Diesel exhaust fluid sensor adapter to suppress fluid bubble formation

Abstract

A fluid sensor adapter for reducing air bubbles in a fluid includes a first chamber including an inlet configured to receive diesel exhaust fluid, the first chamber including a first segment at a proximal end of the fluid sensor adapter, a third segment at a distal end of the fluid sensor adapter, and a second segment between the first and third segments, the diameter of the second segment being smaller than the diameter of the first segment, an inlet from the second segment to the third segment being narrower than the diameter of the second segment, the reduction in diameter from the first segment to the second segment and the narrowing of the inlet from the second segment to the third segment comprising a tortuous vent path configured to prevent air within the fluid from reaching a sensor.

Description

[Technical Field]

[0001] Field of the Disclosure This application claims priority to U.S. Patent Application No. 63 / 404,788, filed September 8, 2022, and entitled "DIESEL EXHAUST FLUID SENSOR ADAPTER FOR FLUID AERATION MITIGATION," which is incorporated herein by reference in its entirety.

[0002] Field of the Disclosure FIELD OF THE DISCLOSURE The present disclosure relates to a diesel exhaust fluid sensor adapter, and more particularly to a diesel exhaust fluid sensor adapter for suppressing fluid aeration.

[0003] Background to the disclosure Diesel exhaust fluid (DEF) tanks have been standard on diesel-powered ground vehicles in the United States since 2010. DEF is a reducing agent and aqueous urea solution (AUS) that can be used in selective catalytic reduction (SCR) diesel exhaust systems. DEF has unique properties that are critical to the performance of the exhaust system on diesel-engine equipment equipped with SCR diesel exhaust systems.

[0004] For this reason, it is common for DEF reservoirs to be equipped with multiple sensors. These sensors may monitor one or more of the following: fluid level, fluid temperature, fluid concentration (e.g., urea in water), etc. For example, a DEF fluid level sensor may measure the level of fluid remaining in the DEF tank. If the fluid level gets low, the DEF fluid level sensor can send a signal to the vehicle's electronic control unit, which in turn triggers a warning light on the vehicle's instrument panel. Multiple sensor methods are used to determine the status of the reservoir and fluid.

[0005] Most, if not all, sensor technologies (e.g., ultrasonic, thermal dispersive, infrared spectroscopy, etc.) are sensitive to air in DEF. Entrained air (hereinafter referred to as entrained air) (e.g., air bubbles) can alter the physical properties of the DEF and the behavior of the sensor. For example, entrained air or bubbles dissolved in DEF can scatter ultrasonic or other signals from the sensor, resulting in the sensor not receiving echo reflections. Such entrained air or bubbles dissolved in DEF can result in erratic or no measurement results. Regardless of the parameter being measured (e.g., speed of sound, resistance / conductance, specific heat, dynamic viscosity, optical properties, etc.), air in the fluid will likely adversely affect the measurement or, at the very least, make the sensor technology and corresponding measurement unreliable and / or unreliable. Entrained air can also cause sensor errors, fault codes, and observed measurement variations (e.g., in DEF level, DEF temperature, DEF / urea concentration, etc.) when the vehicle is in use. Entrained air can cause inaccurate measurement readings and / or measurement readings to be unavailable altogether. No Fault Found (NFF) warranty claims may be due to issues where entrained air affects sensor measurement readings.

[0006] Bubbles that affect sensor function can generally be categorized into two types. In the first example, a large amount of air trapped in an enclosed space can produce larger bubbles (approximately 0.002 ml or larger in size). These larger bubbles have relatively high buoyancy and generally can easily rise in a liquid. The second type of bubbles is extremely small and is referred to as "microbubbles" or "nanobubbles." These "microbubbles" can have relatively low buoyancy and tend to adhere to vertical and horizontal surfaces. For example, the buoyancy of these "microbubbles" is generally insufficient to overcome surface adhesion to vertical and horizontal surfaces, so they instead stick to these surfaces. Thus, these "microbubbles" can adhere to the sensor surface and sensor reflector.

[0007] Larger bubbles typically form from air trapped in an enclosed space filled with DEF. This often occurs in sensors that utilize a cover, shroud, or other enclosure to provide a stable liquid environment for the sensor to operate in (i.e., minimize liquid sloshing or movement). To prevent trapped air, these enclosures may be equipped with vent apertures at their highest point to allow air to escape. Additionally, fill apertures may be equipped at their lowest point to allow liquid to enter the enclosure and displace the air. However, because these vent apertures must be large enough to allow air to escape as liquid enters the enclosure, they also provide a path for "microbubbles" to be forced into the enclosure. Once inside the enclosure, "microbubbles" can adhere to critical surfaces such as the reflector or sensor face. In one example, air entering through a sensor's vent apertures can cause sensor error.

[0008] Smaller "microbubbles" can be the result of excessive agitation or aeration of the DEF. Common causes are aeration during DEF tank filling and sloshing of DEF fluid due to dynamic environments and vehicle use. Another cause is the standard DEF fill nozzle, which utilizes a venturi system to provide an automatic nozzle shutoff when the DEF tank is full. This venturi system actually draws air from the tank and entrains it into the DEF as it passes through the nozzle and enters the DEF tank. For the most part, the entrained air can eventually be released from the DEF and may not adversely affect system operation. However, some of the smaller bubbles ("microbubbles") may adhere to the inner walls of the sensor housing and interfere with sensor readings. Liquid agitation has proven insufficient to remove these bubbles. The most reliable method for removing "microbubbles" is to manually wipe the affected surface and resubmerge the sensor. Naturally, this is not feasible for sensors on operating vehicles, as unwanted air can form during normal vehicle use.

