Diesel exhaust fluid electronic module

Abstract

A DEF electronic module for a diesel exhaust fluid (DEF) system for a diesel internal combustion engine. The DEF electronic module includes electronic components for the DEF system, a housing for the electronic components, and a contaminant indicator. The electronic components are disposed within the housing. The contaminant indicator is disposed within the housing. The contaminant indicator is configured to record the presence of contaminants within the housing.

Description

Technical Field

[0001] This disclosure relates to diesel internal combustion engines. Specifically, this disclosure relates to the treatment of exhaust gases from diesel internal combustion engines. Background Technology

[0002] Aftertreatment systems for diesel internal combustion engines typically include selective catalytic reduction (SCR). SCR can be configured as part of the aftertreatment system to reduce NO present in exhaust gases. x The amount.

[0003] SCR systems utilize an aqueous urea solution (commonly known as diesel exhaust fluid or DEF). DEF is injected into the exhaust gas, where heat from the exhaust gas causes the urea to decompose into ammonia. This ammonia then reacts at the SCR to remove NO. x It is reduced to nitrogen and water.

[0004] DEF used in conjunction with SCR is typically stored in tanks. When the engine is running, DEF can be pumped from the tanks to the aftertreatment system. DEF stored in the tanks can decompose into ammonia. Specifically, when the DEF temperature rises above ambient conditions, the decomposition of urea within the DEF tanks may become more pronounced. Summary of the Invention

[0005] According to a first aspect of this disclosure, a DEF electronic module for a diesel exhaust fluid (DEF) system for a diesel internal combustion engine is provided. The DEF electronic module includes:

[0006] The electronic components of the DEF system;

[0007] A housing for the electronic component, wherein the electronic component is disposed within the housing; and

[0008] A contaminant indicator is installed inside the housing and is configured to record the presence of contaminants inside the housing.

[0009] The inventors have recognized that contaminants (such as ammonia, urea, water, fuel, coolant, and their derivatives) present in a DEF system can unintentionally alter the operation of one or more electronic components of the DEF system. For example, exposure to contaminants may render one or more electronic components inoperable, such as due to protective barrier corrosion and short circuits. Some contaminants (such as fuel or coolant) may also cause damage to sensors or seals, which could unintentionally alter the operation of DEF electronic modules.

[0010] Although the electronic module of the first aspect provides a housing for the electronic components, which provides some isolation between the electronic components and contaminants, the inventors have also recognized that some contaminants (e.g., ammonia) may permeate through the housing during use of the DEF system. Therefore, preventing contaminants from reaching the electronic components of the DEF electronic module can be challenging.

[0011] If contaminants have indeed reached the electronic components, the inventors have recognized that diagnosing whether the contaminants have caused changes in the operation of the electronic components is challenging. For example, reproducing the problem on a test bench can be challenging because the process may be reversible. Therefore, diagnosing the root cause of the contaminants without destructively disassembling the system may not be straightforward. Furthermore, contaminants may be invisible to the naked eye when inspecting a faulty DEF system / DEF electronic module, making it challenging to diagnose contaminant entry. Moreover, in some cases, the electronic module may regain its functionality after the contaminants subsequently migrate away from the electronic module (e.g., through processes such as evaporation or rebalancing of partial pressure). Therefore, correctly diagnosing behavioral changes in the DEF electronic module due to the presence of contaminants can be challenging.

[0012] The electronic module of the first aspect includes a contaminant indicator disposed within the housing. Therefore, if contaminants enter the housing containing the electronic components, the contaminant indicator will record their presence. By recording the presence of contaminants, the DEF electronic module of the first aspect makes it easier and faster to diagnose malfunctions caused by contaminant intrusion. Specifically, even if the contaminants subsequently evaporate or are removed from the DEF electronic module, the contaminant indicator will still record their presence. By using the contaminant indicator to attribute malfunctions to contaminant intrusion in a quick and reliable manner, the DEF electronic module can be repaired / restored in a relatively simple and economical way.

