Reductant delivery system including reductant pump

Abstract

A reductant delivery system designed for rapid thawing of reductant includes a reductant pump. A reductant pump includes a filter housing, a pump, a filter cartridge, a cover, and a start-up heater. The filter housing includes a filter head, a pump chamber, and a transfer channel. A cover is coupled to the filter head to define a filter head cavity. The pump provides reductant from the pump chamber to the transfer passage. The filter cartridge includes a filter cartridge cavity within the filter head cavity. A start-up heater is positioned within the filter cartridge cavity. The reductant delivery system also includes a reductant delivery system controller and a main tank storing reductant, the main tank including a lift pump and a temperature sensor. The temperature sensor is communicatively coupled to the reductant delivery system controller. A reductant delivery system controller receives a signal from the temperature sensor.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 421,061, filed on October 31, 2022, the entire disclosure of which is hereby incorporated by reference into this application. Technical Field

[0003] The present application generally relates to a reductant delivery system including a reductant pump for providing reductant to an exhaust aftertreatment system of an internal combustion engine.

[0004] background

[0005] For internal combustion engines, such as diesel engines, nitrogen oxide (NOx) compounds may be emitted in the exhaust. For example, it may be desirable to reduce NO x emissions to comply with environmental regulations. x emissions, a reductant may be injected into the exhaust gas through a reductant delivery system coupled to a dosing system and within the vehicle system. The reductant helps convert a portion of the exhaust gas into non-NO x emissions, such as nitrogen (N2), carbon dioxide (CO2), and water (H2O), thereby reducing NO x Emissions.

[0006] The reducing agent is stored in tanks and transported through supply lines. When stored at low temperatures, the reducing agent may freeze inside the tanks and supply lines. A heater may be used to thaw the reducing agent. Heating the reducing agent can be a time-consuming and energy-intensive process because the heater typically heats the entire volume of the tank.

[0007] Overview

[0008] In one embodiment, a diesel exhaust fluid system includes a reductant pump, the reductant pump including a filter housing, the filter housing including: an inlet chamber for receiving a reductant; a pump chamber connected to the inlet chamber, the pump chamber receiving the reductant from the inlet chamber and delivering the reductant to a delivery channel; an outlet channel and a filter head. The reductant pump also includes: a pump connected to the filter housing, the pump providing the reductant to the delivery channel; and a filter cartridge, the filter cartridge including a top end plate, a bottom end plate and a center tube surrounded by a filter medium, the top end plate, the bottom end plate and the center tube defining a filter cartridge cavity. A cover is included, which is located outside the filter cartridge and is connected to the filter head. The reductant pump also includes a startup heater, which is at least partially positioned in the filter cavity and is configured to heat the reductant in the filter cartridge cavity.

[0009] In another embodiment, a diesel engine exhaust fluid system includes a reductant delivery system. The reductant delivery system includes a main tank and a starter tank, the main tank also including: a main heater, the main heater is disposed in the main tank volume, the main heater is configured to heat the reductant; a lift pump, the lift pump is configured to deliver the reductant to the supply line; a temperature sensor, the temperature sensor is configured to determine the temperature of the reductant in the main tank volume; and a starter tank. The starter tank also includes a starter tank body and a starter heater. The reductant delivery system also includes a reductant delivery system controller, the reductant delivery system controller is configured to receive a signal from the temperature sensor and selectively activate the main lift pump. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] 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:

[0012] Figure 1 is a schematic block diagram of an example exhaust aftertreatment system;

[0013] Figure 2 is a schematic block diagram of a reductant delivery system for an exhaust aftertreatment system according to various embodiments;

[0014] Figure 3 is a schematic block diagram of another reductant delivery system for an exhaust aftertreatment system according to various embodiments;

[0015] Figure 4 is a schematic block diagram of a portion of yet another reductant delivery system for an exhaust aftertreatment system according to various embodiments;

[0016] Figure 5 is a schematic block diagram of a portion of yet another reductant delivery system for an exhaust aftertreatment system according to various embodiments;

[0017] Figure 6 is a schematic block diagram of a portion of yet another reductant delivery system for an exhaust aftertreatment system according to various embodiments;

[0018] Figure 7 is a schematic block diagram of a portion of yet another reductant delivery system for an exhaust aftertreatment system according to various embodiments;

[0019] Figure 8 is a schematic block diagram of a portion of yet another reductant delivery system for an exhaust aftertreatment system according to various embodiments;

[0020] Fig. 9 is a schematic block diagram of yet another reductant delivery system for an exhaust aftertreatment system according to various embodiments; and

[0021] Fig.10 is a schematic block diagram of a portion of yet another reductant delivery system for an exhaust aftertreatment system according to various embodiments.

[0022] 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.

[0023] Detailed Description

[0024] The following is a more detailed description of various concepts and embodiments related to providing a method, apparatus, and method for providing a reductant delivery system including a reductant pump. The various concepts introduced above and discussed in more detail below can be implemented in any of a variety of ways, as the concepts described are not limited to any particular embodiment. Examples of specific embodiments and applications are provided primarily for illustrative purposes.

[0025] I. Overview

[0026] Internal combustion engines (e.g., diesel internal combustion engines, etc.) produce gases containing NO x , N2, CO2 and / or H2O components. In some applications, an exhaust aftertreatment system is used to distribute a reductant to the exhaust gas to reduce NOx emissions in the exhaust gas. The reductant must be stored in a fluid tank (e.g., a reservoir, a DEF tank, etc.) within the reductant delivery system. The reductant delivery system pumps the reductant out of the fluid tank and delivers the reductant to the aftertreatment system.

[0027] For the reductant delivery system to provide the reductant to the exhaust, the reductant needs to be in liquid form, which requires the reductant to be above freezing temperature (e.g., below 12°F, below -11°C, etc.). When the reductant is stored at or below freezing temperatures, the reductant may freeze in the fluid tank. When a portion of the reductant freezes, the portion of the reductant must be heated to convert from a solid form to a liquid form before the portion of the reductant is provided to the exhaust.

[0028] Various heating devices may be used to heat the reductant. However, the reductant may be heated more efficiently by providing an additional tank or chamber to isolate a smaller volume of the reductant for heating within the reductant delivery system.

[0029] Some embodiments herein relate to a reductant delivery system, which includes a reductant pump and is capable of quickly thawing the reductant before providing the reductant to the reductant pump. The reductant pump includes a filter housing connected to the pump. The filter housing includes an inlet channel, a pump chamber, a transfer channel, an outlet channel and a filter head. The reductant in the reductant pump flows through the inlet channel and enters the pump chamber. The pump draws the reductant from the pump chamber and pushes the reductant into the transfer channel. The reductant pump also includes a filter cartridge, which includes a top end plate, a bottom end plate and a center tube, and the center tube defines a filter cartridge cavity in which the filter medium is disposed. The reductant pump also includes a cover connected to the filter head, which defines the filter head cavity. The filter head cavity includes a startup heater to heat the reductant in the reductant pump.

[0030] Some embodiments of the present invention also relate to a reductant delivery system, which includes a main tank, a starter tank and a reductant delivery system controller. The starter tank includes a starter tank body and a starter heater. The starter heater heats the reductant stored in the starter tank body. The main tank includes a main tank body, a main heater, a lift pump and a temperature sensor. The main heater heats the reductant stored in the main tank body. The temperature sensor provides a signal related to the temperature of the reductant stored in the main tank to the reductant delivery system controller. The reductant delivery system controller determines the temperature of the reductant based on the received signal. The reductant delivery system controller causes the lift pump to deliver the reductant to the reductant pump based on the temperature. The reductant delivery system controller can also operate the main heater based on the temperature.