[0009] Given this, there is a need in the art for sensors, sensor assemblies, and / or sensor adapters that mitigate entrained air or air bubbles in DEF. There is a need to address either or both the cause and dissipation of larger air bubbles and / or “microbubbles” trapped in DEF. The provided adapters and assemblies may prevent air from accumulating on or near the sensor surface or otherwise interfering with sensor measurements, and may provide a solution for separating or directing any air that may enter the sensor assembly or adapter. The structures and designs may provide one or more (or all) of the following: accurate DEF sensor measurements; reliable sensor measurements; reduction of entrained air in DEF; improved dissipation or mitigation of entrained air in DEF and reliable sensor measurements; reduced sensor error readings; reduced sloshing issues introduced by sensor adapters (e.g., upper adapters); a balance of enhanced performance and manufacturing costs; relative ease of manufacturing; and the like.

[0010] overview The following presents a summary of the disclosure to provide a basic understanding of some aspects. This summary is not intended to identify key or critical elements or to define any limitations of the embodiments or claims. This summary may provide a simplified overview of some aspects that may be described in more detail in other parts of the disclosure. Furthermore, any described aspect may be separated from or combined with other described aspects without limitation.

[0011] A diesel exhaust fluid (DEF) sensor adapter is provided. The sensor adapter may include two chambers. The first chamber may include a tortuous path for fluid and / or air flow. The second chamber may be fluidly sealed or isolated from the first chamber and may house electrical components. The tortuous path may include varying stepped segments having a decreasing diameter from the proximal end to the distal end. For example, the first segment at the proximal end may have a larger diameter than the second, intermediate (middle) segment. The inlet from the second segment to the third segment may have a significantly reduced size. The tortuous path may further include a vent inlet positioned approximately at the same height as the inlet, but requiring approximately a 180° turn between them. The inlet may extend into two opposing substantially horizontal sections, each leading to a vent outlet on either side of the sensor adapter. The bend (change of direction) from the inlet to the substantially horizontal section may be approximately 90°. The sensor adapter and tortuous path may inhibit aeration of the DEF. The sensor adapter may prevent aerated DEF from entering the sensor adapter and allow air to escape from the sensor adapter, preventing aeration of the DEF within the sensor adapter.

[0012] A fluid sensor adapter for reducing air bubbles in a fluid is disclosed. In one embodiment, the fluid sensor adapter may include a first chamber including an inlet configured to receive diesel exhaust fluid. In one embodiment, the first chamber may include a first segment at a proximal end of the fluid sensor adapter, a third segment at a distal end of the fluid sensor adapter, and a second segment between the first and third segments. In one embodiment, the diameter of the second segment may be smaller than the diameter of the first segment. In one embodiment, the inlet from the second segment to the third segment may be narrower than the diameter of the second segment. In one embodiment, the reduction in diameter from the first segment to the second segment and the narrowing of the inlet from the second segment to the third segment may include a tortuous ventilation path configured to prevent air in the fluid from reaching the sensor.

[0013] In one embodiment, the second segment and the third segment may have approximately the same diameter. In one embodiment, the first segment may include a shoulder that facilitates a diameter reduction from the first segment to the second segment. In one embodiment, the second segment may include a shoulder that facilitates a narrowing of the inlet from the second segment to the third segment. In one embodiment, the inlet from the second segment to the third segment may further include a shelf that facilitates a narrowing of the inlet from the second segment to the third segment. In one embodiment, the diameter reduction from the first segment to the second segment and the narrowing of the inlet from the second segment to the third segment may occur on the inside and outside of the fluid sensor adapter.

[0014] In one embodiment, the fluid sensor adapter may further include at least one vent in the third segment. In one embodiment, the fluid sensor adapter may further include at least two vents in the third segment. In one embodiment, the at least one vent may have a substantially horizontal portion. In one embodiment, the at least two vents may each have a substantially horizontal portion. In one embodiment, the first segment may include a seal. In one embodiment, the first segment may include an O-ring. In one embodiment, the third segment may include a seal. In one embodiment, the third segment may include a plug and an O-ring. In one embodiment, the fluid sensor adapter may further include a second chamber. In one embodiment, the second chamber may be disposed adjacent to the first chamber but fluidly isolated from the first chamber.

[0015] A fluid sensor adapter for suppressing bubble formation in a fluid is disclosed. In one embodiment, the fluid sensor adapter may include a first chamber. In one embodiment, the first chamber may include a first segment at a proximal end of the fluid sensor adapter, a third segment at a distal end of the fluid sensor adapter, and a second segment between the first and third segments. In one embodiment, the third segment may include at least one vent, an O-ring, and a plug. In one embodiment, the first segment may include an O-ring.

[0016] In one embodiment, the first segment may include a shoulder to facilitate a decrease in diameter from the first segment to the second segment. In one embodiment, the second segment may include a shoulder to facilitate a narrowing at the inlet from the second segment to the third segment. In one embodiment, the plug and O-ring may be located at the top of the third segment. In one embodiment, the at least one vent may be located at the bottom of the third segment. In one embodiment, the inlet from the second segment to the third segment may be adjacent to the inlet of the at least one vent. In one embodiment, the inlet and the inlet may be separated by a shelf. In one embodiment, the fluid and / or air from the inlet to the inlet may require a sharp turn (change of direction). In one embodiment, the fluid and / or air from the inlet to the inlet may require a 180° change of direction. In one embodiment, the at least one vent may have a substantially horizontal portion. In one embodiment, the third segment may include two vents, each venting on either side of the fluid sensor adapter. In one embodiment, each vent may have a substantially horizontal portion. In one embodiment, the third segment may include two vents spaced 180 degrees from each other.

