Diesel exhaust fluid sensor adapter for mitigating fluid entrainment

Abstract

A fluid sensor adapter for mitigating fluid entrainment includes a first chamber including an inlet configured to receive a diesel exhaust treatment fluid; wherein the first chamber comprises a first section at the proximal end of the fluid sensor adapter, a third section at the distal end of the sensor adapter, and a second section between the first section and the third section; wherein the diameter of the second section is smaller than the diameter of the first section, and wherein the inlet from the second section to the third section is narrower than the diameter of the second section; and wherein the decreasing diameter from the first section to the second section and the narrowing of the inlet from the second section to the third section include a tortuous vent passage configured to prevent air in the fluid from reaching the sensor.

Description

[0001] Cross - reference to related applications

[0002] This application claims the priority of U.S. Patent Application No. 63 / 404,788, titled "DIESEL EXHAUST FLUID SENSOR ADAPTER FOR FLUID AERATION MITIGATION", filed on September 8, 2022, the entire content of which is incorporated herein by reference. Technical field

[0003] The present disclosure relates to a diesel exhaust fluid sensor adapter, and more particularly, to a diesel exhaust fluid sensor adapter for mitigating fluid aeration. Background art

[0004] In the United States, since 2010, diesel exhaust fluid (DEF) storage tanks have become standard on diesel - powered on - road vehicles. DEF is an aqueous solution of a reducing agent and urea (AUS) that can be used in selective catalytic reduction (SCR) diesel emission systems. DEF has unique properties and is critical to the performance of the emission system on diesel - engine - equipped vehicles with SCR diesel emission systems.

[0005] Accordingly, multiple sensors are typically provided in the DEF reservoir. These sensors can monitor one or more of fluid level, fluid temperature, fluid concentration (e.g., urea in water), etc. For example, a DEF fluid - level sensor can measure the level of the remaining fluid in the DEF storage tank. When the liquid level is low, the DEF level sensor can send a signal to the vehicle's electronic control unit, which then triggers a warning light located on the vehicle's instrument cluster or panel. Multiple sensor strategies are used to discern reservoir and fluid conditions.

[0006] Most (if not all) sensor technologies (e.g., ultrasonic, thermal diffusion, infrared spectroscopy, etc.) are sensitive to air in DEF. Entrained air (e.g., air bubbles) can change the physical characteristics of DEF as well as the behavior of the sensor. For example, entrained air or air bubbles embedded in DEF can scatter ultrasonic or other signals from the sensor and cause the sensor to not receive echo reflections. Such entrained air or air bubbles embedded in DEF can result in unstable measurement results or no measurement results. Regardless of the parameter being measured (e.g., speed of sound, resistance / conductivity, specific heat, dynamic viscosity, optical characteristics, etc.), air in the fluid will most likely have a negative impact on the measurement or at least make the sensor technology and the corresponding measurement unreliable and / or untrustworthy. Entrained air can also be the cause of sensor errors, fault codes, and measurement fluctuations observed during vehicle use (e.g., DEF level, DEF temperature, DEF / urea concentration, etc.). Entrained air can result in inaccurate measurement readings and / or the measurement readings may be completely unavailable. No Fault Found (NFF) warranty claims can be attributed to problems where entrained air affects sensor measurement readings.

[0007] Air bubbles that affect sensor functionality can generally be classified into two types. In a first example, a large amount of trapped air in an enclosed space can create relatively large bubbles (sized approximately 0.002 ml or greater). These larger bubbles can have relatively high buoyancy and generally rise easily in the liquid. The second type of air bubble is extremely small and is referred to as a "microbubble" or "nanobubble". These "microbubbles" can have relatively low buoyancy and tend to adhere to vertical and horizontal surfaces. For example, the buoyancy of these "microbubbles" is typically not sufficient to overcome the surface adhesion to vertical and horizontal surfaces, so they stick to these surfaces. Thus, these "microbubbles" can adhere to the sensor surface and sensor reflectors.

[0008] Larger bubbles are typically formed by trapped air in an enclosed space filled with DEF. This often occurs in sensors that use a lid, shroud, or other enclosure to provide a stable liquid environment for sensor operation (i.e., one that minimizes liquid sloshing or movement). To prevent trapped air, these enclosures can provide a vent hole at the highest point to allow air to escape. Additionally, a fill hole can be provided at the lowest point to allow liquid to enter the enclosure and displace the air. However, since these vent holes must be large enough to allow air to escape as the liquid enters the enclosure, they also provide a path for "microbubbles" to be driven into the enclosure. Once inside the enclosure, the "microbubbles" can adhere to critical surfaces such as reflector faces or sensor faces. In one example, sensor errors can be caused by air entering through the sensor vent hole.

[0009] Smaller "microbubbles" can be the result of over-agitation or aeration of DEF. The common causes are aeration during DEF tank filling and sloshing of the DEF fluid due to dynamic environments and vehicle use. Another source is the standard DEF fill nozzle, which utilizes a Venturi system to provide automatic shut-off of the nozzle when the DEF tank is full. This Venturi system actually draws air from the storage tank and entrains the air into the DEF as the air passes through the nozzle and into the DEF storage tank. In most cases, the entrained air can eventually be expelled from the DEF and may not have an adverse effect on system operation. However, some of the smaller ( "microbubbles") attach themselves to the inner wall of the sensor housing and interfere with sensor readings. It has been found that liquid agitation is insufficient to remove these bubbles. The most reliable way to remove "microbubbles" is to manually wipe the affected surface and re-immerse the sensor. This is of course impracticable for sensors located on a running vehicle, as unwanted air may form during normal vehicle use.