[0013] According to a second aspect of this disclosure, a DEF manifold for a DEF system is provided. The DEF manifold is configured to circulate DEF from the DEF reservoir of the DEF system to an aftertreatment system for a diesel internal combustion engine. The DEF manifold includes a sensor module and a control module, wherein the sensor module and / or the control module is a DEF electronic module according to a first aspect of this disclosure. In some embodiments, the aftertreatment system may include a DEF injector and / or a SCR.

[0014] According to a third aspect of this disclosure, a DEF system is provided. The DEF system includes a DEF electronic module according to a first aspect or a DEF manifold according to a second aspect. The DEF system includes a DEF storage tank. The DEF system is configured to circulate DEF from the DEF storage tank to an aftertreatment system of a diesel internal combustion engine. Attached Figure Description

[0015] Embodiments of this disclosure will now be described with reference to the following non-limiting drawings, in which:

[0016] Figure 1 This is a block diagram of a DEF system according to an embodiment of the present disclosure;

[0017] Figure 2 This is a schematic diagram of a DEF manifold according to an embodiment of the present disclosure;

[0018] Figure 3 This is a cross-sectional view of a DEF electronic module according to an embodiment of the present disclosure;

[0019] Figure 4 yes Figure 2 Another cross-sectional view of the DEF electronic module;

[0020] Figure 5 This is a schematic cross-sectional view of the lower portion of a DEF manifold according to an embodiment of the present disclosure; and

[0021] Figure 6 This is a schematic cross-sectional view of a DEF electronic module according to an embodiment of the present disclosure. Detailed Implementation

[0022] According to embodiments of this disclosure, a DEF system 1 is provided. Figure 1 A block diagram of DEF system 1 according to this disclosure is shown. (As follows) Figure 1 As shown, DEF system 1 includes DEF storage tank 5 and DEF manifold 10. (As indicated...) Figure 1 As shown, the DEF system circulates DEF from DEF tank 5 to the aftertreatment system 3 of the diesel internal combustion engine. DEF manifold 10 circulates DEF from DEF tank 5 to aftertreatment system 3 via flow path 7. DEF flows back from aftertreatment system 3 to DEF tank 5 via return path 9 and DEF manifold 10.

[0023] Figure 2 A computer-generated diagram of a DEF manifold 10 according to an embodiment of the present disclosure is shown. The DEF manifold 10 includes a sensor module 20 and a control module 30. The DEF manifold 10 also includes a lower portion 40 and an upper portion 50.

[0024] DEF storage tank 5 defines an internal volume. The internal volume of DEF storage tank 5 can store DEF for use in DEF system 1. DEF storage tank 5 may define an opening 6 through which DEF manifold 10 extends. Other openings (in...) Figure 1 (Not shown) can be installed in DEF tank 5, for example, so that DEF can be added to DEF tank 5, etc.

[0025] DEF manifold 10 may be configured to circulate DEF from DEF storage tank 5 of DEF system 1 to aftertreatment system 3. Aftertreatment system 3 may include an SCR catalyst (not shown). Aftertreatment system 3 may also include a DEF injector (not shown) configured to inject DEF into the exhaust gas stream. The exhaust gas stream and DEF then flow through the SCR catalyst to reduce NO in the exhaust gas. x The amount.

[0026] DEF manifold 10 may also include sensing functionality for monitoring one or more variables associated with DEF system 10. For example, DEF manifold 10 may be configured to monitor one or more of the following: the amount of DEF present in DEF tank 5 (e.g., DEF level sensor), the concentration of DEF in DEF tank (e.g., urea concentration), and the temperature of DEF in DEF tank 5.

[0027] like Figure 1 and Figure 2 As shown, the DEF manifold may include a lower portion 40 configured to extend from an opening 6 into the DEF tank 5. Therefore, the lower portion 40 of the DEF manifold 10 may be the portion of the DEF manifold 10 extending into the internal volume of the DEF tank 5. The lower portion 40 may include a plurality of DEF conduits 42 for circulating DEF to the aftertreatment system 3 and back to the DEF tank 5. The lower portion 40 may also include one or more sensor modules 20. The sensor modules 20 may be located at the distal end of the lower portion 40, opposite the upper portion 50.

