftertreatment system 100 also includes a first treatment fluid delivery system 124. As explained in more detail herein, the first treatment fluid delivery system 124 is configured to facilitate the introduction of a first treatment fluid into the exhaust gas. The first treatment fluid delivery system 124 includes a first dispensing module 126 (e.g., a dispenser, reducing agent dispenser, hydrocarbon dispenser, etc.). The first dispensing module 126 is configured to facilitate the first treatment fluid through and into an inlet housing 116. The first dispensing module 126 may include an insulator inserted between a portion of the first dispensing module 126 and a portion of the inlet housing 116 on which the first dispensing module 126 is mounted. In various embodiments, the first dispensing module 126 is coupled to the inlet housing 116.

[0060] The first processing liquid delivery system 124 further includes a first processing liquid source 128 (e.g., a reducing agent tank, a hydrocarbon tank, etc.). The first processing liquid source 128 is configured to contain a first processing liquid. The first processing liquid source 128 is fluidly connected to the first dispensing module 126 and configured to supply the first processing liquid to the first dispensing module 126. The first processing liquid source 128 may include a plurality of first processing liquid sources 128 (e.g., a plurality of tanks connected in series or parallel). The first processing liquid source 128 may, for example, contain... A diesel exhaust fluid tank or a fuel tank containing fuel.

[0061] The first processing fluid delivery system 124 also includes a first processing fluid pump 130 (e.g., a supply unit, etc.). The first processing fluid pump 130 is fluidly coupled to a first processing fluid source 128 and a first dispensing module 126, and is configured to receive first processing fluid from the first processing fluid source 128 and supply the first processing fluid to the first dispensing module 126. The first processing fluid pump 130 is used to pressurize the first processing fluid from the first processing fluid source 128 for delivery to the first dispensing module 126. In some embodiments, the first processing fluid pump 130 is pressure-controlled. In some embodiments, the first processing fluid pump 130 is coupled to the frame of a vehicle having an exhaust aftertreatment system 100.

[0062] In some embodiments, the first processing fluid delivery system 124 further includes a first processing fluid filter 132. The first processing fluid filter 132 is fluidly coupled to a first processing fluid source 128 and a first processing fluid pump 130, and is configured to receive first processing fluid from the first processing fluid source 128 and supply the first processing fluid to the first processing fluid pump 130. The first processing fluid filter 132 filters the first processing fluid before it is supplied to the internal components of the first processing fluid pump 130. For example, the first processing fluid filter 132 may inhibit or prevent solids from being transported to the internal components of the first processing fluid pump 130. In this way, the first processing fluid filter 132 may facilitate extended desired operation of the first processing fluid pump 130.

[0063] The first dispensing module 126 includes at least one first injector 134 (e.g., an insertion device, etc.). The first injector 134 is fluidly coupled to the first processing fluid pump 130 and configured to receive first processing fluid from the first processing fluid pump 130. The first injector 134 is configured to dispense (e.g., inject, inject, etc.) the first processing fluid received by the first dispensing module 126 into an exhaust gas introduced into the housing 116.

[0064] In some embodiments, the first process fluid delivery system 124 further includes a first air pump 136 and a first air source 138 (e.g., an air inlet, etc.). The first air pump 136 is fluidly coupled to the first air source 138 and configured to receive air from the first air source 138. The first air pump 136 is also fluidly coupled to a first dispensing module 126 and configured to supply air to the first dispensing module 126. In some applications, the first dispensing module 126 is configured to mix air and the first process fluid into an air-processing fluid mixture and supply the air-processing fluid mixture to a first injector 134 (e.g., for dispensing to exhaust gas, etc., within the inlet housing 116). The first injector 134 is fluidly coupled to the first air pump 136 and configured to receive air from the first air pump 136. The first injector 134 is configured to dispense the air-processing fluid mixture into exhaust gas within the inlet housing 116. In some of these embodiments, the first process fluid delivery system 124 further includes a first air filter 140. A first air filter 140 is fluidly connected to a first air source 138 and a first air pump 136, and is configured to receive air from the first air source 138 and supply air to the first air pump 136. The first air filter 140 is configured to filter air before it is supplied to the first air pump 136. In other embodiments, the first process fluid delivery system 124 does not include the first air pump 136 and / or the first process fluid delivery system 124 does not include the first air source 138. In such embodiments, the first dispensing module 126 is not configured to mix the first process fluid with air.

[0065] In various embodiments, the first dispensing module 126 is configured to receive air and processing fluid, and dispense an air-processing fluid mixture into the inlet housing 116. In various embodiments, the first dispensing module 126 is configured to receive processing fluid (but not air), and dispense a first processing fluid into the inlet housing 116. In various embodiments, the first dispensing module 126 is configured to receive processing fluid and dispense a first processing fluid into the inlet housing 116. In various embodiments, the first dispensing module 126 is configured to receive air and processing fluid, and dispense an air-processing fluid mixture into the inlet housing 116.

[0066] The exhaust aftertreatment system 100 also includes a first decomposition chamber 142 (e.g., a decomposition reactor, reactor pipe, decomposition tube, reactor tube, etc.). The first decomposition chamber 142 includes a first decomposition chamber shroud 144 (e.g., a shell, outer casing, main body, etc.).

[0067] The housing assembly 104 also includes a third housing panel 146 (e.g., platform, plate, flange, etc.). As explained in more detail herein, the third housing panel 146 is configured to support various components of the exhaust aftertreatment system 100 (e.g., support on the frame of a vehicle having the exhaust aftertreatment system 100, etc.). The third housing panel 146 includes a third housing panel inlet aperture 148 (e.g., orifice, window, opening, etc.).

[0068] The first decomposition chamber cover 144 extends through the inlet hole 148 of the third housing panel. In this way, the third housing panel 146 supports the first decomposition chamber cover 144 (e.g., relative to a frame to which the third housing panel 146 is attached). In various embodiments, the first decomposition chamber cover 144 is attached to the third housing panel 146 (e.g., at least partially surrounding the inlet hole 148 of the third housing panel).

[0069] The first decomposition chamber 142 includes a mixer 150 (e.g., a vortex generator, blade plate, inlet plate, deflector plate, etc.). The mixer 150 is located within the first decomposition chamber shroud 144. The mixer 150 is configured to receive a mixture of exhaust gas from the first aftertreatment unit 118 and a mixture of a first treatment liquid or air treatment liquid received from the first injector 134, and to promote mixing of the exhaust gas and the first treatment liquid or air treatment liquid mixture. The mixer 150 is configured to promote the formation of vortices in the exhaust gas (e.g., tumbling, rotating, etc.) and the mixing of the exhaust gas with the first treatment liquid or air treatment liquid mixture (e.g., combining, etc.) to disperse the first treatment liquid in the exhaust gas downstream of the mixer 150. By using the mixer 150 to disperse the first treatment liquid in the exhaust gas (e.g., to obtain an improved uniformity index, etc.), the reduction of emissions of unwanted components in the exhaust gas can be enhanced, or the temperature of the exhaust gas can be increased.