[0010] In view of this, there is a need in the art for sensors, sensor assemblies, and / or sensor adapters that mitigate the entrainment of air or aeration of DEF. It is necessary to address one or both of the generation and spread of "microbubbles" and / or larger bubbles trapped in DEF. The provided adapters and assemblies can prevent air from accumulating on or near the sensor surface or otherwise inhibit sensor measurements and can provide a solution for dispersing or guiding any air that may enter the sensor assembly or adapter. The structure and design can provide one or more (or all) of the following: accurate DEF sensor measurements, reliable sensor measurements, reduced entrainment of air in DEF, increased diffusion or mitigation of entrained air in DEF, reliable sensor measurements, reduced sensor error readings, reduced sloshing problems from the sensor adapter (e.g., upper adapter, etc.), a balance of enhanced performance and production costs, relatively easy production, etc. Summary of the Invention

[0011] The following presents an overview of the present disclosure to provide a basic understanding of some aspects. This overview is neither intended to identify key or important elements nor to define any limitation of the embodiments or claims. This overview may provide a brief summary of some aspects that may be described in more detail in other parts of the present disclosure. Additionally, any one of the described aspects can be isolated or combined with other described aspects without limitation.

[0012] A diesel exhaust fluid (DEF) sensor adapter is provided. The sensor adapter can include two chambers. The first chamber can include a tortuous passage for fluid and / or air flow. The second chamber can be fluid-sealed or separated from the first chamber and can house electrical components. The tortuous passage can include different stepped sections with a decreasing diameter from the proximal end towards the distal end. For example, the first section located at the proximal end can have a larger diameter than the second section in the middle. The inlet from the second section to the third section can have a greatly reduced size. The tortuous passage can further include a vent inlet located at approximately the same height as the inlet, but requiring an approximate 180° turn between the inlet and the vent inlet. The inlet can extend into two relatively horizontal portions, each leading to a vent outlet located on opposite sides of the sensor adapter. The turn from the inlet to the substantially horizontal portion can be approximately 90°. The sensor adapter and the tortuous passage can mitigate aeration of the DEF. The sensor adapter can prevent aerated DEF from entering the sensor adapter and can allow air to be discharged from the sensor adapter to prevent aeration of the DEF within the sensor adapter.

[0013] A fluid sensor adapter for mitigating fluid aeration is disclosed. In one embodiment, the fluid sensor adapter can include a first chamber that includes an inlet configured to receive diesel exhaust fluid. In one embodiment, the first chamber can include a first section located at the proximal end of the fluid sensor adapter, a third section located at the distal end of the sensor adapter, and a second section located between the first section and the third section. In one embodiment, the diameter of the second section can be smaller than the diameter of the first section. In one embodiment, the inlet from the second section to the third section can be narrower than the diameter of the second section. In one embodiment, the decreasing diameter from the first section to the second section and the narrowing inlet from the second section to the third section can include a tortuous vent passage configured to prevent air in the fluid from reaching the sensor.

[0014] In one embodiment, the second section and the third section can have approximately the same diameter. In one embodiment, the first section can include a shoulder that facilitates the decreasing diameter from the first section to the second section. In one embodiment, the second section can include a shoulder that facilitates the narrowing inlet from the second section to the third section. In one embodiment, the inlet from the second section to the third section can further include a shelf that facilitates the narrowing inlet from the second section to the third section. In one embodiment, the decreasing diameter from the first section to the second section and the narrowing inlet from the second section to the third section can occur both inside and outside the fluid sensor adapter.

[0015] In one embodiment, the fluid sensor adapter may further include at least one vent located in the third section. In one embodiment, the fluid sensor adapter may further include at least two vents located in the third section. In one embodiment, at least one vent may have a substantially horizontal portion. In one embodiment, at least two vents may each have a substantially horizontal portion. In one embodiment, the first section may include a seal. In one embodiment, the first section may include an O-ring. In one embodiment, the third section may include a seal. In one embodiment, the third section may include a plug and an O-ring. In one embodiment, the fluid sensor adapter may further include a second chamber. In one embodiment, the second chamber may be located adjacent to the first chamber but fluidly isolated from the first chamber.

[0016] A fluid sensor adapter for reducing fluid aeration is disclosed. In one embodiment, the fluid sensor adapter may include a first chamber. In one embodiment, the first chamber may include a first section at the proximal end of the sensor adapter, a third section at the distal end of the sensor adapter, and a second section between the first section and the third section. In one embodiment, the third section may include at least one vent, an O-ring, and a plug. In one embodiment, the first section may include an O-ring.

[0017] In one embodiment, the first section may include a shoulder that facilitates a diameter reduction from the first section to the second section. In one embodiment, the second section may include a shoulder that facilitates a narrowing at the entrance from the second section to the third section. In one embodiment, the plug and the O-ring may be located at the top of the third section. In one embodiment, at least one vent may be located at the bottom of the third section. In one embodiment, the entrance from the second section to the third section may be adjacent to the inlet of at least one vent. In one embodiment, the entrance and the inlet may be separated by a shelf. In one embodiment, the fluid and / or air from the entrance to the inlet may need to make a sharp turn. In one embodiment, the fluid and / or air from the entrance to the inlet may need to make a 180° turn. In one embodiment, at least one vent may have a substantially horizontal portion. In one embodiment, the third section may include two vents that each lead to opposite sides of the fluid sensor adapter. In one embodiment, each vent may have a substantially horizontal portion. In one embodiment, the third section may include two vents that are spaced 180° apart from each other.

