Exhaust gas aftertreatment system and in-line heater assembly for an exhaust gas aftertreatment system

Abstract

This application relates to an exhaust aftertreatment system and an in-line heater assembly for the exhaust aftertreatment system. An exhaust aftertreatment system includes: a catalytic converter; an in-line heater assembly disposed upstream of the catalytic converter; a heater controller; and a thermal support element. The in-line heater assembly includes a housing defining an inner cavity. The heater element is disposed within the inner cavity. The heater controller is coupled to the housing via the thermal support element and configured to control the power supplied to the heater element. The thermal support element is disposed between the heater controller and the housing.

Description

Technical Field

[0001] This disclosure generally relates to exhaust aftertreatment systems for internal combustion engine systems. Background Technology

[0002] Internal combustion engine systems typically include exhaust aftertreatment systems, which are configured to reduce harmful emissions produced by the engine. These systems use various technologies, such as particulate filters, selective catalytic reduction (SCR), and oxidation catalysts, to remove or convert pollutants such as nitrogen oxides (NOx), carbon monoxide (CO), hydrocarbons (HC), and particulate matter into less harmful substances before they are released into the atmosphere. Utility Model Content

[0003] One embodiment relates to an exhaust aftertreatment system including a catalyst; an inline heater assembly disposed upstream of the catalyst; a heater controller; and a thermal support element. The inline heater assembly includes a housing defining an inner cavity. A heater element is disposed within the inner cavity. The heater controller is coupled to the housing via the thermal support element and configured to control the power supplied to the heater element. The thermal support element is disposed between the heater controller and the housing.

[0004] In some embodiments, the thermal support element includes a thermally insulating adhesive configured to adhere at least a portion of the heater controller to the housing.

[0005] In some embodiments, the heater controller is directly coupled to the housing via a thermal support element, without any intermediate support structure defining an air gap between the heater controller and the housing.

[0006] In some embodiments, the inline heater assembly also includes a vibration damping pad connected between the heater controller and the housing.

[0007] In some embodiments, the inline heater assembly further includes a spacer that defines at least a portion of the air gap between the heater controller and the housing.

[0008] In some embodiments, the heater controller is spaced apart from the housing by an air gap. In such embodiments, the in-line heater assembly also includes an insulating element disposed within the air gap, such that the insulating element separates the lower surface of the heater controller from the housing.

[0009] In some embodiments, the in-line heater assembly and the catalyst are arranged in a series flow configuration.

[0010] In some embodiments, the exhaust aftertreatment system further includes a second in-line heater assembly fluidly coupled to the catalytic converter. In such embodiments, the second in-line heater assembly may include a second heater controller coupled to the second in-line heater assembly.

[0011] Another embodiment relates to an inline heater assembly comprising: a housing having an outer wall defining an inner cavity; a heater element disposed within the inner cavity; and a heater control unit. The heater control unit includes a heater controller communicatively coupled to the heater element and configured to control power distribution to the heater element; a mounting element supporting the heater controller; and a thermal support element connecting the mounting element to the outer wall.

[0012] In some embodiments, the housing defines an inlet opening and an outlet opening. In some embodiments, the inlet opening and the outlet opening are fluidly connected by an internal cavity. In some embodiments, the housing also includes a mounting flange extending from an outer surface of the outer wall, wherein a heater controller is supported thereon.

[0013] In some embodiments, the heater control unit further includes a vibration damping pad connected between the mounting element and the outer wall.

[0014] In some embodiments, the heater control unit further includes a spacer, and the mounting element includes a mounting plate spaced apart from the housing by the spacer.

[0015] In some embodiments, the heater control unit further includes an insulating element disposed between the heater controller and the outer wall.

[0016] In some embodiments, the in-line heater assembly further includes a sensor disposed within the housing, wherein the sensor is configured to generate sensor data indicating the temperature of exhaust gas flowing through the housing. In some embodiments, a heater controller is communicatively coupled to the sensor and configured to control the heater element based on the sensor data from the sensor.

[0017] In some embodiments, the inline heater assembly further includes a switching device communicatively coupled to a heater controller, and the heater controller is configured to control the switching device to control the power distribution to the heater elements.

[0018] In some embodiments, the housing further includes a mounting flange extending radially from the outer wall, and a thermal support element connects the heater control unit to the mounting flange.

[0019] In some embodiments, the mounting element defines an opening, and the thermal support element includes an insert extending through the opening. In some embodiments, the insert is configured to separate the thermal support element from other parts of the heater control unit.

[0020] Another embodiment relates to a method of manufacturing an inline heater assembly for an exhaust aftertreatment system. The method includes coupling a heater controller to a mounting element to form a heater control unit, wherein the heater controller is configured to control power distribution to the heater element; and coupling the heater control unit to a housing supporting the heater element via a thermal support element, thereby forming the inline heater assembly by coupling the thermal support element between the mounting element and the outer wall of the housing.

[0021] In some embodiments, coupling the heater control unit to the housing further includes inserting an insert into a fastener opening defined by a mounting element, and inserting a fastener into the opening defined by the insert such that the insert insulates the fastener from the mounting element.

[0022] These and other features, as well as the organization and manner of their operation, will become apparent from the following detailed description taken in conjunction with the accompanying drawings. Attached Figure Description

[0023] The foregoing and other features of this disclosure will become more fully apparent from the accompanying drawings, the following description, and the appended claims. It should be understood that these drawings depict only a few embodiments according to this disclosure and are therefore not intended to limit the scope of the disclosure, which will be described with further specific description and detail using the drawings.

