Aftertreatment system including a mixer

Abstract

An aftertreatment system includes a conduit and a mixer disposed in the conduit. The mixer includes a mixer body, an inlet cap, and an outlet flange. The mixer body includes an inlet end, a plurality

Description

AFTERTREATMENT SYSTEM INCLUDING A MIXERCROSS-REFERENCE TO RELATED APPLICATIONS|00O1] The present application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 471,463, filed June 6, 2023, and U.S. Provisional Patent Application No. 63 / 546,706, filed October 31, 2023, the entire disclosures of which are hereby incorporated by reference herein.TECHNICAL FIELD[00021 The present disclosure relates generally to an aftertreatment system for an internal combustion engine.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, a reductant may be dosed into the exhaust by a dosing system coupled to a selective catalytic reduction, or SCR, catalyst member of an aftertreatment system. The reductant facilitates conversion of a portion of the exhaust into non-NOx emissions, such as nitrogen (N2), carbon dioxide (CO2), and water (H2O), thereby reducing NOx emissions. Moving downstream in the aftertreatment system, the exhaust enters a hydrocarbon mixer (e.g., hydrocarbon decomposition chamber) to be mixed with injected hydrocarbon fluid. Upon ignition, the injected hydrocarbon fluid combusts and increases temperature of the exhaust such that any soot or particles affixed to components of the exhaust may be removed and the exhaust be cleaned as a result.SUMMARY[0004[ While existing implementations of hydrocarbon mixers have generally been adequate in facilitating mixing of the exhaust and the hydrocarbon fluid, certain flow conditions may negatively impact the performance of the hydrocarbon mixers. For example, atlow-flow conditions, a spray momentum of particles of an injected hydrocarbon fluid may exceed a momentum of the exhaust, causing the particles to travel backward (e.g., upstream) toward upstream components (e.g., the SCR catalyst members) of the aftertreatment system. This may contaminate and potentially shorten a lifespan of the upstream components.[0005| Furthermore, in some applications, it may be desirable to sample a concentration of a constituent, such as NOx, N2, CO2, and / or H2O, in the exhaust produced by an internal combustion engine and treated by an aftertreatment system. By sampling the concentration of the constituent, operation of the aftertreatment system can be monitored. Such sampling may be obtained using a sensor around which the exhaust is provided. In some instances, however, it can be difficult to integrate a sensor with a hydrocarbon mixer in an aftertreatment systems subject to certain space constraints. For example, these space constraints can limit where the sensor can be positioned without substantially interfering with the performance of the hydrocarbon mixer. It can also be difficult to desirably sample the exhaust gas due to the difference in momentum between the exhaust gas and particles of the hydrocarbon fluid. Certain embodiments of the present disclosure address the above difficulties.[0006| In one embodiment, an aftertreatment system includes an introduction conduit and a mixer disposed within the introduction conduit. The mixer includes a mixer body, an inlet cap, and an outlet flange. The mixer body is centered on a mixer body center axis and configured to receive exhaust and a hydrocarbon fluid. The mixer body includes an inlet end, a plurality of connectors, and an outlet end downstream of the inlet end. The connectors are arranged along a circumference of the inlet end and extending away from the inlet end. The inlet cap is over the inlet end and includes a perforated plate, an inlet flange, and an annular plate. The perforated plate is coupled to the connectors and comprising a plurality of perforations arranged in a circular pattern. The inlet flange is coupled to the perforated plate. The annular plate is downstream of the perforated plate and coupled to the mixer body. The annular plate includes an annular plate aperture centered on the mixer body center axis. The outlet flange includes an outlet flange body coupled to the outlet end. The outlet flange body includes an inner edge and a flared portion extending from the inner edge into the mixer body, where the inner edge defines an outlet flange aperture offset from the mixer body center axis.

[0007] In another embodiment, an aftertreatment system includes an introduction conduit and a mixer disposed within the introduction conduit. The mixer includes a mixer body having an inlet end and an outlet end downstream of the inlet end, an inlet flange coupled to the inlet end, an outlet flange coupled to the outlet end, and an exhaust sampler. The mixer body is centered on a mixer body center axis and configured to receive exhaust and a hydrocarbon fluid. The exhaust sampler includes an inlet portion, an outlet portion, and a base portion. The inlet portion is coupled to the inlet flange. The outlet portion is coupled to the outlet flange. The base portion extends adjacent to a portion of the mixer body and disposed between the inlet portion and the outlet portion in an axial direction. The base portion further defines a recess.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying Figures, wherein like reference numerals refer to like elements unless otherwise indicated, in which:

[0009] Figure 1 is block schematic diagram of a portion of an example aftertreatment system;

[0010] Figure 2 is a perspective view of a portion of an example aftertreatment system;|0011] Figure 3 is a cross-sectional view of the portion of the aftertreatment system shown in Figure 2 taken along plane A-A in Figure 2;[0012 J Figure 4 is a perspective partial-transparency view of a portion of the aftertreatment system of Figure 2;[00131 Figure 5 is an exploded view of a hydrocarbon mixer of the aftertreatment system of Figure 2;

[0014] Figure 6 is a perspective view of a hydrocarbon mixer of the aftertreatment system of Figure 2;

[0015] Figure 7 is an exploded view of the hydrocarbon mixer of Figure 6;

[0016] Figure 8 is a side view of the hydrocarbon mixer of Figure 6;

[0017] Figure 9 is a detailed view of DETAIL A in Figure 8;

[0018] Figure 10 is a detailed view of DETAIL B in Figure 8;

[0019] Figure 11 is a cross-sectional view of the portion of Figure 10 taken along plane B-B in Figure 10;

[0020] Figure 12 is a front view of a perforated plate of the hydrocarbon mixer of Figure 6;

[0021] Figure 13 is a front view of an annular plate of the hydrocarbon mixer of the aftertreatment system of Figure 6;|0022] Figure 14 is an end view of the hydrocarbon mixer of the aftertreatment system of Figure 2 from an upstream perspective;

[0023] Figure 15 is a perspective view of an outlet flange of the hydrocarbon mixer of the aftertreatment system of Figure 6;

[0024] Figure 16 is a cross-sectional view of the outlet flange of Figure 15 taken along plane C-C in Figure 15;

[0025] Figure 17 is a perspective view of a portion of an example aftertreatment system that includes a hydrocarbon mixer, an introduction conduit, and a coupler;

[0026] Figure 18 is an end view of the portion of the example aftertreatment system of Figure 17 from an upstream perspective;

[0027] Figure 19 is a cross-sectional view of the portion of the example aftertreatment system of Figure 17 taken along plane D-D in Figure 18;

[0028] Figure 20 is a cross-sectional view of the portion of the example aftertreatment system of Figure 17 taken along plane E-E in Figure 18;

[0029] Figure 21 is an end view of the portion of the example aftertreatment system of Figure 17 from a downstream perspective;|0030] Figure 22 is a side view of the portion of the example aftertreatment system of Figure 17;

[0031] Figure 23 is a perspective view of the introduction conduit of the portion of the example aftertreatment system of Figure 17;

[0032] Figure 24 is an end view of the introduction conduit of Figure 23 from an upstream perspective;[003 1 Figure 25 is a cross-sectional view of the introduction conduit of Figure 23 taken along plane F-F in Figure 24;

[0034] Figure 26 is a cross-sectional view of the introduction conduit of Figure 23 taken along plane G-G in Figure 24;

[0035] Figure 27 illustrates the introduction conduit of Figure 23 from view I in Figure 24;

[0036] Figure 28 is a cross-sectional view of the introduction conduit of Figure 23 taken along plane H-H in Figure 26;|0037] Figure 29 is a perspective view of the coupler of the portion of the aftertreatment system of Figure 17;

[0038] Figure 30 is a side view of the coupler of Figure 29;

[0039] Figure 31 is an end view of the coupler of Figure 29;

[0040] Figure 32 is a cross-sectional view of the coupler of Figure 29 taken along plane J-J of Figure 31;[0041 [ Figure 33 is a perspective view of a mixer body of the hydrocarbon mixer of the aftertreatment system of Figure 17;

[0042] Figure 34 is an end view of the mixer body of Figure 33 from an upstream perspective;|0043] Figure 35 is a side view of the mixer body of Figure 33;|0044] Figure 36 is a top view of an injector plate of the hydrocarbon mixer of the aftertreatment system of Figure 17;

[0045] Figure 37 is a detailed view of DETAIL C in Figure 36;10046] Figure 38 is a front view of a perforated plate of the hydrocarbon mixer of the aftertreatment system of Figure 17;

[0047] Figure 39 is a cross-sectional view of the perforated plate of Figure 38 taken along plane K-K in Figure 38;

[0048] Figure 40 is a front view of an annular plate of the hydrocarbon mixer of the aftertreatment system of Figure 17;

[0049] Figure 41 is a cross-sectional view of the annular plate of Figure 40 taken along plane L-L in Figure 40;

[0050] Figure 42 is a side view of the annular plate of Figure 40;

[0051] Figure 43 is a side view of an outlet flange of the hydrocarbon mixer of the aftertreatment system of Figure 17;

[0052] Figure 44 is an end view of the outlet flange of Figure 43 from a downstream perspective;

[0053] Figure 45 is an end view of the outlet flange of Figure 43 from an upstream perspective;[0054| Figure 46 is a cross-sectional view of the outlet flange of Figure 43 taken along plane N-N in Figure 45;

[0055] Figure 47 is a perspective view of a hydrocarbon mixer of the aftertreatment system of Figure 2;|0056] Figure 48 is a perspective view of an exhaust sampler of the hydrocarbon mixer of Figure 47;

[0057] Figure 49 is an end view of the exhaust sampler of Figure 48 from an upstream perspective;

[0058] Figure 50 is a cross-sectional view of the exhaust sampler of Figure 48 taken along plane 0-0 in Figure 48;[00591 Figure 51 is a top view of the exhaust sampler of Figure 48;

[0060] Figure 52 is an end view of the hydrocarbon mixer of Figure 47 from an upstream perspective;

[0061] Figure 53 is a cross-sectional view of DETAIL D of Figure 52 taken along plane P- P in Figure 52;

[0062] Figure 54 is a detailed view of DETAIL D in Figure 52;

[0063] Figure 55 is a side view of the hydrocarbon mixer of Figure 47;

[0064] Figure 56 is a cross-sectional view of the hydrocarbon mixer of Figure 47 taken along plane Q-Q in Figure 47;|0065] Figure 57 is a detailed view of DETAIL E in Figure 56;

[0066] Figure 58 is a cross-sectional view of an example aftertreatment system taken along a plane that bisects the example aftertreatment system; and

[0067] Figure 59 is a cross-sectional view of an example aftertreatment system taken along a plane that bisects the example aftertreatment system.

[0068] It will be recognized that 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 the Figures will not be used to limit the scope or the meaning of the claims.DETAILED DESCRIPTION[00691 Following below are more detailed descriptions of various concepts related to, and implementations of, methods, apparatuses, and for treating exhaust of an internal combustion engine with an aftertreatment system (or simply “aftertreatment system”). 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

[0070] In existing implementations, particles of a hydrocarbon fluid injected into a hydrocarbon mixer (or “mixer”) have been observed at low-flow conditions to travel upstream and impinging upon upstream components, such as selective catalytic reduction (SCR) catalyst members, of an aftertreatment system, inadvertently contaminating the catalyst members and shortening its lifespan.[0071 [ Accordingly, in one aspect of the present disclosure, embodiments of a hydrocarbon mixer are configured to limit (or, in some instances, prevent) impingement of particles upon the upstream catalyst members without substantially increasing backpressure within the hydrocarbon mixer. The hydrocarbon mixer provided herein may also be configured to improve swirling of the exhaust and the hydrocarbon fluid within the hydrocarbon mixer, resulting in enhanced mixing performance.

[0072] In some embodiments, an aftertreatment system described herein includes an introduction conduit and a mixer (e.g., a hydrocarbon mixer) disposed within the introduction conduit. The mixer includes a mixer body, an inlet cap, and an outlet flange. The mixer body iscentered on a mixer body center axis and configured to receive exhaust and a hydrocarbon fluid. The mixer body includes an inlet end, a plurality of connectors, and an outlet end downstream of the inlet end. The connectors are arranged along a circumference of the inlet end and extending away from the inlet end.[00731 The inlet cap is over the inlet end and includes a perforated plate, an inlet flange, and an annular plate. The perforated plate is coupled to the connectors and comprising a plurality of perforations arranged in a circular pattern. The inlet flange is coupled to the perforated plate. The annular plate is downstream of the perforated plate and coupled to the mixer body. The annular plate includes an annular plate aperture centered on the mixer body center axis. The outlet flange includes an outlet flange body coupled to the outlet end. The outlet flange body includes an inner edge and a flared portion extending from the inner edge into the mixer body, where the inner edge defines an outlet flange aperture offset from the mixer body center axis.

[0074] By adjusting design factors including, but not limited to, a total open area of the perforated plate and the annular plate, respectively, and a height of the flared portion of the outlet flange body, the hydrocarbon mixer described herein is configured to limit (or, in some instances, prevent) the particles of the hydrocarbon fluid from traveling upstream at low-flow conditions, while ensuring adequate swirling of the fluid and providing means of releasing the buildup of backpressure within the hydrocarbon mixer.

[0075] Furthermore, exhaust produced by an internal combustion engine may be provided to a sensor (e.g., a NOx sensor) positioned adjacent to a body of a hydrocarbon mixer in order to accommodate spatial constraints posed by certain system designs. In some instances, the sensor may be positioned near an aperture through which a hydrocarbon fluid is injected and / or an aperture through which the exhaust flows into a body of the hydrocarbon mixer.Consequently, it is desirable to provide a hydrocarbon mixer capable of reducing or preventing contamination of the exhaust by the hydrocarbon fluid during the sampling process while maintaining or improving proper functions of the hydrocarbon mixer within the body of the mixer.

[0076] Accordingly, in another aspect of the present disclosure, the aftertreatment system described herein further includes an exhaust sampler (or “sampler”) coupled to the hydrocarbon mixer. The exhaust sampler includes an inlet portion coupled to the inlet flange, an outlet portion coupled to the outlet flange, and a base portion disposed between the inlet portion and the outlet portion in an axial direction. The base portion extends adjacent to the mixer body and defines a recess, where the recess is configured to provide a sample of the exhaust to be measured by a sensor coupled to the introduction conduit. The exhaust sampler further includes a transitional portion extending between the inlet portion and the base portion. The inlet portion, the transitional portion, the base portion, and the outlet portion are flanked by two opposing sidewall portions along the axial direction.

[0077] By adjusting the configuration and various dimensions of the exhaust sampler, performance of the hydrocarbon mixer and the efficacy of the sampling process can both be improved. For example, flow distribution of the exhaust being sampled can be enhanced by adjusting the dimensions of various portions of the exhaust sampler, and cross-sensitivity of the sensor to particles of the hydrocarbon fluid can be mitigated by adjusting a height of each sidewall portion, which acts as a barrier against the particles. In various embodiments, the sampling process facilitated by the exhaust sampler provided herein does not substantially interfere with the performance of the hydrocarbon mixer with respect to factors including, for example, uniformity in flow distribution, uniformity in swirling, and backpressure provided by the hydrocarbon mixer.II. Overview of Example Aftertreatment Systems

[0078] Figure 1 depicts an aftertreatment system 100 (e.g., treatment system, etc.) for an internal combustion engine system 101. The internal combustion engine system 101 includes an internal combustion engine (e.g., diesel internal combustion engine, gasoline internal combustion engine, hybrid internal combustion engine, propane internal combustion engine, dual -fuel internal combustion engine, etc.). The internal combustion engine system 101 includes a turbocharger 102. The aftertreatment system 100 is configured to treat exhaust produced by the internal combustion engine. As is explained in more detail herein, theaftertreatment system 100 is configured to facilitate treatment of the exhaust. The treatment may facilitate reduction of emission of undesirable components (e.g., nitrogen oxides (NOx), sulfur oxides (SOx), etc.) in the exhaust. The treatment may also or instead facilitate conversion of various oxidation components (e.g., carbon monoxide (CO), hydrocarbons, etc.) of the exhaust into other components (e.g., CO2, water vapor, etc.). The treatment may additionally or alternatively facilitate removal of particulates (e.g., soot, particulate matter, etc.) from the exhaust.|0079] The aftertreatment system 100 includes an exhaust conduit system 104 (e.g., line system, pipe system, etc.). The exhaust conduit system 104 is configured to facilitate routing of the exhaust produced by the internal combustion engine throughout the aftertreatment system 100 and to atmosphere (e.g., ambient environment, etc.). The exhaust conduit system 104 is centered on a conduit axis 106 (e.g., the conduit axis 106 extends through a center point of the exhaust conduit system 104, etc.). As used herein, the term “axis” describes a theoretical line extending through the centroid (e g., center of mass, etc.) of an object. The object is not necessarily cylindrical (e.g., a non-cylindrical shape may be centered on an axis, etc.), as depicted herein.

[0080] The exhaust conduit system 104 includes an intake chamber 108 (e.g., line, pipe, etc.). The intake chamber 108 is configured to receive exhaust from the internal combustion engine. The intake chamber 108 may receive exhaust from a portion of the internal combustion engine (e.g., header on the internal combustion engine, exhaust manifold on the internal combustion engine, the internal combustion engine, etc.). In some embodiments, the intake chamber 108 is coupled (e.g., attached, fixed, welded, fastened, riveted, adhesively attached, bonded, pinned, press-fit, etc.) to the internal combustion engine. In other embodiments, the intake chamber 108 is integrally formed with the internal combustion engine. As utilized herein, two or more elements are “integrally formed” with each when the two or more elements are formed and joined together as part of a single manufacturing process to create a singlepiece or unitary construction that cannot be disassembled without an at least partial destruction of the overall component. The intake chamber 108 may be centered on the conduit axis 106 (e.g., the conduit axis 106 extends through a center point of the intake chamber 108, etc.). Insome embodiments, the intake chamber 108 may be offset from the conduit axis 106 (e.g., the conduit axis 106 extends adjacent to a center point of the intake chamber 108, etc.).|0081] In some embodiments, the exhaust conduit system 104 also includes an introduction conduit 109 (e.g., conduit, exhaust conduit, decomposition housing, decomposition reactor, decomposition chamber, reactor pipe, decomposition tube, reactor tube, etc.). The introduction conduit 109 is configured to receive exhaust from the intake chamber 108. In various embodiments, the introduction conduit 109 is coupled to the intake chamber 108. For example, the introduction conduit 109 may be fastened (e.g., using a band, using bolts, using twist-lock fasteners, threaded, etc.), welded, riveted, or otherwise attached to the intake chamber 108. In other embodiments, the introduction conduit 109 is integrally formed with the intake chamber 108. As utilized herein, the terms “fastened,” “fastening,” and the like, describe attachment (e.g., joining, etc.) of two structures in such a way that detachment (e.g., separation, etc.) of the two structures remains possible while “fastened” or after the “fastening” is completed, without destroying or damaging either or both of the two structures. The introduction conduit 109 is centered on the conduit axis 106 (e.g., the conduit axis 106 extends through a center point of the introduction conduit 109, etc.). In some embodiments, the introduction conduit 109 is formed by the coupling of the individual housings and chambers, as described herein.|<>082] The aftertreatment system 100 also includes a reductant fluid delivery system 110. As is explained in more detail herein, the reductant fluid delivery system 110 is configured to facilitate the introduction of a reductant fluid, such as a reductant (e.g., diesel exhaust fluid (DEF), AdblueK, a urea-water solution (UWS), an aqueous urea solution, AUS32, etc.) into the exhaust within the exhaust. When the reductant is introduced into the exhaust, reduction of emission of undesirable components in the exhaust using the aftertreatment system 100 may be facilitated. When the hydrocarbon fluid is introduced into the exhaust, the temperature of the exhaust may be increased (e.g., to facilitate regeneration of components of the aftertreatment system 100, etc.). For example, the temperature of the exhaust may be increased by combusting the hydrocarbon fluid within the exhaust (e.g., using a spark plug, etc.).

