Outlet sampling system for aftertreatment system

Abstract

The invention relates to an outlet sampling system for an aftertreatment system. The exhaust aftertreatment system includes an outlet housing body, an outlet housing fitting, an outlet sampling system, and an outlet sensor. And the outlet sampling system comprises a sampling bowl and a sampling ring. A sampling bowl is coupled to the outlet housing body and extends away from the outlet housing body so as to define a sampling bowl cavity between the sampling bowl and the outlet housing body. The sampling ring is coupled to the sampling bowl and is spaced from the outlet housing body by the sampling bowl. A sampling ring is coupled to the outlet housing fitting and defines a sampling ring cavity. The sampling ring includes a plurality of sampling ring inlet apertures and a connector. The sampling ring inlet apertures are each configured to receive exhaust gas from within the outlet housing body and provide the exhaust gas to the sampling ring cavity.

Description

[0001] This application is a divisional application of an application with an application date of August 22, 2022, application number 202280053594.5, and invention name “Outlet sampling system for a post-processing system”. Cross-references

[0002] This application claims priority to Indian Provisional Patent Application No. 202141037998 filed on August 23, 2021, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] The present disclosure generally relates to an outlet sampling system for an aftertreatment system of an internal combustion engine. background

[0004] 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 the fuel. One method of reducing emissions that can be implemented is to treat the exhaust gas using an aftertreatment system. Sensors are typically used at the outlet of the aftertreatment system to measure the characteristics of the exhaust gas at the outlet. Based on the characteristics, the operation of the aftertreatment system can be controlled. However, the sensors typically protrude into the exhaust gas flow. This protrusion may reduce the accuracy of the characteristic measurement and may increase the failure rate of the sensor. Overview

[0005] In one embodiment, an exhaust aftertreatment system includes an outlet housing body, an outlet housing fitting, an outlet sampling system, and an outlet sensor. The outlet sampling system includes a sampling bowl and a sampling ring. The sampling bowl is connected to the outlet housing body and extends away from the outlet housing body so as to define a sampling bowl cavity between the sampling bowl and the outlet housing body. The sampling ring is connected to the sampling bowl and is spaced apart from the outlet housing body by the sampling bowl. The sampling ring is connected to the outlet housing fitting and defines a sampling ring cavity. The sampling ring includes a plurality of sampling ring inlet holes and a connector. Each sampling ring inlet hole is configured to receive exhaust gas from within the outlet housing body and provide the exhaust gas to the sampling ring cavity. The connector extends along the sampling bowl and defines a connector cavity adjacent to the sampling ring cavity and the sampling bowl cavity. The outlet sensor is connected to the outlet housing body so as to have a portion disposed within the sampling bowl cavity.

[0006] In some embodiments, the outlet housing fitting includes a fitting aperture that abuts the sampling bowl cavity and is configured to provide exhaust gas from within the sampling bowl cavity into the outlet housing fitting.

[0007] In some embodiments, the outlet housing fitting is centered about an outlet housing fitting axis; and the sampling ring inlet aperture is disposed circumferentially about the outlet housing fitting axis.

[0008] In some embodiments, the plurality of sampling loop inlet apertures are arranged within an angular range of between 180° and 270° about the outlet housing fitting axis.

[0009] In some embodiments, the outlet housing fitting includes a fitting aperture configured to facilitate flow of exhaust gas from the sampling bowl cavity into the outlet housing fitting.

[0010] In some embodiments, the sampling bowl includes a housing flange coupled to the outlet housing body and a plurality of supports protruding away from the housing flange.

[0011] In some embodiments, the sampling bowl includes a plurality of protrusions protruding within the sampling bowl cavity, the plurality of protrusions being configured to reduce swirl of exhaust gas within the sampling bowl cavity.

[0012] In another embodiment, an exhaust aftertreatment system includes an outlet housing body, an outlet housing fitting, an outlet sampling system, and an outlet sensor. The outlet housing fitting has a fitting hole. The outlet sampling system includes a cover, a sampling ring, and a connector. The cover is connected to the outlet housing body. The sampling ring defines a sampling ring cavity extending around the outlet housing fitting. The sampling ring includes a sampling ring floor flange, a sampling ring base flange, a sampling ring insert flange, a sampling ring inlet flange, and a plurality of sampling ring inlet holes. The sampling ring floor flange is in a facing relationship with the outlet housing body. The sampling ring base flange is contiguous with the sampling ring floor flange. The sampling ring insert flange is contiguous with the sampling ring base flange and is in a facing relationship with the outlet housing fitting. The sampling ring inlet flange is contiguous with the sampling ring base flange. The sampling ring inlet hole is disposed on the sampling ring inlet flange. The sampling ring inlet hole is configured to provide exhaust gas into the sampling ring cavity. The connector defines a connector cavity adjacent to the sampling loop cavity, and the connector cavity is configured to receive exhaust gas from the sampling loop cavity and provide the exhaust gas to the fitting aperture. An outlet sensor is coupled to the outlet housing body so as to have a portion disposed within the connector cavity.

[0013] In some embodiments, the sampling ring further comprises a sampling ring support flange adjacent to the sampling ring base flange.

[0014] In some embodiments, the sampling loop inlet flange is separated from the sampling loop support flange at an obtuse angle.

[0015] In some embodiments, the connector includes a connector base plate flange having a portion coupled to the outlet housing body and configured to flow exhaust gases toward and away from the outlet housing body.

[0016] In some embodiments, the connector chassis flange includes a sensor boss configured to receive the outlet sensor.

[0017] In some embodiments, the connector includes a connector stop flange spaced apart from the outlet housing body and configured to flow exhaust gases toward and away from the outlet housing body.

[0018] In some embodiments, the connector barrier flange includes a barrier flange rib including an inlet surface configured to prevent exhaust gas from flowing within the connector cavity.

[0019] In some embodiments, the outlet housing fitting is centered on an outlet housing fitting axis; and the sampling ring inlet aperture is circumferentially disposed about the outlet housing fitting axis.

[0020] In some embodiments, the sampling loop inlet apertures include louvered apertures extending across a portion of each of the sampling loop inlet apertures.

[0021] In yet another embodiment, an exhaust aftertreatment system includes: outlet housing body; Outlet housing accessories; An outlet sampling system, the outlet sampling system comprising: a sampling bowl coupled to the outlet housing body and extending away from the outlet housing body to define a sampling bowl cavity between the sampling bowl and the outlet housing body, the sampling bowl comprising: Sampling bowl walls, and a sampling bowl support flange adjacent to the sampling bowl wall and spaced apart from the outlet housing body; a sampling ring coupled to the sampling bowl and spaced apart from the outlet casing body by the sampling bowl, the sampling ring coupled to the outlet casing body fitting and defining a sampling ring cavity, the sampling ring comprising: a sampling ring support flange coupled to the sampling bowl support flange, and a sampling loop inlet flange adjacent to the sampling loop support flange and extending from the sampling loop support flange away from the sampling bowl support flange; and An outlet sensor is coupled to the outlet housing body so as to have a portion disposed within the sampling bowl.

[0022] In some embodiments, the sampling loop further comprises a plurality of sampling loop inlet apertures, each of the sampling loop inlet apertures being configured to receive exhaust gas from within the outlet housing body and provide the exhaust gas to the sampling loop cavity.

[0023] In some embodiments, the sampling bowl includes a plurality of protrusions protruding within the sampling bowl cavity, the plurality of protrusions being configured to reduce swirl of exhaust gas within the sampling bowl cavity.

[0024] In some embodiments, the sampling bowl includes a housing flange coupled to the outlet housing body, and a plurality of supports protruding away from the housing flange. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] 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 exemplary exhaust aftertreatment system including a housing assembly having a distribution housing; Figure 2 is a schematic diagram of another example exhaust aftertreatment system including a housing assembly having a distribution housing; Figure 3 is a perspective view of an example housing assembly of an exhaust aftertreatment system; Figure 4 yes Figure 3 A front view of the housing assembly shown in FIG. Figure 5 yes Figure 3 A rear view of the housing assembly shown in FIG. Figure 6 yes Figure 3 A side view of the housing assembly shown in FIG. Figure 7 yes Figure 3 A top view of the housing assembly shown in FIG. Figure 8 It is along Figure 7 The plane AA interception in Figure 3 A cross-sectional view of the housing assembly shown; Fig. 9 It is along Figure 7 The plane AA interception in Figure 3 Another cross-sectional view of the housing assembly shown; Fig.10 yes Figure 3 a perspective view of a portion of the housing assembly shown; Fig.11 It is taken along plane BB Fig.10 A cross-sectional view of a portion of the housing assembly shown; Fig.12 is a cross-sectional view of another example housing assembly; Fig.13 According to some embodiments, Figure 7The plane CC in the Figure 3 A cross-sectional view of the housing assembly and outlet sampling system is shown; Fig.14 yes Fig.13 A perspective view of the housing assembly and outlet sampling system is shown; Fig.15 It is taken along plane DD Fig.13 A cross-sectional view of the housing assembly and outlet sampling system is shown; Fig.16 yes Fig.15 View of detail A; Fig.17 According to some embodiments, Figure 7 The plane CC in the Figure 3 A cross-sectional view of the housing assembly and outlet sampling system is shown; Fig.18 yes Fig.17 A perspective view of the housing assembly and outlet sampling system is shown; Fig.19 yes Fig.17 A cross-sectional view of the housing assembly and outlet sampling system is shown; Fig. 20 yes Fig.17 Another cross-sectional view of the housing assembly and outlet sampling system shown; and Fig.21 yes Fig.17 Rear view of housing assembly and outlet sampling system shown.

[0026] It should be appreciated that these drawings are schematic representations for illustrative purposes. 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

[0027] Below is a more detailed description of various concepts and embodiments related to methods, apparatuses, and embodiments for providing a housing assembly having a flow divider for an exhaust aftertreatment system of 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 implementation. Examples of specific embodiments and applications are provided primarily for illustrative purposes.

[0028] I. Overview In order to reduce emissions and optimize the performance of an internal combustion engine, it may be desirable to use a sensor to determine one or more characteristics of the exhaust gas. For example, it may be desirable to use a sensor to determine the concentration of an undesirable component within the exhaust gas. However, the exhaust gas may expose the sensor to relatively high temperatures for a long time. This may cause the sensor to malfunction, which in turn may cause the system using the sensor to perform poorly or not function. In addition, this may result in an increase in warranty claims related to the sensor.

[0029] Embodiments herein relate to exhaust aftertreatment systems that include an outlet sampling system that facilitates directing exhaust gas to an outlet sensor such that the outlet sensor is not exposed to exhaust gas within an outlet fitting, but instead is provided with a subset of the exhaust gas that would otherwise flow into the outlet fitting. As a result, the outlet sensor is able to sample the exhaust gas while being protected from exposure to relatively high temperatures of the exhaust gas. This can enhance the desired operation of a system employing one of the outlet sampling systems described herein.

[0030] II. Overview of exhaust aftertreatment system Figure 1 An exhaust aftertreatment system 100 (e.g., a treatment system, etc.) for treating exhaust gas generated by an internal combustion engine (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. The exhaust aftertreatment system 100 includes an upstream exhaust conduit 102 (e.g., a pipeline, a pipe, etc.). The upstream exhaust conduit 102 is fluidly coupled to an upstream component (e.g., a header, an exhaust manifold, etc.) and is configured to receive exhaust gas from the upstream component. In some embodiments, the upstream exhaust conduit 102 is coupled to (e.g., attached to, fixed to, welded to, fastened to, riveted to, etc.) the internal combustion engine (e.g., the upstream exhaust conduit 102 is coupled to an outlet of the internal combustion engine, etc.). In other embodiments, the upstream exhaust conduit 102 is integrally formed with the internal combustion engine. As used herein, two or more elements are "integrally formed" with each other 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 entire portion.

[0031] The exhaust aftertreatment system 100 further includes a housing assembly 104. In some embodiments, Figure 1As shown, the housing assembly 104 is configured to change the direction of the exhaust gas (e.g., from a first direction to a second direction, etc.) while facilitating the processing of the exhaust gas. When changing the direction of the exhaust gas, the housing assembly 104 can play a switchback role (e.g., changing the exhaust gas from a first direction to a second direction opposite to the first direction, changing the exhaust gas from the first direction to a second direction opposite to the first direction and parallel to the first direction, etc.). In other embodiments, such as Figure 2 As shown, the housing assembly 104 is substantially straight (eg, in an in-line configuration, etc.).

[0032] The housing assembly 104 includes an intake body 106 (e.g., a chamber, etc.). The intake body 106 is fluidly coupled to the upstream exhaust conduit 102 and is configured to receive exhaust gas from the upstream exhaust conduit 102. The intake body 106 may be configured to change the exhaust gas from a first direction (e.g., a direction extending along a central axis of the upstream exhaust conduit 102, etc.) to a second direction (e.g., a direction orthogonal to the first direction, etc.).

[0033] The housing assembly 104 also includes an upstream housing 108 (e.g., a chamber, a body, etc.). The upstream housing 108 is fluidly coupled to the intake body 106 and is configured to receive exhaust gas from the intake body 106. In various embodiments, the upstream housing 108 is coupled to the intake body 106. For example, the upstream housing 108 can be fastened (e.g., using a band, using bolts, etc.), welded, riveted, or otherwise attached to the intake body 106. In other embodiments, the upstream housing 108 is integrally formed with the intake body 106 (e.g., integrally formed with the intake body 106, formed as a one-piece structure with the intake body 106, inseparable from the intake body 106, etc.).

[0034] In various embodiments, the upstream housing 108 is centered about the upstream housing axis λ. In other words, a center point of a cross-section of the upstream housing 108 is disposed on the upstream housing axis λ along the length of the upstream housing 108. Exhaust gas may be provided (e.g., output, etc.) through the upstream housing 108 in a direction parallel to or coincident with the upstream housing axis λ.

[0035] In some embodiments, the housing assembly 104 includes a heater (e.g., an electric heater, a resistive heater, a fluid heat exchanger, etc.) configured to heat the exhaust gas within the intake body 106 and / or the upstream housing 108. For example, the housing assembly 104 may include a heater that extends within the intake body 106 and is configured to heat the exhaust gas within the intake body 106. By heating the exhaust gas, the ability of the catalyst component to perform a catalytic reaction as desired may be increased. In addition, heating the exhaust gas may facilitate regeneration of various components of the exhaust aftertreatment system 100 (e.g., burning off particulates, etc.).