[0070] In various embodiments, mixer 150 includes an upstream mixing plate (e.g., a blade plate, baffle, etc.). The upstream mixing plate may include a plurality of upstream mixing plate blades (e.g., baffles, guides, etc.) extending from an upstream mixing plate hub (e.g., a base, etc.) of the upstream mixing plate. Adjacent pairs of upstream mixing plate blades define upstream mixing plate orifices (e.g., orifices, openings, etc.). Exhaust gas flows through the upstream mixing plate orifice across the upstream mixing plate. The upstream mixing plate blades are angled relative to the upstream mixing plate hub, which causes the exhaust gas to form vortices as it flows across the upstream mixing plate. These vortices enhance the mixing of the first treatment fluid or air treatment fluid mixture downstream of the upstream mixing plate. In some of these embodiments, mixer 150 also includes a downstream mixing plate (e.g., a blade plate, baffle, etc.). The downstream mixing plate may include a plurality of downstream mixing plate blades (e.g., baffles, guides, etc.) extending from a downstream mixing plate hub (e.g., a base, etc.) of the downstream mixing plate. Adjacent pairs of downstream mixing plate blades define downstream mixing plate orifices (e.g., orifices, openings, etc.). Exhaust gas flows through downstream mixing plate perforations (e.g., after first flowing through upstream mixing plate, etc.). The downstream mixing plate blades are angled relative to the downstream mixing plate hub, causing vortices to form as the exhaust gas flows through the downstream mixing plate. These vortices enhance the mixing of the first treatment fluid or air treatment fluid mixture downstream of the downstream mixing plate. Mixer 150 may also include one or more perforated plates. Each perforated plate includes multiple perforations through which exhaust gas can flow.

[0071] The housing assembly 104 also includes a first exhaust delivery conduit 152 (e.g., a line, pipe, etc.). The first exhaust delivery conduit 152 is coupled to a first decomposition chamber shroud 144 (e.g., downstream of mixer 150, etc.). The first exhaust delivery conduit 152 is fluidly coupled to the first decomposition chamber shroud 144 and is configured to receive a mixture of exhaust gas and a first processing liquid from the first decomposition chamber shroud 144.

[0072] The exhaust aftertreatment system 100 also includes a second aftertreatment component 154 (e.g., exhaust aftertreatment component, aftertreatment module, etc.). The second aftertreatment component 154 includes a second cover 156 (e.g., housing, outer shell, body, etc.).

[0073] The third housing panel 146 also includes a third housing panel first transfer hole 158 (e.g., orifice, window, opening, etc.). A second cover 156 extends through the third housing panel first transfer hole 158. In this way, the third housing panel 146 supports the second cover 156 (e.g., relative to a frame to which the third housing panel 146 is attached). In various embodiments, the second cover 156 is attached to the third housing panel 146 (e.g., at least partially surrounding the third housing panel first transfer hole 158, etc.).

[0074] The second post-processing component 154 also includes a second post-processing component base 160 (e.g., a working member, etc.). The second post-processing component base 160 is positioned within the second cover 156. For example, the second post-processing component base 160 may be coupled to the second cover 156.

[0075] The second aftertreatment component base 160 receives exhaust gas from the first decomposition chamber hood 144 (e.g., via the first exhaust gas delivery duct 152, etc.). The second aftertreatment component base 160 is configured to facilitate treatment of the exhaust gas. This treatment can facilitate the reduction of emissions of unwanted components in the exhaust gas. This treatment can also, or alternatively, facilitate the conversion of various oxidizing components of the exhaust gas into other components. This treatment can also, or alternatively, facilitate the removal of particulate matter from the exhaust gas.

[0076] In various embodiments, the second aftertreatment component base 160 includes a conversion catalyst component (e.g., a selective catalytic reduction (SCR) catalyst component, a vanadium SCR (VSCR) catalyst component, a conversion catalyst component, a catalyst metal, etc.). In these embodiments, the first treatment liquid provided by the first dispensing module 126 may be a reducing agent, and the second aftertreatment component base 160 may be configured to induce the decomposition of exhaust gas components using a reducing agent (e.g., via a catalytic reaction, etc.). Specifically, the reducing agent already provided to the exhaust gas by the first injector 134 undergoes evaporation, pyrolysis, and hydrolysis processes to form non-NO within the second shroud 156. x Emissions. In this way, the second aftertreatment unit base 160 is configured to accelerate the reaction of NO in the reducing agent and exhaust gas. x NO between x The reduction process helps to reduce NO x The emissions are reduced to diatomic nitrogen, water, and / or carbon dioxide. The conversion catalyst component included in the second aftertreatment component base 160 may include, for example, vanadium, platinum, rhodium, palladium, zinc, copper, or other similar materials. In some embodiments, the conversion catalyst component included in the second aftertreatment component base 160 is a ceramic conversion catalyst component.

[0077] The conversion catalyst component included in the second aftertreatment component base 160 can be directional (meaning that exhaust gas is expected to flow through the second aftertreatment component base 160 in a single direction) or non-directional (meaning that exhaust gas is expected to flow through the second aftertreatment component base 160 in any direction). In applications where the conversion catalyst component included in the second aftertreatment component base 160 is directional, the second shroud 156 may include structures or features that facilitate (e.g., in an error-proof manner) fastening the second shroud 156 to the third housing panel 146 in only one orientation relative to the third housing panel 146.

[0078] The exhaust aftertreatment system 100 also includes a third aftertreatment component 162 (e.g., exhaust aftertreatment component, aftertreatment module, etc.). The third aftertreatment component 162 includes a third cover 164 (e.g., housing, outer shell, body, etc.).

[0079] The second housing panel 112 also includes a second housing panel first transfer hole 166 (e.g., orifice, window, opening, etc.). A third cover 164 extends through the second housing panel first transfer hole 166. In this way, the second housing panel 112 supports the third cover 164 (e.g., relative to a frame to which the second housing panel 112 is attached). In various embodiments, the third cover 164 is attached to the second housing panel 112 (e.g., at least partially surrounding the second housing panel first transfer hole 166, etc.).