[0024] Figure 1 This is a front view of an internal combustion engine system according to an embodiment.

[0025] Figure 2 This is a block diagram of an exhaust aftertreatment system according to an embodiment, the exhaust aftertreatment system including a heater control unit coupled to a housing of a heater assembly.

[0026] Figure 3 This is a side sectional view of a heater assembly according to an embodiment, showing a block diagram of a heater control unit connected to the housing of the heater assembly.

[0027] Figure 4 This is a side sectional view of a heater assembly according to an embodiment, the heater assembly including a heater control unit directly coupled to the housing of the heater assembly.

[0028] Figure 5 This is a side sectional view of a heater assembly according to an embodiment, the heater assembly including a heater control unit connected to the housing of the heater assembly via vibration damping pads.

[0029] Figure 6 This is a side sectional view of a heater assembly according to an embodiment, the heater assembly including a thermal insulation element positioned between a heater control unit of the heater assembly and a housing of the heater assembly.

[0030] Figure 7 This is a side sectional view of a heater assembly according to an embodiment, the heater assembly including a spacer that at least partially separates the heater control unit from the heater housing.

[0031] Figure 8 This is a flowchart of a method for manufacturing an inline heater assembly for an exhaust aftertreatment system according to an embodiment.

[0032] In the following detailed description, reference is made to the accompanying drawings. In the drawings, like reference numerals generally identify like parts unless the context otherwise requires. The illustrative embodiments described in the detailed description, drawings, and claims are not intended to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that aspects of this disclosure generally described herein and illustrated in the drawings can be arranged, substituted, combined, and designed in a variety of different configurations, all of which are expressly contemplated and constitute a part of this disclosure. Detailed Implementation

[0033] The following is a more detailed description of various concepts and implementations related to an inline heater assembly for an exhaust aftertreatment system, configured to control the heating of exhaust gas entering other parts of the exhaust aftertreatment system. The various concepts described above and discussed in more detail below can be implemented in various ways, as the described concepts are not limited to any particular implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.

[0034] The embodiments described herein generally relate to an in-line heater assembly including a heater housing and a heater control unit, the heater control unit being directly mounted to the heater housing and / or supported in place within the heater housing without requiring separate mounting or support structures. In some embodiments, the heater control unit is provided as an integral part of the in-line heater assembly (e.g., the heater housing), and is fixedly coupled to the heater housing. By integrating the heater control unit onto the heater housing, the in-line heater assembly of this disclosure can improve the modularity of the heater assembly design and simplify installation by reducing the number of components that need to be mounted and / or integrated during the installation of the in-line heater assembly with an exhaust aftertreatment system. For example, embodiments of this disclosure can enable the heater control unit to be mounted integrally with the heater housing without requiring separate mounting hardware and / or insulation / vibration isolators. The in-line heater assembly design of this disclosure can also reduce the length of wires, etc., required to connect the heater control unit to the heating element and other parts of the in-line heater assembly.

[0035] In some embodiments, the heater control unit includes a mounting element configured to support (e.g., surround) the heater control unit and facilitate coupling of the heater control unit to the housing via a thermal support element. In some embodiments, the in-line heater assembly includes a standoff, such as a spacer, configured to maintain a distance between the heater control unit (e.g., the heater controller of the heater control unit) and the heater housing. Such an arrangement can reduce the risk of damage to the electronic components of the heater control unit that would otherwise be caused by exposure of the electronic components to the hot surfaces of the heater housing during operation.

[0036] In some embodiments, the heater control unit includes an insulating element configured to reduce heat transfer to the heater controller and / or other parts of the heater control unit (e.g., from the heater housing to the mounting element, etc.). As used herein, "insulating element" refers to a material or structure configured to increase the thermal resistance between the heater control unit and the housing. The insulating element may have a high thermal resistance greater than or equal to the thermal resistance of the thermal support element and / or other parts of the in-line heater assembly. In some embodiments, the insulating element is disposed between the mounting element and the heater housing. In some embodiments, the insulating element includes a vibration isolation device (e.g., a vibration isolator, etc.) configured to reduce vibrations output from the heater housing to the heater control unit, which may further reduce the risk of damage to the heater control unit during operation.

[0037] refer to Figure 1An engine system 100 according to an embodiment is illustrated. The engine system 100 includes an engine 101, a power supply 102, an engine control unit (ECM) 103, and an exhaust aftertreatment system 104. In some embodiments, the engine 101 is a diesel engine configured to generate power from diesel fuel. In other embodiments, the engine 101 may include a gasoline engine, a natural gas engine, a dual-fuel engine, a biodiesel engine, an E85 engine, a flexible fuel engine, a gas turbine, or other types of internal combustion engines or drives. The engine 101 can be used to power trucks, boats, locomotives, or other types of vehicles (e.g., on-road or off-road vehicles). In other embodiments, the engine 101 can be used in industrial applications to drive pumps, hydraulic systems, or other types of systems.

[0038] In some embodiments, and as Figure 1 As shown, the engine system 100 also includes an exhaust manifold configured to collect exhaust gas in the form of combustion gases from the engine 101 and direct the exhaust gas to the exhaust aftertreatment system 104. The exhaust manifold fluidly connects the engine 101 (e.g., the combustion cylinders of the engine) to the exhaust aftertreatment system 104.

