Exhaust conduit assembly

Abstract

An exhaust conduit assembly includes an exhaust conduit body, an injection hole, and a dispenser mount portion. The exhaust conduit body defines an exhaust flow path. An injection hole extends through the exhaust conduit body. The dispenser mount portion includes an inlet port, a channel, and an outlet port. The inlet port is configured to receive a coolant. The channel is configured to receive coolant from the inlet port. At least a portion of the channel extends around at least a portion of the injection hole. The outlet port is configured to receive coolant from the channel.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 353,247, filed on June 17, 2022, which is incorporated herein by reference in its entirety. Technical Field

[0002] The present disclosure generally relates to a doser mount for an exhaust aftertreatment system of an internal combustion engine. background

[0003] For internal combustion engine systems, it may be desirable to reduce the emission of certain components in the exhaust gas produced by the combustion of fuel. One method that may be implemented to reduce emissions is to treat the exhaust gas using an aftertreatment system. It is often desirable to mix the exhaust gas with a reductant for treating the exhaust gas. However, heat from the exhaust system may be transferred to the reductant dosing module, which may damage the dosing module. Overview

[0004] In one embodiment, an exhaust duct assembly includes an exhaust duct body, an injection hole, and a distributor mounting portion. The exhaust duct defines an exhaust flow path. The injection hole extends through the exhaust duct body. The distributor mounting portion includes an inlet port, a channel, and an outlet port. The inlet port is configured to receive a coolant. The channel is configured to receive the coolant from the inlet port. At least a portion of the channel extends around at least a portion of the injection hole. The outlet port is configured to receive the coolant from the channel.

[0005] In another embodiment, an exhaust aftertreatment system includes an exhaust duct body defining an exhaust flow path, the exhaust duct body including an inlet and an outlet. The exhaust aftertreatment system includes a support wall extending radially away from the exhaust duct body. The exhaust aftertreatment system includes an outer wall extending around a portion of the exhaust duct body. The outer wall is spaced apart from the exhaust duct body via the support wall. The exhaust aftertreatment system includes an injection hole extending through the exhaust duct body. The exhaust aftertreatment system includes a distributor mounting portion, the distributor mounting portion defining a space extending around the injection hole. The space receives a portion of the distributor. The exhaust duct body, the support wall, and the outer wall define at least one air gap. At least one air gap is disposed between the distributor mounting portion and at least one of the inlet or outlet of the exhaust duct body. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present disclosure will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which like reference numerals refer to like elements unless otherwise indicated, and in which: Figure 1 is a schematic diagram of an example exhaust aftertreatment system including an exhaust conduit assembly; Figure 2is a schematic diagram of another example exhaust aftertreatment system including an exhaust conduit assembly; Figure 3 is a perspective view of an example exhaust duct assembly for an exhaust aftertreatment system; Figure 4 is along Figure 3 The plane AA interception in Figure 3 A cross-sectional view of the exhaust duct assembly shown in ; Figure 5 yes Figure 4 A detailed view of detail A shown in; Figure 6 is along Figure 3 The plane AA interception in Figure 3 A perspective cutaway view of an exhaust duct assembly shown in ; Figure 7 is a perspective view of another example exhaust conduit assembly for an exhaust aftertreatment system; Figure 8 yes Figure 7 a perspective view of a portion of the exhaust duct assembly shown; and Fig. 9 yes Figure 8 A top view of a portion of an exhaust duct assembly is shown.

[0007] It should be appreciated that for purposes of illustration, the drawings are schematic representations. The drawings are provided for the purpose of illustrating one or more embodiments, with the express understanding that they will not be used to limit the scope or meaning of the claims. Detailed Description

[0008] The following is a more detailed description of various concepts and embodiments related to methods, apparatuses, and embodiments of providing an exhaust duct assembly for an exhaust aftertreatment system for an internal combustion engine. The various concepts introduced above and discussed in more detail below can be implemented in any of a variety of ways, as the concepts described are not limited to any particular embodiment. Examples of specific embodiments and applications are provided primarily for illustrative purposes.

[0009] I. Overview In order to reduce emissions and optimize the performance of an internal combustion engine, it may be desirable to reduce the temperature of a dosing module (e.g., a dosing device) of an exhaust aftertreatment system. For example, it may be desirable to reduce the amount of heat transferred from an internal combustion engine system, such as via a turbocharger, an exhaust conduit, and exhaust gas flowing therethrough, to the dosing module.

[0010] Embodiments herein relate to an exhaust aftertreatment system that provides cooling to a dosing module so that the dosing module can operate well in a high temperature environment. For example, when an internal combustion engine begins to run, a coolant can flow through an exhaust duct assembly to remove heat from a dosing device mounting member, and thus cool a dosing module disposed in a dosing device mounting member. Embodiments disclosed herein cool the exhaust duct assembly via a coolant to reduce the amount of heat transferred to the dosing module. Providing a coolant to the exhaust duct assembly allows the dosing module to be disposed within the system closer to a heat source than would otherwise be possible without such cooling. For example, because the coolant supplied to the exhaust duct assembly reduces the amount of heat transferred to the dosing module, the dosing module can be disposed near an internal combustion engine, a turbocharger, or other heat-generating components of an internal combustion engine system. The coolant reduces the amount of heat transferred to the dosing module and protects the dosing module from damage that may occur due to high temperatures. The ability of the dosing module to be positioned near the internal combustion engine and / or turbocharger of the system allows the system to incorporate more dosing modules, which can improve the efficiency and effectiveness of the exhaust aftertreatment system. For example, being able to position a dosing module closer to a heat source allows a system to incorporate more dosing modules so that more reductant can be introduced into the exhaust to more adequately treat the exhaust. Embodiments disclosed herein can enhance the operation of a system employing one of the coolant cooled dosing mounts described herein under good conditions.

[0011] The embodiments disclosed herein can be used with either a DEF cooled or air cooled dosing module, which facilitates the use of less expensive dosing technology. Coolant cooling provides the advantage of locating the dosing module in a hot exhaust temperature area to utilize heat to decompose the DEF. Additionally, coolant cooling allows for the addition of a pressure sensor in the dosing module, which can improve dosing accuracy and performance.

