Exhaust sampling assembly

Abstract

An exhaust sampling assembly includes an end flange, an exhaust conduit, a cover, and a sensor cup. The exhaust sampling assembly is positioned in an exhaust aftertreatment system such that a first portion of exhaust is routed into the exhaust conduit from a central opening of the end flange and through the exhaust aftertreatment system. A second portion of exhaust is routed from apertures of the end flange towards the sensor cup. A portion of a sensor is positioned within the sensor cup and the second portion of exhaust is routed to the sensor for sampling. The second portion of exhaust is then routed out of the sensor cup via an outlet, into the exhaust conduit, and through the exhaust aftertreatment system.

Description

Atty. Docket No. 106389-9664EXHAUST SAMPLING ASSEMBLYCROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This application claims the benefit of and priority to Indian Patent Application No. 202441100943, filed on December 19, 2024, which is incorporated by reference herein in its entirety and for all purposes.TECHNICAL FIELD

[0002] The present disclosure relates generally to an exhaust sampling assembly for an exhaust aftertreatment system. The exhaust sampling assembly routes exhaust to a sensor positioned in an exhaust conduit for sampling (i.e., for determining a composition of the exhaust, etc.).BACKGROUND

[0003] For an exhaust aftertreatment system, it may be desirable to monitor emissions in exhaust to properly treat the emissions. One approach for monitoring emissions is to include an exhaust sampling assembly and a sensor that monitors a level of at least one constituent in a portion of the exhaust. However, some configurations of the exhaust sampling assembly may result in undesirable performance and inaccurate measurements of the constituents and / or be expensive or difficult to assemble.SUMMARY

[0004] In various embodiments, an exhaust sampling assembly includes an end flange, an exhaust conduit, a cover, and a sensor cup. The end flange includes a central opening and a plurality of apertures. The apertures are arrayed around the central opening and extend in a longitudinal direction through the end flange. The exhaust conduit has an exhaust conduit inlet end coupled to the end flange along the central opening of the end flange, and a first sensor opening. The cover is coupled to a transverse surface of the end flange and to an outer circumferential surface of the exhaust conduit. A sampling chamber is formed between an inner-1-4931 -7433-5871.1Atty. Docket No. 106389-9664 surface of the cover, the transverse surface of the end flange, and the outer circumferential surface of the exhaust conduit. The cover includes a second sensor opening aligned with the first sensor opening of the exhaust conduit. The sensor cup is coupled to an inner surface of the exhaust conduit around the first sensor opening and includes an outlet. The exhaust sampling assembly is configured such that exhaust is flowable through the apertures of the end flange to the sampling chamber, from the sampling chamber into the sensor cup, and out of the sensor cup via the outlet into the exhaust conduit. In various embodiments, the cover includes an upstream end coupled to the transverse surface of the end flange and having an upstream end area, and a chamber end between the second sensor opening and the upstream end having a chamber end area less than the upstream end area.[0005J The central opening is centered on an opening axis and the cover includes a concentrating wall extending from an upstream end of the cover. The concentrating wall is coupled to the transverse surface of the end flange such that an inner surface of the concentrating wall forms the sampling chamber. In various embodiments, a distance between the opening axis and the concentrating wall decreases at greater distances from the end flange.

[0006] A portion of the exhaust conduit is centered on a center axis, the first sensor opening is centered on a sensor opening axis, and the center axis lies on a first plane that is orthogonal to the sensor opening axis and intersects the end flange. The cover includes an upstream end coupled to the transverse surface of the end flange. In various embodiments, the upstream end is circular, and the cover has mirror symmetry across the first plane. In various embodiments, the upstream end has an upstream end area, and the exhaust conduit has a conduit area that is at most 70% of the upstream end area. In various embodiments, the upstream end includes a first portion having a first radius of curvature, a second portion having a second radius of curvature less than the first radius of curvature, and a third portion having a third radius of curvature less than or equal to the first radius of curvature. The second portion is positioned circumferentially between the first portion and the third portion. In various embodiments, the upstream end is configured such that the first portion is centered on an axis parallel to the sensor opening axis. In various embodiments, the upstream end is semi-circular and has endpoints that lie on the first plane.-2-4931 -7433-5871.1Atty. Docket No. 106389-9664

[0007] In various embodiments, an exhaust aftertreatment system includes a sensor and the exhaust sampling assembly. The sensor is coupled to the cover along the second sensor opening such that a portion of the sensor extends into the sensor cup within the exhaust conduit through the first sensor opening. A portion of the exhaust conduit is centered on a center axis and has a conduit diameter, and the cover and the exhaust conduit are configured such that the first sensor opening and the second sensor opening are separated by a distance in a direction orthogonal to the center axis and intersecting the center axis. In some embodiments, the distance is between 2% and 7%, inclusive, of the conduit diameter.