[0031] II. Overview of exhaust aftertreatment system

[0032] Figure 1 An exhaust aftertreatment system 100 is depicted having an example reductant delivery system 102 for an exhaust conduit system 104. The exhaust aftertreatment system 100 includes the reductant delivery system 102, a particulate filter 106 (e.g., a diesel particulate filter (DPF)), a decomposition chamber 108 (e.g., a reactor, a reactor conduit, a conduit, etc.), and a catalyst component 110 (e.g., an SCR catalyst component, etc.).

[0033] The particulate filter 106 is configured (e.g., constructed to, capable of, etc.) to remove particulate matter, such as soot, from the exhaust gas flowing in the exhaust duct system 104. The particulate filter 106 includes an inlet at which the exhaust gas is received and an outlet at which the exhaust gas exits after substantially filtering the particulate matter from the exhaust gas and / or converting the particulate matter into carbon dioxide. In some embodiments, the particulate filter 106 may be omitted.

[0034] The decomposition chamber 108 is configured to receive exhaust gas from the particulate filter 106 and a reductant (eg, urea, diesel exhaust fluid (DEF), etc.) from the reductant delivery system 102. Urea aqueous solution (UWS), water-soluble urea solution (e.g., AUS32, etc.). When the reductant is introduced into the exhaust gas, it can promote the reduction of undesirable components in the exhaust gas (e.g., NO x The decomposition chamber 108 includes an inlet and an outlet, the inlet of the decomposition chamber 108 is in fluid communication with the particulate filter 106 to receive the exhaust gas containing NOx emissions, and the outlet of the decomposition chamber 108 is used for the exhaust gas, NOx emissions, ammonia and / or reductant to flow to the catalyst component 110.

[0035] The dispenser assembly 112 is fluidly coupled to a reductant source 114 (eg, fluidly configured to communicate with the reductant source 114, etc.). The reductant source 114 may include a plurality of reductant sources 114. The reductant source 114 may be, for example, a reductant source containing The diesel exhaust fluid tank. The reductant pump 116 (e.g., a supply unit, etc.) is used to pressurize the reductant from the reductant source 114 to deliver it to the dispenser assembly 112. In some embodiments, the reductant pump 116 is pressure-controlled (e.g., controlled to obtain a target pressure, etc.). The reductant pump 116 includes a reductant filter 118. Before the reductant is provided to the internal components (e.g., pistons, blades, etc.) of the reductant pump 116, the reductant filter 118 first filters the reductant (e.g., strains, etc.). For example, the reductant filter 118 can inhibit or prevent solids (e.g., solidified reductant, pollutants, etc.) from being transmitted to the internal components of the reductant pump 116. In this way, the reductant filter 118 can contribute to the extended desired operation of the reductant pump 116. In some embodiments, the reductant pump 116 is connected (e.g., fastened, attached, attached, welded, etc.) to the chassis of the vehicle associated with the exhaust aftertreatment system 100.

[0036] The distributor assembly 112 includes at least one injector 120. Each injector 120 is configured to distribute the reductant into the exhaust gas at the injection axis 119 (e.g., in the decomposition chamber 108, etc.). The exhaust aftertreatment system 100 includes a mixer 121 (e.g., a vortex generating device, a blade plate, an inlet plate, a deflection plate, etc.). At least a portion of the mixer 121 can be located in the decomposition chamber 108. However, at least a portion of the mixer 121 can also be located in a conduit of the exhaust conduit system 104 (e.g., a conduit upstream of the decomposition chamber 108, etc.). The mixer 121 is configured to receive the exhaust gas from the decomposition chamber 108 and the reductant from the injector 120, so that the injection axis 119 extends into the mixer 121. The mixer 121 is also configured to promote mixing of the exhaust gas and the reductant. The mixer 121 is configured to promote swirl (e.g., tumbling, rotation, etc.) of the exhaust gas and mixing (e.g., combining, etc.) of the exhaust gas and the reductant so as to disperse the reductant within the exhaust gas downstream of the mixer 121. By dispersing the reductant within the exhaust gas using the mixer 121 (e.g., to obtain an increased homogeneity index, etc.), the reduction of emissions of undesirable components in the exhaust gas is enhanced or the temperature of the exhaust gas may be increased.

[0037] When the injection axis 119 extends into the mixer 121, the injection axis 119 may extend into the mixer 121 at an angle relative to the central axis of the mixer 121. For example, in some embodiments, the injection axis 119 may coincide with the central axis of the mixer 121. In other embodiments, the injection axis 119 may be perpendicular to the central axis of the mixer 121. In yet another embodiment, the injection axis 119 may be parallel to the central axis of the mixer 121.

[0038] In some embodiments, the ejector 120 is not directly coupled to the mixer 121. In these embodiments, the ejector 120 and the mixer 121 can each be coupled to the same component (e.g., a panel, a chamber, etc.). In other embodiments, the ejector 120 is directly coupled to the mixer 121. In these embodiments, the ejector 120 and the mixer 121 can also each be coupled to the same component. In some embodiments, the ejector 120 is not disposed within the mixer 121. In other embodiments, the ejector 120 can be at least partially disposed within the mixer 121.

[0039] In some embodiments, the reductant delivery system 102 further includes an air pump 122. In these embodiments, the air pump 122 draws air from an air source 124 (e.g., an air intake, etc.) and passes the air through an air filter 126 disposed upstream of the air pump 122. In addition, the air pump 122 provides air to the dispenser assembly 112 via a conduit. In these embodiments, the dispenser assembly 112 is configured to mix air and the reductant into an air-reductant mixture and provide the air-reductant mixture to the decomposition chamber 108. In other embodiments, the reductant delivery system 102 does not include the air pump 122 or the air source 124. In such embodiments, the dispenser assembly 112 is not configured to mix the reductant with air.

[0040] The doser assembly 112 and the reductant pump 116 are also electrically or communicatively coupled to a reductant delivery system controller 128. The reductant delivery system controller 128 controls the doser assembly 112 to dispense the reductant into the decomposition chamber 108. The reductant delivery system controller 128 may also control the reductant pump 116.

[0041] The reductant delivery system controller 128 includes a processing circuit 130. The processing circuit 130 includes a processor 132 and a memory 134. The processor 132 may include a microprocessor, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), etc. or a combination thereof. The memory 134 may include, but is not limited to, an electronic, optical, magnetic or any other storage or transmission device capable of providing program instructions to the processor, ASIC, FPGA, etc. The 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 reductant delivery system controller 128 can read instructions. The instructions may include codes from any suitable programming language. The memory 134 may include a variety of modules including instructions configured to be implemented by the processor 132.

[0042] In various embodiments, the reductant delivery system controller 128 is configured to communicate with a central controller 136 (e.g., an engine control unit (ECU), an engine control module (ECM), etc.) of an internal combustion engine having the exhaust aftertreatment system 100. In some embodiments, the central controller 136 and the reductant delivery system controller 128 are integrated into a single controller.

[0043] In some embodiments, the central controller 136 may communicate with a display device (e.g., a screen, a monitor, a touch screen, a heads up display (HUD), an indicator light, etc.). The display device may be configured to change state in response to receiving information from the central controller 136. For example, the display device may be configured to change between a static state (e.g., displaying a green light, displaying a "system OK" message, etc.) and an alarm state (e.g., displaying a flashing red light, displaying a "maintenance required" message, etc.) based on communications from the central controller 136. By changing state, the display device may provide an indication of the state (e.g., operation, maintenance required, etc.) of the reductant delivery system 102 to a user (e.g., an operator, etc.).