[0028] The lower portion 40 may also include a communication channel 44. The communication channel 44 may extend from the upper portion 50 of the DEF manifold 10 to one or more sensor modules in the sensor module 20. In some embodiments, the communication channel 44 may be configured to connect one or more sensor modules 20 to the control module 30. For example, in Figure 1 and Figure 2 In one embodiment, the communication channel 44 connects the sensor module 20 of the lower portion 40 to the control module 30 of the upper portion 50. In other embodiments, one or more sensor modules 20 may be located in the upper portion 50 and / or the lower portion 40. In some embodiments, multiple communication channels 44 may be provided to interconnect modules 20, 30. The communication channel 44 may be configured to interconnect modules 20, 30 in a manner that isolates the interior of the communication channel 44 from the surrounding environment of the communication channel 44. Thus, the communication channel 44 may define a volume in which cables and / or electronic components may be located. In some embodiments, the communication channel 44 may also include a contaminant indicator 12.

[0029] The upper portion 50 of the DEF manifold 10 may be configured to seal the opening 6 of the DEF tank 5. Therefore, the upper portion of the DEF manifold 10 may be the portion of the DEF manifold extending beyond the internal volume (i.e., outside) of the DEF tank 5. Thus, the DEF manifold 10 may extend through the opening 6 of the DEF tank 5. A control module 30 may be located in the upper portion 50 of the DEF manifold 10. In other embodiments, the control module 30 may be located in the lower portion 40 of the DEF manifold 10. The control module 30 may be connected to the sensor module 20 via a communication channel 44. In some embodiments, the control module 30 may be located in the upper portion 50 of the DEF manifold 10 to allow easy connection to other control systems of the internal combustion engine, such as an engine control unit (not shown). By placing the control module 30 in the upper portion 50 of the DEF manifold 10, the exposure of the control module 30 to contaminants from, for example, the DEF tank 5 is reduced. The inventors have recognized that some contaminants (specifically, ammonia) may migrate. Therefore, even if the control module 30 is substantially located outside the DEF tank 5 (e.g., in the upper portion 50 of the DEF manifold 10), the control module 30 may still be exposed to contaminants migrating from the DEF tank 5 via the DEF manifold 10. Embodiments of this disclosure provide one or more DEF electronic modules including components for indicating when they have been exposed to one or more contaminants.

[0030] According to this disclosure, sensor module 20, control module 30, and communication channel 44 may each be an example of a DEF electronic module according to this disclosure. The DEF electronic module includes: electronic components of the DEF system, a housing for the electronic components, and a contaminant indicator disposed within the housing.

[0031] According to this disclosure, a DEF electronic module can be any part of a DEF system 1 used to house one or more electronic components. Such electronic components may be at risk of accidental exposure to one or more contaminants. Exposure to contaminants (e.g., ammonia) may cause the electronic components (or the DEF system 1 as a whole) to malfunction or behave in an unintended manner. When performing maintenance on the DEF system 1 to diagnose the cause of malfunction or unintended behavior, accurately determining whether contaminant exposure is the cause of the malfunction / unintended behavior can be challenging. For example, ammonia exposure may cause temporary alterations to the electronic components. Therefore, in some cases, subsequent migration of ammonia (e.g., through evaporation or rebalancing of partial pressure equilibrium) from the electronic components may allow the electronic components to function normally. Therefore, inspection and / or electrical testing of the electronic components of the DEF system 1 may not readily identify malfunctions / unintended behavior caused by contaminant exposure. According to this disclosure, a DEF electronic module is provided that includes one or more contaminant indicators, which enable relatively quick and simple diagnosis of contaminant exposure. For example, in Figure 3 and Figure 4 A schematic diagram of the control module 30 of the DEF manifold 10 is shown, which is a DEF electronic module according to the present disclosure.

