Aftertreatment system including bracket for coupling to an aftertreatment system component

Abstract

An aftertreatment system includes a first aftertreatment system component, a second aftertreatment system component, a third aftertreatment system component, a first bracket, and a second bracket. The second aftertreatment system component has a first end and a second end. The first end is connected to the first aftertreatment system component. The second end of the second aftertreatment system component is connected to the third aftertreatment system component. The first bracket has at least a first end and a second end. The first end of the first bracket is coupled to the first aftertreatment system component or the third aftertreatment system component. The second end of the first bracket may be coupled to the second bracket or an isolator. The second bracket may be coupled to the first bracket or may be connected to an isolator and assist in supporting the second aftertreatment system component.

Description

AFTERTREATMENT SYSTEM INCLUDING BRACKET FOR COUPLING TO AN AFTERTREATMENT SYSTEM COMPONENTCROSS-REFERENCE TO RELATED APPLICATION[00011 The present application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 448,427, filed February 27, 2023, the entire disclosure of which is hereby incorporated by reference herein.TECHNICAL FIELD|0002[ The present application relates generally to aftertreatment systems that include a bracket that is configured to be coupled to an aftertreatment system component.BACKGROUND

[0003] For internal combustion engines, such as diesel engines, nitrogen oxide (NOX) compounds may be emitted in exhaust. It is desirable to reduce NOx emissions to comply with environmental regulations, for example. To reduce NOx emissions, an aftertreatment system may be used in which a reductant is dosed into the exhaust. Mounts may be used to secure the aftertreatment system to the chassis of a vehicle.|0004] Aftertreatment system components may be subsystems that are coupled together at their ends to form a conduit for treating exhaust. Exhaust may enter a first aftertreatment system component, flow through a second aftertreatment system component and into a third aftertreatment system component before being released in a more environmentally acceptable form. Although the aftertreatment system itself may be mounted to a vehicle, some components therein may not be directly coupled to the vehicle and may only be connected to other aftertreatment system components at their ends or in such a manner that leads to undesired movement, vibration, and displacement of the components within the aftertreatment system relative to one another. Unsupported aftertreatment system components may be subject to local vibration modes with high displacements and ultimately high stress. These conditions negatively impact aftertreatment system durability and the ability of the aftertreatment systemto meet its expected mechanical design life. Breaks, disconnections, fractures, and leaks in an aftertreatment system caused by undesired movement of unsupported aftertreatment system components may lead to long down times and costly repairs.SUMMARY|0005] In one embodiment, an aftertreatment system includes a first aftertreatment system component, a second aftertreatment system component, a third aftertreatment system component, a first bracket, and a second bracket. The second aftertreatment system component has a first end and a second end. The first end is connected to the first aftertreatment system component. The third aftertreatment system component is connected to the second end of the second aftertreatment system component. The first bracket has at least a first end and a second end. The first end of the first bracket is coupled to the first aftertreatment system component or the third aftertreatment system component. The second bracket is coupled to the second end of the first bracket. The second bracket has a face that interfaces with a portion of the second aftertreatment system component.10006] In another embodiment, an aftertreatment system includes a first aftertreatment system component, a second aftertreatment system component, a third aftertreatment system component, a first bracket, a second bracket, and an isolator. The second aftertreatment system component has a first end and a second end. The first end is connected to the first aftertreatment system component. The third aftertreatment system component is connected to the second end of the second aftertreatment system component. The first bracket has at least a first end and a second end. The first end of the first bracket is coupled to the first aftertreatment system component or the third aftertreatment system component. The second bracket has a first end and a second end. The first end of the second bracket is coupled to the second aftertreatment system component. The isolator is connected to the second end of the first bracket and the second end of the second bracket.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the disclosure will become apparent from the description, the drawings, and the claims, in which:

[0008] Figure 1 is a block schematic diagram of an example vehicle system;|0009[ Figure 2 is a perspective view of an aftertreatment system, according to various embodiments of the present disclosure;|0010] Figure 3 is a cross-sectional view of an aftertreatment system according to various embodiments shown in Figure 2, taken along plane A-A in Figure 2;[00111 Figure 4 is a perspective view of an aftertreatment system, according to various embodiments;

[0012] Figure 5 is a cross-sectional view of the aftertreatment system in Figure 4, taken along plane B-B in Figure 4;

[0013] Figure 6 is a perspective view of an isolator according to various embodiments.

[0014] Figure 7 is a perspective view of an aftertreatment system, according to various embodiments; and|0015[ Figure 8 is a cross-sectional view of the aftertreatment system in Figure 7, taken along plane C-C in Figure 7.

[0016] It will be recognized that some or all of the Figures are schematic representations for purposes of illustration. The Figures are provided for the purpose of illustrating one or more implementations with the explicit understanding that they will not be used to limit the scope or the meaning of the claims.DETAILED DESCRIPTION

[0017] Following below are more detailed descriptions of various concepts related to, and implementations of aftertreatment systems that include at least one bracket for coupling to an aftertreatment system component, according to the present disclosure. The bracket may be self- contained within the aftertreatment system and need not directly connect to outside structures or supportive structures of a vehicle. The various concepts introduced above and discussed in greater detail below may be implemented in any of a number of ways, as the described concepts are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.I. Overview[0(H8| To reduce emissions from an internal engine, it may be desirable to connect an aftertreatment system to the vehicle. Current aftertreatment systems are connected to a vehicle chassis by fixed / welded connections or removable connections (i.e., mounts) at designated locations on certain aftertreatment system components. Mounts are present on only a subset of aftertreatment system components, meaning some aftertreatment system components are not directly connected to the vehicle, but are instead only indirectly supported via other components. Aftertreatment system components that are not directly mounted to the vehicle are subject to increased local vibrations with high displacements and ultimately high stress. The indirectly supported aftertreatment system components may experience bending, cracking, fracture, and other structural failures that shorten the expected mechanical useful life of the aftertreatment system. Such problems are particularly apparent when components of aftertreatment systems are arranged in parallel, or otherwise extend longitudinally with respect to each other and are only connected at ends of each component.|0019] Implementations herein are directed to an aftertreatment system including an apparatus for better securing indirectly supported aftertreatment system components to minimize excess free body motion and vibration. For example, an aftertreatment system may include a first aftertreatment system component, a second aftertreatment system component with a first end and a second end, and a third aftertreatment system component. The first aftertreatment systemcomponent and / or the third aftertreatment system component may be connected to a vehicle. The second aftertreatment system component may not be directly connected to a vehicle. Instead, the second aftertreatment system component’s first end is connected to the first aftertreatment system component, and the second aftertreatment system component’s second end is connected to the third aftertreatment system component. The aftertreatment system may also include a first bracket and a second bracket. The first bracket has at least a first end and a second end. The first end of the first bracket is coupled to the first aftertreatment system component or the third aftertreatment system component. The second end of the first bracket is coupled to the second bracket. The second bracket has a face that interfaces with a portion of the second aftertreatment system component, thereby minimizing excess motion in the second aftertreatment system component. By securing the unsupported aftertreatment system components to other components within the aftertreatment system, stress, displacement, and static loads may be reduced at low cost and in a self-contained manner that requires no additional interfaces with the vehicle.II. Overview of Example Vehicle Systems with Aftertreatment Systems

