Exhaust aftertreatment system including mixer with ejector cone

Abstract

An exhaust aftertreatment system includes an intake gas conduit, a dosing module, and a mixer. The introduction conduit is centered on a conduit axis. The dosing module is coupled to the introduction conduit and includes an injector. An injector is configured to provide hydrocarbon fluid into the introduction conduit and is defined by an injection axis. The mixer includes a mixer body, a first orifice, an injector plate, and an injector cone. A mixer body is disposed within the introduction conduit and is configured to receive exhaust gas and hydrocarbon fluid. A first orifice extends through the mixer body and is configured to promote exhaust gas flow through the mixer body. The injector plate is coupled to the mixer body along the first orifice. A portion of the injector plate is angularly away from the mixer body at a first opening angle. An injector cone is positioned on the injector plate. The injector cone includes an injection orifice configured to promote hydrocarbon fluid flow through the injector cone and the injector plate.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 403,349, filed on September 2, 2022, the entire disclosure of which is hereby incorporated by reference into this application. Technical Field

[0003] The present disclosure generally relates to exhaust aftertreatment systems for internal combustion engines.

[0004] background

[0005] For internal combustion engine systems, it may be desirable to treat the exhaust gas generated by the combustion of fuel in the internal combustion engine. The exhaust gas may be treated using an aftertreatment system. One method that may be implemented in an aftertreatment system is to dispense a reductant to the exhaust gas and pass the exhaust gas and the reductant through a catalyst component. It may be desirable to swirl the exhaust gas and the reductant upstream of the catalyst component in order to increase mixing of the exhaust gas and the reductant. However, in some applications, such swirl may not provide adequate mixing.

[0006] Overview

[0007] In one embodiment, an exhaust gas aftertreatment system includes an inlet gas conduit, a distribution module, and a mixer. The inlet conduit is centered on the conduit axis. The distribution module is connected to the inlet conduit and includes an ejector. The ejector is configured to provide a hydrocarbon fluid into the inlet conduit and is defined by an injection axis. The mixer includes a mixer body, a first orifice, an ejector plate, and an ejector cone. The mixer body is disposed in the inlet conduit and is configured to receive exhaust gas and hydrocarbon fluid. The first orifice extends through the mixer body and is configured to promote exhaust gas to flow through the mixer body. The ejector plate is connected to the mixer body along the first orifice. A portion of the ejector plate is angled away from the mixer body at a first opening angle. The ejector cone is positioned on the ejector plate. The ejector cone includes an ejection orifice configured to promote hydrocarbon fluid to flow through the ejector cone and the ejector plate.

[0008] In one embodiment, an exhaust gas aftertreatment system includes an inlet gas conduit, a distribution module, a mixer, an inlet flange and a louver. The inlet conduit is centered on the conduit axis. The distribution module is coupled to the inlet conduit and includes an ejector. The ejector is configured to provide a hydrocarbon fluid into the inlet conduit and is defined by an injection axis. The mixer includes a mixer body, a first orifice, an ejector plate and an ejector cone. The mixer body is disposed in the inlet conduit and is configured to receive exhaust gas and hydrocarbon fluid. The first orifice extends through the mixer body and is configured to promote exhaust gas to flow through the mixer body. The ejector plate is coupled to the mixer body along the first orifice. A portion of the ejector plate is angled away from the mixer body at a first opening angle. The ejector cone is positioned on the ejector plate. The ejector cone includes an ejection orifice configured to promote hydrocarbon fluid to flow through the ejector cone and the ejector plate. The inlet flange includes an inlet flange orifice and a louver. The inlet flange orifice extends through the inlet flange. The inlet flange aperture is configured to promote exhaust gas flow through the inlet flange and into the mixer body. The louver extends from the inlet flange into the mixer body along a portion of the inlet flange aperture. The louver is configured to receive exhaust gas flowing through the inlet flange aperture.

[0009] In another embodiment, a mixer for an exhaust aftertreatment system includes a mixer body centered on a central axis of the mixer body and configured to receive exhaust gas and hydrocarbon fluids. The mixer also includes a first orifice extending through the mixer body. The first orifice is configured to promote exhaust gas flow through the mixer body. The mixer includes a first guide plate, which is connected to the mixer body along a portion of the first orifice and is centered on the central axis of the first guide plate. The first guide plate includes a first guide plate first flange and a first guide plate second flange, and the first guide plate first flange and the first guide plate second flange are configured to connect a portion of the first guide plate to the mixer body. The first guide plate also includes a first guide plate panel adjacent to each of the first guide plate second flanges. The first guide plate panel forms a first guide plate flow orifice. The first guide plate also includes a first guide plate sidewall adjacent to the first guide plate first flange and the first guide plate panel. The first guide plate sidewall is configured to promote flow between the first guide plate panel and the mixer body. The mixer also includes a first guide plate tab positioned within and along a portion of the second aperture and adjacent to the first guide plate panel. The first guide plate tab is configured to couple the first guide plate to the mixer body and prevent exhaust gas from flowing along an edge of the first guide plate panel.

[0010] In another embodiment, an aftertreatment system includes a mixer. The mixer includes a mixer body that defines a mixer body cavity. The mixer body is centered on the mixer body central axis and is configured to receive exhaust gas and hydrocarbon fluid. The mixer body is configured to receive exhaust gas and hydrocarbon fluid. The mixer also includes a first orifice, a second orifice, and a third orifice extending through the mixer body. Each of the first orifice, the second orifice, and the third orifice is configured to promote exhaust gas to flow through the mixer body. The mixer also includes an injector plate that is coupled to the mixer body along a portion of the first orifice and centered on a reference axis. The injector plate defines an injector plate orifice that is angled away from the mixer body at a first opening angle. The mixer also includes a first guide plate that is coupled to the mixer body along a portion of the adjacent injector plate of the second orifice. A portion of the first guide plate is angled away from the mixer body at a second opening angle and defines a first guide plate flow orifice. The mixer also includes a second guide plate connected to the mixer body along a portion of a third orifice adjacent to the injector plate, opposite the first guide plate. A portion of the second guide plate is angled away from the mixer body at a third opening angle and defines a second guide plate flow orifice. The aftertreatment system also includes an injector cone positioned on the injector plate. The injector cone includes an injection orifice configured to promote hydrocarbon fluid flow through the injector cone and the injector plate along an injection axis. The first guide plate flow orifice is configured to promote exhaust gas flow into the mixer chamber away from the injection axis, and the second guide plate flow orifice is configured to promote exhaust gas flow into the mixer chamber toward the injection axis plate to promote exhaust gas swirling. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] 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:

[0013] Figure 1 is a cross-sectional view of a portion of an example exhaust aftertreatment system;

[0014] Figure 2 yes Figure 1 A perspective view of a portion of an exhaust aftertreatment system;

[0015] Figure 3 Looking from downstream to upstream Figure 1 A perspective view of a portion of an exhaust aftertreatment system;

[0016] Figure 4 yes Figure 1 A perspective view of a portion of an exhaust aftertreatment system;

[0017] Figure 5 It is taken along plane AA Figure 4 a cross-sectional view of a portion of an exhaust aftertreatment system;

[0018] Figure 6 yes Figure 4 A top view of a portion of an exhaust aftertreatment system;

[0019] Figure 7 yes Figure 4 A perspective view of a portion of an exhaust aftertreatment system;

[0020] Figure 8 yes Figure 4 A perspective view of another portion of the exhaust aftertreatment system;

[0021] Fig. 9 It is taken along plane BB Figure 4 a cross-sectional rear view of a portion of an exhaust aftertreatment system;

[0022] Fig.10 is a cross-sectional rear view of another portion of an exhaust aftertreatment system taken along plane BB according to one embodiment.

[0023] Fig.11 yes Figure 4 A perspective view of a portion of an exhaust aftertreatment system;

[0024] Fig.12 yes Figure 4 A perspective view of a portion of an exhaust aftertreatment system;

[0025] Fig.13 According to an embodiment Figure 4 A front view of a portion of an exhaust aftertreatment system;

[0026] Fig.14 According to an embodiment Figure 4 A front partial transparent view of a portion of an exhaust aftertreatment system;

[0027] Fig.15 According to an embodiment Figure 4 A front partial transparent view of a portion of an exhaust aftertreatment system;

[0028] Fig.16 Looking from upstream to downstream Figure 4 A front partial transparent view of a portion of an exhaust aftertreatment system;

[0029] Fig.17 yes Figure 4 A perspective view of another portion of the exhaust aftertreatment system;

[0030] Fig.18 is a perspective view of another portion of the exhaust aftertreatment system;

[0031] Fig.19 Looking from upstream to downstream Fig.17 A top view of a portion of an exhaust aftertreatment system;

[0032] Fig. 20 It is taken along plane CC Fig.18 a side cross-sectional view of a portion of an exhaust aftertreatment system;

[0033] Fig.21 yes Fig.18 A perspective view of a portion of an exhaust aftertreatment system;

[0034] Fig. 22 yes Fig.18 Another cross-sectional view of a portion of an exhaust aftertreatment system;

[0035] Fig.23 yes Fig.18 a bottom view of a portion of an exhaust aftertreatment system;

[0036] Fig.24 is a perspective view of a portion of an exhaust aftertreatment system according to one embodiment; and

[0037] Fig.25 is a perspective view of an exhaust aftertreatment system according to one embodiment.

[0038] It should be appreciated that for purposes of illustration, the drawings are schematic representations. The drawings are provided for the purpose of illustrating one or more embodiments, with the express understanding that they will not be used to limit the scope or meaning of the claims.

[0039] Detailed Description

[0040] The following is a more detailed description of various concepts related to methods, apparatus, and implementations thereof for treating exhaust gas of an internal combustion engine using an exhaust aftertreatment system (or simply "aftertreatment system"). 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 implementations and applications are provided primarily for illustrative purposes.

[0041] I. Overview

[0042] To promote efficient regeneration of downstream components, it may be desirable to increase the ability to raise the exhaust temperature. This can be accomplished using hydrocarbon fluids. The temperature of the exhaust gas can be increased by increasing the mixing of the hydrocarbon fluid and the exhaust gas in the mixer.

[0043] Various devices may be used to mix the hydrocarbon fluid and the exhaust. For example, a device may be used to cause the exhaust to swirl, and this swirl causes dispersion of hydrocarbons in the exhaust. However, the mixing of the hydrocarbon fluid in the exhaust may be further increased by providing an additional mechanism for causing dispersion of the hydrocarbon fluid in the exhaust so that when the mixture is ignited, the temperature of the exhaust increases.

[0044] Embodiments of the present invention relate to an aftertreatment system, which includes a mixer having a mixer body. The mixer body includes a first orifice and an injector plate coupled to the mixer body along a portion of the first orifice and away from the mixer body at an angle. The mixer body also includes a second orifice and a third orifice and a first guide plate and a second guide plate coupled to the mixer body. When the exhaust gas flows through the inlet flange, the exhaust gas is guided around the mixer and toward the injector plate, the first guide plate and the second guide plate. Each of the injector plate, the first guide plate and the second guide plate promotes the flow through the first orifice, the second orifice and the third orifice, respectively, which causes the exhaust gas to swirl in the mixer body when the hydrocarbon fluid is injected into the exhaust gas. By promoting the flow through the first orifice, the second orifice and the third orifice, the hydrocarbon fluid is dispersed so that when the mixture is ignited, a greater number of hydrocarbons are ignited, which increases the efficiency of the regeneration process. Furthermore, by facilitating the flow of exhaust gas through the first, second, and third apertures by the ejector plate, the first guide plate, and the second guide plate, respectively, back pressure on the system is reduced.

[0045] II. Overview of the Aftertreatment System

[0046] Figures 1 to 3 An aftertreatment system 100 (e.g., a treatment system, etc.) for an internal combustion engine system 101 is depicted. The internal combustion engine system 101 includes 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.). The internal combustion engine system 101 includes a turbocharger 102. The aftertreatment system 100 is configured to treat exhaust gas generated by the internal combustion engine. As explained in more detail herein, the aftertreatment system 100 is configured to facilitate treatment of the exhaust gas. The treatment can facilitate the reduction of undesirable components (e.g., nitrogen oxides (NO x )、Sulfur Oxide(SO x ) etc. The treatment may also or alternatively promote the conversion of various oxidized components of the exhaust (e.g., carbon monoxide (CO), hydrocarbons, etc.) into other components (e.g., CO2, water vapor, etc.). The treatment may also or alternatively promote the removal of particles (e.g., soot, particulate matter, etc.) from the exhaust.

[0047] Aftertreatment system 100 includes an exhaust conduit system 104 (e.g., a line system, a pipe system, etc.). Exhaust conduit system 104 is configured to facilitate the drainage of exhaust gas generated by the internal combustion engine through aftertreatment system 100 and to the atmosphere (e.g., the surrounding environment, etc.). Exhaust conduit system 104 is centered on conduit axis 106 (e.g., conduit axis 106 extends through a center point of exhaust conduit system 104, etc.). As used herein, the term "axis" describes a theoretical line extending through the center of mass (e.g., center of mass, etc.) of an object. An object is centered on an axis. An object does not have to be cylindrical (e.g., a non-cylindrical shape can be centered on an axis, etc.).