[0032] According to this disclosure, the electronic component can be any discrete electronic device or physical electronic component forming part of a DEF system. For example, the electronic component can be a processor, integrated circuit, microprocessor, field-programmable gate array (FPGA), logic circuit, transistor, diode, resistor, capacitor, inductor, and transformer, etc. The electronic component can also be sensor 22 of DEF system 1. For example, the electronic component can be a temperature sensor, a level sensor, or a concentration sensor. A temperature sensor can be configured to sense the temperature of DEF system 1, such as the temperature of DEF in DEF tank 5. A level sensor can be configured to sense the level of DEF in the DEF tank. Thus, the level sensor can output a value indicating the amount of DEF in the DEF tank. A concentration sensor can be configured to sense the concentration of DEF in the DEF tank (e.g., the concentration of urea). Sensor 22 can include an ultrasonic sensor, an infrared sensor, a near-infrared sensor, a reed switch, or an optical refractive index sensor. In some embodiments, the electronic component can be an electronic circuit (or part of an electronic circuit) including multiple discrete electronic devices.

[0033] For example, in some embodiments, the electronic component may be a printed circuit board (PCB) 32 comprising a plurality of discrete electronic components. In some embodiments, the electronic component may include a processor configured to control at least a portion of the DEF system 1. In some embodiments, the processor may be configured to receive signals from one or more sensors 22 of the DEF system 1. For example, in Figure 2 In the DEF manifold 10, the processor may be located within the control module 30. In some embodiments, one or more sensors 22 may be located within the sensor module 20. Figure 3 and Figure 4 In the control module 30, a PCB 32 is provided, on which one or more processors (not shown) can be set.

[0034] According to this disclosure, in a DEF electronic module, one or more electronic components are disposed within a housing. Figure 3 and Figure 4 The cross-sectional view shows the control module housing 34 surrounding the PCB 32. The housing may provide a enclosure for one or more electronic components. That is, the housing may define a chamber 35 containing one or more electronic components. The housing may be configured to isolate one or more electronic components from the surrounding environment. For example, the housing may isolate the electronic components from the DEF disposed within the DEF tank 5.

[0035] In some embodiments, the housing may be formed of any suitable material or a composite of materials. In some embodiments, the housing may include a metal, such as aluminum. In other embodiments, the housing may include plastic. Figure 3 and Figure 4 The control module housing 34 may comprise plastic or composite material. It should be understood that the housing for the DEF electronic module can take various shapes and forms depending on the electronic components to be housed within the housing and the space available for the housing. Figure 3 and Figure 4 The control module 30 and the control module housing 34 are part of a two-part assembly. A second part (not shown) with a similar construction may be attached to the control module housing 34 to define a cavity 35 in which the PCB 32 is located. The housing may also include one or more openings 39 that connect the interior of the control module 30 to the interior of the communication channel 44.

[0036] In some embodiments, the potting compound may be disposed within the housing. The potting compound may be configured to encapsulate electronic components and / or contaminant indicators (discussed in more detail below). The potting compound may be configured to fill the volume within cavity 35 of the DEF electronic module not occupied by electronic components, etc. The potting compound may provide additional environmental protection for any electronic components it encapsulates. The potting compound may also be configured to provide an hermetically sealed DEF electronic module. As known to those skilled in the art, various materials can be used as potting compounds. For example, in some embodiments, the potting compound may include resins, or plastics, elastomers, epoxy resins, or composite materials, the composite material including any of the following: resins, or plastics, elastomers, epoxy resins. In some embodiments, the potting compound may be a composite material comprising a potting matrix and potting particles (such as glass beads or plastic spheres).

[0037] In addition to one or more electronic components, a contaminant indicator 36 is also disposed within the housing of the DEF electronic module. The contaminant indicator 36 can be configured to record the presence of contaminants within the housing. According to this disclosure, a contaminant can be considered any chemical substance, element, or molecule whose housing is configured to exclude it from the electronic components. When the electronic components are exposed to a contaminant, the contaminant may cause temporary or permanent changes in the behavior of the electronic components. Examples of contaminants according to this disclosure include urea, ammonia, water, isocyanate, urea derivatives, ammonia derivatives, isocyanate derivatives, water, and organic compounds (such as fuels or coolants).