[0020] Figure 1 depicts a vehicle system 100. The vehicle system 100 includes an internal combustion engine (e.g., diesel internal combustion engine, gasoline internal combustion engine, hybrid internal combustion engine, etc.) that produces exhaust. The exhaust includes particulates, NOx and other gases that require treatment before being released into the atmosphere. The vehicle system 100 also includes an aftertreatment system 101. The aftertreatment system 101 receives the exhaust, treats the exhaust with a reductant, and subsequently provides the treated exhaust to the atmosphere. The aftertreatment system 101 includes an exhaust conduit system 104. The exhaust conduit system 104 is configured to (e.g., structured to, able to, etc.) provide a channel and / or receive the exhaust from the internal combustion engine and provide the same to the atmosphere or to another downstream component.10021] The exhaust conduit system 104 may include an upstream diesel particulate filter(DPF) 106. The DPF 106 is configured to remove particulate matter, such as soot, from exhaustfl owing in the exhaust conduit system 104. The DPF 106 includes an inlet where the exhaust is received, and an outlet where the exhaust exits after having particulate matter substantially fdtered from the exhaust and / or converting the particulate matter into carbon dioxide. In some implementations, the DPF 106 may be omitted.[0022| The exhaust conduit system 104 also has a first aftertreatment system component 108 (e.g., an exhaust conduit, decomposition chamber, reactor, reactor pipe, DPF, selective catalytic reduction (SCR) catalyst, a diesel oxidation catalyst (DOC), etc.). In some embodiments, the first aftertreatment system component 108 is configured to convert a reductant into ammonia. The reductant may be, for example, urea, diesel exhaust fluid (DEF), Adblue®, a urea water solution (UWS), an aqueous urea solution (e.g., AUS32, etc.), and / or other similar fluids. The first aftertreatment system component 108 may include an inlet in fluid communication with the DPF 106 to receive the exhaust containing NOXemissions and an outlet for the exhaust, NOx emissions, ammonia, and / or a reductant exhaust mixture to flow to a second aftertreatment system component 109.[00231 The first aftertreatment system component 108 may be coupled to mounts 111. The mounts 111 may be various structures for securing the first aftertreatment system component 108 to the chassis 142 of a vehicle. Generally, mounts 111 couple a receiving feature or surface of the first aftertreatment system component 108 to the chassis 142. For example, the mounts 111 may consist of V-bands, clamps, welded hangar rods, fasteners, secured flanges, straps, and other similar structures. A mount 111 may be a fastener configured to be received into a fastener aperture on the first aftertreatment system component 108 and couple the same to the chassis 142. The mounts 111 ensure that the aftertreatment system 101 is securely coupled (e.g., fastened, attached, affixed, welded, bolted, etc.) to the vehicle by a direct connection between the vehicle and the first aftertreatment system component 108. Generally, the mounts 111 secure the first aftertreatment system component 108 to a vehicle’s chassis 142. The chassis 142 is a load bearing framework of the vehicle and provides a stable surface on which to affix the first aftertreatment system component 108. When directly affixed to a vehicle in such a manner, the first aftertreatment system component 108 experiences relatively little free body motion or vibration with respect to the other components of the aftertreatment system101. However, other components of the aftertreatment system 101 not directly connected to the chassis 142 may experience local free body movement, vibrations, and stress if not sufficiently supported within the aftertreatment system 101 or coupled to the chassis 142 of the vehicle.

[0024] The aftertreatment system 101 also includes a reductant delivery system 102. As explained in more detail herein, the reductant delivery system 102 is configured to facilitate the introduction of a reductant (e.g., a reductant, a reductant air mixture, etc.) into the exhaust. The reductant delivery system 102 includes a doser 112 (e.g., a dosing module, dosing assembly, etc.) that may be configured to dose the reductant into the first aftertreatment system component 108 to facilitate the treatment of the exhaust. For example, the doser 112 may dose reductant into the path of the exhaust via an injector 120. In some embodiments, the doser 112 may be configured to receive air and reductant and provide an air / reductant mixture into the exhaust. The doser 112 may include an insulator interposed between a portion of the doser 112 and the first aftertreatment system component 108 on which the doser 112 may be mounted.|0025] The doser 112 is fluidly coupled to (e.g., fluidly configured to communicate with, etc.) a reductant source 114. The reductant source 114 may include multiple reductant sources 114. The reductant source 114 may be, for example, a diesel exhaust fluid tank containing Adblue®. A reductant pump 116 (e.g., supply unit, etc.) is used to pressurize the reductant from the reductant source 114 for delivery to the doser 112. In some embodiments, the reductant pump 116 is pressure-controlled (e.g., controlled to obtain a target pressure, etc.). The reductant pump 116 may include a reductant filter 118. The reductant filter 118 filters (e.g., strains, etc.) the reductant prior to the reductant being provided to internal components (e.g., pistons, vanes, etc.) of the reductant pump 116. For example, the reductant filter 118 may inhibit or prevent the transmission of solids (e.g., solidified reductant, contaminants, etc.) to the internal components of the reductant pump 116. In this way, the reductant filter 118 may facilitate prolonged desirable operation of the reductant pump 116. In some embodiments, the reductant pump 116 is coupled to the chassis 142 of a vehicle associated with the aftertreatment system 101.