[0036] The exhaust aftertreatment system 100 also includes an oxidation catalyst 110 (e.g., a diesel oxidation catalyst (DOC), etc.). At least a portion of the oxidation catalyst 110 is positioned within the upstream housing 108 (e.g., contained within the upstream housing 108, contained within the upstream housing 108, located within the upstream housing 108, etc.). In various embodiments, the oxidation catalyst 110 is positioned within the upstream housing 108 and the intake body 106. In other embodiments, the oxidation catalyst 110 is positioned within the upstream housing 108 and not within the intake body 106. In other embodiments, the oxidation catalyst 110 is positioned within the intake body 106 and not within the upstream housing 108.

[0037] The exhaust gas is provided to the oxidation catalyst 110 by the intake body 106. The oxidation catalyst 110 may be configured to oxidize hydrocarbons and / or carbon monoxide in the exhaust gas. In this way, the oxidation catalyst 110 may remove hydrocarbons and / or carbon monoxide from the exhaust gas before providing the exhaust gas to downstream components of the exhaust aftertreatment system 100. The oxidation catalyst 110 may be positioned within the intake body 106 and / or the upstream housing 108 (e.g., using a gasket, using a spacer, using a seal, etc.) so that the exhaust gas flow between the oxidation catalyst and the intake body 106 and / or between the oxidation catalyst 110 and the upstream housing 108 is substantially prevented (e.g., less than 1% of the exhaust gas flow received by the intake body 106 flows between the oxidation catalyst 110 and the intake body 106, less than 1% of the exhaust gas flow received by the intake body 106 flows between the oxidation catalyst 110 and the upstream housing 108, etc.).

[0038] In some embodiments, the oxidation catalyst 110 is centered on the upstream housing axis λ. For example, where the diameter of the oxidation catalyst 110 is approximately equal to the diameter of the upstream housing 108 (e.g., within 5% of the diameter of the upstream housing 108, etc.), the center point of the cross-section of the oxidation catalyst 110 may be disposed on the upstream housing axis λ along the length of the oxidation catalyst 110. Exhaust gas may be provided through the oxidation catalyst 110 in a direction parallel to or coincident with the upstream housing axis λ. As used herein, the term "diameter" means the length of a chord passing through the center point of a shape (e.g., a square, rectangle, hexagon, circle, pentagon, triangle, etc.).

[0039] The exhaust aftertreatment system 100 further includes an exhaust filter device 112 (e.g., a diesel particulate filter (DPF), etc.). The exhaust filter device 112 is positioned in the upstream housing 108 downstream of the oxidation catalyst 110. Exhaust gas is provided by the oxidation catalyst 110 into the upstream housing 108 (e.g., between the oxidation catalyst 110, the upstream housing 108, and the exhaust filter device 112, etc.) and then enters the exhaust filter device 112 (e.g., after hydrocarbons in the exhaust gas have been oxidized by the oxidation catalyst 110, after carbon monoxide in the exhaust gas has been oxidized by the oxidation catalyst 110, etc.). The exhaust filter device 112 may remove particulates (e.g., soot, etc.) from the exhaust gas before providing the exhaust gas to downstream components of the exhaust aftertreatment system 100. The exhaust filter device 112 can be positioned within the upstream housing 108 (e.g., using a gasket, using a spacer, using a seal, etc.) such that flow between the exhaust filter device 112 and the upstream housing 108 is substantially prevented (e.g., less than 1% of the exhaust flow received by the intake body 106 flows between the exhaust filter device 112 and the upstream housing 108, etc.).

[0040] In some embodiments, the exhaust filter device 112 is centered about the upstream housing axis λ. For example, where the diameter of the exhaust filter device 112 is approximately equal to the diameter of the upstream housing 108, the center point of the cross-section of the exhaust filter device 112 may be disposed on the upstream housing axis λ along the length of the exhaust filter device 112. Exhaust gas may be provided through the exhaust filter device 112 in a direction parallel to or coincident with the upstream housing axis λ.

[0041] The housing assembly 104 also includes a decomposition housing 114 (e.g., a decomposition reactor, a decomposition chamber, a reactor conduit, a decomposition tube, a reactor tube, etc.). The decomposition housing 114 is fluidly coupled to the upstream housing 108 and is configured to receive exhaust gas from the upstream housing 108. In various embodiments, the decomposition housing 114 is coupled to the upstream housing 108. For example, the decomposition housing 114 can be fastened (e.g., using a band, using bolts, etc.), welded, riveted, or otherwise attached to the upstream housing 108. In other embodiments, the decomposition housing 114 is integrally formed with the upstream housing 108.

[0042] In various embodiments, the decomposition housing 114 is centered on the upstream housing axis λ. For example, where the diameter of the decomposition housing 114 is approximately equal to the diameter of the upstream housing 108, the center point of the cross-section of the decomposition housing 114 can be disposed on the upstream housing axis λ along the length of the decomposition housing 114. Exhaust gas can be provided through the decomposition housing 114 in a direction parallel to or coincident with the upstream housing axis λ. In other embodiments, the decomposition housing 114 is not centered on the upstream housing axis λ.

[0043] Decomposition housing 114 is located downstream of exhaust filter device 112 and receives exhaust gas from exhaust filter device 112 (e.g., after exhaust filter device 112 has removed particulates from the exhaust gas, etc.). As explained in more detail herein, decomposition housing 114 is configured to facilitate the introduction of a reductant (e.g., diesel exhaust fluid (DEF), Adblue®, urea-water solution (UWS), urea-water solution (e.g., AUS32), etc.) into the exhaust gas to facilitate the reduction of undesirable components (e.g., nitrogen oxides (NOx)) in the exhaust gas. x ) etc.) emissions.

[0044] The exhaust aftertreatment system 100 also includes a reductant delivery system 116. As explained in more detail herein, the reductant delivery system 116 is configured to facilitate the introduction of the reductant into the exhaust gas. The reductant delivery system 116 includes a dosing module 118 (e.g., a dosing device, etc.). The dosing module 118 is configured to facilitate the passage of the reductant through the decomposition housing 114 and into the decomposition housing 114. As explained in more detail herein, the dosing module 118 is configured to receive the reductant, and in some embodiments, the dosing module 118 is configured to receive air and the reductant, and provide the reductant and / or the air-reductant mixture to the decomposition housing 114 to facilitate the treatment of the exhaust gas. The dosing module 118 may include an insulator interposed between a portion of the dosing module 118 and a portion of the decomposition housing 114 on which the dosing module 118 is mounted. In various embodiments, the dosing module 118 is coupled to the decomposition housing 114.

[0045] The reductant delivery system 116 also includes a reductant source 120 (e.g., a reductant tank, etc.). The reductant source 120 is configured to contain a reductant. The reductant source 120 is fluidly coupled to the dosing module 118 and is configured to provide the reductant to the dosing module 118. 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 diesel exhaust fluid tank containing Adblue®.

[0046] The reductant delivery system 116 also includes a reductant pump 122 (e.g., a supply unit, etc.). The reductant pump 122 is fluidly coupled to the reductant source 120 and the dosing module 118 and is configured to receive the reductant from the reductant source 120 and provide the reductant to the dosing module 118. The reductant pump 122 is used to pressurize the reductant from the reductant source 120 for delivery to the dosing module 118. In some embodiments, the reductant pump 122 is pressure controlled. In some embodiments, the reductant pump 122 is coupled to a chassis of a vehicle associated with the exhaust aftertreatment system 100.

[0047] In some embodiments, the reductant delivery system 116 also includes a reductant filter 124. The reductant filter 124 is fluidly coupled to the reductant source 120 and the reductant pump 122, and is configured to receive the reductant from the reductant source 120 and provide the reductant to the reductant pump 122. The reductant filter 124 filters the reductant before the reductant is provided to the internal components of the reductant pump 122. For example, the reductant filter 124 can inhibit or prevent solids from being transmitted to the internal components of the reductant pump 122. In this way, the reductant filter 124 can facilitate the long-term desired operation of the reductant pump 122.

[0048] The dosing module 118 includes at least one injector 126 (eg, an insert device, etc.). The injector 126 is fluidly coupled to the reductant pump 122 and is configured to receive the reductant from the reductant pump 122. The injector 126 is configured to dispense (eg, inject, insert, etc.) the reductant received by the dosing module 118 into the exhaust gas within the decomposition housing 114.

[0049] In some embodiments, the reductant delivery system 116 further includes an air pump 128 and an air source 130 (e.g., an air intake, etc.). The air pump 128 is fluidly coupled to the air source 130 and is configured to receive air from the air source 130. The air pump 128 is fluidly coupled to the dosing module 118 and is configured to provide air to the dosing module 118. The dosing module 118 is configured to mix air and reductant into an air-reductant mixture and provide the air-reductant mixture to the injector 126 (e.g., for dosing into the exhaust gas within the decomposition housing 114, etc.). The injector 126 is fluidly coupled to the air pump 128 and is configured to receive air from the air pump 128. The injector 126 is configured to dosing the air-reductant mixture into the exhaust gas within the decomposition housing 114. In some of these embodiments, the reductant delivery system 116 further includes an air filter 132. The air filter 132 is fluidly coupled to the air source 130 and the air pump 128 and is configured to receive air from the air source 130 and provide the air to the air pump 128. The air filter 132 is configured to filter the air before the air is provided to the air pump 128. In other embodiments, the reductant delivery system 116 does not include the air pump 128 and / or the reductant delivery system 116 does not include the air source 130. In such embodiments, the dosing module 118 is not configured to mix the reductant with the air.

[0050] In various embodiments, the dosing module 118 is configured to receive air and a reductant and to dispense the air-reductant mixture into the decomposition housing 114. In various embodiments, the dosing module 118 is configured to receive a reductant (and not receive air) and to dispense the reductant into the decomposition housing 114. In various embodiments, the dosing module 118 is configured to receive a reductant and to dispense the reductant into the decomposition housing 114. In various embodiments, the dosing module 118 is configured to receive air and a reductant and to dispense the air-reductant mixture into the decomposition housing 114.

[0051] The exhaust aftertreatment system 100 also includes a controller 134 (e.g., control circuitry, a driver, etc.). The dosing module 118, the reductant pump 122, and the air pump 128 are electrically or communicatively coupled to the controller 134. The controller 134 is configured to control the dosing module 118 to dosing the reductant and / or the air-reductant mixture into the decomposition housing 114. The controller 134 may also be configured to control the reductant pump 122 and / or the air pump 128 to control the reductant and / or the air-reductant mixture dosing into the decomposition housing 114.

[0052] The controller 134 includes a processing circuit 136. The processing circuit 136 includes a processor 138 and a memory 140. The processor 138 may include a microprocessor, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), etc. or a combination thereof. The memory 140 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 140 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 134 can read instructions. The instructions may include codes from any suitable programming language. The memory 140 may include various modules including instructions configured to be implemented by the processor 138.

[0053] In various embodiments, controller 134 is configured to communicate with a central controller 142 (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 142 and controller 134 are integrated into a single controller.

[0054] In some embodiments, the central controller 142 may communicate with a display device (e.g., a screen, a monitor, a touch screen, a heads-up display (HUD), an indicator light, etc.). The display device may be configured to change states in response to receiving information from the central controller 142. 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 142. By changing states, the display device may provide an indication to the user of the state of the reductant delivery system 116.

[0055] In various embodiments, the exhaust aftertreatment system 100 also includes a mixer 144 (e.g., a vortex generating device, a blade plate, etc.). At least a portion of the mixer 144 is positioned within the decomposition housing 114. The mixer 144 is configured to receive exhaust gas from the exhaust filter device 112 (e.g., after particles are removed from the exhaust gas by the exhaust filter device 112, etc.). The mixer 144 is also configured to receive the reductant and / or air-reductant mixture from the injector 126. The mixer 144 is configured to promote swirling (e.g., tumbling, rotation, etc.) of the exhaust gas and mixing (e.g., combination, etc.) of the exhaust gas and the reductant or the air-reductant mixture so as to disperse the reductant in the exhaust gas downstream of the mixer 144. By using the mixer 144 to disperse the reductant in the exhaust gas (e.g., to obtain an increased uniformity index, etc.), the reduction of the emission of undesirable components in the exhaust gas is enhanced.

[0056] The housing assembly 104 also includes a distribution housing 146 (e.g., a pressure regulator, a flow plenum, a flow balancer, a flow balancing system, etc.). The distribution housing 146 is fluidly coupled to the decomposition housing 114 and is configured to receive exhaust gas from the decomposition housing 114 (e.g., after reductant has been provided into the exhaust gas by the injector 126 and the reductant and exhaust gas have been mixed by the mixer 144, etc.). In various embodiments, the distribution housing 146 is coupled to the decomposition housing 114. For example, the distribution housing 146 can be fastened, welded, riveted, or otherwise attached to the decomposition housing 114. In other embodiments, the distribution housing 146 is integrally formed with the decomposition housing 114.

[0057] The housing assembly 104 also includes a catalyst component housing 148 (e.g., body, etc.). The catalyst component housing 148 is fluidly coupled to the distribution housing 146 and is configured to receive exhaust gas from the distribution housing 146. In various embodiments, the catalyst component housing 148 is coupled to the distribution housing 146. For example, the catalyst component housing 148 can be fastened, welded, riveted, or otherwise attached to the distribution housing 146. In other embodiments, the catalyst component housing 148 is integrally formed with the distribution housing 146. The catalyst component housing 148 is located downstream of the distribution housing 146 and receives exhaust gas from the distribution housing 146.

[0058] In various embodiments, the catalyst component housing 148 is centered on a catalyst component housing axis p. In other words, a center point of a cross-section of the catalyst component housing 148 is disposed on the catalyst component housing axis p along the length of the catalyst component housing 148. Exhaust gas may be provided through the catalyst component housing 148 in a direction parallel to or coincident with the catalyst component housing axis p.

[0059] In various embodiments, the catalyst member housing axis p is approximately parallel to the upstream housing axis λ (eg, when measured on a plane along which both the catalyst member housing axis p and the upstream housing axis λ extend, etc.).