[0044] The decomposition chamber 108 is located upstream of the catalyst member 110. As a result, the reductant is injected upstream of the catalyst member 110 so that the catalyst member 110 receives a mixture of the reductant and the exhaust gas. The reductant droplets undergo evaporation, pyrolysis, and hydrolysis processes to form non-NOx emissions (e.g., gaseous ammonia, etc.) within the exhaust conduit system 104.

[0045] The catalyst component 110 includes an inlet and an outlet. The inlet of the catalyst component 110 is in fluid communication with the decomposition chamber 108 , exhaust gas and reductant are received from the inlet of the catalyst component 110 , and the outlet of the catalyst component 110 is in fluid communication with one end of the exhaust conduit system 104 .

[0046] The exhaust aftertreatment system 100 may also include an oxidation catalyst component (eg, a diesel oxidation catalyst (DOC)) in fluid communication with the exhaust conduit system 104 (eg, downstream of the catalyst component 110 or upstream of the particulate filter 106 ) to oxidize carbon monoxide in the exhaust gas.

[0047] In some embodiments, the particulate filter 106 may be positioned downstream of the decomposition chamber 108. For example, the particulate filter 106 and the catalyst member 110 may be combined into a single unit. In some embodiments, the doser assembly 112 may alternatively be positioned downstream of the turbocharger or upstream of the turbocharger.

[0048] The exhaust aftertreatment system 100 also includes a distributor mounting bracket 138 (e.g., a mounting bracket, a coupler, a plate, etc.). The distributor mounting bracket 138 couples the distributor assembly 112 to components of the exhaust aftertreatment system 100. The distributor mounting bracket 138 is configured to reduce heat transfer from the exhaust gas passing through the exhaust duct system 104 to the distributor assembly 112. In this way, the distributor assembly 112 can operate more efficiently and more ideally than other distributor assemblies that cannot reduce heat transfer. In addition, the distributor mounting bracket 138 is configured to facilitate reliable installation of the distributor assembly 112. This can reduce manufacturing costs associated with the exhaust aftertreatment system 100 and ensure repeated desired installations of the distributor assembly 112.

[0049] In various embodiments, the dispenser mounting bracket 138 couples the dispenser assembly 112 to the decomposition chamber 108. In some embodiments, the dispenser mounting bracket 138 couples the dispenser assembly 112 to an exhaust duct of the exhaust duct system 104. For example, the dispenser mounting bracket 138 may couple the dispenser assembly 112 to an exhaust duct of the exhaust duct system 104 located upstream of the decomposition chamber 108, or to an exhaust duct of the exhaust duct system 104 located downstream of the decomposition chamber 108. In some embodiments, the dispenser mounting bracket 138 couples the dispenser assembly 112 to the particulate filter 106 and / or the catalyst member 110. The location of the dispenser mounting bracket 138 may vary depending on the application of the exhaust aftertreatment system 100. For example, in some exhaust aftertreatment systems 100, the dispenser mounting bracket 138 may be located at a location more upstream than in other exhaust aftertreatment systems 100. In addition, some exhaust aftertreatment systems 100 may include multiple dispenser assemblies 112, and therefore may include multiple dispenser mounting brackets 138.

[0050] III. Overview of Reducing Agent Delivery Systems

[0051] Figure 2 A reductant delivery system 102 is shown according to various embodiments. The reductant delivery system 102 includes a main tank 202 (e.g., a reductant tank, a main tank, etc.). The main tank 202 includes a main tank body 204. The main tank body 204 defines a main tank volume 206. The main tank body 204 is configured to store the reductant within the main tank volume 206.

[0052] The main tank 202 also includes a main heater 208 (e.g., a heating element, etc.). In various embodiments, a portion of the main heater 208 is coupled to the main tank body 204. For example, a portion of the main heater 208 can be fastened to the main tank body 204 (e.g., using fasteners, etc.). In other embodiments, no portion of the main heater 208 is coupled to the main tank body 204. Instead, a portion of the main heater 208 is coupled to an intermediate coupler (e.g., a bracket, a hanger, a fitting, etc.) that is coupled to the main tank body 204. A portion of the main heater 208 is disposed in the main tank volume 206. The main heater 208 is configured to heat the reductant stored in the main tank volume 206. The main heater 208 can be an electric heater (e.g., a resistive heater, a heating coil, etc.), a heat exchanger (e.g., a fluid heat exchanger, a heating fluid loop, etc.), a Peltier heater (e.g., a thermoelectric heater, etc.), or another heater having similar functionality.

[0053] The main tank 202 also includes a temperature sensor 210. In various embodiments, the temperature sensor 210 is positioned within the main tank body 204. For example, the temperature sensor 210 can be fastened to the main tank body 204. In other embodiments, the temperature sensor 210 can be fastened to other structures positioned within the main tank body 204. The temperature sensor 210 is configured to determine the temperature of the reductant stored in the main tank volume 206. In addition, the temperature sensor 210 is communicatively coupled to the reductant delivery system controller 128. The temperature sensor 210 is also configured to provide a signal associated with the determined temperature of the reductant in the main tank volume 206 to the processing circuit 130 of the reductant delivery system controller 128.

[0054] like Figure 2 As shown, the main tank 202 also includes a lift pump 212 (e.g., a rotary pump, a positive displacement pump, etc.). The lift pump 212 is coupled to the main tank body 204 and is disposed within the main tank volume 206. For example, the lift pump 212 can be fastened to the bottom or side of the main tank body 204. In some embodiments, the lift pump 212 can be coupled to a temperature sensor 210. For example, the lift pump 212 can be fastened to the pressure side of the main tank body 204, and the temperature sensor 210 can be fastened to the lift pump 212 so that the temperature sensor 210 is in continuous contact with the reductant stored in the main tank volume 206. In other embodiments, the lift pump 212 can be fastened to the bottom of the main tank body 204, and the temperature sensor 210 can be coupled to one side (e.g., the bottom or side) of the main tank body 204. The lift pump 212 is configured to pump the warm reductant heated by the main heater 208. The reductant delivery system also includes a supply line 214. A portion of the supply line 214 is positioned within the main tank body 204. Supply line 214 is coupled to lift pump 212 .

[0055] The reductant delivery system 102 also includes a priming tank 216 (e.g., a reductant tank, an auxiliary tank, etc.). The priming tank 216 includes a priming tank body 218. The priming tank body 218 defines a priming tank volume 220. The priming tank body 218 is configured to store the reductant in the priming tank volume 220. The priming tank body 218 is coupled to the supply line 214. The lift pump 212 is configured to pump the reductant from the main tank body 204 through the supply line 214. The supply line 214 is configured to deliver the reductant from the main tank body 204 to the priming tank body 218. The priming tank body 218 is configured to store the reductant contained in the priming tank volume 220.

[0056] The startup tank 216 also includes a startup heater 222 (e.g., a heating element, etc.). In various embodiments, a portion of the startup heater 222 is coupled to the startup tank body 218. For example, a portion of the startup heater 222 can be fastened to the startup tank body 218 (e.g., using fasteners, etc.). In other embodiments, no portion of the startup heater 222 is coupled to the startup tank body 218. Instead, a portion of the startup heater 222 is coupled to an intermediate coupler that is coupled to the startup tank body 218. A portion of the startup heater 222 is disposed in the startup tank volume 220. The startup heater 222 is configured to heat the reductant stored in the startup tank volume 220. The startup heater 222 can be an electric heater, a heat exchanger, a Peltier heater, or other similar heater.