[0039] Power source 102 is configured to supply power to various parts of engine system 100, including exhaust aftertreatment system 104. In some embodiments, and as shown, power source 102 is electrically connected to exhaust aftertreatment system 104. In some embodiments, power source 102 is connected to ECM 103. Power source 102 may also be connected to engine 101 and may be configured to generate electricity from the mechanical power produced by engine 101. For example, power source 102 may include an alternator or electric generator unit configured to convert mechanical input from engine 101 into electricity and provide the electricity to energy storage devices on the vehicle. In some embodiments, the energy storage device includes a battery pack, such as a lead-acid battery, nickel-metal hydride (NiMH) battery pack, lithium-ion battery pack, or other battery pack chemistry, configured to store electricity received from engine 101 and / or external power sources (e.g., line power, etc.). For example, the battery pack may be configured to receive and store electricity from the alternator during engine operation. In some embodiments, the energy storage device includes an overcapacitor / supercapacitor. In some embodiments, the power source 102 includes line power (e.g., grid power) from power facilities.

[0040] In some embodiments, power supply 102 is a direct current (DC) power supply configured to provide power at a voltage of 12V, 24V, 48V, or a voltage between and including the aforementioned values. In other embodiments, power supply 102 includes a higher voltage power supply, such as a battery pack for a hybrid electric vehicle.

[0041] ECM 103 is configured to monitor the operating conditions of engine 101 and control the operation of the aftertreatment system based on the operating conditions. In some embodiments, and as shown, ECM 103 is communicatively connected to sensors of engine system 100 and exhaust aftertreatment system 104.

[0042] The exhaust aftertreatment system 104 is configured to receive exhaust gas (e.g., combustion gases) from the engine 101 and purify or otherwise reduce harmful emissions from the exhaust gas. Figure 1 In one embodiment, the exhaust aftertreatment system 104 includes a catalyst 106 and an inline heater assembly 108. The inline heater assembly 108 is disposed upstream of the catalyst 106. The inline heater assembly 108 includes a housing 110 defining an inner cavity 112. The inline heater assembly 108 also includes a heater element 114 disposed within the inner cavity 112. The inline heater assembly 108 also includes a heater controller (which is included as part of a heater control unit 116), the heater controller being coupled to the housing 110 via a thermal support element 120 and configured to control the power supplied to the heater element 114. The thermal support element 120 is disposed between the heater controller and the housing 110.

[0043] In some embodiments, the heater controller is directly coupled to the housing via a thermal support element, without any intermediate support structure defining an air gap (defining an air gap between the heater controller and the housing). In some embodiments, the thermal support element 120 thermally insulates the heater controller from the housing 110.

[0044] In some embodiments, and as described above, catalyst 106 is a selective catalytic reduction (SCR) catalyst configured to remove or convert contaminants, such as nitrogen oxides (NOx), from exhaust gas. In some embodiments, exhaust aftertreatment system 104 may include a particulate filter (e.g., a diesel particulate filter in a diesel engine system) and / or other oxidation catalysts to remove or convert contaminants such as CO, HC, and particulate matter from exhaust gas before it is released into the atmosphere. Catalyst 106 may be disposed within a catalyst housing located downstream of the exhaust manifold and in-line heater assembly. In some embodiments, the catalyst housing may also surround other catalysts and / or particulate filters. In other embodiments, different catalysts and / or particulate filters may be disposed in separate housings relative to the catalyst housing.

[0045] The in-line heater assembly 108 is configured to preheat the exhaust gas upstream of the catalytic converter 106 and raise its temperature. The in-line heater assembly 108 is configured to control the operating temperature of the catalytic converter 106, which improves the regeneration performance of the catalytic converter 106 and its effectiveness in reducing harmful emissions (such as NOx, CO, and HC) in the exhaust gas. The in-line heater assembly 108 also reduces the time required to raise the temperature of the catalytic converter to its activation temperature during engine start-up, which reduces the amount of pollutants emitted from the engine 101 during the initial phase of engine operation.

[0046] An inline heater assembly 108 is disposed upstream of the catalytic converter 106 and between the catalytic converter 106 and the exhaust manifold. The inline heater assembly 108 is arranged in series with the exhaust manifold and the catalytic converter 106. In some embodiments, the inline heater assembly 108 is one of a plurality of inline heater assemblies (e.g., a first inline heater assembly 108a, a second inline heater assembly 108b, etc.) arranged in series or parallel with each other, which can achieve higher exhaust temperatures and / or greater exhaust flow rates through the exhaust aftertreatment system 104.

[0047] refer to Figure 2 This illustrates a method that can be used according to an embodiment. Figure 1 The inline heater assembly 200 is located in the exhaust aftertreatment system 104. The inline heater assembly 200 is a modular unit that includes all components required to operate within or connected to the shared housing structure of the inline heater assembly. This arrangement simplifies installation, reduces the number of wiring connections, and decreases the number of mounting components required within the engine system 100 for controllers and / or other electronic equipment associated with the inline heater assembly 108.

[0048] The in-line heater assembly 200 includes a housing 202, a heater element 204, and a heater control unit 206. The housing 202 includes an outer wall 208 defining an inner cavity 210. The heater element 204 is disposed within the inner cavity 210. The heater control unit 206 includes a heater controller 212, a mounting element 214, and a thermal support element 216. The heater controller 212 is communicatively coupled to the heater element 204 and configured to control power distribution to the heater element 204. The mounting element 214 supports the heater controller 212. The thermal support element 216 connects the mounting element 214 to the outer wall 208.