[0060] In some of these embodiments, such as Figure 1As shown, the catalyst component housing axis p is spaced apart from the upstream housing axis λ. Therefore, the distribution housing 146 is used to change the direction of the exhaust gas by about 180° (for example, from a first direction along the upstream housing axis λ to a second direction along the catalyst component housing axis p, the second direction differing from the first direction by about 180°, etc.). As a result of this arrangement, the length of the housing assembly 104 along the upstream housing axis λ and / or the length of the housing assembly 104 along the catalyst component housing axis p is significantly shorter than, for example, the catalyst component housing axis p is not spaced apart from the upstream housing axis λ, the catalyst component housing axis p is not approximately parallel to the upstream housing axis λ, and / or the distribution housing 146 does not change the direction of the exhaust gas by about 180°. By reducing the length of the housing assembly 104, the space requirement of the housing assembly 104 can be reduced. Due to the reduced space requirement, the housing assembly 104 may be able to be used in various applications that are incompatible with other aftertreatment systems (for example, because these other aftertreatment systems have excessive space requirements, etc.).

[0061] In other embodiments of these embodiments, Figure 2 As shown, the catalyst member housing axis p is not spaced from the upstream housing axis λ. As a result, the exhaust gas is not redirected by the distribution housing 146. Therefore, the back pressure of the exhaust gas may be reduced compared to other systems that require exhaust gas redirection.

[0062] The exhaust aftertreatment system 100 also includes a first catalyst member 150 (e.g., a first selective catalytic reduction (SCR) catalyst member, etc.). The first catalyst member 150 is configured to receive, process, and output a first portion of the exhaust gas output by the distribution housing 146. At least a portion of the first catalyst member 150 is located within a catalyst member housing 148. The first portion of the exhaust gas received by the distribution housing 146 is provided to the first catalyst member 150 by the distribution housing 146 (e.g., via the catalyst member housing 148, etc.). As explained in more detail herein, the first catalyst member 150 is configured to cause decomposition of components of the exhaust gas using a reductant (e.g., through a catalytic reaction, etc.). Specifically, the reductant supplied to the exhaust gas by the injector 126 undergoes an evaporation, pyrolysis, and hydrolysis process to form non-NO in the distribution housing 146, the catalyst member housing 148, the first catalyst member 150, and / or the housing assembly 104. x The first catalyst member 150 is configured to accelerate the reduction agent and NO in the exhaust gas. x NO x The reduction process into diatomic nitrogen, water and / or carbon dioxide helps reduce NO x emission.

[0063] In various embodiments, the first catalyst member 150 is centered on the first catalyst member axis J1. In other words, the center point of the cross-section of the first catalyst member 150 is disposed on the first catalyst member axis J1 along the length of the first catalyst member 150. Exhaust gas may be provided through the first catalyst member 150 in a direction parallel to or coincident with the first catalyst member axis J1. In various embodiments, the first catalyst member axis J1 is approximately parallel to the upstream housing axis λ (e.g., when measured on a plane along which both the first catalyst member axis J1 and the upstream housing axis λ extend, etc.). In these embodiments, the first catalyst member axis J1 may be spaced apart from the upstream housing axis λ.

[0064] The first catalyst member 150 also includes a first catalyst material 151 (eg, a catalyst metal, etc.). The first catalyst material 151 may include, for example, platinum, rhodium, palladium, or other similar materials. The first catalyst material 151 is configured to accelerate the reduction of the reductant and NO in the exhaust gas. x NO x The reduction process into diatomic nitrogen, water and / or carbon dioxide helps reduce NO x In some embodiments, the first catalyst material 151 is a ceramic catalyst material. In some embodiments, the first catalyst material 151 is an extruded catalyst material.

[0065] The exhaust aftertreatment system 100 also includes a second catalyst member 152 (e.g., a second SCR catalyst member, etc.). The second catalyst member 152 is configured to receive, process, and output a second portion of the exhaust gas output by the distribution housing 146. At least a portion of the second catalyst member 152 is located within the catalyst member housing 148. The second portion of the exhaust gas received by the distribution housing 146 is provided to the second catalyst member 152 by the distribution housing 146 (e.g., via the catalyst member housing 148, etc.). The second catalyst member 152 receives a second portion of the exhaust gas, which is separated from the first portion of the exhaust gas received by the first catalyst member 150. As explained in more detail herein, the second catalyst member 152 is configured to cause decomposition of exhaust gas components using a reductant (e.g., by a catalytic reaction, etc.). Specifically, the reductant supplied to the exhaust gas by the injector 126 undergoes evaporation, pyrolysis, and hydrolysis processes to form non-NO in the distribution housing 146, the catalyst member housing 148, the second catalyst member 152, and / or the housing assembly 104. x The second catalyst member 152 is configured to accelerate the reductant and NO in the exhaust gas. x NO x The reduction process into diatomic nitrogen, water and / or carbon dioxide helps reduce NO x emission.

[0066] In various embodiments, the second catalyst member 152 is centered on the second catalyst member axis J2. In other words, the center point of the cross-section of the second catalyst member 152 is disposed on the second catalyst member axis J2 along the length of the second catalyst member 152. Exhaust gas may be provided through the second catalyst member 152 in a direction parallel to or coincident with the second catalyst member axis J2. In various embodiments, the second catalyst member axis J2 is approximately parallel to the upstream housing axis λ (e.g., when measured on a plane along which both the second catalyst member axis J2 and the upstream housing axis λ extend, etc.). In these embodiments, the second catalyst member axis J2 may be spaced apart from the upstream housing axis λ. The second catalyst member axis J2 may be approximately parallel to the first catalyst member axis J1.

[0067] The second catalyst member 152 also includes a second catalyst material 153 (eg, a catalyst metal, etc.). The second catalyst material 153 may include, for example, platinum, rhodium, palladium, or other similar materials. The second catalyst material 153 is configured to accelerate the reduction of the reductant and NO in the exhaust gas. x NO x The reduction process into diatomic nitrogen, water and / or carbon dioxide helps reduce NO x In some embodiments, the second catalyst material 153 is a ceramic catalyst material. In some embodiments, the second catalyst material 153 is an extruded catalyst material.

[0068] The first portion of the exhaust gas is directed through the first catalyst member 150 in parallel with the second portion of the exhaust gas being directed through the second catalyst member 152. By directing the first portion of the exhaust gas through the first catalyst member 150 and directing the second portion of the exhaust gas through the second catalyst member 152 in parallel, it becomes more desirable to reduce emissions of undesirable components in the exhaust gas. For example, directing the exhaust gas through the first catalyst member 150 and the second catalyst member 152 in parallel may provide an increased ability of the exhaust aftertreatment system 100 to treat the exhaust gas and / or an increased efficiency of the exhaust aftertreatment system 100 to treat the exhaust gas when compared to other aftertreatment systems that do not include two catalyst members and do not direct the exhaust gas through the two catalyst members in parallel.

[0069] The housing assembly 104 also includes an outlet housing 154 (e.g., body, etc.). The outlet housing 154 is fluidly coupled to the catalyst member housing 148 and is configured to receive exhaust gas from the catalyst member housing 148, the first catalyst member 150, and / or the second catalyst member 152. In various embodiments, the outlet housing 154 is coupled to the catalyst member housing 148. For example, the outlet housing 154 can be fastened, welded, riveted, or otherwise attached to the catalyst member housing 148. In other embodiments, the outlet housing 154 is integrally formed with the catalyst member housing 148.

[0070] The outlet housing 154 is located downstream of the catalyst member housing 148 and receives a first portion of the exhaust gas after flowing through the first catalyst member 150 and a second portion of the exhaust gas after flowing through the second catalyst member 152. In some embodiments, at least a portion of the first catalyst member 150 is positioned within the outlet housing 154 and / or at least a portion of the second catalyst member 152 is positioned within the outlet housing 154.

[0071] In various embodiments, the housing assembly 104 also includes a flow distributor 156 (e.g., a flowsplitter, a flow baffle, etc.). The flow distributor 156 is configured to balance (e.g., equalize, evenly distribute, etc.) a first portion of the exhaust gas provided to the outlet housing 154 by the first catalyst member 150 and a second portion of the exhaust gas provided to the outlet housing 154 by the second catalyst member 152. For example, when a first parameter of the first portion (e.g., flow rate, mass flow rate, volume flow rate, velocity, pressure, etc.) is approximately equal to a second parameter (e.g., flow rate, mass flow rate, volume flow rate, velocity, pressure, etc.), the first portion can be balanced with the second portion. By balancing the first portion and the second portion, it is more desirable to reduce the emission of undesirable components in the exhaust gas. For example, balancing the first portion and the second portion can reduce the back pressure of the exhaust aftertreatment system 100, thereby increasing the efficiency and / or output of the internal combustion engine having the exhaust aftertreatment system 100.

[0072] In some embodiments, the flow distributor 156 is located upstream of the first catalyst member 150 and / or the second catalyst member 152. For example, the flow distributor 156 can be located within the distribution housing 146. In this example, the flow distributor 156 can separate a first portion of the exhaust gas provided to the first catalyst member 150 from a second portion of the exhaust gas provided to the second catalyst member 152 after balancing the first portion and the second portion. In another example, a portion of the flow distributor 156 can be coupled to the inlet of the first catalyst member 150, and another portion of the flow distributor 156 can be coupled to the inlet of the second catalyst member 152.

[0073] In some embodiments, the flow distributor 156 is located downstream of the first catalyst member 150 and / or the second catalyst member 152. For example, a portion of the flow distributor 156 may be coupled to the outlet of the first catalyst member 150 and another portion of the flow distributor 156 may be coupled to the outlet of the second catalyst member 152.

[0074] The exhaust aftertreatment system 100 also includes a downstream exhaust conduit 158 ​​(eg, a line, a pipe, etc.). The downstream exhaust conduit 158 ​​is fluidly coupled to the outlet housing 154 and is configured to receive exhaust gas from the outlet housing 154. In some embodiments, the downstream exhaust conduit 158 ​​is coupled to the outlet housing 154. In other embodiments, the downstream exhaust conduit 158 ​​is integrally formed with the outlet housing 154.

[0075] The first catalyst member 150 includes a first catalyst member inlet 159. The second catalyst member 152 includes a second catalyst member inlet 160. The first catalyst member inlet 159 and the second catalyst member inlet 160 are located where a first portion of the exhaust gas (e.g., received, processed, and output by the first catalyst member 150, etc.) is separated from a second portion of the exhaust gas (e.g., received, processed, and output by the second catalyst member 152, etc.). The first catalyst member inlet 159 and the second catalyst member inlet 160 are disposed along a catalyst member inlet plane 161.

[0076] The first catalyst member 150 also includes a first catalyst member outlet 162. The first catalyst member outlet 162 is located along the first catalyst member axis J1 at an average location where the first portion is output from the first catalyst material 151 (e.g., when the flow distributor 156 is located upstream of the first catalyst material 151, etc.) or the first portion is output from the flow distributor 156 (e.g., when the flow distributor 156 is located downstream of the first catalyst material 151, etc.). The first catalyst member outlet 162 is disposed along a first catalyst member outlet plane 163. The first catalyst member outlet plane 163 is orthogonal to the first catalyst member axis J1.

[0077] The first catalyst member 150 is also defined by a first catalyst member spacing length L1 from the catalyst member inlet plane 161 to the first catalyst member outlet plane 163. By minimizing the first catalyst member spacing length L1, the length of the housing assembly 104 along the first catalyst member axis J1 can be reduced. As a result, the space requirement of the housing assembly 104 can be reduced, making the housing assembly 104 more desirable.

[0078] The second catalyst member 152 also includes a second catalyst member outlet 164. The second catalyst member outlet 164 is located along the second catalyst member axis J2 at an average location at which the second portion is output from the second catalyst material 153 (e.g., when the flow distributor 156 is located upstream of the second catalyst material 153, etc.) or the second portion is output from the flow distributor 156 (e.g., when the flow distributor 156 is located downstream of the second catalyst material 153, etc.). The second catalyst member outlet 164 is disposed along a second catalyst member outlet plane 165. The second catalyst member outlet plane 165 is orthogonal to the second catalyst member axis J2.

[0079] The second catalyst member 152 is also defined by a second catalyst member spacing length L2 from the catalyst member inlet plane 161 to the second catalyst member outlet plane 165. By minimizing the second catalyst member spacing length L2, the length of the housing assembly 104 along the second catalyst member axis J2 can be reduced. As a result, the space requirement of the housing assembly 104 can be reduced, making the housing assembly 104 more desirable.

[0080] In contrast to the catalyst member inlet plane 161 which is the same for both the first catalyst member 150 and the second catalyst member 152, the first catalyst member outlet plane 163 is specific to the first catalyst member 150 and the second catalyst member outlet plane 165 is specific to the second catalyst member 152. As a result, the first catalyst member spacing length L1 and the second catalyst member spacing length L2 may be different.

[0081] By minimizing the difference between the first catalyst component spacing length L1 and the second catalyst component spacing length L2 and minimizing both the first catalyst component spacing length L1 and the second catalyst component spacing length L2, the space requirement of the housing assembly 104 is minimized. The desirability of the housing assembly 104 can increase as the space requirement of the housing assembly 104 is reduced (for example, because the housing assembly 104 can be used in more applications, etc.). The function of the flow distributor 156 is to minimize the back pressure, otherwise the back pressure will increase as the difference between the first catalyst component spacing length L1 and the second catalyst component spacing length L2 is reduced. In a system without a flow distributor, the flow of exhaust gas through parallel catalysts cannot be balanced, and the catalysts must be located at different positions to alleviate excessive back pressure. By using the flow distributor 156 to balance the flow of exhaust gas flowing out of the first catalyst component 150 and the flow of exhaust gas flowing out of the second catalyst component 152, the first catalyst component spacing length L1 can be the same as the second catalyst component spacing length L2 without providing excessive back pressure.

[0082] The exhaust aftertreatment system 100 also includes an outlet sampling system 166. The outlet sampling system 166 is configured to facilitate sampling of exhaust gas within the outlet housing 154 (e.g., after a first portion of the exhaust gas has flowed out of the first catalyst member outlet 162 and a second portion of the exhaust gas has flowed out of the second catalyst member outlet 164). As explained in more detail herein, the outlet sampling system 166 does not protrude into the downstream exhaust conduit 158. In contrast, other systems use probes or conduits that protrude through the exhaust flow path to sample the exhaust gas. These probes and conduits used in other systems may provide inaccurate measurements and may be prone to failure. By avoiding these drawbacks, the outlet sampling system 166 may make the exhaust aftertreatment system 100 more desirable than other systems.