[0057] In some embodiments, the priming tank 216 also includes a priming pump 224 (e.g., a lift pump, a pressure pump, etc.). The priming pump 224 is fastened to the priming tank body 218. The priming pump 224 is located in the priming tank volume 220 of the reductant. The reductant delivery system 102 also includes a priming supply line 226 and a reductant pump 228. The priming pump 224 is coupled to the priming supply line 226. The priming pump 224 is configured to deliver the reductant from the priming tank body 218 to the priming supply line 226. A portion of the priming supply line 226 is disposed within the priming tank body 218. The priming supply line 226 is configured to deliver the reductant from the priming tank body 218 to the reductant pump 228.

[0058] The reductant pump 228 is fluidly coupled to the priming tank 216 via the priming supply line 226. The reductant pump 228 includes an inlet 230 and an outlet 232. The inlet 230 is fluidly coupled to the priming tank 216 via the priming supply line 226. The inlet 230 is configured to receive the reductant from the priming tank body 218. The outlet 232 is configured to receive the reductant that has circulated through the reductant pump 228.

[0059] The reductant delivery system 102 also includes a doser supply line 234. The outlet 232 is fluidly coupled to the doser assembly 112 via the doser supply line 234. The doser supply line 234 is configured to deliver the reductant from the outlet 232 of the reductant pump 228 to the doser assembly 112.

[0060] The reductant delivery system 102 also includes a return line 236. The dispenser assembly 112 is fluidly coupled to the main tank 202 via the return line 236. The return line 236 is configured to deliver the reductant from the dispenser assembly 112 back to the main tank volume 206. In some embodiments, the reductant delivery system 102 also includes a warm return line 238. The warm return line 238 is coupled to the return line 236. The reductant delivery system controller 128 is configured to control the dispenser assembly 112 to selectively deliver the reductant to the start tank body 218. The dispenser assembly 112 is configured to selectively deliver the warm reductant back to the start tank body 218 via the warm return line 238. By delivering the warm reductant back to the start tank body 218, the reductant delivery system 102 can deliver the reductant from the start tank 216 without drawing the reductant from the main tank volume 206 into the start tank volume 220.

[0061] In addition, the reductant delivery system controller 128 is communicatively coupled to the temperature sensor 210, the lift pump 212, the reductant pump 228, the priming pump 224, and the dispenser assembly 112. The reductant delivery system controller 128 is configured to receive a signal generated by the temperature sensor 210 associated with the temperature of the reductant within the main tank volume 206. The reductant delivery system controller 128 is also configured to determine the temperature of the reductant within the main tank volume 206 based on the signal. For example, the signal (e.g., resistance, infrared reading, etc.) can be sent to the processing circuit 130 within the reductant delivery system controller 128. The memory 134 of the reductant delivery system controller 128 is configured to store a threshold reductant temperature. The threshold temperature can be determined by user input or otherwise stored in the memory 134. The processor 132 of the processing circuit 130 is configured to determine the temperature of the reductant within the main tank volume 206. For example, the temperature of the reductant stored in the main tank volume 206 determined by the processor 132 can be compared with the threshold reductant temperature stored in the memory 134. For example, the temperature sensor may sense the dwell between two diodes and transmit a reductant temperature value signal (eg, temperature in ° C., etc.) to the reductant delivery system controller 128. The processor 132 is configured to determine whether the reductant temperature value signal is greater than or meets a threshold reductant temperature.

[0062] Reductant delivery system controller 128 is further configured to control lift pump 212, reductant pump 228, and doser assembly 112 based on the determined temperature of the reductant stored within main tank volume 206. For example, if the determined temperature of the reductant stored within main tank volume 206 meets or exceeds a threshold reductant temperature, reductant delivery system controller 128 may activate lift pump 212 and reductant pump 228. If reductant delivery system controller 128 determines that the temperature of the reductant stored within main tank volume 206 does not meet or exceed the threshold reductant temperature, reductant delivery system controller 128 may deactivate lift pump 212, activate reductant pump 228, and further be configured to activate doser assembly 112 to return reductant to starter tank body 218.

[0063] Additionally, reductant delivery system controller 128 is configured to cause lift pump 212 to deliver reductant from main tank volume 206 to start tank volume 220. For example, reductant delivery system controller 128 may be configured to cause lift pump 212 to deliver reductant from main tank volume 206 to start tank volume 220 based on the temperature of the reductant within main tank volume 206. For example, if the temperature of the reductant within main tank volume 206 is too low (e.g., the temperature of the reductant within the main tank volume is below a threshold), reductant delivery system controller 128 may cause lift pump 212 to shut down, thereby preventing reductant from main tank volume 206 from being delivered to start tank volume 220. Reductant delivery system controller 128 is configured to prevent reductant from being delivered from main tank volume 206 to start tank volume 220 so that start tank volume 220 remains heated to a temperature that meets or exceeds a threshold reductant temperature.

[0064] Additionally, if the reductant delivery system controller 128 determines that the temperature of the reductant within the main tank volume 206 meets or exceeds the threshold reductant temperature, the reductant delivery system controller 128 may activate the lift pump 212 to begin delivering the reductant from the main tank volume 206 to the start-up tank volume 220. According to this embodiment, the reductant delivery system controller 128 may also be configured to cause the reductant to be continuously delivered from the main tank volume 206 to the start-up tank volume 220 to replenish the supply of warm reductant in the start-up tank volume 220. For example, in this embodiment, the reductant from the main tank volume 206 is delivered to the start-up tank volume 220 such that the reductant must pass through the start-up tank volume 220 before being delivered to the dispenser assembly 112. In other embodiments, the reductant delivery system controller 128 may be configured to activate the lift pump 212 to begin delivering the reductant from the main tank volume 220 to the reductant pump 228 such that the reductant bypasses the start-up tank 216.

[0065] Figure 3 Another embodiment of a reductant delivery system 102 is shown. Figure 3A reductant delivery system 102 is shown according to some embodiments, which includes a main tank 202, a starter tank 216, and a reductant pump 228. The starter tank 216 is located within the main tank body 204. The starter tank 216 defines a starter tank volume 220 located within the main tank volume 206. According to some embodiments, the starter heater 222 and the main heater 208 can be combined into a single heater. In other embodiments, the starter heater 222 can be fastened to the main heater 208. The main heater 208 can be fastened to the main tank body 204 and fastened to the starter tank body 218. The main heater 208 extends from the main tank body 204 through the main tank volume 206 and into the starter tank body 218. Therefore, a portion of the main heater 208 can be positioned in the starter tank volume 220. In contrast, in another embodiment, the heater positioned in the starter volume 220 can be a separate starter heater 222. For example, a separate starter heater can be fastened to the starter tank body 218. The starter heater can extend into the starter tank volume 220. The starting heater is configured to heat the reductant stored in the starting tank body 218 .

[0066] The startup tank volume 220 is fluidly coupled to the main tank volume 206. The startup tank 216 is configured such that the startup tank volume 220 of reductant is enclosed within the main tank volume 206. For example, the startup tank 216 may include an insulating wall (e.g., a wall including insulation, etc.) to concentrate the transfer of heat from at least one of the startup heater 222, the main heater 208, and the combined single heater so that the reductant stored in the startup tank volume 220 can be heated more quickly. The startup tank volume 220 is smaller than the main tank volume 206 to allow for faster heating of the stored reductant.

[0067] Additionally, in some embodiments, the starter tank 216 is isolated from the main tank volume 206. For example, the starter tank volume 220 may be fluidly coupled (e.g., via a transfer tube) to the main tank volume 206. Conversely, in other embodiments, the starter tank body 218 may include an opening for reductant to flow from the main tank volume 206 into the starter volume 220.