[0038] The contaminant indicator 36 can be configured to record the presence of a specific contaminant. In some embodiments, the contaminant indicator 36 can be configured to record the presence of a selected set of contaminants. Those skilled in the art can select the contaminant indicator 36 based on the contaminants to be detected in the DEF electronic module. For example, the contaminant indicator 36 can be configured to record the presence of one or more of the following: urea, isocyanate, ammonia, water, or derivatives thereof.

[0039] In some embodiments, a plurality of contaminant indicators 36 may be disposed within the housing. In some embodiments, a plurality of contaminant indicators 36 may be distributed throughout the housing. For example, in Figure 4 The control module shown (with the PCB shown in a transparent form) includes multiple contaminant indicators 36. Each contaminant indicator may be arranged in the form of an elongated strip, which may be attached to the inner surface of the control module housing 34.

[0040] In an embodiment of the potting compound (see below), multiple contaminant indicators may be distributed throughout the potting compound.

[0041] According to this disclosure, different types of pollutant indicators 36 can be configured, depending on the desired functionality of the pollutant indicator 36.

[0042] In some embodiments, the contaminant sensor 36 may include a chemical sensor configured to react to the presence of a contaminant in the housing. In some embodiments, the chemical sensor may be configured to permanently alter its physical properties (e.g., change color) in response to the presence of a contaminant in the housing. For example, in some embodiments, the chemical sensor may include a sensor strip impregnated with a chemical substance configured to react in the presence of one or more contaminants. The sensor strip may include paper, fabric, or any other suitable material. When the chemical substance on the sensor strip reacts with the contaminant, the resulting reaction products may cause the sensor strip to change color or become visually identifiable in any other suitable manner. Thus, a chemical sensor may be provided to provide an immediate, visible indication that the chamber 35 of the DEF electronics module has been exposed to contaminants during inspection. For example, in Figure 3 and Figure 4 In the control module 30, one or more of the pollutant sensors 36 may be chemical sensors including sensor strips as described above.

[0043] In some embodiments, the chemical sensors may be distributed throughout the potting material 26. Thus, multiple discrete chemical sensors may be distributed throughout the potting material 26. Upon exposure to a contaminant, the potting material may visibly indicate contaminant exposure due to the reaction of the chemical sensors (e.g., by color change).

[0044] As a complement or alternative to the chemical sensors described above, in some embodiments, one or more contaminant indicators 36 may include an electronic sensor configured to detect the presence of a contaminant in the housing. Various electronic sensors for contaminants are known to those skilled in the art. For example, the electronic sensor may be an electrochemical gas sensor configured to detect the presence of a contaminant gas, such as hydrogen and ammonia. In some embodiments, the electronic sensor may include a conductive grid configured to change its conductivity upon exposure to ammonia in order to detect the presence of ammonia. In some embodiments, the conductive grid may include a wire grid. The wire grid may include a metallic material, such as aluminum or copper wire. The wires may be arranged in the form of a conductive grid to increase the surface area of ​​the electronic sensor. Upon exposure to a contaminant (e.g., ammonia), the conductivity of the grid may change, thereby allowing the detection of the contaminant's presence (due to the change in the grid's conductivity).

[0045] In some embodiments, the electronic sensor may be connected to the processor of the DEF system 1. For example, in Figure 3 and Figure 4 In this embodiment, one or more of the contaminant indicators 36 may be electronic sensors. Each electronic sensor may be configured to communicate with a processor disposed on the PCB 32. Upon receiving a signal from an electronic sensor indicating the presence of contaminants within the housing, the processor may be configured to output an alarm indicating the presence of contaminants in the housing.

[0046] In some embodiments, one or more electronic sensors may be used to monitor the DEF electronic module in real time. Upon detecting the presence of contaminants, the processor may then prompt the DEF system 1 to change its operating state in an attempt to reduce the influx of contaminants. For example, upon receiving a signal from an electronic sensor indicating the presence of contaminants within the housing, the processor may be configured to output a signal that lowers the temperature of the DEF system. Since diffusion can drive contaminant migration, lowering the temperature of the DEF system reduces the rate at which the DEF electronic module is exposed to contaminants. Such a reduction reduces the risk that the contaminant level will reach a level within the DEF electronic module that causes changes in the behavior of the electronic components. In some embodiments, upon receiving a signal from an electronic sensor indicating the presence of contaminants within the housing, the processor is configured to receive the signal for a predetermined buffer time before outputting the signal that lowers the temperature of the DEF system. Thus, the controller can implement a buffer time to reduce the risk that false positive detection events will prompt the processor to change the operating state of the DEF system 1. For example, after receiving the signal for the predetermined buffer time, the processor may escalate an error code to instruct a maintenance engineer that further action is required (e.g., component or seal replacement is required, or preventative action is needed).