[0012] II. Overview of exhaust aftertreatment system Figure 1 and Figure 2 An exhaust aftertreatment system 100 (e.g., treatment system, etc.) for treating exhaust generated by an internal combustion engine 102 (e.g., a diesel internal combustion engine, a gasoline internal combustion engine, a hybrid internal combustion engine, a propane internal combustion engine, a dual-fuel internal combustion engine, etc.) is depicted in accordance with various embodiments. The exhaust aftertreatment system 100 includes an exhaust conduit system 104. The exhaust conduit system 104 is configured (e.g., constructed to, capable of, etc.) to receive exhaust gas from the internal combustion engine 102 and provide the exhaust gas to the atmosphere.

[0013] The exhaust conduit system 104 includes an upstream exhaust conduit 106 (e.g., a line, a pipe, etc.). The upstream exhaust conduit 106 is configured to receive exhaust gas from an upstream component (e.g., a header, an exhaust manifold, a turbocharger, a diesel oxidation catalyst, an internal combustion engine 102, etc.). In some embodiments, the upstream exhaust conduit 106 is coupled to (e.g., attached to, fixed to, welded to, fastened to, riveted to, etc.) the internal combustion engine 102 (e.g., the upstream exhaust conduit 106 is coupled to an outlet of the internal combustion engine 102, etc.). In other embodiments, the upstream exhaust conduit 106 is integrally formed with the internal combustion engine 102. As used herein, two or more elements are "integrally formed" when they are formed and joined together as part of a single manufacturing step to produce a single piece or unitary structure that cannot be disassembled without at least partially destroying the single piece or unitary structure.

[0014] The exhaust aftertreatment system 100 also includes a turbocharger 108. The turbocharger 108 is configured to receive exhaust gas from the internal combustion engine 102. Although not shown, the turbocharger 108 also receives air and provides air to the internal combustion engine 102. The turbocharger 108 uses energy from the exhaust gas generated by the internal combustion engine 102 to provide energy to the air provided to the internal combustion engine 102. Specifically, the turbocharger 108 can pressurize the air provided to the internal combustion engine 102. In some embodiments, the turbocharger 108 includes a compressor impeller coupled to a turbine wheel via a connector shaft, wherein the exhaust gas generated by the internal combustion engine 102 rotates the turbine impeller, and the turbine impeller rotates the shaft and the compressor impeller to compress the air provided to the internal combustion engine 102. By compressing the air, the turbocharger 108 can enable the internal combustion engine 102 to operate with increased power and / or efficiency.

[0015] The exhaust duct system 104 includes an exhaust duct assembly 110. The exhaust duct assembly 110 defines an exhaust gas flow path. Figure 1 and Figure 2As shown, the exhaust duct assembly 110 is coupled to the turbocharger 108. For example, the exhaust duct assembly 110 can be fastened (e.g., using a band, using bolts, etc.), welded, riveted, or otherwise attached to the turbocharger 108. In other embodiments, the exhaust duct assembly 110 is integrally formed with the housing of the turbocharger 108. In some embodiments, the exhaust duct assembly 110 is disposed upstream of the turbocharger 108 (e.g., the exhaust duct assembly 110 provides exhaust gas to the turbocharger 108, etc.). For example, the exhaust duct assembly can be disposed between the internal combustion engine 102 and the turbocharger 108. In some embodiments, the exhaust duct assembly 110 is disposed downstream of the turbocharger 108. For example, exhaust gas can be provided from the turbocharger 108 to the exhaust duct assembly 110, and then provided to other downstream components of the exhaust aftertreatment system 100. As explained in more detail herein, the exhaust conduit assembly 110 is configured to facilitate the introduction of a reductant (e.g., diesel exhaust fluid (DEF), Adblue®, urea-water solution (UWS), an aqueous urea solution (e.g., AUS32, etc.) into the exhaust gas to facilitate subsequent downstream components of the exhaust aftertreatment system 100 to treat the exhaust gas. The exhaust conduit assembly 110 is also configured to facilitate cooling of a device configured to inject the reductant into the exhaust gas (e.g., the upstream dosing module 116, the downstream dosing module 160 described in more detail herein).

[0016] The exhaust aftertreatment system 100 also includes a reductant delivery system 114. As explained in more detail herein, the reductant delivery system 114 is configured to facilitate the introduction of a reductant (e.g., a reductant, a reductant-air mixture, etc.) into the exhaust gas. The reductant delivery system 114 includes an upstream dosing module 116 (e.g., a dosing device, a dosing assembly, etc.). The upstream dosing module 116 is configured to facilitate the entry of the reductant into the exhaust duct assembly 110. As explained in more detail herein, the upstream dosing module 116 is configured to receive a reductant, and in some embodiments, is configured to receive air and a reductant, and provide the reductant and / or the air-reductant mixture to the exhaust duct assembly 110 to facilitate the treatment of the exhaust gas. The upstream dosing module 116 may include an insulator inserted between a portion of the upstream dosing module 116 and a portion of the exhaust duct assembly 110 where the upstream dosing module 116 is mounted. The upstream dosing module 116 is coupled to the exhaust duct assembly 110.

[0017] The upstream dosing module 116 includes an injector 118 (eg, an insertion device, etc.). The injector 118 is configured to dose (eg, inject, insert, etc.) the reductant received by the upstream dosing module 116 into the exhaust gas within the exhaust conduit assembly 110.

[0018] The reductant delivery system 114 also includes a reductant source 120 (e.g., a reductant tank, etc.). The reductant source 120 is configured to contain a reductant. The reductant delivery system 114 also includes a reductant supply line 122. The reductant source 120 is configured to provide the reductant to the upstream dosing module 116 via the reductant supply line 122. The reductant source 120 may include a plurality of reductant sources 120 (e.g., a plurality of tanks connected in series or in parallel, etc.). The reductant source 120 may be, for example, a reductant containing Adblue. ® The reductant supplied to the upstream dosing module 116 and not injected into the exhaust conduit assembly 110 may be returned to the reductant source 120 via the reductant return line 124. The reductant from the reductant source 120 may be continuously circulated through the reductant supply line 122 and the return line 124 to keep the reductant cool and / or prevent the reductant from freezing.