[0017] The following description and drawings disclose various exemplary aspects. Certain improvements and novel aspects will be clearly identified, while other aspects may become apparent from the description and drawings.

[0018] The operation of the present teachings may be better understood by reference to the detailed description taken in conjunction with the following drawings, which form a part of this specification and the information set forth therein should be treated as part of this disclosure. [Brief explanation of the drawings]

[0019] [Figure 1A] FIG. 1 is a perspective view of an embodiment of a DEF sensor adapter according to various aspects disclosed herein.

[0020] [Figure 1B] FIG. 1 is a perspective view of an embodiment of a DEF sensor adapter according to various aspects disclosed herein.

[0021] [Figure 2] FIG. 1 is a bottom perspective view of an embodiment of a DEF sensor adapter according to various aspects disclosed herein.

[0022] [Figure 3A] FIG. 1 is a top perspective view of an embodiment of a DEF sensor adapter according to various aspects disclosed herein.

[0023] [Figure 3B] FIG. 1 is a partial cross-sectional view of a perspective view of one embodiment of a DEF sensor adapter according to various aspects disclosed herein.

[0024] [Figure 4A] FIG. 1 is a cross-sectional view of an embodiment of a DEF sensor adapter according to various aspects disclosed herein.

[0025] [Figure 4B] FIG. 1 is a cross-sectional view of one embodiment of a DEF sensor adapter selectively attached to a mating component in accordance with various aspects disclosed herein.

[0026] [Figure 5] FIG. 1 is a cross-sectional view of one embodiment of an upper portion of a DEF sensor adapter selectively attached to a mating component in accordance with various aspects disclosed herein.

[0027] [Figure 6] FIG. 1 is a cross-sectional view of one embodiment of a lower portion of a DEF sensor adapter selectively attached to a mating component in accordance with various aspects disclosed herein.

[0028] [Figure 7] FIG. 1 is a perspective view of an embodiment of a DEF sensor adapter according to various aspects disclosed herein.

[0029] The present invention may be embodied in several forms without departing from its spirit or essential characteristics. The scope of the present invention is defined by the appended claims, rather than the specific description preceding them. Accordingly, all embodiments that come within the meaning and range of equivalency of the claims are intended to be embraced by them.

[0030] Detailed Description of the Disclosure Reference will now be made in detail to embodiments of the present teachings, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized, and structural and functional changes may be made, without departing from the scope of the present teachings. Furthermore, features of the embodiments may be combined, substituted, or changed without departing from the scope of the present teachings. For example, features of each disclosed embodiment may be combined, substituted, or substituted for features of other disclosed embodiments. Accordingly, the following description is presented by way of example and not as a limitation on the various substitutions and modifications that may be made to the illustrated embodiments and that remain within the spirit and scope of the present teachings.

[0031] As used herein, the words "example" and "exemplary" mean an example (instance) or illustration. The words "example" or "exemplary" do not indicate a required or preferred aspect or embodiment. The word "or" is intended to be inclusive rather than exclusive, unless the context suggests otherwise. As an example, the phrase "A utilizes B or C" includes all inclusive permutations (e.g., A utilizes B; A utilizes C; or A utilizes both B and C). Additionally, the articles "a" and "an" are generally intended to mean "one or more," unless the context suggests otherwise.

[0032] Furthermore, unless the context suggests otherwise, descriptions of shapes (e.g., circular, rectangular, triangular, etc.) mean shapes that meet the definition of such shapes and general representations of such shapes. For example, a triangle or general triangle may include shapes that generally represent a triangle, such as a shape with three sides and three vertices, or a shape with three major sides that may or may not have straight edges, a triangle-like shape with rounded vertices, etc.

[0033] 1-7, an embodiment of sensor adapter 100 is shown that may be used in DEF applications. It is noted that sensor adapter 100 may also be used in other applications where the fluid is susceptible to entrained air or where it is otherwise possible to mitigate fluid aeration. While the present disclosure describes use in DEF applications, such information may be applied to these other applications with little or no modification.

[0034] The sensor adapter 100 may be selectively coupled to a sensor (not shown) to provide a sensor assembly of any suitable configuration. The sensor assembly may be installed in a DEF reservoir or tank (not shown) of any suitable configuration. The sensor assembly (e.g., either the sensor adapter 100 or the sensor) may include a controller housing and a controller. In one example, the controller may include a circuit board. The sensing element may be electrically coupled to the controller and may share a housing or have a separate sensing element housing. In one example, the controller, sensing element, or any other electrical components or connections, as needed, may be embedded in a waterproof material.

[0035] Sensor adapter 100 may include housing 110. Housing 110 may include exterior surface 112 and interior surface 114, as shown in FIG. 4A , where the interior may include one or more internal cavities, conduits, chambers, pathways, or hollow portions. Each of the internal cavities, conduits, chambers, pathways, or hollow portions may have one or more portions, segments, paths, etc. Sensor adapter 100 and housing 110, or portions thereof, may be configured to selectively restrict and allow the flow of fluid, air, and / or fluid / air therethrough. For example, sensor adapter 100 may include a tortuous path 193 through an internal chamber to and from a vent to separate and / or release any entrained air (if present) from the DEF and / or prevent any air and entrained air / fluid from entering the body of sensor adapter 100 and affecting sensor readings. In some embodiments, the tortuous path 193 may include a path that does not have a straight path therethrough, i.e., it includes bends and curves such that there is no clear line of sight through the path. The configuration of the tortuous path 193 may include any form of bends and curves and is not limited to those shown in the drawings. Sensor adapter 100 and housing 110, or portions thereof, may be configured to house electrical components or connections.