[0018] The following description and drawings disclose various illustrative aspects. Some improvements and novel aspects may be explicitly identified, while other aspects may be apparent from the description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The operation of the present teachings can be better understood by reference to the following detailed description in conjunction with the accompanying drawings. These drawings form a part of this specification, and the written information in the drawings should be regarded as a part of the present disclosure. In the drawings:

[0020] Figure 1A A perspective view of an embodiment of a DEF sensor adapter in accordance with various aspects disclosed herein is shown;

[0021] Figure 1B A perspective view of an embodiment of a DEF sensor adapter in accordance with various aspects disclosed herein is shown;

[0022] Figure 2 A bottom perspective view of an embodiment of a DEF sensor adapter in accordance with various aspects disclosed herein is shown;

[0023] Figure 3A A top perspective view of an embodiment of a DEF sensor adapter in accordance with various aspects disclosed herein is shown;

[0024] Figure 3B A partial cross-sectional view of a perspective view of an embodiment of a DEF sensor adapter in accordance with various aspects disclosed herein is shown;

[0025] Figure 4A A cross-sectional view of an embodiment of a DEF sensor adapter in accordance with various aspects disclosed herein is shown;

[0026] Figure 4B A cross-sectional view of an embodiment of a DEF sensor adapter selectively attached to a mating component in accordance with various aspects disclosed herein is shown;

[0027] Figure 5 A cross-sectional view of an upper portion of an embodiment of a DEF sensor adapter selectively attached to a mating component in accordance with various aspects disclosed herein is shown;

[0028] Figure 6 A cross-sectional view of a lower portion of an embodiment of a DEF sensor adapter selectively attached to a mating component in accordance with various aspects disclosed herein is shown; and,

[0029] Figure 7 A perspective view of an embodiment of a DEF sensor adapter in accordance with various aspects disclosed herein is shown.

[0030] Without departing from the spirit or essential characteristics of the present invention, the present invention can be embodied in several forms. The scope of the present invention is defined in the appended claims rather than in the specific description before them. Accordingly, all embodiments falling within the meaning and equivalent scope of the claims are intended to be covered by the claims. Detailed Description

[0031] Reference will now be made in detail to embodiments of the present teachings, examples of which are illustrated in the accompanying drawings. It should be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the scope of the present teachings. Additionally, features of the embodiments may be combined, switched, or altered without departing from the scope of the present teachings. For example, features of each disclosed embodiment may be combined, switched, or substituted with features of other disclosed embodiments. Accordingly, the following description is presented by way of illustration and does not limit the various alternatives and modifications that may be made to the illustrated embodiments and still be within the spirit and scope of the present teachings.

[0032] As used herein, the words "example" and "exemplary" mean an instance or illustration. The words "example" or "exemplary" do not denote a key or preferred aspect or embodiment. The word "or" is intended to be inclusive rather than exclusive unless the context clearly dictates otherwise. For example, the phrase "A employs B or C" includes any inclusive arrangement (e.g., A employs B; A employs C; or A employs both B and C). On the other hand, the articles "a" and "an" generally are intended to mean "one or more" unless the context clearly dictates otherwise.

[0033] Furthermore, unless the context clearly dictates otherwise, a description of a shape (e.g., circular, rectangular, triangular, etc.) refers to a shape that conforms to the definition of such a shape and the general representation of such a shape. For example, a triangular shape or a substantially triangular shape may include a shape having three sides and three vertices or a shape that generally represents a triangle (such as a shape having three main sides that may or may not have straight edges), a triangle-like shape having rounded vertices, etc.

[0034] Turning to FIG. 1- Figure 7 , an embodiment of a sensor adapter 100 that can be used in a DEF application is shown. It should be noted that the sensor adapter 100 can also be used in other applications where the fluid is susceptible to entrained air or for otherwise mitigating fluid aeration. Although the present disclosure discloses use in a DEF application, such information can be applied to these other applications with little modification.

[0035] The sensor adapter 100 can be selectively coupled to a sensor (not shown) to provide a sensor assembly configured in any suitable manner. The sensor assembly can be installed in any suitable configured DEF reservoir or storage tank (not shown). The sensor assembly (e.g., the sensor adapter 100 or the sensor) can include a controller housing and a controller. In one example, the controller can include a circuit board. The sensing element can be electrically coupled to the controller and can share the housing or have a separate sensing element housing. In one example, the controller, the sensing element, or any other desired electrical components or connections can be encapsulated in a waterproof material.

[0036] The sensor adapter 100 can include a housing 110. The housing 110 can include an outer surface 112 and an inner surface 114, as shown, for example, in Figure 4A which the interior can include one or more internal cavities, conduits, chambers, passages, or hollow portions therein. The internal cavities, conduits, chambers, passages, or hollow portions can each have one or more sections, segments, passages, etc. The sensor adapter 100 and the housing 110 or a portion thereof can be configured to selectively restrict and permit the flow of fluids, air, and / or fluid / air into it. For example, the sensor adapter 100 can include a tortuous passage 193 that passes through a chamber in the sensor adapter and out to a vent to separate and / or release any entrained air (if present) from the DEF and / or prevent any air and entrained air / fluid from entering the body of the sensor adapter 100 and affecting the sensor readings. In some embodiments, the tortuous passage 193 can include a path that does not have a straight line path through it, i.e., it includes bends and turns, so there is no clear line of site through the passage. The configuration of the tortuous passage 193 can include any form of bends and turns and is not limited to that shown in the drawings. The sensor adapter 100 and the housing 110 or a portion thereof can be configured to house electrical components or connections.

[0037] It should be noted that the terms fluid and DEF as referred to herein generally can include fluids and DEF with entrained air as well as fluids and DEF without entrained air, unless otherwise stated or the context otherwise clearly indicates (e.g., before and after the tortuous passage 193 that is intended to separate entrained air or prevent fluids with air from entering the area near the sensor). It should be noted that the terms DEF and fluid as referred to herein generally can be used interchangeably, and even though DEF may be described, the embodiments described herein can be used in non-diesel engine applications. It should be noted that the terms fluid connection and fluid seal as used herein can refer to liquid and air connections and seals.