[0068] like Figure 3As shown, the main tank 202 includes a lift pump 212. According to some embodiments, the lift pump 212 is secured to the main tank body 204 and may also be secured to the priming tank body 218. According to other embodiments, a portion of the lift pump 212 may be positioned within the priming tank volume 220. According to some embodiments, the lift pump 212 is configured to selectively deliver reductant from the main tank volume 206 and the priming tank volume 220 to the supply line 214. For example, the reductant delivery system controller 128 may be configured to activate the lift pump 212 based on a temperature signal received from the temperature sensor 210. If the reductant delivery system controller 128 determines that the temperature of the reductant in the main tank volume 206 does not meet or exceed a threshold reductant temperature, the lift pump 212 may be activated to deliver reductant only from the priming volume 220. Otherwise, if the reductant delivery system controller 128 determines that the temperature of the reductant in the main tank volume 206 meets or exceeds the threshold reductant temperature, the lift pump 212 may be activated to deliver reductant from the main tank volume 206. According to another embodiment, the reductant delivery system controller may activate lift pump 212 to draw reductant from both the start tank volume 220 and the main tank volume 206 simultaneously.

[0069] According to yet another embodiment, lift pump 212 may be positioned only in main tank volume 206. For example, in some embodiments, lift pump 212 is coupled to main tank body 204 such that the lift pump is positioned only within main tank volume 206. In other embodiments, a portion of lift pump 212 may be positioned inside main tank volume 206 and another portion of lift pump 212 may be positioned outside of main tank volume 206. In yet another embodiment, lift pump 212 may be located outside of main tank volume 206. Lift pump 212 is configured to draw reductant only from main tank volume 206 when activated by reductant delivery system controller 128.

[0070] Furthermore, according to this embodiment, priming pump 224 is positioned only within priming tank volume 220. In other embodiments, priming pump 224 may be positioned outside of priming tank volume 220. For example, a portion of priming pump 224 may be positioned within priming tank volume 220, and another portion of priming pump 224 may be positioned outside of priming tank volume 220. In yet another embodiment, priming pump 224 may be located outside of priming tank volume 220. Priming pump 224 is configured to draw reductant from priming tank volume 220 only when activated by reductant delivery system controller 128. For example, reductant delivery system controller 128 may activate priming pump 224 when the temperature of the reductant stored within main tank volume 206 does not meet or exceed a threshold reductant temperature. Conversely, reductant delivery system controller 128 may shut down (e.g., deactivate, etc.) priming pump 224 and activate (e.g., turn on, etc.) lift pump 212 when the reductant within main tank volume 206 meets or exceeds a threshold reductant temperature. According to yet another embodiment, reductant delivery system controller 128 may simultaneously activate priming pump 224 and lift pump 212. Additionally, in some embodiments, lift pump 212 and priming pump 224 may be a single pump.

[0071] The lift pump 212 and the priming pump 224 are fluidly coupled to the reductant pump 228 via the supply line 214. According to some embodiments, the lift pump 212 and the priming pump 224 are configured to pump the reductant from the main tank volume 206 and the priming tank volume 220 into the supply line 214. The supply line 214 is configured to deliver the reductant from the main tank volume 206 and the priming tank volume 220 to the inlet 230 of the reductant pump 228. In addition, the dispenser assembly 112 is fluidly coupled to the main tank body 204 and the priming tank body 218 via the return line 236. The return line 236 is configured to selectively return the reductant to the main tank volume 206. The reductant delivery system 102 may include an optional warming line 302. The optional warming line 302 is coupled to the return line 236. The optional warming line is also coupled to the main tank body 204 and the priming tank body 218. A portion of the optional warm line 302 is positioned in the main tank volume 206 and extends such that another portion of the optional warm line 302 is positioned within the start tank volume 220. The optional warm line 302 is configured to return the reductant to the start tank volume 220 when the reductant stored in the main tank volume 206 does not meet or exceed a threshold reductant temperature determined by the reductant delivery system controller 128. For example, upon determining that the main tank volume 206 does not meet or exceed the threshold reductant temperature, the reductant delivery system controller 128 is configured to activate the doser assembly 112 to deliver the warmed reductant back to the start tank volume 220 via the optional warm line 302.

[0072] Figures 4 to 6The priming tank 216 and reductant pump 228 are shown incorporated into the various reductant delivery systems 102 as previously shown. Figure 4 The embodiment depicts a method that may include Figure 2 A detailed cross-sectional view of the reductant pump 228 in the system is shown. The reductant pump 228 is fluidly coupled to the priming tank 216 via a priming supply line 226. In various embodiments, the priming tank 216 may be positioned proximate to the reductant pump 228 such that the length of the priming supply line 226 is shortened.

[0073] In addition, according to some embodiments, the priming pump 224 is configured to purge (e.g., empty the reductant, no reductant is stored when the system is shut down, etc.) the priming supply line 226 to prevent the reductant from stagnating in the line and freezing. For example, the priming pump can be configured to draw the reductant from the priming supply line 226 back to the priming tank volume 220. Discharging the priming supply line 226 can reduce the time required to thaw the reductant in the reductant delivery system 102. The priming tank 216 includes a priming tank body 218 that defines the priming tank volume 220. The priming tank includes a priming pump 224 located within the priming tank volume 220. The priming pump 224 is configured to pump the reductant from the priming tank volume 220 into the priming supply line 226. The priming supply line 226 is configured to deliver the reductant from the priming tank body to the inlet 230 of the reductant pump 228.

[0074] In addition, the reductant pump 228 includes a reductant pump body 402. The reductant pump body 402 includes a filter housing 404. The inlet 230 is configured to deliver the reductant from the start-up supply line 226 to the reductant pump body 402. The filter housing 404 includes a filter head 406. The reductant pump 228 also includes a filter cartridge 408. The filter cartridge 408 is positioned in the filter housing 404. The filter cartridge 408 includes a top end plate 410, a bottom end plate 412 and a center tube 414. The top end plate 410 is connected to the filter head 406. The bottom end plate 412 is positioned relative to the top end plate 410. The center tube 414 is connected to the top end plate 410 and the bottom end plate 412. The filter cartridge 408 also includes a filter cartridge chamber 416. The top end plate 410, the bottom end plate 412 and the center tube 414 jointly define the filter cartridge chamber 416. The filter cartridge chamber 416 includes a filter medium 418. The filter media 418 is configured to capture debris or other particles (sand, dust, etc.) within the reductant to facilitate the normal function and life extension of the reductant pump 228. The filter cartridge 408 is configured to be removable and replaceable. For example, a new filter cartridge 408 can be placed in the filter cartridge cavity 416 after a period of time to ensure proper filtering of the reductant.

[0075] like Figure 4As shown, the reductant pump 228 further includes a cover 420 and a filter head cavity 422. The cover 420 is coupled to the filter head 406 to define the filter head cavity 422. The cover 420 is positioned outside the filter cartridge 408. The filter head cavity 422 extends between the cover 420 and the bottom end plate 412.

[0076] Figure 5 A reductant pump 228 is shown according to another exemplary embodiment. Figure 5 The illustrated embodiment of the reductant pump 228 also includes a startup heater 502. The startup heater 502 is secured to the filter head 406. A portion of the startup heater 502 is positioned within the filter cartridge cavity 416. For example, the startup heater 502 can be positioned within the center tube 414 of the filter cartridge 408. The startup heater 502 is configured to radiate heat outward through the filter media 418 and into the filter head cavity 422. As heat radiates outward from the startup heater 502, the reductant within the filter head cavity 422 can be heated as it travels through the filter media 418 and up the center tube 414.