[0083] The reductant fluid delivery system 110 includes an intake chamber dosing module 112 (e.g., doser, reductant doser, etc.). The intake chamber dosing module 112 is configured to facilitate passage of the reductant fluid through the intake chamber 108 and into intake chamber 108. In some embodiments, the intake chamber dosing module 112 is positioned within a dosing module mount. The dosing module mount is configured to facilitate mounting of the intake chamber dosing module 112 to the intake chamber 108. The dosing module mount may provide insulation (e.g., thermal insulation, vibrational insulation, etc.) between the intake chamber dosing module 112 and the intake chamber 108. In some embodiments, the reductant fluid delivery system 110 does not include the intake chamber dosing module 112. In some embodiments the intake chamber dosing module 112 is a close coupled dosing module. That is, the intake chamber dosing module 112 is coupled to the introduction conduit 109 proximate an outlet of the internal combustion engine system 101 (e.g., proximate an outlet of the engine and / or proximate an outlet of the turbocharger 102). For example, the intake chamber dosing module 112 may be coupled to the introduction conduit 109 downstream from the internal combustion engine system 101 and / or the turbocharger 102.

[0084] The reductant fluid delivery system 110 also includes a reductant fluid source 114 (e.g., reductant tank, etc.). The reductant fluid source 114 is configured to contain the reductant fluid. The reductant fluid source 114 is configured to provide the reductant fluid to the intake chamber dosing module 112. The reductant fluid source 114 may include multiple reductant fluid sources 114 (e.g., multiple tanks connected in series or in parallel, etc.). The reductant fluid source 114 may include, for example, a diesel exhaust fluid tank containing Adblue®.

[0085] The reductant fluid delivery system 110 also includes a reductant fluid pump 116 (e.g., supply unit, etc.). The reductant fluid pump 116 is configured to receive the reductant fluid from the reductant fluid source 114 and to provide the reductant fluid to the intake chamber dosing module 112. The reductant fluid pump 116 is used to pressurize the reductant fluid from the reductant fluid source 114 for delivery to the intake chamber dosing module 112. In some embodiments, the reductant fluid pump 116 is pressure-controlled. In some embodiments, the reductant fluid pump 116 is coupled to a chassis of a vehicle associated with the aftertreatment system 100.

[0086] In some embodiments, the reductant fluid delivery system 110 also includes a reductant fluid filter 118. The reductant fluid filter 118 is configured to receive the reductant fluid from the reductant fluid source 114 and to provide the reductant fluid to the reductant fluid pump 116. The reductant fluid filter 118 filters the reductant fluid prior to the reductant fluid being provided to internal components of the reductant fluid pump 116. For example, the reductant fluid filter 118 may inhibit or reduce the transmission of solids to the internal components of the reductant fluid pump 116. In this way, the reductant fluid filter 118 may facilitate and / or prolong desirable operation of the reductant fluid pump 116.

[0087] The intake chamber dosing module 112 includes at least one intake chamber dosing module injector 120 (e.g., insertion device, etc.). The intake chamber dosing module injector 120 configured to receive the reductant fluid from the reductant fluid pump 116. The intake chamber dosing module injector 120 is configured to dose (e.g., provide, inject, insert, etc.) the reductant fluid received by the intake chamber dosing module 112 into the exhaust within the intake chamber 108.[0088[ In some embodiments, the reductant fluid delivery system 110 also includes an air pump 122 and an air source 124 (e.g., air intake, etc.). The air pump 122 is configured to receive air from the air source 124. The air pump 122 is configured to provide the air to the intake chamber dosing module 112. In some applications, the intake chamber dosing module 112 is configured to mix the air and the reductant fluid into an air-reductant fluid mixture and to provide the air-reductant fluid mixture to the intake chamber dosing module injector 120 (e.g., for dosing into the exhaust within the intake chamber 108, etc.). As used herein, it is understood that a reductant fluid may include an air-reductant fluid mixture.|0089] The intake chamber dosing module injector 120 is configured to receive the air from the air pump 122. The intake chamber dosing module injector 120 is configured to dose the air into the exhaust within the intake chamber 108. In some embodiments, the reductant fluid delivery system 110 also includes an air filter 126. The air filter 126 is configured to receive the air from the air source 124 and to provide the air to the air pump 122. The air filter 126 is configured to filter the air prior to the air being provided to the air pump 122. In someembodiments, the reductant fluid delivery system 110 does not include the air pump 122, the air source 124, or both. In such embodiments, the intake chamber dosing module 112 is not configured to mix the reductant fluid with the air.

[0090] In some embodiments, the intake chamber dosing module 112 is configured to receive the air and the reductant fluid, and doses both the air and the reductant fluid into the intake chamber 108. In some embodiments, the intake chamber dosing module 112 is configured to receive the reductant fluid (and does not receive air), and doses the reductant fluid into the intake chamber 108.|009.1] The aftertreatment system 100 also includes an aftertreatment system controller 128 (e.g., control circuit, driver, etc.). The intake chamber dosing module 112, the reductant fluid pump 116, and the air pump 122 are also electrically or communicatively coupled to the aftertreatment system controller 128. The aftertreatment system controller 128 is configured to control the intake chamber dosing module 1 12 to dose the reductant fluid into the intake chamber 108. The aftertreatment system controller 128 may also be configured to control the reductant fluid pump 116 and / or the air pump 122 in order to control the reductant fluid that is dosed into the intake chamber 108.[O092| The aftertreatment system controller 128 includes an aftertreatment system processing circuit 130. The aftertreatment system processing circuit 130 includes an aftertreatment system processor 132 and an aftertreatment system memory 134. The aftertreatment system processor 132 may include a microprocessor, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), etc., or combinations thereof. The aftertreatment system 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. The aftertreatment system 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 aftertreatment system controller 128 can read instructions. The instructions may include code from any suitable programming language. The aftertreatmentsystem memory 134 may include various modules that include instructions that are configured to be implemented by the aftertreatment system processor 132.

[0093] In various embodiments, the aftertreatment system controller 128 is configured to communicate with a central controller 136 (e.g., engine control unit (ECU), engine control module (ECM), etc.) to control the turbocharger 102. The turbocharger 102 includes a compressor wheel coupled to an exhaust turbine wheel via a connector shaft, where hot exhaust spins the turbine wheel, thereby rotating the shaft and the compressor wheel to draw air in. By compressing the air, the turbocharger 102 allows for more air to enter the cylinders (or combustion chamber) to burn more fuel and increase power and efficiency. The turbocharger 102 may include a heat exchanger to cool the compressed air before the air enters the cylinders.[0094| 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 and an alarm state based on a communication from the central controller 136. By changing the state, the display device may provide an indication to a user of a status of the reductant fluid delivery system 110.[0095[ The aftertreatment system 100 includes an upstream catalyst member 138 (e.g., selective catalytic reduction (SCR) catalyst member, conversion catalyst member, catalytic metals, etc.). The upstream catalyst member 138 is positioned downstream of the intake chamber 108. The upstream catalyst member 138 is configured to cause decomposition of components of the exhaust using the reductant fluid (e.g., via catalytic reactions, etc.). The upstream catalyst member 138 includes an upstream catalyst housing 140. The upstream catalyst housing 140 may be coupled to the intake chamber 108. In some embodiments, the upstream catalyst housing 140 is integrally formed with the intake chamber 108. The upstream catalyst member 138 includes an upstream catalyst substrate 142. The upstream catalyst substrate 142 is coupled to the upstream catalyst housing 140. In some embodiments, the upstream catalyst substrate 142 is integrally formed with the upstream catalyst housing 140. Insome embodiments, the upstream catalyst substrate 142 includes a vanadium catalyst member such that the upstream catalyst member 138 may alternatively be referred to as a vanadium selective catalytic reduction (VSCR) catalyst member.

[0096] The upstream catalyst member 138 receives the exhaust from the intake chamber 108. The exhaust flows through the upstream catalyst substrate 142 and reacts with the upstream catalyst substrate 142 so as to cause the exhaust to undergo the processes of evaporation, thermolysis, and / or hydrolysis to form non-NOx emissions within the introduction conduit 109 and / or the upstream catalyst member 138. In some embodiments, the exhaust and the reductant fluid within the exhaust react with the upstream catalyst substrate 142. In this regard, the upstream catalyst member 138 is configured to assist the reduction of NOx emissions by accelerating a NOx reduction process between the reductant and the NOx of the exhaust into diatomic nitrogen, water, and / or carbon dioxide. The upstream catalyst substrate 142 may include vanadia. Vanadia may be used due to its lengthy deactivation time and the ability to react with the exhaust at high temperatures. In some embodiments, vanadia is used for emitting lower N2O emissions into the environment when exhaust temperatures are below about 420°C.

[0097] In some embodiments, referring to Figures 2 and 3, the aftertreatment system 100 includes more than one upstream catalyst members positioned downstream of the intake chamber 108. For example, the aftertreatment system 100 may include two upstream catalyst members 138. In some embodiments, the upstream catalyst members 138 may be considered “light-off’ (LO) upstream catalyst members (e.g., LOSCR1 and LOSCR2, respectively) located immediately downstream of the internal combustion engine system 101. In some instances, the light-off upstream catalyst member(s) 138 may be heated up by the exhaust quickly to attain a desirable temperature suitable for treating the exhaust by the upstream catalyst substrate 142. For example, the desirable temperature (e.g., a light-off temperature) may be a temperature at which catalytic reactions between the exhaust and the upstream catalyst substrate 142 are initiated. As will be discussed in detail herein, it may be desirable to obtain measurement of an amount of NOx emission in the exhaust downstream of the LO upstream catalyst member(s) 138.

[0098] The aftertreatment system 100 may optionally include an upstream ammonia slip catalyst (ASC) substrate (not depicted). The upstream ammonia slip catalyst substrate is positioned downstream of the upstream catalyst member 138. In some embodiments, the upstream ammonia slip catalyst substrate is a coating applied to a portion of the outlet of the upstream catalyst member 138. The upstream ammonia slip catalyst substrate is configured to receive the exhaust from the upstream catalyst member 138 and assist in the reduction of the byproducts (e.g., ammonia, etc.) of the processes of the intake chamber dosing module 112 and the upstream catalyst member 138. Specifically, the intake chamber dosing module 112 may introduce ammonia into the exhaust, though a portion of the ammonia introduced may not react with the exhaust. As a result, excess ammonia may slip from the upstream catalyst member 138 into the exhaust downstream of the upstream catalyst member 138. The upstream ammonia slip catalyst substrate functions to reduce the ammonia such that the exhaust downstream of the upstream ammonia slip catalyst substrate does not contain an undesirable amount of ammonia. In some embodiments, the aftertreatment system 100 does not include the upstream ammonia slip catalyst substrate.

[0099] The aftertreatment system 100 also includes a hydrocarbon mixer 146 (e.g., hydrocarbon decomposition chamber, hydrocarbon mixing chamber mixer, etc.). The hydrocarbon decomposition chamber is positioned downstream of the upstream catalyst member 138 (and downstream of the upstream ammonia slip catalyst substrate, if present). The hydrocarbon mixer 146 is configured to receive exhaust via the introduction conduit 109. In some embodiments, the hydrocarbon mixer 146 is coupled to the upstream catalyst housing 140. In some embodiments, the hydrocarbon mixer 146 is integrally formed with the upstream catalyst housing 140. In still other embodiments, the hydrocarbon mixer 146 is coupled to the intake chamber 108. The hydrocarbon mixer 146 is configured to receive the exhaust from the upstream catalyst member 138.

[0100] The hydrocarbon mixer 146 is configured to mix the hydrocarbon fluid with the exhaust. The hydrocarbon mixer 146 is also configured to facilitate swirling (e.g., rotation, etc.) of the exhaust and mixing (e.g., combination, etc.) of the exhaust and the hydrocarbon fluid so as to disperse the hydrocarbon fluid within the exhaust downstream of the mixer (e.g., toincrease the ability of the hydrocarbon fluid to heat the gas, etc.). By dispersing the hydrocarbon fluid within the exhaust using the hydrocarbon mixer 146, reduction of emission of undesirable components in the exhaust is enhanced and / or an ability of the aftertreatment system 100 to increase a temperature of the exhaust may be enhanced.[01011 The aftertreatment system 100 includes a hydrocarbon fluid system 147. The hydrocarbon fluid system 147 includes a hydrocarbon dosing module 148. The hydrocarbon dosing module 148 doses the exhaust within the hydrocarbon mixer 146 with a hydrocarbon fluid. The hydrocarbon dosing module 148 is configured to facilitate passage of hydrocarbon fluid into the hydrocarbon mixer 146. The hydrocarbon dosing module 148 includes at least one hydrocarbon injector 150 (e.g., dozer, insertion device, etc.). The hydrocarbon injector 150 is configured to dose the hydrocarbon fluid into the exhaust within the hydrocarbon mixer 146.

[0102] The hydrocarbons within the hydrocarbon mixer 146 may be configured to increase the temperature of the exhaust within the hydrocarbon mixer 146. Specifically, the aftertreatment system 100 includes an igniter 151 (e.g., spark plug, etc.,) coupled to the hydrocarbon mixer 146. The igniter 151 is electrically connected to the aftertreatment system controller 128 and is configured to combust the hydrocarbon fluid in the exhaust within the hydrocarbon mixer 146, causing an increase in temperature of the exhaust. Consequently, regeneration of downstream components may occur. For example, regeneration occurs when the hydrocarbon fluid in the exhaust combust and increase the temperature of the exhaust such that the exhaust burns any soot or particles which may be affixed to the downstream components. By burning the affixed soot or particles, the downstream components may be cleaned off such that they are like new and operate as such.|0103] The hydrocarbon fluid system 147 further includes a hydrocarbon source 152 (e.g., hydrocarbon tank, etc.). The hydrocarbon source 152 is configured to contain the hydrocarbon fluid. The hydrocarbon source 152 is configured to provide the hydrocarbon fluid to the hydrocarbon dosing module 148. The hydrocarbon source 152 may include multiple hydrocarbon sources 152 (e.g., multiple tanks connected in series or in parallel, etc.). The hydrocarbon fluid system 147 also includes a hydrocarbon fluid pump 154. Specifically, thehydrocarbon fluid pump 154 is configured to provide hydrocarbon fluid to the hydrocarbon injector 150. The hydrocarbon injector 150 receives hydrocarbon fluid from the hydrocarbon fluid pump 154 and is configured to dose the hydrocarbon fluid received by the hydrocarbon dosing module 148 into the exhaust within the hydrocarbon mixer 146. The hydrocarbon fluid pump 154 is used to pressurize the hydrocarbon fluid received from the hydrocarbon source 152 for delivery to the hydrocarbon dosing module 148 and the hydrocarbon injector 150. In some embodiments, the hydrocarbon fluid pump 154 is pressure controlled. In some embodiments, the hydrocarbon fluid pump 154 is coupled to a chassis of a vehicle associated with the aftertreatment system.[0104I In some embodiments, the hydrocarbon fluid system 147 includes a hydrocarbon filter 156 (e.g., fuel filter, lubricant filter, oil filter, etc.). The hydrocarbon filter 156 is configured to receive the hydrocarbon fluid from the hydrocarbon source 152 and to provide the hydrocarbon fluid to the hydrocarbon fluid pump 154. The hydrocarbon filter 156 filters the hydrocarbon fluid prior to the hydrocarbons being provided to internal components of the hydrocarbon fluid pump 154. For example, the hydrocarbon filter 156 may inhibit or reduce the transmission of solids to the internal components of the hydrocarbon fluid pump 154. In this way, the hydrocarbon filter 156 may facilitate prolonged desirable operation of the hydrocarbon fluid pump 154.

[0105] In some embodiments, the air pump 122 is also configured to provide the air to the hydrocarbon dosing module 148. The hydrocarbon dosing module 148 is configured to provide the air into the hydrocarbon mixer 146. In some applications, the hydrocarbon dosing module 148 is configured to mix the air and the hydrocarbon fluid into an air-hydrocarbon fluid mixture and to provide the air-hydrocarbon fluid mixture to the hydrocarbon injector 150 (e.g., for dosing into the exhaust within the hydrocarbon mixer 146, etc.).

[0106] In various embodiments, the hydrocarbon dosing module 148 is configured to receive air and hydrocarbon fluid, and doses the mixture of air and hydrocarbon fluid into the hydrocarbon mixer 146. In various embodiments, the hydrocarbon dosing module 148 isconfigured to receive hydrocarbons, and doses the hydrocarbon into the hydrocarbon mixer 146.|0107] In some embodiments, the hydrocarbon dosing module 148 and the hydrocarbon fluid pump 154 are also electrically or communicatively coupled to the aftertreatment system controller 128. The aftertreatment system controller 128 is further configured to control the hydrocarbon dosing module 148 to dose the hydrocarbon fluid into the hydrocarbon mixer 146. The aftertreatment system controller 128 may also be configured to control the hydrocarbon fluid pump 154 and / or the air pump 122 in order to control the hydrocarbon fluid that is dosed into the hydrocarbon mixer 146.

[0108] The aftertreatment system 100 includes a first oxidation catalyst member 158 (e.g., first diesel oxidation catalyst (DOC), etc.). The first oxidation catalyst member 158 is positioned downstream of the hydrocarbon mixer 146 (e.g., the hydrocarbon mixer 146 is positioned upstream of the first oxidation catalyst member 158). As a result, the hydrocarbon mixer 146 is located downstream of the upstream catalyst member 138 and upstream of the first oxidation catalyst member 158.[0109[ The first oxidation catalyst member 158 includes a first oxidation catalyst housing 160. The first oxidation catalyst housing 160 is coupled to hydrocarbon mixer 146. The first oxidation catalyst housing 160 may also be integrally formed with the hydrocarbon mixer 146.

[0110] The first oxidation catalyst member 158 also includes a first oxidation catalyst substrate 162. The first oxidation catalyst substrate 162 is positioned within the first oxidation catalyst housing 160. The first oxidation catalyst substrate 162 may be coupled to the first oxidation catalyst housing 160. The exhaust including hydrocarbon fluid reacts with the first oxidation catalyst substrate 162 and causes the conversion of the hydrocarbon fluid in the exhaust. For example, as the exhaust flows through the first oxidation catalyst substrate 162, the hydrocarbons react with the first oxidation catalyst substrate 162 and begin to oxidize. The first oxidation catalyst substrate 162 facilitates conversion of the carbon monoxide, the hydrocarbon fluid, and / or the air-hydrocarbon fluid mixture in the exhaust into carbon dioxide.

[0111] The aftertreatment system 100 also includes an upstream particulate filter assembly 164. The upstream particulate filter assembly 164 includes an upstream particulate filter housing 166. The upstream particulate filter housing 166 is positioned downstream of the first oxidation catalyst housing 160. In some embodiments, the upstream particulate filter housing 166 is integrally formed with the first oxidation catalyst housing 160. The upstream particulate filter assembly 164 includes an upstream particulate filter 168 (e.g., diesel particulate filter (DPF), filtration member, etc.). The upstream particulate filter 168 is disposed within the upstream particulate filter housing 166 such that the upstream particulate filter 168 is positioned downstream of the first oxidation catalyst member 158 (e.g., the first oxidation catalyst member 158 is positioned upstream of the upstream particulate filter 168). In some embodiments, the upstream particulate filter housing 166 and the upstream particulate filter 168 are positioned downstream of the intake chamber 108.