[0038] The sensor adapter 100 may include a first end 120 and a second end 130. It should be noted that the first end 120 may also be referred to as the proximal end, and the second end 130 may also be referred to as the distal end, or vice versa, where the first end 120 is referred to as the distal end and the second end 130 is referred to as the proximal end. It should be noted that the first end 120 may also be referred to as the bottom end, and the second end 130 may also be referred to as the top end.

[0039] A cross-sectional view of the first end 120 and the upper portion of the sensor adapter 100 is shown in Figure 5 FIG. A cross-sectional view of the second end 130 and the lower portion of the sensor adapter 100 is shown in Figure 6 FIG. Figure 4A - Figure 4B A cross-sectional view of the sensor adapter 100 is also shown. Figure 2 、 Figure 3B 、 Figure 4A and Figure 4B show examples of the tortuous passage 193.

[0040] In one embodiment, the first end 120 may be a free end or may be selectively attached to a DEF reservoir or tank (or other component within a diesel engine or vehicle system). For example, the first end 120 may be generally cylindrical or circular and may include threads 122 on an outer surface (such as 112) of the first end 120. The threaded portion 122 of the first end 120 may facilitate selective installation in a DEF manifold or within a DEF reservoir or tank. For example, a DEF manifold, reservoir, tank, or other component within a diesel engine or vehicle system may include a member having internal threads and sized and shaped to selectively receive the threaded portion 122 of the first end 120 of the sensor adapter 100. An example of a mating attachment portion of the first end 120 is shown in Figure 5 FIG. Although threads are disclosed herein and shown in the drawings, it should be noted that other mating attachment portions and connectors may also be used, including but not limited to friction fit mating components, press fit mating components, snap fit mating components, adhesives, O-rings, seals, fasteners, brackets, brackets, tabs, pins, latches, snaps, bayonet mounts or interlocks, sliding interlocks, magnetic interlocks, any other male-female engagement mechanism, etc.

[0041] In one embodiment, the second end 130 may be a free end or may be selectively attached to a sensor, sensor housing, or other component to form a sensor assembly. It should be noted that the second end 130 may be selectively attached to a DEF reservoir or tank (or other component within a diesel engine or vehicle system). The second end 130 may be selectively attached to its mating component by any mating attachment and connector, including but not limited to threaded mating components, friction fit mating components, press fit mating components, snap fit mating components, adhesives, O-rings, seals, fasteners, brackets, brackets, tabs, pins, latches, snaps, bayonet mounts or interlocks, sliding interlocks, magnetic interlocks, any other male-female engagement mechanism, etc.

[0042] The sensor adapter 100 may further include a first member 140 and a second member 150. Each member 140, 150 may include an internal chamber 145, 155. In one embodiment, one or both of the first member 140 and the second member 150 may be a hollow tubular member. The first member 140 and the second member 150 and the corresponding internal chambers 145, 155 may be separated by a wall 160. The wall 160 may extend between all or part of the internal chambers 145, 155. For example, the wall 160 may terminate at the first end 120 of the sensor adapter but may not extend completely through the second end 130 of the sensor adapter 100, compare Figure 4B and Figure 5 - Figure 6 , which respectively show cross-sectional views of the first end 120 and upper portion of the sensor adapter 100 and the second end 130 and lower portion of the sensor adapter 100. In one embodiment, the second end 130 may be used as an attachment portion for Figure 6 the housing components and other sensors visible in. For example, in the first chamber 145, an O-ring 230 may be incorporated as shown to seal the liquid level and / or concentration chamber. The O-ring may prevent DEF and aerated DEF from entering the liquid level and / or concentration chamber. Although the wall 160 may not extend completely through the second end 130 of the sensor adapter 100 to physically separate the internal chambers 145, 155 at the second end 130, in some embodiments, it should be noted that the internal chambers 145, 155 may not be fluidly connected and may be separated and sealed off by attachment to other sensors and housing components in the second end 130. In one embodiment, the second chamber 155 may be fluidly enclosed or sealed and house the electrical components of the sensor adapter 100.

[0043] The first member 140 and the internal chamber 145 therein may include a first portion 142 and a second portion 144 (the portions may also be referred to as segments). In one embodiment, the first portion 142 may have a greater diameter or internal dimension than the second portion 144. In one embodiment, the first portion 142 having the greater diameter may be located at or near the second end 130 of the sensor adapter 100 or within the second end 130 of the sensor adapter 100, and the second portion 144 having the smaller diameter may be located at or near the first end 120 of the sensor adapter 100 or in the middle of the sensor adapter 100. The first portion 142 may have a first dimension at the first portion 142 and may taper, step, or otherwise change to a second dimension at the second portion 144. For example, the point of dimension change may occur at a step or shoulder 146. The step 146 (which may also be referred to as the shoulder 146) may be seen on the exterior 112 of the housing 120 and within the internal chamber 145 (e.g., on the interior 114 of the housing), providing a change in the exterior and interior dimensions or diameters of the first portion 142 and the second portion 144 of the first member 140. As shown in FIGS. 4 and Figure 5 - Figure 6 As shown, the step 146 may include a single step or two separate steps. It should be noted that other numbers of steps may also be used with respect to the step 146 and other steps described herein (e.g., step 126 and step 156). It should be noted that the first portion 142 and the second portion 144 of the first member 140 and the first chamber 145 may refer to the exterior 112 or the interior 114 of the sensor adapter 100, unless the context or the present disclosure otherwise indicates. The resulting step or shoulder 146 may provide a stop point or mating attachment for the housing components and other sensors visible in Figure 6 As shown.