[0008] In various embodiments, the apertures of the end flange include a first aperture having a first diameter, a second aperture having a second diameter less than the first diameter, and a third aperture having a third diameter less than the first diameter. In such embodiments, the second aperture is disposed circumferentially between the first aperture and the third aperture. In various embodiments, the second diameter is between 50% and 75%, inclusive of the first diameter, and the third diameter is between 25% and 60%, inclusive of the first diameter. In various embodiments, a portion of the exhaust conduit is centered on a center axis, the first sensor opening is centered on a sensor opening axis, and a reference axis parallel to the sensor opening axis extends along the transverse surface. In various embodiments, the first aperture has a first aperture center that is angled from the reference axis along the transverse surface by a first angle in a first rotational direction, the second aperture has a second aperture center that is angled from the reference axis along the transverse surface by a second angle in the first rotational direction, and the third aperture has a third aperture center that is angled from the reference axis along the transverse surface by a third angle in the first rotational direction. The second angle is greater than the first angle, and the third angle is greater than the second angle. In various embodiments, the apertures further include a fourth aperture having a fourth diameter greater than or equal to the third diameter and less than the first diameter. The fourth aperture has a fourth aperture center that is angled from the reference axis along the transverse surface of the end flange by a fourth angle in the first rotational direction. The fourth angle is greater than the third angle and greater than 180 degrees. In various embodiments, the apertures include a fifth aperture having a fifth diameter equal to the first diameter. The fifth-3-4931 -7433-5871.1Atty. Docket No. 106389-9664 aperture has a fifth aperture center that is angled from the reference axis along the transverse surface of the end flange by a fifth angle in the first rotational direction. The fifth angle is greater than the fourth angle.

[0009] In various embodiments, the sensor cup has at least one of a sensor cup first opening or a sensor cup second opening. The sensor cup first opening is disposed on the sensor cup along a sensor cup plane and the sensor cup first opening is opposite of the outlet of the sensor cup. The sensor cup second opening is disposed on the sensor cup along a bottom surface. The sensor opening axis does not intersect the sensor cup plane and extends through the bottom surface. The sensor cup second opening centered on the sensor opening axis. In various embodiments, the outlet of the sensor cup has an outlet area, and the sensor cup second opening has a sensor cup second area that is between 30% and 50%, inclusive of the outlet area.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying Figures, in which like reference numerals refer to like elements unless otherwise indicated, in which:

[0011] Figure 1 is a schematic diagram of an example exhaust aftertreatment system including a housing assembly with a distributing housing;

[0012] Figure 2 is a perspective view of a portion of an example exhaust aftertreatment system including an example exhaust sampling assembly of Figure 1;

[0013] Figure 3 is a perspective view of the portion of the exhaust aftertreatment shown in Figure 2;

[0014] Figure 4 is a cross-sectional view of the portion of the exhaust aftertreatment shown in Figure 2 taken along plane A-A;

[0015] Figure 5 is a cross-sectional view of the portion of the exhaust aftertreatment shown in Figure 2 taken along plane B-B;-4-4931 -7433-5871.1Atty. Docket No. 106389-9664

[0016] Figure 6 is a cross-sectional view of the portion of the exhaust aftertreatment shown in Figure 2 taken along plane C-C;

[0017] Figure 7 is a perspective view of a portion of the exhaust sampling assembly shown in Figure 2;

[0018] Figure 8 is a perspective view of an example cover of the exhaust sampling assembly shown in Figure 2;

[0019] Figure 9 is another perspective view of the cover shown in Figure 8;

[0020] Figure 10 is a perspective view of a portion of another example exhaust aftertreatment system including an example exhaust sampling assembly;

[0021] Figure 11 is a perspective view of an example cover of the exhaust sampling assembly shown in Figure 10;

[0022] Figure 12 is another perspective view of the cover shown in Figure 11;

[0023] Figure 13 is a perspective view of a portion of another example exhaust aftertreatment system including an example exhaust sampling assembly;

[0024] Figure 14 is a perspective view of an example cover of the exhaust sampling assembly shown in Figure 13;

[0025] Figure 15 is another perspective view of the cover shown in Figure 14; and

[0026] Figure 16 is a perspective view of the sensor cup of an exhaust sampling assembly.