[0083] The exhaust aftertreatment system 100 also includes an outlet sensor 168 (eg, a probe, etc.). The outlet sensor 168 is exposed to the exhaust gas sampled by the outlet sampling system 166. The outlet sensor 168 does not protrude into the downstream exhaust conduit 158 ​​or the outlet housing 154. Instead, the outlet sensor 168 is positioned to sample the exhaust gas within the outlet sampling system 166.

[0084] The outlet sensor 168 is electrically or communicatively coupled to the controller 134. The controller 134 is configured to receive a signal from the outlet sensor 168 and determine a characteristic of the exhaust gas sampled by the outlet sampling system 166 (e.g., NO x The controller 134 may then control the operation of the exhaust aftertreatment system 100 based on the reading of the characteristic. For example, the controller 134 may compare the reading of the characteristic with a threshold value (e.g., a maximum desired amount of the characteristic, a minimum desired amount of the characteristic, etc.), and then control the operation of the exhaust aftertreatment system 100 based on the comparison. In some applications, the controller 134 controls the operation of the exhaust aftertreatment system 100 by causing the dosing module 118 to dose additional reductant into the decomposition housing 114.

[0085] 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.

[0086] III. Exemplary Housing Assemblies Figures 3 to 12The housing assembly 104 is illustrated according to various embodiments. The intake body 106 includes an intake body inlet 200 (e.g., a fitting, a connector, etc.). The intake body inlet 200 is coupled to or integrally formed with the upstream exhaust conduit 102. For example, the upstream exhaust conduit 102 may be inserted into the intake body inlet 200, and the intake body inlet 200 may be coupled to the upstream exhaust conduit 102 using a clamp (e.g., a band clamp, etc.).

[0087] In various embodiments, such as Fig. 9 As shown, the intake body inlet 200 is centered on the intake body inlet central axis μ. In other words, the center point of the cross-section of the intake body inlet 200 is disposed on the intake body inlet central axis μ along the length of the intake body inlet 200. Exhaust gas may be provided through the intake body inlet 200 in a direction parallel to or coinciding with the intake body inlet central axis μ.

[0088] In various embodiments, the intake body inlet central axis μ is approximately orthogonal to the upstream housing axis λ (e.g., when measured on a plane along which both the intake body inlet central axis μ and the upstream housing axis λ extend, etc.). This arrangement of the intake body inlet 200 can help further reduce the length of the housing assembly 104 along the upstream housing axis λ and / or the length of the housing assembly 104 along the catalyst member housing axis p. This can further reduce the space requirements of the housing assembly 104. In some embodiments, the intake body inlet central axis μ coincides with the upstream housing axis λ.

[0089] The exhaust aftertreatment system 100 also includes a perforated panel 202 (e.g., a plate, etc.). The perforated panel 202 is located within the intake body 106. The perforated panel 202 includes a plurality of perforated panel perforations 204 (e.g., openings, perforations, holes, etc.). At least a portion of the exhaust gas provided by the intake body 106 to the oxidation catalyst 110 flows through the perforated panel 202 via the perforated panel perforations 204 before being provided to the oxidation catalyst 110. The perforated panel 202 is configured to facilitate redirecting the exhaust gas from flowing along the intake body inlet central axis μ to flowing along the upstream housing axis λ.

[0090] The exhaust aftertreatment system 100 also includes a straightener 206 (e.g., a flow straightener, an orifice plate, etc.). The straightener 206 is located within the intake body 106. The straightener 206 includes a plurality of straightener perforations 208 (e.g., openings, holes, holes, etc.). At least a portion of the exhaust provided by the intake body 106 to the oxidation catalyst 110 flows through the straightener 206 via the straightener perforations 208 before being provided to the oxidation catalyst 110. The straightener 206 is configured to facilitate straightening of the exhaust gas before providing the exhaust gas to the oxidation catalyst 110. Due to the straightening facilitated by the straightener 206, the turbulence of the exhaust gas flowing into the oxidation catalyst 110 is reduced, and the back pressure of the exhaust aftertreatment system 100 is reduced, thereby making the exhaust aftertreatment system 100 more ideal.

[0091] The exhaust aftertreatment system 100 also includes an inlet band clamp 210 (e.g., a strap, a hose clamp, etc.). The inlet band clamp 210 is configured to facilitate coupling of the inlet body 106 and the upstream housing 108. For example, the inlet band clamp 210 may overlap a first flange of the inlet body 106 and a second flange of the upstream housing 108 and be tightened to couple the inlet body 106 and the upstream housing 108.

[0092] By using the inlet band clamp 210, the assembly and / or maintenance of the housing assembly 104 can be simplified. For example, the perforated panel 202 and / or the straightener 206 can be inserted into the intake body 106 before the intake body 106 and the upstream housing 108 are coupled. This can simplify the assembly of the intake body 106, thereby making the exhaust aftertreatment system 100 more ideal. In another example, when the inlet band clamp 210 is removed and the intake body 106 is separated from the upstream housing 108, the oxidation catalyst 110 and the exhaust filter device 112 can be removed from the upstream housing 108 without separating the upstream housing 108 from the decomposition housing 114 or separating the decomposition housing 114 from the distribution housing 146. This can simplify the removal of the oxidation catalyst 110 and / or the exhaust filter device 112, thereby making the exhaust aftertreatment system 100 more ideal.

[0093] The exhaust aftertreatment system 100 also includes an explosion housing band clamp 212 (e.g., a strap, a hose clamp, etc.). The explosion housing band clamp 212 is configured to facilitate coupling of the upstream housing 108 and the explosion housing 114. For example, the explosion housing band clamp 212 may overlap a first flange of the upstream housing 108 and a second flange of the explosion housing 114 and be tightened to couple the upstream housing 108 and the explosion housing 114.

[0094] By using the disassembly housing band clamp 212, the assembly and / or maintenance of the housing assembly 104 can be simplified. For example, the mixer 144 can be inserted into the disassembly housing 114 before the disassembly housing 114 and the upstream housing 108 are coupled. This can simplify the assembly of the disassembly housing 114, thereby making the exhaust aftertreatment system 100 more ideal. In another example, when the disassembly housing band clamp 212 is removed and the upstream housing 108 is separated from the disassembly housing 114, the oxidation catalyst 110 and the exhaust filter device 112 can be inserted into the upstream housing 108 without separating the upstream housing 108 from the intake body 106. This can simplify the installation of the oxidation catalyst 110 and / or the exhaust filter device 112, thereby making the exhaust aftertreatment system 100 more ideal.

[0095] The mixer 144 includes a mixer housing 214 (e.g., a housing, a body, etc.). Exhaust gas flows through the mixer 144 via the mixer housing 214. The mixer housing 214 includes a mixer housing opening 215 (e.g., a hole, an eyelet, etc.). The mixer housing opening 215 receives the reductant or air-reductant mixture from the injector 126. The mixer 144 may, for example, include a flow guide (e.g., a cone, etc.) extending from the mixer housing 214 to the decomposition housing 114 and extending around the injector 126 and the mixer housing opening 215. The flow guide may facilitate providing the reductant or air-reductant mixture from the injector 126 via the mixer housing opening 215 into the mixer housing 214. The flow guide may include a perforation for receiving the exhaust gas, which may help push the reductant or air-reductant mixture into the mixer housing 214.

[0096] The mixer 144 also includes a first mixer flange 216 (e.g., a rib, a ring, etc.). The first mixer flange 216 supports (e.g., suspends, etc.) the mixer 144 within the decomposition housing 114. The first mixer flange 216 is disposed upstream of the ejector 126. In various embodiments, the first mixer flange 216 is coupled to the mixer housing 214 and coupled to the decomposition housing 114. In some embodiments, the first mixer flange 216 is integrally formed with the mixer housing 214 (e.g., and coupled to the decomposition housing 114 and integrally formed with the decomposition housing 114). In some embodiments, the first mixer flange 216 is integrally formed with the decomposition housing 114 (e.g., and coupled to the mixer housing 214 and integrally formed with the mixer housing 214).

[0097] In various embodiments, the first mixer flange 216 includes at least one mixer flange hole 218 (e.g., an eyelet, an opening, a window, etc.). The mixer flange hole 218 facilitates exhaust gas flow through the first mixer flange 216. In this way, the exhaust gas can flow between the mixer housing 214 and the decomposition housing 114. The exhaust gas can heat the mixer housing 214, thereby reducing the formation of deposits (e.g., reductant deposits, solidified reductant, etc.) on the mixer housing 214. In addition, the exhaust gas can help push the reductant into the mixer housing 214 via the mixer housing opening 215.

[0098] The mixer 144 also includes an upstream mixing plate 220 (e.g., a blade plate, a baffle plate, etc.). The upstream mixing plate 220 is located upstream of the mixer housing opening 215. The upstream mixing plate 220 includes a plurality of upstream mixing plate blades 222 (e.g., baffles, guides, etc.) extending from an upstream mixing plate hub 224 (e.g., a base, etc.) of the upstream mixing plate 220. Adjacent pairs of upstream mixing plate blades 222 define upstream mixing plate holes 226 (e.g., holes, openings, etc.). Exhaust gas flows through the upstream mixing plate 220 via the upstream mixing plate holes 226. The upstream mixing plate blades 222 are angled relative to the upstream mixing plate hub 224, which causes the exhaust gas to swirl as it flows through the upstream mixing plate 220. The swirl enhances mixing of the reductant or air-reductant mixture downstream of the upstream mixing plate 220.

[0099] The mixer 144 also includes a downstream mixing plate 228 (e.g., a blade plate, a baffle, etc.). The downstream mixing plate 228 is located downstream of the mixer housing opening 215. The downstream mixing plate 228 includes a plurality of downstream mixing plate blades 230 (e.g., baffles, guides, etc.) extending from a downstream mixing plate hub 232 (e.g., a base, etc.) of the downstream mixing plate 228. Adjacent pairs of downstream mixing plate blades 230 define downstream mixing plate holes 234 (e.g., holes, openings, etc.). Exhaust gas flows through the downstream mixing plate 228 via the downstream mixing plate holes 234. The downstream mixing plate blades 230 are angled relative to the downstream mixing plate hub 232, which causes the exhaust gas to swirl as it flows through the downstream mixing plate 228. The swirl enhances mixing of the reductant or air-reductant mixture downstream of the downstream mixing plate 228.

[0100] The mixer 144 also includes a second mixer flange 236 (e.g., a rib, a ring, etc.). The second mixer flange 236 supports (e.g., suspends, etc.) the mixer 144 within the decomposition housing 114. The second mixer flange 236 is disposed downstream of the ejector 126. In various embodiments, the second mixer flange 236 is coupled to the mixer housing 214 and coupled to the decomposition housing 114. In some embodiments, the second mixer flange 236 is integrally formed with the mixer housing 214 (e.g., and coupled to the decomposition housing 114 and integrally formed with the decomposition housing 114). In some embodiments, the second mixer flange 236 is integrally formed with the decomposition housing 114 (e.g., and coupled to the mixer housing 214 and integrally formed with the mixer housing 214).

[0101] The mixer 144 also includes a third mixer flange 238 (e.g., ribs, rings, etc.). The third mixer flange 238 supports (e.g., suspends, etc.) the mixer 144 within the decomposition housing 114. The third mixer flange 238 is disposed downstream of the second mixer flange 236. In various embodiments, the third mixer flange 238 is coupled to the mixer housing 214 and coupled to the decomposition housing 114. In some embodiments, the third mixer flange 238 is integrally formed with the mixer housing 214 (e.g., and coupled to the decomposition housing 114 and integrally formed with the decomposition housing 114). In some embodiments, the third mixer flange 238 is integrally formed with the decomposition housing 114 (e.g., and coupled to the mixer housing 214 and integrally formed with the mixer housing 214).

[0102] The distribution housing 146 includes an inlet coupler 240 (e.g., a spacer, etc.). The inlet coupler 240 is coupled to the decomposition housing 114. In various embodiments, the exhaust aftertreatment system 100 also includes a distribution housing band clamp 242 (e.g., a strap, a hose clamp, etc.). The distribution housing band clamp 242 is configured to facilitate coupling of the decomposition housing 114 and the distribution housing 146. For example, the distribution housing band clamp 242 can overlap the first flange of the decomposition housing 114 and the inlet coupler 240, and be tightened to couple the decomposition housing 114 and the inlet coupler 240.

[0103] By using the distribution housing band clamp 242, the assembly and / or maintenance of the housing assembly 104 can be simplified. For example, the mixer 144 can be inserted into the disassembly housing 114 before the disassembly housing 114 and the inlet coupler 240 are coupled. This can simplify the assembly of the disassembly housing 114, thereby making the exhaust aftertreatment system 100 more desirable.

[0104] The distribution housing 146 also includes a distribution housing flange body 244 (eg, flange member, etc.) The distribution housing flange body 244 facilitates coupling of the distribution housing 146 with the decomposition housing 114 and the catalyst member housing 148 as explained in greater detail herein.

[0105] The distribution housing flange body 244 includes a distribution housing inlet flange 246 (e.g., a ring, annular flange, rib, wall, etc.). The distribution housing 146 receives exhaust gas from the decomposition housing 114 through the distribution housing inlet flange 246. In various embodiments, the distribution housing inlet flange 246 is coupled to the inlet coupler 240. For example, the distribution housing inlet flange 246 can be fastened, welded, riveted, or otherwise attached to the inlet coupler 240. In other embodiments, the distribution housing inlet flange 246 is integrally formed with the inlet coupler 240.

[0106] The distribution housing flange body 244 also includes a housing 248 (e.g., a wall, a cap, etc.). The housing 248 is used to direct the exhaust gas toward the catalyst member housing 148 after flowing into the distribution housing 146 via the distribution housing inlet flange 246. In various embodiments, the housing 248 is coupled to the distribution housing inlet flange 246. For example, the housing 248 can be fastened, welded, riveted, or otherwise attached to the distribution housing inlet flange 246. In other embodiments, the housing 248 is integrally formed with the distribution housing inlet flange 246.