[0044] The second member 150 and the internal chamber 155 therein may include a first portion 152 and a second portion 154 (the portions may also be referred to as segments). In one embodiment, the first portion 152 may have a larger diameter or internal dimension than the second portion 154. In one embodiment, the first portion 152 having the larger diameter may be located at or near the second end 130 of the sensor adapter 100 or within the second end 130 of the sensor adapter 100, and the second portion 154 having the smaller diameter may be located at or near the first end 120 of the sensor adapter 100 or in the middle of the sensor adapter 100. The first portion 152 may have a first dimension at the first portion 152 and may taper, step down, or otherwise change to a second dimension at the second portion 154. For example, the point of dimension change may occur at the step 156 or shoulder. The step 156 (which may also be referred to as the shoulder 156) may be visible on the exterior 112 of the housing 120 and in the internal chamber 155 (e.g., on the interior 114 of the housing), providing a change in the exterior and interior dimensions or diameters of the first portion 152 and the second portion 154 of the first member 150. It should be noted that the first portion 152 and the second portion 154 of the second member 150 and the second chamber 155 may refer to the exterior 112 or the interior 114 of the sensor adapter 100, unless the context or the present disclosure otherwise indicates explicitly. The resulting step or shoulder 156 may provide a stop point or mating attachment for the housing components and other sensors visible in Figure 6 the Figure 6 .

[0045] In one embodiment, the step 146 of the first member 140 may be at approximately the same height on the body 110 of the sensor adapter 100 as the step 156 of the second member 150. In one embodiment, the step 146 of the first member 140 may be at a different height on the body 110 of the sensor adapter 100 than the step 156 of the second member 150. In one embodiment, the step 146 of the first member 140 may be lower on the body 110 of the sensor adapter 100 than the step 156 of the second member 150. In one embodiment, the step 156 of the second member 150 may be higher on the body 110 of the sensor adapter 100 than the step 146 of the first member 140. It should be noted that the opposite configurations are also contemplated and disclosed.

[0046] In one embodiment, the first chamber 145 may receive fluid, such as DEF and sometimes entrained air (if present), from a corresponding DEF storage tank or reservoir where the sensor adapter 100 (and sensor assembly) may be positioned. In one embodiment, the first chamber 145 of the sensor adapter 100 may permit DEF to pass through, and the first chamber 145 or a portion thereof may be fluidly connected to another component, such as a sensor housing (e.g., via the second end 130), such that the sensor may measure an aspect of the DEF (e.g., fluid level, fluid temperature, fluid concentration, etc.). The fluid may include entrained air, which is undesirable if in the vicinity of the sensor. The first chamber 145 and vent openings 190, 192 may provide a tortuous path 193 to prevent air from entering and reaching the sensor, and for the fluid, such that any entrained air may be removed from the fluid so that it does not affect the sensor. The first chamber 145 and the fluid therein may be fluidly connected to the surrounding DEF storage tank or reservoir and fluid-tightly sealed from the second chamber 155 of the sensor adapter 100, such that the fluid may selectively be present in the first chamber 145 and not in the second chamber 155.

[0047] In one embodiment, the second chamber 155 may be a wiring conduit that may house electrical components or wires (e.g., wire 158) and provide an electrical connection between the sensor (e.g., located at the second end 130 of the sensor adapter 100) and the remainder of the vehicle system via the second chamber 155 and the first end 120. The second chamber 155 and the electrical components or wires therein may be fluid-tightly sealed from the surrounding DEF storage tank or reservoir and the first chamber 145 of the sensor adapter 100, such that the fluid may selectively be present in the first chamber 145 and not in the second chamber 155.

[0048] It should be noted that the first end 120 of the sensor adapter 100 may further include a cap 124 that encloses the first chamber 145 and the second chamber 155, but the cap may include a hole or passage therethrough to allow the wire 158 to extend out from the first end 120. The cap 124 may be permanently or fixedly attached. The first chamber 145 may further include an additional plug 210 and an O-ring 220 that are designed to seal the DEF from exposure to the atmosphere. The plug 210 and the O-ring 220 may prevent debris and external fluids from entering the sensor adapter 100 from the outside of the DEF storage tank. The plug 210 and the O-ring 220 may prevent the DEF inside the storage tank from leaking out of the DEF storage tank.

[0049] In one embodiment, the sensor adapter 100 may include a tortuous passageway 193. The tortuous passageway 193 may assist in separating any entrained air (if present) from the DEF and / or preventing any entrained air from entering the sensor adapter 100 through the vent. In one example, the first chamber 145 may include a third portion 148 (which may also be referred to as a section) and an inlet 194 located between the second portion 144 and the third portion 148. In one embodiment, the first portion 142 of the first chamber 145 may have a greater diameter or internal dimension than the third portion 148. In one embodiment, the second portion 144 of the first chamber 145 may have a greater diameter or internal dimension than the third portion 148. In one embodiment, both the first portion 142 and the second portion 144 of the first chamber 145 may have a greater diameter or internal dimension than the third portion 148. In one embodiment, the first portion 142 may have a greater diameter than the second portion 144, and the second portion 144 may have a greater diameter or internal dimension than the third portion 148. It should be noted that the first member 140 and the first portion 142, the second portion 144, and the third portion 148 of the first chamber 145 may refer to the exterior 112 or the interior 114 of the sensor adapter 100, unless the context or the present disclosure indicates otherwise.