[0077] Figure 6 A reductant pump 228 according to another embodiment is shown. The reductant pump 228 includes a reductant tank body 602 and an additional startup volume 604. The additional startup volume 604 is positioned in the filter head cavity 422. The additional startup volume 604 is heated by the startup heater 502. The additional startup volume 604 can store a small amount of reductant compared to the main tank volume 206. For example, the additional startup volume 604 can be a minimum of 0.5% of the main tank volume 206 and a maximum of 8% of the main tank volume 206. The reductant in the additional startup tank 216 can be heated faster than the reductant stored in the main tank volume 206, so that the engine can be started faster at low temperatures (e.g., below freezing, etc.). In addition, the additional startup volume 604 can be positioned in the filter head cavity 422 and sucked through the filter medium 418. The filter medium 418 is configured to capture any debris present in the reductant to prevent any damage to the reductant delivery system 102. The reductant then travels up the center tube 414 and out the outlet 232 of the reductant pump 228. According to this embodiment, the reductant pump 228 is integrated with the priming tank 216 so that the reductant pump can store the reductant in the additional priming volume 604. The priming tank 216 is integrated with the reductant pump 228 so that the reductant pump 228 is configured to store the additional priming volume 604, reducing the amount of space and contact points within the reductant delivery system 102.

[0078] Figure 7A cross-sectional top view of the reductant pump 228 is shown. The reductant pump 228 of the reductant delivery system 102 includes a reductant pump body 700, an inlet 230, an inlet passage 702, and a filter passage 704. The inlet passage 702 is coupled to the supply line 214 and the inlet 230. The inlet 230 is also coupled to the filter passage 704. The inlet passage 702 is configured to receive the reductant from the supply line 214 and deliver the reductant to the filter passage 704 through the inlet 230. A portion of the filter passage 704 is positioned within the reductant pump body 700, and another portion of the filter passage 704 is positioned within the filter housing 404. The filter passage 704 includes a first filter 706. The first filter 706 (e.g., a 190 micron filter, etc.) is configured to filter large debris from the reductant as the reductant flows into the reductant pump body 700 and the filter housing 404.

[0079] The filter housing 404 also includes a pump chamber 708. The pump chamber 708 includes a pump inlet passage 710, a pump plate suction check valve 712, a pump plate 714, and a pump 716. The filter passage 704 is configured to deliver the reductant to the pump chamber 708. The filter passage 704 is coupled to the pump inlet passage 710. A portion of the pump inlet passage 710 is positioned in the filter housing 404, and another portion of the pump inlet passage 710 is positioned within the pump chamber 708. The pump inlet passage 710 is configured to receive the reductant from the filter passage 704 and deliver the reductant to the pump plate suction check valve 712. The pump plate suction check valve 712 is coupled to the pump plate 714. The pump plate suction check valve 712 (e.g., a one-way valve, etc.) is configured to allow the reductant to flow through the pump plate 714 and prevent the reductant from flowing back through the pump plate suction check valve 712 and flowing back into the pump inlet passage 710.

[0080] The reductant pump 228 also includes a first plate channel 718, a diaphragm 720, and a second plate channel 722. The first plate channel 718 is configured to receive the reductant from the pump plate suction check valve 712. The pump 716 is configured to draw the reductant through the first plate channel 718 and push the reductant downward through the second plate channel 722. The pump plate suction check valve 712 is fluidly coupled to the first plate channel 718. A portion of the first plate channel 718 is disposed within the pump plate 714.

[0081] The diaphragm 720 is coupled to the pump plate 714. The diaphragm 720 is configured to operate between a first position and a second position. When in the first position, the diaphragm 720 is configured to receive the reductant from the first plate channel 718 and deliver the reductant to the second plate channel 722. A portion of the second plate channel 722 is disposed within the pump plate 714. When in the second position, the diaphragm 720 is configured to prevent the reductant from flowing from the first plate channel 718 to the second plate channel 722. The diaphragm 720 is configured to generate suction to draw the reductant through the pump plate 714 via the first plate channel 718.

[0082] The pump chamber 708 also includes a pressure check valve 724, an outlet chamber 726, and an outlet passage 728. The pressure check valve 724 is fluidly coupled to the second plate passage 722. The pressure check valve 724 is configured to receive the reductant from the second plate passage 722. In addition, the pressure check valve 724 is configured to prevent the reductant from flowing back through the second plate passage 722. The reductant flows from the pressure check valve 724 into the filter head chamber 422, where the reductant is heated by the startup heater 502. The reductant then flows upward through the center tube 414. The outlet chamber 726 is coupled to the center tube 414 and coupled to the outlet 232. The outlet passage 728 is coupled to the outlet 232. The center tube 414 is configured to deliver the filtered reductant from the filter head chamber 422 to the outlet chamber 726. The outlet chamber 726 is configured to deliver the reductant from the center tube 414 through the outlet 232 to the outlet passage 728.

[0083] Figure 8 A cross-sectional front view of the reductant pump 228 according to an exemplary embodiment is shown. The reductant pump 228 includes a pump motor 802 (e.g., an electric motor, a servo motor, etc.), a piston 804, and a transfer passage 806. The pump motor 802 is positioned within the pump chamber 708. According to some embodiments, the pump motor 802 is coupled to the pump plate 714. The pump motor 802 is coupled to the piston 804 and to the diaphragm. The piston 804 is also coupled to the diaphragm 720.

[0084] The diaphragm 720 is configured to draw the reductant upward through the pump plate 714 via the first plate channel 718. The diaphragm 720 is also configured to pump the reductant downward through the pump plate 714 and back via the second plate channel 722. The pump motor 802 is configured to reposition the piston 804. The piston 804 is configured to move the diaphragm 720 from the first position to the second position. For example, the pump motor 802 repositions the piston 804. For example, the piston 804 can be vertically repositioned so that the piston 804 moves to a higher position, pulling the diaphragm 720 upward. The upward movement of the diaphragm 720 draws the reductant through the first plate channel 718. In addition, the pump motor 802 repositions the piston 804 a second time so that the piston 804 moves vertically to a lower position. The downward movement of the piston 804 pushes the diaphragm 720 downward. The downward movement of the diaphragm pushes the reductant through the second plate channel 722. The transfer channel 806 is connected to the second plate channel 722. A portion of the transfer channel 806 is positioned within the pump chamber 708, and another portion of the transfer channel 806 is positioned in the filter head cavity 422. The second plate channel 722 is configured to deliver the reductant from the first plate channel 718 to the transfer channel 806. The transfer channel 806 is configured to deliver the reductant from the second plate channel 722 to the filter head cavity 422.

[0085] Fig. 9 A reductant delivery system 102 is shown according to another exemplary embodiment. The reductant delivery system 102 includes a main tank 202, and a main tank body 204 is configured to store a reductant for a diesel engine contained in a main tank volume 206. The main tank 202 includes a primary heater 208 disposed within the main tank volume 206. According to some embodiments, the primary heater 208 includes a primary heater housing 902. The primary heater housing 902 is positioned around the primary heater 208. The primary heater housing 902 is configured to prevent the primary heater 208 from directly contacting the reductant stored in the main tank volume 206.

[0086] According to other embodiments, the primary heater 208 is sealed (e.g., liquid-resistant, etc.). For example, the primary heater 208 can be sealed such that the primary heater 208 is configured to directly contact the reductant in the main tank volume 206. In addition, the main tank 202 includes a lift pump 212 configured to pump the reductant from the main tank volume 206 to the reductant pump 228 via a supply line 214. In some embodiments, the main tank lift pump 212 is located on the pressure side of the main tank 202.