[0107] The distribution housing flanged body 244 also includes an outlet flange 250 (e.g., a ring, rib, wall, etc.). As explained in more detail herein, the outlet flange 250 facilitates coupling of the distribution housing 146 to the catalyst member housing 148. In various embodiments, the outlet flange 250 is coupled to the housing 248. For example, the outlet flange 250 can be fastened, welded, riveted, or otherwise attached to the housing 248. In other embodiments, the outlet flange 250 is integrally formed with the housing 248.

[0108] The distribution housing flanged body 244 also includes a connecting wall 252 (e.g., a flange, a rib, etc.). The connecting wall 252 facilitates separation of the decomposition housing 114 and the catalyst member housing 148. In various embodiments, the connecting wall 252 is coupled to the distribution housing inlet flange 246 and / or the outlet flange 250. For example, the connecting wall 252 can be fastened, welded, riveted, or otherwise attached to the distribution housing inlet flange 246 and / or the outlet flange 250. In other embodiments, the connecting wall 252 is integrally formed with the distribution housing inlet flange 246 and / or the outlet flange 250.

[0109] The catalyst member housing 148 includes a first support 254. The first support 254 is configured to facilitate coupling of the catalyst member housing 148 to the distribution housing 146 while also supporting the first catalyst member 150 and the second catalyst member 152 to the catalyst member housing 148.

[0110] The first support 254 includes a first housing support flange 256 (e.g., a rib, a wall, etc.). In various embodiments, the first housing support flange 256 is coupled to the outlet flange 250. For example, the first housing support flange 256 can be fastened, welded, riveted, or otherwise attached to the outlet flange 250. In other embodiments, the first housing support flange 256 is integrally formed with the outlet flange 250.

[0111] The first support 254 also includes a first support first catalyst member flange 258 (eg, rib, wall, etc.) As explained in greater detail herein, the first support first catalyst member flange 258 is configured to support the first catalyst member 150 within the catalyst member housing 148 .

[0112] The first catalyst member 150 includes a first casing 260 (e.g., shell, skin, etc.). The first casing 260 interfaces with the first support first catalyst member flange 258. In some embodiments, the first casing 260 is coupled to the first support first catalyst member flange 258. For example, the first casing 260 can be fastened, welded, riveted, or otherwise attached to the first support first catalyst member flange 258. In other embodiments, the first casing 260 is integrally formed with the first support first catalyst member flange 258.

[0113] The first support 254 also includes a first support second catalyst member flange 262 (e.g., ribs, walls, etc.). As explained in more detail herein, the first support second catalyst member flange 262 is configured to support the second catalyst member 152 within the catalyst member housing 148. The first support 254 is configured such that the first support second catalyst member flange 262 is spaced apart from the first support first catalyst member flange 258. In some embodiments, the first support 254 is configured such that the catalyst member housing axis p extends between the first catalyst member 150 and the second catalyst member 152.

[0114] The second catalyst member 152 includes a second outer cover 264 (e.g., a shell, a skin, etc.). The second outer cover 264 interfaces with the first support member second catalyst member flange 262. In some embodiments, the second outer cover 264 is coupled to the first support member second catalyst member flange 262. For example, the second outer cover 264 can be fastened, welded, riveted, or otherwise attached to the first support member second catalyst member flange 262. In other embodiments, the second outer cover 264 is integrally formed with the first support member second catalyst member flange 262.

[0115] The catalyst member housing 148 also includes an outer wall 266 (e.g., an outer cover, etc.). The outer wall 266 partially covers the first catalyst member 150 and the second catalyst member 152. The first support 254 is configured to support the first catalyst member 150 above the outer wall 266 so that an air gap extends at least partially between the outer wall 266 and the first catalyst member 150. In various embodiments, the outer wall 266 is coupled to the first housing support flange 256. For example, the outer wall 266 can be fastened, welded, riveted, or otherwise attached to the first housing support flange 256. In other embodiments, the outer wall 266 is integrally formed with the first housing support flange 256.

[0116] The catalyst member housing 148 includes a second support 268. The second support 268 is configured to facilitate coupling of the catalyst member housing 148 with the outlet housing 154 while also supporting the first and second catalyst members 150, 152 within the catalyst member housing 148.

[0117] The second support 268 includes a second housing support flange 270 (eg, rib, wall, etc.) As explained in greater detail herein, the second housing support flange 270 is configured to facilitate coupling of the second support 268 to the outlet housing 154 .

[0118] The second support 268 also includes a second support first catalyst member flange 272 (eg, rib, wall, etc.) As explained in greater detail herein, the second support first catalyst member flange 272 is configured to support the first catalyst member 150 within the catalyst member housing 148 .

[0119] The first housing 260 interfaces with the second support first catalyst member flange 272. In some embodiments, the first housing 260 is coupled to the second support first catalyst member flange 272. For example, the first housing 260 can be fastened, welded, riveted, or otherwise attached to the second support first catalyst member flange 272. In other embodiments, the first housing 260 is integrally formed with the second support first catalyst member flange 272.

[0120] The second support 268 also includes a second support second catalyst member flange 274 (e.g., ribs, walls, etc.). As explained in more detail herein, the second support second catalyst member flange 274 is configured to support the second catalyst member 152 within the catalyst member housing 148. The second support 268 is configured such that the second support second catalyst member flange 274 is spaced apart from the second support first catalyst member flange 272. In some embodiments, the second support 268 is configured such that the catalyst member housing axis p extends between the first catalyst member 150 and the second catalyst member 152.

[0121] The second outer cover 264 interfaces with the second support member second catalyst member flange 274. In some embodiments, the second outer cover 264 is coupled to the second support member second catalyst member flange 274. For example, the second outer cover 264 can be fastened, welded, riveted, or otherwise attached to the second support member second catalyst member flange 274. In other embodiments, the second outer cover 264 is integrally formed with the second support member second catalyst member flange 274.

[0122] The outlet housing 154 includes an outlet housing flange 276 (e.g., wall, rib, etc.). In various embodiments, the outlet housing flange 276 is coupled to the second housing support flange 270. For example, the outlet housing flange 276 can be fastened, welded, riveted, or otherwise attached to the second housing support flange 270. In other embodiments, the outlet housing flange 276 is integrally formed with the second housing support flange 270.

[0123] The outlet housing 154 also includes an outlet housing body 278 (e.g., a wall, a shell, etc.). The outlet housing body 278 is configured to collect exhaust gas flowing from both the first catalyst member 150 and the second catalyst member 152 and provide the exhaust gas to the downstream exhaust conduit 158. In various embodiments, the outlet housing body 278 is coupled to the outlet housing flange 276. For example, the outlet housing body 278 can be fastened, welded, riveted, or otherwise attached to the outlet housing flange 276. In other embodiments, the outlet housing body 278 is integrally formed with the outlet housing flange 276.

[0124] The outlet sampling system 166 includes an outlet housing fitting 280 (e.g., a coupler, etc.). The outlet housing fitting 280 is configured to provide exhaust gas from the outlet housing body 278 to the downstream exhaust conduit 158. In various embodiments, the outlet housing fitting 280 is coupled to the outlet housing body 278. For example, the outlet housing fitting 280 may be fastened, welded, riveted, or otherwise attached to the outlet housing body 278. In other embodiments, the outlet housing fitting 280 is integrally formed with the outlet housing body 278.

[0125] The outlet housing fitting 280 is centered on the outlet housing fitting axis ω. In other words, the center point of the cross-section of the outlet housing fitting 280 is disposed on the outlet housing fitting axis ω along the length of the outlet housing fitting 280. Exhaust gas may be provided through the outlet housing fitting 280 in a direction parallel to or coincident with the outlet housing fitting axis ω. In various embodiments, the outlet housing fitting axis ω is approximately parallel to the catalyst member housing axis ρ (e.g., when measured on a plane along which both the outlet housing fitting axis ω and the catalyst member housing axis ρ extend, etc.).

[0126] The flow distributor 156 includes a first end cap 282 (eg, a plate, etc.) As explained in greater detail herein, the first end cap 282 is configured to control exhaust gas flow out of the first catalyst member 150 .

[0127] The first end cap 282 includes a first end cap flange 284 (e.g., a wall, a rib, etc.). In various embodiments, the first end cap flange 284 is coupled to the first support first catalyst member flange 258. For example, the first end cap flange 284 can be fastened, welded, riveted, or otherwise attached to the first support first catalyst member flange 258. In other embodiments, the first end cap flange 284 is integrally formed with the first support first catalyst member flange 258.

[0128] The first end cap 282 also includes a first end cap panel 286 (e.g., plate, face, etc.). In some embodiments, the first end cap panel 286 extends across the first support first catalyst member flange 258, and thus extends across the inlet face of the first catalyst member 150. In various embodiments, the first end cap panel 286 is coupled to the first end cap flange 284. For example, the first end cap panel 286 can be fastened, welded, riveted, or otherwise attached to the first end cap flange 284. In other embodiments, the first end cap panel 286 is integrally formed with the first end cap flange 284.

[0129] The first end cover 282 also includes a plurality of first apertures 288 (eg, openings, perforations, etc.). The first apertures 288 facilitate exhaust gas flow through the first end cover 282. In various embodiments, each of the first apertures 288 extends through the first end cover panel 286. In other embodiments, at least one of the first apertures 288 extends through the first end cover flange 284.

[0130] The first holes 288 are configured to receive exhaust gas from the distribution housing 146 and facilitate a first portion of the exhaust gas to flow through the first end cover 282 and to the outlet housing 154. The first portion of the exhaust gas is processed by the first catalyst member 150. Each first hole 288 defines a first hole area A1. The first hole area A1 of each first hole 288 can be different from or the same as the first hole area A1 of the other first holes 288. In various embodiments, each of the first hole areas A1 is approximately 0.50 square inches (in 2 ) to 2.50in 2 (0.50 square inches and 2.50 square inches inclusive), (e.g., 0.475 in 2 、0.50 in 2 、1.0in 2 、1.8 in 2 、2.50 in 2 、2.625 in 2 As used herein, the range of X to Y includes X, Y, values ​​between X and Y, and values ​​approximately equal to X and approximately equal to Y. In some embodiments, the first hole area A1 of each first hole 288 is equal.

[0131] The sum of the first hole areas A1 of all the first holes 288 defines a first total area ε of the first end cover 282 . The first total area ε is the total area in the first end cover 282 through which exhaust gas can flow toward the outlet housing 154 .

[0132] The flow distributor 156 includes a second end cap 290 (eg, a plate, etc.) As explained in greater detail herein, the second end cap 290 is configured to control exhaust gas flow out of the second catalyst member 152 .

[0133] The second end cap 290 includes a second end cap flange 292 (e.g., a wall, a rib, etc.). In various embodiments, the second end cap flange 292 is coupled to the first support second catalyst member flange 262. For example, the second end cap flange 292 can be fastened, welded, riveted, or otherwise attached to the first support second catalyst member flange 262. In other embodiments, the second end cap flange 292 is integrally formed with the first support second catalyst member flange 262.

[0134] The second end cap 290 also includes a second end cap panel 294 (e.g., plate, face, etc.). In some embodiments, the second end cap panel 294 extends across the first support second catalyst member flange 262, and therefore extends across the inlet face of the second catalyst member 152. In various embodiments, the second end cap panel 294 is coupled to the second end cap flange 292. For example, the second end cap panel 294 can be fastened, welded, riveted, or otherwise attached to the second end cap flange 292. In other embodiments, the second end cap panel 294 is integrally formed with the second end cap flange 292.

[0135] The second end cap 290 also includes a plurality of second apertures 296 (eg, openings, perforations, etc.). The second apertures 296 facilitate exhaust gas flow through the second end cap 290. In various embodiments, each second aperture 296 extends through the second end cap panel 294. In other embodiments, at least one of the second apertures 296 extends through the second end cap flange 292.

[0136] The second holes 296 are configured to receive exhaust gas from the distribution housing 146 and facilitate a second portion of the exhaust gas to flow through the second end cover 290 and reach the outlet housing 154. The second portion of the exhaust gas is processed by the second catalyst member 152. The second holes 296 each define a second hole area A2. The second hole area A2 of each second hole 296 can be different from or the same as the second hole area A2 of the other second holes 296. In addition, the second hole area A2 of each second hole 296 can be different from or the same as the first hole area A1 of the first hole 288.

[0137] In various embodiments, the second aperture areas A2 are each approximately 0.50 in. 2 Up to 2.50 in 2 (Including 0.50 in 2 and 2.50 in 2 within the range of (for example, 0.475 in 2 、0.50 in 2 、1.0 in 2 、1.8 in 2 、2.50 in 2 、2.625in 2 In some embodiments, the second hole area A2 of each second hole 296 is equal.

[0138] The sum of the second hole areas A2 of all the second holes 296 defines a second total area ɳ of the second end cover 290. The second total area ɳ is a total area through which the exhaust gas in the second end cover 290 can flow toward the outlet housing 154.

[0139] In various embodiments, the second total area ɳ is not equal to the first total area ε. The ratio of the first total area ε to the second total area ɳ , ( is selected so that the flow of exhaust gas is balanced between the first catalyst component 150 and the second catalyst component 152. As a result, the first catalyst component 150 and the second catalyst component 152 receive the same amount (e.g., the same volume per unit time, etc.) of exhaust gas. Balancing the flow of exhaust gas between the first catalyst component 150 and the second catalyst component 152 reduces back pressure on an internal combustion engine having the exhaust aftertreatment system 100.

[0140] In various embodiments, the ratio Approximately in the range of 1.25 to 10 (inclusive) (1.1875, 1.25, 2, 4, 10, 10.5, etc. inclusive).

[0141] In various embodiments, dispense housing 146 includes one or more sensor assemblies 298 (eg, temperature sensors, pressure sensors, oxygen sensors, volumetric flow sensors, etc.). Fig.10 and Fig.11 One of the sensor assemblies 298 is shown in greater detail. The sensor assembly 298 is disposed downstream of the distribution housing inlet flange 246. The sensor assembly 298 is configured to determine a reading (e.g., temperature, pressure, etc.) of exhaust gas within the distribution housing 146 (e.g., downstream of the distribution housing inlet flange 246, etc.).

[0142] Each sensor assembly 298 may include a conduit inlet 300 (e.g., a channel inlet, a duct opening, etc.). The conduit inlet 300 may be fluidly coupled within the distribution housing 146 and configured to receive a small portion of the exhaust gas. The small portion of the exhaust gas may be used to determine a reading of the exhaust gas. Each sensor assembly 298 may also include an internal conduit 302 (e.g., an internal channel, an internal duct, etc.). The internal conduit 302 may be disposed within the distribution housing 146. The internal conduit 302 may be fluidly coupled to the conduit inlet 300 and may be configured to receive a small portion of the exhaust gas.