[0036] It is noted that the terms fluid and DEF as referred to herein generally include fluid and DEF with entrained air present and fluid and DEF without entrained air present (e.g., before and after a tortuous path 193 intended to separate entrained air or prevent air-laden fluid from entering the area near the sensor), unless otherwise specified or the context suggests otherwise. It is also noted that the terms DEF and fluid as referred to herein may generally be used interchangeably, and the embodiments described herein may be used in non-diesel applications, even though DEF may be described. It is noted that, as used herein, the terms fluidly connected and fluidly sealed may refer to both liquid and air connections and seals.

[0037] The sensor adapter 100 may include a first end 120 and a second end 130. It is noted that the first end 120 may also be referred to as the proximal end and the second end 130 may also be referred to as the distal end, or vice versa, in which case the first end 120 is referred to as the distal end and the second end 130 is referred to as the proximal end. It is noted that the first end 120 may also be referred to as the bottom end and the second end 130 may also be referred to as the top end.

[0038] A cross-sectional view of first end 120 and the top of sensor adapter 100 is shown in Figure 5. A cross-sectional view of second end 130 and the bottom of sensor adapter 100 is shown in Figure 6. Figures 4A-4B also show cross-sectional views of sensor adapter 100. Figures 2, 3B, 4A, and 4B show examples of tortuous path 193.

[0039] In one embodiment, first end 120 may be a free end or may be selectively attachable to a DEF reservoir or tank (or other component within a diesel or vehicle system). For example, first end 120 may be generally cylindrical or circular and may include threads 122 on an exterior surface (e.g., 112) of first end 120. Threaded portion 122 of first end 120 may facilitate selective attachment within a DEF header or DEF reservoir or tank. For example, a DEF header, reservoir, tank, or other component within a diesel or vehicle system may have internal threads and include a member sized and shaped to selectively receive threaded portion 122 of first end 120 of sensor adapter 100. An example of a mating connection mechanism for first end 120 is shown in FIG. 5. Although the drawings herein disclose and show threads, it is noted that other mating connection mechanisms and connectors may also be used, including, but not limited to, friction fit matings, pressure fit matings, snap fit matings, adhesives, O-rings, seals, fasteners, clamps, brackets, tabs, pins, latches, snaps, bayonet mount or interlocks, sliding interlocks, magnetic interlocks, any other female-to-male engagement mechanism, and the like.

[0040] In one embodiment, second end 130 may be free or selectively attachable to a sensor, sensor housing, or other component to form a sensor assembly. It is also noted that second end 130 may be selectively attachable to a DEF reservoir or tank (or other component in a diesel or vehicle system). Second end 130 may be selectively attachable to its mating component via any mating connection mechanism and connector, including, but not limited to, threaded fittings, friction-fit fittings, pressure-fit fittings, snap-fit ​​fittings, adhesives, O-rings, seals, fasteners, clamps, brackets, tabs, pins, latches, snaps, bayonet mounts or interlocks, sliding interlocks, magnetic interlocks, any other female-to-male engagement mechanism, and the like.

[0041] Sensor adapter 100 may further include a first member 140 and a second member 150. Each member 140, 150 may include an internal chamber 145, 155. In one embodiment, either or both of first member 140 and second member 150 may be hollow tubular members. First member 140 and second member 150 and the corresponding internal chambers 145, 155 may be separated by a wall 160. Wall 160 may extend between all or a portion of internal chambers 145, 155. For example, wall 160 may extend to first end 120 of sensor adapter 100 but may not extend all the way to second end 130 of sensor adapter 100; compare FIGS. 4B and 5-6. FIGS. 4B and 5-6 show cross-sectional views of first end 120 and the top and second end 130 and the bottom of sensor adapter 100, respectively. In one embodiment, second end 130 may serve as an attachment point to other sensor and housing components, as seen in FIG. 6 . For example, first chamber 145 may incorporate O-ring 230 for sealing the level chamber and / or concentration chamber, as shown. The O-ring may prevent DEF and aerated DEF from entering the level chamber and / or concentration chamber. While wall 160 may not extend completely through second end 130 of sensor adapter 100 to physically separate internal chambers 145, 155 at second end 130, it is noted that in some embodiments, internal chambers 145, 155 may not be fluidly connected but may be separated and sealed at second end 130 by attachment to other sensor and housing components. In one embodiment, second chamber 155 may be closed or sealed from the fluid and may house the electrical components of sensor adapter 100 .

[0042] First member 140 and its interior chamber 145 may include first portion 142 and second portion 144 (the portions may also be referred to as segments). In one embodiment, first portion 142 may have a larger diameter or interior size than second portion 144. In one embodiment, first portion 142 having the larger diameter may be at or near second end 130 of sensor adapter 100 or within second end 130 of sensor adapter 100, and second portion 144 having the smaller diameter may be at or near first end 120 of sensor adapter 100 or in the center of sensor adapter 100. First portion 142 may have a first size at first portion 142 and may be tapered, stepped, or otherwise transition to a second size at second portion 144. The transition in size may occur, for example, at a step or shoulder 146. Step 146 (also referred to as shoulder 146) may be found on exterior 112 and interior chamber 145 of housing 120 (e.g., interior 114 of the housing) and provides a transition in both the exterior and interior size or diameter of first and second portions 142, 144 of first member 140. As shown in FIGS. 4 and 5-6 , step 146 may include one single step or two separate steps. It is noted that other numbers of steps may be used with respect to step 146 and other steps described herein (e.g., step 126 and step 156). It is noted that unless otherwise indicated by context or in this disclosure, first portion 142 and second portion 144 of first member 140 and first chamber 145 may refer to either exterior 112 or interior 114 of sensor adapter 100. The resulting step or shoulder 146 may provide a stop or mating connection to other sensor and housing components seen in FIG.