[0087] The temperature sensor 210 is configured to determine the temperature of the reductant stored in the main tank volume 206. The temperature sensor 210 is also configured to transmit the temperature of the reductant in the main tank volume 206 to the reductant delivery system controller 128. The reductant delivery system controller 128 includes a memory 134 configured to store a threshold reductant temperature value. In some embodiments, the threshold reductant temperature value can be a user-defined value. In other embodiments, the threshold reductant temperature value can be hard-coded in the memory 134. The reductant delivery system controller 128 is configured to receive the temperature of the reductant stored in the main tank volume 206 from the temperature sensor 210. The reductant delivery system controller 128 is also configured to determine whether the temperature of the reductant stored in the main tank volume 206 meets or exceeds the threshold reductant temperature value of the reductant delivery system 102.

[0088] The reductant delivery system 102 also includes a first selector valve 904. The first selector valve 904 is communicatively coupled to the reductant delivery system controller 128. The reductant delivery system controller 128 is also communicatively coupled to the temperature sensor 210. The first selector valve 904 is fluidly coupled to the supply line 214 and is fluidly coupled to the reductant pump 228. The supply line 214 is configured to deliver the reductant from the main tank volume 206 to the first selector valve 904 (e.g., a main tank selector valve, etc.). The first selector valve 904 is configured to prevent or allow the reductant from the main tank volume 206 to pass through the supply line 214. In response to the reductant delivery system controller 128 determining that the reductant stored in the main tank volume 206 reaches or exceeds a threshold reductant temperature value, the reductant delivery system controller 128 is configured to open the first selector valve 904 to allow the reductant to flow from the main tank volume 206 toward the reductant pump 228. In response to the reductant delivery system controller 128 determining that the reductant stored in the main tank volume 206 is less than the threshold reductant temperature value, the reductant delivery system controller 128 is configured to close the first selector valve 904 .

[0089] According to some embodiments, the reductant delivery system 102 further includes a suction side accumulator 906. The suction side accumulator 906 is fluidly coupled to the first selector valve 904 via the supply line 214. The suction side accumulator 906 is also fluidly coupled to the reductant pump 228. When the first selector valve 904 is in an open position, the suction side accumulator 906 is configured to deliver a dose of reductant to the reductant pump 228 so that the reductant pump 228 does not overflow. The suction side accumulator 906 is also configured to prevent the reductant from flowing back out of the reductant pump 228 and back into the main tank volume 206. 228.

[0090] In addition, the reductant delivery system controller 128 is communicatively coupled to the integrated reductant pump 228. In response to the reductant delivery system controller 128 closing the first selector valve 904, the reductant delivery system controller 128 is also configured to communicate to the reductant pump 228 that the first selector valve 904 is in the closed position. When the first selector valve 904 is in the closed position, the reductant pump 228 is configured to draw reductant only from the additional priming volume 604 located within the filter head cavity 422.

[0091] According to this exemplary embodiment, filter head cavity 422 is configured to have larger horizontal and vertical dimensions to store additional priming volume 604. In contrast, in other embodiments, filter head cavity 422 is configured to have only a larger vertical dimension or only a larger horizontal dimension to store additional priming volume 604.

[0092] In addition, the reductant delivery system includes a pressure side accumulator (e.g., a nitrogen bag, etc.) 908. The pressure side accumulator is connected to the outlet channel 728 of the reductant pump 228. For example, according to some embodiments, the pressure side accumulator 908 can be a nitrogen bag pressure accumulator. The nitrogen bag pressure accumulator 908 is configured to receive the reductant from the reductant pump 228. The nitrogen bag pressure accumulator 908 may include a rubber or elastomer bag filled with nitrogen, which can be surrounded by the reductant. The volume of the reductant introduced into the pressure side accumulator 908 may exceed the pressure of the nitrogen from the bag. Once enough reductant has entered the pressure side accumulator 908 to fully reach the maximum pressure, the nitrogen in the bag expands, forcing the reductant to leave the pressure side accumulator 908 and pass through the distributor supply line 234. The distributor supply line 234 is configured to deliver the reductant to the distributor assembly 112. Alternatively, in other embodiments, the reductant delivery system 102 may include one of the suction-side accumulator 906 and the pressure-side accumulator 908 .

[0093] The dispenser assembly 112 is coupled to a return line 236 that is configured to return reductant from the aftertreatment system 100 to the reductant delivery system 102. The reductant delivery system 102 also includes a second selector valve 910. The second selector valve 910 is coupled to the return line 236 and the optional warm line 302. The second selector valve 910 is communicatively coupled to the reductant delivery system controller 128. The reductant delivery system controller 128 is configured to receive a signal associated with a reductant temperature of the main tank volume 206 from the temperature sensor 210. In response to the reductant delivery system controller 128 determining that the temperature of the reductant in the main tank volume meets or exceeds a threshold reductant temperature value, the reductant delivery system controller 128 is configured to open the second selector valve 910. When in the open position, the second selector valve is configured to deliver reductant from the dispenser assembly 112 back to the main tank volume 206. In response to the reductant delivery system controller 128 determining that the temperature of the reductant stored in the main tank volume 206 does not meet or exceed the threshold reductant temperature value, the reductant delivery system controller 128 is configured to close the second selector valve 910. When in the closed position, the second selector valve 910 is configured to deliver the reductant to the reductant pump 228 through the optional warm line 302. For example, the reductant pump 228 stores the warm reductant in the additional startup volume 604.

[0094] According to an exemplary embodiment, Fig.10 The main tank 202 of the reductant delivery system 102 is shown. The main tank 202 includes a main tank body 204 that defines a main tank volume 206. The main tank 202 also includes a main tank fill tube 912, a heating element 914, and a heating pot 916. The main tank fill tube 912 is coupled to the main tank body 204. A portion of the main tank fill tube 912 is positioned within the main tank volume 206. The main tank fill tube 912 is configured to open and close to allow a user to add reductant to the main tank volume 206.

[0095] The heating element 914 is coupled to a heating container 916. The heating element 914 and the heating container 916 are located within the main tank volume 206. The heating container 916 is configured to store an antifreeze liquid that can be heated and circulated through the heating element 914. The heating element 914 is configured to heat the reductant stored within the main tank volume 206. According to other embodiments, the main tank 202 includes a main heater 208, such as a heating rod or a positive temperature coefficient (PTC) heater as previously described.

[0096] The main tank 202 also includes a temperature sensor 918 and a level sensor 920. The temperature sensor 918 and the level sensor 920 are located within the main tank volume 206. The level sensor 920 is secured to the main tank body 204 and is communicatively coupled to the reductant delivery system controller 128. The temperature sensor 918 is coupled to the level sensor 920 and is communicatively coupled to the reductant delivery system controller 128 (as shown in the previous embodiment). The temperature sensor 918 is configured to determine the temperature of the reductant in the main tank volume 206. The temperature sensor 918 is also configured to transmit a temperature signal to the reductant delivery system controller 128. The level sensor 920 is configured to determine the level of the reductant stored in the main tank volume 206. The level sensor is also configured to transmit a level signal to the reductant delivery system controller 128. For example, according to some embodiments, the reductant delivery system controller 128 can use the level determined by the level sensor 920 to indicate to a user that the reductant level within the main tank volume 206 is below a level threshold.

[0097] In addition, the main tank 202 includes a main tank delivery pump 922 (e.g., a lift pump) and a suction pipe 924. According to this embodiment, the main tank delivery pump 922 is coupled to the outside of the main tank body 204. In contrast, in other embodiments, the main tank delivery pump 922 can be positioned on the inside of the main tank body 204 or positioned within the main tank volume 206, as previously described. The main tank delivery pump 922 is coupled to the suction pipe 924. The suction pipe 924 is configured to deliver the reductant from the main tank volume 206 to the main tank delivery pump 922. The main tank delivery pump 922 is fluidly coupled to the supply line 214 (e.g., a supply line). The main tank delivery pump 922 is configured to draw the reductant from the main tank volume 206 upward to the suction pipe 924. As previously described, the main tank delivery pump 922 is also configured to push the reductant through the supply line 214 to deliver the reductant to the reductant pump 228.