[0019] The reductant delivery system 114 also includes a reductant pump 126 (e.g., a supply unit, etc.). The reductant pump 126 is configured to receive the reductant from the reductant source 120 and provide the reductant to the upstream dosing module 116. For example, the reductant pump 126 is configured to provide the reductant to the injector 118. The reductant pump 126 is used to pressurize the reductant from the reductant source 120 for delivery to the upstream dosing module 116. In some embodiments, the reductant pump 126 is pressure controlled. In some embodiments, the reductant pump 126 is coupled to a chassis of a vehicle associated with the exhaust aftertreatment system 100.

[0020] In some embodiments, the reductant delivery system 114 also includes a reductant filter 128. The reductant filter 128 is configured to receive the reductant from the reductant source 120 and provide the reductant to the reductant pump 126. The reductant filter 128 filters the reductant before the reductant is provided to the internal components of the reductant pump 126. For example, the reductant filter 128 can inhibit or prevent solids from being transferred to the internal components of the reductant pump 126. In this way, the reductant filter 128 can facilitate the reductant pump 126 to operate in good condition for a longer period of time.

[0021] In various embodiments, the reductant delivery system 114 further includes an air source 130 (e.g., an air intake, etc.) and an air pump 132. The air pump 132 is configured to receive air from the air source 130. The air pump 132 is configured to provide air to the upstream dosing module 116 via an air supply line 134. The upstream dosing module 116 is configured to mix air and reductant into an air-reductant mixture and provide the air-reductant mixture to an injector 118 (e.g., for dosing into the exhaust gas within the exhaust duct assembly 110, etc.). The injector 118 is configured to receive air from the air pump 132. The injector 118 is configured to dosing the air-reductant mixture into the exhaust gas within the exhaust duct assembly 110. In some of these embodiments, the reductant delivery system 114 further includes an air filter 136. The air filter 136 is configured to receive air from the air source 130 and provide the air to the air pump 132. The air filter 136 is configured to filter the air before the air is provided to the air pump 132. In other embodiments, the reductant delivery system 114 does not include the air pump 132 and / or the reductant delivery system 114 does not include the air source 130. In such embodiments, the upstream dosing module 116 is not configured to mix the reductant with air.

[0022] The exhaust aftertreatment system 100 also includes a coolant delivery system 138 (e.g., an engine coolant system, etc.). As explained in more detail herein, the coolant delivery system 138 is configured to facilitate cooling of components of the exhaust aftertreatment system 100. For example, the coolant delivery system 138 may be configured to cool at least one of the internal combustion engine 102, the turbocharger 108, and the upstream distribution module 116, etc. For example, the exhaust duct assembly 110 may be disposed proximate to (e.g., adjacent to, coupled to, etc.) the turbocharger 108, such that the upstream distribution module 116 is disposed proximate to the turbocharger 108. For example, the upstream distribution module 116 may be between 0 and 500 centimeters (cm) from the turbocharger 108.

[0023] The turbocharger 108 is heated by the exhaust gas during operation of the exhaust aftertreatment system 100. In order to maximize the energy that can be collected from the exhaust gas, it is generally desirable to position the turbocharger 108 as close to the internal combustion engine 102 as possible. Therefore, the exhaust gas received by the turbocharger 108 is relatively hot. The heat from the turbocharger 108 can be transferred to the exhaust duct assembly 110 and thus to the upstream distribution module 116, which causes the temperature of the upstream distribution module 116 to increase. Therefore, the coolant delivery system 138 is configured to cool the upstream distribution module 116 by providing coolant to the exhaust duct assembly 110, which receives and surrounds at least a portion of the upstream distribution module 116. Cooling the upstream distribution module 116 enables the upstream distribution module 116 to be disposed in a higher temperature environment without being damaged by the higher temperature.

[0024] The coolant delivery system 138 includes a coolant source 140 (e.g., a coolant tank). The coolant source 140 may contain any type of fluid capable of capturing heat. The coolant delivery system 138 also includes a coolant supply line 142. As described in more detail herein, the coolant source 140 is configured to provide coolant to the exhaust duct assembly 110 via the coolant supply line 142. The coolant supply line 142 may directly or indirectly fluidly couple the coolant source 140 with the exhaust duct assembly 110. For example, the coolant supply line 142 may provide coolant to the internal combustion engine 102, then from the internal combustion engine 102 to the turbocharger 108, and then from the turbocharger 108 to the exhaust duct assembly 110. In other embodiments, the coolant supply line extends directly from the coolant source 140 to the exhaust duct assembly 110.

[0025] The coolant delivery system 138 also includes a coolant return line 144 . The coolant return line 144 is configured to return coolant from the exhaust duct assembly 110 to the coolant source 140 .

[0026] The coolant delivery system 138 also includes a coolant pump 146. The coolant pump 146 can be configured to provide coolant to the exhaust duct assembly 110 or other components of the exhaust aftertreatment system 100. The coolant pump 146 and all other pumps disclosed herein (e.g., reductant pump 126, air pump 132) can be disposed on the supply side or return side of their respective systems. For example, the coolant pump 146 can be coupled to the coolant return line 144 or the coolant supply line 142.

[0027] The exhaust aftertreatment system 100 also includes a controller 148 (e.g., control circuitry, a driver, etc.). The controller 148 is configured to control components of the reductant delivery system 114. For example, the upstream dosing module 116, the reductant pump 126, the air pump 132, and the coolant pump 146 are electrically or communicatively coupled to the controller 148. The controller 148 is configured to control the upstream dosing module 116 to dosing the reductant and / or the air-reductant mixture into the exhaust duct assembly 110. The controller 148 may also be configured to control the reductant pump 126 and / or the air pump 132 to control the reductant and / or the air-reductant mixture dosing into the exhaust duct assembly 110. The controller 148 is also configured to control the coolant pump 146 to control the coolant provided to the exhaust duct assembly 110.