[0112] The upstream particulate filter 168 is configured to remove first particulates (e g., soot, solidified particles of hydrocarbon fluid, ash, etc.,) from the exhaust. For example, the upstream particulate filter 168 may receive exhaust (e.g., from the first oxidation catalyst member 158, from the intake chamber 108, etc.) having a first concentration of the first particulates and may provide the exhaust downstream having a second concentration of the first particulates, where the second concentration is lower than the first concentration. In this way, the upstream particulate filter 168 may facilitate reduction of a particulate number (PN) of the exhaust. Decreasing the PN of the exhaust may be desirable in a variety of applications. For example, emissions regulations may prescribe a maximum PN for exhaust emitted to atmosphere and the upstream particulate filter 168 may ensure that the PN of the exhaust emitted to atmosphere by the aftertreatment system 100 is below the maximum PN.

[0113] In some embodiments, the upstream particulate filter 168 is a catalyzed DPF. The catalyzed DPF is a filter that has a catalyst coating. The catalyst coating is configured to react with a component of the exhaust to reduce undesirable components in the exhaust. For example, the catalyst coating could be an oxidation catalyst to reduce member fluid within the exhaust. In some embodiments, the catalyst coating is a SCR catalyst configured to reduce NOx emissions. In some embodiments, the aftertreatment system 100 includes a pressure sensor 169.The pressure sensor 169 is configured to provide a signal to the aftertreatment system controller 128. The aftertreatment system controller 128 is configured to determine a pressure difference between an inlet of the upstream particulate filter assembly 164 and an outlet of the upstream particulate filter assembly 164 based on the signal from the pressure sensor 169. The pressure difference may be indicative of the reduction of the PN of the exhaust.[0114| The aftertreatment system 100 also includes a mixer 170 (e.g., swirl generating device, etc.). The mixer 170 is positioned downstream of the upstream particulate filter assembly 164 (e.g., the mixer 170 is positioned downstream of the upstream particulate filter 168) and configured to receive exhaust from the upstream particulate filter assembly 164. The mixer 170 may be coupled to the upstream particulate filter housing 166. In some embodiments, the mixer 170 is integrally formed with the upstream particulate filter housing 166. In some embodiments, the mixer 170 is positioned upstream of the first oxidation catalyst member 158.|0115) The reductant fluid delivery system 110 includes a dosing module 172. The dosing module 172 is configured to facilitate passage of the reductant fluid into the mixer 170 and through the mixer 170. In some embodiments, the dosing module 172 is positioned within a dosing module mount. The dosing module mount is configured to facilitate mounting of the dosing module 172 to the mixer 170. The dosing module mount may provide insulation (e.g., thermal insulation, vibrational insulation, etc.) between the dosing module 172 and the decomposition chamber.[0116| The dosing module 172 includes at least one injector 174 (e.g., insertion device, etc.). The injector 174 is configured to receive the reductant fluid from the reductant fluid pump 116. The injector 174 is configured to dose the reductant fluid received by the dosing module 172 into the exhaust within the mixer 170. In some embodiments, the injector 174 is centered on an injection axis 175. The injection axis 175 intersects with and is orthogonal to the conduit axis 106. In some embodiments, the injection axis 175 intersects with the conduit axis 106 and extends at an angle away from the conduit axis 106.

[0117] In some embodiments, the dosing module 172 is configured to receive air from the air pump 122. In some applications, the dosing module 172 is configured to mix the air and the reductant fluid into an air-reductant fluid mixture and to provide the air-reductant fluid mixture to the injector 174 (e.g., for dosing into the exhaust within the mixer 170, etc.). Specifically, the injector 174 is configured to receive the air from the air pump 122. The intake chamber dosing module injector 120 is configured to dose the air into the exhaust within the mixer 170.

[0118] In various embodiments, the dosing module 172 is configured to receive air and reductant fluid, and doses the mixture of air and reductant fluid into the mixer 1 0. In various embodiments, the dosing module 172 is configured to receive reductant fluid (and does not receive air), and doses the reductant fluid into the mixer 170. In various embodiments, the dosing module 172 is configured to receive reductant fluid, and doses the reductant fluid into the mixer 170.

[0119] In some embodiments, the aftertreatment system 100 includes a second oxidation catalyst member (e.g., second diesel oxidation catalyst (DOC), etc.). The second oxidation catalyst is positioned downstream of the mixer 170. The second oxidation catalyst is substantially similar to the first oxidation catalyst and therefore is not described in further detail.

[0120] The aftertreatment system 100 includes a first downstream catalyst member 176 (e.g., conversion catalyst member, SCR catalyst member, catalytic metals, etc.). The first downstream catalyst member 176 is positioned downstream of the mixer 170. In some embodiments, the first downstream catalyst member 176 is downstream of the second oxidation catalyst. The first downstream catalyst member 176 is configured to cause decomposition of components of the exhaust using the reductant fluid (e.g., via catalytic reactions, etc.). The first downstream catalyst member 176 includes a first downstream catalyst housing 178 and a first downstream catalyst substrate 180. The first downstream catalyst housing 178 may be coupled to the mixer 170. In some embodiments, the first downstream catalyst housing 178 is integrally formed with the mixer 170. The first downstream catalyst substrate 180 is coupled to the firstdownstream catalyst housing 178. In some embodiments, the first downstream catalyst substrate 180 is integrally formed with the first downstream catalyst housing 178.|0121] The first downstream catalyst member 176 receives the exhaust from the mixer 170. The exhaust flows through the first downstream catalyst substrate 180 and reacts with the first downstream catalyst substrate 180 so as to cause the exhaust to undergo the processes of evaporation, thermolysis, and / or hydrolysis to form non-NOx emissions within the introduction conduit 109 and / or the first downstream catalyst member 176. In some embodiments, the exhaust and the reductant fluid within the exhaust react with the first downstream catalyst substrate 180. In this way the first downstream catalyst member 176 is configured to assist the reduction of NOx emissions by accelerating a NOx reduction process between the reductant and the NOx of the exhaust into diatomic nitrogen, water, and / or carbon dioxide and also configured to assist in the reduction of particulates from the exhaust. The first downstream catalyst member 176 may include iron zeolite. The first downstream catalyst member 176 may include copper zeolite. In some embodiments, the aftertreatment system 100 does not include a first downstream catalyst member 176.

[0122] The aftertreatment system 100 also includes a second downstream catalyst member 182 (e.g., conversion catalyst member, SCR catalyst member, catalytic metals, etc.). The second downstream catalyst member 182 is positioned downstream of the mixer 170. The second downstream catalyst member 182 is configured to cause decomposition of components of the exhaust using the reductant fluid (e.g., via catalytic reactions, etc.). The second downstream catalyst member 182 includes a second downstream catalyst housing 184. In some embodiments, the second downstream catalyst housing 184 is integrally formed with the first downstream catalyst housing 178. In some embodiments, the second downstream catalyst housing 184 is the first downstream catalyst housing 178. The second downstream catalyst member 182 includes a second downstream catalyst substrate 186. The second downstream catalyst substrate 186 is coupled to the second downstream catalyst housing 184. In some embodiments, the second downstream catalyst substrate 186 is integrally formed with the second downstream catalyst housing 184.

[0123] The second downstream catalyst member 182 receives the exhaust from the first downstream catalyst member 176. The exhaust flows through the second downstream catalyst substrate 186 and reacts with the second downstream catalyst substrate 186 so as to cause the exhaust to undergo the processes of evaporation, thermolysis, and / or hydrolysis to form non- NOx emissions within the introduction conduit 109 and / or the second downstream catalyst member 182. In some embodiments, the exhaust and the reductant fluid within the exhaust react with the second downstream catalyst substrate 186. In this way, the second downstream catalyst member 182 is configured to assist the reduction of NOx emissions by accelerating a NOXreduction process between the reductant and the NOx of the exhaust into diatomic nitrogen, water, and / or carbon dioxide, and also configured to assist in the reduction of particulates from the exhaust. The second downstream catalyst member 182 may include iron zeolite. The second downstream catalyst member 182 may include copper zeolite. In some embodiments, the aftertreatment system 100 does not include a second downstream catalyst member 182.

[0124] The aftertreatment system 100 includes a downstream ammonia slip catalyst substrate 188. The downstream ammonia slip catalyst substrate 188 is positioned downstream of the second downstream catalyst member 182. In some embodiments, the downstream ammonia slip catalyst substrate 188 is a coating applied to a portion of the outlet of the first downstream catalyst member 176. The downstream ammonia slip catalyst substrate 188 may be a coating applied to a portion of the outlet of the second downstream catalyst member 182. The downstream ammonia slip catalyst substrate 188 is configured to receive the exhaust from the second downstream catalyst member 182 and assist in the reduction of the byproducts (e.g., ammonia, etc.) of the processes of the dosing module 172 and the second downstream catalyst member 182. In some embodiments, the downstream ammonia slip catalyst substrate 188 is positioned downstream of the first downstream catalyst member 176 and is configured to receive the exhaust from the first downstream catalyst member 176 and assist in the reduction of the byproducts (e.g., ammonia, etc.) of the processes of the dosing module 172 and the first downstream catalyst member 176. Specifically, the dosing module 172 may introduce ammonia into the exhaust, however a portion of the ammonia introduced may not react with the exhaust.NS, a result, excess ammonia may slip from the first downstream catalyst member 176 and / or the second downstream catalyst member 182 into the exhaust downstream of the first downstream catalyst member 176 and / or the second downstream catalyst member 182 such that the exhaust downstream of the downstream ammonia slip catalyst substrate 188 does not contain an undesirable amount of ammonia. In some embodiments, the aftertreatment system 100 does not include the downstream ammonia slip catalyst substrate 188.

[0125] The aftertreatment system 100 also includes an outlet chamber 189. The outlet chamber 189 is positioned downstream of the downstream ammonia slip catalyst substrate 188 and is configured to receive the exhaust from downstream ammonia slip catalyst substrate 188. In various embodiments, the outlet chamber 189 is coupled to the downstream ammonia slip catalyst substrate 188. For example, the outlet chamber 189 may be fastened, welded, riveted, or otherwise attached to the downstream ammonia slip catalyst substrate 188. In some embodiments, the outlet chamber 189 is coupled to the introduction conduit 109. In some embodiments, the outlet chamber 189 is the introduction conduit 109 (e g., only the introduction conduit is included in the exhaust conduit system 104 and the introduction conduit 109 functions as both the introduction conduit 109 and the outlet chamber 189). The outlet chamber 189 is centered on the conduit axis 106 (e.g., the conduit axis 106 extends through a center point of the outlet chamber 189, etc ).

[0126] In various embodiments, the exhaust conduit system 104 only includes a single conduit that functions as the intake chamber 108, the introduction conduit 109, and the outlet chamber 189.

[0127] In some embodiments, referring to Figures 2 and 3, the aftertreatment system 100 includes an elbow conduit 111 positioned downstream of the upstream particulate fdter assembly 164 (and the mixer 170) and is contiguous with the introduction conduit 109. The elbow conduit I l l is configured to receive exhaust from the upstream particulate filter assembly 164 in a first direction and facilitate a change of direction of the exhaust. For example, the elbow conduit 111 receives the exhaust in a first direction and causes the exhaust to change from a first direction to a second direction that is parallel to and opposite of the first-TIdirection. The exhaust may then flow to the first downstream catalyst member 176, which is positioned downstream of the elbow conduit 111 and parallel to the upstream catalyst members 138 and the hydrocarbon mixer 146, for example. A portion 100-1 in Figure 3, which depicts a cross-sectional view of the aftertreatment system 100 along the plane A- A, illustrates a portion of the introduction conduit 109 upstream of the elbow conduit 111, and a portion 100-2 illustrates a portion of the introduction conduit 109 downstream of the elbow conduit 111. The elbow conduit 111 may provide certain benefits. For example, the total length of the aftertreatment system 100 is reduced and total space necessary for the aftertreatment system 100 is reduced.[0128| In various embodiments, the aftertreatment system 100 includes a sensor 191 (e.g., NOXsensor, CO sensor, CO2 sensor, O2 sensor, temperature sensor, particulate sensor, nitrogen sensor, etc.). The sensor 191 is positioned upstream of the downstream ammonia slip catalyst substrate 188. In some embodiments, the sensor 191 is coupled to the intake chamber 108. The sensor 191 is configured to measure (e.g., sense, detect, etc.) a signal associated with a parameter (e.g., NOXconcentration, CO concentration, CO2 concentration, O2 concentration, temperature, particulate concentration, nitrogen concentration, SOx etc.) of the exhaust and the reductant fluid upstream of the upstream particulate filter 168. The sensor 191 may be configured to measure a signal associated with the parameter of the exhaust within the intake chamber 108. In some embodiments, the parameter is a temperature of the exhaust upstream of the downstream ammonia slip catalyst substrate 188, and the sensor 191 may be referred to as an exhaust gas temperature sensor (EGTS). In some embodiments, the parameter is the particulate concentration in the exhaust upstream of the downstream ammonia slip catalyst substrate 188. In some embodiments, the parameter is the SOXconcentration of the exhaust upstream of the downstream ammonia slip catalyst substrate 188. In some embodiments, the sensor 191 measures signals associated with the one or more of the temperature, the particulate concentration, and the SOx concentration of the exhaust upstream of the downstream ammonia slip catalyst substrate 188.

[0129] In some embodiments, the aftertreatment system 100 includes sensors 192, 193, 194, 195, 196, and 197, which are each similar to the sensor 191 in function and means ofoperation. For example, the sensors 192, 193, 194, 195, 196, and 197 may each be configured as a NOx sensor, a CO sensor, a CO2 sensor, an O2 sensor, a temperature sensor, a particulate sensor, a nitrogen sensor, or the like. The sensors 192, 193, 194, 195, 196, and 197 may be coupled to the introduction conduit 109 and / or the outlet chamber 189 at various positions, such that they may each be configured to measure (e.g., sense, detect, etc.) a signal associated with a parameter (e.g., NOx concentration, CO concentration, CO2 concentration, O2 concentration, temperature, particulate concentration, nitrogen concentration, sulfur oxide concentration (SOx), etc.) of the exhaust and / or the reductant fluid. In some embodiments, the sensors 192, 193, 194, 195, and 196 are configured to measure a signal associated with a parameter of the exhaust upstream of the downstream ammonia slip catalyst substrate 188, and the sensor 197 is configured to measure a signal associated with a parameter of the exhaust downstream of the downstream ammonia slip catalyst substrate 188.

[0130] For example, the sensor 192 may be configured to measure a signal associated with a temperature of the exhaust downstream of the upstream ammonia slip catalyst substrate; the sensor 193 may be configured to measure a signal associated with the temperature of the exhaust downstream of the hydrocarbon mixer 146; the sensor 194 may be configured to measure a signal associated with the temperature of the exhaust downstream of the first oxidation catalyst member 158; the sensor 195 may be configured to measure a signal associated with the temperature of the exhaust downstream of the upstream particulate filter assembly 164; the sensor 196 may be configured to measure a signal associated with the temperature of the exhaust downstream of the mixer 170; and the sensor 197 may be configured to measure a signal associated with the temperature of the exhaust downstream of the downstream ammonia slip catalyst substrate 188. In this regard, the sensors 192, 193, 194, 195, 196, and 197 may be referred to as exhaust temperature sensors, or EGTSs.[0131 [ In some embodiments, the aftertreatment system 100 includes one or more of the sensors 192, 193, 194, 195, 196, and 197. In some embodiments, one or more of the sensors 192, 193, 194, 195, 196, and 197 may be omitted from the aftertreatment system 100. In some embodiments, the aftertreatment system 100 includes additional sensors similar to one or more of the sensors 192, 193, 194, 195, 196, and 197. In this way, the aftertreatment system 100 maybe tailored to utilize temperature of the exhaust at various locations within the aftertreatment system in order to facilitate optimal control of, for example, injection of the hydrocarbon fluid (e.g., by adjusting operation of the hydrocarbon fluid pump 154, etc ).

[0132] In various embodiments, the aftertreatment system 100 also includes a sensor 198 (e.g., NOx sensor, CO sensor, CO2 sensor, O2 sensor, particulate sensor, nitrogen sensor, etc.). The sensor 198 is positioned downstream of the downstream ammonia slip catalyst substrate188. In some embodiments, the sensor 198 is coupled to the outlet chamber 189. The sensor198 is configured to measure (e.g., sense, detect, etc.) a signal associated with a parameter (e.g., NOx concentration, CO concentration, CO2 concentration, O2 concentration, particulate concentration, nitrogen concentration, sulfur oxide concentration (SOx), etc.) of the exhaust and the reductant fluid downstream of the downstream ammonia slip catalyst substrate 188. The sensor 198 may be configured to measure the signal associated with a parameter within the outlet chamber 189. In some embodiments, the parameter is the particulate concentration in the exhaust downstream of the downstream ammonia slip catalyst substrate 188. In some embodiments, the parameter is the SOx concentration of the exhaust within the outlet chamber189. In some embodiments, the sensor 198 measures signals associated with both the particulate concentration and the SOx concentration.|<>133] In various embodiments, the aftertreatment system 100 also includes a sensor 199 (e.g., NOx sensor, CO sensor, CO2 sensor, O2 sensor, particulate sensor, nitrogen sensor, etc.). The sensor 199 is positioned downstream of the downstream ammonia slip catalyst substrate 188. In some embodiments, the sensor 199 is coupled to the outlet chamber 189. The sensor199 is configured to measure (e.g., sense, detect, etc.) a signal associated with a parameter (e.g., NOx concentration, CO concentration, CO2 concentration, O2 concentration, particulate concentration, nitrogen concentration, SOx etc.) of the exhaust and the reductant fluid downstream of the downstream ammonia slip catalyst substrate 188. The sensor 199 may be configure to measure a signal associated with the parameter of the exhaust within the outlet chamber 189. In some embodiments, the parameter is the particulate concentration in the exhaust downstream of the downstream ammonia slip catalyst substrate 188. In some embodiments, the parameter is the NOx concentration of the exhaust downstream of thedownstream ammonia slip catalyst substrate 188. In some embodiments, the sensor 199 measures signals associated with both the particulate concentration and the NOXconcentration.|0134] In various embodiments, the aftertreatment system 100 includes a sensor 190 (e.g., NOx sensor, CO sensor, CO2 sensor, O2 sensor, particulate sensor, nitrogen sensor, etc.). The sensor 190 is positioned downstream of the upstream catalyst member 138 (and the upstream ammonia slip catalyst substrate, if present) and coupled to the hydrocarbon mixer 146. The sensor 190 is configured to measure (e.g., sense, detect, etc.) a signal associated with a parameter (e.g., NOXconcentration, CO concentration, CO2 concentration, O2 concentration, particulate concentration, nitrogen concentration, SOx etc.) of the exhaust downstream of the upstream catalyst member 138. In some embodiments, the sensor 190 is configured to measure a signal associated with the parameter of the exhaust as it enters the hydrocarbon mixer 146 to be mixed with the hydrocarbon fluid. In some embodiments, the parameter is the NOx concentration of the exhaust downstream of the upstream catalyst member 138.10135] Each of the sensors 190-199 is electrically or communicatively coupled to the aftertreatment system controller 128 and is configured to provide a signal associated with the parameter to the aftertreatment system controller 128. The aftertreatment system controller 128 (e.g., via the aftertreatment system processing circuit 130, etc.) is configured to determine a measurement based on the signal. The aftertreatment system controller 128 may be configured to control the intake chamber dosing module 112, the dosing module 172, the reductant fluid pump 116, and / or the air pump 122 based on the signal. Furthermore, the aftertreatment system controller 128 may be configured to communicate the signal to the central controller 136.III. Overview of Example Mixers[0136 j Referring to Figures 5-8 the hydrocarbon mixer 146 of the aftertreatment system 100 is shown in greater detail, according to various embodiments. As shown in Figure 5, the aftertreatment system 100 further includes a coupler 149 coupled to the introduction conduit 109. The hydrocarbon injector 150 is coupled to the introduction conduit 109 through the coupler 149. In some embodiments, the coupler 149 is not included in the aftertreatment system 100 and the hydrocarbon injector 150 is coupled directly to the introduction conduit 109.