[0026] The doser 112 includes at least one injector 120. Each injector 120 is configured to dose the reductant into the exhaust (e.g., within the first aftertreatment system component 108, etc.).In some embodiments, the reductant delivery system 102 also includes an air pump 122. In these embodiments, the air pump 122 may draw air from an air source 124 (e.g., air intake, etc.) and through an air fdter 126 disposed upstream of the air pump 122. In such embodiments, the air pump 122 provides the air to the doser 112 via a conduit. In these embodiments, the doser 112 is configured to mix the air and the reductant into an air-reductant mixture and to provide the air-reductant mixture into the exhaust (e.g., within the first aftertreatment system component 108, etc ). In other embodiments, the reductant delivery system 102 does not include the air pump 122 or the air source 124. In such embodiments, the doser 112 is not configured to mix the reductant with air. As a result, the reductant may be injected upstream of the second aftertreatment system component 109 such that the second aftertreatment system component 109 receives a mixture of the reductant and exhaust. The reductant droplets undergo the processes of evaporation, thermolysis, and hydrolysis to form non-NOxemissions (e.g., gaseous ammonia, etc.) within the exhaust conduit system 104.[00271 In some embodiments, the reductant delivery system 102 may include a reductant delivery system controller 128 that is electrically or communicatively coupled to the doser 112, the reductant pump 116, and / or the air pump 122. The reductant delivery system controller 128 may be configured to control the doser 112 to dose the reductant into the first aftertreatment system component 108. The reductant delivery system controller 128 may also be configured to control the reductant pump 116 and air pump 122.[0028| The reductant delivery system controller 128 includes a processing circuit 130. The processing circuit 130 includes a processor 132 and a memory 134. The processor 132 may include a microprocessor, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), etc., or combinations thereof. The memory 134 may include, but is not limited to, electronic, optical, magnetic, or any other storage or transmission device capable of providing a processor, ASIC, FPGA, etc. with program instructions. This memory 134 may include a memory chip, Electrically Erasable Programmable Read-Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM), flash memory, or any other suitable memory from which the reductant delivery system controller 128 can read instructions. The instructions may include code from any suitable programming language. Thememory 134 may include various modules that include instructions, which are configured to be implemented by the processor 132.|0029[ In various embodiments, the reductant delivery system controller 128 is configured to communicate with a central controller 136 (e.g., engine control unit (ECU)), engine control module (ECM), etc.) of an internal combustion engine having the aftertreatment system 101. In some embodiments, the central controller 136 and the reductant delivery system controller 128 are integrated into a single controller.

[0030] In some embodiments, the central controller 136 is communicable with a display device (e.g., screen, monitor, touch screen, heads up display (HUD), indicator light, etc.). The display device may be configured to change state in response to receiving information from the central controller 136. For example, the display device may be configured to change between a static state (e.g., displaying a green light, displaying a “SYSTEM OK” message, etc.) and an alarm state (e.g., displaying a blinking red light, displaying a “SERVICE NEEDED” message, etc.) based on a communication from the central controller 136. By changing state, the display device may provide an indication to a user (e.g., operator, etc.) of a status (e.g., operation, in need of service, etc.) of the reductant delivery system 102.[00311 The aftertreatment system 101 may also include a doser mounting bracket 138 (e.g., mounting bracket, coupler, plate, etc.). The doser mounting bracket 138 couples the doser 112 to a component of the aftertreatment system 101. The doser mounting bracket 138 is configured to mitigate the transfer of heat from the exhaust passing through the exhaust conduit system 104 to the doser 112. In this way, the doser 112 is capable of operating more efficiently and desirably than other dosers which are not able to mitigate the transfer of heat. The doser mounting bracket 138 is configured to aid in reliable installation of the doser 112. This may decrease manufacturing costs associated with the aftertreatment system 101 and ensure repeated desirable installation of the doser 112.

[0032] In various embodiments, the doser mounting bracket 138 couples the doser 112 to the first aftertreatment system component 108. In some embodiments, the doser mounting bracket 138 couples the doser 112 to an exhaust conduit of the exhaust conduit system 104. Forexample, the doser mounting bracket 138 may couple the doser 112 to an exhaust conduit of the exhaust conduit system 104 that is upstream of the first aftertreatment system component108 or to an exhaust conduit of the exhaust conduit system 104 that is downstream of the first aftertreatment system component 108. In some embodiments, the doser mounting bracket 138 couples the doser 112 to the DPF 106 and / or the second aftertreatment system component 109. The location of the doser mounting bracket 138 may be varied depending on the application of the aftertreatment system 101. For example, in some embodiments of the aftertreatment system 101, the doser mounting bracket 138 may be located further upstream. Furthermore, some aftertreatment systems 101 may include multiple dosers 112 and therefore may include multiple doser mounting brackets 138.The exhaust conduit system 104 also has a second aftertreatment system component 109 (e.g., an exhaust conduit, decomposition chamber, reactor, reactor pipe, DPF, SCR catalyst, a DOC, etc.). The second aftertreatment system component 109 includes an inlet in fluid communication with the first aftertreatment system component 108 from which exhaust, an exhaust-reductant, etc. are received. Generally, the inlet of the second aftertreatment system component 109 is located at a first end 150 of the second aftertreatment system component 109. The exhaust or fluid mixture then flows through the second aftertreatment system component109 and arrives at an outlet. The outlet of the second aftertreatment system component 109 is in fluid communication with a third aftertreatment system component 110. The outlet of the second aftertreatment system component 109 is generally located at a second end 152 of the second aftertreatment system component 109. In this way, the second aftertreatment system component 109 is connected to the aftertreatment system 101 at least at its first end 150 and its second end 152.