[0143] Each sensor assembly 298 includes a sensor boss 304 (e.g., a protruding member, a protrusion, etc.). The sensor boss 304 includes a hole through which the duct inlet 300 can extend. After placing the duct inlet 300 through the hole of the sensor boss 304, the duct inlet 300 can be placed into its desired position. The duct inlet 300 can then be coupled to the sensor boss 304.

[0144] Each sensor assembly 298 may also include an external conduit 306 (eg, an external passage, an external pipe, etc.). The external conduit 306 may be coupled to the sensor boss 304 at a first end. The external conduit 306 may be fluidly coupled to the internal conduit 302 such that the external conduit 306 is configured to receive a small portion of the exhaust gas.

[0145] Each sensor assembly 298 may also include a conduit seal 308 (e.g., a channel plug, a pipe gasket, etc.). The conduit seal 308 may be fluidly coupled to the external conduit 306 and may be configured to receive a small portion of the exhaust gas. The conduit seal 308 may be fluidly coupled to a sensor (e.g., a temperature sensor, a pressure sensor, an oxygen sensor, a volume flow sensor, etc.) and may be configured to provide a small portion of the exhaust gas to the sensor.

[0146] Fig.12 The housing assembly 104 is illustrated according to various embodiments. The first catalyst material 151 includes a first catalyst material first portion 900 (eg, a catalyst metal, etc.). The first catalyst material first portion 900 may include, for example, platinum, rhodium, palladium, or other similar materials. The first catalyst material first portion 900 is configured to accelerate the reduction of NO by the reductant and the exhaust gas. x NO x The reduction process into diatomic nitrogen, water and / or carbon dioxide helps reduce NO x In some embodiments, the first catalyst material first portion 900 is a ceramic catalyst material. In some embodiments, the first catalyst material first portion 900 is an extruded catalyst material.

[0147] The first catalyst material 151 also includes a first catalyst material second portion 902 (eg, a catalyst metal, etc.). The first catalyst material second portion 902 may include, for example, platinum, rhodium, palladium, or other similar materials. The first catalyst material second portion 902 is configured to accelerate the reduction of NO by the reducing agent and the exhaust gas. x NO x The reduction process into diatomic nitrogen, water and / or carbon dioxide helps reduce NO x In some embodiments, the first catalyst material second portion 902 is a ceramic catalyst material. In some embodiments, the first catalyst material second portion 902 is an extruded catalyst material.

[0148] In various embodiments, the first catalyst material second portion 902 includes a different material than the first catalyst material first portion 900. For example, the first catalyst material second portion 902 may include platinum and the first catalyst material first portion 900 may include rhodium or palladium. In another example, the first catalyst material second portion 902 may include platinum, rhodium, or palladium and the first catalyst material first portion 900 may include a ceramic material. By including different materials in the first catalyst material first portion 900 and the first catalyst material second portion 902, the first catalyst material 151 helps reduce NO x The emission capability may be tailored to the target application, and / or the first catalyst member separation length L1 may be reduced.

[0149] In various embodiments, the first catalyst material second portion 902 is separated from the first catalyst material first portion 900 by a first gap G1 (eg, spacing, etc.). The first gap G1 can provide a mechanism for redistributing the exhaust gas after leaving the first catalyst material first portion 900 and before entering the first catalyst material second portion 902. By selecting the first gap G1, the first catalyst material 151 helps reduce NO x The emission capability may be tailored to the target application, and / or the first catalyst member separation length L1 may be reduced.

[0150] The second catalyst material 153 includes a first second catalyst material portion 904 (eg, a catalyst metal, etc.). The first second catalyst material portion 904 may include, for example, platinum, rhodium, palladium, or other similar materials. The first second catalyst material portion 904 is configured to accelerate the reduction of NO in the reductant and the exhaust gas. x NO x The reduction process into diatomic nitrogen, water and / or carbon dioxide helps reduce NO x In some embodiments, the second catalyst material first portion 904 is a ceramic catalyst material. In some embodiments, the second catalyst material first portion 904 is an extruded catalyst material.

[0151] The second catalyst material 153 also includes a second catalyst material second portion 906 (eg, a catalyst metal, etc.). The second catalyst material second portion 906 may include, for example, platinum, rhodium, palladium, or other similar materials. The second catalyst material second portion 906 is configured to accelerate the reduction of NO in the reductant and the exhaust gas. x NO x The reduction process into diatomic nitrogen, water and / or carbon dioxide helps reduce NO xIn some embodiments, the second catalyst material second portion 906 is a ceramic catalyst material. In some embodiments, the second catalyst material second portion 906 is an extruded catalyst material.

[0152] In various embodiments, the second catalyst material second portion 906 includes a different material than the second catalyst material first portion 904. For example, the second catalyst material second portion 906 may include platinum and the second catalyst material first portion 904 may include rhodium or palladium. In another example, the second catalyst material second portion 906 may include platinum, rhodium, or palladium and the second catalyst material first portion 904 may include a ceramic material. By including different materials in the second catalyst material first portion 904 and the second catalyst material second portion 906, the second catalyst material 153 helps reduce NO x The emission capability may be tailored to the target application, and / or the second catalyst member separation length L2 may be reduced.

[0153] In various embodiments, the second catalyst material second portion 906 is separated from the second catalyst material first portion 904 by a second gap G2 (eg, spacing, etc.). The second gap G2 can provide a mechanism to redistribute the exhaust gas after leaving the second catalyst material first portion 904 and before entering the second catalyst material second portion 906. By selecting the second gap G2, the second catalyst material 153 helps reduce NO x The emission capability may be tailored to the target application, and / or the second catalyst member separation length L2 may be reduced.

[0154] In some embodiments, the first catalyst material 151 does not include the first catalyst material first portion 900 and the first catalyst material second portion 902, and the second catalyst material 153 includes the second catalyst material first portion 904 and the second catalyst material second portion 906. In some embodiments, the first catalyst material 151 includes the first catalyst material first portion 900 and the first catalyst material second portion 902, and the second catalyst material 153 does not include the second catalyst material first portion 904 or the second catalyst material second portion 906.

[0155] As discussed in more detail herein, the flow distributor 156 can be deployed in a variety of configurations. Figure 4 , Figure 8 and Fig. 9In the embodiment, the flow distributor 156 is arranged so that the first end cover flange 284 of the first end cover 282 is coupled to the first support member first catalyst member flange 258 of the first support member 254 or is formed integrally with the first support member first catalyst member flange 258 of the first support member 254, and the second end cover flange 292 of the second end cover 290 is coupled to the first support member second catalyst member flange 262 of the first support member 254 or is formed integrally with the first support member second catalyst member flange 262 of the first support member 254. Fig.12 , the flow distributor 156 is arranged so that the first end cover flange 284 of the first end cover 282 is coupled to the second support member first catalyst member flange 272 of the second support member 268 or is formed integrally with the second support member first catalyst member flange 272 of the second support member 268, and the second end cover flange 292 of the second end cover 290 is coupled to the second support member second catalyst member flange 274 of the second support member 268 or is formed integrally with the second support member second catalyst member flange 274 of the second support member 268.

[0156] IV. First Example Outlet Sampling System Figures 13 to 16 The outlet sampling system 166 is illustrated according to various embodiments. As described above, the outlet sampling system 166 includes the outlet housing fitting 280. The exhaust aftertreatment system 100 also includes a flange coupling 1300 (eg, a joint, etc.), such as Fig.15 and Fig.16 The flange coupler 1300 is coupled to the outlet housing body 278 and is configured to receive the outlet housing fitting 280 so that the outlet housing fitting 280 can be coupled to the flange coupler 1300. In some embodiments, a band clamp (e.g., a Marmon clamp, etc.) is placed around the flange coupler 1300, the outlet housing fitting 280 is inserted into the flange coupler 1300, and the flange coupler 1300 is tightened onto the outlet housing fitting 280. In some applications, the flange coupler 1300 is welded to the outlet housing fitting 280.

[0157] The outlet sampling system 166 also includes a sampling bowl 1302 (eg, a sampling cover, etc.). The sampling bowl 1302 includes a housing flange 1304 (eg, a lip, etc.). The housing flange 1304 is coupled to the outlet housing body 278. In various embodiments, the housing flange 1304 is coupled to the outlet housing body 278 around a flange coupling 1300.

[0158] The sampling bowl 1302 also includes a sampling bowl wall 1306 (e.g., a panel, etc.). The sampling bowl wall 1306 cooperates with the outlet housing body 278 to define a sampling bowl cavity 1308 (e.g., a void, etc.). The outlet sensor 168 is coupled to the outlet housing body 278 so that the outlet sensor 168 is exposed to the exhaust gas within the sampling bowl cavity 1308 sampled by the outlet sampling system 166. The sampling bowl wall 1306 separates the exhaust gas within the sampling bowl cavity 1308 from the exhaust gas outside the sampling bowl cavity 1308.

[0159] The sampling bowl wall 1306 includes a plurality of supports 1310 (e.g., arms, brackets, protrusions, etc.). Each support 1310 is adjacent to the sampling bowl 1302 and protrudes away from the housing flange 1304. The sampling bowl wall 1306 also includes a plurality of protrusions 1312 (e.g., ribs, etc.). Each protrusion 1312 protrudes into the sampling bowl cavity 1308. As a result, exhaust gas flowing within the sampling bowl cavity 1308 is caused to flow around the protrusion 1312. The protrusion 1312 can help to reduce swirl of the exhaust gas within the sampling bowl cavity 1308, which can increase the accuracy of the determination facilitated by the outlet sensor 168.

[0160] The sampling bowl 1302 also includes a sampling bowl support flange 1314 (e.g., a bracket, etc.). The sampling bowl support flange 1314 is adjacent to the sampling bowl wall 1306 and is separated from the outlet housing body 278 by the sampling bowl wall 1306. In some embodiments, the sampling bowl support flange 1314 is disposed along a first plane and the housing flange 1304 is disposed along a second plane parallel to the first plane.

[0161] The outlet sampling system 166 also includes a sampling ring 1316 (e.g., a guide, etc.). The sampling ring 1316 cooperates with the sampling bowl 1302 to define a sampling ring cavity 1318 (e.g., a gap, etc.). As explained in more detail herein, the sampling ring cavity 1318 is configured to receive exhaust gas from within the outlet housing body 278 and facilitate sampling of the exhaust gas by the outlet sensor 168 by providing the exhaust gas to the sampling bowl cavity 1308.

[0162] The sampling ring 1316 includes a sampling ring support flange 1320 (eg, a bracket, etc.). The sampling ring support flange 1320 is coupled to the sampling bowl support flange 1314. The sampling ring support flange 1320 is supported above the outlet housing body 278 by the sampling bowl wall 1306.

[0163] The sampling ring 1316 also includes a sampling ring inlet flange 1322 (e.g., a wall, etc.). The sampling ring inlet flange 1322 is adjacent to the sampling ring support flange 1320. The sampling ring inlet flange 1322 extends from the sampling ring support flange 1320 away from the sampling bowl support flange 1314. In some embodiments, the sampling ring inlet flange 1322 is separated from the sampling ring support flange 1320 at an obtuse angle. For example, the sampling ring inlet flange 1322 can be separated from the sampling ring support flange 1320 by an angle approximately in the range of 120 degrees (°) to 170 degrees (inclusive).

[0164] The sampling ring 1316 also includes a plurality of sampling ring inlet holes 1324 (e.g., holes, windows, etc.). Each sampling ring inlet hole 1324 is disposed on the sampling ring inlet flange 1322 and is configured to facilitate supplying exhaust gas through the sampling ring inlet flange 1322 into the sampling ring cavity 1318. The sampling ring inlet holes 1324 are disposed around (e.g., circumferentially around, etc.) the outlet housing fitting axis ω. For example, the sampling ring inlet holes 1324 can be disposed around the outlet housing fitting axis ω within an angular range approximately equal to 360°. In some embodiments, the sampling ring inlet holes 1324 are disposed around only a portion of the sampling ring inlet flange 1322. For example, the sampling ring inlet holes 1324 can be disposed around the outlet housing fitting axis ω within an angular range of approximately 180° to 270°.

[0165] The sampling ring 1316 may include various numbers of sampling ring inlet holes 1324. For example, the sampling ring 1316 may include a number of sampling ring inlet holes 1324 in the range of approximately 10 to 30. The sampling ring 1316 may also include 10 or fewer sampling ring inlet holes 1324. The sampling ring inlet holes 1324 may be arranged in rows along the sampling ring inlet flange 1322. For example, the sampling ring inlet holes 1324 may be arranged in two or more staggered rows.

[0166] By selecting the diameter of each sampling loop inlet hole 1324, the flow of exhaust gas to the outlet sensor 168 can be controlled. For example, by reducing the diameter of each sampling loop inlet hole 1324, less exhaust gas can be provided to the outlet sensor 168, which may be desirable (e.g., to facilitate desired operation of the outlet sensor 168, etc.). In various embodiments, the diameter of all sampling loop inlet holes 1324 is the same. For example, the sampling loop inlet holes 1324 can all have a diameter of 0.50 inches. In other embodiments, each sampling loop inlet hole 1324 has a diameter approximately in the range of 0.0787 inches (e.g., 2 millimeters, etc.) to 0.591 inches (e.g., 15 millimeters, etc.), inclusive.

[0167] The sampling loop inlet apertures 1324 may be circular, square, rectangular, hexagonal, pentagonal, triangular, or other similar shapes. In addition, the sampling loop inlet apertures 1324 may all have the same shape (e.g., all sampling loop inlet apertures 1324 are circular, etc.) or may be different shapes (e.g., some sampling loop inlet apertures 1324 are circular, while other sampling loop inlet apertures 1324 are rectangular, etc.). In some embodiments, the sampling loop inlet apertures 1324 are formed as louvers (e.g., portions of the sampling loop 1316 extend across portions of each sampling loop inlet aperture 1324, etc.).

[0168] The sampling loop 1316 also includes a barrier flange 1326 (eg, a wall, etc.) The barrier flange 1326 is adjacent to the sampling loop inlet flange 1322 and extends over the entirety of the sampling loop inlet flange 1322 .