[0080] The third post-processing component 162 also includes a third post-processing component base 168 (e.g., a working member, etc.). The third post-processing component base 168 is positioned within the third housing 164. For example, the third post-processing component base 168 may be coupled to the third housing 164.

[0081] The third aftertreatment component base 168 receives exhaust gas from the second shroud 156 (e.g., via the third shroud 164, etc.). The third aftertreatment component base 168 is configured to facilitate treatment of the exhaust gas. This treatment can facilitate the reduction of emissions of unwanted components in the exhaust gas. This treatment can also, or alternatively, facilitate the conversion of various oxidizing components of the exhaust gas into other components. This treatment can also, or alternatively, facilitate the removal of particulate matter from the exhaust gas.

[0082] In various embodiments, the third aftertreatment component base 168 includes an exhaust gas filtering member (e.g., a diesel particulate filter (DPF)). In these embodiments, the third aftertreatment component base 168 is configured to remove particles from the exhaust gas before it is supplied from the third shroud 164. For example, the exhaust gas received by the third shroud 164 may have a first concentration of particles, the third aftertreatment component base 168 may remove at least some particles from the exhaust gas, and the third shroud 164 may provide exhaust gas with a second concentration of particles lower than the first concentration.

[0083] The exhaust filter included in the third aftertreatment component base 168 may be directional (meaning that exhaust is expected to flow through the third aftertreatment component base 168 in a single direction) or non-directional (meaning that exhaust is expected to flow through the third aftertreatment component base 168 in any direction). In applications where the exhaust filter included in the third aftertreatment component base 168 is directional, the third cover 164 may include structures or features that facilitate (e.g., in an error-proof manner) fastening the third cover 164 to the second housing panel 112 in only one orientation relative to the second housing panel 112.

[0084] The third cover 164 can be selectively attached to the housing assembly 104 and selectively removed from the second housing panel 112. This allows the DPF to be removed from the housing assembly 104 for maintenance and / or replacement. For example, a user can remove the third cover 164 from the housing assembly 104, remove the third aftertreatment component 162 from the housing assembly 104, insert a new third aftertreatment component 162 into the housing assembly 104, and attach the third cover 164 to the second housing panel 112. In this way, the exhaust aftertreatment system 100's ability to treat exhaust gases can be maintained or modified.

[0085] In various embodiments, the first housing panel 106 also includes a first housing panel first transfer hole 170 (e.g., orifice, window, opening, etc.). A third cover 164 extends through the first housing panel first transfer hole 170. In this way, the first housing panel 106 supports the third cover 164 (e.g., relative to a frame to which the first housing panel 106 is attached). In various embodiments, the third cover 164 is attached to the first housing panel 106 (e.g., at least partially surrounding the first housing panel first transfer hole 170, etc.).

[0086] The housing assembly 104 also includes a second exhaust delivery conduit 172 (e.g., a line, pipe, etc.). The second exhaust delivery conduit 172 is coupled to a third shroud 164 (e.g., downstream of a third aftertreatment component 162, etc.). The second exhaust delivery conduit 172 is fluidly coupled to the third shroud 164 and is configured to receive exhaust gas from the third shroud 164 (e.g., after particles have been removed from the exhaust gas, etc.).

[0087] The exhaust aftertreatment system 100 also includes a second decomposition chamber 174 (e.g., a decomposition reactor, reactor pipe, decomposition tube, reactor tube, etc.). The second decomposition chamber 174 includes a second decomposition chamber shroud 176 (e.g., a shell, outer casing, main body, etc.).

[0088] The second housing panel 112 also includes a second housing panel second transfer hole 178 (e.g., orifice, window, opening, etc.). A second decomposition chamber cover 176 extends through the second housing panel second transfer hole 178. In this way, the second housing panel 112 supports the second decomposition chamber cover 176 (e.g., relative to a frame to which the second housing panel 112 is attached). In various embodiments, the second decomposition chamber cover 176 is coupled to the second housing panel 112 (e.g., at least partially surrounding the second housing panel second transfer hole 178, etc.).

[0089] In various embodiments, the first housing panel 106 also includes a first housing panel second transfer hole 180 (e.g., orifice, window, opening, etc.). A second decomposition chamber shroud 176 extends through the first housing panel second transfer hole 180. In this way, the first housing panel 106 supports the second decomposition chamber shroud 176 (e.g., relative to a frame to which the first housing panel 106 is attached). In various embodiments, the second decomposition chamber shroud 176 is coupled to the first housing panel 106 (e.g., at least partially surrounding the first housing panel second transfer hole 180, etc.).

[0090] The exhaust aftertreatment system 100 also includes a second treatment fluid delivery system 182. As explained in more detail herein, the second treatment fluid delivery system 182 is configured to facilitate the introduction of a second treatment fluid into the exhaust gas. The second treatment fluid delivery system 182 includes a second dispensing module 184 (e.g., a dispenser, reducing agent dispenser, hydrocarbon dispenser, etc.). The second dispensing module 184 is configured to facilitate the passage of the second treatment fluid through and into the second decomposition chamber shroud 176. The second dispensing module 184 may include an insulator inserted between a portion of the second dispensing module 184 and a portion of the second decomposition chamber shroud 176 on which the second dispensing module 184 is mounted. In various embodiments, the second dispensing module 184 is coupled to the second decomposition chamber shroud 176.

[0091] The second processing liquid delivery system 182 further includes a second processing liquid source 186 (e.g., a reducing agent tank, a hydrocarbon tank, etc.). The second processing liquid source 186 is configured to contain a second processing liquid. The second processing liquid source 186 is fluidly connected to the second dispensing module 184 and configured to supply the second processing liquid to the second dispensing module 184. The second processing liquid source 186 may include a plurality of second processing liquid sources 186 (e.g., a plurality of tanks connected in series or parallel). The second processing liquid source 186 may, for example, contain... A diesel exhaust fluid tank or a fuel tank containing fuel.

[0092] The second processing fluid delivery system 182 also includes a second processing fluid pump 188 (e.g., a supply unit, etc.). The second processing fluid pump 188 is fluidly coupled to a second processing fluid source 186 and a second dispensing module 184, and is configured to receive second processing fluid from the second processing fluid source 186 and supply the second processing fluid to the second dispensing module 184. The second processing fluid pump 188 is used to pressurize the second processing fluid from the second processing fluid source 186 for delivery to the second dispensing module 184. In some embodiments, the second processing fluid pump 188 is pressure-controlled. In some embodiments, the second processing fluid pump 188 is coupled to the frame of a vehicle having an exhaust aftertreatment system 100.