[0049] In some embodiments, such as referring to Figure 3Furthermore, the inline heater assembly 200 also includes a sensor configured to enable feedback-based control of the heater element 204 by the heater controller 212.

[0050] Housing 202 (which may also be referred to as heater housing, shell, and / or heater outer casing) is configured to support the heater element 204 of the in-line heater assembly 200 and to guide exhaust gas through the heater element 204. Housing 202 defines an outer wall whose dimensions are determined to receive the heater element 204 therein. Figure 2 In one embodiment, the housing 202 is a cylindrical housing having a circular cross-section perpendicular to the flow direction passing through it. In other embodiments, the shape of the housing 202 may be different.

[0051] refer to Figure 1 The housing 202 (e.g., outer wall 208) defines an inlet opening 122 and an outlet opening 124, the inlet opening 122 being configured to fluidly connect a heater element to an exhaust manifold, and the outlet opening 124 being configured to fluidly connect a heater element to a catalytic converter 106.

[0052] refer to Figure 2 In some embodiments, the housing 202 includes a mounting flange 218 (which may also be referred to as a mounting element and / or heater controller support) configured to engage with the heater control unit 206 and / or the thermal support element 216. In some embodiments, the mounting flange 218 defines a substantially flat support surface, which simplifies the alignment and mounting of the heater control unit 206 and / or the thermal support element 216 on the mounting flange 218. Figure 2 In some embodiments, the mounting flange 218 extends from the outer surface of the outer wall 208 along a circumferential portion of the outer wall 208 and supports the heater control unit 206 thereon. In some embodiments, the mounting flange 218 also includes an electrical pathway (e.g., a through-hole) configured to electrically connect the heater control unit 206 to the heater element 204 and / or a sensor within the housing 202.

[0053] Heater element 204 is configured to provide heat to exhaust gas flowing through housing 202. In some embodiments, heater element 204 includes a resistance heater, such as a nichrome wire heater extending across the inner cavity 210. In some embodiments, heater element 204 includes an infrared heating element and / or a grid heating element, a ceramic heating element, a cylinder heater, and / or other types of gas heating elements.

[0054] The heater control unit 206 includes the electronic components necessary to control the operation of the heater element 204. The heater control unit 206 is electrically connected to the ECM 219 and a power supply. Figure 2In one embodiment, the input of the heater control unit 206 is electrically connected to the ECM 103, the energy storage device 220, and the alternator 222.

[0055] The heater control unit 206 is configured to receive control signals from the ECM 219 and control the operation of the heater element 204 based on the control signals. For example, the ECM 219 may be configured to monitor NOx, CO, HC emission levels and / or other exhaust emission parameters within and / or downstream of the catalyst 106, and transmit control signals to the heater control unit 206 to adjust the exhaust temperature based on the emission parameters. In some embodiments, the ECM 219 may be configured to transmit control signals to the heater control unit 206 based on other engine operating conditions (such as the substitution rate of a dual-fuel engine, engine torque, and / or other engine operating conditions). In some embodiments, the ECM 219 may be configured to transmit control signals to the heater control unit 206 based on the exhaust temperature within and / or downstream of the engine's combustion chamber (such as within the exhaust manifold).

[0056] The heater control unit 206 (e.g., heater controller 212) (which may also be referred to as a heater control module and / or heater control circuit) is configured to selectively electrically connect a power source (e.g., at least one of energy storage device 220 and / or alternator 222, etc.) based on control signals received from the ECM 219. Figure 2 In some embodiments, the output terminal of the heater control unit 206 is electrically connected to the heater element 204 and to the input terminal (which may also be referred to as the first terminal and / or positive terminal) of the heater element 204. In some embodiments, and as shown, the second output terminal of the heater control unit 206 is connected to a reference voltage (e.g., ground), which facilitates the operation of the switching device within the heater control unit 206. In some embodiments, the alternator 222 may also be directly electrically connected to the output terminal (which may also be referred to as the second terminal, negative terminal, and / or power return terminal) of the heater element 204 to complete the circuit between the alternator 222 and the heater element 204 when the heater element 204 is activated.

[0057] refer to Figure 3 A block diagram of a heater control unit 306 for an inline heater assembly according to an embodiment is shown. The heater control unit 306 includes a heater controller 312, which includes processing circuitry 324 and a communication interface 326; and a switching device 328.

[0058] Processing circuitry 324 is communicatively coupled to communication interface 326 and configured to control the operation of switching device 328 based on data (e.g., control signals) received from ECM and sensor 334. In some embodiments, processing circuitry 324 is also communicatively coupled (e.g., via communication interface 326) to sensor 334, such as a temperature sensor configured to provide an indication of exhaust temperature at one or more locations within an inline heater assembly.

[0059] The processing circuitry 324 includes a memory 330 on which machine-readable instructions are stored and a processor 332 communicatively connected to the memory 330 and configured to execute the machine-readable instructions to perform any control operations described herein.

[0060] The heater control unit 306 also includes control modules, such as the temperature determination module 336 and the heater control module 338 shown. In some embodiments, the modules are implemented as machine-readable instructions in memory 330. In other embodiments, at least one of the modules is implemented as one or more control circuits communicatively coupled to processing circuitry 324.

[0061] In some embodiments, the temperature determination module 336 is configured (e.g., via communication interface 326) to receive sensor data from sensor 334 and provide data indicating temperature to processing circuit 324.