[0169] The sampling ring 1316 also includes a sampling ring insert flange 1328 (eg, an annular flange, etc.). The sampling ring insert flange 1328 is adjacent to the blocking flange 1326. In various embodiments, the sampling ring insert flange 1328 extends from the blocking flange 1326 in a direction parallel to the direction in which the sampling ring support flange 1320 extends.

[0170] The sampling bowl support flange 1314 defines a support flange hole 1329 (e.g., an eyelet, an opening, etc.). The sampling loop insert flange 1328 is received within the support flange hole 1329. The sampling loop insert flange 1328 can be coupled to the sampling bowl support flange 1314 around at least a portion of the support flange hole 1329. For example, the sampling loop insert flange 1328 can be welded to the sampling bowl support flange 1314 around the entire support flange hole 1329. In another example, the sampling loop insert flange 1328 is press-fit (e.g., friction-fit, etc.) within the support flange hole 1329.

[0171] Similarly, the sampling loop insert flange 1328 defines a sampling loop insertion hole 1330 (e.g., an eyelet, an opening, etc.). The outlet housing fitting 280 is received within the sampling loop insertion hole 1330. The outlet housing fitting 280 can be coupled to the sampling loop insert flange 1328 around at least a portion of the sampling loop insertion hole 1330. For example, the outlet housing fitting 280 can be welded to the sampling loop insert flange 1328 around the entire sampling loop insertion hole 1330. In another example, the outlet housing fitting 280 is press-fit (e.g., friction-fit, etc.) within the sampling loop insertion hole 1330.

[0172] The sampling ring 1316 also includes a connector 1332 (e.g., a runner, etc.). The connector 1332 is configured to provide exhaust gas from the sampling ring cavity 1318 to the sampling bowl cavity 1308, where the outlet sensor 168 samples the exhaust gas. The connector 1332 includes a connector wall 1334 (e.g., a panel, etc.). The connector wall 1334 is adjacent to the blocking flange 1326 and extends toward the outlet housing body 278. The connector wall 1334 is coupled to one of the supports 1310.

[0173] The sampling bowl wall 1306 also includes a connector hole 1336 (eg, an opening, a window, a slot, etc.). The connector hole 1336 is disposed on the support 1310 to which the connector wall 1334 is coupled. The connector hole 1336 facilitates the flow of exhaust gas through the sampling bowl wall 1306. In various embodiments, as Fig.15 As shown, connector hole 1336 is aligned with outlet sensor 168.

[0174] The connector wall 1334 defines a connector cavity 1338 (e.g., a void, etc.). The connector cavity 1338 is adjacent to the sampling ring cavity 1318 and the sampling bowl cavity 1308. Exhaust gas first flows into the sampling ring cavity 1318 (e.g., via one of the sampling ring inlet holes 1324), then flows into the connector cavity 1338, and then flows into the sampling bowl cavity 1308 (e.g., via the connector hole 1336).

[0175] After flowing into the sampling bowl cavity 1308, the exhaust gas can be sampled by the outlet sensor 168. The outlet housing fitting 280 includes a fitting aperture 1340 (e.g., an opening, a window, a slot, etc.). The fitting aperture 1340 facilitates the flow of exhaust gas from the sampling bowl cavity 1308 into the outlet housing fitting 280. In various embodiments, the fitting aperture 1340, the connector aperture 1336, and the outlet sensor 168 are aligned. As a result, the exhaust gas can flow directly from the connector aperture 1336 through the outlet sensor 168 to the fitting aperture 1340.

[0176] In some applications, exhaust gas flowing through the outlet housing fitting 280 (e.g., without flowing through the sampling loop inlet hole 1324) may create a vacuum at the fitting hole 1340, which may draw exhaust gas from the sampling bowl cavity 1308 into the outlet housing fitting 280. In this manner, exhaust gas may be sampled by the outlet sensor 168 while minimizing exposure of the outlet sensor 168 to the exhaust gas and thereby maintaining desired operation of the outlet sensor 168 for a longer period of time. As a result, the outlet sampling system 166 is more desirable than other systems.

[0177] In some embodiments, the sampling bowl 1302 and / or the sampling ring 1316 are made by a metal forming process, such as a stamping process. This can make the sampling bowl 1302 and / or the sampling ring 1316 more economical to produce, and therefore more desirable, than other components that require the use of more complex or expensive manufacturing processes.

[0178] V. Second Example Outlet Sampling System Figures 17 to 21 The outlet sampling system 166 is illustrated according to various embodiments. As described above, the outlet sampling system 166 includes the outlet housing fitting 280. The exhaust aftertreatment system 100 also includes a flange coupling 1700 (eg, a joint, etc.), such as Fig. 20 and Fig.21 The flange coupler 1700 is coupled to the outlet housing body 278 and is configured to receive the outlet housing fitting 280 so that the outlet housing fitting 280 can be coupled to the flange coupler 1700. In some embodiments, a band clamp is placed around the flange coupler 1700, the outlet housing fitting 280 is inserted into the flange coupler 1700, and the flange coupler 1700 is tightened onto the outlet housing fitting 280. In some applications, the flange coupler 1700 is welded to the outlet housing fitting 280.

[0179] The outlet sampling system 166 also includes a cover 1702. The cover 1702 is coupled to the outlet housing body 278. In various embodiments, the cover 1702 is coupled to the outlet housing body 278 around a flange coupling 1700. The cover 1702 cooperates with the outlet housing body 278 to define a cover cavity 1704 (e.g., a void, etc.). As explained in more detail herein, the cover cavity 1704 provides a space within which additional components of the outlet sampling system 166 can be located and used to sample the exhaust gas.

[0180] The outlet sampling system 166 also includes a sampling ring 1706 (eg, guide, etc.). The sampling ring 1706 is coupled to the cover 1702. The sampling ring 1706 may also be coupled to the outlet housing body 278. A portion of the sampling ring 1706 is located within the cover cavity 1704.

[0181] Sampling ring 1706 defines a sampling ring cavity 1708 (eg, a void, etc.) As explained in greater detail herein, sampling ring cavity 1708 is configured to receive exhaust gas from within outlet housing body 278 and facilitate sampling of the exhaust gas by outlet sensor 168 by providing the exhaust gas to sampling bowl cavity 1308 .

[0182] The sampling ring 1706 includes a sampling ring floor flange 1709. The sampling ring floor flange 1709 is in a facing relationship with the outlet housing body 278. In some embodiments, at least a portion of the sampling ring floor flange 1709 is coupled to the outlet housing body 278. The sampling ring 1706 also includes a sampling ring base flange 1710. The sampling ring base flange 1710 is adjacent to the sampling ring floor flange 1709 and extends away from the outlet housing body 278. In some embodiments, at least a portion of the sampling ring base flange 1710 is coupled to the cover 1702.

[0183] The sampling loop 1706 also includes a sampling loop support flange 1711 (eg, a bracket, etc.). The sampling loop support flange 1711 abuts the sampling loop base flange 1710. The sampling loop support flange 1711 is coupled to the cover 1702. The sampling loop support flange 1711 is supported by the cover 1702 above the outlet housing body 278.

[0184] The sampling ring 1706 also includes a sampling ring inlet flange 1712 (e.g., a wall, etc.). The sampling ring inlet flange 1712 is adjacent to the sampling ring support flange 1711. The sampling ring inlet flange 1712 extends away from the sampling ring support flange 1711 away from the cover 1702. In some embodiments, the sampling ring inlet flange 1712 is separated from the sampling ring support flange 1711 at an obtuse angle. For example, the sampling ring inlet flange 1712 can be separated from the sampling ring support flange 1711 by an angle approximately in the range of 120° to 170° (including 120° and 170°).

[0185] The sampling ring 1706 also includes a plurality of sampling ring inlet holes 1714 (e.g., holes, windows, etc.). Each sampling ring inlet hole 1714 is disposed on the sampling ring inlet flange 1712 and is configured to facilitate supplying exhaust gas into the sampling ring cavity 1708 through the sampling ring inlet flange 1712. The sampling ring inlet holes 1714 are disposed around (e.g., circumferentially around, etc.) the outlet housing fitting axis ω. For example, the sampling ring inlet holes 1714 may be disposed around the outlet housing fitting axis ω within an angular range approximately equal to 360°. In some embodiments, the sampling ring inlet holes 1714 are disposed around only a portion of the sampling ring inlet flange 1712. For example, the sampling ring inlet holes 1714 may be disposed around the outlet housing fitting axis ω within an angular range of approximately 180° to 270°.

[0186] The sampling ring 1706 can include various numbers of sampling ring inlet holes 1714. For example, the sampling ring 1706 can include a number of sampling ring inlet holes 1714 in the range of approximately 10 to 30 (inclusive). The sampling ring 1706 can also include 10 or fewer sampling ring inlet holes 1714. The sampling ring inlet holes 1714 can be arranged in rows along the sampling ring inlet flange 1712. For example, the sampling ring inlet holes 1714 can be arranged in two or more staggered rows.

[0187] By selecting the diameter of each sampling loop inlet hole 1714, the flow of exhaust gas to the outlet sensor 168 can be controlled. For example, by reducing the diameter of each sampling loop inlet hole 1714, less exhaust gas can be provided to the outlet sensor 168, which may be desirable (e.g., to facilitate desired operation of the outlet sensor 168, etc.). In various embodiments, the diameter of all sampling loop inlet holes 1714 is the same. For example, the sampling loop inlet holes 1714 can all have a diameter of 0.50 inches. In other embodiments, each sampling loop inlet hole 1714 has a diameter approximately in the range of 0.0787 inches (e.g., 2 millimeters, etc.) to 0.591 inches (e.g., 15 millimeters, etc.), inclusive.

[0188] The sampling loop inlet apertures 1714 may be circular, square, rectangular, hexagonal, pentagonal, triangular, or other similar shapes. In addition, the sampling loop inlet apertures 1714 may all have the same shape (e.g., all sampling loop inlet apertures 1714 are circular, etc.) or may be different shapes (e.g., some sampling loop inlet apertures 1714 are circular, while other sampling loop inlet apertures 1714 are rectangular, etc.). In some embodiments, the sampling loop inlet apertures 1714 are formed as louvered apertures (e.g., a portion of the sampling loop 1706 extends across a portion of each sampling loop inlet aperture 1714, etc.).

[0189] The sampling loop 1706 also includes a sampling loop blocking flange 1716 (eg, a wall, etc.) The sampling loop blocking flange 1716 is adjacent to the sampling loop inlet flange 1712 and extends over the entire sampling loop inlet flange 1712 and the entire sampling loop bottom flange 1709 .

[0190] The sampling ring 1706 also includes a sampling ring insert flange 1718 (e.g., annular flange, etc.). The sampling ring insert flange 1718 is adjacent to the sampling ring stop flange 1716 and the sampling ring insert base plate flange 1709. In various embodiments, the sampling ring insert flange 1718 extends from the sampling ring stop flange 1716 in a direction parallel to the direction in which the sampling ring support flange 1711 extends and / or the direction in which the sampling ring base flange 1710 extends.

[0191] The sampling loop insert flange 1718 defines a sampling loop insertion hole 1720 (e.g., an eyelet, an opening, etc.). The outlet housing fitting 280 is received in the sampling loop insertion hole 1720. The outlet housing fitting 280 can be coupled to the sampling loop insert flange 1718 around at least a portion of the sampling loop insertion hole 1720. For example, the outlet housing fitting 280 can be welded to the sampling loop insert flange 1718 around the entire sampling loop insertion hole 1720. In another example, the outlet housing fitting 280 is press-fit (e.g., friction-fit, etc.) in the sampling loop insertion hole 1720.

[0192] The sampling loop 1706 also includes a connector 1722 (eg, a flow channel, etc.). The connector 1722 defines a connector cavity 1723 (eg, a gap, etc.) in which the exhaust flows. The connector 1722 is configured such that the connector cavity 1723 receives the exhaust from the sampling loop cavity 1708 .

[0193] As explained in more detail herein, connector 1722 is configured to provide exhaust gas from sampling loop cavity 1708 to a location where the exhaust gas is sampled by outlet sensor 168. This location is spaced apart from outlet housing fitting 280 so as to separate outlet sensor 168 from the exhaust gas flowing within outlet housing fitting 280, which ensures that outlet sensor 168 maintains ideal operation.

[0194] Connector 1722 includes connector outer flange 1724. Connector outer flange 1724 abuts sampling loop base flange 1710 and cover 1702. Connector outer flange 1724 may also abut sampling loop support flange 1711. Connector 1722 also includes connector inner flange 1726. Connector inner flange 1726 abuts sampling loop base flange 1710 and cover 1702. Connector inner flange 1726 may also abut sampling loop support flange 1711.

[0195] The connector 1722 also includes a connector bottom plate flange 1728. The connector bottom plate flange 1728 is in a facing relationship with the outlet housing body 278. In some embodiments, at least a portion of the connector bottom plate flange 1728 is coupled to the outlet housing body 278. As explained in more detail herein, the connector bottom plate flange 1728 is configured to allow exhaust gas to flow both toward the outlet housing body 278 and away from the outlet housing body 278.

[0196] The connector base plate flange 1728 includes an outlet flange inlet portion 1730 (e.g., an upstream portion, etc.). The outlet flange inlet portion 1730 can cause exhaust gases to flow toward the outlet housing body 278. The outlet flange inlet portion 1730 is adjacent to the sampling loop base flange 1710, the cover 1702, the connector outer flange 1724, and the connector inner flange 1726. As explained in more detail herein, the outlet flange inlet portion 1730 facilitates providing the exhaust gases to the outlet sensor 168.

[0197] The connector base flange 1728 also includes a sensor boss 1732 (e.g., a groove, etc.). The sensor boss 1732 is adjacent to the outlet flange inlet portion 1730, the connector outer flange 1724, and the connector inner flange 1726. In various embodiments, the sensor boss 1732 is aligned with a portion of the outlet flange inlet portion 1730 (e.g., the outlet portion, etc.) so that when the exhaust gas flows from the outlet flange inlet portion 1730 to the sensor boss 1732, the exhaust gas does not substantially change direction.

[0198] Sensor boss 1732 includes at least one sensor hole 1734 (eg, eyelet, etc.). Each sensor hole 1734 is configured to receive a sensor, such as outlet sensor 168. Outlet sensor 168 samples exhaust gas within sensor boss 1732, rather than within outlet housing fitting 280.