[0033] The exhaust conduit system 104 also has a third aftertreatment system component 110. The third aftertreatment system component 110 may be an exhaust conduit, decomposition chamber, reactor, reactor pipe, DPF, SCR catalyst, etc. In some embodiments, the third aftertreatment system component 110 may be an oxidation catalyst (e.g., DOC) in fluid communication with the exhaust conduit system 104 (e.g., downstream of the secondaftertreatment system component 109 or upstream of the DPF 106) to oxidize hydrocarbons and carbon monoxide in the exhaust.|0034] The third aftertreatment system component 110 may also include mounts 111. The mount 111 may be any structure for securing the third aftertreatment system component 110 to the chassis 142 as discussed above. The mounts 111 may directly connect the third aftertreatment system component 110 to the vehicle’s chassis 142. Other components of the aftertreatment system 101 not directly connected to the chassis 142 may experience local free body movement. Local free body motion of an aftertreatment system component may include oscillations of the component, unintended displacements of the component with respect to other components, and expansions or contractions at joints / connections between components. For example, a component that experiences excessive free body motion may sway, vibrate, bounce, or shift in a position that causes undesirable wear on the aftertreatment system 101. Components of the aftertreatment system 101 not directly connected to a chassis 142 may also experience excessive vibrations, forces, and stress if not sufficiently supported within the aftertreatment system 101. Free body motion may lead to fractures, brakes, or cracks of components that require costly or extensive repair. An aftertreatment system 101 would benefit from centralizing wear or breaks to sections / smaller structures that may be readily and inexpensively repaired, rather than having breaks occur at costly or expensive components where failure would lead to significant downtime, etc.[00351 The aftertreatment system 101 includes an aftertreatment support system 140. As described in more detail herein, the aftertreatment support system 140 is configured to reduce excess free body motion in the aftertreatment system 101 by securing the second aftertreatment system component 109 to the first aftertreatment system component 108 and / or the third aftertreatment system component 110. In this way, the aftertreatment support system 140 reduces stress experienced by the aftertreatment system 101, lowers the likelihood of fractures or brakes, and ensures the aftertreatment system 101 meets its expected mechanical useful life. Further, by securing the second aftertreatment system component 109 to the first aftertreatment system component 108 and / or the third aftertreatment system component 110, the aftertreatment support system 140 is self-contained (e.g., does not require an additionalmounting interface or connection between the vehicle and the aftertreatment system 101). The self-contained nature of the aftertreatment support system 140 within the aftertreatment system 101 allows for reduced maintenance and upkeep costs — no additional links, connectors, fasteners, or supports spanning between or directly connecting the aftertreatment support system 140 and the vehicle are required. The self-contained nature of the aftertreatment support system 140 also results in a minimized and more efficient use of space while simultaneously decreasing the risk of fractures / brakes and increasing the likelihood that the aftertreatment system 101 meets its expected mechanical useful life. This efficient use of space is a result of the smaller profile of the self-contained aftertreatment support system 140 (which is connected only to other components of the aftertreatment system 101) as compared to a bulkier profile of a support system which requires connections extending outward from the aftertreatment system 101 and requires additional connectors to the vehicle. Further, a self-contained aftertreatment support system 140 allows the aftertreatment system 101 to connect to a vehicle without requiring additional mounts 111, facets, or linkages — ensuring that the aftertreatment system 101 can still connect to the same variety and scope of compatible vehicles (e.g., no modifications to vehicles are required to facilitate use of the self-contained aftertreatment support system 140).

[0036] In some embodiments, the aftertreatment support system 140 includes brackets connected to the first aftertreatment system component 108, the second aftertreatment system component 109, and / or the third aftertreatment system component 110. In other embodiments, the aftertreatment support system 140 utilizes brackets connected to the first aftertreatment system component 108, the second aftertreatment system component 109, and / or the third aftertreatment system component 110 and may use vibration reducing structures connected to the brackets.[0037| Figure 2 depicts an exhaust conduit system 104 of an aftertreatment system 101. The exhaust conduit system 104 provides a channel for treating exhaust that flows from the vehicle’s internal combustion engine before being released into the atmosphere. The exhaust conduit system 104 includes a first aftertreatment system component 108. The first aftertreatment system component 108 may be a Light-Off (LO) catalyst assembly that mayfilter particulate matter from the exhaust, controls the temperature of the exhaust for treatment, and inject a reductant into the exhaust. The first aftertreatment system component 108 may include mounts 111. In other embodiments, the first aftertreatment system component 108 may be an exhaust conduit, decomposition chamber, reactor, reactor pipe, DPF, SCR catalyst, a diesel oxidation catalyst (DOC), etc. Figures 2-7 depict the first aftertreatment system component 108, for example, as a LO catalyst assembly.