[0048] Exhaust duct system 104 includes an intake chamber 108 (e.g., a line, a pipe, etc.). The intake chamber 108 is configured to receive exhaust gas from an internal combustion engine. The intake chamber 108 can receive exhaust gas from a part of the internal combustion engine (e.g., a header on the internal combustion engine, an exhaust manifold on the internal combustion engine, an internal combustion engine, etc.). In some embodiments, the intake chamber 108 is connected (e.g., attached, fixed, welded, fastened, riveted, adhered, bonded, pinned, press-fitted, etc.) to the internal combustion engine. In other embodiments, the intake chamber 108 is formed integrally with the internal combustion engine. As used herein, when two or more elements are formed and connected together as part of a single manufacturing process to produce a single piece or integral structure that cannot be disassembled without at least partially destroying the entire component, the two or more elements are "integrally formed" with each element. The intake chamber 108 can be centered on the duct axis 106 (e.g., the duct axis 106 extends through the center point of the intake chamber 108, etc.). In some embodiments, the inlet chamber 108 may be offset from the conduit axis 106 (eg, the conduit axis 106 extends proximate a center point of the inlet chamber 108 , etc.).

[0049] In some embodiments, the exhaust duct system 104 also includes an inlet duct 109 (e.g., a decomposition housing, a decomposition reactor, a decomposition chamber, a reactor tube, a decomposition tube, a reactor tube, etc.). The inlet duct 109 is configured to receive exhaust gas from the intake chamber 108. In various embodiments, the inlet duct 109 is coupled to the intake chamber 108. For example, the inlet duct 109 can be fastened, welded, riveted or otherwise attached to the intake chamber 108 (e.g., using a band, using a bolt, using a twist-lock fastener, a thread, etc.). In other embodiments, the inlet duct 109 is integrally formed with the intake chamber 108. As used herein, the terms "fastened", "fastening", etc. describe the attachment (e.g., joining, etc.) of two structures so that at the time of "fastening" or after the "fastening" is completed, the separation (e.g., separation, etc.) of the two structures is still possible without destroying or damaging either or both of the two structures. The inlet duct 109 is centered on the duct axis 106 (e.g., the duct axis 106 extends through the center point of the inlet duct 109, etc.). In some embodiments, the inlet conduit 109 is formed by a connection of separate housings and chambers, as described herein.

[0050] The aftertreatment system 100 also includes a reductant fluid delivery system 110. As explained in more detail herein, the reductant fluid delivery system 110 is configured to facilitate the delivery of a reductant fluid (such as a reductant (e.g., diesel exhaust fluid (DEF), Urea-water solution (UWS, urea-water solution, AUS32, etc.) is introduced into the exhaust gas. When the reductant is introduced into the exhaust gas, it can promote the use of the aftertreatment system 100 to reduce the emission of undesirable components in the exhaust gas. When hydrocarbons are introduced into the exhaust gas, the temperature of the exhaust gas may increase (e.g., to promote the regeneration of components of the aftertreatment system 100, etc.). For example, the temperature of the exhaust gas can be increased by burning hydrocarbons in the exhaust gas (e.g., using a spark plug, etc.).

[0051] The reductant fluid delivery system 110 includes an intake chamber distribution module 112 (e.g., a distributor, a reductant distributor, etc.). The intake chamber distribution module 112 is configured to facilitate the passage of the reductant fluid through the intake chamber 108 and into the intake chamber 108. In some embodiments, the intake chamber distribution module 112 is positioned within a distribution module mounting member. The distribution module mounting member is configured to facilitate the installation of the intake chamber distribution module 112 to the intake chamber 108. The distribution module mounting member can provide insulation (e.g., thermal insulation, vibration insulation, etc.) between the intake chamber distribution module 112 and the intake chamber 108. In some embodiments, the reductant fluid delivery system 110 does not include the intake chamber distribution module 112. In some embodiments, the distribution module 112 is a tightly coupled distribution module. That is, the distribution module 112 is connected to the introduction conduit 109 near the outlet of the internal combustion engine system 101 (e.g., near the outlet of the engine and / or near the outlet of the turbocharger 102). For example, the dosing module 112 may be coupled to the inlet conduit 109 downstream of the internal combustion engine system 101 and / or the turbocharger 102 .

[0052] The reductant fluid delivery system 110 also includes a reductant fluid source 114 (e.g., a reductant tank, etc.). The reductant fluid source 114 is configured to contain a reductant fluid. The reductant fluid source 114 is configured to provide the reductant fluid to the intake chamber dosing module 112. The reductant fluid source 114 may include a plurality of reductant fluid sources 114 (e.g., a plurality of tanks connected in series or in parallel, etc.). The reductant fluid source 114 may be, for example, a reductant fluid source 114 containing a reductant fluid. of diesel exhaust fluid tank.

[0053] The reductant fluid delivery system 110 also includes a reductant fluid pump 116 (e.g., a supply unit, etc.). The reductant fluid pump 116 is configured to receive the reductant fluid from the reductant fluid source 114 and provide the reductant fluid to the intake chamber dosing module 112. The reductant fluid pump 116 is used to pressurize the reductant fluid from the reductant fluid source 114 for delivery to the intake chamber dosing module 112. In some embodiments, the reductant fluid pump 116 is pressure controlled. In some embodiments, the reductant fluid pump 116 is coupled to the chassis of a vehicle associated with the aftertreatment system 100.

[0054] In some embodiments, the reductant fluid delivery system 110 also includes a reductant fluid filter 118. The reductant fluid filter 118 is configured to receive the reductant fluid from the reductant fluid source 114 and provide the reductant fluid to the reductant fluid pump 116. The reductant fluid filter 118 filters the reductant fluid before the reductant fluid is provided to the internal components of the reductant fluid pump 116. For example, the reductant fluid filter 118 can inhibit or prevent solids from being transmitted to the internal components of the reductant fluid pump 116. In this way, the reductant fluid filter 118 can promote extended desired operation of the reductant fluid pump 116.

[0055] The intake chamber dosing module 112 includes at least one intake chamber dosing module injector 120 (e.g., an insertion device, etc.). The intake chamber dosing module injector 120 is configured to receive the reductant fluid from the reductant fluid pump 116. The intake chamber dosing module injector 120 is configured to dispense (e.g., provide, inject, insert, etc.) the reductant fluid received by the intake chamber dosing module 112 into the exhaust gas within the intake chamber 108.

[0056] In some embodiments, the reductant fluid delivery system 110 also includes an air pump 122 and an air source 124 (e.g., an air intake, etc.). The air pump 122 is configured to receive air from the air source 124. The air pump 122 is configured to provide air to the intake chamber distribution module 112. In some applications, the intake chamber distribution module 112 is configured to mix air and reductant fluid into an air-reductant fluid mixture and provide the air-reductant fluid mixture to the intake chamber distribution module injector 120 (e.g., for distribution to exhaust gas within the intake chamber 108, etc.). As used herein, it is understood that the reductant fluid may include or consist of an air-reductant fluid mixture.

[0057] The intake chamber dosing module injector 120 is configured to receive air from an air pump 122. The intake chamber dosing module injector 120 is configured to dispense air into the exhaust gas within the intake chamber 108. In some of these embodiments, the reductant fluid delivery system 110 also includes an air filter 126. The air filter 126 is configured to receive air from an air source 124 and provide the air to the air pump 122. The air filter 126 is configured to filter the air before the air is provided to the air pump 122. In other embodiments, the reductant fluid delivery system 110 does not include an air pump 122, and / or the reductant fluid delivery system 110 does not include an air source 124. In such embodiments, the intake chamber dosing module 112 is not configured to mix the reductant fluid with the air.

[0058] In various embodiments, the intake chamber dosing module 112 is configured to receive air and fluid, and to distribute the reductant fluid into the intake chamber 108. In various embodiments, the intake chamber dosing module 112 is configured to receive the reductant fluid (and not receive air), and to distribute the reductant fluid into the intake chamber 108. In various embodiments, the intake chamber dosing module 112 is configured to receive the reductant fluid, and to distribute the reductant fluid into the intake chamber 108. In various embodiments, the intake chamber dosing module 112 is configured to receive air and the reductant fluid, and to distribute the reductant fluid into the intake chamber 108.

[0059] The aftertreatment system 100 also includes an aftertreatment system controller 128 (e.g., control circuitry, a driver, etc.). The intake chamber dosing module 112, the reductant fluid pump 116, and the air pump 122 are also electrically or communicatively coupled to the aftertreatment system controller 128. The aftertreatment system controller 128 is configured to control the intake chamber dosing module 112 to dosing the reductant fluid into the intake chamber 108. The aftertreatment system controller 128 may also be configured to control the reductant fluid pump 116 and / or the air pump 122 to control the reductant fluid dosing into the intake chamber 108.

[0060] The aftertreatment system controller 128 includes a aftertreatment system processing circuit 130. The aftertreatment system processing circuit 130 includes a aftertreatment system processor 132 and a aftertreatment system memory 134. The aftertreatment system processor 132 may include a microprocessor, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), etc. or a combination thereof. The aftertreatment system memory 134 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 aftertreatment system memory 134 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 aftertreatment system 128 can read instructions. The instructions may include code from any suitable programming language. The aftertreatment system memory 134 may include various modules including instructions configured to be implemented by the aftertreatment system processor 132.

[0061] In various embodiments, the aftertreatment system controller 128 is configured to communicate with a central controller 136 (e.g., an engine control unit (ECU), an engine control module (ECM), etc.) to control the turbocharger 102. The turbocharger 102 includes a compressor wheel coupled to an exhaust turbine wheel via a connector shaft, wherein hot exhaust gas rotates the turbine wheel, which rotates the shaft and the compressor to draw in air. By compressing the air, the turbocharger 102 allows more air to enter the cylinder (or combustion chamber) to burn more fuel and increase power and efficiency. The turbocharger 102 may include a heat exchanger to cool the compressed air before the air enters the cylinder.

[0062] In some embodiments, the central controller 136 may communicate with a display device (e.g., a screen, a monitor, a touch screen, a heads up display (HUD), an indicator light, etc.). The display device may be configured to change state in response to receiving information from the central controller 136. For example, the display device may be configured to change between a static state and an alarm state based on communications from the central controller 136. By changing state, the display device may provide an indication of the state of the reductant fluid delivery system 110 to the user.

[0063] The aftertreatment system 100 includes an upstream catalyst component 138 (e.g., a conversion catalyst component, a selective catalytic reduction (SCR) catalyst component, a catalytic metal, etc.). The upstream catalyst component 138 is positioned downstream of the intake chamber 108. The upstream catalyst component 138 is configured to cause decomposition of components of the exhaust gas using a reductant fluid (e.g., via a catalytic reaction, etc.). The upstream catalyst component 138 includes an upstream catalyst housing 140. The upstream catalyst housing 140 can be coupled to the intake chamber 108. In some embodiments, the upstream catalyst housing 140 is formed integrally with the intake chamber 108. The upstream catalyst component 138 includes an upstream catalyst substrate 142. The upstream catalyst substrate 142 is coupled to the upstream catalyst housing 140. In some embodiments, the upstream catalyst substrate 142 is formed integrally with the upstream catalyst housing 140.

[0064] The upstream catalyst member 138 receives exhaust gas from the intake chamber 108. The exhaust gas flows through the upstream catalyst substrate 142 and reacts with the upstream catalyst substrate 142 to cause the exhaust gas to undergo evaporation, pyrolysis and / or hydrolysis processes to form non-NO in the inlet conduit 109 and / or the upstream catalyst member 138. x In some embodiments, the exhaust gas and the reductant fluid in the exhaust gas react with the upstream catalyst substrate 142. In this manner, the upstream catalyst member 138 is configured to accelerate the removal of NO in the reductant and the exhaust gas. x The conversion of NO into diatomic nitrogen, water and / or carbon dioxide xThe reduction process helps NO x The upstream catalyst substrate 142 may include vanadium. Vanadium is used because it has a long deactivation time and can react with the exhaust gas at high temperatures. In some embodiments, vanadium is used because it has the advantage of emitting lower N2O emissions to the environment when the exhaust temperature is less than 420°C. In some embodiments, the aftertreatment system 100 does not include the upstream catalyst component 138.

[0065] The aftertreatment system 100 includes an upstream ammonia slip catalyst substrate 144. Upstream ammonia slip catalyst substrate 144. The upstream ammonia slip catalyst substrate 144 is positioned downstream of the upstream catalyst component 138. In some embodiments, the upstream ammonia slip catalyst substrate 144 is a coating applied to a portion of the outlet of the upstream catalyst component 138. The upstream ammonia slip catalyst substrate 144 is configured to receive exhaust gas from the upstream catalyst component 138 and help reduce byproducts (e.g., ammonia, etc.) of the process of the intake chamber dosing module 112 and the upstream catalyst component 138. Specifically, the intake chamber dosing module 112 can introduce ammonia into the exhaust gas, however, a portion of the introduced ammonia may not react with the exhaust gas. Therefore, excess ammonia may leak from the upstream catalyst component 138 into the exhaust gas downstream of the upstream catalyst component 138. The upstream ammonia slip catalyst substrate 144 is used to reduce ammonia so that the exhaust gas downstream of the upstream ammonia slip catalyst substrate 144 does not contain an undesirable amount of ammonia. In some embodiments, the aftertreatment system 100 does not include an upstream ammonia slip catalyst substrate 144 .