[0047] In some embodiments, to further reduce the risk of contaminant exposure affecting electron exposure, the DEF electronic module may include a contaminant adsorbent material configured to adsorb contaminants when they are present in the housing. For example, in Figure 3 and Figure 4 In one embodiment, the control module 30 is provided with three strips of pollutant adsorption material 38. Figure 3 and Figure 4 In some embodiments, the pollutant adsorbent material 38 may be configured to adsorb ammonia. For example, a suitable pollutant adsorbent material 38 may include activated carbon. In other embodiments, the pollutant adsorbent material 38 (such as silica gel) may be configured to adsorb water. In some embodiments, a combination of different pollutant adsorbent materials 38 may be provided, wherein each pollutant adsorbent material 38 may be configured to adsorb different pollutants.

[0048] In some other embodiments, the DEF electronic module for the DEF system 1 for a diesel internal combustion engine may include: electronic components for the DEF system 1; a housing for the electronic components, wherein the electronic components are disposed within the housing; and a contaminant adsorbent material 38 configured to adsorb contaminants when they are present in the housing.

[0049] Although Figure 3 and Figure 4 In one embodiment, the contaminant adsorbent material 38 is configured as a strip attached to the control module housing 34; however, in other embodiments, the contaminant adsorbent material 38 may be configured in other ways. For example, in some embodiments, the contaminant adsorbent material 38 may be distributed throughout the potting material 26 disposed within the housing.

[0050] Therefore, according to this disclosure, a DEF electronic module can be provided that incorporates one or more contaminant indicators 36 for assisting in the diagnosis of malfunctions or unexpected behavior of the DEF system 1 caused by contaminant exposure.

[0051] As discussed above, the DEF electronic module according to this disclosure can be the sensor module 20 of the DEF manifold 10. Figure 5 A schematic cross-section of the lower portion 40 of the DEF manifold 10 is shown, which includes a first sensor module 20a, a second sensor module 20b, and a communication channel 44.

[0052] like Figure 5 As shown, the lower portion 40 has a generally L-shaped cross-section. The first sensor module 20a is disposed at one end of the L-shaped cross-section. Figure 5 As shown, the first sensor module 20a includes a first sensor 22a for the DEF system, a first sensor housing 24a for the first sensor 22a, and a contaminant indicator 36. The first sensor 22a may be, for example, a DEF level sensor. The contaminant indicator may be configured according to the contaminant indicator 36 discussed above.

[0053] The second sensor module 20b includes a second sensor 22b, a second sensor housing 24b, a contaminant indicator 36, potting material 26, a communication channel 44, and a contaminant adsorption material 38. For example... Figure 5 As shown, the communication channel 44 is connected to the interior of the second sensor housing 24b, such that the communication channel 44 is actually an extension of the cavity 25 where the second sensor 22b is located. That is, the communication channel 44 effectively forms part of the housing of the DEF electronic control module according to this disclosure. Figure 5As shown, the second sensor 22b is surrounded by potting material 26. The potting material partially fills the cavity 25 defined by the second sensor housing 24b. A contaminant indicator 36 is disposed in the portion of the cavity 25 not filled with potting material 26.

[0054] like Figure 5 As shown, the communication channel includes one or more cables 46 that connect the first sensor module 20a and the second sensor module 20b to the control module 30. The communication channel also includes a contaminant indicator 36 and a contaminant adsorption material 38. Therefore, checking the communication channel 44 can indicate whether the interconnected modules 20a, 20b, and 30 may have been exposed to contaminants.