[0062] The heater control module 338 is configured to control the activation of the switching device 328 based on (i) data from the temperature determination module 336 and / or the sensor 334, and (ii) the ECM. In some embodiments, the heater control module 338 may be configured to traverse a lookup table comprising a list of control signals or power values ​​associated with data from the temperature determination module 336 and the ECM. In some embodiments, the heater control module 338 is configured to provide control signals to the switching device 328 based on an algorithm stored in memory (e.g., an algorithm configured to determine the amount of power to be supplied to the heater element based on data from the sensor 334 and the ECM). In some embodiments, the heater control module 338 is configured to perform proportional-integral-derivative (PID) control on the heater element based on data from the sensor 334 to satisfy a threshold exhaust temperature based on data received from the ECM (e.g., to control the heater element such that the exhaust temperature is greater than, equal to, or within a threshold range of the threshold exhaust temperature).

[0063] It should be understood that the hardware and data processing components used to implement the various processes, operations, illustrative logic, logic blocks, modules, and circuits described in conjunction with the embodiments disclosed herein can be implemented or performed by a general-purpose single-chip or multi-chip processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. The general-purpose processor can be a microprocessor, or any conventional processor, controller, microcontroller, or state machine. The processor can also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, multiple microprocessors, one or more microprocessors combined with a DSP core, or any other such configuration.

[0064] In some embodiments, specific processes and methods may be performed by circuitry specific to a given function. Memory (e.g., memory, memory cell, storage device) may include one or more devices (e.g., RAM, ROM, flash memory, hard disk storage) for storing data and / or computer code to perform or facilitate the various processes, layers, and modules described herein. Memory may be or may include volatile or non-volatile memory and may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described herein. According to an example embodiment, memory is communicatively connected to a processor via processing circuitry and includes computer code for (e.g., by the processing circuitry or processor) performing one or more processes described herein.

[0065] The communication interface 326 is communicatively connected to the processing circuitry 324, the ECM, the switching device 328, and the sensor 334, and is configured to enable data transmission between each of these components.

[0066] Switching device 328 is configured to selectively electrically connect a power source (e.g., an energy storage device, an alternator / generator unit, etc.) to a heater element based on a control signal received from processing circuitry 324. In some embodiments, switching device 328 includes a relay. In some embodiments, switching device 328 includes a transistor configured to control power distribution from the power source to the heater element. Figure 3 In this embodiment, the switching device 328 is electrically connected to a power source (e.g., Figure 2 Energy storage device 220 Figure 2 The alternator 222) and reference voltage are used to make the circuit complete and to activate the switching device 328 in response to the control signal from the heater controller 312.

[0067] refer to Figure 2 Mounting element 214 is configured to support various components of heater control unit 206 and at least partially define a mounting interface to facilitate coupling of heater control unit 206 to housing 202 (e.g., to mounting flange 218).

[0068] refer to Figure 3 In some embodiments, mounting element 314 includes mounting plate 340, which may also be referred to as support plate and / or mounting plate. Mounting plate 340 is configured to support electronic components of heater control unit 306 thereon. In some embodiments, mounting plate 340 is at least partially formed as a printed electronic circuit board, which also provides electrical connections between electrical components of heater control unit 306. In some embodiments, mounting plate 340 is made of a thermally insulating material, such as polyamide or other types of polymers or polymer laminates. In such embodiments, mounting plate 340 also forms part of an insulating element.

[0069] Mounting plate 340 defines a mounting interface that may include fastener openings to facilitate coupling of heater control unit 306 to the housing. In some embodiments, and as... Figure 3 As shown, mounting plate 340 forms part of heater control unit housing for heater control unit 306, which is configured to surround various electrical components of heater control unit 306. Mounting element 314 may also include electrical pathways (e.g., electrical connectors) configured to electrically connect heater control unit 306 to ECM, sensors, heater elements and / or power sources.

[0070] exist Figure 3 In one embodiment, the mounting plate 340 is configured to engage the housing 302 of the inline heater assembly (e.g., the mounting flange of the housing) to directly connect the heater control unit 306 to the housing 302.

[0071] Refer again Figure 2 In some embodiments, the thermal support element 216 is configured to be thermally insulated from the housing 202 (e.g., mounting flange 218) and the electronic components of the heater control unit 206 (e.g., heater controller 212, switching devices, etc.) (e.g., to reduce heat transfer between the housing 202 (e.g., mounting flange 218) and the electronic components of the heater control unit 206 (e.g., heater controller 212, switching devices, etc.)). Figure 3 In one embodiment, the thermal support element 316 includes a thermally insulating adhesive 342 configured to adhere at least a portion of the heater control unit 306 to the housing 302. The thermally insulating adhesive 342 may include epoxy, silicone, polyurethane, or other thermally insulating adhesive products. Figure 3In one embodiment, thermally insulating adhesive 342 is applied directly between the mounting plate 340 and the housing 302 across the flat surfaces of the mounting plate 340 and the housing to securely attach the heater control unit 306 to the housing 302.

[0072] In various embodiments, the design and arrangement of the mounting element 314 and / or the thermal support element 316 can be different. For example, refer to Figure 4 The image shows a portion of an inline heater assembly 400, including a heater control unit 406 directly attached to a housing (e.g., a mounting flange attached to the housing). In some embodiments, the heater control unit 406 may be directly fastened to the housing by a thermal support element (e.g., via bolts, screws, rivets, or another mechanical fastener). In some embodiments, as described above, the heater control unit 406 is fixed in place relative to the housing by an adhesive product. In other embodiments, at least a portion of the heater control unit 406 (e.g., a thermal support element) is welded or otherwise permanently attached to the housing.