[0066] The aftertreatment system 100 also includes a hydrocarbon decomposition chamber 146. The hydrocarbon decomposition chamber is positioned downstream of the upstream ammonia slip catalyst substrate 144. In some embodiments, the hydrocarbon decomposition chamber 146 is coupled to the upstream catalyst housing 140. In some embodiments, the hydrocarbon decomposition chamber 146 is integrally formed with the upstream catalyst housing 140. In yet other embodiments, the hydrocarbon decomposition chamber 146 is coupled to the intake chamber 108. In some embodiments, the aftertreatment system 100 does not include the upstream catalyst component 138, so that the hydrocarbon decomposition chamber 146 can also be integrally formed with the intake chamber 108. The hydrocarbon decomposition chamber 146 is configured to receive exhaust gas from the upstream ammonia slip catalyst substrate 144. The aftertreatment system 100 includes a hydrocarbon fluid system 147. The hydrocarbon fluid system 147 includes a hydrocarbon dosing module 148. The hydrocarbon dosing module 148 distributes hydrocarbons to the exhaust gas within the hydrocarbon decomposition chamber 146. The hydrocarbon dosing module 148 is configured to facilitate hydrocarbons passing through and into the hydrocarbon decomposition chamber 146. The hydrocarbon dosing module 148 includes at least one hydrocarbon injector 150 (eg, an insert device, etc.). The hydrocarbon injector 150 is configured to dose hydrocarbons into the exhaust gas within the hydrocarbon decomposition chamber 146.

[0067] The hydrocarbons within the hydrocarbon decomposition chamber 146 may be configured to increase the temperature of the exhaust gas within the hydrocarbon decomposition chamber 146. Specifically, the aftertreatment system 100 includes an igniter 151 (e.g., a spark plug, etc.) coupled to the hydrocarbon decomposition chamber 146. The igniter 151 is electrically connected to the aftertreatment system controller 128 and is configured to burn the hydrocarbons in the exhaust gas within the hydrocarbon decomposition chamber 146, which causes the temperature of the exhaust gas to increase. As a result, regeneration of downstream components may occur. For example, regeneration occurs when the hydrocarbons in the exhaust gas burn and increase the temperature of the exhaust gas so that the exhaust gas burns any soot or particles that may be attached to the downstream components. By burning the attached soot or particles, the downstream components can be cleaned so that they operate like new.

[0068] The hydrocarbon fluid system 147 also includes a hydrocarbon source 152 (e.g., a hydrocarbon tank, etc.). The hydrocarbon source 152 is configured to contain hydrocarbons. The hydrocarbon source 152 is configured to provide hydrocarbons to the hydrocarbon distribution module 148. The hydrocarbon source 152 may include a plurality of hydrocarbon sources 152 (e.g., a plurality of tanks connected in series or in parallel, etc.). The hydrocarbon fluid system 147 also includes a hydrocarbon fluid pump 154. Specifically, the hydrocarbon fluid pump 154 ​​is configured to provide hydrocarbon fluid to the hydrocarbon injector 150. The hydrocarbon injector 150 receives the hydrocarbon fluid from the hydrocarbon fluid pump 154 ​​and is configured to distribute the hydrocarbon fluid received by the hydrocarbon distribution module 148 into the exhaust gas within the hydrocarbon decomposition chamber 146. The hydrocarbon fluid pump 154 ​​is used to pressurize the hydrocarbon fluid received from the hydrocarbon source 152 to deliver it to the hydrocarbon dosing module 148 and the hydrocarbon injector 150. In some embodiments, the hydrocarbon fluid pump 154 ​​is pressure controlled. In some embodiments, the hydrocarbon fluid pump 154 ​​is coupled to the chassis of the vehicle associated with the aftertreatment system.

[0069] In some embodiments, the hydrocarbon fluid system 147 includes a hydrocarbon filter 156 (e.g., a fuel filter, a lubricant filter, an oil filter, etc.). The hydrocarbon filter 156 is configured to receive hydrocarbons from the hydrocarbon source 152 and provide the hydrocarbons to the hydrocarbon fluid pump 154. The hydrocarbon filter 156 filters the hydrocarbons before the hydrocarbons are provided to the internal components of the hydrocarbon fluid pump 154. For example, the hydrocarbon filter 156 can inhibit or prevent solids from being transferred to the internal components of the hydrocarbon fluid pump 154. In this way, the hydrocarbon filter 156 can facilitate extended desired operation of the hydrocarbon fluid pump 154.

[0070] In some embodiments, the air pump 122 is also configured to provide air to a hydrocarbon dosing module 148. The hydrocarbon dosing module 148 is configured to provide air into the hydrocarbon decomposition chamber 146. In some applications, the hydrocarbon dosing module 148 is configured to mix air and hydrocarbon fluid into an air-hydrocarbon fluid mixture and provide the air-hydrocarbon fluid mixture to the hydrocarbon injector 150 (e.g., for dosing into exhaust gas within the hydrocarbon decomposition chamber 146, etc.).

[0071] In various embodiments, the hydrocarbon dosing module 148 is configured to receive air and hydrocarbon fluid, and to dispense the hydrocarbon fluid into the hydrocarbon decomposition chamber 146. In various embodiments, the hydrocarbon dosing module 148 is configured to receive hydrocarbons (and not receive air), and to dispense the hydrocarbon fluid into the intake chamber 108. In various embodiments, the hydrocarbon dosing module 148 is configured to receive hydrocarbons, and to dispense the hydrocarbons into the hydrocarbon decomposition chamber 146.

[0072] In some embodiments, the hydrocarbon dosing module 148 and the hydrocarbon fluid pump 154 ​​are also electrically or communicatively coupled to the aftertreatment system controller 128. The aftertreatment system controller 128 is also configured to control the hydrocarbon dosing module 148 to dose hydrocarbons into the hydrocarbon decomposition chamber 146. The aftertreatment system controller 128 may also be configured to control the hydrocarbon fluid pump 154 ​​and / or the air pump 122 to control the hydrocarbons dosed into the hydrocarbon decomposition chamber 146. In some embodiments, the aftertreatment system 100 does not include the hydrocarbon decomposition chamber 146, the hydrocarbon dosing module 148, the hydrocarbon injector 150, the hydrocarbon source 152, the hydrocarbon fluid pump 154, and / or the hydrocarbon filter 156.

[0073] The aftertreatment system 100 includes a first oxidation catalyst component 158 ​​(eg, a first diesel oxidation catalyst (DOC), etc.) The first oxidation catalyst component 158 ​​is positioned downstream of the hydrocarbon decomposition chamber 146 (ie, the hydrocarbon decomposition chamber 146 is positioned upstream of the first oxidation catalyst component 158).

[0074] The first oxidation catalyst component 158 ​​includes a first oxidation catalyst housing 160. The first oxidation catalyst housing 160 is coupled to the hydrocarbon decomposition chamber 146. The first oxidation catalyst housing 160 may also be integrally formed with the hydrocarbon decomposition chamber 146.

[0075] The first oxidation catalyst component 158 ​​also includes a first oxidation catalyst substrate 162 (e.g., DOC, etc.). The first oxidation catalyst substrate 162 is positioned within the first oxidation catalyst housing 160. The first oxidation catalyst substrate 162 can be coupled to the first oxidation catalyst housing 160. Exhaust gas including hydrocarbons reacts with the first oxidation catalyst substrate 162 and causes conversion of hydrocarbons in the exhaust gas. For example, when the exhaust gas flows through the first oxidation catalyst substrate 162, the hydrocarbons react with the first oxidation catalyst substrate 162 and begin to oxidize. The first oxidation catalyst substrate 162 promotes the conversion of carbon monoxide and hydrocarbons and / or air-hydrocarbon mixtures in the exhaust gas into carbon dioxide.

[0076] In some embodiments, the aftertreatment system 100 does not include the upstream catalyst component 138, the upstream ammonia slip catalyst substrate 144, and / or the hydrocarbon decomposition chamber 146, such that the first oxidation catalyst component 158 ​​may be positioned downstream of the intake chamber 108. In such embodiments, the first oxidation catalyst housing 160 may be coupled to the intake chamber 108. In other such embodiments, the first oxidation catalyst housing 160 may also be integrally formed with the intake chamber 108.

[0077] The aftertreatment system 100 also includes an upstream particulate filter assembly 164. The upstream particulate filter assembly 164 includes an upstream particulate filter housing 166. The upstream particulate filter housing 166 is positioned downstream of the first oxidation catalyst housing 160. In some embodiments, the upstream particulate filter housing 166 is formed integrally with the first oxidation catalyst housing 160. The upstream particulate filter assembly 164 includes an upstream particulate filter 168 (e.g., a diesel particulate filter (DPF), a filter member, etc.). The upstream particulate filter 168 is disposed in the upstream particulate filter housing 166, so that the upstream particulate filter 168 is positioned downstream of the first oxidation catalyst member 158 (i.e., the first oxidation catalyst member 158 is positioned upstream of the upstream particulate filter 168). In some embodiments, the upstream particulate filter housing 166 and the upstream particulate filter 168 are positioned downstream of the intake chamber 108.

[0078] The upstream particulate filter 168 is configured to remove first particles (e.g., soot, solidified hydrocarbons, ash, etc.) from the exhaust gas. For example, the upstream particulate filter 168 can receive exhaust gas with a first concentration of first particles (e.g., from the first oxidation catalyst component 158, from the intake chamber 108, etc.), and can provide exhaust gas with a second concentration of first particles to the downstream, wherein the second concentration is lower than the first concentration. In this way, the upstream particulate filter 168 can promote a reduction in the particle number (PN) of the exhaust gas. In various applications, it may be desirable to reduce the PN of the exhaust gas. For example, emission regulations may specify a maximum PN of the exhaust gas discharged into the atmosphere, and the upstream particulate filter 168 can ensure that the PN of the exhaust gas discharged into the atmosphere by the aftertreatment system 100 is lower than the maximum PN.

[0079] In some embodiments, the upstream particulate filter 168 is a catalytic DPF. A catalytic DPF is a filter having a catalyst washcoat. The catalyst washcoat is configured to react with components of the exhaust gas to reduce undesirable components in the exhaust gas. For example, the catalyst washcoat may be an oxidation catalyst to reduce hydrocarbons in the exhaust gas. In some embodiments, the catalyst washcoat is configured to reduce NO x SCR catalyst for emissions.

[0080] The aftertreatment system 100 also includes a mixer 170 (e.g., a vortex generating device, etc.). The mixer 170 is positioned downstream of the upstream particulate filter assembly 164 (i.e., the mixer 170 is positioned downstream of the upstream particulate filter 168) and is configured to receive exhaust gas from the upstream particulate filter assembly 164. The mixer 170 can be coupled to the upstream particulate filter housing 166. In some embodiments, the mixer 170 is integrally formed with the upstream particulate filter housing 166. In some embodiments, the mixer 170 is positioned upstream of the first oxidation catalyst component 158.

[0081] The reductant fluid delivery system 110 includes a dosing module 172. The dosing module 172 is configured to facilitate the passage of the reductant fluid through the mixer 170 and into the mixer 170. In some embodiments, the dosing module 172 is positioned within a dosing module mount. The dosing module mount is configured to facilitate mounting the dosing module 172 to the mixer 170. The dosing module mount can provide insulation (e.g., thermal insulation, vibration insulation, etc.) between the dosing module 172 and the decomposition chamber.

[0082] The dosing module 172 includes at least one injector 174 (e.g., an insert device, etc.). The injector 174 is configured to receive the reductant fluid from the reductant fluid pump 116. The injector 174 is configured to dispense the reductant fluid received by the dosing module 172 into the exhaust gas within the mixer 170. In some embodiments, the injector 174 is centered on an injection axis 175. The injection axis 175 intersects and is orthogonal to the conduit axis 106. In some embodiments, the injection axis 175 intersects the conduit axis 106 and extends away from the conduit axis 106 at a certain angle.

[0083] In some embodiments, the dosing module 172 is configured to receive air from the air pump 122. In some applications, the dosing module 172 is configured to mix air and a reductant fluid into an air-reductant fluid mixture and provide the air-reductant fluid mixture to the injector 174 (e.g., for dosing into the exhaust gas within the mixer 170, etc.). Specifically, the injector 174 is configured to receive air from the air pump 122. The plenum dosing module injector 120 is configured to dosing air into the exhaust gas within the mixer 170.

[0084] In various embodiments, the dosing module 172 is configured to receive air and fluid, and to dose the reductant fluid into the mixer 170. In various embodiments, the dosing module 172 is configured to receive the reductant fluid (and not receive air), and to dose the reductant fluid into the mixer 170. In various embodiments, the dosing module 172 is configured to receive the reductant fluid, and to dose the reductant fluid into the mixer 170. In various embodiments, the dosing module 172 is configured to receive air and the reductant fluid, and to dose the reductant fluid into the mixer 170.

[0085] In some embodiments, aftertreatment system 100 includes a second oxidation catalyst component (eg, a second diesel oxidation catalyst (DOC), etc.) The second oxidation catalyst is positioned downstream of mixer 170. The second oxidation catalyst is substantially similar to the first oxidation catalyst and therefore will not be described in further detail.