[0055] Although the contaminant adsorbent material 38 and sensors 22a, 22b are shown in generally rectangular cross-sections, it should be understood that the contaminant adsorbent material 38 and sensor 22a can be arranged in any suitable shape and / or relative to the arrangement of the respective housings 24a, 24b. For example, the contaminant adsorbent material 38 and sensors 22a, 22b may each be arranged in the communication channel 44 as a strip surrounding the circumference of the cable 46. In other embodiments, the contaminant adsorbent material 38 and / or sensors 22a, 22b may each be attached to the inner surface of the sensor housings 24a, 24b or the communication channel 44. Therefore, it should be understood that the shape and / or positioning of the contaminant adsorbent material 38 and sensors 22a, 22b can be arranged in any suitable location of the respective sensor modules 20a, 20b, depending on the available space.

[0056] Figure 6 A further cross-sectional schematic diagram of the sensor module 30 of the DEF system 1 is shown, which may be a DEF electronic module according to the present disclosure. The sensor module 30 may be configured as part of the DEF manifold 10. Figure 6 The sensor module 30 is configured to be immersed in DEF during normal use. Therefore, the sensor module 30 may be affected by a relatively high contaminant migration rate.

[0057] like Figure 6 As shown, the DEF electronic module includes a sensor housing 24a that defines a first cavity 35a, a second cavity 35b, and a third cavity 35c. The first cavity 35a, the second cavity 35b, and the third cavity 35c are interconnected. Figure 6 As shown, the first cavity 35a of the DEF electronic module includes a first sensor 22a. The third cavity includes a second sensor 22b. The second cavity includes a PCB 32. Each of the sensors 22a and 22b is encapsulated in potting material 26.

[0058] Each cavity 35a, 35b, 35c of the DEF electronic module includes at least one contaminant indicator 36. For example... Figure 6 As shown, the second cavity 35b includes multiple contaminant indicators 36. Figure 6 In some embodiments, each of the contaminant indicators 36 may be configured to detect ammonia. In some embodiments, one or more contaminant indicators 36 configured to detect water may also be disposed in one or more of the cavities 35a, 35b, 35c. Each cavity in the cavity may also be provided with a contaminant adsorbent material 38.

[0059] Therefore, according to this disclosure, a DEF electronic module for a DEF system 1 is provided.

[0060] Industry Applicability

[0061] According to this disclosure, a DEF electronic module is provided. This DEF electronic module can form part of a DEF system (e.g., a DEF manifold) for a diesel internal combustion engine. The DEF electronic module of the first aspect provides a housing for electronic components, which provides some isolation of the electronic components from contaminants. A contaminant indicator is disposed within the housing and configured to record the presence of contaminants in the housing. Thus, if a contaminant enters the housing containing the electronic components, the contaminant indicator can permanently record the presence of the contaminant. By recording the presence of the contaminant, the DEF electronic module makes it easier and faster to diagnose failures caused by the ingress of contaminants. Specifically, even if the contaminant subsequently migrates (e.g., by evaporation) or is removed from the DEF electronic module, the contaminant indicator will still record the presence of the contaminant. By using the contaminant indicator to attribute failures to contaminant ingress in a fast and reliable manner, the DEF electronic module can be repaired / restored or replaced in a relatively simple and economical manner.

[0062] In some embodiments, the DEF electronic module may also include a contaminant adsorbent material within the housing. This adsorbent material helps reduce or prevent contaminants from entering and affecting the behavior of electronic components within the DEF electronic module. The adsorbent material also extends the durability of the DEF electronic module and / or the DEF manifold 10 / DEF system 1. While the contaminant adsorbent material 38 may adsorb small amounts of contaminants, it should be understood that providing a contaminant indicator 36 can help quickly identify events where contaminant entry has exceeded the capacity of the adsorbent material 38.

Claims

1. A DEF electronic module for a diesel exhaust fluid (DEF) system for a diesel internal combustion engine, the DEF electronic module comprising: The electronic components of the DEF system; A housing for the electronic component, wherein the electronic component is disposed within the housing; and A contaminant indicator is disposed within the housing and is configured to record the presence of contaminants within the housing.