[0028] The controller 148 includes a processing circuit 150. The processing circuit 150 includes a processor 152. The processor 152 may include a microprocessor, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), etc. or a combination thereof. The processing circuit 150 also includes a memory 154. The memory 154 may include, but is not limited to, an electronic, optical, magnetic or any other storage device or transmission device capable of providing program instructions to the processor, ASIC, FPGA, etc. The memory 154 may include a memory chip, an electrically erasable programmable read-only memory (EEPROM), an erasable programmable read-only memory (EPROM), a flash memory, or any other suitable memory from which the controller 148 can read instructions. The instructions may include code from any suitable programming language. The memory 154 may include various modules that include instructions configured to be implemented by the processor 152.

[0029] In various embodiments, controller 148 is configured to communicate with a central controller 156 (eg, engine control unit (ECU), engine control module (ECM), etc.) of an internal combustion engine having exhaust aftertreatment system 100. In some embodiments, central controller 156 and controller 148 are integrated into a single controller.

[0030] In some embodiments, the central controller 156 may communicate with a display device (e.g., a screen, monitor, touch screen, head-up display (HUD), indicator light, etc.). The display device may be configured to change states in response to receiving information from the central controller 156. For example, the display device may be configured to change between a static state and an alarm state based on communications from the central controller 156. By changing states, the display device may provide an indication of the state of the reductant delivery system 114 to the user.

[0031] In some embodiments, the exhaust aftertreatment system 100 also includes a particulate filter 158 (e.g., a diesel particulate filter (DPF)). The particulate filter 158 is configured to receive exhaust gas from an upstream exhaust conduit (e.g., the exhaust conduit assembly 110). The particulate filter 158 is configured to remove particulate matter, such as soot, from the exhaust gas flowing in the exhaust conduit system 104. The particulate filter 158 includes an inlet and an outlet, the exhaust gas is received at the inlet, and the exhaust gas exits at the outlet after substantially filtering the particulate matter from the exhaust gas and / or converting the particulate matter into carbon dioxide. In some embodiments, the particulate filter 158 can be omitted. In various embodiments, the particulate filter 158 is coupled to the exhaust conduit assembly 110. For example, the particulate filter 158 can be fastened (e.g., using a strap, using bolts, etc.), welded, riveted, or otherwise attached to the exhaust conduit assembly 110. In other embodiments, the particulate filter 158 is integrally formed with the exhaust duct assembly 110 (eg, unitarily formed with the exhaust duct assembly 110 , formed as a one-piece structure with the exhaust duct assembly 110 , inseparable from the exhaust duct assembly 110 , etc.).

[0032] In some embodiments, the exhaust aftertreatment system 100 may include an exhaust duct assembly 110 extending from or coupled to an outlet of the particulate filter 158. For example, the exhaust duct assembly 110 may be disposed downstream of the particulate filter 158. In some embodiments, the exhaust duct system 104 includes more than one exhaust duct assembly 110. For example, a first exhaust duct assembly 110 may be disposed upstream of the particulate filter 158, and a second exhaust duct assembly 110 may be disposed downstream of the particulate filter 158.

[0033] In the case where the exhaust duct assembly 110 is disposed downstream of the particulate filter 158, the reductant delivery system 114 of the exhaust aftertreatment system 100 may include a downstream dosing module 160. The downstream dosing module 160 may be similar to the upstream dosing module 116. For example, the downstream dosing module 160 receives the reductant from the reductant source 120 (or a different reductant source) and may receive air from the air source 130 (or a different air source) to provide the reductant or reductant mixture to the exhaust. Figure 1As shown, both the downstream distribution module 160 and the upstream distribution module 116 have a separate reductant supply line 122 extending from the reductant source 120 (or after the reductant pump 126) and a separate air supply line 134 extending from the air source 130 (or after the air pump 132). In some embodiments, the downstream distribution module 160 or the second exhaust duct assembly 110 also receives coolant from the coolant source 140 (or a different cooling source). In other embodiments, the downstream distribution module 160 and the second exhaust duct assembly 110 do not receive coolant. For example, the downstream distribution module 160 can be far enough away from the turbocharger so that heat transfer does not constitute an issue for the downstream distribution module 160. Therefore, the downstream distribution module 160 may not need to be cooled.

[0034] The downstream dosing module 160 is also electrically or communicatively coupled to the controller 148. The controller 148 is configured to control the downstream dosing module 160 to dosing the reductant and / or the air-reductant mixture into the second exhaust duct assembly 110. The controller 148 may also be configured to control the reductant pump 126 and / or the air pump 132 to control the reductant and / or the air-reductant mixture dosing into the second exhaust duct assembly 110.

[0035] In various embodiments, the exhaust duct system 104 of the exhaust aftertreatment system 100 further includes a decomposition chamber 162 (e.g., a decomposition reactor, a decomposition chamber, a reactor tube, a decomposition conduit, a reactor conduit, etc.). The decomposition chamber 162 is configured to receive exhaust gas (e.g., after the reductant has been provided to the exhaust gas) and the reductant from the exhaust duct assembly 110 and / or another exhaust duct of the exhaust duct system 104. For example, the decomposition chamber 162 can be coupled to the exhaust duct assembly 110. The decomposition chamber 162 can be fastened, welded, riveted, or otherwise attached to the exhaust duct assembly 110. In other embodiments, the decomposition chamber 162 is integrally formed with the exhaust duct assembly 110.

[0036] The decomposition chamber 162 is configured to convert the reductant into ammonia. The reductant may be, for example, urea, diesel exhaust fluid (DEF), Adblue®, urea water solution (UWS), aqueous urea solution (e.g., AUS32, etc.), and / or other similar fluids. The decomposition chamber 162 includes an inlet and an outlet, and the inlet may be in fluid communication with the exhaust conduit assembly 110 to receive the NO x Exhaust of emissions, outlet for exhaust, NO x Exhaust, ammonia and / or reductant flow to downstream components.