[0043] Second member 150 and its internal chamber 155 may include first portion 152 and second portion 154 (the portions may also be referred to as segments). In one embodiment, first portion 152 may have a larger diameter or interior size than second portion 154. In one embodiment, first portion 152 having the larger diameter may be at or near second end 130 of sensor adapter 100 or within second end 130 of sensor adapter 100, and second portion 154 having the smaller diameter may be at or near first end 120 of sensor adapter 100 or in the center of sensor adapter 100. First portion 152 may have a first size at first portion 152 and may be tapered, stepped, or otherwise transition to a second size at second portion 154. The transition in size may occur, for example, at a step 156 or shoulder. A step 156 (which may also be referred to as a shoulder 156) may be found on the exterior 112 and interior chamber 155 of housing 120 (e.g., the interior 114 of the housing), resulting in a change in both the exterior and interior size or diameter of first portion 152 and second portion 154 of first member 150. It is noted that unless otherwise indicated by context or this disclosure, first portion 152 and second portion 154 of second member 150 and second chamber 155 may refer to the exterior 112 or the interior 114 of sensor adapter 100. The resulting step or shoulder 156 may provide a stop or mating connection mechanism to other sensor and housing components, as seen in FIG. 6 .

[0044] In one embodiment, the step 146 of the first member 140 may be at approximately the same height on the body 110 of the sensor adapter 100 as the step 156 of the second member 150. In one embodiment, the step 146 of the first member 140 may be located at a different height on the body 110 of the sensor adapter 100 compared to the step 156 of the second member 150. In one embodiment, the step 146 of the first member 140 may be lower on the body 110 of the sensor adapter 100 than the step 156 of the second member 150. In one embodiment, the step 156 of the second member 150 may be higher on the body 110 of the sensor adapter 100 than the step 146 of the first member 140. It is noted that the opposite configuration is also contemplated and disclosed.

[0045] In one embodiment, first chamber 145 may receive fluid (e.g., DEF) and possibly entrained air (if present) from a corresponding DEF tank or reservoir in which sensor adapter 100 (and the sensor assembly) may be disposed. In one embodiment, first chamber 145 of sensor adapter 100 may allow DEF to pass through, and first chamber 145 or a portion thereof may be fluidly connected (e.g., via second end 130) to another component, such as a sensor housing, so that the sensor may measure an aspect of the DEF (e.g., fluid level, fluid temperature, fluid concentration, etc.). The fluid may contain entrained air, which may be undesirable if it is near the sensor. First chamber 145 and vents 190, 192 may prevent air from entering and reaching the sensor and provide a tortuous path 193 for the fluid, so that any entrained air is removed from the fluid and does not affect the sensor. The first chamber 145 and the fluid therein may be fluidly connected to a surrounding DEF tank or reservoir and fluidly sealed from the second chamber 155 of the sensor adapter 100, so that fluid may selectively be present in the first chamber 145 but not in the second chamber 155.

[0046] In one embodiment, second chamber 155 may be a wiring conduit that houses electrical components or wires (e.g., wire 158) and provides an electrical connection between a sensor (e.g., at second end 130 of sensor adapter 100) and the rest of the vehicle system via second chamber 155 and first end 120. Second chamber 155 and the electrical components or wires therein may be fluidly sealed from the surrounding DEF tank or reservoir and from first chamber 145 of sensor adapter 100, such that fluid may selectively be present in first chamber 145 but not second chamber 155.

[0047] It is noted that first end 120 of sensor adapter 100 may further include a cap 124 that closes first and second chambers 145, 155, but may include an aperture or channel therethrough to allow wire 158 to extend from first end 120. Cap 124 may be permanently or fixedly attached. First chamber 145 may further include an additional plug 210 and O-ring 220 designed to shield the DEF from exposure to the atmosphere. Plug 210 and O-ring 220 may prevent debris and external liquid from outside the DEF tank from entering sensor adapter 100. Plug 210 and O-ring 220 may prevent DEF in the tank from leaking out of the DEF tank.

[0048] In one embodiment, sensor adapter 100 may include a tortuous path 193. Tortuous path 193 may help separate any entrained air (if present) from the DEF and / or from entering sensor adapter 100 via the vent. In one example, first chamber 145 may include a third portion 148 (which may also be referred to as a segment) and an inlet 194 between second portion 144 and third portion 148. In one embodiment, first portion 142 of first chamber 145 may have a larger diameter or interior size than third portion 148. In one embodiment, second portion 144 of first chamber 145 may have a larger diameter or interior size than third portion 148. In one embodiment, both first portion 142 and second portion 144 of first chamber 145 may have a larger diameter or interior size than third portion 148. In one embodiment, first portion 142 may have a larger diameter than second portion 144, which may have a larger diameter or interior size than third portion 148. It is noted that first portion 142, second portion 144, and third portion 148 of first member 140 and first chamber 145 may refer to exterior 112 or interior 114 of sensor adapter 100, unless the context or this disclosure suggests otherwise.