[0137] The hydrocarbon mixer 146 includes a mixer body 202 (e.g., shell, frame, etc.). The mixer body 202 is supported within the introduction conduit 109. The mixer body 202 is centered on a mixer body center axis 204. In some embodiments, the mixer body center axis 204 is the same as (e.g., coincides with) the conduit axis 106. In other embodiments, the mixer body center axis 204 is separated from the conduit axis 106. For example, the mixer body center axis 204 may be parallel to the conduit axis 106 and offset from the conduit axis 106. The mixer body 202 includes an inlet end 210 and an outlet end 212 opposite to and downstream of the inlet end 210. The inlet end 210 is adjacent and downstream of the upstream catalyst member 138. The outlet end 212 is adjacent the first oxidation catalyst member 158.

[0138] As shown in Figures 5-7, for example, the mixer body 202 is tapered. In some embodiments, the mixer body 202 extends from the inlet end 210 to the outlet end 212 at an angle approximately in a range of 91 degrees (°) to 102° (e.g., 91°, 93°, 95°, 97°, 99°, 99.6°, 100.6°, 101°, 102°, etc.). The mixer body 202 extends from the inlet end 210 to the outlet end 212 such that the height of the mixer body is approximately in a range of 120 millimeters (mm) to 165 mm (e.g., 114 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 165 mm 173.25 mm, etc.). Referring to Figure 7, for example, an inner core diameter G1 of the mixer body 202 may be approximately in a range of 195 mm to 210 mm, or in a range of 199 mm to 205 mm (e.g., 200.5 mm, 202 mm, 204.6 mm, etc ). An outer core diameter G2 of the mixer body 202 may be approximately in a range of 220 mm to 236 mm, or in a range of 230 mm to 234 mm (e.g., 231 mm, 232 mm, 233.5 mm, etc.).

[0130] The mixer body 202 includes a first aperture 214 (see Figures 5-8, for example). The first aperture 214 may have a length along the mixer body 202 measured from the inlet end 210 to the outlet end 212 approximately in the range of 70 mm to 100 mm (e.g., 66.5 mm, 70 mm, 75 mm, 76.71 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 105 mm, etc ). In some embodiments, the first aperture 214 may have a width measured orthogonally from the length of the first aperture 214 approximately in a range of 70 mm to 100 mm (e.g., 66.5 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 99.01 mm, 95 mm, 100 mm, 105 mm, etc.). The first aperture 214 is configured to facilitate flow of the exhaust from the outer portion of the mixer body 202 through the mixer body 202 and into a mixer body cavity 216 (e.g., void, etc.). The mixer bodycavity 216 receives the exhaust from the first aperture 214. As is explained in more detail herein, the exhaust is caused to swirl within the mixer body 202, and this swirling facilitates mixing of the exhaust and the hydrocarbon fluid.

[0140] The hydrocarbon mixer 146 includes an injector plate 218 (e.g., guide, blade, louver, guide plate, etc.). The injector plate 218 (see Figures 6 and 7, for example) is coupled to the mixer body 202 along a portion of the first aperture 214. The injector plate 218 is configured to facilitate flow of the exhaust from the outer portion of the mixer body 202 through the first aperture 214. The injector plate 218 includes an injector plate flange 220. The injector plate flange 220 is configured to couple a portion of the injector plate 218 to the mixer body 202.[01411 The injector plate 218 also includes an injector plate panel 224. The injector plate panel 224 is contiguous with the injector plate flange 220. The injector plate panel 224 is positioned such that the injector plate 218 is angled away from the mixer body at a first opening angle approximately in a range of 15° to 30° (e.g., 15°, 20°, 20.5°, 25°, 30°, etc.), measured counterclockwise from the mixer body 202 to form a flow aperture 226. As used herein, angles are measured positive in a counterclockwise direction from a downstream perspective (e.g., from the outlet end 212 looking upstream toward the inlet end 210). The flow aperture 226 is formed between a first edge of the injector plate panel 224 and the mixer body 202 and between a second edge of the injector plate panel 224 and the mixer body 202. The flow aperture 226 is configured to facilitate flow of exhaust between the mixer body 202 and the injector plate panel 224 such that the exhaust flows through the first aperture 214 and into the mixer body cavity 216.

[0142] The injector plate 218 includes an injector cone 234. The injector cone 234 is positioned on the injector plate 218. The injector cone 234 includes an injection aperture 236. The injection aperture 236 is configured to facilitate flow of the hydrocarbon fluid from the hydrocarbon injector 150 through the injector cone 234 and the injector plate 218 to the mixer body cavity 216. For example, the hydrocarbon injector 150 injects hydrocarbon fluid throughthe injection aperture 236 into the mixer body cavity 216 such that the hydrocarbon fluid and the exhaust may mix.|0143] The mixer body 202 incudes a plurality of second apertures 238A, 238B, and 238C (see Figures 5-7, for example). The second apertures 238A-238C have substantially the same shape and dimensions. As shown in at Figure 5, for example, each of the second apertures 238A-238C has a width that is less than that of the first aperture 214 as described above. Collectively, the second apertures 238A-238C are annularly adjacent (e.g., adjacent along a circumference of the mixer body 202) to the first aperture 214 such that a portion of the mixer body 202 extends between the first aperture 214 and the second apertures 238A-238C. The hydrocarbon mixer 146 includes a plurality of first guide plates 240 A, 240B, and 240C (e.g., plate, louver, blade, etc.). The first guide plates 240A-240C are coupled to the mixer body 202 and extend over a portion of the second apertures 238A-238C, respectively. The first guide plates 240A-240C are configured to facilitate portions of the exhaust at the outer portion of the mixer body 202 to enter through the second apertures 238A-238C and into the mixer body cavity 216. The second apertures 238A-238C have substantially the same shape and dimensions.(01 4] Each of the first guide plates 240A-240C includes first guide plate flange (not depicted separately). The first guide plate flange is configured to couple a portion of each of the corresponding first guide plates 240A-240C to the mixer body 202. Each of the first guide plates 240A-240C further includes a first guide plate panels 246 A, 246B, and 246C, respectively (see Figure 5, for example). Each of the first guide plate panels 246A-246C is contiguous with each corresponding first guide plate flange. Each of the first guide plate panels 246A-246C is positioned such that each corresponding first guide plate 240A-240C is angled away from the mixer body 202 at a second opening angle approximately in a range of 40° to 46°, or in a range of 40° to 43.5° (e.g., 41.5°, 42°, 42.8°, 43.5°, etc.) to form a corresponding first guide plate flow aperture 242A, 242B, or 242C.

[0145] The second opening angle described herein is determined based on a number of design considerations. For example, on one hand, if the second opening angle is too small (e.g.,less than approximately 40°), the reduced first guide plate flow aperture 242A-242C causes a greater amount of the particles of the hydrocarbon fluid to be contained within the mixer body cavity 216, thereby increasing the backpressure within the mixer body cavity 216. On the other hand, if the second opening angle is too large (e.g., greater than approximately 46°), the enlarged first guide plate flow aperture 242A-242C allows a greater amount of the particles to escape from the hydrocarbon mixer 146, resulting in contamination of the upstream catalyst member 138 and reduction in the swirling of the fluid (e g., the exhaust and the hydrocarbon fluid) within the mixer body cavity 216. In many instances, contamination of the upstream catalyst member 138 by the particles escaped from the hydrocarbon mixer 146 may be observed at low-flow conditions when the spray momentum of the particles of the hydrocarbon fluid exceeds the momentum of the exhaust.

[0146] The mixer body 202 further includes a plurality of third apertures 254A, 254B, and 254C (see Figure 8). Shape and dimension of each of the third apertures 254A-254C are substantially identical to each other and to those of the second apertures 238A-238C.Collectively, the third apertures 254A-254C are annularly adjacent to the first aperture 214 and on a side of the first aperture 214 opposite to the second apertures 238A-238C such that a portion of the mixer body 202 extends between the first aperture 214 and the third apertures 254A-254C. The hydrocarbon mixer 146 includes second guide plates 256A, 256B, and 256C (e.g., plate, louver, blade, etc.) coupled to the mixer body 202 and extending over a portion of the third apertures 254A-254C, respectively.

[0147] The second guide plates 256A-256C each include a second guide plate flange (not depicted separately), which is substantially similar to the first guide plate flange. The second guide plates 256A-256C each include a second guide plate panel 262A, 262B, 262C, respectively, which are each substantially the same as the first guide plate panel 246A-246C in shape and dimensions. The second guide plate panels 262A-262C are positioned such that each corresponding second guide plate 256A-256C is angled away from the mixer body at a third opening angle approximately in a range of in a range of 40° to 46°, or in a range of 40° to 43.5° (e.g., 41.5°, 42°, 42.8°, 43.5°, etc.) to form a second guide plate flow aperture (not depicted separately). The second guide plate flow apertures are configured in a manner substantially thesame as the first guide plate flow apertures such that the third opening angles are substantially the same as the second opening angles.|0148] The shape and dimension of each of the second guide plate panels 246A-246C are illustrated in Figure 9, which is a detailed view of DETAIL A of Figure 8. For example, each of the second guide plate panels 246A-246C has a trapezoid shape with an upper width Ml (e.g., the width measured near the inlet end 210) and a lower width M2 (e.g., the width measured near the outlet end 212) substantially parallel to the upper width Ml, where the lower width M2 is greater than the upper width Ml but less than a width of the injector plate 218. In one example, the upper width Ml may be approximately 12.09 mm and the bottom width M2 may be approximately 14.13 mm. A height of each of the second guide plate panels 246A-246C is substantially the same as that of the injector plate 218. It is noted that the definitions of “width” and “height” are provided above with respect to the dimensions of the injector plate 218.|0149] In some embodiments, the mixer body 202 includes equal numbers of the first guide plates 240A-240C (thus the second apertures 238A-238C) and the second guide plates 256A- 256C (thus the third apertures 254A-354C). In some examples, the mixer body 202 includes three of each of the first guide plates 240A-240C and the second guide plates 256A-256C. In this regard, a total opening area over which the first guide plates 240A-240C extend is substantially the same as that of the second guide plates 256A-256C. In some examples, the hydrocarbon mixer 146 may include two or four of each of the first guide plates 240A-240C and the second guide plates 256A-256C.[0150| In comparison to existing implementations, the multiple, smaller first guide plates 240A-240C and second guide plates 256A-256C of the present disclosure may enhance the manufacturability of the hydrocarbon mixer 146. Furthermore, having multiple apertures (e.g., the second apertures 238A-238C and the third apertures 254A-254C) and guide plates (e.g., the first guide plates 240A-240C and the second guide plates 256A-256C) extending over their corresponding apertures increases the swirling of the fluid (e.g., the exhaust and the hydrocarbon fluid) inside the mixer body cavity 216, thereby improving the mixing between the exhaust and the hydrocarbon fluid in the hydrocarbon mixer 146.

[0151] As shown in Figure 5, for example, the aftertreatment system 100 includes a sensor 205 (e.g., NOx sensor, CO sensor, CO2 sensor, O2 sensor, particulate sensor, nitrogen sensor, EGTS, etc.), the sensor 190, and the hydrocarbon injector 150 coupled to the introduction conduit 109 through the coupler 149. In some embodiments, the sensors 190 and 205 are positioned between the first guide plates 240A-240C collectively and the second guide plates 256A-256C collectively, along the circumference of the mixer body 202. In some examples, the sensor 190 is a NOx sensor and the sensor 205 is an EGTS.|0152] The sensors 190 and 205 are electrically or communicatively coupled to the aftertreatment system controller 128, which is configured to determine a measurement based on the signal (e.g., via the aftertreatment system processing circuit 130, etc.). The aftertreatment system controller 128 may be configured to control the intake chamber dosing module 112, the dosing module 172, the reductant fluid pump 116, and / or the air pump 122 based on the signal measured by the sensor 190. Furthermore, the aftertreatment system controller 128 may be configured to communicate the signal to the central controller 136.[01531 The mixer body 202 further includes an inlet circumferential edge 211 at the inlet end 210 and a plurality of connectors (e.g., tabs) 260 disposed along the inlet circumferential edge 211 (see Figures 5, 7, 8, 10, and 11, for example). The connectors 260 extend along the mixer body center axis 204 inlet circumferential edge 21 lover a distance (e.g., height) JI. In some embodiments, the distance JI is approximately in a range of 11.6 mm to 15 mm, and further in a range of 11.6 mm to 13 mm (e.g., 11.6 mm, 12 mm, 12,8 mm, 13 mm, etc.).[0154| As will be discussed in detail below, the connectors 260 are configured to couple a portion of an inlet cap 270 with the mixer body 202 at the inlet circumferential edge 211. In this regard, the connectors 260 physically bridge a circumferential edge of a perforated plate 272 (discussed in detail below) with the inlet circumferential edge 211, thereby providing rigidity (e.g., as welding point) and stability at a junction between the inlet cap 270 and the mixer body 202. The connectors 260 and a portion of the mixer body 202 (e.g., portion 264 of Figure 11, discussed in detail below) to which the connectors 260 are coupled provide a barrieragainst at least some escaping particles of the hydrocarbon fluid from the mixer body cavity 216.|0I 55] The hydrocarbon mixer 146 further includes the inlet cap 270 coupled to the mixer body 202 at the inlet end 210 (see Figure 7, for example). The inlet cap 270 includes an inlet flange 271 (e.g., panel, coupler, ring, etc.) coupled to the perforated plate 272 (e.g., cap, panel, etc.). The perforated plate 272 and the inlet flange 271 are centered about the mixer body center axis 204, where the inlet flange 271 is coupled to a circumferential edge of the perforated plate 272. The circumferential edge of the perforated plate 272 is also coupled to the inlet circumferential edge 211 of the mixer body 202 by the connectors 260. In other words, the connectors 260 extend between the circumferential edge of the perforated plate 272 and the inlet circumferential edge 211 of the mixer body 202 along the mixer body center axis 204. The inlet cap 270 further includes an annular plate 274 downstream of the perforated plate 272 and coupled to the inlet circumferential edge 211 of the mixer body 202.10156] The inlet flange 271 includes inlet flange apertures 276 (e.g., windows, holes, slots, etc.). The inlet flange apertures 276 are arrayed (e.g., arranged, positioned, etc.) circumferentially around the perforated plate 272. Each of the inlet flange apertures 276 is configured to facilitate passage of the exhaust through the inlet flange 271 within the introduction conduit 109. In various embodiments, the inlet flange 271 includes inlet flange supports 278 (e.g., arms, bars, support structures, etc.). The inlet flange supports 278 are coupled to the circumferential edge of perforated plate 272 and are configured to couple the inlet flange 271 to the introduction conduit 109. The inlet flange 271 functions to separate the mixer body 202 from the introduction conduit 109 and support the mixer body 202 within the introduction conduit 109. Each of the inlet flange supports 278 may define a portion of one of the inlet flange apertures 276. For example, where the inlet flange 271 includes four inlet flange supports 278, the inlet flange includes four inlet flange apertures 276. In various embodiments, a number of inlet flange supports 278 and the distance between each of the inlet flange supports 278 may vary.

[0157] The perforated plate 272 includes perforations 273 (e.g., apertures, openings, holes, etc.) arranged near the circumferential edge of the perforated plate 272 and centered about the mixer body center axis 204 (see Figure 12, for example). In various embodiments, the perforations 273 are arranged in a pattern that includes a first concentric ring 273A and a second concentric ring 273B centered about the mixer body center axis 204, where the second concentric ring 273B is enclosed in the first concentric ring 273A. An innermost concentric ring of the pattern encloses a non-perforated region 277. For example, as shown herein, the second concentric ring 273B encloses the non-perforated region 277 that is free of any perforations 273. In various embodiments, the non-perforated region 277 occupies a central region of the perforated plate 272. Furthermore, the non-perforated region 277 overlaps (e.g., is aligned with) an annular plate aperture 275 of the annular plate 274 (described in detail below) along the mixer body center axis 204. In some examples, the pattern of the perforations 273 may further include a third concentric ring within the second concentric ring 273B, and the third concentric ring encloses the non-perforated region 277.

[0158] In some examples, a separation distance Fl between the first concentric ring 273A and the second concentric ring 273B may be approximately in a range of 12.20 mm to 14.92 mm (e.g., 12.35 mm, 12.80 mm, 13.56 mm, 14.20 mm, 14.75 mm, etc.) and a separation distance F2 between the first concentric ring 272A and the circumferential edge of the perforated plate 272 may be approximately in a range of 14.54 mm to 17.78 mm (e.g., 15.00 mm, 15.85 mm, 16.16 mm, 16.55 mm, 17.00 mm, 17.60 mm, etc.). In some examples, a radius KI of the perforated plate 272 may be approximately in a range of 89.42 to 109.28 mm (e.g., 90.20 mm, 93.50 mm, 95.7 mm, 98.5 mm, 99.35 mm, 102.00 mm, 105.7 mm, 108.3 mm, etc.). In various embodiments, the perforations 273 have substantially identical shapes and are each defined by a radius K2 approximately in a range of 2.86 mm to 3.50 mm (e.g., 2.90 mm, 3.10 mm, 3.18 mm, 3.35 mm, 3.42 mm, etc.).

[0150] In some embodiments, a target total open area of the perforations 273 is configured based on a number of design considerations including, but not limited to, reduction in amount of the particles of the hydrocarbon fluid impinging on the upstream catalyst member 138, reduction in backpressure within the hydrocarbon mixer 146, and improvement in the swirlingbehavior within the mixer body cavity 216 towards more uniform mixing. On one hand, if the total open area of the perforations 273 is too large, the inlet cap 270 may not provide adequate barrier against the particles of the hydrocarbon fluid that travel upstream to impinge on the upstream catalyst member 138, and the swirling of the exhaust and the hydrocarbon fluid may be reduced. On the other hand, if the total open area of the perforations 273 is too small, the inlet cap 270 may contribute to the accumulation of backpressure within the mixer body cavity 216. In some embodiments, the total open area is adjusted by changing the number, dimension, or both, of the perforations 273.

[0160] The annular plate 274 is coupled to the mixer body 202 at the inlet circumferential edge 211 and includes an annular plate aperture 275 centered about the mixer body center axis 204 (see Figure 13, for example). In various embodiments, the annular plate aperture 275 overlap the region 277 of the perforated plate 272 along the mixer body center axis 204. In this regard, the area of the annular plate aperture 275 is at least the same as the area of the region 277. In some examples, a diameter G3 of the annular plate 274 is approximately in a range of 183.61 mm to 224.41 mm (e.g., 185.00 mm, 192.50 mm, 200.40 mm, 204.01 mm, 215.50 mm, 220.65 mm, etc.) and a diameter G4 of the annular plate aperture 275 is approximately in a range of 112.18 mm to 128.18 mm, or in a range of 114 mm to 117 mm (e.g., 114 mm, 116.18 mm, 115.5 mm, 116 mm, 117 mm, etc.).

[0161] Similar to the perforated plate 272, the dimension of the annular plate 274 (e.g., the annular plate aperture 275) is adjusted to achieve a target total open area suitable for reducing the amount of the particles of the hydrocarbon fluid from traveling towards the upstream catalyst member 138, reducing the backpressure within the mixer body cavity 216, and improving the mixing of the fluid within the mixer body cavity 216. Overlapping the annular plate aperture 275 with the region 277 of the perforated plate 272 provides partial barrier between the mixer body cavity 216 and the upstream catalyst member 138 without completely blocking the release of backpressure within the mixer body cavity 216. In this regard, if the annular plate aperture 275 is too large (e.g., the diameter G4 is greater than 117 mm), the inlet cap 270 may not provide adequate barrier against the particles of the hydrocarbon fluid that travel toward the upstream catalyst member 138, and the swirling of the exhaust and thehydrocarbon fluid may be reduced within the mixer body cavity 216. On the other hand, if the annular plate aperture 275 is too small (e.g., the diameter G4 is less than 114 mm), backpressure may accumulate within the mixer body cavity 216.