[0093] In some embodiments, the second processing fluid delivery system 182 further includes a second processing fluid filter 190. The second processing fluid filter 190 is fluidly coupled to a second processing fluid source 186 and a second processing fluid pump 188, and is configured to receive second processing fluid from the second processing fluid source 186 and supply the second processing fluid to the second processing fluid pump 188. The second processing fluid filter 190 filters the second processing fluid before it is supplied to the internal components of the second processing fluid pump 188. For example, the second processing fluid filter 190 may inhibit or prevent solids from being transported to the internal components of the second processing fluid pump 188. In this way, the second processing fluid filter 190 may facilitate extended desired operation of the second processing fluid pump 188.

[0094] The second dispensing module 184 includes at least one second injector 192 (e.g., an injection device, etc.). The second injector 192 is fluidly connected to the second processing fluid pump 188 and is configured to receive second processing fluid from the second processing fluid pump 188. The second injector 192 is configured to dispense (e.g., spray, inject, etc.) the second processing fluid received by the second dispensing module 184 into exhaust gas within the second decomposition chamber shroud 176.

[0095] In some embodiments, the second process fluid delivery system 182 further includes a second air pump 194 and a second air source 196 (e.g., an air inlet, etc.). The second air pump 194 is fluidly coupled to the second air source 196 and configured to receive air from the second air source 196. The second air pump 194 is also fluidly coupled to a second dispensing module 184 and configured to supply air to the second dispensing module 184. In some applications, the second dispensing module 184 is configured to mix air and the second process fluid into an air-processing fluid mixture and supply the air-processing fluid mixture to a second injector 192 (e.g., for dispensing to exhaust gas within the second decomposition chamber shroud 176, etc.). The second injector 192 is fluidly coupled to the second air pump 194 and configured to receive air from the second air pump 194. The second injector 192 is configured to dispense the air-processing fluid mixture to exhaust gas within the second decomposition chamber shroud 176. In some of these embodiments, the second process fluid delivery system 182 further includes a second air filter 198. The second air filter 198 is fluidly connected to the second air source 196 and the second air pump 194, and is configured to receive air from the second air source 196 and supply air to the second air pump 194. The second air filter 198 is configured to filter air before it is supplied to the second air pump 194. In other embodiments, the second process fluid delivery system 182 does not include the second air pump 194 and / or the second process fluid delivery system 182 does not include the second air source 196. In such embodiments, the second dispensing module 184 is not configured to mix the second process fluid with air.

[0096] In various embodiments, the second dispensing module 184 is configured to receive air and processing liquid, and dispense an air-processing liquid mixture into the second decomposition chamber shroud 176. In various embodiments, the second dispensing module 184 is configured to receive processing liquid (but not air), and dispense a second processing liquid into the second decomposition chamber shroud 176. In various embodiments, the second dispensing module 184 is configured to receive processing liquid and dispense a second processing liquid into the second decomposition chamber shroud 176. In various embodiments, the second dispensing module 184 is configured to receive air and processing liquid, and dispense an air-processing liquid mixture into the second decomposition chamber shroud 176.

[0097] In various embodiments, the exhaust gas and the second treatment fluid or air treatment fluid are configured to mix within the second decomposition chamber 174. For example, the second decomposition chamber 174 may include a mixer (e.g., a vortex generator, blade plate, inlet plate, deflector plate, etc.). The mixer may be similar to the mixer described above with respect to mixer 150. The mixer is located within the second decomposition chamber shroud 176. The mixer is configured to receive exhaust gas from the third aftertreatment component 162. The mixer is also configured to mix the second treatment fluid or air treatment fluid mixture received from the second injector 192. The mixer is configured to promote the formation of vortices in the exhaust gas (e.g., tumbling, rotating, etc.) and the mixing of the exhaust gas with the second treatment fluid or air treatment fluid mixture (e.g., combining, etc.) to disperse the second treatment fluid in the exhaust gas downstream of the mixer. By using a mixer to disperse the second treatment fluid in the exhaust gas (e.g., to obtain an improved uniformity index, etc.), the reduction of emissions of unwanted components in the exhaust gas can be enhanced, or the temperature of the exhaust gas can be increased.

[0098] In various embodiments, the second processing fluid delivery system 182 utilizes a first processing fluid pump 130. In these embodiments, the first processing fluid pump 130 is fluidly coupled to a first processing fluid source 128 and a second dispensing module 184, and is configured to receive first processing fluid from the first processing fluid source 128 and supply the first processing fluid to the first dispensing module 126 and the second dispensing module 184. Similarly, the second processing fluid delivery system 182 may additionally or alternatively utilize a first air pump 136. For example, the first air pump 136 may be fluidly coupled to a first air source 138 and is configured to receive air from the first air source 138 and supply air to the first dispensing module 126 and the second dispensing module 184.

[0099] In various embodiments, a second processing fluid pump 188 is fluidly coupled to a first processing fluid source 128 and a second dispensing module 184, and configured to receive first processing fluid from the first processing fluid source 128 and supply the first processing fluid to the second dispensing module 184. The second processing fluid pump 188 is used to pressurize the first processing fluid from the first processing fluid source 128 for delivery to the second dispensing module 184. In various embodiments, the first processing fluid source 128 is the same as the second processing fluid source 186.

[0100] In some embodiments, a second air pump 194 is fluidly connected to a first air source 138 and configured to receive air from the first air source 138. The second air pump 194 is also fluidly connected to a second dispensing module 184 and configured to supply air to the second dispensing module 184. In some embodiments, the first air source 138 is the same as the second air source 196.

[0101] In some embodiments, the first processing liquid (e.g., provided by the first processing liquid source 128, etc.) is different from the second processing liquid (e.g., provided by the second processing liquid source 186, etc.). For example, the first processing liquid may be a high-temperature processing liquid (e.g., a reducing agent optimized for high-temperature exhaust gas, etc.) and the second processing liquid may be a medium-temperature processing liquid (e.g., a reducing agent optimized for medium-temperature exhaust gas, etc.).

[0102] The housing assembly 104 also includes a fourth housing panel 200 (e.g., platform, plate, flange, etc.). As explained in more detail herein, the fourth housing panel 200 is configured to support various components of the exhaust aftertreatment system 100 (e.g., support on the frame of a vehicle having the exhaust aftertreatment system 100, etc.). The fourth housing panel 200 includes a fourth housing panel transfer aperture 202 (e.g., orifice, window, opening, etc.).