[0086] The aftertreatment system 100 includes a first downstream catalyst component 176 (e.g., a conversion catalyst component, an SCR catalyst component, a catalytic metal, etc.). The first downstream catalyst component 176 is positioned downstream of the mixer 170. In some embodiments, the first downstream catalyst component 176 is downstream of the second oxidation catalyst. The first downstream catalyst component 176 is configured to cause decomposition of components of the exhaust gas using a reductant fluid (e.g., via a catalytic reaction, etc.). The first downstream catalyst component 176 includes a first downstream catalyst housing 178 and a first downstream catalyst substrate 180. The first downstream catalyst housing 178 can be coupled to the mixer 170. In some embodiments, the first downstream catalyst housing 178 is formed integrally with the mixer 170. The first downstream catalyst substrate 180 is coupled to the first downstream catalyst housing 178. In some embodiments, the first downstream catalyst substrate 180 is formed integrally with the first downstream catalyst housing 178.

[0087] The first downstream catalyst component 176 receives the exhaust gas from the mixer 170. The exhaust gas flows through the first downstream catalyst substrate 180 and reacts with the first downstream catalyst substrate 180 to cause the exhaust gas to undergo evaporation, pyrolysis and / or hydrolysis processes to form non-NO x In some embodiments, the exhaust gas and the reductant fluid in the exhaust gas react with the first downstream catalyst substrate 180. In this manner, the first downstream catalyst member 176 is configured to accelerate the removal of NO in the reductant and the exhaust gas. x The conversion of NO into diatomic nitrogen, water and / or carbon dioxide x The reduction process helps NO xThe aftertreatment system 100 may include a first downstream catalyst component 176, a first downstream catalyst component 176, and a second downstream catalyst component 176. The first downstream catalyst component 176 may include a first downstream catalyst component 176.

[0088] The aftertreatment system 100 also includes a second downstream catalyst component 182 (e.g., a conversion catalyst component, an SCR catalyst component, a catalytic metal, etc.). The second downstream catalyst component 182 is positioned downstream of the mixer 170. The second downstream catalyst component 182 is configured to cause decomposition of components of the exhaust gas using a reductant fluid (e.g., via a catalytic reaction, etc.). The second downstream catalyst component 182 includes a second downstream catalyst housing 184. In some embodiments, the second downstream catalyst housing 184 is formed integrally with the first downstream catalyst housing 178. In some embodiments, the second downstream catalyst housing 184 is the first downstream catalyst housing 178. The second downstream catalyst component 182 includes a second downstream catalyst substrate 186. The second downstream catalyst substrate 186 is coupled to the second downstream catalyst housing 184. In some embodiments, the second downstream catalyst substrate 186 is formed integrally with the second downstream catalyst housing 184.

[0089] The second downstream catalyst component 182 receives the exhaust gas from the first downstream catalyst component 176. The exhaust gas flows through the second downstream catalyst substrate 186 and reacts with the second downstream catalyst substrate 186 to cause the exhaust gas to undergo evaporation, pyrolysis and / or hydrolysis processes to form non-NO x In some embodiments, the exhaust gas and the reductant fluid in the exhaust gas react with the second downstream catalyst substrate 186. In this way, the second downstream catalyst member 182 is configured to accelerate the NO in the reductant and the exhaust gas. x The conversion of NO into diatomic nitrogen, water and / or carbon dioxide x The reduction process helps NO x The aftertreatment system 100 may include a second downstream catalyst component 182, a second downstream catalyst component 182, and a second downstream catalyst component 182.

[0090] The aftertreatment system 100 includes a downstream ammonia slip catalyst substrate 188. The downstream ammonia slip catalyst substrate 188 is positioned downstream of the second downstream catalyst component 182. In some embodiments, the downstream ammonia slip catalyst substrate 188 is a coating applied to a portion of the outlet of the first downstream catalyst component 176. The downstream ammonia slip catalyst substrate 188 may be a coating applied to a portion of the outlet of the second downstream catalyst component 182. The downstream ammonia slip catalyst substrate 188 is configured to receive exhaust gas from the second downstream catalyst component 182 and help reduce byproducts (e.g., ammonia, etc.) in the process of the dosing module 172 and the second downstream catalyst component 182. In some embodiments, the downstream ammonia slip catalyst substrate 188 is positioned downstream of the first downstream catalyst component 176 and is configured to receive exhaust gas from the first downstream catalyst component 176 and help reduce byproducts (e.g., ammonia, etc.) in the process of the dosing module 172 and the first downstream catalyst component 176. Specifically, the dosing module 172 may introduce ammonia into the exhaust gas, however, a portion of the introduced ammonia may not react with the exhaust gas. Therefore, excess ammonia may leak from the first downstream catalyst component 176 and / or the second downstream catalyst component 182 into the exhaust gas downstream of the first downstream catalyst component 176 and / or the second downstream catalyst component 182, so that the exhaust gas downstream of the downstream ammonia slip catalyst substrate 188 does not contain an undesirable amount of ammonia. In some embodiments, the aftertreatment system 100 does not include a downstream ammonia slip catalyst substrate 188.

[0091] The aftertreatment system 100 also includes an outlet chamber 190. The outlet chamber 190 is positioned downstream of the downstream ammonia slip catalyst substrate 188 and is configured to receive exhaust gas from the downstream ammonia slip catalyst substrate 188. In various embodiments, the outlet chamber 190 is coupled to the downstream ammonia slip catalyst substrate 188. For example, the outlet chamber 190 can be fastened, welded, riveted, or otherwise attached to the downstream ammonia slip catalyst substrate 188. In some embodiments, the outlet chamber 190 is coupled to the inlet conduit 109. In some embodiments, the outlet chamber 190 is the inlet conduit 109 (e.g., only the inlet conduit is included in the exhaust conduit system 104, and the inlet conduit 109 serves as both the inlet conduit 109 and the outlet chamber 190). The outlet chamber 190 is centered on the conduit axis 106 (e.g., the conduit axis 106 extends through the center point of the outlet chamber 190, etc.).

[0092] In various embodiments, the exhaust duct system 104 includes only a single duct that serves as the inlet plenum 108 , the intake duct 109 , and the outlet plenum 190 .

[0093] In various embodiments, the aftertreatment system 100 also includes a first sensor 192 (eg, NO xThe first sensor 192 is positioned downstream of the downstream ammonia slip catalyst substrate 188. In some embodiments, the first sensor 192 is coupled to the outlet chamber 190. The first sensor 192 is configured to measure (e.g., sense, detect, etc.) a parameter of the exhaust gas and the reductant fluid downstream of the downstream ammonia slip catalyst substrate 188 (e.g., NO x concentration, CO concentration, CO2 concentration, O2 concentration, particulate matter concentration, nitrogen concentration, sulfur oxide concentration (SO x ) etc.). The first sensor 192 may be configured to measure a parameter within the outlet chamber 190. In some embodiments, the parameter measured by the first sensor 192 is a concentration of particulate matter in the exhaust gas downstream of the downstream ammonia slip catalyst substrate 188. In some embodiments, the parameter measured by the first sensor 192 is a concentration of SO in the exhaust gas within the outlet chamber 190. x In some embodiments, the first sensor 192 measures the concentration of particulate matter and SO x Concentration of both.

[0094] The first sensor 192 is electrically or communicatively coupled to the aftertreatment system controller 128 and is configured to provide a first signal associated with the parameter to the aftertreatment system controller 128. The aftertreatment system controller 128 (e.g., via the aftertreatment system processing circuit 130, etc.) is configured to determine a first measurement value based on the first signal. The aftertreatment system controller 128 can be configured to control the intake chamber dosing module 112, the dosing module 172, the reductant fluid pump 116, and / or the air pump 122 based on the first signal. In addition, the aftertreatment system controller 128 can be configured to transmit the first signal to the central controller 136.

[0095] In various embodiments, the aftertreatment system 100 also includes a second sensor 194 (eg, NO x The second sensor 194 is positioned downstream of the downstream ammonia slip catalyst substrate 188. In some embodiments, the second sensor 194 is coupled to the outlet chamber 190 and is positioned downstream of the first sensor 192. The second sensor 194 is configured to measure (e.g., sense, detect, etc.) a parameter of the exhaust gas and the reductant fluid downstream of the downstream ammonia slip catalyst substrate 188 (e.g., NO x concentration, CO concentration, CO2 concentration, O2 concentration, particulate matter concentration, nitrogen concentration, SO xThe second sensor 194 may be configured to measure a parameter of the exhaust gas within the outlet chamber 190. In some embodiments, the parameter measured by the second sensor 194 is a concentration of particulate matter in the exhaust gas downstream of the downstream ammonia slip catalyst substrate 188. In some embodiments, the parameter measured by the second sensor 194 is a concentration of SO in the exhaust gas downstream of the downstream ammonia slip catalyst substrate 188. x In some embodiments, the second sensor 194 measures the concentration of particulate matter and SO x Concentration of both.

[0096] The second sensor 194 is electrically or communicatively coupled to the aftertreatment system controller 128 and is configured to provide a second signal associated with the parameter to the aftertreatment system controller 128. The aftertreatment system controller 128 (e.g., via the aftertreatment system processing circuit 130, etc.) is configured to determine a second measurement value based on the second signal. The aftertreatment system controller 128 can be configured to control the intake chamber dosing module 112, the dosing module 172, the reductant fluid pump 116, and / or the air pump 122 based on the second signal. In addition, the aftertreatment system controller 128 can be configured to transmit the second signal to the central controller 136.

[0097] In various embodiments, the aftertreatment system 100 also includes a third sensor 196 (eg, NO x The third sensor 196 is positioned upstream of the upstream particulate filter 168. In some embodiments, the third sensor 196 is coupled to the intake chamber 108. The third sensor 196 is configured to measure (e.g., sense, detect, etc.) a parameter of the exhaust gas and the reductant fluid upstream of the upstream particulate filter 168 (e.g., NO x concentration, CO concentration, CO2 concentration, O2 concentration, particulate matter concentration, nitrogen concentration, SO x The third sensor 196 may be configured to measure a parameter of the exhaust gas within the intake chamber 108. In some embodiments, the parameter measured by the first sensor 192 is the concentration of particulate matter in the exhaust gas upstream of the upstream particulate filter 168. In some embodiments, the parameter measured by the third sensor 196 is the SO concentration in the exhaust gas upstream of the upstream particulate filter 168. x In some embodiments, the third sensor 196 measures the concentration of particulate matter and SO x Concentration of both.

[0098] The third sensor 196 is electrically or communicatively coupled to the aftertreatment system controller 128 and is configured to provide a third signal associated with the parameter to the aftertreatment system controller 128. The aftertreatment system controller 128 (e.g., via the aftertreatment system processing circuit 130, etc.) is configured to determine a third measurement value based on the third signal. The aftertreatment system controller 128 can be configured to control the intake chamber dosing module 112, the dosing module 172, the reductant fluid pump 116, and / or the air pump 122 based on the third signal. In addition, the aftertreatment system controller 128 can be configured to transmit the third signal to the central controller 136.

[0099] III. Mixer Overview

[0100] refer to Figures 4 to 16 , a mixer 200 (e.g., hydrocarbon decomposition chamber 146, mixer 170, etc.) of aftertreatment system 100 is shown. Mixer 200 is configured to receive exhaust gas via inlet conduit 109. Mixer 200 also receives hydrocarbon fluid from injector 174. Mixer 200 is configured to mix hydrocarbon fluid with exhaust gas. Mixer 200 is also configured to promote exhaust gas swirling (e.g., rotation, etc.) and mixing (e.g., combining, etc.) of the exhaust gas and hydrocarbon fluid so as to disperse the hydrocarbon fluid in the exhaust gas downstream of the mixer (e.g., increase the ability of hydrocarbons to heat the gas, etc.). By using mixer 200 to disperse the hydrocarbon fluid in the exhaust gas, the reduction of emissions of undesirable components in the exhaust gas is enhanced and / or the ability of aftertreatment system 100 to increase the temperature of the exhaust gas can be enhanced.

[0101] The mixer 200 includes a mixer body 202 (e.g., a housing, a frame, etc.). The mixer body 202 is supported in the introduction conduit 109. The mixer body 202 is centered on a mixer body central axis 204. In some embodiments, the mixer body central axis 204 is the same as the conduit axis 106. In other embodiments, the mixer body central axis 204 is separated from the conduit axis 106. For example, the mixer body central axis 204 can be parallel to the conduit axis 106 and offset relative to the conduit axis 106. The mixer body 202 is divided into two by a mixer body first plane 206 (e.g., a mixer body plane, etc.). The mixer body first plane 206 intersects with the mixer body central axis 204 and is orthogonal to the mixer body central axis 204. In some embodiments, the mixer body first plane 206 intersects with the conduit axis 106 and is orthogonal to the conduit axis 106. The mixer body is divided into two by a mixer body second plane 208. The mixer body second plane 208 intersects and is orthogonal to the mixer body central axis 204 and the mixer body first plane 206. In some embodiments, the mixer body second plane 208 intersects and is orthogonal to the catheter axis 106.