[0162] In some embodiments, referring to Figure 10, for example, the perforated plate 272 and the annular plate 274 are separated by a distance JI, which is a height of the connectors 260 along the mixer body center axis 204. In this regard, the connectors 260 may block some particles of the hydrocarbon fluid from escaping the annular plate aperture 275, while also form cavity to allow release of backpressure built up within the mixer body cavity 216. A portion 264 of the mixer body 202 extending between the annular plate 274 and the inlet end 210 (i.e., the inlet circumferential edge 211) provides additional barrier against any particles of the hydrocarbon fluid traveling toward the upstream catalyst member 138. As depicted in Figure 11, the portion 264 protrudes a vertical distance J2 from the annular plate 274 to the inlet end 210 along the mixer body center axis 204. In some examples, the distance JI may be approximately in a range of 11.6 mm to 15 mm, or in a range of 11.6 mm to 13 mm (e g., 11.6 mm, 12 mm, 12.5 mm, 13 mm, etc.), and the distance J2 may be approximately in a range of 3.32 mm to 4.06 mm (e.g., 3.40 mm, 3.69 mm, 3.83 mm, 3.96 mm, etc.). In some embodiments, the perforated plate 272 and the annular plate 274 are machined or cast as a monolithic structure. In some embodiments, the perforated plate 272 and the annular plate 274 are chined or cast as two separate structures.{01631 The hydrocarbon mixer 146 further includes an outlet flange 280 (e.g., panel, coupler, ring, etc.) coupled to the outlet end 212 of the mixer body 202 and further to the introduction conduit 109 (see Figures 5 and 14-16, for example). The outlet flange 280 is centered on the mixer body center axis 204, which may coincide with the conduit axis 106. The outlet flange 280 includes an outlet flange body 284 centered on the mixer body center axis 204. The outlet flange 280 include an outlet flange aperture 286 that extends through the outlet flange body 284.

[0164] The outlet flange aperture 286 is configured to allow the exhaust to pass from the mixer body cavity 216 through the outlet flange 280 to downstream components of theaftertreatment system 100 (e.g., the first oxidation catalyst member 158, the upstream particulate filter 168, the mixer 170, the first downstream catalyst member 176, the second downstream catalyst member 182, and the downstream ammonia slip catalyst substrate 188, etc.). The outlet flange aperture 286 has a diameter approximately in the range of 145 mm to 215 mm (e.g., 137.75 mm, 145 mm, 150 mm, 155 mm, 160 mm, 165 mm, 200 mm, 171.18 mm, 175 mm, 180 mm, 185 mm, 189 mm, 195 mm, 200 mm, 205 mm, 210 mm, 215 mm, 225.75 mm, etc.). The outlet flange aperture 286 may be offset from the center of the outlet flange 280. By offsetting the outlet flange aperture 286 from the center of the outlet flange 280, the pressure of the exhaust flowing from the mixer body cavity 216 is reduced.[0165| The outlet flange body 284 includes an inner edge 285 and an outer edge 287, where the inner edge 285 defines the outlet flange aperture 286 and the outer edge 287 is coupled to the outlet end 212 of the mixer body 202. A portion of the outlet flange body 284 that extends between the inner edge 285 and the outer edge 287 defines an annular region 289 that is along a plane that is substantially perpendicular to the mixer body center axis 204. The outlet flange body 284 includes a first flared portion 288 extending upstream from the inner edge 285 and a second flared portion 290 extending upstream from the outer edge 287, where the annular region 289 extends between the inner edge 285 and the outer edge 287. Furthermore, the outlet flange body 284 includes a lip 292 that extends downstream from the second flared portion 290.

[0166] In various embodiments, both the first flared portion 288 and the second flared portion 290 provide barrier to contain or restrict the fluid (e.g., the exhaust and the hydrocarbon fluid) within the mixer body cavity 216, thereby improving the swirling of the fluid for improved mixing performance. Additionally, the second flared portion 290 provides rigidity to the overall structure of the outlet flange 280 when coupled to the mixer body 202.

[0167] As shown in Figure 16, for example, which illustrates a cross-sectional view of the outlet flange body 284 taken along the plane C-C that extends radially from the mixer body center axis 204. As shown in this view, the first flared portion 288 is angled away from the inner edge 285 (e.g., toward the mixer body center axis 204) and the second flared portion 290is angled away from the outer edge 287 (e.g., away from the mixer body center axis 204). In some embodiments, a first angle El between the first flared portion 288 and a radial direction extending over the plane of the annular region 289 is less than a second angle E2 between the second flared portion and the radial direction extending over the plane of the annular region 289. The radial direction extends along a shortest separation distance (e.g., along a radius of the outlet flange body 284) between the inner edge 285 and the outer edge 387 in the annular region 289. In addition, the first flared portion 288 has a height J3 (e.g., an outlet web height) and the second flared portion 290 has a height J4 that is less than the height J3, where the heights J3 and J4 are both measured along the mixer body center axis 204. In some examples, the height J3 is may be approximately in a range of 10 mm to 25 mm, or in a range of 17.5 mm to 21.5 mm (e.g., 17.5 mm, 18 mm, 19.5 mm, 20.07 mm, 21.5 mm, etc.), and the height J4 may be approximately in a range of 12.74 mm to 15.58 mm (e.g., 12.8 mm, 13.5 mm, 14.16 mm, 15.2 mm, etc.).[0168| In some embodiments, the second flared portion extends a distance M3 along a direction substantially perpendicular to the mixer body center axis 204, where the distance M3 may be approximately 17.9 mm in some examples. Furthermore, a portion of the outlet flange body 284 where the annular region 289 meets the second flared portion 290 may be defined by a first rounded corner having a radius K3, and a portion of the outlet flange body 284 at where the second flared portion 290 where the second flared portion 290 meets the lip 292 may be defined by a second rounded corner having a radius K4 that is greater than the radius K3. The radius K3 may be approximately in a range of 1.8 mm to 2.2 mm (e.g., 1.9 mm, 2.00 mm, 2.15 mm, etc.) and the radius K4 may be approximately in a range of 3.65 mm to 4.47 mm (e.g., 3.75 mm, 3.9 mm, 4.06 mm, 4.25 mm, 4.4 mm, etc.).

[0169] The outlet flange 280 further includes a slot 282 (e.g., opening, aperture, window, etc.) adjacent to the outlet flange aperture 286, where the slot 282 extends through the outlet flange body 284. As shown in Figure 14, the slot 282 includes an edge 269 that is aligned with an axis Bl extending through a centerline of the hydrocarbon injector 150, where the axis Bl is substantially perpendicular to the mixer body center axis 204. In this regard, the slot 282 is adjacent to but circumferentially offset from the hydrocarbon injector 150, where such offsetmay be defined by an angle E3 between the axis B l and an axis B2, which is substantially perpendicular to the mixer body center axis 204 and extends through a centerline of the slot 282 in the plane of the annular region 289. In some examples, the angle E3 may be approximately in a range of 10° to 40° (e.g., 10°, 14.5°, 18.3°, 25°, 38.7°, 40°, etc.). Furthermore, the axis Bl is laterally offset from an axis B3, which extends through a centerline of the outlet flange aperture 286 and is substantially parallel to the axis Bl, by a separation distance F3. In some examples, the separation distance F3 may be approximately in a range of 0 mm (e.g., no offset) to 18 mm (e.g., 3 mm, 12 mm, 16.45 mm, 17 mm, and 18mm, etc.).

[0170] In comparison to existing implementations, the single slot 282 provides better restriction and containment of the fluid (e.g., the exhaust and the hydrocarbon fluid) within the mixer body cavity 216, thereby improving the swirling of the fluid within the mixer body cavity 216. In addition, the single slot 282 simplifies the design of the outlet flange 280 and improves the manufacturability of the hydrocarbon mixer 146. Furthermore, configuring the slot 282 to be adjacent to but circumferentially offset from the hydrocarbon injector 150 reduces the amount of the injected particles of the hydrocarbon fluid that directly exit the hydrocarbon mixer 146 from the slot 282, which may occur if the hydrocarbon injector 150 is too close to the slot 282, and while also reducing negative impact on the swirling of the fluid within the mixer body cavity 216, which may occur if the hydrocarbon injector 150 is too far away from the slot 282.[01711 Now referring to Figures 17-46, the hydrocarbon mixer 146 is described below in accordance with various embodiments. Dimensions and angles of the various components of the portion of the aftertreatment system 100 are provided for illustrative purposes only and are therefore not intended to limit the embodiments of the present disclosure. Furthermore, unless indicated otherwise, such dimensions and angles are approximate and may range within ± 10% within each stated value, including any± variation provided.[01721 Referring to Figures 17-22, a portion of the aftertreatment system 100 including the introduction conduit 109 and the hydrocarbon mixer 146 disposed within the introduction conduit 109, which is centered on the mixer body center axis 204, is shown. In someembodiments, the aftertreatment system 100 includes the coupler 149 coupled to the introduction conduit 109. The coupler 149 is centered on the axis Bl, which also extends through the centerline of the hydrocarbon injector 150 described herein. The axis Bl is oriented at a non-orthogonal angle with respect to the mixer body center axis 204.[01731 In some embodiments, referring to Figures 18 and 19, an inner diameter (ID) 1702 of the introduction conduit 109 measured at an upstream end 109A (i.e., in proximity to the inlet flange 271 and the inlet end 210) is approximately 282.7 mm ± 0.5 mm and an outer diameter (OD) 1704 of the introduction conduit 109 measured at a downstream end 109B (i.e., in proximity to the outlet flange 280 and the outlet end 212) is approximately 290.7 mm ± 0.8 mm. In some embodiments, a length 1706 extending from the upstream end 109A to the lip 292 is approximately 108.57 mm. In some embodiments, a length 1708 extending from the inlet flange 271 to the lip 292 is approximately 137.3 mm ± 0.5 mm. In some embodiments, a length 1710 extending from the upstream end 109A to the downstream end 109B is approximately 145.3 mm.[0174| Referring to Figure 21, an axis B4 extends through a centerline of the outlet flange 280, where the axis B4 is perpendicular to the axis Bl and the mixer body center axis 204. In some embodiments, an angle 1720 between the axes Al and A4 is approximately 110.8°. In some embodiments, referring to Figure 20, a separation distance 1712 between the coupler 149 and the downstream end 109B along the mixer body center axis 204 is approximately 58.9 mm ± 1.5 mm. In some embodiments, referring to Figure 22, a separation distance 1724 between the coupler 149 and the upstream end 109A along the mixer body center axis 204 is approximately 86.4 mm.|0175[ In some embodiments, referring to Figures 23-26, the introduction conduit 109 further includes a plurality of slots 1802. In some embodiments, the slots 1802 are evenly positioned around a circumference of the introduction conduit 109. In the example depicted herein, the introduction conduit 109 includes four slots 1802. The slots 1802 are configured to accommodate the coupling of the inlet flange 271 to the introduction conduit 109. In this configuration, the slots 1802 are positioned in proximity to the upstream end 109A of theintroduction conduit 109. In some embodiments, the slots 1802 are positioned equidistant from one another along the circumference of the introduction conduit 109. In other words, an angle between centerlines of two adjacent slots 1802 remains substantially the same.

[0176] Furthermore, the introduction conduit 109 includes an opening 1804 positioned between two adjacent slots 1802 along the circumference of the introduction conduit 109. The opening 1804 is in fluid communication with the injection aperture 236. In various embodiments, the opening 1804 is configured to receive the coupler 149 and accommodate the coupling of the coupler 149 to the introduction conduit 109. As a result, the coupler 149 is configured to facilitate the injection of the hydrocarbon fluid into the mixer body cavity 216 through the opening 1804 and the injection aperture 236.[O177| Further still, the introduction conduit 109 includes an outlet flange receiving portion 1806 extending upstream from the downstream end 109B along the mixer body center axis 204. The outlet flange receiving portion 1806 is configured to accommodate the receiving and coupling of the outlet flange 280 to an interior of the introduction conduit 109. In some embodiments, the outlet flange receiving portion 1806 is positioned between two adjacent slots 1802 along the circumference of the introduction conduit 109. The outlet flange receiving portion 1806 is angularly offset from the opening 1804 along the circumference of the introduction conduit 109.|<>178] Referring to Figures 24-26, where Figure 25 is a cross-sectional view of the introduction conduit 109 taken along plane F-F in Figure 24 and Figure 26 is a cross-sectional view of the introduction conduit 109 taken along plane G-G in Figure 24, the upstream end 109A is separated from the centerline Al of the opening 1804 by the separation distance 1724, which is approximately 86.4 mm as described herein. In some embodiments, a width 1816 of the slot 1802 along the mixer body center axis 204 is approximately 3 mm ± 0.5 mm. In some embodiments, a separation distance 1818 extending between the upstream end 109A and an edge of the slot 1802 proximate to the upstream end 109A along the mixer body center axis 204 is approximately 36.2 mm ± 0.5 mm. In some embodiments, the outlet flange receiving portion 1806 has a length 1820 of approximately 37.3 mm. The ID 1702 of the introduction conduit109 measured at the upstream end 109 A is approximately 282.7 mm ± 0.5 mm and the OD 1704 of the introduction conduit 109 measured at the downstream end 109B is approximately 290.7 mm ± 0.8 mm as described herein.

[0179] Referring to Figure 27, which illustrates the opening 1804 from view I in Figure 24, the opening 1804 has a diameter 1840 of approximately 21.2 mm ± 0.5 mm. The opening 1804 is annularly surrounded by a recessed portion 1808. In some embodiments, the recessed portion 1808 has a diameter 1842 of approximately 41.5 mm.

[0180] Referring to Figure 28, which is a cross-sectional view of the introduction conduit 109 taken along plane H-H in Figure 26, an angle 1830 between an axis B5 and a centerline of a first nearest neighboring slot 1802 to the axis B5 is approximately 21.1°, where the axis B5 is parallel to and offset from the axis Bl along the mixer body center axis 204. In other words, the centerline of the first nearest neighboring slot 1802 is annularly offset from the axis B5 (i.e., the axis Bl) by approximately 21.1 °. In some embodiments, an angle 1832 of an arc traversing each of the slots 1802 is approximately 30°. In some embodiments, the slots 1802 are positioned equidistant from one another along the circumference of the introduction conduit 109. In other words, an angle 1834 between centerlines of any two adjacent slots 1802 remains substantially the same and is approximately 111.1°, according to some embodiments.

[0181] Referring to Figures 29-32, details of the coupler 149 are provided. In some embodiments, referring to Figure 29, the coupler 149 includes a coupler body 1901. The coupler body 1901 defines a coupler cavity 1903. The couple 149 and the coupler cavity 1903 are both centered on the axis Bl. The coupler body 1901 includes a distal end 1901A and a proximal end 1901B opposite the distal end 1901A. The proximal end 1901B is coupled to the opening 1804 of the introduction conduit 109. The coupler body 1901 includes a distal portion 1912 coupled to a proximal portion 1914, where the distal portion 1912 is adjacent to the distal end 1901A and the proximal portion 1914 is adjacent to the proximal end 1901B.

[0182] In some embodiments, referring to Figure 30, which is a side view of the coupler 149, the distal end 1901A has a diameter 1904 of approximately 29 mm ± 0.35 mm, and theproximal end 1901B has a diameter 1906 of approximately 20 mm ± 0.5 mm. In some embodiments, the coupler 149 has a length 1908 along the axis Bl of approximately 26.41 mm.|0183] Referring to Figure 32, which is a cross-sectional view of the coupler 149 taken along plane J-J in Figure 31, the coupler cavity 1903 includes a first portion 1920, a second portion 1924, and a third portion 1922 coupling the first portion 1920 to the second portion 1924. The first portion 1920 is adjacent to the distal end 1901 A and the second portion 1924 is adjacent to the proximal end 1901B. In some embodiments, the first portion 1920 has a diameter 1931 of approximately 15 mm, and the second portion 1924 has a diameter 1932 of approximately 11.7 mm ± 0.25 mm. In some embodiments, the first portion 1920 has a length 1934 along the axis Bl of approximately 11 mm ± 0.1 mm. In some embodiments, the third portion 1922 includes slanted sidewalls 1925 that are separated from one another by an angle 1938 of approximately 90°. In some embodiments, the proximal portion 1914 protrudes along the axis Bl from the distal portion 1912 by a distance 1952 of approximately 2 mm.|0I84] Referring to Figures 33-35, the hydrocarbon mixer 146 includes the mixer body 202. The mixer body 202 includes the connectors 260 disposed along the inlet circumferential edge 211. In some embodiments, the connectors 260 are substantially identical in size. The mixer body 202 includes an outlet circumferential edge 213 at the outlet end 212 opposite to the inlet end 210.|(H 85] In some embodiments, a diameter 2002 of the mixer body 202 measured at the inlet circumferential edge 211 is approximately 202.1 mm. In some embodiments, an angle 2004 of an arc traversing the first aperture 214 is approximately 49°. Referring to Figure 35, in some embodiments, a length 2020 of the mixer body 202 along the mixer body center axis 204 is approximately 120.45 mm ± 1 mm.]0186] In some embodiments, referring to Figure 34, an angle 2006 of an arc traversing each of the connectors 160 is approximately 18° ± 0.4°. In some embodiments, an angle 2008 of an arc extending between a first edge of one of the third apertures 254A-254C (or the second apertures 238A-238C) and a corresponding first edge of a first nearest neighboring third apertures 254A-254C (or of any of the second apertures 238A-238C) is approximately 14.4°.

[0187] Referring to Figure 34, the mixer body 202 additionally includes a connector 261 disposed between two adjacent connectors 260, where the connector 261 differs from each of the connectors 260 in size. In some embodiments, the mixer body 202 includes four connectors 260 and one connector 261. In some embodiments, a position of the connector 261 along the inlet circumferential edge 211 corresponds to a position of the second apertures 238B. An axis B6 extends through a centerline of the connector 261 as depicted and is perpendicular to the mixer body center axis 204. In some embodiments, referring to Figure 33, the mixer body 202 further includes a plurality of connectors 263 and a connector 265 disposed along the outlet circumferential edge 213. In some embodiments, the connectors 263 are substantially identical in size but each different from the connector 265 in size.

[0188] In some embodiments, an angle 2010 of an arc traversing the connector 261 is approximately 10° ± 0.4°. In some embodiments, an angle 2012 of an arc extending between the axis B6 and a centerline of a first nearest neighboring connector 260 to the connector 261 is approximately 72° ± 1°. In some embodiments, an angle 2014 of an arc extending between the axis B6 and a centerline of a second nearest neighboring connector 260 to the connector 261 is approximately 144° ± 1°. In some embodiments, an angle between centerlines of any two adjacent connectors 260 or between centerlines of the connector 261 and an adjacent connector 260 can be defined by the angle 2012, which is approximately 72° ± 1°.