[0103] The second decomposition chamber cover 176 extends through the transfer hole 202 of the fourth housing panel. In this way, the fourth housing panel 200 supports the second decomposition chamber cover 176 (e.g., relative to a frame to which the fourth housing panel 200 is attached). In various embodiments, the second decomposition chamber cover 176 is attached to the fourth housing panel 200 (e.g., at least partially surrounding the transfer hole 202 of the fourth housing panel).

[0104] The housing assembly 104 also includes a fifth housing panel 204 (e.g., platform, plate, flange, etc.). As explained in more detail herein, the fifth housing panel 204 is configured to support various components of the exhaust aftertreatment system 100 (e.g., support on the frame of a vehicle having the exhaust aftertreatment system 100, etc.). The fifth housing panel 204 includes a fifth housing panel transfer aperture 206 (e.g., orifice, window, opening, etc.).

[0105] The second decomposition chamber cover 176 extends through the transfer hole 206 of the fifth housing panel. In this way, the fifth housing panel 204 supports the second decomposition chamber cover 176 (e.g., relative to a frame to which the fifth housing panel 204 is attached). In various embodiments, the second decomposition chamber cover 176 is attached to the fifth housing panel 204 (e.g., at least partially around the transfer hole 206 of the fifth housing panel).

[0106] At the outlet of the second decomposition chamber 174, the exhaust gas is divided into a first portion and a second portion. As described in more detail herein, the first and second portions are processed simultaneously by the exhaust gas aftertreatment system 100. In this way, the efficiency of the exhaust gas aftertreatment system 100 can be improved, making it more desirable than other aftertreatment systems that do not divide the exhaust gas into multiple portions for simultaneous processing.

[0107] The housing assembly 104 also includes a first exhaust diversion conduit 208 (e.g., a line, pipe, etc.). The first exhaust diversion conduit 208 is coupled to a second decomposition chamber shroud 176 (e.g., downstream of the second decomposition chamber 174, etc.). The first exhaust diversion conduit 208 is fluidly coupled to the second decomposition chamber shroud 176 and configured to receive a first portion of a mixture of exhaust gas and a second processing liquid from the second decomposition chamber shroud 176.

[0108] The exhaust aftertreatment system 100 also includes a fourth aftertreatment component 210 (e.g., exhaust aftertreatment component, aftertreatment module, etc.). The fourth aftertreatment component 210 includes a fourth cover 212 (e.g., housing, outer shell, body, etc.).

[0109] The fifth housing panel 204 also includes a fifth housing panel first transport hole 214 (e.g., orifice, window, opening, etc.). A fourth cover 212 extends through the fifth housing panel first transport hole 214. In this way, the fifth housing panel 204 supports the fourth cover 212 (e.g., relative to a frame to which the fifth housing panel 204 is attached). In various embodiments, the fourth cover 212 is attached to the fifth housing panel 204 (e.g., at least partially surrounding the fifth housing panel first transport hole 214, etc.).

[0110] The fourth housing panel 200 also includes a fourth housing panel first transport hole 216 (e.g., orifice, window, opening, etc.). A fourth cover 212 extends through the fourth housing panel first transport hole 216. In this way, the fourth housing panel 200 supports the fourth cover 212 (e.g., relative to a frame to which the fourth housing panel 200 is attached). In various embodiments, the fourth cover 212 is attached to the fourth housing panel 200 (e.g., at least partially surrounding the fourth housing panel first transport hole 216, etc.).

[0111] The fourth post-processing component 210 also includes a fourth post-processing component base 218 (e.g., a working member, etc.). The fourth post-processing component base 218 is positioned within the fourth housing 212. For example, the fourth post-processing component base 218 may be coupled to the fourth housing 212.

[0112] The fourth aftertreatment component base 218 receives exhaust gas from the second decomposition chamber hood 176 (e.g., via the first exhaust splitter duct 208, etc.). The fourth aftertreatment component base 218 is configured to facilitate treatment of the exhaust gas. This treatment can facilitate the reduction of emissions of unwanted components in the exhaust gas. This treatment can also, or alternatively, facilitate the conversion of various oxidized components of the exhaust gas into other components. This treatment can also, or alternatively, facilitate the removal of particulate matter from the exhaust gas.

[0113] In various embodiments, the fourth aftertreatment component base 218 includes a conversion catalyst component (e.g., an SCR catalyst component, a conversion catalyst component, a catalyst metal, etc.). In these embodiments, the second treatment liquid provided by the second dispensing module 184 may be a reducing agent, and the fourth aftertreatment component base 218 may be configured to use a reducing agent (e.g., via a catalytic reaction, etc.) to induce the decomposition of a first portion of the exhaust gas components. Specifically, the reducing agent already provided to the exhaust gas by the second injector 192 undergoes evaporation, pyrolysis, and hydrolysis processes to form a non-NOx compound in the fourth shroud 212. x Emissions. In this way, the fourth aftertreatment component base 218 is configured to accelerate the reaction of NO in the reducing agent and exhaust gas. x NO between x The reduction process helps to reduce NO x The emissions are reduced to diatomic nitrogen, water, and / or carbon dioxide. The conversion catalyst component included in the fourth aftertreatment component base 218 may include, for example, vanadium, platinum, rhodium, palladium, zinc, copper, or other similar materials. In some embodiments, the conversion catalyst component included in the fourth aftertreatment component base 218 is a ceramic conversion catalyst component.

[0114] The conversion catalyst component included in the fourth aftertreatment component base 218 can be directional (meaning that exhaust gas is expected to flow through the fourth aftertreatment component base 218 in a single direction) or non-directional (meaning that exhaust gas is expected to flow through the fourth aftertreatment component base 218 in any direction). In applications where the conversion catalyst component included in the fourth aftertreatment component base 218 is directional, the fourth cover 212 may include structures or features that facilitate (e.g., in an error-proof manner) fastening the fourth cover 212 to the fourth housing panel 200 and / or the fifth housing panel 204 in only one orientation relative to the fourth housing panel 200 and / or the fifth housing panel 204.

[0115] In various embodiments, the third housing panel 146 further includes a third housing panel first transport hole 220 (e.g., orifice, window, opening, etc.). A fourth cover 212 extends through the third housing panel first transport hole 220. In this way, the third housing panel 146 supports the fourth cover 212 (e.g., relative to a frame to which the third housing panel 146 is attached). In various embodiments, the fourth cover 212 is attached to the third housing panel 146 (e.g., at least partially surrounding the third housing panel first transport hole 220, etc.).