[0102] The mixer body 202 includes an inlet side 210. The inlet side 210 is located adjacent to the upstream particulate filter 168. The inlet side 210 has a diameter approximately in the range of 190 millimeters (mm) to 255 mm (e.g., 180.5 mm, 190 mm, 196.91 mm, 200 mm, 210 mm, 216.29 mm, 220 mm, 230 mm, 240 mm, 250 mm, 254.23 mm, 255 mm, 267.75 mm, etc.). The mixer body 202 includes an outlet side 212. The outlet side 212 is located adjacent to the first downstream catalyst component 176. The outlet side 212 has a diameter approximately in the range of 230 mm to 330 mm (e.g., 218.5 mm, 230 mm, 235.49 mm, 240 mm, 250 mm, 264 mm, 261.60 mm, 270 mm, 272.87 mm, 280 mm, 290 mm, 300 mm, 310 mm, 315 mm, 315.92 mm, 320 mm, 330 mm, 346.5 mm, etc.). The mixer body 202 has a mixer body length ML measured from the inlet side 210 to the outlet side 212 approximately in the range of between 120 mm and 180 mm (e.g., 114 mm, 120 mm, 125 mm, 130 mm, 133.38 mm, 135 mm, 140 mm, 145 mm, 150 mm, 155 mm, 160 mm, 163.38 mm, 165 mm, 200 mm, 175 mm, 180 mm, 189 mm, etc.).

[0103] like Figure 5 As shown, Figure 4 2. In a cross-sectional view of a portion of an exhaust aftertreatment system of FIG. 2 taken along plane AA, the mixer body 202 may be tapered. In some embodiments, the mixer body 202 extends from the inlet side 210 to the outlet side 212 at an angle θt approximately in the range of 91 degrees (°) to 102° (e.g., 91°, 93°, 95°, 97°, 99°, 99.6°, 100.6°, 101°, 102°, etc.). The mixer body 202 extends from the inlet side 210 to the outlet side 212 such that the height of the mixer body is approximately in the range of 120 mm to 165 mm (e.g., 114 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 165 mm, 173.25 mm, etc.).

[0104] The mixer body 202 includes a first orifice 214. The first orifice 214 extends through the mixer body 202. The first orifice 214 can have a length measured along the mixer body 202 from the inlet side 210 to the outlet side 212 that is approximately in the range of 70 mm to 100 mm (e.g., 66.5 mm, 70 mm, 75 mm, 76.71 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 105 mm, etc.). In some embodiments, the first orifice 214 can have a width measured orthogonally relative to the length of the first orifice 214 that is approximately in the range of 70 mm to 100 mm (e.g., 66.5 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 99.01 mm, 95 mm, 100 mm, 105 mm, etc.). The first aperture 214 is configured to facilitate exhaust gas flow from an exterior portion of the mixer body 202 through the mixer body 202 and into a mixer body cavity 216 (e.g., a void, etc.). The mixer body cavity 216 receives the exhaust gas from the first aperture 214. As explained in greater detail herein, the exhaust gas swirls within the mixer body 202, and this swirling facilitates mixing of the exhaust gas and the hydrocarbon fluid.

[0105] The mixer 200 includes an ejector plate 218. The ejector plate 218 is coupled to the mixer body along a portion of the first aperture 214. The ejector plate 218 is configured to facilitate exhaust gas flow from an outer portion of the mixer body 202 through the first aperture. The ejector plate 218 may have a length L1 approximately in the range of 70 mm to 100 mm (e.g., 66.5 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 99.01 mm, 95 mm, 100 mm, 105 mm, etc.). The ejector plate 218 includes an ejector plate first flange 220. The ejector plate first flange 220 is configured to couple a portion of the ejector plate 218 to the mixer body 202. The ejector plate 218 includes an ejector plate second flange 222. The second injector plate flange 222 is configured to couple a portion of the injector plate 218 to the mixer body 202 opposite the portion of the injector plate 218 to which the first injector plate flange 220 is coupled.

[0106] The ejector plate 218 includes an ejector plate face plate 224. The ejector plate face plate 224 is adjacent to the ejector plate second flange 222. The face plate of the ejector plate 218 is positioned such that the ejector plate 218 is angled away from the mixer body at a first opening angle θ, etc., measured counterclockwise relative to the mixer body 202, approximately in the range of 15° to 30° (e.g., 15°, 20°, 20.5°, 25°, 30°, etc.) to form a flow aperture 226. As used herein, angles are measured counterclockwise from the outlet side 212 upstream toward the inlet side 210 as positive. The flow aperture 226 is formed between a first edge of the ejector plate face plate 224 and the mixer body 202 and between a second edge of the ejector plate face plate 224 and the mixer body 202. The flow apertures 226 are configured to facilitate the flow of exhaust gas between the mixer body 202 and the ejector plate face plate 224 such that the exhaust gas flows through the first apertures 214 and into the mixer body cavity 216 .

[0107] The ejector plate 218 includes an ejector plate sidewall 228 (e.g., ejector plate side, etc.). The ejector plate sidewall 228 is adjacent to the ejector plate first flange 220 and the ejector plate faceplate 224. The ejector plate sidewall 228 is configured to prevent exhaust gas from flowing between the ejector plate faceplate 224 and the ejector plate first flange 220. In some embodiments, the ejector plate sidewall 228 is configured to direct a portion of the exhaust gas flowing between the ejector plate faceplate 224 and the mixer body 202 through the first orifice 214. For example, as the exhaust gas flows downstream toward the ejector plate 218, a portion of the exhaust gas flows through the flow orifice 226, and a portion of the portion of the exhaust gas contacts the ejector plate sidewall 228 and is directed toward the first orifice 214 and into the mixer body cavity 216. In some embodiments, the ejector plate sidewall 228 is rounded to promote exhaust gas swirling.

[0108] The ejector plate 218 includes a tab 230. The tab 230 is positioned within and along a portion of the first aperture 214. The tab 230 abuts the ejector plate panel 224 and is configured to prevent (e.g., obstruct, etc.) exhaust gas from flowing along an edge of the ejector plate panel 224. The tab 230 also couples the ejector plate 218 to the mixer body 202.

[0109] The ejector plate 218 is coupled to the mixer body 202 such that a portion of the ejector plate 218 is centered about a reference axis 232. The reference axis 232 extends along the mixer body first plane 206. The reference axis 232 is centered about a reference angle approximately in the range of 2° to 10° (e.g., 2°, 4°, 6°, 8°, 10°, etc.). Angled away from the mixer body second plane 208 .

[0110] The injector plate 218 includes an injector cone 234. The injector cone 234 is positioned on the injector plate. The injector cone 234 includes an injection orifice 236. The injection orifice 236 is configured to facilitate the flow of hydrocarbon fluid from the injector 174 through the injector cone 234 and the injector plate 218 to the mixer body cavity 216. For example, the injector 174 injects the hydrocarbon fluid into the mixer body cavity 216 through the injection orifice 236 so that the hydrocarbon fluid and the exhaust gas can mix. In some embodiments, the injection orifice 236 is centered on the injection axis 175. In some embodiments, the injection axis 175 can be angled away from the center of the injector cone 234.

[0111] The mixer 200 includes a second orifice 238. The second orifice 238 is substantially similar to the first orifice 214, and therefore will not be described in further detail. The mixer 200 includes a first guide plate 240. The first guide plate 240 is coupled to the mixer body 202 along a portion of the second orifice 238. The first guide plate 240 is configured to facilitate a portion of the exhaust gas at the outer portion of the mixer body 202 to pass through the mixer body 202 and enter the mixer body cavity 216 through the second orifice 238. The first guide plate 240 has a length GP1 approximately in the range of 70mm to 100mm (e.g., 66.5mm, 70mm, 75mm, 80mm, 80.12mm, 84.18mm, 85mm, 90mm, 95mm, 100mm, 105mm, etc.). The first guide plate 240 is centered on a first guide plate axis 241 (e.g., a guide plate axis, etc.). The first guide plate axis 241 extends along the mixer body first plane 206 and intersects the conduit axis 106. The first guide plate axis 241 is at a first separation angle relative to the reference axis 232. Positioning. First separation angle Roughly in the range of 30° to 60° (e.g., 30°, 35°, 40°, 45°, 50°, 55°, 60°, etc.).

[0112] The first guide plate 240 includes a first guide plate first flange 242. The first guide plate first flange 242 is configured to couple a portion of the first guide plate 240 to the mixer body 202. The first guide plate 240 includes a first guide plate second flange 244. The first guide plate second flange 244 is configured to couple a portion of the first guide plate 240 to the mixer body 202, opposite to the portion of the first guide plate 240 coupled by the first guide plate first flange 242.

[0113] The first guide plate 240 includes a first guide plate panel 246. The first guide plate panel 246 is adjacent to the first guide plate second flange 244. The first guide plate panel 246 is positioned so that the first guide plate 240 is angled away from the mixer body at a second opening angle θ2 approximately in the range of 15° to 30° (e.g., 15°, 20°, 20.5°, 22.1°, 25°, 30°, etc.) to form a first guide plate flow orifice 248. The first guide plate flow orifice 248, if formed between a first edge of the first guide plate panel 246 and the mixer body 202 and between a second edge of the first guide plate panel 246 and the mixer body 202, allows the exhaust gas to flow through the second orifice 238 and enter the mixer body cavity 216. Fig.10 As shown, in some embodiments, the first guide plate 240 is angled inwardly and toward the mixer body central axis 204 such that the first guide plate 240 extends within the mixer body cavity 216 .

[0114] The first guide plate 240 includes a first guide plate sidewall 250 (e.g., guide plate side, first guide plate side, etc.). The first guide plate sidewall 250 is adjacent to the first guide plate first flange 242 and the first guide plate panel 246. The first guide plate sidewall 250 is configured to prevent exhaust gas from flowing between the first guide plate panel 246 and the first guide plate first flange 242. In some embodiments, the first guide plate sidewall 250 is configured to guide a portion of the exhaust gas flowing between the first guide plate panel 246 and the mixer body 202 through the second orifice 238. For example, when the exhaust gas flows downstream toward the first guide plate 240, a portion of the exhaust gas flows through the first guide plate flow orifice 248, and a portion of the portion of the exhaust gas contacts the first guide plate sidewall 250 and is guided toward the second orifice 238 and into the mixer body cavity 216. In some embodiments, the first guide plate sidewall 250 is rounded to promote exhaust gas swirling.

[0115] The first guide plate 240 includes a first guide plate tab 252. The first guide plate tab 252 is positioned within and along a portion of the second aperture 238. The first guide plate tab 252 abuts the first guide plate panel 246 and is configured to prevent exhaust gas from flowing along an edge of the first guide plate panel 246. The first guide plate tab 252 also couples the first guide plate 240 to the mixer body 202.

[0116] The mixer 200 includes a third orifice 254. The third orifice is substantially similar to the first orifice 214 and therefore will not be described in further detail. The mixer 200 includes a second guide plate 256. The second guide plate 256 is substantially similar to the first guide plate 240. The second guide plate 256 is centered on a second guide plate axis 255. The second guide plate axis 255 extends along the mixer body first plane 206 and intersects the conduit axis 106. The second guide plate axis 255 is at a second separation angle relative to the reference axis 232. Positioning. Second separation angle Approximately in the range of 300° to 330° (e.g., 300°, 305°, 310°, 315°, 320°, 325°, 330°, etc.).

[0117] The second guide plate 256 includes a second guide plate first flange 258, which is substantially similar to the first guide plate first flange 242 and is therefore not described in further detail. The second guide plate 256 includes a second guide plate second flange 260, which is similar to the first guide plate second flange 244 and is therefore not described in further detail.

[0118] The second guide plate 256 includes a second guide plate panel 262 that is substantially similar to the first guide plate panel 246. The second guide plate panel 262 is positioned such that the second guide plate 256 is angled away from the mixer body at a third opening angle θ, etc., approximately in the range of 15° to 30° (e.g., 15°, 20°, 20.5°, 22.1°, 25°, 30°, etc.) to form a second guide plate flow aperture 264. The second guide plate flow aperture 264 is substantially similar to the first guide plate flow aperture 248 and therefore will not be described in further detail. Fig.10 As shown, in some embodiments, the second guide plate 256 is angled inwardly and toward the mixer body central axis 204 at an angle relative to the third aperture 254 such that the second guide plate 256 extends within the mixer body cavity 216 .

[0119] The second guide plate 256 includes a second guide plate sidewall 266 (e.g., second guide plate side, etc.). The second guide plate sidewall 266 is similar to the first guide plate sidewall 250, and therefore will not be described in further detail. The second guide plate 256 includes a second guide plate tab 268. The second guide plate tab 268 is substantially similar to the first guide plate tab 252, and therefore will not be described in further detail.

[0120] like Fig.11 As shown in FIG. 1 , in some embodiments, the mixer 200 includes a fourth sensor 270 (eg, NO xThe fourth sensor 270 is coupled to the mixer body 202. In some embodiments, the fourth sensor 270 is coupled to the mixer body 202 between the first guide plate 240 and the injector plate 218. In some embodiments, the fourth sensor 270 is coupled to the mixer body 202 between the second guide plate 256 and the injector plate 218. The fourth sensor 270 is configured to measure (e.g., sense, detect, etc.) a parameter of the exhaust and hydrocarbon fluid within the mixer body cavity 216 (e.g., NO x concentration, CO concentration, CO2 concentration, O2 concentration, particulate matter concentration, nitrogen concentration, SO x The fourth sensor 270 is electrically or communicatively coupled to the aftertreatment system controller 128 and is configured to provide a fourth signal associated with the parameter to the aftertreatment system controller 128. The aftertreatment system controller 128 (e.g., via the aftertreatment system processing circuit 130, etc.) is configured to determine a fourth measurement value based on the fourth signal. The aftertreatment system controller 128 may be configured to control the intake chamber dosing module 112, the dosing module 172, the hydrocarbon fluid pump 154, and / or the air pump 122 based on the fourth signal. In addition, the aftertreatment system controller 128 may be configured to transmit the fourth signal to the central controller 136.