[0189] Referring to Figures 36 and 37, the hydrocarbon mixer 146 includes the injector plate 218, which has a length 2102 along the mixer body center axis 204 that is approximately 83.7 mm, according to some embodiments. The length 2102 extends between an upstream edge 218A and a downstream edge 218B of the injector plate 218. The injector plate 218 includes the injector plate panel 224, which has a length 2104 along the mixer body center axis 204 that is approximately 71.7 mm, according to some embodiments. The injector plate 218 includes the injector cone 234, which further includes the injection aperture 236. In some embodiments, a separation distance 2106 extending between the upstream edge 218A of the injector plate panel 224 and a centerline of the injection aperture 236 is approximately 34.3 mm, where the centerline extends along a direction substantially perpendicular to the mixer body center axis 204. The injector plate 218 includes the injector plate flange 220, which has a length 2108along the mixer body center axis 204 that is approximately 74.5 mm, according to some embodiments. In some embodiments, referring to Figure 36, a width 2110 of the injector plate 218 along the direction substantially perpendicular to the mixer body center axis 204 is approximately 92 mm. In some embodiments, a width 2114 of the injector plate flange 220 is approximately 26.5 mm.[0190| Referring to Figure 37, which depicts DETAIL C in Figure 36 in detail, the injection aperture 236 has a diameter 2120 of approximately 20.7 mm ± 0.5 mm, according to some embodiments. In some embodiments, a separation distance 2122 extending between the downstream edge 218B and the centerline of the injection aperture 236 is approximately 33.8 mm.[01911 Referring to Figures 38 and 39, the hydrocarbon mixer 146 includes the perforated plate 272 having a plurality of slots 2202 disposed along a circumference of the perforated plate 272. As described herein, the perforated plate 272 is coupled to the inlet flange 271, which are both portions of the inlet cap 270. The slots 2202 are substantially identical in size. The perforated plate 272 includes a slot 2203 disposed between two adjacent slots 2202, where the slot 2203 differs from each of the slots 2202 in size. The axis B6 extends through a centerline of the slot 2203. In some embodiments, the perforated plate 272 includes four slots 2202 and one slot 2203. In the depicted embodiments, the slot 2203 is annularly aligned with the connector 261 along the mixer body center axis 204, and each of the slots 2202 is annularly aligned with each of the connectors 260. In this regard, the mixer body 202 is configured to be coupled to the perforated plate 272 by coupling the connector 261 to the slot 2203 and by coupling each of the connectors 260 to a corresponding one of the slots 2202.|01 2] In some embodiments, referring to Figure 38, a diameter 2204 of the perforated plate is 198 mm ± 0.5 mm. In some embodiments, a diameter 2206 of a circle traversing outer edges of the inlet flange apertures 276 is approximately 256 mm. In some embodiments, an angle 2207 of an arc traversing the slot 2203 is approximately 11° ± 0.4°. In some embodiments, an angle 2208 between the axis B6 and a centerline through a first nearest neighboring slot 2202 to the slot 2203 is approximately 72° ± 1°. In some embodiments, anangle 2210 between the axis B6 and a centerline through a third nearest neighboring slot 2202 to the slot 2203 is approximately 144° ± 1°. In some embodiments, an angle 2216 between adjacent edges of two neighboring inlet flange apertures 276 is approximately 8.5° ± 1°. In some embodiments, an angle between centerlines of any two adjacent slots 2202 or between centerlines of the slot 2203 and an adjacent slot 2202 can be defined by the angle 2208, which is approximately 72° ± 1°.

[0193] Referring to Figure 39, which depicts a cross-sectional view of the inlet flange 271 taken along plane K-K in Figure 38, an OD 2220 of the inlet flange 271 is approximately 285.6 mm ± 0.4 mm, according to some embodiments. Furthermore, a thickest portion of the inlet flange 271 has a thickness 1 of approximately 14 mm ± 1 mm, according to some embodiments.

[0194] Referring to Figures 40-42, the inlet cap 270 further includes the annular plate 274 coupled to the inlet end 210 (i.e., at the inlet circumferential edge 211) of the mixer body 202. In some embodiments, the annular plate 274 includes a plurality of connectors 2302 (e.g., tabs) disposed along a circumference of the annular plate 274. The connectors 2302 are substantially identical in size. The annular plate 274 further includes a connector 2303, where the connector 2303 differs from each of the connectors 2302 in size. In some embodiments, the annular plate 274 includes four connectors 2302 and one connector 2303. The connectors 2302 and 2303 are configured to accommodate the coupling of the annular plate 274 to the mixer body 202 at the inlet circumferential edge 211. In some embodiments, the connectors 2302 and 2303 are configured to be inserted into the mixer body cavity 216 such that they extend along an interior surface of the mixer body 202.|0195] In some embodiments, referring to Figure 40, a diameter 2304 of the annular plate aperture 275 is approximately 116.2 mm ± 1 mm. In some embodiments, an angle 2310 of an arc traversing each of the connectors 2302 is approximately 18°, and an angle 2312 of an arc traversing the connector 2303 is approximately 14.6°. In some embodiments, an angle 2314 between a centerline of the connector 2303, which extends along an axis B7 that is perpendicular to the axis Bl but annularly offset from the axis B6, and a centerline of a firstnearest neighboring connector 2302 to the connector 2303 is approximately 40°. In some embodiments, an angle 2316 between the centerline of the connector 2303 and a centerline of a second nearest neighboring connector 2302 to the connector 2303 is approximately 98°. In some embodiments, an angle 2318 between the centerline of the connector 2303 and a centerline of a third nearest neighboring connector 2302 to the connector 2303 is approximately 156°.

[0196] Referring to Figure 41, which depicts a cross-sectional view of the annular plate 274 taken along plane L-L in Figure 40, the annular plate 274 has a diameter 2320 of approximately 191.5 mm, according to some embodiments. In some embodiments, each of the connectors 2302 is angled outwardly from the mixer body center axis 204 such that an angle 2322 separating two opposite connectors 2302 is approximately 18° + 27-1°. Referring to Figure 42, a thickness 2326 of a portion of the annular plate 274 between two adjacent connectors 2302 (or between one of the connectors 2302 and an adjacent connector 2303) is approximately 6 mm ± 0.5 mm, and a thickness 2328 of the connectors 2302 (or the connector 2303) is approximately 14.8 mm ± 1 mm.

[0197] Referring to Figures 43-46, the hydrocarbon mixer 146 includes the outlet flange 280 coupled to the outlet end 212 (i.e., the outlet circumferential edge 213) of the mixer body 202. The outlet flange 280 includes an upstream end 280A, which is depicted in an end view in Figure 45, and a downstream end 280B, which is opposite the upstream end 280A along the mixer body center axis 204 and depicted in an end view in Figure 44. The outlet flange 280 includes the outlet flange body 284, which further includes a plurality of slots 2402. The slots 2402 are substantially identical in size. The outlet flange body 284 further includes a slot 2403, which differs from each of the slots 2402 in size. In some embodiments, referring further to Figures 33, each of the slots 2402 is positioned to correspond to each of the connectors 263 of the mixer body 202, and the slot 2403 is positioned to correspond to the connector 265. In this configuration, the outlet flange 280 is configured to be coupled to the mixer body 202 at the outlet end 212 (i.e., the outlet circumferential edge 213) by coupling the connector 265 to the slot 2403 and by coupling each of the connectors 263 to a corresponding one of the slots 2402.

[0198] In some embodiments, referring to Figure 44, the outlet flange 280 has an OD 2408 of approximately 285.6 mm ± 0.4 mm. The outlet flange 280 includes the slot 282 and an angle 2410 of an arc traversing the slot 282 is approximately 40° ± 1°, according to some embodiments. A centerline of the slot 2403 extends along an axis B8, which is perpendicular to the mixer body center axis 204 but is annularly offset from the axis Bl. In some embodiments, an angle 2412 between the axis B8 and a centerline of a first nearest neighboring slot 2402 to the slot 2403 is approximately 64° ± 1°, and an angle 2414 between the axis B8 and a centerline of a second nearest neighboring slot 2402 to the slot 2403 is approximately 64° ± 1°. In some embodiments, an angle 2416 of an arc traversing each of the slots 2402 is approximately 20° ± 0.4°. In some embodiments, a width 2418 of the slot 2402 measured along a radial direction of the outlet flange 280 is approximately 3.2 mm.

[0199] In some embodiments, referring to Figure 45, an angle 2420 of an arc traversing the slot 2403 is approximately 10° ± 0.4°. In some embodiments, an angle 2422 between the axis B8 and a nearest neighboring edge of the slot 282 is approximately 10° ± 1°. The outlet flange aperture 286 has a centerline that extends along axis B9, which is substantially parallel to the axis B8. In some embodiments, a lateral separation distance 2430 (i.e., extending perpendicular to the axis B8) is approximately 17.2 mm, and a vertical separation distance 2432 extending along the axis B9 between the centers of the outlet flange aperture 286 and the outlet flange 280 is approximately 8.5 mm. In some embodiments, a diameter 2434 of a circle traversing an inner edge of the slot 282 is approximately 190 mm, and a diameter 2436 of a circle traversing an outer edge of the slot 282 is approximately 211.3 mm. In some embodiments, a diameter 2438 of a circle traversing an inner edge of the slot 2402 is approximately 216.7 mm ± 0.4 mm, and a diameter 2439 of a circle traversing an outer edge of the slot 2402 is approximately 223.09 mm ± 0.4 mm.

[0200] Referring to Figure 46, which is a cross-sectional view of the outlet flange 280 taken along plane N-N in Figure 45, the outlet flange 280 includes the first flared portion 288 having a frustoconical shape centered on the mixer body center axis 204. The inner edge 285 of the first flared portion 288 defines the outlet flange aperture 286. In some embodiments, an opening defined by an upstream edge of the frustoconical shape has a diameter 2440 ofapproximately 156.9 mm, and an opening defined by a downstream edge of the frustoconical shape has a diameter 2442 of approximately 170 mm ± 1 mm. In some embodiments, a distance 2444 between the outer edge 287 of the outlet flange body 284 and the mixer body center axis 204 is approximately 115.4 mm. In some embodiments, a distance 2446 between an outer edge of the lip 292 and the mixer body center axis 204 is approximately 141.8 mm.[02011 In some embodiments, the hydrocarbon mixer 146 may be configured with additional components. For example, referring to Figures 47 and 52, the inlet flange 271 further includes an inlet flange receiver 279 recessed relative to a circumferential edge of the inlet flange 271, where the inlet flange receiver 279 is configured to receive and couple to (by welding, for example) an inlet coupler 407 of an exhaust sampler 400 described in detail below. The inlet flange receiver 279 is disposed between the first aperture 214 and the third aperture 254A along the circumferential edge of the inlet flange 271. In some embodiments, the inlet flange receiver 279 provides a location for welding the exhaust sampler 400 to the inlet flange 271.[02021 Referring to Figures 47 and 53, for example, the outlet flange 280 further includes an outlet flange receiver 281 recessed relative to a circumferential edge 283 of the outlet flange 280. The outlet flange receiver 281 is configured to receive and couple to an outlet coupler 411 of the exhaust sampler 400. The outlet flange receiver 281 is disposed between the first aperture 214 and the third aperture 254A along the circumferential edge 283 of the outlet flange 280. In some embodiments, the outlet flange receiver 281 provides a location for welding the exhaust sampler 400 to the outlet flange 280.

[0203] In various embodiments, referring to Figures 47-57 and 59 collectively, the hydrocarbon mixer 146 further includes an exhaust sampler 400 (e.g., sampling shield, etc.) coupled to both the inlet flange 271 and the outlet flange 280. In various embodiments, the exhaust sampler 400 is configured to facilitate the sampling (e.g., measuring, detection, etc.) of a signal associated with a parameter (e.g., concentration) of a constituent, such as NOx, N2, CO2, and / or H2O, in the exhaust by the sensor 190 depicted herein. In various embodiments,the exhaust sampler 400 is configured to facilitate the sampling of a concentration of N0xby the sensor 190.

[0204] In various embodiments, the exhaust sampler 400 is integrated with the hydrocarbon mixer 146 in a compact design such that a space required for packaging the exhaust sampler 400 is reduced, allowing the exhaust sampler 400 be applied in aftertreatment systems of various architectures. In some embodiments, the exhaust sampler 400 facilitates the sampling of NOx in the exhaust in such a way that allows the sensor 190 be mounted adjacent to the mixer body 202 at a clocking angle that may not be achievable otherwise. The clocking angle, such as angle A7 depicted in Figure 52, represents an angular separation between the sensor 190 and the hydrocarbon injector 150. In some embodiments, the exhaust sampler 400 allows the sensor 190 to be mounted near the hydrocarbon injector 150 to meet the sensor’s installation guidelines (e.g., at + / - 45° with respect to direction of gravity) while protecting the sensor 190 against impingement of hydrocarbon fluid particles from the hydrocarbon injector 150. In some embodiments, the exhaust sampler 400 further allows flexibility to mount the sensor 190 at a designated location to reduce or prevent interference from adjacent, peripheral chassis components of the aftertreatment system 100. Accordingly, the exhaust sampler 400 allows various design considerations including, for example, reduction of particle impingement, adoption of the sensor’s installation guideline, and reduction of interference with peripheral components, to be met with respect to integrating the sensor 190 with the hydrocarbon mixer 146.

[0205] In some embodiments, the exhaust sampler 400 is configured to reduce an amount of hydrocarbon fluid particles impinging upon the sensor 190 without substantially impacting the operations of the exhaust sampler 400 and the hydrocarbon mixer 146 with respect to factors including, for example, flow distribution, swirling, and backpressure build-up. For example, on one hand, a height (e.g., height H4) of sidewalls (e.g., sidewalls 412 and 414) of the exhaust sampler 400 is configured to be sufficiently high to provide blockage against the hydrocarbon fluid particles from impinging upon the sensor 190. On the other hand, an upper limit of such height is capped to maintain an open space between the sidewalls and the mixerbody 202, which allows the exhaust to flow into the mixer body cavity 216 without significant interference.|0206j Referring to Figures 47 and 48, the exhaust sampler 400 includes an inlet portion 406 and an outlet portion 410 opposite the inlet portion 406, where the inlet portion 406 and the outlet portion 410 are disposed along an axial (or lengthwise) direction AD and each extend across a lateral (or widthwise) direction LD of the exhaust sampler 400. The inlet portion 406 is located at an upstream end of the exhaust sampler 400 such that it serves as an entrance for a portion (e.g., sample) of the exhaust being sampled by the sensor 190. The outlet portion 410 is located at a downstream end of the exhaust sampler 400 such that it serves as an exit for the sample of the exhaust after it is measured by the sensor 190. The exhaust sampler 400 includes an inlet coupler 407 configured to couple the inlet portion 406 to the inlet flange 271 and an outlet coupler 411 configured to couple the outlet portion 410 to the outlet flange 280.|02O7] The exhaust sampler 400 includes a base portion 402 extending between the inlet portion 406 and the outlet portion 410 along the axial direction AD. The base portion 402 defines a recess 420 at a location corresponding to a location of a probing end of the sensor 190, where the recess 420 provides the sample of the exhaust for measurement by the sensor 190. The exhaust sampler 400 further includes a transitional portion 404 extending between the inlet portion 406 and the base portion 402 (including an upstream end of the base portion 402) along the axial direction AD. The inlet portion 406, the transitional portion 404, and the base portion 402 extend adjacent to a portion of the mixer body 202.[02081 The exhaust sampler 400 further includes a first sidewall 412 and a second sidewall 414 opposite the first sidewall 412, where the inlet portion 406, the transitional portion 404, and the base portion 402 are flanked with the first sidewall 412 and the second sidewall 414. The first sidewall 412 and the second sidewall 414 are configured to provide a barrier against impingement of particles of the hydrocarbon fluid injected into the mixer body 202 through the first aperture 214, which is located adjacent to the exhaust sampler 400. A height of each of the sidewalls 412 and 414 extend along a radial direction RD with respect to the mixer body center axis 204.

[0209] In various embodiments, components of the exhaust sampler 400 are designed to allow the exhaust (e.g., from the upstream catalyst member 138) to flow through the exhaust sampler 400 at a low flow rate and in a continuous manner so as to reduce interference with performance of the hydrocarbon mixer 146 including, for example, flow distribution of the exhaust, uniform mixing of the exhaust with the hydrocarbon fluid provided to the mixer body 202 through the hydrocarbon injector 150, and reduced backpressure inside the mixer body cavity 216.

[0210] Referring to Figures 47 and 54, for example, the inlet portion 406 is coupled to the inlet flange receiver 279 through the inlet coupler 407. In this regard, the exhaust sampler 400 is positioned between the first aperture 214 and the third aperture 254A, through which at least portions of the exhaust enter the mixer body cavity 216. In various embodiments, the inlet coupler 407 overlaps at least a portion of the inlet flange 271 and extends annularly in a space defined by the inlet flange receiver 279. Accordingly, a curvature of the inlet coupler 407 conforms to a curvature of the circumferential edge of the inlet flange 271. In some embodiments, the inlet coupler 407 does not extend over any portion of the inlet flange apertures 276 such that obstruction to the flow of the exhaust through one or more of the third apertures 254A-254C located on the mixer body 202 is reduced or minimized.[0211 [ Referring to Figure 49, two opposing edges of the inlet coupler 407 form an angle Al along the curvature of the inlet coupler 407. In some embodiments, the angle Al is approximately 20.43° to approximately 24.97°, such as approximately 22.7°. Similarly, the first sidewall 412 and the second sidewall 414 form an angle A2 that is larger than the angle Al. In some embodiments, the angle A2 is approximately 23.4° to approximately 28.6°, such as approximately 26°. In this regard, referring to Figure 49, an angle A3 between the first sidewall 412 (or the second sidewall 414) and a plane P0 bisecting the exhaust sampler 400 along the axial direction AD, where the plane P0 is equidistant to each of the first sidewall 412 and the second sidewall 414, is approximately half of the angle A2.

[0212] Still referring to Figure 49, the exhaust sampler 400 has a width W 1 defined by a separation distance between the first sidewall 412 and the second sidewall 414. In someembodiments, the width W1 is approximately 57.87 mm to approximately 70.73 mm, such as approximately 64.3 mm. Referring to Figure 51, the two opposing edges of the inlet coupler 407 is separated by a width W2. In some embodiments, the width W2 is approximately 47.7 mm to approximately 58.3 mm, such as approximately 53 mm. The inlet coupler 407 overlaps the inlet flange 271 over a distance Tl. In some embodiments, the distance T1 is approximately 9 mm to approximately 11 mm, such as approximately 10 mm. Curvature R3 and curvature R4 each represent a lap joint for a radial overlap over the distance Tl. In some embodiments, the curvature R3 is approximately 112.4 mm to approximately 137.4 mm, such as approximately 124.9 mm. In some embodiments, the curvature R4 is approximately 121.4 mm to approximately 148.4 mm, such as approximately 134.9 mm. Referring to Figures 50 and 51, the exhaust sampler 400 has a length Y1 measured along the mixer body center axis 204. In some embodiments, the length Y1 is approximately 108.36 mm to approximately 132.44 mm, such as approximately 120.4 mm. The inlet coupler 407 is separated from a center line CL1 through a center of the recess 420 by a distance Y2. In some embodiments, the distance Y2 is approximately 49.95 mm to approximately 61.05 mm, such as approximately 55.5 mm.|0213] Still referring to Figure 49, the inlet coupler 407 includes a rounded corner having a radius of curvature Rl . In some embodiments, the radius of curvature R1 is approximately 1.8 mm to approximately 2.2 mm, such as approximately 2 mm. The first sidewall 412 (or the second sidewall 414) adjoins the transitional portion 404 at a rounded comer having a radius of curvature R2. In some embodiments, the radius of curvature R2 is approximately 3.6 mm to approximately 4.4 mm, such as approximately 4 mm.