[0116] The housing assembly 104 also includes a first exhaust supply conduit 222 (e.g., a line, pipe, etc.). The first exhaust supply conduit 222 is connected to the fourth shroud 212 (e.g., downstream of the fourth aftertreatment component 210, etc.). The first exhaust supply conduit 222 is fluidly connected to the fourth shroud 212 and is configured to receive exhaust from the fourth shroud 212 (e.g., after the exhaust has been processed by the fourth aftertreatment component 210, etc.).

[0117] The exhaust duct system 102 includes an outlet exhaust duct 224 (e.g., a line, pipe, etc.). The outlet exhaust duct 224 is connected to a first exhaust supply duct 222 and is configured to receive exhaust gas from the first exhaust supply duct 222.

[0118] The third housing panel 146 also includes a third housing panel outlet aperture 226 (e.g., orifice, window, opening, etc.). An outlet exhaust duct 224 extends through the third housing panel outlet aperture 226. In this way, the third housing panel 146 supports the outlet exhaust duct 224 (e.g., relative to a frame to which the third housing panel 146 is attached). In various embodiments, the outlet exhaust duct 224 is coupled to the third housing panel 146 (e.g., at least partially surrounding the third housing panel outlet aperture 226, etc.).

[0119] The second housing panel 112 also includes a second housing panel outlet aperture 228 (e.g., orifice, window, opening, etc.). An outlet exhaust duct 224 extends through the second housing panel outlet aperture 228. In this way, the second housing panel 112 supports the outlet exhaust duct 224 (e.g., relative to a frame to which the second housing panel 112 is attached). In various embodiments, the outlet exhaust duct 224 is coupled to the second housing panel 112 (e.g., at least partially surrounding the second housing panel outlet aperture 228, etc.).

[0120] The first housing panel 106 also includes a first housing panel outlet aperture 230 (e.g., orifice, window, opening, etc.). An outlet exhaust duct 224 extends through the first housing panel outlet aperture 230. In this way, the first housing panel 106 supports the outlet exhaust duct 224 (e.g., relative to a frame to which the first housing panel 106 is attached). In various embodiments, the outlet exhaust duct 224 is coupled to the first housing panel 106 (e.g., at least partially surrounding the first housing panel outlet aperture 230, etc.).

[0121] The housing assembly 104 also includes a second exhaust diversion conduit 232 (e.g., a line, pipe, etc.). The second exhaust diversion conduit 232 is coupled to the second decomposition chamber shroud 176 (e.g., downstream of the second decomposition chamber 174, etc.). The second exhaust diversion conduit 232 is fluidly coupled to the second decomposition chamber shroud 176 and configured to receive a second portion of a mixture of exhaust gas and a second processing liquid from the second decomposition chamber shroud 176.

[0122] The exhaust aftertreatment system 100 also includes a fifth aftertreatment component 234 (e.g., an exhaust aftertreatment component, an aftertreatment module, etc.). The fifth aftertreatment component 234 includes a fifth cover 236 (e.g., a housing, an outer shell, a body, etc.).

[0123] The fifth housing panel 204 also includes a fifth housing panel second transport hole 238 (e.g., orifice, window, opening, etc.). A fifth cover 236 extends through the fifth housing panel second transport hole 238. In this way, the fifth housing panel 204 supports the fifth cover 236 (e.g., relative to a frame to which the fifth housing panel 204 is attached). In various embodiments, the fifth cover 236 is coupled to the fifth housing panel 204 (e.g., at least partially surrounding the fifth housing panel second transport hole 238, etc.).

[0124] The fourth housing panel 200 also includes a fourth housing panel second transport hole 240 (e.g., orifice, window, opening, etc.). A fifth cover 236 extends through the fourth housing panel second transport hole 240. In this way, the fourth housing panel 200 supports the fifth cover 236 (e.g., relative to a frame to which the fourth housing panel 200 is attached). In various embodiments, the fifth cover 236 is attached to the fourth housing panel 200 (e.g., at least partially surrounding the fourth housing panel second transport hole 240, etc.).

[0125] The fifth post-processing component 234 also includes a fifth post-processing component base 242 (e.g., a working member, etc.). The fifth post-processing component base 242 is positioned within the fifth housing 236. For example, the fifth post-processing component base 242 may be coupled to the fifth housing 236.

[0126] The fifth aftertreatment component base 242 receives exhaust gas from the second decomposition chamber hood 176 (e.g., via the second exhaust splitter duct 232, etc.). The fifth aftertreatment component base 242 is configured to facilitate treatment of the exhaust gas. This treatment can facilitate the reduction of emissions of unwanted components in the exhaust gas. This treatment can also, or alternatively, facilitate the conversion of various oxidizing components of the exhaust gas into other components. This treatment can also, or alternatively, facilitate the removal of particulate matter from the exhaust gas.

[0127] In various embodiments, the fifth aftertreatment component base 242 includes a conversion catalyst component (e.g., an SCR catalyst component, a conversion catalyst component, a catalyst metal, etc.). In these embodiments, the second treatment fluid provided by the second dispensing module 184 may be a reducing agent, and the fifth aftertreatment component base 242 may be configured to induce the decomposition of a second portion of the exhaust gas components using a reducing agent (e.g., via a catalytic reaction, etc.). Specifically, the reducing agent already provided to the exhaust gas by the second injector 192 undergoes evaporation, pyrolysis, and hydrolysis processes to form non-NO within the fifth shroud 236. x Emissions. In this way, the fifth aftertreatment component base 242 is configured to accelerate the reaction of NO in the reducing agent and exhaust gas. x NO between x The reduction process assists in removing NO x The emissions are reduced to diatomic nitrogen, water, and / or carbon dioxide. The conversion catalyst component included in the fifth aftertreatment component base 242 may include, for example, vanadium, platinum, rhodium, palladium, zinc, copper, or other similar materials. In some embodiments, the conversion catalyst component included in the fifth aftertreatment component base 242 is a ceramic conversion catalyst component.

[0128] The conversion catalyst component included in the fifth aftertreatment component base 242 can be directional (meaning that exhaust gas is expected to flow through the fifth aftertreatment component base 242 in a single direction) or non-directional (meaning that exhaust gas is expected to flow through the fifth aftertreatment component base 242 in any direction). In applications where the conversion catalyst component included in the fifth aftertreatment component base 242 is directional, the fifth shroud 236 may include structures or features that facilitate (e.g., in an error-proof manner) fastening the fifth shroud 236 to the fourth housing panel 200 and / or the fifth housing panel 204 in only one orientation relative to the fourth housing panel 200 and / or the fifth housing panel 204.