[0027] 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.-5-4931 -7433-5871.1Atty. Docket No. 106389-9664DETAILED DESCRIPTION

[0028] Following below are more detailed descriptions of various concepts related to, and implementations of, methods, apparatuses, and systems for an exhaust sampling assembly of an exhaust 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

[0029] In order to facilitate desirable treatment of exhaust, it may be desirable to monitor and measure a level of at least one constituent of the exhaust. For example, a sensor positioned in an exhaust sampling assembly may be utilized to facilitate measurement of the level of the at least one constituent, and a controller that the sensor is electronically or communicatively coupled to can adjust the treatment of the emissions based on the level. One approach to measuring the level of at least one constituent is to include an exhaust sampling assembly in an exhaust aftertreatment system that directs a first portion of the exhaust to the sensor and a second portion of the exhaust through the exhaust aftertreatment system. However, the configuration of the exhaust sampling assembly may result in an undesirable velocity flow at which the exhaust reaches the sensor or water ingress within the exhaust sampling assembly. These can negatively impact the exhaust aftertreatment system and the measurements of the level of at least one constituent.

[0030] Implementations described herein are related to an exhaust sampling assembly for an exhaust aftertreatment system. The exhaust sampling assembly collects exhaust from a catalyst member and routes a first portion of exhaust into an exhaust conduit and through the exhaust aftertreatment system. A second portion of exhaust is routed towards a sensor for sampling. The configuration of the exhaust sampling assembly allows for flow to be collected for sensing from a periphery of the catalyst member, resulting in less dependency on orientation of the exhaust sampling assembly. Additionally, the exhaust sampling assembly results in reduced backpressure and contributes to ensuring the second portion of exhaust-6-4931 -7433-5871.1Atty. Docket No. 106389-9664 routed towards the sensor is properly utilized for sensing. In this way, the exhaust sampling assembly allows for a desirable collection of exhaust for sensing.II. Overview of Exhaust Aftertreatment System

[0031] Figure 1 depicts an exhaust aftertreatment system 100 (e.g., treatment system, etc.) for treating emissions produced by 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 exhaust aftertreatment system 100 includes an upstream exhaust conduit 102 (e.g., line, pipe, etc.). The upstream exhaust conduit 102 is fluidly coupled to an upstream component (e.g., header, exhaust manifold, etc.) and is configured to receive exhaust from the upstream component. In some embodiments, the upstream exhaust conduit 102 is coupled to (e.g., attached to, fixed to, welded to, fastened to, riveted to, etc.) the internal combustion engine (e.g., the upstream exhaust conduit 102 is coupled to an outlet of the internal combustion engine, etc.). In other embodiments, the upstream exhaust conduit 102 is integrally formed with the internal combustion engine.

[0032] The exhaust aftertreatment system 100 also includes a housing assembly 104. As is explained in more detail herein, the housing assembly 104 is configured to redirect the exhaust (e.g., from a first direction to a second direction etc.) while facilitating treatment of the exhaust. In redirecting the exhaust, the housing assembly 104 may function as a switchback (e.g., redirecting the exhaust from a first direction to a second direction that is opposite to the first direction, redirecting the exhaust from a first direction to a second direction that is opposite to the first direction and parallel to the first direction, etc.).

[0033] The housing assembly 104 includes an intake body 106 (e.g., chamber, etc.). The intake body 106 is fluidly coupled to the upstream exhaust conduit 102 and is configured to receive exhaust from the upstream exhaust conduit 102. The intake body 106 may be configured to redirect the exhaust from a first direction (e.g., extending along a center axis of the upstream exhaust conduit 102, etc.) to a second direction (e.g., that is orthogonal to the first direction, etc.).-7-4931 -7433-5871.1Atty. Docket No. 106389-9664

[0034] The housing assembly 104 also includes an upstream housing 108 (e.g., chamber, body, etc.). The upstream housing 108 is fluidly coupled to the intake body 106 and is configured to receive exhaust from the intake body 106. In various embodiments, the upstream housing 108 is coupled to the intake body 106. For example, the upstream housing 108 may be fastened (e.g., using a band, using bolts, etc.), welded, riveted, or otherwise attached to the intake body 106. In other embodiments, the upstream housing 108 is integrally formed with (e.g., unitarily formed with, formed as a one-piece construction with, inseparable from, etc.) the intake body 106.