[0214] Referring to Figure 50, which depicts a cross-section of the exhaust sampler 400 taken along a plane 0-0 as shown in Figure 48, the inlet portion 406 extends between the inlet coupler 407 and the transitional portion 404, and the transitional portion 404 extends between the inlet portion 406 and the base portion 402 (including a lower sub-portion 402L). In various embodiments, the inlet coupler 407 overlaps the portion of the inlet flange 271 along a plane Pl, where the plane Pl is perpendicular, or approximately perpendicular, to the mixer body center axis 204. The inlet portion 406 wraps around a portion of the edge of the inlet flange 271, where a plane P2 extending along a surface of the inlet portion 406 is parallel, orapproximately parallel, to the mixer body center axis 204. Furthermore, a plane P3 extending along a surface of the transitional portion 404 slants towards the mixer body center axis 204, and a plane P4 extending along a surface of the lower sub-portion 402L slants away from the mixer body center axis 204. Accordingly, an angle between the planes P3 and P4 is acute (or less than 90°), indicating that the transitional portion 404 and the lower sub-portion 402L form a depressed (or recessed) area relative to the inlet portion 406 and the outlet portion 410. In various embodiments, such depressed area causes the portion of the exhaust entering the exhaust sampler 400 to have a reduced flow rate compared to portions of the exhaust exiting or outside of the exhaust sampler 400, thereby reducing interference of the sampling process on the operation of the hydrocarbon mixer 146.|0215] In some embodiments, referring to Figure 50, an angle A4 between the planes Pl and P3 is approximately 28.8° to approximately 35.2°, such as approximately 32°. In some embodiments, an angle A5 between the plane P4 and an outer edge 413 of the first sidewall (or the second sidewall), which is substantially parallel to the mixer body center axis 204, is approximately 7.65° to approximately 9.35°, such as approximately 8.5°. A portion of the inlet coupler 407 extending along the plane Pl has a width T2. In some embodiments, the width T2 is approximately 5.4 mm to approximately 6.6 mm, such as approximately 6 mm. An outer edge 409 of the inlet coupler 407, which is substantially parallel to the mixer body center axis 204, is separated from the outer edge 413 of the first sidewall 412 (or the second sidewall 414) by a distance T3. In some embodiments, the distance T3 is approximately 13.23 mm to approximately 16.17 mm, such as approximately 14.7 mm.

[0216] The base portion 402 couples the transitional portion 404 to the outlet portion 410 and extends adjacent to a portion of the mixer body 202 covered by the second guide plate 262A, as depicted in Figures 47 and 56, for example. The base portion 402 includes the lower sub-portion 402L proximal to the inlet portion 406, an upper sub-portion 402U proximal to the outlet portion 410, and a middle sub-portion 402R extending between the lower sub-portion 402L and the upper sub-portion 402U.

[0217] Referring to Figure 50, the middle sub-portion 402R defines the recess 420 extending depth-wise towards a portion of the mixer body 202. In various embodiments, a lowest portion of the recess 420 (e.g., a lowest portion 420L; see Figure 53) protrudes from a lowest portion of the sidewall 414 (e.g., a lowest portion 414L; see Figure 53) towards the portion of the mixer body 202. In various embodiments, the middle sub-portion 402R includes a bottom surface 402RB surrounded by, and contiguous with, a lower curved sidewall 402RL and an upper curved sidewall 402RU contiguous with the lower curved sidewall 402RL, where the lower curved sidewall 402RL is coupled to the lower sub-portion 402L and the upper curved sidewall 402RU is coupled to the upper sub-portion 402U. The bottom surface 402RB is coupled to each of the lower sub-portion 402L and the upper curved sidewall 402RU at a curved (or rounded) edge having a radius of curvature R8. Furthermore, the lower sub-portion 402L and the upper curved sidewall 402RU each have a radius of curvature R9. In various embodiments, an asymmetry between the lower curved sidewall 402RL and the upper curved sidewall 402RU is attributed to a slope of the lower sub-portion 402L (e.g., the plane P4) relative to the upper sub-portion 402U, which extends along a plane P5 that is parallel, or approximately parallel, to the mixer body center axis 204.|0218] Referring to Figures 48, 53, and 56, for example, the recess 420 is positioned at a proximity to, and separated from, a probing end of the sensor 190. Various dimensions defining a shape and size of the recess 420 are adjusted to improve uniformity of a distribution of the exhaust sampled by the sensor 190. For example, in some embodiments, the conical shape of the recess 420 is defined by a first diameter DI (a minimum diameter; see Figure 50) of the bottom surface 402RB, which is distal to the sensor 190, and by a second diameter D2 (a maximum diameter; see Figure 51) of the portion of the recess 420 proximal to the sensor 190, where the second diameter D2 is greater than the first diameter DI. A difference between the first diameter and the second diameter can be adjusted to control a volume of the recess 420, which can influence the uniform distribution of the exhaust sampled by the sensor 190. In some embodiments, the first diameter DI is approximately 8.37 mm to approximately 10.23 mm, such as approximately 9.3 mm, and the second diameter D2 is approximately 37.53 mm to approximately 45.87 mm, such as approximately 41.7 mm.

[0219] Additionally or alternatively, the volume of the recess 420 can be adjusted by changing a depth of the recess 420, which is also a separation distance SI (see Figures 53 and 57, for example) between the probing end of the sensor 190 and the bottom surface 402RB of the recess 420, resulting in changes in the distribution of the exhaust. For example, increasing the separation distance SI can improve the uniform distribution of the exhaust during the sampling process. Furthermore, the volume of the recess 420 can also be adjusted by changing the slope of the lower sub-portion 402L (e.g., the plane P4) relative to the upper sub-portion 402U (e.g., the plane P5). In various embodiments, sampling the exhaust using the recess 420 with configurations provided here has the additional benefit of reducing restriction of the flow of exhaust entering the mixer body 202 through at least one of the apertures disposed on the mixer body 202, such as the first aperture 214 and the third aperture 254A.

[0220] As described above, the upper sub-portion 402U extends along the plane P5 that is parallel, or approximately parallel, to the mixer body center axis 204. The outlet portion 410 extends from the upper sub-portion 402U along the plane P5 and is coupled to the outlet flange receiver 281 by the outlet coupler 411, as depicted in Figure 53. Referring to Figure 50, the outlet coupler 411 extends along a plane P6 disposed at an obtuse angle A6 relative to the plane P5. In other words, the outlet coupler 411 is disposed at an angle relative to the outlet portion 410. In some embodiments, the angle A6 is approximately 127.62° to approximately 155.98°, such as approximately 141.8°. In various embodiments, analogous to the inlet coupler 407, the outlet coupler 411 overlaps at least a portion of the outlet flange 280 and extends annularly in a space defined by the outlet flange receiver 281. Accordingly, a curvature of the outlet coupler 411 conforms to a curvature of the circumferential edge 283 of the outlet flange 280. Referring to Figure 51, the outlet portion 410 has a width W3. In some embodiments, the width W3 is approximately 46.26 mm to approximately 56.54 mm, such as approximately 51.4 mm.Referring to Figure 51, a portion of the outlet coupler 411 overlapping the outlet flange 480 has a width Y4. In some embodiments, the width Y4 is approximately 5.04 mm to approximately 6.16 mm, such as approximately 5.6 mm.

[0221] In contrast to the depressed area formed by the transitional portion 404 and the lower sub-portion 402L, the upper sub-portion 402U and the outlet portion 410 extend along acontinuous plane, namely the plane P5, providing an open area that encourages the exhaust to exit the exhaust sampler 400 without accumulating near the probing end of the sensor 190 (e.g., in the recess 420). In this regard, the exhaust sampler 400 allows continuous replacement of the exhaust being sampled in the exhaust sampler 400, leading to a more robust and accurate detection of NOXpresent in the exhaust.[02221 In various embodiments, any two adjacent portions of the exhaust sampler 400 adjoin one another along a rounded (e.g., curved) edge defined by a radius of curvature. For example, referring to Figure 50, a rounded edge between the inlet portion 406 and the transitional portion 404 has a radius of curvature R5. In some embodiments, the radius of curvature R5 is approximately 5.4 mm to approximately 6.6 mm, such as approximately 6 mm. A rounded edge between the transitional portion 404 and the lower sub-portion 402L has a radius of curvature R6. In some embodiments, the radius of curvature R6 is approximately 7.2 mm to approximately 8.8 mm, such as approximately 8 mm. A rounded edge between the lower sub-portion 402L and the middle sub-portion 402R (including the lower curved sidewall 402RL) has a radius of curvature R7. In some embodiments, the radius of curvature R7 is approximately 5.4 mm to approximately 6.6 mm, such as approximately 6 mm. A rounded edge between the middle sub-portion 402R (including the upper curved sidewall 402RU) and the upper sub-portion 402U has a radius of curvature R10. In some embodiments, the radius of curvature R10 is approximately 5.4 mm to approximately 6.6. mm. A rounded edge between the outlet portion 410 and the outlet coupler 411 has a radius of curvature R11. In some embodiments, the radius of curvature R11 is approximately 3.6 mm to approximately 4.4 mm, such as approximately 4 mm.|0223] With respect to the middle sub-portion 402R and the recess 420, still referring to Figure 50, the rounded edge between the lower curved sidewall 402RL (or the upper curved sidewall 402RU) and the bottom surface 402RB has the radius of curvature R8. In some embodiments, the radius of curvature R8 is approximately 5.4 mm to approximately 6.6 mm, such as approximately 6 mm. In some embodiments, a radius of curvature R9 of each of the lower curved sidewall 402RL and the upper curved sidewall 402RU is approximately 54.41 mm to approximately 66.51 mm, such as approximately 60.46 mm. The outer edge 413 isseparated from the bottom surface 402RB by a distance T4. In some embodiments, the distance T4 is approximately 23.67 mm to approximately 28.93 mm, such as approximately 26.3 mm.|0224] Referring to Figures 48 and 50, the first sidewall 412 extends along a first edge of each of the inlet portion 406, the transitional portion 404, and the base portion 402.Accordingly, the first sidewall 412 includes a first sidewall inlet portion 412A, a first sidewall transitional portion 412B, and a first sidewall base portion 412C. Similarly, the second sidewall 414 extends along a second edge of each of the inlet portion 406, the transitional portion 404, and the base portion 402, where the second edge is opposite the first edge. In this regard, the second sidewall 414 includes a second sidewall inlet portion 414A, a second sidewall transitional portion 414B, and a second sidewall base portion 414C.[0225| A length Y3 of the first sidewall 412 and the second sidewall 414 is configured to provide barrier for the exhaust sampler 400 against impingement of hydrocarbon fluid particles, which can potentially foul the sensor 190 and produce inaccurate detection of the content of NOx in the exhaust due to cross-sensitivity of the sensor 190. In some embodiments, referring to Figure 50, the length Y3 is approximately 88.74 mm to approximately 108.46 mm, such as approximately 98.6 mm. Referring to Figure 51, the first sidewall 412 and the second sidewall 414 do not extend along a first edge and a second edge, respectively, of the outlet portion 410. In some embodiments, a length Y6 of the outlet portion 410 and the outlet coupler 411 along a lengthwise direction of the exhaust sampler 400 is approximately 16.02 mm to approximately 19.58 mm, such as approximately 17.8 mm.[0226| Furthermore, referring to Figures 52 and 54, where Figure 54 depicts a detailed view of DETAIL D of Figure 52, the first sidewall 412 and the second sidewall 414 each abut an edge of the inlet portion receiver 279 such that the first sidewall 412 and the second sidewall 414 form the angle A2, which is described in detail above. The width W1 of the exhaust sampler 400, which is the separation distance between the first sidewall 412 and the second sidewall 414, is configured to allow the exhaust to flow from the upstream components of the aftertreatment system 100 through the exhaust sampler 400 without substantial hindrance.

[0227] As the first sidewall 412 and the second sidewall 414 are symmetrically arranged, the following descriptions of one of the first sidewall 412 and the second sidewall 414 (and portions thereof) also apply to the corresponding components of the other one of the two sidewalls.[0228[ In various embodiments, referring to Figure 53, which is a cross-sectional view of DETAIL D taken along a plane P-P (which coincides with the plane P0 in Figure 49) as depicted in Figure 52, the second sidewall 414 extends outward from the mixer body 202 along the radial direction RD, where the outer edge 413 of the second sidewall 414 is substantially parallel to the mixer body center axis 204. A separation distance Hl between the outer edge 413 and an inner wall of the introduction conduit 109 is adjusted to control blockage of the hydrocarbon fluid particles from impinging the sensor 190 within the exhaust sampler 400 and causing inaccurate measurement of the NOXcontent in the exhaust. In addition, the separation distance Hl is configured to provide ease of installing the hydrocarbon mixer 146 in the introduction conduit 109. In this regard, the separation distance Hl is selected to provide sufficient blockage of the hydrocarbon fluid particles while maintaining a suitable clearance between the exhaust sampler 400 and the inner wall of the introduction conduit 109 needed for the ease of assembling. In some embodiments, the separation distance Hl is approximately 0.56 mm to approximately 0.66 mm, such as approximately 0.62 mm.

[0229] Referring to Figure 53, a portion of the second sidewall inlet portion 414A is welded onto a surface of the inlet flange 271 that faces the outlet flange 280, while the inlet coupler 407 is welded onto a surface of the inlet flange 271 that faces the upstream catalyst member 138 (not depicted in Figure 53). In this regard, a height H2 of the second sidewall inlet portion 414A determines a size of a welded interface (or a contact area) between the exhaust sampler 400 and the inlet flange 271. For example, increasing the height H2 increases a contact area between the second sidewall 414 and the inlet flange 271, which improves the welded bond between the two components.

[0230] Additionally, the height H2 may also influence the performance of the hydrocarbon mixer 146 and the efficacy of the sampling process facilitated by the exhaust sampler 400. Forexample, referring to Figure 54, an increase in the height H2 may lead to a decrease in a separation distance H3, which is a minimum separation distance between the exhaust sampler 400 at the middle sub-portion 402R and a portion of the mixer body 202, resulting in reduction in an open space (or plenum) through which the exhaust flows before entering the mixer body cavity 216, such as through one or more of the third apertures 254A-254C. Such reduction in the open space may inadvertently increase backpressure and decrease the uniformity of the swirling within the mixer body cavity 216.|0231] On the other hand, a decrease in the height H2 reduces the flow of the exhaust entering the exhaust sampler 400 at the inlet portion 406 and negatively impacting flow distribution of the exhaust near the sensor 190 (e.g., in the recess 420) and the accuracy of the measurement of NOx by the sensor 190. Accordingly, the height H2 is adjusted to provide a sufficiently large welded interface between the exhaust sampler 400 and the inlet flange 271 without substantially affecting the performance of the hydrocarbon mixer 146. In some embodiments, the height H2 is approximately 4.23 mm to approximately 5.17 mm, such as approximately 4.7 mm.[0232| Referring to Figure 53, a height H4 of the second sidewall base portion 414C is the greatest (H4 (max)) at a location proximal to the transitional portion 404 and gradually decreases from the towards the outlet portion 410 along the axial direction AD, where a minimum value (H4 (min)) of the height H4 is measured proximal to the outlet portion 410. In some embodiments, the minimum value of the height H4 is greater than the height H2. Independent of other factors (such as those described below), an extent of protection offered by the second sidewall base portion 414C against impingement of the hydrocarbon fluid particles increases with an increase in the height H4.|0233] Analogous to the second sidewall inlet portion 414A, the second sidewall base portion 414C is welded to a surface of the outlet flange 280 that faces the inlet flange 271. In this regard, the height H4 determines a size of a welded interface between the exhaust sampler 400 and the outlet flange 280. For example, increasing the height H4 increases a contact areabetween the second sidewall 414 and the outlet flange 280, which improves the welded bond between the two components.|0234[ In some instances, similar to the impact of changing the height H2 on the performance of the hydrocarbon mixer 146 and the efficacy of the sampling process facilitated by the exhaust sampler 400, an increase in the height H4 may lead to a decrease in a separation distance H5, which is a separation distance between the exhaust sampler 400 at the upper subportion 402U and a corresponding portion of the mixer body 202, resulting in reduction in an open space through which the exhaust flows into the mixer body cavity 216 such as through one or more of the third apertures 254A-254C. Such reduction in the open space may inadvertently increase the backpressure and decrease the extent of swirling within the mixer body cavity 216. Furthermore, such reduction in the open space may create an imbalance between an available volume of the exhaust provided to the exhaust sampler 400 and the flow of the exhaust entering the exhaust sampler 400 at the inlet portion 406. In some examples, increasing the height H4 while keeping the height H2 constant can create possible backflow of hydrocarbon fluid particles from the opening created by the height H4 towards the sensor 190 and change flow field (e.g., flow distribution) of the exhaust around the tip of the sensor 190. In some embodiments, the height H4 decreases from approximately 34.6 mm to approximately 8.3 mm, and the height H5 that corresponds to the minimum value of the height H4, i.e., approximately 8.3 mm, is approximately 11.79 mm to approximately 14.3 mm, such as approximately 13.1 mm.

[0235] On the other hand, a decrease in the height H4 (i.e., an increase in the separation distance H5) limits an open space between the inner wall of the introduction conduit 109 and the upper sub-portion 402U of the exhaust sampler 400, thereby increasing the backpressure within the exhaust sampler 400. Such reduction in the height H4 may also negatively impact the flow distribution of the exhaust near the sensor 190 and the accuracy of the measurement of NOXby the sensor 190.

[0236] Still referring to Figure 53, a lowest portion 420L of the recess 420 is disposed in closer proximity to the mixer body 202 than a lowest portion 414L of the sidewall 414 (and alowest portion of the sidewall 412). Stated differently, the lowest portion 420L protrudes from the lowest portion 414L of the sidewall 414 towards the portion of the mixer body 202 adjacent to which the exhaust sample 400 extends.

[0237] Referring to Figure 55, a portion of an inner edge 415 of the second sidewall base portion 414C opposite the outer edge 413 extends along an axis Cl, and an edge of the second guide plate 256A extends along an axis C2. In some embodiments, the axes Cl and C2 are substantially parallel to one another and separated by a distance H7. In various embodiments, the distance H7 between the parallel axes Cl and C2 is configured to provide sufficient open space between the exhaust sampler 400 and the second guide plate 256A, thereby allowing entry of the flow of exhaust into the mixer body cavity 216 without substantial interference arising from the sampling process facilitated by the exhaust sampler 400. In some embodiments, the distance H7 is approximately 15.75 mm to approximately 19.25 mm, such as approximately 17.5 mm.|0238] Still referring to Figure 55, a portion of an inner edge 417 of the second sidewall transitional portion 414B opposite the outer edge 413 extends along an axis C3, which forms an angle A8 with the axis Cl . In some embodiments, the angle A8 is designed to allow the exhaust sampler 400 be formed using a positive deep drawing operation. In addition, the slanted inner edge 417 forms additional open space between the second sidewall 414 and the inlet flange 271, thereby reducing restriction on the entry of the exhaust into the mixer body cavity 216 at a given height H3. In some embodiments, the angle A8 is approximately 59.13° to approximately 72.27°, such as approximately 65.7°.[0239| As discussed above, the first sidewall 412 and the second sidewall 414 are configured to partially enclose the exhaust sampler 400 to reduce or prevent inadvertent impingement of hydrocarbon fluid particles escaped from the injection aperture 236, the first aperture 214, or both, onto the sensor 190. Accordingly, referring to Figures 53 and 55, the second sidewall 414 continuously extends between the inlet flange 271 and the outlet flange 280 and does not include any openings between the inlet flange 271 and the outlet flange 280.

[0240] Figure 56 depicts an end view of the hydrocarbon mixer 146 from the downstream perspective, and Figure 57 depicts a detailed view of DETAIL E of Figure 56. Referring to Figure 57, the mixer body 202 (e.g., the second guide plate 262A) and the lowest portion of the exhaust sampler 400 (i.e., the bottom surface 402RB of the middle sub-portion 402R), which corresponds to the lowest portion 420L of the recess 420, are separated by a separation distance S3. Changing the separation distance S3 may have a similar effect on the performance of the hydrocarbon mixer 146 as changing the separation distance H5. For example, a decrease in the separation distance S3 can lead to reduction in the open space through which the exhaust flows into the mixer body cavity 216, such as through one or more of the third apertures 254A-254C, for example, and can inadvertently increase the backpressure and decrease the extent of swirling within the mixer body cavity 216. On the other hand, an increase in the separation distance S3 can reduce the open space provided by the exhaust sampler 400 and increase the backpressure within the exhaust sampler 400. In some embodiments, the separation distance S3 is approximately 5.31 mm to approximately 6.49 mm, such as approximately 5.90 mm.[02411 Referring to Figures 53 and 57, the introduction conduit 109 includes a sensor receiver 460 configured to couple the sensor 190 to the introduction conduit 109. The sensor receiver 460 includes a receiver body 462 that surrounds a circular cavity 464, where the circular cavity 464 has a depth S2 that extends outward from the exhaust sampler 400. The receiver body 462 is configured to conform to surrounding components, thus creating a flat welded interface for improved bonding between the sensor 190 and the components. In some embodiments, the depth S2 is approximately 5.4 mm to approximately 6.6 mm, such as approximately 6 mm. In various embodiments, the combination of the circular cavity 464 and the recess 420 provides additional space for integrating the sensor 190 with the introduction conduit 109 and the exhaust sampler 400, thereby improving the uniform distribution of the exhaust in the exhaust sampler 400.