[0049] As shown in FIG. 4A , the second portion 144 and the third portion 146 may generally have the same diameter, but the entrance or point 194 between the second portion 144 and the third portion 148 may have a reduced diameter as described. The entrance 194 may be part of a serpentine path 193 as described. The reduced diameter of the entrance 194 may be caused by a step 126 and / or a shelf 195. In one embodiment, the third portion 148, the entrance 194 between the second portion 144 and the third portion 148, or both, have a diameter that is significantly reduced from the first portion 142 and the second portion 144. In one example, the entrance 194 between the second portion 144 and the third portion 148 may be less than half the size of the second portion 144. In one example, the entrance 194 between the second portion 144 and the third portion 148 may be about one-third or less the size of the second portion 144. In one embodiment, the opening 194 between the second portion 144 and the third portion 148 may be approximately 2 mm. In one embodiment, the opening 194 between the second portion 144 and the third portion 148 may be approximately 0.5-4 mm, 1-3 mm, 1.5-2.5 cm, etc. The opening 194 between the second portion 144 and the third portion 148 may be an aperture. The opening 194 between the second portion 144 and the third portion 148 may be circular, but may also be oval, square, or rectangular.

[0050] In one embodiment, first portion 142 having a larger diameter may be at or near second end 130 of sensor adapter 100 or within second end 130 of sensor adapter 100, second portion 144 having an intermediate diameter may be at or near first end 120 of sensor adapter 100 or in the center of sensor adapter 100, and third portion 148 having a smaller diameter, or a smaller diameter entrance 194 between second portion 144 and third portion 148, may be at or near first end 120 of sensor adapter 100 or within first end 120 of sensor adapter 100. In one embodiment, second portion 144 may have a first size at second portion 144 and may taper, step, or otherwise transition to a second size at third portion 148, or at least at entrance 194 between second portion 144 and third portion 148.

[0051] The change in size may occur, for example, at a step or shoulder 126. The step 126 (which may also be referred to as a shoulder 126) may be found on the exterior 112 of the housing 120 as part of the first end 120 or between the first end 120 and the first and second members 140, 150. The step 126 may be found on the interior chamber 145 (e.g., the interior 114 of the housing), see, for example, FIGS. 3B and 4A. The step 126 may result in a change in both the exterior and interior size or diameter of the first member 140 and / or the second and third portions 144, 148 of the first chamber 145 (or the entrance 194 between the second and third portions 144, 148). The shelf 195 may also provide a change in the internal size or diameter of the first member 140 and / or the second and third portions 144, 148 of the first chamber 145 (or the entrance 194 between the second portion 144 and the third portion 148).

[0052] In one embodiment, step 126 of first member 140 may be closer to first end 120 of sensor adapter 100 than step 146, which may be closer to second end 130 of sensor adapter 100. In one embodiment, step 126 of first member 140 may be located at a different height above body 110 of sensor adapter 100 compared to step 156 of second member 150. In one embodiment, step 126 of first member 140 may be higher above body 110 of sensor adapter 100 than step 156 of second member 150 (e.g., closer to first end 120 than to second end 130). It is noted that the opposite configuration is also contemplated and disclosed.

[0053] In one embodiment, a fluid such as DEF may enter sensor adapter 100 through second end 130 of sensor adapter 100 or through sensor and housing components attached to second end 130. In one embodiment, a fluid such as DEF may enter sensor adapter 100 directly from a DEF reservoir or tank (e.g., from sloshing) through vents 190, 192. Air that may be present in the fluid may enter through first, second, and third portions 142, 144, 148 of first chamber 145, respectively, rise, and remain accumulated at the top of third portion 148 or may be released through vents 190, 192. The various reduced diameters of or between first, second, and third portions 142, 144, 148 of first chamber 145 may help separate air bubbles from the fluid and direct the separated air into third portion 148 and out of sensor adapter 100. The structure of the vents 190, 192, the connection of the vents 190, 192 to the third portion 148, and the connection of the third portion 148 to a point 194 (sometimes called an inlet) into the second portion 144 may also help separate air bubbles from the fluid, etc., and may further prevent air from entering the vents 190, 192, into the third portion 148 of the first chamber 145, into the second portion 144, and further toward the sensor.

[0054] A fluid, such as DEF, typically enters a vent, inlet, or sensor adapter 100 and reaches a sensor that may indicate an aspect of the fluid, such as, for example, the fluid level, the fluid temperature, the fluid concentration (e.g., urea in water), etc. Various measures may be taken to sense the DEF characteristics. For example, a fluid level sensing waveguide, such as first member 140 and first chamber 145, may be provided. Providing such a waveguide may improve accuracy because the fluid in the fluid level sensing waveguide may change less than a typical DEF fluid tank, which may experience sloshing when the vehicle is in motion.

[0055] As described herein, the fluid may contain entrained air, which, if it reaches the sensor, may affect the sensor readings, accuracy, and functionality. Sensor adapter 100 may include a tortuous path 193 to vents 190, 192 and through third, second, and first portions 148, 144, 142 of first chamber 145, respectively, to separate any entrained air (if present) from the DEF and / or prevent air and entrained air / fluid from entering the body of sensor adapter 100 and reaching the sensor. Sensor adapter 100 may include a tortuous path 193 through first, second, and third portions 142, 144, 148 of first chamber 145, respectively, and out vents 190, 192 to separate any entrained air (if present) from the DEF and / or prevent air and entrained air / fluid from entering the body of sensor adapter 100 and reaching the sensor.