[0129] In various embodiments, the third housing panel 146 further includes a second transport aperture (e.g., orifice, window, opening, etc.). A fifth cover 236 extends through the second transport aperture of the third housing panel. In this way, the third housing panel 146 supports the fifth cover 236 (e.g., relative to a frame to which the third housing panel 146 is attached). In various embodiments, the fifth cover 236 is coupled to the third housing panel 146 (e.g., at least partially surrounding the second transport aperture of the third housing panel, etc.).

[0130] The housing assembly 104 also includes a second exhaust supply conduit 244 (e.g., a line, pipe, etc.). The second exhaust supply conduit 244 is connected to the fifth shroud 236 (e.g., downstream of the fourth aftertreatment component 210, etc.). The second exhaust supply conduit 244 is fluidly connected to the fifth shroud 236 and is configured to receive exhaust from the fifth shroud 236 (e.g., after the exhaust has been processed by the fourth aftertreatment component 210, etc.).

[0131] The outlet exhaust duct 224 is connected to the second exhaust supply duct 244 and is configured to receive exhaust gas from the second exhaust supply duct 244.

[0132] In some embodiments, the dimensions of the exhaust aftertreatment system may be as follows: The volume of the first aftertreatment component base 122, in liters (L), may be in the range of 4.0L-6.0L (inclusive) (e.g., 4.1L, 4.26L, 4.85L, etc.). The volume of the second aftertreatment component base 160, in liters, may be in the range of 2.1L-9.0L (inclusive) (e.g., 2.1L, 5.0L, 8.5L, etc.). The volume of the third aftertreatment component base 168, in liters, may be in the range of 6.0L-9.0L (inclusive) (e.g., 6.0L, 7.8L, 8.0L, etc.). The volume of the fourth after-treatment component base 218, in liters (L), can be in the range of 23.0L to 27.0L (inclusive) (e.g., 23.5L, 25.0L, 25.22L, etc.). The volume of the fifth after-treatment component base 242, in liters, can also be in the range of 23.0L to 27.0L (inclusive) (e.g., 23.5L, 25.0L, 25.22L, etc.). However, other volumes can also be used (e.g., within ±15% of the provided volume, etc.).

[0133] The diameter of the first post-processing component base 122, measured in millimeters (mm), can be in the range of 100mm-300mm (inclusive) (e.g., 100.5mm, 266.7mm, 280mm, etc.). The diameter of the second post-processing component base 160, measured in millimeters, can be in the range of 90mm-280mm (inclusive) (e.g., 100.5mm, 266.7mm, 270mm, etc.). The diameter of the third post-processing component base 168, measured in millimeters, can be in the range of 90mm-280mm (inclusive) (e.g., 100.5mm, 266.7mm, 270mm, etc.). The diameter of the fourth post-processing component base 218, measured in millimeters, can be in the range of 200mm-300mm (inclusive) (e.g., 211.1mm, 226.0mm, 240.5mm, etc.). The diameter of the fifth post-processing component base 242, measured in millimeters, can also be in the range of 200mm-300mm (inclusive) (e.g., 211.1mm, 226.0mm, 240.5mm, etc.). However, other diameters can also be used (e.g., within ±15% of the provided diameter, etc.).

[0134] The length of the first post-processing component base 122, measured in millimeters (mm), can be in the range of 50 mm and 100 mm (e.g., 60.7 mm, 76.2 mm, 91.0 mm, etc.). The length of the second post-processing component base 160, measured in millimeters, can be in the range of 100 mm to 170 mm (inclusive) (e.g., 101.3 mm, 125.0 mm, 152.4 mm, etc.). The length of the fourth post-processing component base 218, measured in millimeters, can be in the range of 100 mm to 270 mm (inclusive) (e.g., 110.0 mm, 139.7 mm, 142.3 mm, 226 mm, etc.). The length of the fifth post-processing component base 242, in millimeters, may include a range between 100mm and 270mm (inclusive) (e.g., 110.0mm, 139.7mm, 142.3mm, 226mm, etc.). However, other lengths may also be used (e.g., within ±15% of the provided length, etc.).

[0135] like Figure 1As shown, the exhaust aftertreatment system 100 illustrates the exhaust flow path with arrows. For example, a second portion of the exhaust is guided parallel to the first portion of the exhaust being guided through the fourth shroud 212 through the fifth shroud 236. By guiding the second portion of the exhaust parallel to the first portion of the exhaust being guided through the fourth shroud 212 through the fifth shroud 236, the exhaust is treated more efficiently than in other systems where it is not convenient to guide exhaust in parallel to multiple aftertreatment components. For example, compared to other aftertreatment systems where it is not convenient to guide exhaust in parallel to multiple aftertreatment components, parallel guidance of the exhaust can provide the exhaust aftertreatment system 100 with increased exhaust processing capacity and / or increased efficiency in processing exhaust.

[0136] Although 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 can be used with other internal combustion engines, such as gasoline internal combustion engines, hybrid internal combustion engines, propane internal combustion engines, dual-fuel internal combustion engines and other similar internal combustion engines.

[0137] III. Configuration of Example Implementation

[0138] While this specification contains many specific implementation details, these should not be construed as limiting the scope of the claims, but rather as descriptions of features specific to particular embodiments. Certain features described in the context of individual embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented individually or in any suitable sub-combination in multiple embodiments. Furthermore, while features may be described as functioning in certain combinations and even initially claimed in this way, in some cases, one or more features from the claimed combination may be removed from that combination, and the claimed combination may refer to a sub-combination or a variation of a sub-combination.

[0139] As used herein, the terms “substantially,” “generally,” and similar terms are intended to have a broad meaning consistent with common and accepted use by one of ordinary skill in the art to which the subject matter of this disclosure pertains. Those skilled in the art who consult this disclosure will understand that these terms are intended to allow for the description of certain features described and claimed, without limiting the scope of those features to the precise numerical ranges provided. Therefore, these terms should be interpreted as indicating that non-substantial or irrelevant modifications or alterations to the described and claimed subject matter are considered to be within the scope of the appended claims.

[0140] As used herein, the term "link" and similar terms mean that two components are directly or indirectly connected to each other. Such a link can be fixed (e.g., permanent) or movable (e.g., removable or releasable). Such a link can be achieved by two components or two components and any additional intermediate components being integrally formed into a single whole, wherein the two components or two components and any additional intermediate components are attached to each other.

[0141] As used herein, the term "fluid connection" refers to two components or objects having a channel formed between them in which a fluid (such as air, reducing agent, air-reducing agent mixture, exhaust gas, hydrocarbon, air-hydrocarbon mixture) can flow with or without an intermediate component or object. Examples of fluid connections or configurations used to achieve fluid communication may include pipes, channels, or any other suitable means of enabling fluid flow from one component or object to another.