[0242] Referring to Figure 57, an angle A9 between the center line CL1 and a center line CL2 through a center of the hydrocarbon injector 150 is adjusted to reduce the amount of hydrocarbon fluid particles impinging on the sensor 190 without substantially disrupting the swirling of the hydrocarbon fluid with the exhaust within the mixer body 202. In someembodiments, the angle A9 is approximately 29.73° to approximately 36.33°, such as approximately 33.03°.IV. Additional Example Aftertreatment Systems|0243] Referring to Figure 58, a cross-sectional view of a portion of an aftertreatment system 300 taken along a plane that bisects the portion of the aftertreatment system 300 is depicted. The aftertreatment system 300 is similar to the aftertreatment system 100. The aftertreatment system 300 includes various components of the aftertreatment system 100. For example, the aftertreatment system 300 includes an introduction conduit 302 that is similar to the introduction conduit 109. The aftertreatment system 300 includes an upstream catalyst member 304 similar to the upstream catalyst member 138. The aftertreatment system 300 also includes a hydrocarbon mixer 306 that operates similar to the hydrocarbon mixer 146.[0244 The hydrocarbon mixer 306 includes a mixer body 310 similar to the mixer body 202, the mixer body 310 having an inlet end 311 opposite an outlet end 313 that is downstream of the inlet end 311. The mixer body 310 is centered on a mixer body center axis 301. The mixer body 310 includes a plurality of connectors 326 arranged along a circumference of the inlet end 311, the connectors 326 being similar to the connectors 260. The hydrocarbon mixer 306 includes an inlet cap 320 coupled to the inlet end 311 of the mixer body 310, the inlet cap 320 being similar to the inlet cap 270. The inlet cap 320 includes a perforated plate 322 coupled to the connectors 326, an inlet flange (not depicted) coupled to the perforated plate 322, and an annular plate 324 downstream of the perforated plate 322 and coupled to the mixer body 310, the perforated plate 322 and the annular plate 324 being similar to the perforated plate 272 and the annular plate 274, respectively. The hydrocarbon mixer 306 further includes an outlet flange 340 having an outlet flange body 342 coupled to the outlet end 313 of the mixer body 310, the outlet flange 340 and the outlet flange body 342 being similar to the outlet flange 280 and the outlet flange body 284, respectively. In various embodiments, the aftertreatment system 300 includes an exhaust sampler (not depicted in the view of Figure 58) coupled to the inlet flange and the outlet flange 340 of the mixer body 310 in a fashion similar to that of the exhaust sampler 400 coupling to the inlet flange 271 and the outlet flange 280 in thehydrocarbon mixer 146 as described in detail above. For example, the exhaust sampler is configured to facilitate the sampling of exhaust by a sensor (not depicted separately), where the exhaust is provided from the upstream component, such as the upstream catalyst member 304.

[0245] The aftertreatment system 300 is different from the aftertreatment system 100 in that the aftertreatment system 300 includes an elbow conduit 350. The elbow conduit 350 is positioned downstream of the hydrocarbon mixer 306 and is contiguous with the introduction conduit 302. The elbow conduit 350 is separated from an inlet of the oxidation catalyst member 360 by a perforated plate 354. The elbow conduit 350 is configured to receive exhaust from the hydrocarbon mixer 306 in a first direction and facilitate a change of direction of the exhaust. For example, the elbow conduit 350 receives the exhaust in a first direction and causes the exhaust to change from a first direction to a second direction where the second direction is parallel and opposite of the first direction. The exhaust may then flow to an oxidation catalyst member 360 downstream of the hydrocarbon mixer 306. The oxidation catalyst member 360 is similar to the first oxidation catalyst member 158. However, rather than the oxidation catalyst member 360 being aligned with the upstream catalyst member 304 (see Figures 1 and 4), the oxidation catalyst member 360 is adjacent and parallel to the upstream catalyst member 304.

[0246] Consequently, the aftertreatment system 300 including the elbow conduit 350 may provide certain benefits. For example, the total length of the aftertreatment system 300 is reduced and total space necessary for the aftertreatment system is reduced.

[0247] As depicted in Figure 58, the upstream catalyst member 304 and the oxidation catalyst member 360 have the same diameter (e.g., an inner diameter) D3. In some embodiments, the diameter D3 is approximately 240.03 mm to approximately 293.37 mm, such as bout 266.7 mm. The upstream catalyst member 304 has a length LI and the oxidation catalyst member 360 has a length L2 that is less than the length LI, where the lengths LI and L2 are each measured along the direction of the flow of exhaust. In some embodiments, the length LI is approximately 160.02 mm to approximately 195.58 mm, such as approximately 177.8 mm. In some embodiments, the length L2 is approximately 91.44 mm to approximately 111.76 mm, such as approximately 101.6 mm. In some embodiments, a distance L3 between anoutlet of the upstream catalyst member 304 and a cap 352 of the elbow conduit 350, which includes a length of the hydrocarbon mixer 306, is approximately 184.14 mm to approximately 225.06 mm, such as approximately 204.6 mm. In some embodiments, a distance L4 between the outlet of the upstream catalyst member 304 and the inlet cap 320 (including the perforated plate 322) is approximately 13.5 mm to approximately 16.5 mm, such as approximately 15 mm. In some embodiments, a distance L5 between the perforated plate 354 and the cap 352 is approximately 92.20 mm to approximately 112.70 mm, such as approximately 102.45 mm. In some embodiments, a distance L6 between an inlet of the oxidation catalyst member 360 and the cap 352 is approximately 148.05 mm to approximately 180.95 mm, such as approximately 164.5 mm. In this regard, a separation distance between the perforated plate 354 and the inlet of the oxidation catalyst member 360 is a difference between the distances L5 and L6, which is approximately 55.85 mm to approximately 68.25 mm, such as approximately 62.05 mm.

[0248] Referring to Figure 59, a cross-sectional view of a portion of an aftertreatment system 500 taken along a plane that bisects the portion of the aftertreatment system 500 is depicted. The aftertreatment system 500 is similar to the aftertreatment system 100. The aftertreatment system 500 includes various components of the aftertreatment system 100. For example, the aftertreatment system 500 includes an introduction conduit 502 that is similar to the introduction conduit 109. The aftertreatment system 500 includes an upstream catalyst member 304 similar to the upstream catalyst member 138. The aftertreatment system 500 also includes a hydrocarbon mixer 506 that operates similar to the hydrocarbon mixer 146.

[0249] The hydrocarbon mixer 506 includes a mixer body 510 similar to the mixer body 202, the mixer body 510 having an inlet end 511 opposite an outlet end 513 that is downstream of the inlet end 511. The mixer body 310 is centered on a mixer body center axis 301. The mixer body 510 includes a plurality of connectors 526 arranged along a circumference of the inlet end 511, the connectors 526 being similar to the connectors 260. The hydrocarbon mixer 306 includes an inlet cap 520 coupled to the inlet end 511 of the mixer body 510, the inlet cap 320 being similar to the inlet cap 270. The inlet cap 520 includes a perforated plate 522 coupled to the connectors 526, an inlet flange (not depicted) coupled to the perforated plate 522, and an annular plate 524 downstream of the perforated plate 522 and coupled to the mixer body 510,the perforated plate 522 and the annular plate 524 being similar to the perforated plate 272 and the annular plate 274, respectively. The hydrocarbon mixer 506 further includes an outlet flange 540 having an outlet flange body 542 coupled to the outlet end 513 of the mixer body 510, the outlet flange 540 and the outlet flange body 542 being similar to the outlet flange 280 and the outlet flange body 284, respectively. In various embodiments, the aftertreatment system 500 includes an exhaust sampler 546 coupled to the inlet flange and the outlet flange 540 of the mixer body 510 in a fashion similar to that of the exhaust sampler 400 coupled to the inlet flange 271 and the outlet flange 280 in the hydrocarbon mixer 146 as described in detail above. For example, the exhaust sampler 546 defines a recess 548 configured to facilitate the sampling of exhaust by a sensor (not depicted separately), where the exhaust is provided from the upstream component, such as the upstream catalyst member 504.

[0250] The aftertreatment system 500 is similar to the aftertreatment system 300 in that the aftertreatment system 500 also includes an elbow conduit 550 positioned downstream of the hydrocarbon mixer 506 and contiguous with the introduction conduit 502. The elbow conduit 550 is separated from an inlet of the oxidation catalyst member 560 by a perforated plate 554. The elbow conduit 550 is configured to receive exhaust from the hydrocarbon mixer 506 in a first direction and facilitate a change of direction of the exhaust. In this regard, the oxidation catalyst member 560 is adjacent and parallel to the upstream catalyst member 504 in a manner similar to the positions of the oxidation catalyst member 360 and the upstream catalyst member 304 as depicted in Figure 58. However, as described in detail below, certain dimensions of the aftertreatment system 500 are reduced in comparison to the aftertreatment system 300, resulting in a more compact design suitable to be used with engines of different architectures.|0251] The upstream catalyst member 504 has a length L8 and the oxidation catalyst member 560 has a length L10 that is less than the length L8, where the lengths L8 and L10 are each measured along the direction of the flow of exhaust. In some embodiments, the length L8 is approximately 160.02 mm to approximately 195.58 mm, such as approximately 177.8 mm. In some embodiments, the length L10 is approximately 114.3 mm to approximately 139.7 mm, such as approximately 127 mm. In some embodiments, a distance L12 between an outlet of the upstream catalyst member 504 and a cap 552 of the elbow conduit 550 is approximately 164.35mm to approximately 200.87 mm, such as approximately 182.61 mm. In some embodiments, a length L14 of the hydrocarbon mixer 506 is approximately 149.50 mm to approximately 182.72 mm, such as approximately 166.11 mm. In some embodiments, a distance Li l between the outlet of the upstream catalyst member 304 and the inlet cap 520 (including the perforated plate 522) is approximately 13.5 mm to approximately 16.5 mm, such as approximately 15 mm. In some embodiments, a distance L16 between the perforated plate 554 and the cap 352 is approximately 61.60 mm to approximately 75.28 mm, such as approximately 68.44 mm. In some embodiments, a distance L17 between an inlet of the oxidation catalyst member 560 and the cap 352 is approximately 83.27 mm to approximately 101.77 mm, such as approximately 92.52 mm. In this regard, a separation distance L18 between the perforated plate 554 and the inlet of the oxidation catalyst member 560 is a difference between the distances L17 and L16, which approximately 19.87 mm to approximately 25.08 mm, such as approximately 22.08 mm.

[0252] In some embodiments, the separation distance LI 8 between the perforated plate 554 and the inlet of the oxidation catalyst member 560 of the aftertreatment system 500 is designed to be substantially less than the separation distance between the perforated plate 354 and the inlet of the oxidation catalyst member 360 of the aftertreatment system 300. In this regard, positioning the exhaust sampler 546 adjacent to the mixer body 510 circumvents the space constraints associated with the design of the aftertreatment system 500, providing a compact design solution for the monitoring of NOxin various system architectures.{02531 While the aftertreatment system 100, the aftertreatment system 300, and the aftertreatment system 500 have been shown and described in the context of use with a diesel internal combustion engine, the aftertreatment system 100, the aftertreatment system 300, the aftertreatment system 500 may be used with other internal combustion engines, such as gasoline internal combustion engines, hybrid internal combustion engines, propane internal combustion engines, dual-fuel internal combustion engines, and other similar internal combustion engines.V. Configuration of Example Embodiments

[0254] 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.

[0255] 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 or alterations of the subject matter described and claimed are considered to be within the scope of the appended claims.

[0256] 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.[0257| The terms “fluidly coupled to” 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, hydrocarbon fluid, an air-hydrocarbon fluid mixture, exhaust, 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.[0258| 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.|0259] 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, X and 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.

[0260] Additionally, the use of ranges of values (e.g., W1 to W2, etc.) herein are inclusive of their maximum values and minimum values (e.g., W1 to W2 includes W1 and includes W2, etc.), unless otherwise indicated. Furthermore, a range of values (e.g., W1 to W2, etc.) does not necessarily require the inclusion of intermediate values within the range of values (e.g., W1 to W2 can include only W1 and W2, etc.), unless otherwise indicated.

Claims

WHAT IS CLAIMED IS:

1. An aftertreatment system, comprising: an introduction conduit; and a mixer disposed within the introduction conduit, the mixer comprising: a mixer body centered on a mixer body center axis and configured to receive exhaust and a hydrocarbon fluid, the mixer body comprising: an inlet end, a plurality of connectors arranged along a circumference of the inlet end and extending away from the inlet end, and an outlet end downstream of the inlet end, an inlet cap over the inlet end, the inlet cap comprising: a perforated plate coupled to the connectors and comprising a plurality of perforations arranged in a circular pattern, an inlet flange coupled to the perforated plate; and an annular plate downstream of the perforated plate and coupled to the mixer body, the annular plate comprising an annular plate aperture centered on the mixer body center axis, and an outlet flange having an outlet flange body coupled to the outlet end, the outlet flange body comprising: an inner edge, and a flared portion extending from the inner edge into the mixer body, the inner edge defining an outlet flange aperture offset from the mixer body center axis.

2. The aftertreatment system of claim 1, wherein: the mixer body further comprises a first aperture; the mixer further comprises an injector plate coupled to the mixer body adjacent to the first aperture, the injector plate comprising: an injector plate panel angled away from the mixer body and extending over at least a portion of the first aperture, andan injection aperture configured to facilitate injection of the hydrocarbon fluid into the mixer body, the injection aperture extending through the injector plate panel; and the outlet flange body further comprises a slot adjacent to the outlet flange aperture, the slot comprising an edge aligned with an axis through a center of the injection aperture along the mixer body center axis.

3. The aftertreatment system of claim 2, wherein the mixer body further comprises: a plurality of second apertures on a first side of the first aperture, and a plurality of third apertures on a second side of the first aperture opposite the first side, the second apertures and the third apertures each having a first width extending along a circumference of the mixer body, the first aperture having a second width extending along the circumference of the mixer body, and the second width being greater than the first width.

4. The aftertreatment system of claim 2, further comprising a coupler centered on the axis; wherein the introduction conduit comprises an opening in fluid communication with the injection aperture; and wherein the coupler is coupled to the opening such that the coupler is configured to facilitate the injection of the hydrocarbon fluid into the mixer body through the opening and the injection aperture.

5. The aftertreatment system of claim 4, wherein: the axis is a first axis; a second axis extends through a centerline of the outlet flange aperture; and the first axis and the second axis are parallel and laterally offset from one another.

6. The aftertreatment system of claim 1, wherein: the flared portion is a first flared portion; and the outlet flange body further comprises: an outer edge coupled to the outlet end, an annular region extending between the inner edge and the outer edge, anda second flared portion angled away from the outer edge.

7. The aftertreatment system of claim 6, wherein: a first angle between the annular region and the first flared portion is less than a second angle between the annular region and the second flared portion; and a first height of the first flared portion is greater than a second height of the second flared portion.

8. The aftertreatment system of claim 1, wherein: the perforated plate includes a non-perforated region enclosed by the perforations; and the annular plate aperture overlaps the non-perforated region along the mixer body center axis.

9. The aftertreatment system of claim 1, wherein the mixer body comprises a portion that protrudes from the annular plate to the inlet end.

10. The aftertreatment system of claim 1, wherein the mixer further comprises an exhaust sampler, the exhaust sampler comprising: an inlet portion coupled to the inlet flange; an outlet portion coupled to the outlet flange; and a base portion disposed between the inlet portion and the outlet portion in an axial direction, the base portion extending adjacent to a portion of the mixer body and defining a recess, a lowest portion of the recess protruding from a lowest portion of a sidewall of the exhaust sampler towards the portion of the mixer body.

11. An aftertreatment system comprising: an introduction conduit; and a mixer disposed within the introduction conduit, the mixer comprising:a mixer body centered on a mixer body center axis and configured to receive exhaust and a hydrocarbon fluid, the mixer body comprising an inlet end and an outlet end downstream of the inlet end, an inlet flange coupled to the inlet end, an outlet flange coupled to the outlet end, and an exhaust sampler comprising: an inlet portion coupled to the inlet flange, an outlet portion coupled to the outlet flange, and a base portion disposed between the inlet portion and the outlet portion in an axial direction, the base portion extending adjacent to a portion of the mixer body and defining a recess.

12. The aftertreatment system of claim 11, further comprising a sensor coupled to the introduction conduit, the sensor extending towards the mixer body and into the recess.

13. The aftertreatment system of claim 11, wherein a lowest portion of the recess is disposed in closer proximity to the mixer body than a lowest portion of a sidewall of the exhaust sampler.

14. The aftertreatment system of claim 11, wherein the exhaust sampler further comprises: a transitional portion extending from the inlet portion to the base portion; a first sidewall extending along the inlet portion, the transitional portion, and the base portion in the axial direction and away from the mixer body center axis along a radial direction, and a second sidewall opposite the first sidewall and extending along the inlet portion, the transitional portion, and the base portion in the axial direction and away from the mixer body center axis.

15. The aftertreatment system of claim 14, wherein:the first sidewall comprises a first sidewall inlet portion, a first sidewall transitional portion, and a first sidewall base portion adjacent to the inlet portion, the transitional portion, and the base portion, respectively, the first sidewall base portion having a first height; the second sidewall comprises a second sidewall inlet portion, a second sidewall transitional portion, and a second sidewall base portion adjacent to the inlet portion, the transitional portion, and the base portion, respectively, the second sidewall base portion having a second height; and the first height and the second height each decrease along the axial direction.

16. The aftertreatment system of claim 14, wherein: the mixer body further comprises a first aperture; the mixer further comprises an injector plate coupled to the mixer body adjacent to the first aperture, the injector plate comprising: an injector plate panel angled away from the mixer body and extending over at least a portion of the first aperture, and an injection aperture configured to facilitate injection of the hydrocarbon fluid into the mixer body, the injection aperture extending through the injector plate panel; and the exhaust sampler extends over a portion of the mixer body adjacent to the first aperture such that one of the first sidewall or the second sidewall separates the first aperture from the recess.

17. The aftertreatment system of claim 16, wherein the mixer body further comprises a second aperture adjacent to the first aperture, wherein the exhaust sampler extends between the first aperture and the second aperture.

18. The aftertreatment system of claim 11, wherein: the outlet flange comprises an outlet flange body, the outlet flange body comprising: a circumferential edge, and an outlet flange receiver recessed relative to the circumferential edge; and the outlet portion is coupled to the outlet flange receiver.

19. The aftertreatment system of claim 11, wherein the outlet flange comprises an outlet flange body, the outlet flange body comprising: an inner edge; and a flared portion extending from the inner edge into the mixer body, the inner edge defining an outlet flange aperture, the outlet flange aperture being offset from the mixer body center axis.

20. The aftertreatment system of claim 11, wherein: the mixer body further comprises a plurality of connectors arranged along a circumference of the inlet end and extending away from the inlet end; and the mixer further comprises: a perforated plate coupled to the connectors, the perforated plate comprising a plurality of perforations arranged in a circular pattern, and an annular plate downstream of the perforated plate and coupled to the inlet end, the annular plate comprising an annular plate aperture centered on the mixer body center axis.

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