[0037] In various embodiments, the exhaust duct system 104 includes a midstream exhaust duct 164. The midstream exhaust duct 164 is disposed downstream of the upstream exhaust duct 106. The exhaust duct system 104 may include more than one midstream exhaust duct 164. The midstream exhaust duct 164 may be configured to couple the decomposition chamber 162 to another component of the exhaust duct system 104 downstream of the decomposition chamber. The midstream exhaust duct 164 defines an exhaust flow path so that exhaust gas can flow from the decomposition chamber 162 to a downstream component. The midstream exhaust duct 164 may be used to couple any components of the exhaust duct system 104 together to provide a path for exhaust gas to flow between components and through the exhaust duct system. For example, if the exhaust aftertreatment system 100 does not include a downstream dosing module 160, the midstream exhaust duct 164 may couple the particulate filter 158 to the decomposition chamber 162 in place of the exhaust duct assembly 110.

[0038] In some embodiments, instead of coupling the decomposition chamber 162 to the downstream component by the midstream exhaust conduit 164, the exhaust conduit system 104 includes another exhaust conduit assembly 110 that couples the decomposition chamber 162 to the downstream component. For example, the exhaust aftertreatment system 100 may include another downstream distribution module 160 disposed between the decomposition chamber 162 and the downstream component. In such an embodiment, the exhaust conduit assembly 110 may couple the decomposition chamber 162 to the downstream component, and the downstream distribution module 160 may be coupled to the exhaust conduit assembly 110.

[0039] In various embodiments, the exhaust gas conduit system 104 of the exhaust gas aftertreatment system 100 includes an SCR catalyst component 166. The SCR catalyst component 166 is located downstream of the decomposition chamber 162 and is configured to receive a mixture of a reductant and exhaust gas. The reductant droplets undergo evaporation, pyrolysis, and hydrolysis processes to form non-NO in the exhaust gas conduit system 104. x Emissions (e.g., gaseous ammonia, etc.).

[0040] The SCR catalyst member 166 includes an inlet and an outlet, the inlet is in fluid communication with the decomposition chamber 162, receives exhaust gas and reductant from the inlet, and the outlet is in fluid communication with the downstream component or the end of the exhaust duct system 104. In various embodiments, the SCR catalyst member 166 is coupled to the decomposition chamber 162. For example, the SCR catalyst member 166 can be fastened, welded, riveted or otherwise attached to the decomposition chamber 162. In other embodiments, the SCR catalyst member 166 is integrally formed with the decomposition chamber 162. The SCR catalyst member 166 is located downstream of the decomposition chamber 162 and receives exhaust gas from the decomposition chamber 162. In some embodiments, the SCR catalyst member 166 is fluidly coupled to the decomposition chamber 162 via the exhaust duct assembly 110 or some other exhaust duct of the exhaust duct system 104 (e.g., the midstream exhaust duct 164 described in more detail herein).

[0041] The SCR catalyst component 166 is configured to receive, process, and output exhaust gas. For example, the SCR catalyst component 166 is configured to cause decomposition of components of the exhaust gas using a reductant (e.g., via a catalytic reaction, etc.). Specifically, the reductant in the exhaust gas that has been provided to the exhaust conduit assembly 110 undergoes a process of evaporation, pyrolysis, and hydrolysis to form non-NO in the decomposition chamber 162 and the SCR catalyst component 166. x The SCR catalyst component 166 is configured to accelerate the reaction of the reductant with the exhaust gas to remove NO x NO x Reduction process helps reduce NO by converting to diatomic nitrogen, water and / or carbon dioxide x emission.

[0042] The exhaust aftertreatment system 100 also includes a downstream exhaust conduit 168 (e.g., a line, a tube, etc.). The downstream exhaust conduit 168 is downstream of the midstream exhaust conduit 164. The downstream exhaust conduit 168 is downstream of the SCR catalyst component 166 and is configured to receive exhaust gas from the SCR catalyst component 166. In some embodiments, the downstream exhaust conduit 168 is coupled to the SCR catalyst component 166. In other embodiments, the downstream exhaust conduit 168 is integrally formed with the SCR catalyst component 166.

[0043] Figure 2 Another embodiment of the exhaust aftertreatment system 100 is shown. In such an embodiment, both the upstream dosing module 116 and the downstream dosing module 160 receive reductant from the reductant source 120. The reductant pump 126 first provides the reductant to the upstream dosing module 116 via the reductant supply line 122, and then the reductant supply line 122 extends from the upstream dosing module 116 to the downstream dosing module 160, so that the reductant travels from the upstream dosing module 116 to the downstream dosing module 160. The reductant return line 124 receives the reductant from the downstream dosing module 160 and returns the reductant to the reductant source 120.

[0044] Both the upstream dosing module 116 and the downstream dosing module 160 receive air from the air source 130. The air pump 132 first provides air to the upstream dosing module 116 via the air supply line 134, and then the air supply line 134 extends from the upstream dosing module 116 to the downstream dosing module 160, so that the air travels from the upstream dosing module 116 to the downstream dosing module 160. The air may be released from the downstream dosing module 160, or the reductant delivery system 114 may include an air return line to return the air to the air source 130.

[0045] In some embodiments, the first exhaust duct assembly 110 and the second exhaust duct assembly 110 receive coolant from a coolant source 140. Similar to the reductant and air, the coolant may be provided to each exhaust duct assembly 110 separately, or the coolant may be provided to the first exhaust duct assembly 110 first and then transferred from the first exhaust duct assembly 110 to the second exhaust duct assembly 110.

[0046] 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 may 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.

[0047] Although the reductant delivery system 114 has been shown and described in the context of use with a reductant, it should be understood that the reductant delivery system 114 may alternatively be used with a hydrocarbon fluid (e.g., fuel, lubricant, oil, etc.). In these embodiments, an igniter (e.g., a spark plug, etc.) may be positioned downstream of the upstream dosing module 116 and used to ignite the hydrocarbon fluid. The ignition results in an increase in the temperature of the exhaust gas downstream of the upstream dosing module 116, which may be used to regenerate the SCR catalyst member 166.