[0121] Return to reference Figure 4 , the aftertreatment system 100 includes an inlet flange 272 (e.g., a panel, a coupler, a ring, etc.). The inlet flange 272 includes an inlet flange body 274. The inlet flange body 274 is coupled to the mixer body 202. The inlet flange body 274 prevents exhaust gas from flowing directly into the mixer body cavity 216. In some embodiments, the inlet flange body 274 is also coupled to the inlet duct 109. The inlet flange 272 is used to separate the mixer body 202 from the inlet duct 109 and support the mixer body 202 within the inlet duct 109.

[0122] The inlet flange 272 includes a plurality of inlet flange orifices 276 (e.g., windows, holes, etc.). Each inlet flange orifice 276 extends through the inlet flange body 274. The inlet flange orifices 276 are arranged (e.g., arranged, positioned, etc.) circumferentially around the inlet flange body 274. Each of the inlet flange orifices 276 is configured to facilitate exhaust gas to reach the passage through the inlet flange body 274. The passage is positioned between the mixer body 202 and the inlet conduit 109, and is configured to receive exhaust gas flowing from the inlet flange orifices 276, so that the ejector plate 218 facilitates a portion of the exhaust gas to pass through the first orifice 214, the first guide plate 240 facilitates a portion of the exhaust gas to pass through the second orifice 238, and the second guide plate facilitates a portion of the exhaust gas to pass through the third orifice 254.

[0123] In various embodiments, such as Figure 4 As shown, the inlet flange 272 includes a plurality of inlet flange supports 278 (e.g., arms, rods, support structures, etc.). The inlet flange supports 278 are coupled to the inlet flange body 274 and are configured to couple the inlet flange 272 to the inlet conduit 109. In some embodiments, the inlet flange supports 278 can be integrally formed with the inlet flange body 274.

[0124] Each of the inlet flange supports 278 may define a portion of one of the inlet flange apertures 276. For example, where the inlet flange 272 includes four inlet flange supports 278, the inlet flange includes four inlet flange apertures 276 (e.g., a first inlet flange aperture 276 between a first inlet flange support 278 and a second inlet flange support 278, a second inlet flange aperture 276 between a second inlet flange support 278 and a third inlet flange support 278, a third inlet flange aperture 276 between a third inlet flange support 278 and a fourth inlet flange aperture 276 between a fourth inlet flange support 278 and the first inlet flange support 278). In various embodiments, the distance between each inlet flange support 278 may vary. For example, the distance between the first inlet flange support 278 and the second inlet flange support 278 may be greater than the distance between the second inlet flange support 278 and the third inlet flange support 278. Thus, the size of the first inlet flange aperture 276 is greater than the size of the second inlet flange aperture 276.

[0125] In operation, exhaust gas flows from the internal engine to the intake chamber 108. As described herein, the exhaust gas flows through upstream components (e.g., upstream catalyst component 138, upstream ammonia slip catalyst substrate 144, etc.), and flows through multiple inlet flange orifices 276. The exhaust gas flows toward the injector plate 218, the first guide plate 240, and the second guide plate 256. As described herein, the injector plate 218 helps a portion of the exhaust gas pass through the first orifice 214 and enter the mixer body cavity 216. As described herein, the first guide plate 240 helps a portion of the exhaust gas pass through the second orifice 238 and enter the mixer body cavity 216. As described herein, the second guide plate 256 helps a portion of the exhaust gas pass through the third orifice and enter the mixer body cavity 216. The exhaust gas is caused to swirl in the mixer body cavity 216 so as to mix with the hydrocarbon fluid. The exhaust gas flows downstream from the mixer body cavity 216.

[0126] refer to Fig.12 and Fig.13, the mixer 200 includes an outlet flange 280. The outlet flange 280 (e.g., a panel, a coupler, a ring, etc.). The outlet flange 280 is coupled to the inlet conduit 109. The outlet flange 280 is bisected by an outlet flange plane 281. The outlet flange 280 is centered on an outlet flange central axis 282. The outlet flange central axis 282 intersects and is orthogonal to the outlet flange plane 281. In some embodiments, the outlet flange central axis 282 is the same as the conduit axis 106. The outlet flange 280 includes an outlet flange body 284. The outlet flange body 284 is centered on the outlet flange central axis 282.

[0127] The outlet flange 280 includes an outlet flange opening 286. The outlet flange opening 286 extends through the outlet flange body 284. The outlet flange opening 286 is configured to provide exhaust gas from the mixer body cavity 216 through the outlet flange 280 to downstream components (e.g., the first oxidation catalyst component 158, the upstream particulate filter 168, the mixer 170, the first downstream catalyst component 176, the second downstream catalyst component 182, and the downstream ammonia slip catalyst substrate 188, etc.). The outlet flange opening 286 has a diameter approximately in the range of 145 mm to 215 mm (e.g., 137.75 mm, 145 mm, 150 mm, 155 mm, 160 mm, 165 mm, 200 mm, 171.18 mm, 175 mm, 180 mm, 185 mm, 190 mm, 195 mm, 200 mm, 205 mm, 210 mm, 215 mm, 225.75 mm, etc.).

[0128] refer to Fig.14 , the outlet flange opening center axis 288 deviates from the outlet flange center axis 282, so that the outlet flange opening 286 deviates from the center of the outlet flange 280. The outlet flange opening center axis 288 deviates from the outlet flange center axis 282 in the horizontal direction d1 by a range of about 25 mm to 45 mm (for example, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, etc.). The outlet flange opening center axis 288 deviates from the outlet flange center axis 282 in the vertical direction d2 by a range of about 25 mm to 45 mm (for example, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, etc.). By making the outlet flange opening 286 deviate from the center of the outlet flange 280, the pressure of the exhaust gas flowing out of the mixer body chamber 216 is reduced.

[0129] In some embodiments, the outlet flange opening 286 is centered about the outlet flange opening central axis 288. Fig.15 As shown, in some embodiments, the outlet flange opening central axis 288 is the same as the outlet flange central axis 282 such that the outlet flange opening 286 is centered on the outlet flange body 284 .

[0130] refer to Fig.16 , aftertreatment system 100 includes a perforated baffle 290. Perforated baffle 290 is positioned downstream of outlet flange 280 and coupled to inlet conduit 109. Perforated baffle 290 includes a perforated baffle body 292. Perforated baffle body 292 is centered on a perforated baffle body central axis (not shown).

[0131] The perforated baffle 290 includes a perforated region 294. The perforated baffle 290 includes a plurality of perforated baffle perforations 296 disposed on a perforated baffle body 292 within the perforated region 294.

[0132] In some embodiments, the perforated region 294 is configured such that at least three of the perforated baffle perforations 296 are intercepted (e.g., intersected, etc.) by a boundary (e.g., edge, border, etc.) of the perforated region 294. In other embodiments, the perforated region 294 is configured such that none of the perforated baffle perforations 296 are intercepted by a boundary (e.g., edge, border, etc.) of the perforated region 294.

[0133] The perforated diaphragm perforations 296 may be uniformly (eg, uniformly sized, uniformly spaced, uniformly sized and spaced, etc.) arranged within the perforated region 294, etc. The perforated diaphragm perforations 296 may be circumferentially arranged within the perforated region 294 in a grid pattern.

[0134] The perforated area 294 is positioned on the perforated baffle body 292 and is centered about the perforated baffle central axis. The perforated area 294 is defined by a certain shape (eg, circular, elliptical, oval, rectangular, etc.). In various embodiments, the perforated area 294 is circular.

[0135] The perforated baffle perforations 296 extend through the perforated baffle body 292. Each of the perforated baffle perforations 296 is configured to facilitate passage of exhaust and hydrocarbon fluid through the perforated baffle 290. As the exhaust and hydrocarbon fluid flow downstream through the outlet flange 280 toward the perforated baffle 290, the flow of the exhaust and hydrocarbon fluid is impeded by the perforated baffle body 292. As a result of the impediment, the exhaust and hydrocarbon fluid is redirected toward the plurality of perforated baffle perforations 296. The exhaust and hydrocarbon fluid then flow through the perforated baffle perforations 296, which creates further mixing of the exhaust and hydrocarbon fluid to facilitate regeneration of downstream components.

[0136] refer to Fig.17, the outlet flange 280 may include a plurality of cross members 298. The plurality of cross members 298 are coupled to the outlet flange body 284 and extend across the outlet flange opening 286. The plurality of cross members 298 are configured to impede the flow of exhaust gas flowing out of the outlet flange opening 286. For example, when the exhaust gas flows from the outlet flange opening 286, the exhaust gas contacts the plurality of cross members 298 and is redirected to flow around the plurality of cross members 298. Therefore, recirculation at the center of the outlet flange opening 286 is reduced, which facilitates regeneration of downstream components.

[0137] refer to Figures 18 to 23 According to one embodiment, the aftertreatment system 100 includes a mixer 300. The mixer 300 is substantially similar to the mixer 200. The mixer 300 includes a mixer body 302. The mixer body 302 is substantially similar to the mixer body 202. The mixer 300 includes an ejector plate 304 that is substantially similar to the ejector plate 218, and therefore will not be described in further detail. The mixer 300 also includes a first guide plate 306 that is substantially similar to the first guide plate 240 and a second guide plate 308 that is substantially similar to the second guide plate 256, and therefore will not be described in further detail. The mixer 300 includes a mixer body cavity 310 that is substantially similar to the mixer body cavity 216, and therefore will not be described in further detail.

[0138] The aftertreatment system 100 may include an inlet flange 312 (e.g., a panel, a coupler, a ring, etc.). The inlet flange 312 is used to separate the mixer body 302 from the inlet duct 109 and support the mixer body 302 in the inlet duct 109. The inlet flange 312 includes an inlet flange body 314. The inlet flange body 314 is coupled to the mixer body 202. The inlet flange body 314 is centered on the inlet flange body axis 316. In some embodiments, the inlet flange body axis 316 is the same as the duct axis 106. The inlet flange body 314 hinders the flow of exhaust gas into the mixer body cavity 310. In some embodiments, the inlet flange 312 is separated from the mixer body by a distance approximately in the range of 5 mm to 15 mm (e.g., 4.75 mm, 5 mm, 7 mm, 9 mm, 10 mm, 11 mm, 13 mm, 15 mm, 15.75 mm, etc.).

[0139] The inlet flange 312 includes a plurality of inlet flange apertures 318 (e.g., windows, holes, etc.). Each inlet flange aperture 318 extends through the inlet flange body 314. The inlet flange apertures 318 are arranged circumferentially around the inlet flange body 314. In some embodiments, the inlet flange apertures 318 are arranged around the inlet flange body axis 316. Each inlet flange aperture 318 is configured to facilitate a portion of the exhaust gas to pass through the mixer body 302 and enter the mixer body cavity 310.

[0140] Each inlet flange aperture 318 includes a first aperture edge 320. The first aperture edge has a radius of curvature approximately in the range of 60 mm to 100 mm (e.g., 57 mm, 60 mm, 65 mm, 70 mm, 72.5 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 105 mm, etc.).

[0141] Each inlet flange aperture 318 includes a second aperture edge 322 extending from the first aperture edge 320. Each inlet flange aperture includes a third aperture edge 324 extending from the first aperture edge 320 and opposite the second aperture edge 322. The second aperture edge 322 extends from the first aperture edge 320 a distance approximately in the range of 20 mm to 30 mm (e.g., 19 mm, 20 mm, 21 mm, 21.92 mm, 22 mm, 22.5 mm, 23 mm, 23.64 mm, 24 mm, 25 mm, 26 mm, 27 mm, 27.65 mm, 28 mm, 28.76 mm, 29 mm, 29.2 mm, 29.79 mm, 30 mm, 31.5 mm, etc.). The third aperture edge 324 extends a distance approximately in the range of 20 mm to 30 mm (e.g., 19 mm, 20 mm, 21 mm, 21.92 mm, 22 mm, 22.5 mm, 23 mm, 23.64 mm, 24 mm, 25 mm, 26 mm, 27 mm, 27.65 mm, 28 mm, 28.76 mm, 29 mm, 29.2 mm, 29.79 mm, 30 mm, 31.5 mm, etc.) from the first aperture edge 320. In some embodiments, the second aperture edge 322 and the third aperture edge 324 extend the same distance from the first aperture edge 320. In some embodiments, the third aperture edge 324 and the second aperture edge 322 extend different distances from the first aperture edge 320 relative to each other.

[0142] Each inlet flange aperture 318 includes a fourth aperture edge 326. The fourth aperture edge 326 extends between the second aperture edge 322 and the third aperture edge 324 and is opposite the first aperture edge 320. The fourth aperture edge 326 has a radius of curvature approximately in the range of 90 mm to 110 mm (e.g., 85.5 mm, 90 mm, 95 mm, 100 mm, 105 mm, 105.66 mm, 110 mm, 115.5 mm, etc.).