[0073] The heater control unit 406 also includes an insulating element in the form of a vibration damping pad 444 connecting the heater control unit 406 and the housing. In some embodiments, the vibration damping pad 444 may form part of a thermal support element. The vibration damping pad 444 is configured to reduce output vibration and heat transfer to the heater control unit 406. Figure 4 In one embodiment, the vibration damping pad 444 extends across the lower surface of the heater control unit 406 (e.g., a mounting element) and radially separates the heater control unit 406 from the housing by a certain distance. In such an embodiment, the vibration damping pad 444 also serves as a spacer between the heater control unit 406 and the housing.

[0074] Vibration damping pad 444 may be made of rubber, foam, fiberboard, wool felt, and / or other flexible insulating materials. In some embodiments, an adhesive product (e.g., a thermal support element in the form of a thermally insulating adhesive) is used to bond the mounting element to the vibration damping pad 444. In some embodiments, the vibration damping pad 444 is overmolded onto the mounting element, for example through an opening defined by the lower wall of the mounting element, which simplifies assembly and eliminates the need for separate adhesives or fasteners.

[0075] In other embodiments, the insulating element is a thermally insulating spacer (e.g., a gasket) made of a thermally insulating material with high thermal resistance, which may or may not provide additional vibration isolation. In some embodiments, the insulating element comprises multilayer spacers and / or vibration isolators, which can improve overall vibration isolation and thermal insulation performance (by combining different materials with different properties between the heater control unit 406 and the housing).

[0076] refer to Figure 5This illustration shows another form of vibration isolator for a heater control unit 506 according to an embodiment. The vibration isolator includes an insert 546 that extends through a corresponding one of fastener openings 548 in the heater control unit 506 (e.g., in a mounting element of the heater control unit 506). The insert 546 extends through the fastener opening in an axial direction relative to the central axis of the fastener opening. The insert 546 is configured to separate the fastener from the inner surface of the heater control unit 506 (e.g., the mounting element).

[0077] exist Figure 5 In this embodiment, the insert 546 is a hollow cylindrical insert configured to receive a corresponding fastener therein. The insert 546 also includes a radial protrusion at either axial end of the insert 546 that radially protrudes beyond the fastener opening. The protrusion is configured to space the lower surface of the heater control unit 506 (e.g., the lower surface of the mounting element) from the housing, which further reduces heat transfer between the housing and the heater control unit 506. The protrusion also helps to retain the insert 546 within the fastener opening. This arrangement prevents heat transfer and reduces vibrations output to the heater control unit 506 via the fastener without requiring any intermediate vibration isolators.

[0078] exist Figure 5 In one embodiment, the insert 546 separates the heater control unit 506 (e.g., mounting element) from the housing via an air gap 550, which reduces heat transfer between the housing and the heater control unit 506.

[0079] refer to Figure 6 Another embodiment of the heater control unit 606 is shown, which is similar to the reference numeral. Figure 5 The heater control unit 506 is described. The heater control unit 606 includes an insulating element 652 disposed within an air gap between a mounting element and a housing, such that the insulating element 652 separates the lower surface of the mounting element from the housing. The insulating element 652 may be made of a material referenced in the reference... Figure 4 The vibration damping pads described are made of the same or similar materials. The insulating element 652 may be made of phenolic foam (e.g., rock wool) or other fiber-based or non-fiber-based insulating materials. In some embodiments, the insulating element 652 comprises a radiative heat shield made of a metallic material (such as aluminum) or other heat-shielding material. In such embodiments, the insulating element 652 may be at least partially suspended between the lower surface / wall of the mounting element and the housing. This arrangement can increase the durability and lifespan of the insulating element 652.

[0080] refer to Figure 7Another embodiment of a heater control unit 706 for an inline heater assembly is shown. The inline heater assembly (e.g., the insulating element of an inline heater assembly) includes a spacer 754 extending at least partially radially between the housing and the mounting element. In some embodiments, the spacer 754 extends away from the housing in a substantially perpendicular orientation relative to the housing. Figure 7 In some embodiments, spacer 754 includes a hollow cylindrical spacer that engages a mounting element at a first end of spacer 754 and a housing (e.g., a mounting flange of the housing) at a second end of spacer 754 opposite to the first end. Spacer 754 defines at least a portion of an air gap 750 separating the mounting element from the housing. In some embodiments, spacer 754 has a smaller total cross-sectional area than the mounting element and covers only a portion of the lower surface of the mounting element. In some embodiments, and as shown, the in-line heater assembly also includes a vibration isolator (e.g., which may form part of another insulating element) at least partially disposed between spacer 754 and housing. In some embodiments, spacer 754 may be formed of a compliant material, which may also provide vibration isolation between heater control unit 706 and housing.

[0081] It should be understood that the various aspects of the heater control unit (e.g., thermal support elements, mounting elements, insulating elements, etc.) described in the various embodiments herein can be combined with each other to further reduce output vibration and increase overall heat transfer between the housing and the heater control unit.

[0082] refer to Figure 8 A method 800 for manufacturing an inline heater assembly according to an embodiment is shown. Method 800 can be used to form any inline heater assembly described herein. Method 800 includes coupling a heater controller at 802 to a mounting element to form a heater control unit. The heater controller is configured to control power distribution to the heater element. Method 800 also includes coupling the heater control unit to a housing that supports the heater element via a thermal support element to form the inline heater assembly by coupling the thermal support element between the mounting element and the outer wall of the housing.