[0038] In Figure 2, the exhaust conduit system 104 also includes a second aftertreatment system component 109. The second aftertreatment system component 109 may be an exhaust conduit, decomposition chamber, reactor, reactor pipe, DPF, SCR catalyst, a diesel oxidation catalyst (DOC), etc. Figures 2-7 depicts the second aftertreatment system component 109, for example, as a decomposition reactor tube (DRT) and transfer tube assembly. The second aftertreatment system component 109 may receive exhaust, an exhaust-reductant mixture, and / or an exhaust-reductant-air mixture, etc. The second aftertreatment system component 109 may convert exhaust and reductant into ammonia through hydrolysis. The second aftertreatment system component 109 has a first end 150. The first end 150 may be an inlet that receives exhaust or an exhaust mixture from the outlet of the first aftertreatment system component 108. The first end 150 also provides structural support for the second aftertreatment system component 109 by connecting it to the first aftertreatment system component 108. The second aftertreatment system component 109 also has a second end 152. The second end 152 may be an outlet that provides exhaust, an exhaust mixture, or ammonia to the inlet of the third aftertreatment system component 110. The second end 152 also provides structural support for the second aftertreatment system component 109 by connecting it to the third aftertreatment system component 110. In this way, the second aftertreatment system component 109 may extend parallel or longitudinal to the first aftertreatment system component 108 and the third aftertreatment system component 110. The first end 150 and second end 152 may not support the second aftertreatment system component 109 at or near its center of gravity.|0039] As discussed above, the exhaust conduit system 104 also includes a third aftertreatment system component 110. The third aftertreatment system component 110 may convert exhaust, an exhaust mixture, NOx, etc. into nitrogen gas and water vapor to be expelled into theenvironment. In some embodiments, the third aftertreatment system component 110 may be an exhaust conduit, decomposition chamber, reactor, reactor pipe, DPR, SCR catalyst, a diesel oxidation catalyst (DOC), etc. Figures 2-7 depict the third aftertreatment system component110, for example, as a dual SCR catalyst assembly.[0040| Figure 2 shows that the aftertreatment support system 140 provides support to the longitudinal region or body of the second aftertreatment system component 109 that is otherwise unsupported. As depicted, the aftertreatment support system 140 may be located near the center of gravity of the second aftertreatment system component 109. However, the aftertreatment support system 140 may take on a variety of embodiments and configurations. For example, the aftertreatment support system 140 or multiple variations thereof may support the second aftertreatment system component 109 at one or multiple locations along the length of the second aftertreatment system component 109. Further, the aftertreatment support system 140 may be connected to multiple combinations of at least the first aftertreatment system component 108, the second aftertreatment system component 109, and / or the third aftertreatment system component 110.111. Overview of Example Aftertreatment Support Systems[00411 Turning to Figure 3, a cross-sectional view of the exhaust conduit system 104 from Figure 2 is shown, taken along plane A-A. The cross section of the exhaust conduit system 104 includes a middle portion of the first aftertreatment system component 108. The middle portion of the first aftertreatment system component 108 may connect to the aftertreatment support system 140. Similarly, a middle portion of the third aftertreatment system component 110 is shown. The middle portion of the third aftertreatment system component 110 may also connect to the aftertreatment support system 140. The aftertreatment support system 140 then may connect the middle portion of the first aftertreatment system component 108 and / or the middle portion of the third aftertreatment system component 110 to a middle portion of the second aftertreatment system component 109. During operation of conventional systems, replacement of some components can be complex due to their location and configuration. The aftertreatment support system 140 may provide for simple and efficient replacement of subcomponents withinthe aftertreatment support system 140 should failure occur. Moreover, the aftertreatment support system 140 can be configured to accommodate stresses in other aftertreatment system components so that failure can be directed to components which are simple and efficient to replace, such as the brackets within the aftertreatment support system 140. For example, a replacement of the aftertreatment support system 140 or a part thereof may be significantly less expensive than a replacement of another component of the aftertreatment system 101. Additionally, a break, fracture, etc. of the aftertreatment support system 140 may prevent a break in a separate component that would result in a release of harmful exhaust, lower the performance of the system as a whole, or result in a time-consuming repair.[00421 Figure 4 shows an aftertreatment support system 140 coupled to the first aftertreatment system component 108 and the second aftertreatment system component 109. In other embodiments, the aftertreatment support system 140 may be coupled to the second aftertreatment system component 109 and any combination of the first aftertreatment system component 108 and / or the third aftertreatment system component 110. In this way, the aftertreatment support system 140 or multiples thereof of any variation may be positioned along the length of the second aftertreatment system component 109 in order to provide additional support to the second aftertreatment system component 109. Particularly, the aftertreatment support system 140 may be located such that it supports a location at the center of gravity of the second aftertreatment system component 109.[00431 Turning to Figure 5, a cross-sectional view of the exhaust conduit system 104 from Figure 4 is shown, taken along plane B-B of Figure 4. The aftertreatment support system 140 includes a first bracket 300. The first bracket 300 forms part of the structure that secures the aftertreatment support system 140 to the first aftertreatment system component 108 and / or the third aftertreatment system component 110. The first bracket 300 may be made of stainless steel, zinc-plated carbon steel, aluminum, or other suitable materials. The first bracket 300 may be in the shape of a hollow bar, a solid bar, a prism, or the like such that the first bracket 300 will sufficiently support the components of the aftertreatment system 101.

[0044] The first bracket 300 includes a first end 301. The first end 301 couples the first bracket 300 to the first aftertreatment system component 108. In other embodiments, the first end 301 may couple the first bracket 300 to the third aftertreatment system component 110. The first end 301 may be coupled or fixed to the first aftertreatment system component 108 in a variety of ways. For example, the first end 301 may be welded to the surface of the first aftertreatment system component 108, may be bolted or riveted to a separate linking structure fastened to the first aftertreatment system component 108, may be secured to the first aftertreatment system component 108 via a clamp, or the like. As shown in Figure 5, the first end 301 may be curved or otherwise contoured to align or interface with the profile of the first aftertreatment system component 108. In other embodiments, a slot, anchor, or other recess may be formed on the surface of the first aftertreatment system component 108 such that the first end 301 may be received therein and secured in place.

[0045] The first bracket 300 also includes a second end 302. The second end 302 may be contiguous with the first end 301 of the first bracket 300. The second end 302 may extend away from the surface of the first aftertreatment system component 108 or the third aftertreatment system component 110 to facilitate a connection to the second aftertreatment system component 109. In some embodiments, the second end 302 includes a first bar and a second bar in parallel that facilitate connection to the second aftertreatment system component 109.

[0046] The aftertreatment support system 140 also includes a second bracket 310. The second bracket 310 forms part of the structure that secures the aftertreatment support system 140 to the first aftertreatment system component 108 and / or the third aftertreatment system component 110. Like the first bracket 300, the second bracket 310 may be made of stainless steel, zinc- plated carbon steel, aluminum, or other suitable materials.

[0047] The second bracket 310 includes at a first end 311. The first end 311 may be coupled to the second aftertreatment system component 109 via a weld, clasps, or may be bolted or fastened onto a separate surface secured to the second aftertreatment system component 109, etc. In other embodiments, the first end 311 may fully or partially extend / wrap around the circumference / perimeter of the second aftertreatment system component 109 and thereby besecured in place. In further embodiments, a slot, recess, or groove may be formed in or on the surface of the second aftertreatment system component 109 such that the first end 311 may be received therein and secured in place.