[0143] The inlet flange 312 includes a plurality of inlet flange supports 328 (eg, arms, rods, support structures, etc.) The inlet flange supports 328 are coupled to the inlet flange body 314 and are configured to couple the inlet flange 312 to the inlet conduit 109. Each inlet flange support 328 may define a portion of the inlet flange aperture 318.

[0144] The inlet flange 312 includes a plurality of louvers 330 (e.g., guides, guide plates, etc.). The plurality of louvers 330 may include louvers in a range of approximately between 1 louver and 10 louvers (e.g., 1 louver, 2 louvers, 3 louvers, 4 louvers, 5 louvers, 6 louvers, 7 louvers, 8 louvers, 9 louvers, 10 louvers, etc.). Each louver 330 extends from the inlet flange 312 into the mixer body cavity 310. Each louver 330 also extends along a portion of one of the inlet flange apertures 318. Each of the plurality of louvers 330 is configured to receive a portion of the exhaust gas flowing through the inlet flange aperture 318, and is configured to swirl a portion of the exhaust gas while promoting a portion of the exhaust gas to flow to the mixer body cavity 310. Thus, when exhaust flows through the system, the plurality of louvers 330 can help reduce the back pressure of the exhaust. Each louver 330 includes a first louver side 332. The first louver side 332 extends from the inlet flange body 314 into the mixer body cavity 310. The first louver side 332 can extend approximately in the range of 10 mm to 15 mm (e.g., 9.5 mm, 10 mm, 11 mm, 12 mm, 12.45 mm, 12.49 mm, 13 mm, 14 mm, 15 mm, 15.75 mm, etc.) into the mixer body cavity 310. Each louver 330 includes a second louver side 334. The second louver side 334 extends from the inlet flange body 314 into the mixer body cavity and is opposite to the first louver side 332. The second louver side 334 may extend into the mixer body cavity 310 by a length approximately in the range of 10 mm to 15 mm (eg, 9.5 mm, 10 mm, 11 mm, 12 mm, 12.45 mm, 12.49 mm, 13 mm, 14 mm, 15 mm, 15.75 mm, etc.).

[0145] Each louver 330 includes a third louver side 336. The third louver side 336 extends from the first louver side 332 to the second louver side 334 for a length approximately in the range of 20 mm to 30 mm (e.g., 19 mm, 20 mm, 21 mm, 22 mm, 23 mm, 24 mm, 25 mm, 26 mm, 27 mm, 27.71 mm, 28 mm, 29 mm, 30 mm, 31.5 mm, etc.). The third louver side 336 is configured to obstruct a portion of the exhaust gas from flowing through the orifice and cause the portion of the exhaust gas to change direction so as to swirl when the exhaust gas enters the mixer body cavity 310. In some embodiments, the plurality of louvers 330 may be tapered such that the side opposite the third louver side 336 is flush with the inlet flange body 314.

[0146] The aftertreatment system 100 can include an outlet flange 338 (e.g., a panel, a coupler, a ring, etc.). The outlet flange 338 is coupled to the inlet conduit 109. The outlet flange 338 is centered on an outlet flange central axis 340. In some embodiments, the outlet flange central axis 282 is the same as the conduit axis 106. The outlet flange 338 includes an outlet flange body 342. The outlet flange body 342 is centered on the outlet flange central axis 282.

[0147] The outlet flange body includes a plurality of outlet flange apertures 344. The plurality of outlet flange apertures 344 extend through the outlet flange body 342. The plurality of outlet flange apertures 344 are arranged around the outlet flange central axis 340. Each of the outlet flange apertures 344 is configured to facilitate a portion of the exhaust gas from the mixer body cavity 310 to pass through the outlet flange body 342.

[0148] Each outlet flange aperture 344 includes a first outlet aperture edge 346. The first outlet aperture edge has a radius of curvature approximately in the range of 60mm to 100mm (e.g., 57mm, 60mm, 65mm, 70mm, 72.5mm, 75mm, 80mm, 85mm, 90mm, 95mm, 100mm, 105mm, etc.).

[0149] Each outlet flange aperture 344 includes a second outlet aperture edge 348. The second outlet aperture edge 348 extends from the first outlet aperture edge 346. Each outlet flange aperture 344 includes a third outlet aperture edge 350. The third outlet aperture edge 350 extends from the first outlet aperture edge 346 and is opposite to the second outlet aperture edge 348. The second outlet aperture edge 348 extends from the first outlet aperture edge 346 by a distance in the range of approximately 20 mm to 30 mm (e.g., 19 mm, 20 mm, 21 mm, 21.92 mm, 22 mm, 22.5 mm, 23 mm, 23.64 mm, 24 mm, 25 mm, 26 mm, 27 mm, 27.65 mm, 28 mm, 28.76 mm, 29 mm, 29 mm, 22 mm, 29.79 mm, 30 mm, 31.5 mm, etc.). The third outlet orifice edge 350 extends a distance approximately in the range of 20 mm to 30 mm (e.g., 19 mm, 20 mm, 21 mm, 21.92 mm, 22 mm, 22.5 mm, 23 mm, 23.64 mm, 24 mm, 25 mm, 26 mm, 27 mm, 27.65 mm, 28 mm, 28.76 mm, 29 mm, 29.2 mm, 29.79 mm, 30 mm, 31.5 mm, etc.) from the first outlet orifice edge 346. In some embodiments, the second outlet orifice edge 348 and the third outlet orifice edge 350 extend the same distance. In other embodiments, the second outlet orifice edge 348 and the third outlet orifice edge 350 extend different distances.

[0150] Each outlet flange aperture 344 includes a fourth outlet aperture edge 352. The fourth outlet aperture edge 352 extends between the second outlet aperture edge 348 and the third outlet aperture edge 350 and is opposite the first outlet aperture edge 346. The fourth outlet aperture edge 352 has a radius of curvature approximately in the range of 90 mm to 110 mm (e.g., 85.5 mm, 90 mm, 95 mm, 100 mm, 105 mm, 105.66 mm, 110 mm, 115.5 mm, etc.).

[0151] The outlet flange 338 includes a plurality of outlet flange louvers 354 (e.g., louvers, guides, guide plates, etc.). The plurality of outlet flange louvers 354 may include a range of approximately 1 outlet flange louver to 10 outlet flange louvers (e.g., 1 outlet flange louver, 2 outlet flange louvers, 3 outlet flange louvers, 4 outlet flange louvers, 5 outlet flange louvers, 6 outlet flange louvers, 7 outlet flange louvers, 8 outlet flange louvers, 9 outlet flange louvers, 10 outlet flange louvers, etc.). Each outlet flange louver 354 extends from the outlet flange body 342 and extends along a portion of one of the plurality of outlet flange apertures 344. Each of the plurality of outlet flange louvers 354 is configured to receive a portion of the exhaust gas flowing downstream from the mixer body cavity 310 and swirl the portion of the exhaust gas while promoting downstream flow. Thus, the plurality of outlet flange louvers 354 can help reduce the back pressure of the exhaust gas as it flows through the system.

[0152] Each outlet flange louver 354 includes a first outlet flange louver edge 356. The first outlet flange louver edge 356 extends away from the outlet flange body 342. The first outlet flange louver edge 356 can extend away from the outlet flange body by a length in the range of approximately 15 mm to 30 mm (e.g., 14.25 mm, 15 mm, 16 mm, 17 mm, 17.19 mm, 17.3 mm, 18 mm, 18.7 mm, 19 mm, 20 mm, 21 mm, 22 mm, 23 mm, 23.84 mm, 24 mm, 25 mm, 26 mm, 27 mm, 28 mm, 28.12 mm, 28.41 mm, 29 mm, 30 mm, 31.5 mm, etc.). Each outlet flange louver 354 includes a second outlet flange louver edge 358. The second outlet flange louver edge 358 extends away from the outlet flange body 342 and is opposite the first outlet flange louver edge 356. The second outlet flange louver edge 358 extends away from the outlet flange body by a length approximately in the range of 15 mm to 30 mm (e.g., 14.25 mm, 15 mm, 16 mm, 17 mm, 17.19 mm, 17.3 mm, 18 mm, 18.7 mm, 19 mm, 20 mm, 21 mm, 22 mm, 23 mm, 23.84 mm, 24 mm, 25 mm, 26 mm, 27 mm, 28 mm, 28.12 mm, 28.41 mm, 29 mm, 30 mm, 31.5 mm, etc.).

[0153] Each outlet flange louver 354 includes a third outlet flange louver edge 360. The third outlet flange louver edge 360 ​​extends a length approximately in the range of 20 mm to 40 mm (e.g., 19 mm, 20 mm, 21 mm, 22 mm, 23 mm, 24 mm, 25 mm, 26 mm, 27 mm, 28 mm, 28.44 mm, 29 mm, 30 mm, 31 mm, 32 mm, 33 mm, 34 mm, 34.27 mm, 35 mm, 35.53 mm, 36 mm, 37 mm, 38 mm, 39 mm, 40 mm, etc.) from the first outlet flange louver edge 356 to the second outlet flange louver edge 358. The third outlet flange louver edge 360 ​​is configured to obstruct a portion of the exhaust gas from flowing through the outlet flange aperture 344 and redirect the portion of the exhaust gas to swirl as the exhaust gas flows downstream of the mixer 300. In some embodiments, plurality of outlet flange louvers 354 are tapered such that the side opposite third outlet flange louver edge 360 ​​is flush with outlet flange body 342 .

[0154] The outlet flange 338 also includes an outlet flange opening 362. The outlet flange opening 362 is substantially similar to the outlet flange opening 286 and therefore will not be described in further detail.

[0155] refer to Fig.24 , depicting a portion of the aftertreatment system 100. The mixer 300 is coupled to the inlet conduit 109. Downstream of the mixer 300, downstream components (e.g., the first oxidation catalyst member 158, etc.) are coupled to the inlet conduit 109. In some embodiments, the downstream components are positioned at a length L2 approximately in the range of between 15 mm and 40 mm (e.g., 14.25 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, etc.).

[0156] refer to Fig.25, depicts an aftertreatment system 400. Aftertreatment system 400 is substantially similar to aftertreatment system 100. Aftertreatment system 400 includes various components of aftertreatment system 100. For example, aftertreatment system 400 includes an inlet conduit 402 that is substantially similar to inlet conduit 109. Aftertreatment system 400 includes an upstream catalyst component 404 that is substantially similar to upstream catalyst component 138. Aftertreatment system 400 also includes a hydrocarbon decomposition chamber 406 that operates substantially similar to hydrocarbon decomposition chamber 146. Hydrocarbon decomposition chamber 406 is a mixer that is substantially similar to mixer 300. Hydrocarbon decomposition chamber 406 includes a plurality of outlet flange louvers 408. The plurality of outlet flange louvers 408 are substantially similar to the plurality of outlet flange louvers 354. The plurality of outlet flange louvers 408 help to change the direction of exhaust gas flowing out of hydrocarbon decomposition chamber 406.

[0157] The aftertreatment system 400 is different from the aftertreatment system 100 in that the aftertreatment system 400 includes an elbow conduit 410. The elbow conduit 410 is positioned downstream of the hydrocarbon decomposition chamber 406 and adjacent to the introduction conduit 402. The elbow conduit 410 is configured to receive exhaust gas from the hydrocarbon decomposition chamber 406 in a first direction and facilitate the change of the direction of the exhaust gas. In some embodiments, a plurality of outlet flange shutters 408 help the elbow conduit change direction. For example, the elbow conduit 410 receives exhaust gas in a first direction and causes the exhaust gas to change from the first direction to a second direction, wherein the second direction is parallel to the first direction and opposite to the first direction. The exhaust gas can then flow to the oxidation catalyst component 412. The oxidation catalyst component 412 is substantially similar to the first oxidation catalyst component 158. However, the oxidation catalyst component 412 is not aligned with the upstream catalyst component 404, but the oxidation catalyst component 412 is adjacent to and parallel to the upstream catalyst component 404.

[0158] Thus, the aftertreatment system 400 including the elbow conduit 410 may provide certain benefits. For example, the overall length of the aftertreatment system 400 is reduced, and the overall space required for the aftertreatment system is reduced.

[0159] Although aftertreatment systems 100 and 400 have been shown and described in the context of use with a diesel internal combustion engine, aftertreatment systems 100 and 400 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.

[0160] IV. Example Embodiment Configuration

[0161] 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. Conversely, 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.

[0162] As utilized herein, the terms "substantially," "generally," "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 a description of certain features described and claimed without limiting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating 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.

[0163] 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.

[0164] As used herein, the term "fluidically coupled to" and the like means that two components or objects have a path formed between the two components or objects, and a fluid (such as air, reductant, air-reductant mixture, hydrocarbon fluid, air-hydrocarbon mixture, exhaust gas) can flow in the path with or without an intermediate component or object. Examples of fluid couplings or configurations for achieving fluid communication may include pipes, channels, or any other suitable components for achieving fluid flow from one component or object to another component or object.