[0035] In some embodiments, the housing assembly 104 includes a heater (e.g., electrical heater, resistance heater, fluid heat exchanger, etc.) that is configured to heat the exhaust in the intake body 106 and / or the upstream housing 108. For example, the housing assembly 104 may include a heater that extends in the intake body 106 and is configured to heat the exhaust in the intake body 106. By heating the exhaust, an ability of catalyst members to desirably perform catalytic reactions may be increased. Additionally, heating the exhaust may facilitate regeneration (e.g., bum-off of particulates, etc.) of various components of the exhaust aftertreatment system 100.

[0036] The exhaust aftertreatment system 100 also includes an oxidation catalyst 110 (e.g., a diesel oxidation catalyst (DOC), etc.). At least a portion of the oxidation catalyst 110 is positioned in (e.g., contained in, housed in, located in, etc.) the upstream housing 108. In various embodiments, the oxidation catalyst 110 is positioned in the upstream housing 108 and the intake body 106. In other embodiments, the oxidation catalyst 110 is positioned in the upstream housing 108 and is not positioned in the intake body 106. In still other embodiments, the oxidation catalyst 110 is positioned in the intake body 106 and is not positioned in the upstream housing 108.

[0037] The exhaust is provided by the intake body 106 to the oxidation catalyst 110. The oxidation catalyst 110 may be configured to oxidize hydrocarbons and / or carbon monoxide in the exhaust. In this way, the oxidation catalyst 110 may remove hydrocarbons and / or carbon monoxide from the exhaust prior to the exhaust being provided to downstream components of-8-4931 -7433-5871.1Atty. Docket No. 106389-9664 the exhaust aftertreatment system 100. The oxidation catalyst 110 may be positioned in the intake body 106 and / or the upstream housing 108 (e.g., using a gasket, using a spacer, using a seal, etc.) such that flow of the exhaust between the oxidation catalyst 110 and the intake body 106 and / or between the oxidation catalyst 110 and the upstream housing 108 is substantially prevented (e.g., less than 1% of the exhaust flow received by the intake body 106 flows between the oxidation catalyst 110 and the intake body 106, less than 1% of the exhaust flow received by the intake body 106 flows between the oxidation catalyst 110 and the upstream housing 108, etc.).

[0038] The exhaust aftertreatment system 100 also includes an exhaust filtration device 112 (e.g., a diesel particulate filter (DPF), etc.). The exhaust filtration device 112 is positioned in the upstream housing 108 downstream of the oxidation catalyst 110. The exhaust is provided by the oxidation catalyst 110 into the upstream housing 108 (e.g., between the oxidation catalyst 110, the upstream housing 108, and the exhaust filtration device 112, etc.) and subsequently into the exhaust filtration device 112 (e.g., after hydrocarbons in the exhaust have been oxidized by the oxidation catalyst 110, after carbon monoxide in the exhaust has been oxidized by the oxidation catalyst 110, etc.). The exhaust filtration device 112 may remove particulates (e.g., soot, etc.) from the exhaust prior to the exhaust being provided to downstream components of the exhaust aftertreatment system 100. The exhaust filtration device 112 may be positioned in the upstream housing 108 (e.g., using a gasket, using a spacer, using a seal, etc.) such that flow of the exhaust between the exhaust filtration device 112 and the upstream housing 108 is substantially prevented (e.g., less than 1% of the exhaust flow received by the intake body 106 flows between the exhaust filtration device 112 and the upstream housing 108, etc.).

[0039] The housing assembly 104 also includes a decomposition housing 114 (e.g., decomposition reactor, decomposition chamber, reactor pipe, decomposition tube, reactor tube, etc.). The decomposition housing 114 is fluidly coupled to the upstream housing 108 and is configured to receive exhaust from the upstream housing 108. In various embodiments, the decomposition housing 114 is coupled to the upstream housing 108. For example, the decomposition housing 114 may be fastened (e.g., using a band, using bolts, etc.), welded, -9-4931 -7433-5871.1Atty. Docket No. 106389-9664 riveted, or otherwise attached to the upstream housing 108. In other embodiments, the decomposition housing 114 is integrally formed with the upstream housing 108.