[0048] The second bracket 310 also includes a second end 312. The second end 312 of the second bracket 310 may be contiguous with the first end 311. The second end 312 may extend away from the surface of the second aftertreatment system component 109 to facilitate a connection to at least one of the first aftertreatment system component 108 or the third aftertreatment system component 110.|0049] The aftertreatment support system 140 also includes an isolator 320. The isolator 320 dampens excess free body motion and vibrations experienced by the second aftertreatment system component 109. The isolator 320 may be made of a soft, malleable, or flexible material with sufficient durability to lessen the movement of the second aftertreatment system component 109. For example, the isolator 320 may be made of rubber, elastomers, neoprene, or other materials. The isolator 320 couples the second end 302 of the first bracket 300 to the second end 312 of the second bracket 310. In this way, the isolator 320 may complete the structure of the aftertreatment support system 140 and secure a longitudinal portion of the second aftertreatment system component 109 to one or both of the first aftertreatment system component 108 and the third aftertreatment system component 110.|0050J Turning to Figure 6, in one embodiment, the isolator 320 has two first through-holes 321 configured to receive the second end 302 of the first bracket 300. For example, in this embodiment, the second end 302 of the first bracket 300 includes a first bar and a second bar in parallel, each bar extending through a respective one of the first through-holes 321. The second end 302 may further include flanges or projecting surfaces on each rod to abut against the isolator 320 such that the flanges or projecting surfaces do not pass through the first through- holes 321. Endcaps may be used to secure the first rod and second rod of the second end 302 in place within the first through-holes 321. In other embodiments, the isolator 320 includes additional first through-holes 321. In another embodiment, the isolator 320 includes only a single first through-hole 321. In such an embodiment, the isolator 320 may be ovular,rectangular, or another shape and place the first through-hole 321 and the second through-hole 322 in vertical alignment with one another.|0051 ] The isolator 320 includes a second through-hole 322 configured to receive the second end 312 of the second bracket 310. The second end 312 may also include a flange or projecting surface to abut against the isolator 320 such that the flange or projecting surface does not pass through the second through-hole 322. The second end 312 is positioned through the second through-hole 322 and connects the second bracket 310 to the isolator 320. An endcap may be used to secure the second end 312 in place within the second through-hole 322. Just like the first through-hole 321, in other embodiments, multiple or single second through-holes 322 may be used depending on the configuration of the second end 312 of the second bracket 310 (e.g., multiple rods in parallel, a flat bar, etc.).

[0052] In other embodiments, multiple isolators 320 or an assembly containing isolators 320 may be used to connect a second end 302 of the first bracket 300 to the second end 312 of the second bracket 310. For example, two isolators 320 may be used, each including a respective first through-hole 321 and second through-hole 322. The second end 302 of the first bracket 300 may connect to the first through-hole 321 of one isolator 320, while the second end 312 of the second bracket 310 may connect to the second through-hole 322 of the other isolator 320. The remaining first through-hole 321 and second through-hole 322 of the isolators 320 may then be coupled together with a separate rod, clasp, ring, spring, clamp, or assembly such that the second end 302 of the first bracket 300 to the second end 312 of the second bracket 310.

[0053] Turning to Figure 7, an aftertreatment support system 140 is coupled to the third aftertreatment system component 110 and interfaces with the second aftertreatment system component 109. In other embodiments, the aftertreatment support system 140 may be coupled to the first aftertreatment system component 108 and interface with the second aftertreatment system component 109 or be coupled to the first aftertreatment system component 108 and the third aftertreatment system component 110 and interface with the second aftertreatment system component 109, or any like combination.

[0054] Turning to Figure 8, a cross-sectional view of the exhaust conduit system 104 from Figure 7 is shown, taken along plane C-C of Figure 7. The aftertreatment support system 140 includes a first bracket 400. The first bracket 400 may be made of stainless steel, zinc-plated carbon steel, aluminum, or other suitable materials to provide support to the second aftertreatment system component 109. The body of the first bracket 400 may take on various configurations or shapes. For example, the first bracket 400 may be a solid bar, a hollow rod, a scaffold, a frame, or other like structures. In other embodiments, the first bracket 400 is made of a rigid body such as a three-point support (tripod) rigid body.

[0055] The first bracket 400 may also include vibration reducing or shock absorbing system to facilitate reduced, but minimal, motion of the second aftertreatment system component 109. For example, the body of the first bracket 400 may be segmented and include a shock absorbing system including gas springs, compression springs, piston assemblies, and / or hydraulic assemblies to dampen vibrations or oscillations of the second aftertreatment system component 109 (e g., relative to the chassis 142). Other brackets as described herein may also include such a shock absorbing system.

[0056] The first bracket 400 includes a first end 401. The first end 401 supports the first bracket 400 by anchoring it either permanently or in a removable manner to a component of the aftertreatment system 101. In some embodiments, the first end 401 may be coupled to the first aftertreatment system component 108 or to the third aftertreatment system component 110. For example, the first end 401 may be welded, secured with fasteners such as a clamp, bolt, clasp, or the like. In other embodiments, a slot, groove, or opening in the surface of the third aftertreatment system component 110 or on a structure affixed to the third aftertreatment system component 110 may receive the first end 401 and secure it in place. In other embodiments, the first end 401 resembles the opposite end of the first bracket 400. For example, in some embodiments, the first end 401 fits to the contours of the third aftertreatment system component 110 or the first aftertreatment system component 108. In this way, the first end 401 may have a u-shaped face or face that fits along the contours of the third aftertreatment system component 110 or the first aftertreatment system component 108. By extending at leastpartially around the contours of the third aftertreatment system component 110, the first end 401 may provide more support for the first bracket 400.

[0057] The first bracket 400 also includes a second end 402. The second end 402 of the first bracket 400 may be contiguous with the first end 401. Generally, the second end 402 is located closer to the second aftertreatment system component 109 than is the first end 401.[00581 The aftertreatment support system 140 may also include a second bracket 410. The second bracket 410 may interface with and provide support for the second aftertreatment system component 109. The second bracket 410 may be coupled to the second end 402 of the first bracket 400. The second bracket 410 may be a solid bar, a hollow bar, a frame, or a scaffold structure configured to fit to the contours of the second aftertreatment system component 109. In some embodiments, the second bracket 410 may be coupled directly to the second aftertreatment system component 109 with a weld, clamp, clasps, or may be fastened with rivets, bolts, or the like onto a separate structure secured to the second aftertreatment system component 109. In other embodiments, the second bracket 410 may not be coupled to the second aftertreatment system component 109, but instead may be located adjacent to the second aftertreatment system component 109 and extend around at least a portion thereof to minimize vibration, free body motion, and stress.