[0165] It is important to note that the structure and arrangement of the various systems shown in the various example embodiments are illustrative and non-restrictive in nature. All changes and modifications within the spirit and / or scope of the described embodiments need to be protected. It should be understood that some features may not be necessary, and embodiments lacking various features may be considered to be within the scope of the present disclosure, which is defined by the appended claims. When the language "a portion" is used, the item may include a portion and / or the entire item unless explicitly stated to the contrary.

[0166] In addition, the term "or" is used in its inclusive sense (rather than its exclusive meaning) in the context of a series of elements, such that when used to connect a series of elements, the term "or" means one, some, or all of the elements in the series. Unless otherwise explicitly stated, conjunction language such as the phrase "at least one of X, Y, and Z" is understood in the context to be generally used to express 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.

[0167] In addition, unless otherwise indicated, the range of values ​​used herein (e.g., W1 to W2, etc.) includes the maximum and minimum values ​​of the range (e.g., W1 to W2 includes W1 and includes W2, etc.). In addition, unless otherwise indicated, the range of values ​​(e.g., W1 to W2, etc.) is not necessarily required to include intermediate values ​​within the range of values ​​(e.g., W1 to W2 may only include W1 and W2, etc.).

Claims

1. An exhaust aftertreatment system, comprising: an introducing catheter centered on the catheter axis; a dosing module coupled to the inlet conduit and comprising an injector configured to provide a hydrocarbon fluid into the inlet conduit along an injection axis; and A mixer comprising: a mixer body disposed within the inlet conduit, the mixer body being configured to receive the exhaust gas and the hydrocarbon fluid, a first aperture extending through the mixer body, the first aperture being configured to facilitate exhaust gas flow through the mixer body, an ejector plate coupled to the mixer body along a portion of the first aperture, a portion of the ejector plate angled away from the mixer body at a first opening angle, and An injector cone is positioned on the injector plate, the injector cone including an injection orifice configured to facilitate flow of the hydrocarbon fluid through the injector cone and the injector plate.

2. The exhaust aftertreatment system according to claim 1, wherein: The mixer body is bisected by a mixer body plane, the mixer body plane intersecting the conduit axis and being orthogonal to the conduit axis; a portion of the ejector plate centered about a reference axis extending along the mixer body plane and intersecting the conduit axis; The mixer also includes: a second aperture extending through the mixer body, the second aperture being configured to facilitate exhaust gas flow through the mixer body, and a guide plate coupled to the mixer body along a portion of the second aperture, a portion of the guide plate angled away from the mixer body at a second opening angle, a portion of the guide plate centered about a guide plate axis extending along a plane of the mixer body and intersecting the conduit axis; and The mixer body, the ejector plate, and the guide plate are configured such that the reference axis is separated from the guide plate axis by a first separation angle, the first separation angle being between 30 degrees and 60 degrees.

3. The exhaust aftertreatment system according to claim 1, further comprising: an inlet flange coupled to the mixer body and the inlet conduit, the inlet flange comprising a plurality of inlet flange apertures, each of the inlet flange apertures being configured to facilitate flow of exhaust gas through the inlet flange apertures and around the mixer body; and An outlet flange is coupled to the mixer body and the inlet conduit downstream of the inlet flange, the outlet flange including an outlet flange opening configured to facilitate exhaust gas flow through the outlet flange.

4. The exhaust aftertreatment system according to claim 2, further comprising: a third aperture extending through the mixer body, the third aperture configured to facilitate exhaust gas flow through the mixer body; and a second guide plate coupled to the mixer body along a portion of the third aperture, a portion of the second guide plate angled away from the mixer body at a third opening angle, a portion of the second guide plate centered about a second guide plate axis extending along a plane of the mixer body and intersecting the conduit axis; Wherein the mixer body, the ejector plate and the second guide plate are configured such that the reference axis is separated from the second guide plate axis by a second separation angle, the second separation angle being between 300 degrees and 330 degrees.

5. The exhaust aftertreatment system according to claim 2, wherein: The mixer body is bisected by a mixer body second plane, the mixer body second plane intersecting the conduit axis and being orthogonal to the conduit axis and the mixer body plane; and The mixer body is configured such that the reference axis is separated from the mixer body second plane by a reference angle, the reference angle being between 2 degrees and 10 degrees.

6. The exhaust aftertreatment system according to claim 4, wherein: the ejector plate including an ejector plate side coupling the ejector plate to the mixer body along a portion of the first aperture and facilitating passage of a portion of exhaust gas flow through the first aperture; the guide plate including a guide plate side that couples the guide plate to the mixer body along a portion of the second aperture and facilitates flow of exhaust gas through the second aperture; and The second guide plate includes a second guide plate side that couples the second guide plate to the mixer body along a portion of the third aperture and facilitates flow of exhaust gas through the third aperture.

7. The exhaust aftertreatment system according to claim 3, wherein: The outlet flange is divided into two by an outlet flange plane, and the outlet flange plane intersects with the conduit axis and is orthogonal to the conduit axis; The outlet flange is centered on an outlet flange central axis, the outlet flange central axis intersects with the outlet flange plane and is orthogonal to the outlet flange plane; and The outlet flange opening is centered on the central axis of the outlet flange opening, which intersects the outlet flange plane and is orthogonal to the outlet flange plane, and deviates from the outlet flange plane by 25 mm to 45 mm in the horizontal direction, and deviates from the outlet flange plane by 25 mm to 45 mm in the vertical direction.

8. The exhaust aftertreatment system according to claim 1, further comprising: An inlet flange, the inlet flange comprising: an inlet flange aperture extending through the inlet flange, the aperture being configured to facilitate exhaust gas flow through the inlet flange and into the mixer body, and A louver extends from the inlet flange into the mixer body along a portion of the inlet flange aperture and is configured to receive exhaust gas flowing through the inlet flange aperture.

9. The exhaust aftertreatment system according to claim 8, wherein: The inlet flange further includes a plurality of support structures disposed circumferentially between the inlet flange and the mixer body, each of the support structures being configured to couple the inlet flange to the mixer body; and At least two of the support structures, the mixer body, and the inlet flange form an aperture between the inlet flange and the mixer body, the aperture being configured to facilitate flow of exhaust gas within the mixer body.

10. A mixer for an exhaust gas aftertreatment system, comprising: a mixer body centered about a mixer body central axis and configured to receive exhaust gas and hydrocarbon fluid; a first aperture extending through the mixer body, the first aperture being configured to facilitate flow of exhaust gas through the mixer body; and A first guide plate coupled to the mixer body along a portion of the first aperture and centered about a first guide plate central axis, the first guide plate comprising: a first guide plate first flange and a first guide plate second flange, the first guide plate first flange and the first guide plate second flange coupling a portion of the first guide plate to the mixer body, a first guide plate panel abutting each of the first guide plate second flanges, the first guide plate panel forming a first guide plate flow aperture, a first guide plate sidewall abutting the first guide plate first flange and the first guide plate panel, the first guide plate sidewall being configured to facilitate flow between the first guide plate panel and the mixer body, and A first guide plate tab is positioned within and along a portion of the second aperture and adjacent to the first guide plate panel, wherein the first guide plate tab couples the first guide plate to the mixer body and is configured to prevent exhaust gas from flowing along an edge of the first guide plate panel.

11. The mixer according to claim 10, further comprising: a second aperture extending through the mixer body, the second aperture configured to facilitate exhaust gas flow through the mixer body; an ejector plate coupled to the mixer body along a portion of the second aperture and centered about a reference axis; a first plane of the mixer body, the first plane of the mixer body being orthogonal to the central axis of the mixer body; and a mixer body second plane, the mixer body second plane being orthogonal to each of the central axis and the mixer body first plane; wherein the reference axis is separated from the second plane of the mixer body by a reference angle, the reference angle being in a range between 2 degrees and 10 degrees; and Wherein, the central axis of the first guide plate forms a first separation angle with respect to the reference axis, and the first separation angle is between 30 degrees and 60 degrees.

12. The mixer assembly of claim 10, further comprising: a third aperture extending through the mixer body, the third aperture being configured to facilitate exhaust gas flow through the mixer body, A second guide plate coupled to the mixer body along a portion of the third aperture and positioned at a second guide plate center, the second guide plate comprising: a second guide plate first flange and a second guide plate second flange, the second guide plate first flange and the second guide plate second flange coupling a portion of the second guide plate to the mixer body, a second guide plate panel abutting each of the second guide plate second flanges, the second guide plate panel forming a second guide plate flow aperture; a second guide plate side wall, the second guide plate side wall being adjacent to the second guide plate first flange and the second guide plate panel, the second guide plate side wall being configured to facilitate flow between the second guide plate panel and the mixer body, a second guide plate tab positioned within and along a portion of the third aperture and adjacent to the second guide plate panel, wherein the second guide plate tab couples the second guide plate to the mixer body and prevents exhaust gas from flowing along an edge of the second guide plate panel; and An injector cone is positioned on the injector plate, the injector cone including an injection orifice configured to facilitate flow of the hydrocarbon fluid through the injector cone and the injector plate.

13. The mixer assembly of claim 12, further comprising: a second aperture extending through the mixer body, the second aperture configured to facilitate exhaust gas flow through the mixer body; an ejector plate coupled to the mixer body along a portion of the second aperture and centered about a reference axis; a first plane of the mixer body, the first plane of the mixer body being orthogonal to the central axis of the mixer body; and a mixer body second plane, the mixer body second plane being orthogonal to each of the central axis and the mixer body first plane; wherein the reference axis is separated from the second plane of the mixer body by a reference angle, the reference angle being in a range between 2 degrees and 10 degrees; and Wherein, the central axis of the second guide plate is at a second separation angle relative to the reference axis, and the second separation angle is between 300 degrees and 330 degrees.

14. An exhaust aftertreatment system comprising: The mixer according to claim 10; An introducer catheter centered on the catheter axis; and an outlet flange coupled to the mixer body and the inlet conduit downstream of the inlet flange, the outlet flange comprising: an outlet flange opening configured to facilitate exhaust gas flow through the outlet flange, and A plurality of outlet flange apertures are defined around the outlet flange opening.

15. The exhaust aftertreatment system according to claim 14, wherein: The outlet flange is divided into two by an outlet flange plane, and the outlet flange plane intersects with the conduit axis and is orthogonal to the conduit axis; The outlet flange is centered on an outlet flange central axis, the outlet flange central axis intersects with the outlet flange plane and is orthogonal to the outlet flange plane; and The outlet flange opening is centered on the central axis of the outlet flange opening, which intersects the outlet flange plane and is orthogonal to the outlet flange plane, and deviates from the outlet flange plane by 25 mm to 45 mm in the horizontal direction, and deviates from the outlet flange plane by 25 mm to 45 mm in the vertical direction.

16. The exhaust aftertreatment system according to claim 15, wherein: The outlet flange also includes a plurality of outlet flange louvers extending from an edge of each of the plurality of outlet flange apertures, the plurality of outlet flange louvers being configured to receive a portion of the exhaust gas from the mixer body to induce a swirl of the exhaust gas moving downstream in the aftertreatment system.

17. The exhaust aftertreatment system according to claim 14, further comprising: An inlet flange is coupled to the mixer body and the inlet conduit and is positioned a distance in the range of 5 mm to 15 mm away from the mixer body, the inlet flange comprising a plurality of inlet flange orifices, each of the inlet flange orifices being configured to facilitate exhaust gas flow through the inlet flange orifice and around the mixer body.

18. A post-processing system comprising: A mixer, comprising: a mixer body defining a mixer body cavity, the mixer body being centered about a mixer body central axis and configured to receive exhaust gas and a hydrocarbon fluid; a first aperture, a second aperture, and a third aperture extending through the mixer body, each of the first aperture, the second aperture, and the third aperture being configured to facilitate exhaust gas flow through the mixer body; an ejector plate coupled to the mixer body along a portion of the first aperture and centered about a reference axis, the ejector plate defining an ejector plate aperture at an angle away from the mixer body at a first opening angle; a first guide plate coupled to the mixer body along a portion of the second aperture adjacent the ejector plate, a portion of the first guide plate being at a second opening angle relative to the mixer body to define a first guide plate flow aperture; a second guide plate coupled to the mixer body along a portion of the third aperture adjacent the ejector plate, opposite the first guide plate, a portion of the second guide plate being at a third opening angle relative to the mixer body to define a second guide plate flow aperture; and an injector cone positioned on the injector plate, the injector cone including an injection orifice configured to facilitate flow of the hydrocarbon fluid through the injector cone and the injector plate along an injection axis; wherein the first guide plate flow aperture is configured to promote exhaust gas flow into the mixer chamber away from the injection axis, and the second guide plate flow aperture is configured to promote exhaust gas flow into the mixer chamber toward the injection axis plate to promote exhaust gas swirling.

19. The aftertreatment system according to claim 18, wherein: A portion of the first guide plate is angled away from the mixer body at the second opening angle, and the second guide plate is angled away from the mixer body at the third opening angle, the first opening angle and the second opening angle being within a range between 15 degrees and 30 degrees.

20. The aftertreatment system of claim 18, wherein: A portion of the first guide plate is angled inwardly and toward the mixer body central axis at the second opening angle, and the second guide plate is angled inwardly and toward the mixer body central axis at the third opening angle, the first opening angle and the second opening angle being within a range between 15 degrees and 30 degrees.

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