[0048] III. Exemplary Exhaust Duct Assemblies Figures 3 to 9 An exhaust duct assembly 110 is shown according to various embodiments. The exhaust duct assembly 110 includes an exhaust duct body 302. The exhaust duct body 302 defines an exhaust flow path. For example, the exhaust duct body 302 includes an inlet 304 and an outlet 306. The inlet 304 can be configured to receive exhaust gas from an upstream component (e.g., the turbocharger 108), and the downstream component (e.g., the particulate filter 158) can be configured to receive exhaust gas from the outlet 306, so that the exhaust gas flows from the inlet 304 through the exhaust duct body 302 to the outlet 306. In some embodiments, the area of ​​the inlet 304 is the same as the area of ​​the outlet 306 (e.g., the exhaust duct body 302 has a constant cross-sectional area from the inlet 304 to the outlet 306). In some embodiments, the area of ​​the inlet 304 is different from the area of ​​the outlet 306. For example, the area of ​​the inlet 304 can be less than the area of ​​the outlet 306. The area of ​​the inlet 304 can also be greater than the area of ​​the outlet 306. For example, the exhaust duct body 302 can be made of 316L or 439L stainless steel.

[0049] In some embodiments, the exhaust duct assembly 110 also includes a distributor mounting portion 308. The distributor mounting portion 308 can be coupled to the exhaust duct body 302. For example, Figures 7 to 9As shown, the distributor mount portion 308 can be fastened (e.g., using straps, using bolts, etc.), welded, riveted, or otherwise attached to the exhaust duct body 302. In some embodiments, the distributor mount portion 308 is integrally formed with the exhaust duct body 302. For example, as shown in FIG. Figures 3 to 6 As shown, the dispenser mounting portion 308 and the exhaust duct body 302 form a single component. The dispenser mounting portion 308 facilitates injecting the reductant into the exhaust duct body 302 to treat the exhaust. For example, the exhaust duct assembly 110 includes an injection hole 310. The injection hole 310 extends through the exhaust duct body 302. The injection hole 310 provides a path for the reductant to enter the exhaust duct body 302. The injection hole 310 can have a conical shape. For example, the inlet of the injection hole 310 can have a smaller area than the outlet of the injection hole 310.

[0050] The dispenser mount portion 308 is configured to be coupled to the upstream dispenser module 116 so that the injector 118 of the upstream dispenser module 116 is configured to provide the reductant through the injection hole 310 and into the exhaust duct body 302. In some embodiments, the dispenser mount portion 308 defines a space 312 extending around the injection hole 310. The dispenser mount portion 308 is configured to receive a portion of the upstream dispenser module 116 within the space 312. The dispenser mount portion 308 has a ridge 314, which is configured to directly or indirectly interface with the upstream dispenser module 116. For example, when the upstream dispenser module 116 is received in the space 312, the face of the upstream dispenser module 116 can rest on the ridge 314 or interface with the ridge 314. The ridge 314 can define the base or bottom of the space 312. The ridge 314 can define the entrance of the injection hole 310. In some embodiments, an insulator 316 may be disposed between the face of the upstream distribution module 116 and the ridge 314. The insulator 316 facilitates further reduction of heat transfer from the exhaust gas to the upstream distribution module 116.

[0051] While the dosing mount portion 308 and the exhaust duct assembly 110 are generally described as interacting with and coupled to the upstream dosing module 116, the embodiments described herein may interact with and / or couple to other dosing modules, including but not limited to the downstream dosing module 160. The exhaust aftertreatment system 100 may include any number of dosing modules configured to couple to the exhaust duct system 104 via the exhaust duct assembly 110.

[0052] The dispenser mounting part 308 includes a mounting member 318. The mounting member 318 extends from the dispenser mounting part 308. The mounting member 318 is connected to the dispenser mounting part 308 at the center of the dispenser mounting part 308 or is integral with the dispenser mounting part 308. For example, the mounting member 318 can be welded to the dispenser mounting part 308. For example, the mounting member 318 can be made of 316L or 439L stainless steel. The mounting member 318 is centrally positioned so that a channel 328 (described in more detail below) can surround at least a portion of the dispensing module received by the mounting member 318. The mounting member 318 defines a portion of the space 312. The mounting member 318 is configured to dock with the upstream dispensing module 116. For example, the mounting member 318 includes an edge 320. The upstream dispensing module 116 can have a corresponding flange 322. The edge 320 of the mounting member 318 can dock with the flange 322 of the upstream dispensing module 116. The exhaust aftertreatment system 100 may include an outer component 324 (eg, a clamp) configured to at least temporarily secure the flange 322 and the rim 320 together to couple the upstream dosing module 116 with the dosing mount portion 308 .

[0053] The distributor mount portion 308 includes an inlet port 326 configured to receive a coolant. The inlet port 326 may receive the coolant from the coolant source 140 or from other components of the exhaust aftertreatment system 100. For example, the exhaust aftertreatment system 100 may include a turbocharger 108. The turbocharger 108 may be configured to receive a coolant and exhaust gas. The turbocharger 108 and the exhaust duct system 104 may be configured such that the exhaust duct body 302 receives the exhaust gas from the turbocharger 108, and the inlet port 326 of the distributor mount portion 308 receives the coolant from the turbocharger 108. In some embodiments, the inlet port 326 is connected to the internal combustion engine 102. For example, the internal combustion engine 102 may first receive the coolant from the coolant source 140, and then the coolant may be transferred from the internal combustion engine 102 to the upstream distribution module 116 via the coolant supply line 142. The exhaust aftertreatment system 100 may be configured such that in response to the internal combustion engine 102 being started, coolant flows to the distributor mount portion 308 to remove heat from the distributor mount portion 308 to cool the upstream distributor module 116 .

[0054] The dispenser mount portion 308 includes a channel 328. The channel 328 is configured to receive coolant from the inlet port 326. At least a portion of the channel 328 extends around at least a portion of the injection hole 310. In some embodiments, the channel 328 extends around the entire injection hole 310. A portion of the channel 328 can be disposed adjacent to the space 312 of the dispenser mount portion 308. A portion of the channel 328 can be disposed adjacent to the injection hole 310. A portion of the channel 328 can be disposed adjacent to the ridge 314 (e.g., below the space 312). The channel 328 can surround the injection hole 310 and at least a portion of the space 312 to surround an area with a high thermal potential.