2. The DEF electronic module according to claim 1, wherein the electronic components include one or more of the following: A processor configured to control at least a portion of the DEF system and / or receive signals from one or more sensors of the DEF system; Sensors configured to sense properties of the DEF system; and Printed circuit board.

3. The DEF electronic module according to any one of the preceding claims, wherein The contaminant indicator is configured to record the presence of one or more of the following: ammonia, water, or hydrogen.

4. The DEF electronic module according to any one of the preceding claims, wherein The contaminant indicator includes a chemical sensor configured to respond to the presence of a contaminant in the housing.

5. The DEF electronic module according to claim 4, wherein The chemical sensor is configured to permanently change color in response to the presence of contaminants in the housing.

6. The DEF electronic module according to any one of the preceding claims, wherein The housing also includes a pollutant adsorption material configured to adsorb the pollutant when it is present in the housing.

7. The DEF electronic module according to any one of the preceding claims, wherein The contaminant indicator includes an electronic sensor configured to detect the presence of contaminants in the housing.

8. The DEF electronic module according to claim 7, wherein The electronic sensor includes a conductive grid, the aluminum grid being configured to change its conductivity when exposed to ammonia in order to detect the presence of ammonia.

9. The DEF electronic module according to claim 7 or claim 8, wherein... The electronic sensor is connected to the processor of the DEF system, wherein when the processor receives a signal from the electronic sensor indicating the presence of contaminants in the housing, the processor is configured to output an alarm indicating the presence of contaminants in the housing.

10. The DEF electronic module according to claim 9, wherein Upon receiving a signal from the electronic sensor indicating the presence of contaminants within the housing, the processor is configured to output a signal that lowers the temperature of the DEF system.

11. The DEF electronic module according to claim 10, wherein... Upon receiving the signal from the electronic sensor indicating the presence of contaminants within the housing, the processor is configured to receive the signal for a predetermined buffer time before outputting the signal that lowers the temperature of the DEF system.

12. The DEF electronic module according to any one of the preceding claims, wherein the DEF electronic module further comprises... A potting compound disposed within the housing, wherein the potting compound is configured to encapsulate the electronic components and / or the contaminant indicator.

13. The DEF electronic module according to any one of the preceding claims, wherein Multiple contaminant indicators are disposed within the housing and distributed throughout the potting compound.

14. A DEF manifold for a DEF system, the DEF manifold being configured to circulate DEF from a DEF reservoir of the DEF system to a selective catalytic reduction system of a diesel internal combustion engine, the DEF manifold comprising: Sensor module; and A control module, wherein the sensor module and / or the control module is a DEF electronic module according to any one of claims 1 to 13.

15. The DEF manifold according to claim 14, wherein The sensor module is a DEF electronic module, which includes: The sensors of the DEF system; A sensor housing for the sensor, wherein the sensor is disposed within the sensor housing; and A contaminant indicator is disposed within the sensor housing and is configured to record the presence of contaminants within the sensor housing; and The control module is a DEF electronic module, which includes: The processor of the DEF system; A control housing for the processor, wherein the processor is disposed within the control housing; and A contaminant indicator disposed within the control housing is configured to record the presence of contaminants within the control housing.

16. The DEF manifold according to claims 14 to 15, wherein the DEF manifold further comprises: Upper part; and The lower part, The lower portion of the DEF manifold is configured to extend from the opening of the DEF tank into the DEF tank, and The upper portion of the DEF manifold is configured to seal the opening of the DEF tank.

17. The DEF manifold according to claim 16, wherein The sensor module is located in the lower portion of the DEF manifold; and The control module is located in the upper part of the DEF manifold.

18. The DEF manifold according to claim 16 or claim 17, wherein the lower portion comprises A communication channel is configured to extend from the sensor module to the upper portion of the DEF manifold, wherein the sensor module is electrically connected to the control module via the communication channel.

19. The DEF manifold according to claim 18, wherein The communication channel also includes a pollutant indicator and / or includes a pollutant adsorption material configured to adsorb the pollutants.

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