[0040] The decomposition housing 114 is located downstream of the exhaust filtration device 112 and receives the exhaust from the exhaust filtration device 112 (e.g., after particulates have been removed from the exhaust by the exhaust filtration device 112, etc.). As is explained in more detail herein, the decomposition housing 114 is configured to facilitate introduction of reductant (e.g., diesel exhaust fluid (DEF), Adblue®, a urea-water solution (UWS), an aqueous urea solution (e.g., AUS32, etc.), into the exhaust, so as to facilitate reduction of emission of undesirable components (e.g., nitrogen oxides (NOx), etc.) in the exhaust.

[0041] The exhaust aftertreatment system 100 also includes a reductant delivery system 116. As is explained in more detail herein, the reductant delivery system 116 is configured to facilitate the introduction of the reductant into the exhaust. The reductant delivery system 1 16 includes a dosing module 118 (e.g., doser, etc.). The dosing module 118 is configured to facilitate passage of the reductant through the decomposition housing 114 and into the decomposition housing 114. As is explained in more detail herein, the dosing module 118 is configured to receive reductant, and in some embodiments, configured to receive air and reductant, and provide the reductant and / or air-reductant mixture into the decomposition housing 114 to facilitate treatment of the exhaust. The dosing module 118 may include an insulator interposed between a portion of the dosing module 118 and the portion of the decomposition housing 114 on which the dosing module 118 is mounted. In various embodiments, the dosing module 118 is coupled to the decomposition housing 114.

[0042] The reductant delivery system 116 also includes a reductant source 120 (e.g., reductant tank, etc.). The reductant source 120 is configured to contain reductant. The reductant source 120 is fluidly coupled to the dosing module 118 and configured to provide the reductant to the dosing module 118. The reductant source 120 may include multiple reductant sources 120 (e.g., multiple tanks connected in series or in parallel, etc.). The reductant source 120 may be, for example, a diesel exhaust fluid tank containing Adblue®.-10-4931 -7433-5871.1Atty. Docket No. 106389-9664

[0043] The reductant delivery system 116 also includes a reductant pump 122 (e.g., supply unit, etc.). The reductant pump 122 is fluidly coupled to the reductant source 120 and the dosing module 118 and configured to receive the reductant from the reductant source 120 and to provide the reductant to the dosing module 118. The reductant pump 122 is used to pressurize the reductant from the reductant source 120 for delivery to the dosing module 118. In some embodiments, the reductant pump 122 is pressure controlled. In some embodiments, the reductant pump 122 is coupled to a chassis of a vehicle associated with the exhaust aftertreatment system 100.

[0044] In some embodiments, the reductant delivery system 116 also includes a reductant filter 124. The reductant filter 124 is fluidly coupled to the reductant source 120 and the reductant pump 122 and is configured to receive the reductant from the reductant source 120 and to provide the reductant to the reductant pump 122. The reductant filter 124 filters the reductant prior to the reductant being provided to internal components of the reductant pump 122. For example, the reductant filter 124 may inhibit or prevent the transmission of solids to the internal components of the reductant pump 122. In this way, the reductant filter 124 may facilitate prolonged desirable operation of the reductant pump 122.

[0045] The dosing module 118 includes at least one injector 126 (e.g., insertion device, etc.). The injector 126 is fluidly coupled to the reductant pump 122 and configured to receive the reductant from the reductant pump 122. The injector 126 is configured to dose (e.g., inject, insert, etc.) the reductant received by the dosing module 118 into the exhaust in the decomposition housing 114.

[0046] In some embodiments, the reductant delivery system 116 also includes an air pump 128 and an air source 130 (e.g., air intake, etc.). The air pump 128 is fluidly coupled to the air source 130 and is configured to receive air from the air source 130. The air pump 128 is fluidly coupled to the dosing module 118 and is configured to provide the air to the dosing module 118. The dosing module 118 is configured to mix the air and the reductant into an air-reductant mixture and to provide the air-reductant mixture to the injector 126 (e g., for dosing into the exhaust in the decomposition housing 114, etc.). The injector 126 is fluidly coupled to the air-11-4931 -7433-5871.1Atty. Docket No. 106389-9664 pump 128 and configured to receive the air from the air pump 128. The injector 126 is configured to dose the air-reductant mixture into the exhaust in the decomposition housing 114. In some of these embodiments, the reductant delivery system 116 also includes an air filter 132. The air filter 132 is fluidly coupled to the air source 130 and the air pump 128 and is configured to receive the air from the air source 130 and to provide the air to the air pump 128. The air filter 132 is configured to filter the air prior to the air being provided to the air pump 128. In other embodiments, the reductant delivery system 116 does not include the air pump 128 and / or the reductant delivery system 116 does not include the air source 130. In such embodiments, the dosing module 118 is not configured to mix the reductant with air.