[0055] The passage 328 is configured to provide a path for coolant to flow around the upstream distribution module 116 to reduce the amount of heat transferred from the internal combustion engine 102, the turbocharger 108, the exhaust gas from within the exhaust duct body 302, etc. to the upstream distribution module 116. As the passage 328 extends around the injection hole 310, the passage 328 may have a constant cross-sectional area. For example, Figure 4 As shown, the first portion of the channel 328 may have a first height 340 and a first width 342. The second portion of the channel 328 may have a second height 344 and a second width 346. The first height 340 may be, for example, at least 9.5 mm (e.g., 9.518180 mm). The first height 340 may be in the range of 9 mm to 10 mm. The first width 342 may be, for example, at least 15.3 mm (e.g., 15.394981 mm). The first width 342 may be in the range of 14.5 mm to 16.5 mm. The second height 344 may be shorter than the first height 340, and the second width 346 may be shorter than the first width 342. The first portion of the channel 328 may be disposed adjacent to both the space 312 and the injection hole, and the second portion of the channel 328 may be disposed adjacent to the injection hole 310. A portion of the second portion of the channel 328 may be disposed below the space 312.

[0056] The channel 328 can be configured to surround at least a portion of the injection hole 310. For example, the channel 328 can have an outer diameter 348 of at least 68.7 mm (e.g., 68.7928 mm), or a radius of at least 34.395 mm (e.g., 34.396400 mm). The outer diameter 348 can be in the range of 65 mm to 70 mm. The outer diameter 348 is measured from the central axis 350 of the injection hole 310 to the outer wall of the channel 328.

[0057] The distributor mounting portion 308 also includes an outlet port 330. The outlet port 330 is configured to receive coolant from the passage 328. The passage 328 fluidly couples the inlet port 326 to the outlet port 330. The coolant can flow out of the passage 328 via the outlet port 330 and flow to another component of the exhaust aftertreatment system 100. For example, the outlet port 330 can be fluidly coupled to the inlet of the coolant pump 146. The coolant pump 146 can be configured to receive the coolant. In some embodiments, the inlet port 326 and the outlet port 330 can be disposed on a top surface of the distributor mounting portion 308. In other embodiments, the inlet port 326 and / or the outlet port 330 extend from a side of the distributor mounting portion 308.

[0058] In some embodiments, the exhaust duct assembly 110 includes an air gap 332. The air gap 332 can be disposed adjacent to a portion of the passage 328. The air gap 332 is configured to provide additional thermal control and isolation to the upstream distribution module 116. For example, the air gap 332 reduces the direct contact path for heat to propagate to the mounting member 318. The air gap 332 is at least partially defined by an inner wall 334. The inner wall can be the exhaust duct body 302. The air gap 332 is also at least partially defined by a support wall 336. The support wall 336 is coupled to or integrally formed with the inner wall 334 and extends radially away from the inner wall 334. The support wall 336 separates the air gap 332 from the passage 328. The air gap 332 is also at least partially defined by an outer wall 338. The outer wall 338 is coupled to or integrally formed with the support wall 336. The outer wall 338 is spaced apart from the inner wall 334 via the support wall 336 so that the air gap 332 extends between the outer wall 338 and the inner wall 334. For example, the distance between the inner wall 334 and the outer wall 338 can be 3 mm so that the height 352 of the air gap 332 is 3 mm. The air gap height 352 can be in the range of 2 mm to 5 mm. The outer wall 338 extends around a portion of the inner wall 334. For example, the outer wall 338 can extend around less than half of the inner wall 334.

[0059] The exhaust duct assembly 110 may include a plurality of air gaps 332. For example, a first air gap 332 may be at least partially disposed between a first portion of the channel 328 and the inlet 304 of the exhaust duct body 302. A second air gap 332 may be at least partially disposed between a second portion of the channel 328 and the outlet 306 of the exhaust duct body 302. In some embodiments, a portion of the first air gap 332 and the second air gap 332 are connected to form a larger air gap 332 that extends along the length of the exhaust duct body 302.

[0060] IV. Configuration of Example Embodiments As used herein, unless otherwise indicated, area is measured along a plane (e.g., a two-dimensional plane, etc.). Unless otherwise indicated, the area may vary in a direction not disposed along the plane (e.g., along a direction orthogonal to the plane, etc.).

[0061] Although this specification contains many specific implementation details, these should not be interpreted as limitations on the scope of the content that can be claimed, but should be interpreted as descriptions of features that are unique to specific implementations. Certain features described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. On the contrary, the various features described in the context of a single implementation can also be implemented individually or in any suitable sub-combination in multiple implementations. Moreover, although features can be described as working in certain combinations and even initially claimed as such, one or more features from the claimed combination can be deleted from the combination in some cases, and the claimed combination can involve a sub-combination or a deformation of the sub-combination.

[0062] As utilized herein, the terms "substantially," "approximately," "about," and similar terms are intended to have a broad meaning consistent with common and accepted usage by those of ordinary skill in the art to which the subject matter of the present disclosure belongs. Those skilled in the art who review the present disclosure should understand that these terms are intended to allow for a description of certain features described and claimed without limiting the scope of these features to the precise numerical ranges provided. Therefore, these terms should be interpreted as indicating insubstantial or inconsequential modifications or variations of the subject matter described and claimed and are considered to be within the scope of the appended claims.

[0063] As used herein, the term "coupled" and similar terms mean the joining of two components directly or indirectly to one another. 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, or by the two components, or the two components and any additional intermediate components, being attached to one another.

[0064] As used herein, the terms "configured to receive exhaust gas from", "configured to receive air from", "configured to receive reductant from", etc., mean that two components or objects have a pathway formed between the two components or objects, and a fluid (such as air, reductant, air-reductant mixture, etc.) can flow with or without an intermediate component or object. Examples of fluid couplings or configurations for achieving fluid communication may include pipes, channels, or any other suitable components for achieving the flow of a fluid from one component or object to another component or object.