[0056] For example, the tortuous path 193 may include a stepped chamber (e.g., steps 146, 126) and varying diameters between the first portion 142, the second portion 144, and / or the third portion 148 as described. For example, the tortuous path 193 may include a reduced diameter inlet 194 between the second portion 144 and the third portion 148 as described. The tortuous path 193 may further include vents 190, 192.

[0057] Sensor adapter 100 may include one or more vents 190, 192. It is noted that sensor adapter 100 may include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more vents, or any range therebetween. Vent 190, 192 and vent pathways may be integrated into first chamber 145, or first chamber 145 may branch into as many separate vents as desired. For example, as shown in FIG. 2, first chamber 145 may branch into two vents 190, 192 located on opposite sides of sensor adapter 100. In one embodiment, two vents 190, 192 may be positioned 180° from each other (see, e.g., FIG. 2). It is noted that other geometries may be used without departing from this disclosure. In one embodiment, the two vents 190, 192 may be at relatively the same horizontal level in the first chamber 145 (see, for example, FIG. 2). The vents 190, 192 and the vent path before entering the third portion 148 may include a substantially horizontal portion 197.

[0058] In one embodiment, vents 190, 192 may be located on a bottom or lower surface of third portion 148. In one embodiment, the bottom or lower surface of third portion 148 may include a shelf 195. The shelf may separate second portion 144 and third portion 148 and contribute to a reduced diameter entrance 194 to third portion 148 (e.g., along with step 126). Vents 190, 192 may include an entrance 196. Entrance 196 may be located on or near shelf 195 and may correspond to one end (or a first end) of vents 190, 192. Shelf 195 may form or lead to entrance 196. Shelf 195 may be located approximately in the center of sensor adapter 100 or on or near wall 160. Inlet 196 may be located approximately in the center of sensor adapter 100, or on or near wall 160. Inlet 196 may be located adjacent to inlet 194, near inlet 194, or proximate to inlet 194. In one embodiment, inlet 196 and inlet 194 may be at relatively the same horizontal level of first chamber 145 (see, e.g., FIGS. 3B and 4A). Although proximate to each other, fluid flow between inlet 194 and inlet 196 may have or require a 180° turn (see, e.g., the serpentine path 193 shown in FIGS. 3B and 4A). It is noted that other geometries may be used without departing from the scope of this disclosure.

[0059] Inlet 196 may lead to substantially horizontal portion 197. It is noted that each vent 190, 192 may include its own horizontal portion 197 from inlet 196 (see, e.g., FIG. 2). In one embodiment, sensor adapter 100 with two vents 190, 192 may include two substantially horizontal portions 197. Vent 190, 192 may include outlet 198. Outlet 198 may correspond to the other (or second) end of vent 190, 192. Substantially horizontal portion 197 may lead to outlet 198. In one embodiment, sensor adapter 100 with two vents 190, 192 and two substantially horizontal portions 197 may further include two outlets 198 (see FIG. 2). In one embodiment, the transition from inlet 196 to substantially horizontal portion 197 may include or require a 90° turn (see, for example, serpentine path 193 shown in FIG. 3B ). It is noted that other geometries may be used without departing from this disclosure. In one embodiment, two substantially horizontal portions 197 may extend across a majority of the width of sensor adapter 100. In one embodiment, each substantially horizontal portion 197 may extend across at least half of the width of sensor adapter 100.

[0060] In one embodiment, the substantially horizontal portion 197 may generally prevent fluid and air within the horizontal portion from entering the third portion 148 of the first chamber 145, while allowing air to escape from the third portion 148 through the vents 190, 192.

[0061] In one embodiment, the third portion 148 of the first chamber 145 is positioned above the substantially horizontal portions 197 of the vents 190, 192 and may serve to capture air entering through the vents or air separating / rising from the first and second portions 142, 144 of the first chamber 145.

[0062] In one embodiment, the step 126 and small inlet 194 between the second portion 144 and the third portion 148 may help separate entrained air from the fluid in the second portion 144 (e.g., as the air rises into the third portion 148) and may help prevent air from flowing back into the second portion 144 from the third portion 148.

[0063] In one embodiment, sensor adapter 100 may be provided as a one-piece design or may be formed from one or more pieces that are selectively assembled. In one embodiment, sensor adapter 100 may be monolithically formed. In these monolithic embodiments, sensor adapter 100 may be formed in any suitable manner, such as via 3D printing, extrusion, injection molding, other molding, casting, or any manufacturing process.

[0064] In one embodiment, sensor adapter 100 or its components may be made of any desired material, including, but not limited to, metal, plastic, rubber, composite materials, etc. Sensor adapter 100 may be made of the same material, or different components or portions of sensor adapter 100 may be made of different materials.

[0065] In one embodiment, the sensor adapter 100 may adapt the vent path design to isolate (separate) the level chamber and / or concentration chamber with a vent while placing the vent at an optimal height. In one embodiment, the sensor adapter 100 may install an O-ring seal to address leakage from the gap between the extruded tube and the upper adapter.