[0083] In some embodiments, operation 802 includes directly coupling the heater controller and / or a switching device communicatively coupled to the heater controller to a mounting plate. In some embodiments, operation 802 includes inserting the heater controller and / or the switching device into a heater controller housing at least partially formed by the mounting plate. In some embodiments, operation 802 includes forming mounting features at least partially into the heater controller and / or the switching element (e.g., through the heater controller and / or the switching element). For example, operation 802 may include forming fastener openings (e.g., through holes) in a substrate (e.g., a PCB) that electrically connects various components of the heater controller.

[0084] As described above, method 800 further includes at 804 using a thermal support element to attach the heater control unit to the housing of the heater element to form an inline heater assembly. In some embodiments, operation 804 includes attaching the heater control unit directly to the housing via a thermal support element, such as by attaching the thermal support element between a mounting flange extending from the outer wall of the housing and the outer wall. In some embodiments, operation 804 includes using a thermally insulating adhesive to bond (e.g., glue) the mounting element to the housing.

[0085] In some embodiments, operation 804 includes securing the heater control unit (e.g., a mounting element) to the housing. In such embodiments, operation 804 may include positioning thermal insulation material between the mounting element and the housing. In some embodiments, the thermal insulation material may also serve as a vibration isolator to reduce vibrations output from the housing to the heater controller and / or switching devices.

[0086] In some embodiments, operation 804 includes at least partially positioning an insert made of a vibration-damping material and / or a thermally insulating material (e.g., a compliant material with low thermal conductivity, such as rubber, plastic, etc.) into a mounting element. For example, operation 804 may include inserting the insert into a fastener opening defined by the mounting element. In some embodiments, operation 804 further includes inserting a fastener into the opening defined by the insert such that the insert at least partially insulates the fastener from the mounting element.

[0087] In some embodiments, operation 804 includes positioning a spacer between the mounting element and the housing to space the mounting element and the housing by a certain distance and / or to form an air gap between the mounting element and the housing. In some embodiments, operation 804 includes positioning thermally insulating material into the air gap to increase the thermal resistance between the housing and the mounting element. In some embodiments, operation 804 includes coupling the mounting element to the housing using any combination of the above operations.

[0088] In some embodiments, operation 804 further includes electrically connecting the heater control unit to the heater element. Operation 804 may also include electrically connecting the heater control unit to a sensor disposed within the housing and configured to transmit sensor data indicating the exhaust temperature flowing through the inline heater assembly to the heater controller.

[0089] Method 800 further includes coupling the inline heater assembly to the exhaust aftertreatment system at 806. In some embodiments, operation 806 includes coupling the inlet and outlet ends of the housing to the exhaust aftertreatment system upstream of the catalyst. In such embodiments, operation 806 includes coupling a heater control unit to the exhaust aftertreatment system through the housing of the inline heater assembly and without any external mounting to the inline heater assembly. Operation 806 may also include electrically connecting the heater control unit to the ECM and at least one power source.

[0090] In some embodiments, method 800 includes coupling a plurality of in-line heater assemblies as modular units to an exhaust aftertreatment system, each modular unit including its own heater control unit mounted on a housing.

[0091] The various numerical values ​​used herein are provided for illustrative purposes only. Unless otherwise indicated, all figures used in this specification and claims to indicate quantities of properties, parameters, conditions, etc., should be understood to be modified in all cases by the term "approximately." Therefore, unless indicated to the contrary, the numerical parameters set forth in the specification and appended claims are approximate values. Any numerical parameter should be interpreted at least according to the number of significant figures reported and by applying common rounding techniques. The term "approximately," when used before a numerical designation, for example, indicates a quantity and / or a range that may vary by (+) or (-) 10%, 5%, or 1%.

[0092] As used herein, the term "connected" and its variations refer to two components that are directly or indirectly connected to each other. This connection can be static (e.g., permanent or fixed) or movable (e.g., removable or releasable). Such a connection can be achieved using two components directly connected to each other, where the two components are connected to each other using a separate intermediate component and any additional intermediate components joined together, or where the two components are connected to each other using an intermediate component integrally formed with one of the two components as a single unit. If "connected" or its variations are modified by an additional term (e.g., directly connected), the general definition of "connected" provided above is modified by the simple linguistic meaning of the additional term (e.g., "directly connected" means the connection of two components without any separate intermediate component), resulting in a narrower definition than the general definition of "connected" provided above. Such a connection can be mechanical, electrical, or fluid.

[0093] It is important to note that the structures and arrangements of the various systems illustrated in the example embodiments are illustrative in nature and not restrictive. All changes and modifications within the spirit and / or scope of the described embodiments are protected. It should be understood that some features may not be necessary, and embodiments lacking various features may be considered within the scope of this disclosure, defined by the appended claims. When the language “part” is used, it may include a part and / or the entire item, unless expressly stated otherwise.

[0094] Furthermore, in the context of the component list, the term "or" is used in its inclusive sense (rather than its exclusive meaning), such that when used to relate the component list, the term "or" means one, some, or all of the components in the list. Unless otherwise expressly stated, conjunctions such as "at least one of X, Y, and Z" are understood in the context to generally convey that items, terms, etc., can be X, Y, Z, X and Y, X and Z, Y and Z, or X, Y, and Z (i.e., any combination of X, Y, and Z). Therefore, unless otherwise stated, such conjunctions are generally not intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to be present.