[0142] It is important to note that the constructions and arrangements of the various systems illustrated in the various example embodiments are illustrative in nature and not restrictive. All variations and modifications within the spirit and / or scope of the described embodiments are intended to be protected. It should be understood that some features may not be essential, and embodiments lacking various features may be considered within the scope of this disclosure, defined by the appended claims. When the language “part” is used, it may include a part and / or the entire item, unless specifically stated to the contrary.

[0143] Furthermore, in the context of a series of elements, the term "or" is used in its inclusive sense (rather than its exclusive sense), and thus, when used to connect a series of elements, the term "or" refers to one, some, or all of the elements in the list. Unless otherwise specified, conjunctions such as "at least one of X, Y, and Z" are understood in conjunction with the context in which they are typically used to express items, terms, etc., and can 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). Therefore, unless otherwise indicated, 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.

[0144] Additionally, unless otherwise indicated, the range of values ​​used herein (e.g., W1 to W2, etc.) includes both their maximum and minimum values ​​(e.g., W1 to W2 includes W1 and includes W2, etc.). Furthermore, unless otherwise indicated, the range of values ​​(e.g., W1 to W2, etc.) does not necessarily require that intermediate values ​​be included within the range of values ​​(e.g., W1 to W2 may include only W1 and W2, etc.).

Claims

1. An exhaust gas aftertreatment system, comprising: a first decomposition chamber configured to receive exhaust gas; a first dosing module coupled to the first decomposition chamber and configured to provide a first treatment fluid into the first decomposition chamber; a first conversion catalyst member configured to receive a mixture of the first treatment fluid and the exhaust gas from the first decomposition chamber; a second decomposition chamber configured to receive the exhaust gas from the first conversion catalyst member; a second dosing module coupled to the second decomposition chamber and configured to provide a second treatment fluid into the second decomposition chamber; a second conversion catalyst member configured to receive a first portion of a mixture of the second treatment fluid and the exhaust gas from the second decomposition chamber; a third conversion catalyst member configured to receive a second portion of the mixture of the second treatment fluid and the exhaust gas from the second decomposition chamber; an inlet exhaust conduit configured to provide the exhaust gas into the first decomposition chamber; a first housing panel supporting the inlet exhaust conduit and the second decomposition chamber; a second housing panel supporting the inlet exhaust conduit and the second decomposition chamber; and a third housing panel supporting the first decomposition chamber and the first conversion catalyst member.

2. The exhaust gas aftertreatment system of claim 1, further comprising a mixer configured to receive the first treatment fluid and the exhaust gas from the first decomposition chamber and mix the first treatment fluid and the exhaust gas upstream of the first conversion catalyst member. The mixer further comprises at least one of an upstream mixing plate, a downstream mixing plate, and a perforated plate.

3. The exhaust gas aftertreatment system of claim 2, wherein, 4. The exhaust gas aftertreatment system of claim 1, further comprising a mixer configured to receive the second treatment fluid and the exhaust gas from the second decomposition chamber and mix the second treatment fluid and the exhaust gas upstream of the second conversion catalyst member and the third conversion catalyst member.

5. The exhaust gas aftertreatment system of claim 1, further comprising a fourth conversion catalyst member configured to provide the exhaust gas to the first decomposition chamber; the first conversion catalyst member is a selective catalytic reduction (SCR) catalyst member; and wherein wherein the fourth conversion catalyst member is an oxidation catalyst member.

6. The exhaust gas aftertreatment system of claim 1, further comprising an outlet exhaust conduit configured to receive the exhaust gas from the second conversion catalyst member and the third conversion catalyst member. At least one of the first dosing module and the second dosing module is configured to mix air with at least one of the first treatment fluid and the second treatment fluid.

7. The exhaust gas aftertreatment system of claim 1, wherein, ​ 8. The exhaust aftertreatment system of claim 7, further comprising at least one air filter configured to filter air.

9. The exhaust aftertreatment system of any one of claims 1-8, further comprising a heater positioned within the inlet exhaust conduit and configured to heat the exhaust.

10. The exhaust aftertreatment system of any one of claims 1-8, further comprising at least one treatment fluid filter configured to filter at least one of the first treatment fluid and the second treatment fluid.

11. The exhaust aftertreatment system of claim 1, further comprising an exhaust filtration member configured to remove particulates from the exhaust.

12. The exhaust gas aftertreatment system of claim 11, wherein, The exhaust filtration member is selectively attachable to and detachable from the exhaust aftertreatment system.

13. The exhaust aftertreatment system of any one of claims 1-8 and 11-12, further comprising: a first exhaust split conduit configured to receive the first portion of the mixture of the exhaust and the second treatment fluid from the second decomposition chamber; and a second exhaust split conduit configured to receive the second portion of the mixture of the exhaust and the second treatment fluid from the second decomposition chamber.

14. The exhaust gas aftertreatment system of any one of claims 1-8 and 11-12, wherein, The second dosing module is coupled to a treatment fluid pump coupled to the first dosing module and uses the treatment fluid pump.

15. The exhaust aftertreatment system of any of claims 1-8 and 11-12, wherein, At least one of the first, second, and third conversion catalyst members further comprises vanadium, platinum, rhodium, palladium, zinc, or copper.

16. The exhaust aftertreatment system of any of claims 1-8 and 11-12, wherein, At least one of the first, second, and third conversion catalyst members is a ceramic conversion catalyst member.

17. The exhaust aftertreatment system of any one of claims 1-8 and 11-12, further comprising: a first shroud configured to receive the first portion of the mixture of the second treatment fluid and the exhaust from the second conversion catalyst member; and a second shroud configured to receive the second portion of the mixture of the second treatment fluid and the exhaust from the third conversion catalyst member; wherein the first and second shrouds are parallel to each other.

18. The exhaust aftertreatment system of any of claims 1-8 and 11-12, wherein, The second conversion catalyst member processes the first portion of the mixture of the second treatment fluid and the exhaust while the third conversion catalyst member processes the second portion of the mixture of the second treatment fluid and the exhaust.

19. The exhaust gas aftertreatment system of any one of claims 1-8 and 11-12, wherein, The first treatment fluid is different than the second treatment fluid.

20. The exhaust aftertreatment system of any of claims 1-8 and 11-12, wherein, The first treatment fluid is the same as the second treatment fluid.

21. The exhaust gas aftertreatment system of claim 6, wherein, The third housing panel supports the outlet exhaust conduit.

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