[0050] As shown in Figure 4A the second portion 144 and the third portion 146 may have substantially the same diameter, but the inlet or point 194 located between the second portion 144 and the third portion 148 may have a reduced diameter, as described. The inlet 194 may be part of the tortuous passageway 193, as described. The reduced diameter of the inlet 194 may be due to the step 126 and / or the shelf 195. In one embodiment, the third portion 148, the inlet 194 located between the second portion 144 and the third portion 148, or both have a diameter significantly reduced from the first portion 142 and the second portion 144. In one example, the inlet 194 located between the second portion 144 and the third portion 148 may be less than half the size of the second portion 144. In one example, the inlet 194 located between the second portion 144 and the third portion 148 may be approximately or less than one-third the size of the second portion 144. In one embodiment, the inlet 194 located between the second portion 144 and the third portion 148 may be approximately 2 mm. In one embodiment, the inlet 194 located between the second portion 144 and the third portion 148 may be approximately between 0.5 mm - 4 mm, between 1 mm - 3 mm, between 1.5 cm - 2.5 cm, etc. The inlet 194 located between the second portion 144 and the third portion 148 may be a hole. The inlet 194 located between the second portion 144 and the third portion 148 may be circular, but may also be oval, square, or rectangular.

[0051] In one embodiment, a first portion 142 having a larger diameter may be located at or near the second end 130 of the sensor adapter 100 or within the second end 130 of the sensor adapter 100, a second portion 144 having an intermediate diameter may be located at or near the first end 120 of the sensor adapter 100 or in the middle of the sensor adapter 100, and a third portion 148 having a smaller diameter or a smaller diameter inlet 194 between the second portion 144 and the third portion 148 may be located at or near the first end 120 of the sensor adapter 100 or within the first end 120 of the sensor adapter 100. In one embodiment, the second portion 144 may have a first size at the second portion 144 and may taper, step, or otherwise change to a second size at the third portion 148 or at least at the inlet 194 located between the second portion 144 and the third portion 148.

[0052] For example, the size change point may occur at a step or shoulder 126. The step 126 (which may also be referred to as a shoulder 126) may be visible on the exterior 112 of the housing 120, as part of the first end 120, or located between the first end 120 and the first member 140 and the second member 150. The step 126 may be visible in the internal chamber 145 (e.g., on the interior 114 of the housing), see, for example Figure 3B and Figure 4A . The step 126 may provide a change in the external and internal dimensions or diameters of the first member 140 and / or the second portion 144 and the third portion 148 (or the inlet 194 located between the second portion 144 and the third portion 148) of the first chamber 145. The shelf 195 may also provide a change in the internal dimensions or diameters of the first member 140 and / or the second portion 144 and the third portion 148 (or the inlet 194 located between the second portion 144 and the third portion 148) of the first chamber 145.

[0053] In one embodiment, the step 126 of the first member 140 may be closer to the first end 120 of the sensor adapter 100 than the step 146, and the step 146 may be closer to the second end 130 of the sensor adapter 100. In one embodiment, the step 126 of the first member 140 may be at a different height on the body 110 of the sensor adapter 100 than the step 156 of the second member 150. In one embodiment, the step 126 of the first member 140 may be higher on the body 110 of the sensor adapter 100 than the step 156 of the second member 150 (e.g., closer to the first end 120 compared to the second end 130). It should be noted that the opposite configurations are also contemplated and disclosed.

[0054] In one embodiment, fluid (such as DEF) may enter into sensor adapter 100 through the second end 130 of sensor adapter 100 or through sensor and housing components attached to the second end 130. In one embodiment, fluid (such as DEF) may enter directly into sensor adapter 100 from a DEF reservoir or tank through vents 190, 192 (e.g., due to sloshing). Air that may be present in the fluid may enter and rise through the first portion 142, second portion 144, and third portion 148 of the first chamber 145, and remain accumulated at the top of the third portion 148, or may be discharged through vents 190, 192. The various reduced diameters of the first portion 142, second portion 144, and third portion 148 of the first chamber 145 or the various reduced diameters between them may help separate air bubbles from the fluid and direct the separated air into the third portion 148 and out of sensor adapter 100. The structure of vents 190, 192, the connection from vents 190, 192 into the third portion 148, and the connection from the third portion 148 into the second portion 144 at point 194 (which may be referred to as an inlet) may also help separate air bubbles from the fluid and may further prevent air from entering vents 190, 192, entering into the third portion 149 of the first chamber 145, and entering into the second portion 144 or further towards the sensor.

[0055] Fluid (such as DEF) may generally enter into the vents, inlets, or sensor adapter 100 to reach the sensor and indicate aspects of the fluid such as fluid level, fluid temperature, fluid concentration (e.g., urea in water), etc. Various provisions may be made for sensing DEF characteristics. For example, a fluid level sensing waveguide such as the first member 140 and the first chamber 145 may be provided. Providing such a waveguide may improve accuracy because generally the fluid inside the fluid level sensing waveguide may vary less compared to a DEF fluid tank that may experience sloshing during vehicle movement.

[0056] As described herein, the fluid may include entrained air, which may affect sensor readings, accuracy, and functionality if it reaches the sensor. The sensor adapter 100 may include tortuous passages 193 that enter vent ports 190, 192 and pass through the third portion 148, second portion 144, and first portion 142 of the first chamber 145, respectively, to separate any entrained air (if present) from the DEF and / or prevent air and entrained air / fluid from entering the body of the sensor adapter 100 and reaching the sensor. The sensor adapter 100 may include tortuous passages 193 that pass through the first portion 142, second portion 144, and third portion 148 of the first chamber 145 and exit vent ports 190, 192, respectively, to separate any entrained air (if present) from the DEF and / or prevent air and entrained air / fluid from entering the body of the sensor adapter 100 and reaching the sensor.