[0095] This disclosure contemplates methods, systems, and program products on any machine-readable medium for performing various operations. Embodiments of this disclosure can be implemented using existing computer processors, or by a dedicated computer processor with a suitable system introduced for this or another purpose, or by a hard-wired system. Embodiments within the scope of this disclosure include program products comprising machine-readable media for carrying or having machine-executable instructions or data structures stored thereon. Such machine-readable media can be any available medium accessible by a general-purpose or special-purpose computer or other machine having a processor. For example, such machine-readable media may include RAM, ROM, EPROM, EEPROM, or other optical disc storage devices, magnetic disk storage devices, or other magnetic storage devices, or any other medium that can be used to carry or store desired program code in the form of machine-executable instructions or data structures and accessible by a general-purpose or special-purpose computer or other machine having a processor. Combinations of the above are also included within the scope of machine-readable media. Machine-executable instructions include, for example, instructions and data that cause a general-purpose computer, special-purpose computer, or special-purpose processing machine to perform a function or a set of functions.

[0096] Although the accompanying drawings and specifications may show a specific order of method steps, this order may differ from that depicted and described, unless otherwise specified above. Furthermore, two or more steps may be performed simultaneously or partially simultaneously, unless otherwise specified above.

[0097] It is important to note that any element disclosed in one embodiment may be combined with or used in conjunction with any other embodiment disclosed herein. Although only one example of an element from one embodiment that may be combined with or utilized in another embodiment has been described above, it should be understood that other elements of various embodiments may be combined with or used in conjunction with any other embodiment disclosed herein.

Claims

1. An exhaust gas aftertreatment system characterized by, The exhaust aftertreatment system includes: --catalyst; and --A linear heater assembly, disposed upstream of the catalyst, the linear heater assembly comprising: ---Housing shell, which defines an internal cavity; ---Heater element, the heater element being disposed within the inner cavity; ---Heater controller, which is connected to the housing via a thermal support element and configured to control the power supplied to the heater element, the thermal support element being disposed between the heater controller and the housing.

2. The exhaust gas aftertreatment system of claim 1, wherein, The thermal support element includes a thermally insulating adhesive configured to adhere at least a portion of the heater controller to the housing.

3. The exhaust gas aftertreatment system of claim 1, wherein, The heater controller is directly connected to the housing via the thermal support element, without any intermediate support structure defining an air gap between the heater controller and the housing.

4. The exhaust gas aftertreatment system of claim 1, wherein, The in-line heater assembly also includes a vibration damping pad connected between the heater controller and the housing.

5. The exhaust gas aftertreatment system of claim 1, wherein, The in-line heater assembly also includes a spacer that defines at least a portion of the air gap between the heater controller and the housing.

6. The exhaust gas aftertreatment system of claim 1, wherein, The heater controller is spaced apart from the housing by an air gap, and the inline heater assembly further includes an insulating element disposed within the air gap, such that the insulating element separates the lower surface of the heater controller from the housing.

7. The exhaust aftertreatment system of any one of claims 1-6, wherein, The in-line heater assembly and the catalyst are arranged in a series flow configuration.

8. The exhaust aftertreatment system according to any one of claims 1-6, characterized in that, The exhaust aftertreatment system further includes a second inline heater assembly fluidly connected to the catalyst, the second inline heater assembly including a second heater control unit connected to the second inline heater assembly.

9. An in-line heater assembly for an exhaust aftertreatment system, characterized in that, The in-line heater assembly includes: --A housing, the housing including an outer wall defining an inner cavity; --A heater element, the heater element being disposed within the inner cavity; and --Heater control unit, the heater control unit includes: ---Heater controller, which is communicatively connected to the heater element and configured to control the power distribution to the heater element; --- Mounting element, which supports the heater controller; and ---Thermal support element, which connects the mounting element to the outer wall.

10. The in-line heater assembly of claim 9, wherein, The housing defines an inlet opening and an outlet opening, the inner cavity fluidly connecting the inlet opening and the outlet opening, and the housing also includes a mounting flange extending from the outer surface of the outer wall, the mounting flange supporting the heater controller.

11. The in-line heater assembly of claim 9, wherein, The heater control unit also includes a vibration damping pad connected between the mounting element and the outer wall.

12. The in-line heater assembly of claim 9, wherein, The heater control unit further includes a spacer, wherein the mounting element includes a mounting plate spaced apart from the housing by the spacer.

13. The in-line heater assembly of claim 9, wherein, The heater control unit also includes an insulating element disposed between the heater controller and the outer wall.

14. The in-line heater assembly of any of claims 9-13, wherein, The inline heater assembly also includes a sensor disposed within the housing, the sensor being configured to generate sensor data indicating the temperature of exhaust gas flowing through the housing, and a heater controller communicatively coupled to the sensor, the heater controller being configured to control the heater element based on the sensor data from the sensor.

15. The in-line heater assembly of any of claims 9-13, wherein, The inline heater assembly also includes a switching device communicatively connected to the heater controller, the heater controller being configured to control the switching device to control the power distribution to the heater elements.

16. The in-line heater assembly of claim 9, wherein, The housing also includes a mounting flange extending radially from the outer wall, and the thermal support element connects the heater control unit to the mounting flange.

17. The in-line heater assembly of any of claims 9-13, wherein, The mounting element defines an opening, and the inline heater assembly further includes an insert extending through the opening.

18. The in-line heater assembly of claim 17, wherein, The insert is configured to separate the thermal support element from the rest of the heater control unit.

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