[0059] In other embodiments, the second bracket 410 may be integrally formed with the first bracket 400. For example, the first bracket 400 and second bracket 410 may be formed by casting. More specifically, the first bracket 400 and second bracket 410 may be formed by a casting process in which at least one core is placed in a mold and molten material (e.g., metal, etc.) is poured into the mold around the core(s). The mold and / or the core(s) may be used to incorporate features into the first bracket 400 and / or second bracket 410. For example, an extension can be provided in a core (e.g., jacket core, etc.) to form the first bracket 400 and the second bracket 410.[0060 [ In some embodiments, the first bracket 400 and the second bracket 410 may be integrally formed via additive manufacturing. For example, first bracket 400 and the second bracket 410 may be integrally formed using 3D printing, selective laser sintering, selectivelaser melting (SLM), direct metal laser sintering (DMLS), electron beam melting (EBM), ultrasonic additive manufacturing (UAM), fused deposition modeling (FDM), fused filament fabrication (FFF), stereolithography (SLA), material jetting, binder jetting or other similar processes. As explained above, the first bracket 400 and the second bracket 410 are formed as part of a single manufacturing step (e.g., 3D printing, selective laser sintering, SLM, DMLS, EBM, UAM, FDM, FFF, SLA, material jetting, binder jetting, etc.) to a create a single-piece or unitary construction that cannot be disassembled without at least partial destruction the first bracket 400 and / or the second bracket 410. For example, the portions of the first bracket 400 and the second bracket 410 are: (i) not separable from each other (e.g., one portion of the first bracket 400 cannot be separated from the second bracket 410 without destroying the first bracket 400, etc.); (ii) not formed separately from each other; and (iii) there are no gaps or joints along borders between contiguous portions of the first bracket 400 and the second bracket 410 (e.g., portions that share a border, etc.).[00611 The second bracket 410 of the aftertreatment support system 140 may include a face 415 that interfaces with a portion of the second aftertreatment system component 109. The face 415 may include padding, vibrational dampeners, or other barriers to reduce noise or friction between the surfaces of the face 415 and the second aftertreatment system component 109. The face 415 may be solid or may contain openings therein to expose portions of the second aftertreatment system component 109.[00621 In some embodiments, the second bracket 410 may also include at least a first coupling end 411 and a second coupling end 412. The first coupling end 411 and the second coupling end 412 may be located adjacent to the second aftertreatment system component 109 and / or at opposite sides of the face 415 of the second bracket 410. In this way, the first coupling end 411 and the second coupling end 412 may be contiguous with the second bracket 410. In such a configuration, the face 415 may be located between the first coupling end 411 and the second coupling end 412. The first coupling end 411 and the second coupling end 412 may interface with a device (e.g., a strap 440, a clamp, a locking grate, moveable bars, etc.) configured surround a perimeter of the second aftertreatment system component 109 or otherwiseconfigured to urge the second aftertreatment system component 109 towards the face 415 of the second bracket 410.|0063] In various embodiments, a strap 440 may be connected to the first coupling end 411 and the second coupling end 412 of the second bracket 410. By tightening the strap 440, the strap 440 may urge the second aftertreatment system component 109 towards the face 415 of the second bracket 410. In this way, the strap 440 may reduce vibration, free body motion, and stress experienced by the second aftertreatment system component 109. The strap 440 may be made of polyester, Dyneema®, Kevlar®, nylon, polypropylene, aluminized Mylar®, or other sufficient materials. In other embodiments, clamps, clasps, cordage, wire, etc. may be used to urge the second aftertreatment system component 109 towards the face 415.IV. Configuration of Example Embodiments[0064| While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed but rather as descriptions of features specific to particular implementations. Certain features described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.[0065| As utilized herein, the terms “substantially,” “generally,” “approximately,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications oralterations of the subject matter described and claimed are considered to be within the scope of the appended claims.|0066] The term “coupled” and the like, as used herein, mean the joining of two components directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two components or the two components and any additional intermediate components being integrally formed as a single unitary body with one another, with the two components, or with the two components and any additional intermediate components being attached to one another.|0067] The terms “configured to receive exhaust from,” “configured to receive air from,” “configured to receive reductant from,” and the like, as used herein, mean the two components or objects have a pathway formed between the two components or objects in which a fluid, such as air, reductant, an air-reductant mixture, etc., may flow, either with or without intervening components or objects. Examples of fluid couplings or configurations for enabling fluid communication may include piping, channels, or any other suitable components for enabling the flow of a fluid from one component or object to another.

[0068] It is important to note that the construction and arrangement of the various systems shown in the various example implementations is illustrative only and not restrictive in character. All changes and modifications that come within the spirit and / or scope of the described implementations are desired to be protected. It should be understood that some features may not be necessary, and implementations lacking the various features may be contemplated as within the scope of the disclosure, the scope being defined by the claims that follow. When the language “a portion” is used, the item can include a portion and / or the entire item unless specifically stated to the contrary.|O069[ Also, the term “or” is used, in the context of a list of elements, in its inclusive sense (and not in its exclusive sense) so that when used to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, Z, X and Y, Xand Z, Y and Z, or X, Y, and Z (i.e., any combination of X, Y, and Z). Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present, unless otherwise indicated.

Claims

WHAT IS CLAIMED IS:

1. An aftertreatment system comprising: a first aftertreatment system component; a second aftertreatment system component having a first end and a second end, the first end being coupled to the first aftertreatment system component; a third aftertreatment system component coupled to the second end; a first bracket having at least a first end and a second end, the first end of the first bracket being coupled to the first aftertreatment system component or the third aftertreatment system component; and a second bracket coupled to the second end of the first bracket, the second bracket having a face that interfaces with a portion of the second aftertreatment system component.