[0098] IV. Example Embodiment Configuration

[0099] 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.

[0100] 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 that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the present invention as described in the appended claims.

[0101] 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.

[0102] 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 in which a fluid (such as air, exhaust gas, liquid reductant, gaseous reductant, aqueous reductant, gaseous ammonia, etc.) can flow with or without an intermediate component or object. Examples of fluid couplings or configurations for achieving fluid communication may include pipes, channels, or any other suitable components for achieving fluid flow from one component or object to another component or object.

[0103] 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.

[0104] 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.

[0105] 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. A reducing agent pump, comprising: A filter housing, the filter housing comprising: an inlet passage configured to receive a reducing agent, a pump chamber configured to receive a reducing agent from the inlet passage, a transfer channel configured to receive reducing agent from the pump chamber, --Exit channels, and --Filter head; a pump coupled to the filter housing and operable to supply the reductant in the pump chamber to the delivery passage; A filter cartridge, the filter cartridge comprising: a top end plate defining a top end plate aperture, the top end plate being coupled to the filter head such that the top end plate aperture is aligned with the outlet passage, a bottom end plate, the bottom end plate being opposite to the top end plate, a center tube coupled to the top end plate and the bottom end plate, the center tube defining a filter cartridge cavity, and a filter medium positioned around the center tube and between the top and bottom end plates; a cover coupled to the filter head and positioned outside the filter cartridge, the cover cooperating with the filter head to define a filter head cavity extending between the cover and the bottom end plate; and A startup heater has a portion positioned within the filter cartridge cavity and is configured to heat the reductant within the filter cartridge cavity.

2. The reducing agent pump according to claim 1, wherein: The pump further comprises: A pump plate is positioned within the pump chamber, the pump plate comprising: a first plate channel configured to receive a reductant from an inlet chamber via the pump chamber, and a second plate channel configured to receive reductant from the first plate channel and to provide the reductant to the transfer channel via the pump chamber; a diaphragm coupled to the pump plate across the first plate channel and the second plate channel, the diaphragm being operable between: a first position in which the reducing agent flows from the first plate channel to the second plate channel, and a second position in which the reducing agent is prohibited from flowing from the first plate channel to the second plate channel; a piston coupled to the diaphragm; and A motor is coupled to the piston and is configured to reposition the piston to transition the diaphragm between the first position and the second position.

3. A reducing agent delivery system, comprising: The reducing agent pump according to claim 1; and An accumulator, the accumulator being configured to: - providing a reducing agent to the inlet passage, or --Receive a reducing agent from the outlet passage.

4. The reductant delivery system of claim 3, further comprising a first selector valve coupled to the reductant pump, the first selector valve being operable between the following positions: a first position in which the flow of reductant to the inlet passage is inhibited, and A second position in which reductant is allowed to flow to the inlet passage.

5. The reducing agent delivery system according to claim 3, further comprising: a main tank configured to provide a reductant to the reductant pump; and a second selector valve configured to receive reductant from the reductant pump and provide reductant to the main tank, the second selector valve being operable between the following positions: a first position in which the flow of reductant to the main tank is prohibited; and A second position, in which reductant is allowed to flow to the main tank.

6. The reducing agent delivery system according to claim 5, further comprising: a return line coupling each of the first selector valve and the second selector valve, wherein: The second selector valve is also operable in a third position in which reductant is prohibited from flowing to the main tank and is permitted to flow to the inlet passage. 7 . The reductant delivery system of claim 5 , further comprising a primary heater coupled to the main tank, the primary heater configured to heat a portion of the reductant stored in the main tank. 8 . The reductant pump of claim 1 , further comprising a priming volume positioned within the filter head cavity and configured to store a volume of reductant ranging between 0.5% and 8% of a maximum volume of the main tank.

9. A reducing agent delivery system comprising: A main tank, the main tank comprising: a main tank body configured to store the reductant within the main tank volume, a primary heater configured to heat the reductant within the main tank volume, a portion of the primary heater being at least one of: coupled to the main tank body, or disposed within the main tank body volume, --Lift pump, and a temperature sensor coupled to the main tank and configured to provide a signal associated with a temperature of the reductant within the main tank volume; and A starter tank, comprising: a starter tank body configured to store reductant within a starter tank volume configured to receive reductant from the lift pump, and a start-up heater configured to heat the reductant in the start-up tank volume, a portion of the start-up heater being at least one of: coupled to the start-up tank body, or disposed in the start-up tank volume; A controller, the controller being configured to: -- receiving a signal from the temperature sensor, - determining a temperature based on the signal, causing the lift pump to deliver reductant from the main tank volume to the starter tank volume based on the temperature, and --Operate the main tank based on the temperature.

10. The reductant delivery system of claim 9, further comprising a supply line coupled to the main tank body and the starter tank body, the supply line being configured to receive reductant from the main tank volume and provide reductant to the starter tank volume; wherein: The priming tank body is separated from the main tank body; and The startup tank volume is configured to receive reductant from the main tank volume via the supply line.

11. The reducing agent delivery system according to claim 10, wherein: The controller is also configured to cause the priming pump to discharge reductant from the priming line into the priming tank volume.

12. The reducing agent delivery system according to claim 9, wherein: The priming tank body is positioned within the main tank body.

13. The reducing agent delivery system according to claim 12, wherein: A portion of the main tank heater is positioned in the startup tank volume.

14. The reducing agent delivery system according to claim 12, wherein: The startup tank includes an insulating wall configured to focus transfer of heat from at least one of the startup heater or the main heater within the startup tank body.

15. The reducing agent delivery system according to claim 12, wherein: The starter tank body includes a plurality of openings configured to allow reductant to flow from the main tank volume to the starter tank volume.

16. The reducing agent delivery system of claim 9, wherein: The startup heater and the main heater are part of a single heater; or The startup heater is fixed to the main heater.

17. The reducing agent delivery system according to claim 9, wherein: At least one of the following exists: The main heater is an electric heater; or The startup heater is an electric heater.

18. The reducing agent delivery system according to claim 9, wherein: The startup tank volume is between 0.5% and 8% of the main tank volume, inclusive.

19. The reducing agent delivery system according to claim 9, wherein: The controller is also configured to: determining that the temperature reaches a threshold value; and The lift pump is caused to deliver reductant from the main tank volume to the reductant pump bypassing the start-up tank volume.

20. The reducing agent delivery system of claim 9, further comprising: A reducing agent pump, the reducing agent pump comprising: --A filter housing, the filter housing comprising: ---an inlet passage configured to receive a reducing agent, ---a pump chamber, the pump chamber being configured to receive a reducing agent from the inlet passage, ---a delivery channel configured to receive a reducing agent from the pump chamber, ---Exit channel, and ---Filter head; a pump coupled to the filter housing and operable to provide the reducing agent in the pump chamber to the transfer passage; --Filter cartridge, the filter cartridge comprising: ---a top end plate, the top end plate defining a top end plate hole, the top end plate being coupled to the filter head such that the top end plate hole is aligned with the outlet passage, --- bottom end plate, the bottom end plate is opposite to the top end plate, --- a center tube coupled to the top end plate and the bottom end plate, the center tube defining a filter cartridge cavity, and --- A filter medium positioned around the center tube and between the top and bottom end plates.

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