[0065] It is important to note that the structure and arrangement of the various systems shown in the various example embodiments are illustrative and non-restrictive in nature. All changes and modifications within the spirit and / or scope of the described embodiments need to be protected. It should be understood that some features may not be necessary, and embodiments lacking various features may be considered to be within the scope of the present disclosure, which is defined by the appended claims. When the language "a portion" is used, the item may include a portion and / or the entire item unless explicitly stated to the contrary.

[0066] Additionally, in the context of a list of elements, the term "or" is used in its inclusive sense (rather than its exclusive meaning) such that when used in relation to a list of elements, the term "or" means one, some, or all of the elements in the list. Unless explicitly stated otherwise, conjunction language such as the phrase "at least one of X, Y, and Z" is understood in the context to generally convey that an item, term, etc. 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). Therefore, unless otherwise indicated, such conjunction language is generally not intended and implies that certain embodiments require that at least one X, at least one Y, and at least one Z each be present.

[0067] In addition, unless otherwise indicated, the range of values ​​used herein (e.g., W1 to W2, etc.) includes the maximum and minimum values ​​of the range (e.g., W1 to W2 includes W1 and includes W2, etc.). In addition, unless otherwise indicated, the range of values ​​(e.g., W1 to W2, etc.) is not necessarily required to include intermediate values ​​within the range of values ​​(e.g., W1 to W2 may only include W1 and W2, etc.).

Claims

1. An exhaust duct assembly, comprising: an exhaust duct body defining an exhaust gas flow path; an injection hole extending through the exhaust conduit body; and A dispenser mounting part, the dispenser mounting part comprising: an inlet port configured to receive a coolant, a channel configured to receive coolant from the inlet port, at least a portion of the channel extending around at least a portion of the injection hole, and - an outlet port configured to receive coolant from the passage.

2. The exhaust duct assembly according to claim 1, wherein: The distributor mount portion is integrally formed with the exhaust duct body.

3. The exhaust duct assembly according to claim 1, wherein: The at least a portion of the channel extends around the entire injection hole.

4. The exhaust duct assembly according to claim 1, wherein: The inlet port and the outlet port are both disposed on a top surface of the dispenser mount portion, or both the inlet port and the outlet port extend from a side of the dispenser mount portion.

5. The exhaust duct assembly according to claim 1, wherein: The dispenser mount portion defines a space extending about the injection aperture, the space being configured to receive at least a portion of a dispense module; A first region of the passageway is disposed adjacent the space; and The second region of the channel is disposed adjacent to the injection hole.

6. The exhaust duct assembly according to claim 1, further comprising: A support wall at least partially defines an air gap, the support wall separating the channel from the air gap.

7. The exhaust duct assembly according to claim 6, wherein: The air gap is defined by an inner wall and an outer wall, the inner wall being the exhaust duct body, and the outer wall being spaced apart from the inner wall via the supporting wall.

8. The exhaust duct assembly according to claim 7, wherein: The outer wall extends around a portion of the inner wall.

9. The exhaust duct assembly according to claim 1, further comprising: a first support wall, the first support wall at least partially defining a first air gap, the first support wall separating the first air gap from a first region of the channel; and a second support wall, the second support wall at least partially defining a second air gap, the second support wall separating the second air gap from a second region of the channel; wherein: The exhaust duct body includes an inlet and an outlet; The first air gap is disposed between the first region of the passage and the inlet of the exhaust duct body; and The second air gap is disposed between the second region of the passage and the outlet of the exhaust duct body.

10. An exhaust aftertreatment system, comprising: a dispenser, the dispenser comprising an injector; and The exhaust duct assembly according to claim 1; Wherein, the distributor is coupled to the distributor mounting portion such that the injector is configured to provide the reductant through the injection hole and into the exhaust conduit body.

11. The exhaust aftertreatment system according to claim 10, wherein: The dispenser mount portion defines a space extending around the injection hole; and A portion of the dispenser is received in the space.

12. The exhaust aftertreatment system according to claim 10, further comprising: a turbocharger configured to receive coolant and exhaust gas; The turbocharger and the exhaust duct assembly are configured such that the exhaust duct assembly receives exhaust gas from the turbocharger and the inlet port receives coolant from the turbocharger.

13. The exhaust aftertreatment system according to claim 12, wherein: The turbocharger includes a housing integrally formed with the exhaust duct assembly.

14. The exhaust aftertreatment system according to claim 10, further comprising: a water pump configured to receive a coolant; Wherein, the water pump and the exhaust conduit assembly are configured such that the water pump receives coolant from the outlet port.

15. The exhaust aftertreatment system according to claim 10, wherein: The exhaust duct assembly comprises: Inner wall, a support wall coupled to the inner wall and extending radially away from the inner wall, and An outer wall is coupled to the support wall, the outer wall being spaced apart from the inner wall via the support wall such that an air gap extends between the outer wall and the inner wall.

16. The exhaust aftertreatment system according to claim 15, wherein: The support wall separates the air gap from the channel.

17. The exhaust aftertreatment system according to claim 10, further comprising: a turbocharger configured to receive the exhaust gas; and a coolant source configured to store a coolant; wherein the exhaust conduit assembly receives exhaust gas from the turbocharger; and Wherein the exhaust duct assembly receives coolant from the coolant source.

18. An exhaust duct assembly comprising: an exhaust duct body defining an exhaust gas flow path, the exhaust duct body including an inlet and an outlet; a support wall extending radially away from the exhaust duct body; an outer wall extending around a portion of the exhaust duct body, the outer wall being spaced apart from the exhaust duct body via the support wall; an injection hole extending through the exhaust conduit body; and a dispenser mount portion defining a space extending around the injection hole, the space being adapted to receive a portion of a dispenser; Wherein, the exhaust duct body, the support wall and the outer wall define at least one air gap, and the at least one air gap is disposed between the distributor mounting portion and at least one of the inlet or the outlet of the exhaust duct body.

19. The exhaust duct assembly of claim 18, further comprising: an inlet port configured to receive a coolant; a passage configured to receive coolant from the inlet port, at least a portion of the passage extending around at least a portion of the injection hole; and An outlet port is configured to receive coolant from the passage.

20. The exhaust duct assembly of claim 18, wherein: The support wall separates the at least one air gap from the channel.

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