[0066] Generally, the described sensor adapter 100 provides improved performance compared to conventional systems. The sensor adapter 100 can prevent or minimize the entry of aerated DEF into the vents 190, 192 and into the internal chamber 145. For example, to enter the internal chamber 145 (and, e.g., the first and second segments 144, 142), aerated DEF must enter the outlets 198 of the vents 190, 192, pass through the horizontal portion 197, travel upward through the inlet 196, enter the third segment 148, cross the shelf 195, and pass through smaller inlets 194 (each of which constitutes a tortuous path 193). Each of these aspects of the tortuous path 193 (and other aspects) individually and in combination can make it more difficult or challenging for aerated DEF to enter the sensor adapter 100 and its components. Each of these (and other) aspects of serpentine path 193, individually and in combination, can also allow air to be evacuated from internal chamber 145, for example, through inlet 196, horizontal portion 197, and outlet 198. Sensor adapter 100 and serpentine path 193 can also prevent fluid in internal chamber 145 from bubbling with air that may be in sensor adapter 100 (e.g., third segment 148) based on, for example, various diameters, stepped configurations, small entry points, 180° turns, etc.

[0067] In one example, the tortuous ventilation path 193 may include a path that requires a first turn to traverse (which may be a left turn, a right turn, or a combination of both). The tortuous path 193 may then include another turn to traverse (which may be a left turn, a right turn, or a combination of both). The tortuous path 193 may also be at different elevations, meaning that the turns may be at different heights or at the same elevation. The tortuous path 193 may include any number of turns, for example, 1, 2, 3, 4, 5, 6, or more. The present disclosure is not limited by the number of turns. Additionally, the winding path 193 may include any number of left turns (e.g., 1, 2, 3, 4, 5, 6, or more) and any number of right turns (e.g., 1, 2, 3, 4, 5, 6, or more). Additionally, the turns in the winding path 193 may be of any suitable angle, for example, between 20° and 110°, between 110° and 160°, between 190° and 270°.

[0068] Overall, the sensor adapter 100 can help prevent, minimize, and / or remove air, entrained air, and aerated DEF in the system, allowing for more accurate measurements of concentration, liquid level, and the like. In one example, the sensor adapter 100 demonstrated improved performance using liquid slosh tests conducted at various frequencies. Sensor errors can result from aerated DEF entering through the sensor's vent holes. The sensor adapter 100 may provide an improved upper sensor adapter and may insulate (separate) the level sensor and concentration chamber. The sensor adapter 100 can prevent or minimize sensor errors.

[0069] While embodiments of the present invention are illustrated in the accompanying drawings and described in the foregoing detailed description, it should be understood that the invention is not limited to the disclosed embodiments, and the invention described herein is susceptible to numerous rearrangements, modifications, and substitutions without departing from the scope of the following claims, which are intended to include all modifications and alternatives insofar as they come within the scope of the claims or their equivalents.

Claims

1. 1. A fluid sensor adapter for suppressing air bubble generation in a fluid, comprising: a first chamber including an inlet configured to receive diesel exhaust fluid; the first chamber includes a first segment at a proximal end of the fluid sensor adapter, a third segment at a distal end of the fluid sensor adapter, and a second segment between the first and third segments; a diameter of the second segment is smaller than a diameter of the first segment, and an entrance from the second segment to the third segment is narrower than a diameter of the second segment; a reduction in diameter from the first segment to the second segment and a narrowing of an inlet from the second segment to the third segment, the reduction in diameter from the first segment to the second segment comprising a tortuous ventilation path configured to prevent air within the fluid from reaching a sensor;

2. The fluid sensor adapter of claim 1 , wherein the second segment and the third segment have approximately the same diameter.

3. The fluid sensor adapter of claim 1 , wherein the first segment includes a shoulder that facilitates a reduction in diameter from the first segment to the second segment.

4. The fluid sensor adapter of claim 1 , wherein the second segment includes a shoulder that facilitates narrowing of an entrance from the second segment to the third segment.

5. 2. The fluid sensor adapter of claim 1, wherein the reduction in diameter from the first segment to the second segment and the narrowing of the entrance from the second segment to the third segment occur on the inside and outside of the fluid sensor adapter.

6. The fluid sensor adapter of claim 1 further comprising at least one vent in the third segment.

7. The fluid sensor adapter of claim 6 , wherein the at least one vent has a substantially horizontal portion.

8. The fluid sensor adapter of claim 1 , wherein the first segment includes an O-ring.

9. The fluid sensor adapter of claim 1 , wherein the third segment includes a plug and an O-ring.

10. 10. The fluid sensor adapter of claim 1, further comprising a second chamber disposed adjacent to but fluidly isolated from the first chamber.

11. 1. A fluid sensor adapter for suppressing air bubble generation in a fluid, comprising: a first chamber including a first segment at a proximal end of the fluid sensor adapter, a third segment at a distal end of the fluid sensor adapter, and a second segment between the first and third segments; the third segment includes at least one vent, an O-ring, and a plug; The fluid sensor adapter, wherein the first segment includes an O-ring.

12. The fluid sensor adapter of claim 11 , wherein the first segment includes a shoulder that facilitates a reduction in diameter from the first segment to the second segment.

13. The fluid sensor adapter of claim 11 , wherein the second segment includes a shoulder that facilitates narrowing at an entrance from the second segment to the third segment.

14. The fluid sensor adapter of claim 11 , wherein the plug and the O-ring are located on top of the third segment.

15. The fluid sensor adapter of claim 11 , wherein the at least one vent is located at a bottom of the third segment.

16. 16. The fluid sensor adapter of claim 15, wherein an entrance from the second segment to the third segment is adjacent to an entrance of the at least one vent.

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

18. The fluid sensor adapter of claim 11 , wherein the at least one vent has a substantially horizontal portion.

19. 12. The fluid sensor adapter of claim 11, wherein the third segment includes two vents emitting to opposite sides of the fluid sensor adapter, each vent having a substantially horizontal portion.

20. The fluid sensor adapter of claim 11 , wherein the third segment includes two vents spaced 180° apart from each other.

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