2. The aftertreatment system of claim 1, further comprising a strap; wherein the second bracket further comprises: a first coupling end adjacent to the second aftertreatment system component, and a second coupling end adjacent to the second aftertreatment system component; wherein the face is located between the first coupling end and the second coupling end; and wherein the strap is coupled to the first coupling end and the second coupling end such that the strap urges the second aftertreatment system component towards the face.

3. A vehicle system comprising: the aftertreatment system of claim 1; and a chassis coupled to the first aftertreatment system component and the third aftertreatment system component; wherein the second aftertreatment system component is coupled to the chassis via the first bracket, the second bracket, and at least one of the first aftertreatment system component or the third aftertreatment system component.

4. The aftertreatment system of claim 3, wherein the first bracket further comprises: a body extending between the first end and the second end, the body comprising a shock absorbing system configured to dampen a vibration of the second aftertreatment system component relative to the chassis; and the shock absorbing system comprises at least one of a gas spring, a compression spring, a piston assembly, or a hydraulic assembly.

5. The aftertreatment system of claim 1, wherein: the first aftertreatment system component, the second aftertreatment system component, and the third aftertreatment system component each comprise at least one of an exhaust conduit, a decomposition chamber, a reactor, a reactor pipe, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, a diesel oxidation catalyst (DOC), or an ammonia slip (AMOX) catalyst.

6. The aftertreatment system of claim 1, wherein: the first aftertreatment system component comprises a diesel particulate filter (DPF); the second aftertreatment system component comprises a decomposition chamber; the third aftertreatment system component comprises a selective catalytic reduction (SCR)catalyst; and the first aftertreatment system component, the second aftertreatment system component, and the third aftertreatment system component are coupled in series such that an exhaust gas flows from the first aftertreatment system component through the second aftertreatment system component then into the third aftertreatment system component.

7. The aftertreatment system of claim 1, wherein the first bracket is integrally formed with the second bracket.

8. The aftertreatment system of claim 1, wherein the first end of the first bracket further comprises a face configured to abut and extend at least partially around a perimeter of at least one of the first aftertreatment system component or the third aftertreatment system component.

9. The aftertreatment system of claim 1, wherein: the face further comprises: at least one of padding, a vibration dampener, or a barrier configured to reduce noise or friction between a surface of the face and the second aftertreatment system component; and the second bracket and the face comprise an opening therein to create an exposed portion of the second aftertreatment system component adjacent to the portion of the second aftertreatment system component that interfaces with the face.

10. The aftertreatment system of claim 1, wherein the second bracket interfaces with the second aftertreatment system component at a location of a maximum vibration, a free body motion, or a stress along a length of the second aftertreatment system component.

11. An aftertreatment system comprising: a first aftertreatment system component; a second aftertreatment system component having a first end and a second end, wherein the first end is coupled to the first aftertreatment system component; a third aftertreatment system component coupled to the second end of the second aftertreatment system component; a first bracket having at least a first end and a second end, wherein the first end of the first bracket is coupled to the first aftertreatment system component or the third aftertreatment system component; a second bracket having a first end and a second end, wherein the first end of the second bracket is coupled to the second aftertreatment system component; and an isolator coupled to the second end of the first bracket and the second end of the second bracket.

12. The aftertreatment system of claim 11, wherein: the isolator comprises a first through-hole and a second through-hole; andthe second end of the first bracket is positioned within the first through-hole and couples the first bracket to the isolator, and the second end of the second bracket is positioned within the second through-hole and couples the second bracket to the isolator.

13. A vehicle system comprising: the aftertreatment system of claim 11; and a chassis coupled to the first aftertreatment system component and the third aftertreatment system component; wherein the second aftertreatment system component is coupled to the chassis via the first bracket, the second bracket, the isolator, and at least one of the first aftertreatment system component or the third aftertreatment system component.

14. The aftertreatment system of claim 11, wherein: the first aftertreatment system component, the second aftertreatment system component, and the third aftertreatment system component are coupled in series such that an exhaust gas flows from the first aftertreatment system component through the second aftertreatment system component then into the third aftertreatment system component; and the first aftertreatment system component, the second aftertreatment system component, and the third aftertreatment system component each comprise at least one of an exhaust conduit, a decomposition chamber, a reactor, a reactor pipe, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, a diesel oxidation catalyst (DOC), or an ammonia slip (AMOX) catalyst.

15. The aftertreatment system of claim 14, wherein: the first aftertreatment system component comprises the DPF; the second aftertreatment system component comprises the decomposition chamber; and the third aftertreatment system component comprises the SCR catalyst.

16. The aftertreatment system of claim 11, wherein the first end of the first bracket is contoured such that the first end extends along a surface of the first aftertreatment system component or the third aftertreatment system component.

17. The aftertreatment system of claim 16, wherein: at least one of the first aftertreatment system component or the third aftertreatment system component comprise a slot or recess; and the first end of the first bracket is received within the slot or recess.

18. The aftertreatment system of claim 11, wherein the first end of the second bracket is coupled to the second aftertreatment system component at a location of a maximum vibration, a free body motion, or a stress along a length of the second aftertreatment system component.

19. The aftertreatment system of claim 11, further comprising: a third bracket having at least a first end and a second end, the first end of the third bracket being coupled to the third aftertreatment system component; a fourth bracket having a first end and a second end, the first end of the fourth bracket being coupled to the second aftertreatment system component; and a second isolator coupled to the second end of the third bracket and the second end of the fourth bracket; wherein the first end of the first bracket is coupled to the first aftertreatment system component.

20. An aftertreatment system comprising: a first aftertreatment system component; a second aftertreatment system component having a first end and a second end, wherein the first end is coupled to the first aftertreatment system component; a third aftertreatment system component coupled to the second end of the second aftertreatment system component;a first bracket having at least a first end and a second end, wherein the first end of the first bracket is coupled to the first aftertreatment system component; a second bracket having a first end and a second end, wherein the second bracket is coupled to the second aftertreatment system component; a first isolator coupled to the second end of the first bracket and the second end of the second bracket; a third bracket having at least a first end and a second end, wherein the first end of the third bracket is coupled to the third aftertreatment system component; and a second isolator coupled to the second end of the second bracket and the second end of the third bracket.

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