[0057] For example, the tortuous passage 193 may include stepped chambers (e.g., steps 146, 126) and varying diameters between the first portion 142, second portion 144, and / or third portion 148, as described. For example, the tortuous passage 193 may include a reduced-diameter inlet 194 located between the second portion 144 and the third portion 148, as described. The tortuous passage 193 may further include vent ports 190, 192.

[0058] The sensor adapter 100 may include one or more vent ports 190, 192. It should be noted that the sensor adapter 100 may include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more, and any range therebetween, etc., of vent ports. The vent ports 190, 192 and the vent passage may be combined into the first chamber 145, or the first chamber 145 may branch into a number of individual vent ports as needed. As shown in Figure 2 , for example, the first chamber 145 may branch into two vent ports 190, 192 located on opposite sides of the sensor adapter 100. In one embodiment, the two vent ports 190, 192 may be positioned 180° from each other, for example, see Figure 2 . It should be noted that other geometries may also be used without departing from the present disclosure. In one embodiment, the two vent ports 190, 192 may be located at relatively the same horizontal height of the first chamber 145, for example, see Figure 2 . Before entering the third portion 148, the vent ports 190, 192 and the vent passage may include a substantially horizontal portion 197.

[0059] In one embodiment, the vents 190, 192 may be located on the bottom surface or lower portion of the third part 148. In one embodiment, the bottom surface or lower portion of the third part 148 may include a shelf 195. The shelf (e.g., together with the step 126) may separate the second part 144 and the third part 148 and may contribute to the reduced diameter inlet 194 of the third part 148. The vents 190, 192 may include inlets 196. The inlets 196 may be located on or near the shelf 195 and may correspond to one end (or first end) of the vents 190, 192. The shelf 195 may form or lead to the inlets 196. The shelf 195 may be positioned approximately in the middle of the sensor adapter 100 or at or near the wall 160. The inlets 196 may be positioned approximately in the middle of the sensor adapter 100 or at or near the wall 160. The inlets 196 may be positioned adjacent to, near, or close to the inlet 194. In one embodiment, the inlets 196 and the inlet 194 may be at relatively the same horizontal height in the first chamber 145, e.g., see Figure 3B and Figure 4A . Although close to each other, the fluid flow between the inlet 194 and the inlets 196 may have or require a 180° turn, e.g., see the tortuous passage 193 shown in Figure 3B and Figure 4A . It should be noted that other geometries may also be used without departing from the present disclosure.

[0060] The inlets 196 may lead to a substantially horizontal portion 197. It should be noted that each vent 190, 192 may include its own horizontal portion 197 from the inlets 196, e.g., see Figure 2 . In an embodiment, the sensor adapter 100 having two vents 190, 192 may include two substantially horizontal portions 197. The vents 190, 192 may include outlets 198. The outlets 198 may correspond to the other end (or second end) of the vents 190, 192. The substantially horizontal portion 197 may lead to the outlets 198. In an embodiment, the sensor adapter 100 having two vents 190, 192 and two substantially horizontal portions 197 may further include two outlets 198, see Figure 2 . In one embodiment, the transition from the inlets 196 to the substantially horizontal portion 197 may have or require a 90° turn, e.g., see in Figure 3BThe tortuous passage 193 shown in [figure]. It should be noted that other geometries can also be used without departing from the present disclosure. In one embodiment, two substantially horizontal portions 197 can extend across most of the width of the sensor adapter 100. In one embodiment, each substantially horizontal portion 197 can extend across at least half of the width of the sensor adapter 100.

[0061] In one embodiment, the substantially horizontal portions 197 can generally prevent fluid and air in the horizontal portions from entering the third portion 148 of the first chamber 145, while still allowing air to escape from the third portion 148 through the vent openings 190, 192.

[0062] In one embodiment, the third portion 148 of the first chamber 145 can be located above the substantially horizontal portions 197 of the vent openings 190, 192 for intercepting air that enters through the vent openings or separates / rises from the first portion 142 and the second portion 144 of the first chamber 145.

[0063] In one embodiment, the step 126 and the small inlet 194 located between the second portion 144 and the third portion 148 can help separate entrained air from the fluid in the second portion 144 (e.g., at the position where the air rises into the third portion 148), and can help prevent air from returning downward from the third portion 148 into the second portion 144.

[0064] In one embodiment, the sensor adapter 100 can be provided as a one-piece design or can be formed by one or more selectively assembled components. In one embodiment, the sensor adapter 100 can be integrally formed. In these integral embodiments, the sensor adapter 100 can be formed in any suitable manner, such as by 3-D printing, extrusion molding, injection molding, other molding, casting, or any manufacturing process.

[0065] In one embodiment, the sensor adapter 100 or its components can be made of any desired material, including but not limited to metals, plastics, rubbers, composite materials, etc. The sensor adapter 100 can be made of the same material, or different components or parts of the sensor adapter 100 can be made of different materials.

[0066] In one embodiment, the sensor adapter 100 can adapt the vent path design to isolate the liquid level and / or concentration chamber from the vent openings while positioning the vent openings at an optimal height. In one embodiment, the sensor adapter 100 can address leakage through the gap between the extrusion tube and the upper adapter by installing an O-ring seal.

[0067] Typically, compared to conventional systems, the described sensor adapter 100 provides improved performance. The sensor adapter 100 can prevent or minimize aerated DEF from entering the vent ports 190, 192, and the internal chamber 145. For example, for aerated DEF to enter the internal chamber 145 (e.g., the first section 142 and the second section 144), the aerated DEF would have to enter the outlets 198 of the vent ports 190, 192, travel through the horizontal portion 197, travel upward through the inlet 196, and enter the third section 148, cross the shelf 195, and pass through the smaller inlet 194 (each of which includes a tortuous passage 193). Each of these aspects (and other aspects) of the tortuous passage 193 (individually and in combination) can make it difficult or unlikely for aerated DEF to enter the sensor adapter 100 and its components. Each of these aspects (and other aspects) of the tortuous passage 193 (individually and in combination) can also allow air to escape from the internal chamber 145, e.g., through the inlet 196, the horizontal portion 197, and the outlet 198. The sensor adapter 100 and the tortuous passage 193 can also prevent the fluid within the internal chamber 145 from being aerated by air that may be located within the sensor adapter 100 (e.g., within the third section 148), e.g., based on varying diameters, stepped structures, small inlet points, 180° turns, etc.