[0199] In some embodiments, exhaust aftertreatment system 100 includes a second outlet sensor in addition to outlet sensor 168. In these embodiments, second outlet sensor is received within one sensor aperture 1734 while outlet sensor 168 is received within another sensor aperture 1734.

[0200] The connector base flange 1728 also includes an outlet flange outlet portion 1735 (eg, downstream portion, etc.). The outlet flange outlet portion 1735 abuts the sensor boss 1732, the sampling loop base flange 1710, the cover 1702, the connector outer flange 1724, and the connector inner flange 1726. The outlet flange outlet portion 1735 facilitates providing exhaust from the outlet sensor 168.

[0201] In various embodiments, such as Fig.19As shown, outlet flange outlet portion 1735 is elevated relative to sensor boss 1732. As a result, when exhaust flows from sensor boss 1732 to sensor boss 1732, the exhaust is caused to flow away from outlet housing body 278. In this manner, outlet flange outlet portion 1735 can prevent exhaust from flowing through connector cavity 1723, which can enhance the ability of outlet sensor 168 to sample the exhaust. For example, by preventing exhaust from flowing through connector cavity 1723, the residence time of the exhaust within connector cavity 1723 can be increased, which can enhance the ability of outlet sensor 168 to sample the exhaust.

[0202] The connector 1722 also includes a connector stop flange 1736. The connector stop flange 1736 is spaced apart from the outlet housing body 278 by the connector outer flange 1724, the connector inner flange 1726, and the connector bottom flange 1728. As explained in more detail herein, the connector stop flange 1736 is configured to allow exhaust gases to flow both toward and away from the outlet housing body 278.

[0203] Connector barrier flange 1736 includes barrier flange inlet portion 1738 (e.g., upstream portion, etc.). Barrier flange inlet portion 1738 can cause exhaust to flow toward outlet housing body 278. Barrier flange inlet portion 1738 abuts sampling loop barrier flange 1716, connector outer flange 1724, and connector inner flange 1726. As explained in more detail herein, barrier flange inlet portion 1738 facilitates providing exhaust to outlet sensor 168.

[0204] The connector blocking flange 1736 also includes a blocking flange rib 1740 (eg, a groove, etc.) The blocking flange rib 1740 abuts the blocking flange inlet portion 1738, the connector outer flange 1724, and the connector inner flange 1726. The blocking flange rib 1740 protrudes toward the sensor boss 1732 between the sensor holes 1734.

[0205] like Fig. 20 As shown, the blocking flange rib 1740 includes an inlet surface 1742 (e.g., a face, etc.). The blocking flange rib 1740 extends toward the sensor boss 1732 so that the inlet surface 1742 blocks the exhaust gas from flowing within the connector cavity 1723. As a result, when the exhaust gas flows along the inlet surface 1742, the exhaust gas is caused to flow toward the outlet housing body 278. In this manner, the blocking flange rib 1740 can direct the exhaust gas flow through the outlet sensor 168 in a desired manner, which can enhance the ability of the outlet sensor 168 to sample the exhaust gas within the connector cavity 1723. For example, by directing the exhaust gas flow toward the outlet housing body 278, the residence time of the exhaust gas within the connector cavity 1723 can be increased, which can enhance the ability of the outlet sensor 168 to sample the exhaust gas.

[0206] The barrier flange rib 1740 also includes an outlet surface 1744 (e.g., a face, etc.). The barrier flange rib 1740 extends away from the sensor boss 1732 so that the outlet surface 1744 does not assist the exhaust gas flow within the connector cavity 1723. As a result, when the exhaust gas flows along the outlet surface 1744, the exhaust gas is caused to flow away from the outlet housing body 278. The degree of inclination of the outlet surface 1744 can be significantly less than the degree of inclination of the inlet surface 1742. For example, the inlet surface 1742 can be approximately orthogonal to the sensor boss 1732, and the outlet surface 1744 can be separated from the sensor boss 1732 by an angle approximately in the range of 20° to 60° (including 20° and 60°).

[0207] The connector barrier flange 1736 also includes a barrier flange outlet portion 1746 (eg, downstream portion, etc.). The barrier flange outlet portion 1746 abuts the barrier flange rib 1740, the connector outer flange 1724, the connector inner flange 1726, and the sampling loop barrier flange 1716. The barrier flange outlet portion 1746 facilitates providing exhaust from the outlet sensor 168.

[0208] The outlet housing fitting 280 includes a fitting aperture 1748 (e.g., an opening, a window, a slot, etc.). The fitting aperture 1748 facilitates the flow of exhaust gas from the connector cavity 1723 into the outlet housing fitting 280. For example, exhaust gas flowing through the outlet housing fitting 280 (e.g., not flowing through the sampling loop inlet aperture 1714) can create a vacuum at the fitting aperture 1748, which can draw exhaust gas from the sampling bowl cavity 1308 into the outlet housing fitting 280. In this manner, exhaust gas can be sampled by the outlet sensor 168 while minimizing the exposure of the outlet sensor 168 to the exhaust gas and thereby maintaining the desired operation of the outlet sensor 168 over a long period of time. As a result, the outlet sampling system 166 is more desirable than other systems.

[0209] In some embodiments, the cap 1702, sampling ring 1706, and / or connector 1722 are integrally formed and made by a metal casting process, such as investment casting, sand casting, or another casting process. This can make the production of the cap 1702, sampling ring 1706, and / or connector 1722 more economical, and therefore more desirable, than other components that require the use of more complex or expensive manufacturing processes.

[0210] In some embodiments, the cover 1702, the sampling ring 1706, and / or the connector 1722 are integrally formed via additive manufacturing. For example, the cover 1702, the sampling ring 1706, and / or the connector 1722 can be integrally formed using 3D printing, selective laser sintering, selective laser melting (SLM), direct metal laser sintering (DMLS), electron beam melting (EBM), ultrasonic additive manufacturing (UAM), fused deposition modeling (FDM), fused filament fabrication (FFF), stereolithography (SLA), material jetting, binder jetting, or other similar processes. As described above, when portions of the cover 1702, portions of the sampling ring 1706, and / or portions of the connector 1722 are formed and coupled together as part of a single manufacturing step (e.g., 3D printing, selective laser sintering, SLM, DMLS, EBM, UAM, FDM, FFF, SLA, material jetting, adhesive jetting, etc.), the cover 1702, the sampling ring 1706, and / or the connector 1722 are integrally formed to produce a one-piece or unitary structure, i.e., the cover 1702, the sampling ring 1706, and / or the connector 1722 cannot be disassembled without at least partially destroying the cover 1702, the sampling ring 1706, and / or the connector 1722. For example, portions of the cover 1702, portions of the sampling ring 1706, and / or portions of the connector 1722: (i) cannot be separated from each other (e.g., portions of the cover 1702, the sampling ring 1706, and / or the connector 1722 cannot be separated from the cover 1702, the sampling ring 1706, and / or the connector 1722 without destroying the cover 1702, the sampling ring 1706, and / or the connector 1722, etc.); (ii) are not formed separately from each other (e.g., portions of the cover 1702, the sampling ring 1706, and / or the connector 1722 are formed simultaneously, portions of the cover 1702, the sampling ring 1706, and / or the connector 1722 are formed as a single component in a single process, etc.); and (iii) there is no gap or joint along the boundary between adjacent portions (e.g., portions that share a boundary, etc.) of the cover 1702, the sampling ring 1706, and / or the connector 1722.

[0211] VI. Construction of Example Embodiments As used herein, area is measured along a plane (e.g., a two-dimensional plane, etc.) unless otherwise specified. The area may vary in directions not disposed along the plane (e.g., along a direction orthogonal to the plane, etc.) unless otherwise specified.

[0212] 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 the context of separate implementations in this specification may also be implemented in combination in a single implementation. On the contrary, the various features described in the context of a single implementation may also be implemented individually or in any suitable sub-combination in multiple implementations. Moreover, although features may be described as working in certain combinations and even initially claimed as such, one or more features from the claimed combination may be deleted from the combination in some cases, and the claimed combination may involve a sub-combination or a deformation of a sub-combination.

[0213] As utilized herein, the terms "substantially," "approximately," "approximately," 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.

[0214] 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.

[0215] As used herein, the term "fluidically coupled to" and the like refers to two components or objects having a path formed between the two components or objects in which a fluid (e.g., air, reductant, air-reductant mixture, etc.) can flow, with or without an intervening component or object. Examples of fluid couplings or configurations for achieving fluid communication may include pipes, channels, or any other suitable components for achieving the flow of a fluid from one component or object to another component or object.

[0216] It is important to note that the construction and arrangement of the various systems shown in the various example embodiments are merely illustrative and non-restrictive in nature. All changes and modifications within the spirit and / or scope of the described embodiments are expected 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 expressly stated to the contrary.

[0217] In addition, in the context of an enumeration of elements, the term "or" is used in its inclusive sense (rather than its exclusive meaning) so that when used to connect a series of elements, the term "or" means one, some, or all of the elements in the enumeration. Unless otherwise explicitly stated, 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. 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 specified, 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.

[0218] 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, the range of values ​​(e.g., W1 to W2, etc.) does not necessarily require that intermediate values ​​be included in the range of values ​​(e.g., W1 to W2 may only include W1 and W2.), unless otherwise indicated.

Claims

1. An exhaust aftertreatment system, comprising: outlet housing body; An outlet sampling system, the outlet sampling system comprising: -- a sampling bowl cooperating with the outlet housing body to define a sampling bowl cavity, and a sampling ring coupled to the sampling bowl and defining a sampling ring cavity, the sampling ring defining a plurality of sampling ring inlet apertures configured to receive a portion of the exhaust gas from within the outlet housing body, the sampling ring configured to provide the portion of the exhaust gas to the sampling ring cavity, the sampling ring cavity providing communication with the sampling bowl exhaust gas.

2. The exhaust aftertreatment system of claim 1, further comprising an outlet sensor coupled to the outlet housing body so as to have a portion disposed within the sampling bowl, the outlet sensor being configured to sample exhaust gas in the sampling bowl.

3. The exhaust aftertreatment system according to claim 1, wherein: The sampling bowl comprises: A sampling bowl wall includes a plurality of supports adjacent the sampling bowl, the sampling bowl wall defining an aperture disposed on one of the supports and configured to provide exhaust gas received from the sampling loop.

4. The exhaust aftertreatment system of claim 3 further comprising an outlet sensor coupled to the outlet housing body, wherein the aperture is aligned with the outlet sensor such that exhaust gas flows through the outlet sensor and into an outlet housing body fitting. 5 . The exhaust aftertreatment system of claim 1 , further comprising an outlet housing fitting defining an outlet housing fitting axis, wherein each of the sampling bowl and the sampling ring is centered about the outlet housing fitting axis.

6. The exhaust aftertreatment system according to claim 1, further comprising: A connector is adjacent the sampling ring and extends along the sampling bowl toward the outlet housing, the connector being configured to provide exhaust gas from the sampling ring cavity to the sampling bowl cavity.

7. The exhaust aftertreatment system according to claim 1, wherein: The sampling bowl includes a plurality of protrusions protruding within the sampling bowl cavity, the plurality of protrusions being configured to reduce swirl of exhaust gas within the sampling bowl cavity.

8. An exhaust aftertreatment system comprising: outlet housing body; Outlet housing accessories; and An outlet sampling system, the outlet sampling system comprising: a sampling ring defining a sampling ring cavity and a plurality of sampling ring inlet apertures configured to receive a portion of the exhaust gas from the outlet housing body and provide the portion of the exhaust gas to the sampling ring cavity, and -- A connector defining a connector cavity and comprising a connector bottom plate flange, the connector bottom plate flange comprising: a connector base plate flange upstream portion, the connector base plate flange upstream portion being configured to cause exhaust gas to flow in a direction toward the outlet housing body, a sensor boss abutting an upstream portion of the connector base flange, the sensor boss defining a sensor aperture, and A connector base plate flange downstream portion is adjacent to the sensor boss and is configured to flow exhaust gas in a direction away from the outlet housing body and provide the exhaust gas to the outlet housing fitting.

9. The exhaust aftertreatment system according to claim 8, wherein: The connector is coupled to the outlet housing body.

10. The exhaust aftertreatment system according to claim 8, wherein: The sensor boss is aligned with the upstream portion of the connector base plate flange to facilitate exhaust gas to flow from the sampling ring cavity to the sensor boss.

11. The exhaust aftertreatment system according to claim 8, wherein: The downstream portion of the connector flange is elevated relative to the sensor boss to prevent exhaust gas from flowing through the connector cavity.

12. The exhaust aftertreatment system according to claim 8, wherein: The connector further comprises: A barrier flange rib extends toward the sensor boss and is configured to direct exhaust gas flow through the outlet sensor.

13. The exhaust aftertreatment system according to claim 12, wherein: The barrier flange rib includes an inlet surface having a first degree of inclination and an outlet surface having a second degree of inclination.

14. The exhaust aftertreatment system according to claim 13, wherein: The second degree of inclination is less than the first degree of inclination, causing exhaust gases to flow away from the outlet housing body.

15. The exhaust aftertreatment system according to claim 13, wherein: The inlet surface is normal to the sensor boss.

16. The exhaust aftertreatment system according to claim 13, wherein: The outlet surface extends at an angle in a range between 20 degrees and 60 degrees relative to the sensor boss.

17. The exhaust aftertreatment system according to claim 8, wherein: The sensor hole is a first sensor hole, and the sensor boss defines a second sensor hole adjacent to the first sensor hole, and wherein the exhaust aftertreatment system includes a first sensor received by the first sensor hole and a second sensor received by the second sensor hole, each of the first sensor and the second sensor being configured to sample exhaust gas in the connector cavity.

18. The exhaust aftertreatment system according to claim 8, wherein: The sampling loop is coupled to the outlet housing body.

19. The exhaust aftertreatment system of claim 18, wherein: The outlet housing fitting is centered about an outlet housing fitting axis; and The sampling ring inlet aperture is disposed circumferentially about the outlet housing fitting axis.

20. The exhaust aftertreatment system of claim 8, further comprising a cover coupled to the outlet housing body and defining a cover cavity, wherein a portion of the sampling loop is positioned within the cover cavity.

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