[0068] In one example, the tortuous vent passage 193 can include a passage that requires a first turn to pass through (the turn can be a left turn or a right turn or a combination of both). The tortuous passage 193 can then include another turn to pass through (the turn can be a left turn, a right turn, or a combination of both). The tortuous passage 193 can also be located at different heights, which means the turns can be turns with height or can be located at the same height. The tortuous passage 193 can include any number of turns, e.g., 1, 2, 3, 4, 5, 6, or more. The present disclosure is not limited by the number of turns. Additionally, the tortuous passage 193 can include any number of left turns (e.g., 1, 2, 3, 4, 5, 6, or more), and can include any number of right turns (e.g., 1, 2, 3, 4, 5, 6, or more). Further, the turns of the tortuous passage 193 can be any suitable angle, e.g., 20 degrees - 110 degrees, 110 degrees - 160 degrees, 190 degrees - 270 degrees.

[0069] Generally speaking, the sensor adapter 100 can help prevent, minimize, and / or eliminate air, entrained air, and aerated DEF in the system, and can allow for more precise measurements of concentration, fluid level, etc. In one example, using liquid sloshing tests performed at different frequencies, the sensor adapter 100 shows improved performance. Sensor errors can be caused by aerated DEF entering through the sensor vent holes. The sensor adapter 100 can provide an improved upper sensor adapter and can isolate the level sensor and the concentration chamber. The sensor adapter 100 can prevent or minimize sensor errors.

[0070] Although embodiments of the invention have been shown in the drawings and described in the foregoing detailed description, it should be understood that the invention is not limited solely to the disclosed embodiments, but rather the invention described herein is capable of many rearrangements, modifications, and substitutions without departing from the scope of the appended claims. The appended claims are intended to cover all modifications and variations as long as they fall within the scope of the claims or their equivalents.

Claims

1. A fluid sensor adapter for reducing fluid aeration, comprising: A first chamber including an inlet configured to receive diesel exhaust fluid; Wherein the first chamber includes a first section at a proximal end of the fluid sensor adapter, a third section at a distal end of the sensor adapter, and a second section between the first section and the third section; Wherein the diameter of the second section is less than the diameter of the first section, and wherein the inlet from the second section to the third section is narrower than the diameter of the second section; and Wherein the diameter reduction from the first section to the second section and the narrowing of the inlet from the second section to the third section include a tortuous vent passage configured to prevent air in the fluid from reaching the sensor.

2. The fluid sensor adapter according to claim 1, wherein, The second section and the third section have approximately the same diameter.

3. The fluid sensor adapter according to claim 1, wherein, The first section includes a shoulder facilitating the diameter reduction from the first section to the second section.

4. The fluid sensor adapter according to claim 1, wherein, The second section includes a shoulder facilitating the narrowing of the inlet from the second section to the third section.

5. The fluid sensor adapter according to claim 1, wherein, The diameter reduction from the first section to the second section and the narrowing of the inlet from the second section to the third section occur both inside and outside the fluid sensor adapter.

6. The fluid sensor adapter according to claim 1, further comprising at least one vent opening in the third section.

7. The fluid sensor adapter according to claim 6, wherein, The at least one vent opening has a substantially horizontal portion.

8. The fluid sensor adapter according to claim 1, wherein, The first section includes an O-ring.

9. The fluid sensor adapter according to claim 1, wherein, The third section includes a plug and an O-ring.

10. The fluid sensor adapter according to claim 1, further comprising a second chamber, wherein, The second chamber is positioned adjacent to the first chamber but is fluidly isolated from the first chamber.

11. A fluid sensor adapter for reducing fluid aeration, comprising: A first chamber, wherein the first chamber includes a first section at a proximal end of the sensor adapter, a third section at a distal end of the sensor adapter, and a second section between the first section and the third section; Wherein the third section includes at least one vent opening, an O-ring, and a plug; and Wherein the first section includes an O-ring.

12. The fluid sensor adapter according to claim 11, wherein, The first section includes a shoulder facilitating the diameter reduction from the first section to the second section.

13. The fluid sensor adapter according to claim 11, wherein, The second section includes a shoulder facilitating the narrowing at the inlet from the second section to the third section.

14. The fluid sensor adapter according to claim 11, wherein, The plug and the O-ring are located at the top of the third section.

15. The fluid sensor adapter according to claim 11, wherein, The at least one vent opening is located at the bottom of the third section.

16. The fluid sensor adapter according to claim 15, wherein, The inlet from the second section to the third section is adjacent to the inlet of the at least one vent opening.

17. The fluid sensor adapter according to claim 16, wherein, The inlet and the inlet are separated by a shelf, and the fluid flow from the inlet to the inlet requires a 180° turn.

18. The fluid sensor adapter according to claim 11, wherein, The at least one vent opening has a substantially horizontal portion.

19. The fluid sensor adapter according to claim 11, wherein, The third section includes two vent openings each leading to opposite sides of the fluid sensor adapter, and each vent opening has a substantially horizontal portion.

20. The fluid sensor adapter according to claim 11, wherein, The third section includes two vent openings spaced 180° apart from each other.

Images