[0047] In various embodiments, the dosing module 118 is configured to receive air and reductant and dose the air-reductant mixture into the decomposition housing 114. In various embodiments, the dosing module 118 is configured to receive reductant (and does not receive air) and dose the reductant into the decomposition housing 114.

[0048] The exhaust aftertreatment system 100 also includes a controller 134 (e.g., control circuit, driver, etc.). The dosing module 118, the reductant pump 122, and the air pump 128 are also electrically or communicatively coupled to the controller 134. The controller 134 is configured to control the dosing module 118 to dose the reductant and / or the air-reductant mixture into the decomposition housing 114. The controller 134 may also be configured to control the reductant pump 122 and / or the air pump 128 in order to control the reductant and / or the air-reductant mixture that is dosed into the decomposition housing 114.

[0049] The controller 134 includes a processing circuit. The processing circuit includes a processor and a memory. The processor may include a microprocessor, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), etc., or combinations thereof. The memory may include, but is not limited to, electronic, optical, magnetic, or any other storage or transmission device capable of providing a processor, ASIC, FPGA, etc. with program instructions. This memory 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 controller 134 can read-12-4931 -7433-5871.1Atty. Docket No. 106389-9664 instructions. The instructions may include code from any suitable programming language. The memory may include various modules that include instructions which are configured to be implemented by the processor.

[0050] In various embodiments, the controller 134 is configured to communicate with a central controller 136 (e g., engine control unit (ECU), engine control module (ECM), etc.) of an internal combustion engine having the exhaust aftertreatment system 100. In some embodiments, the central controller 136 and the controller 134 are integrated into a single controller.

[0051] 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 state, the display device may provide an indication to a user of a status of the reductant delivery system 116.

[0052] In various embodiments, the exhaust aftertreatment system 100 also includes a mixer 138 (e.g., a swirl generating device, a vaned plate, etc., etc.). At least a portion of the mixer 138 is positioned in the decomposition housing 114. The mixer 138 is configured to receive the exhaust from the exhaust filtration device 112 (e.g., after particulates have been removed from the exhaust by the exhaust filtration device 112, etc.). The mixer 138 is also configured to receive the reductant and / or the air-reductant mixture from the injector 126. The mixer 138 is configured to facilitate swirling (e.g., tumbling, rotation, etc.) of the exhaust and mixing (e.g., combination, etc.) of the exhaust and the reductant or the air-reductant mixture so as to disperse the reductant in the exhaust downstream of the mixer 138. By dispersing the reductant in the exhaust (e.g., to obtain an increased uniformity index, etc.) using the mixer 138, reduction of emission of undesirable components in the exhaust is enhanced.

[0053] The housing assembly 104 also includes a distributing housing 140 (e.g., pressure regulator, flow plenum, flow balancer, flow balancing system, etc.). The distributing housing -13-4931 -7433-5871.1Atty. Docket No. 106389-9664140 is fluidly coupled to the decomposition housing 114 and is configured to receive exhaust from the decomposition housing 114 (e.g., after the reductant has been provided into the exhaust by the injector 126 and the reductant and the exhaust have been mixed by the mixer 138, etc.). In various embodiments, the distributing housing 140 is coupled to the decomposition housing 114. For example, the distributing housing 140 may be fastened, welded, riveted, or otherwise attached to the decomposition housing 114. In other embodiments, the distributing housing 140 is integrally formed with the decomposition housing 114.

[0054] The housing assembly 104 also includes a catalyst member housing 142 (e.g., body, etc.). The catalyst member housing 142 is fluidly coupled to the distributing housing 140 and is configured to receive exhaust from the distributing housing 140. In various embodiments, the catalyst member housing 142 is coupled to the distributing housing 140. For example, the catalyst member housing 142 may be fastened, welded, riveted, or otherwise attached to the distributing housing 140. In other embodiments, the catalyst member housing 142 is integrally formed with the distributing housing 140. The catalyst member housing 142 is located downstream of the distributing housing 140 and receives the exhaust from the distributing housing 140.

[0055] The exhaust aftertreatment system 100 also includes a catalyst member 144 (e.g., first selective catalytic reduction (SCR) catalyst member, ammonia oxidation (AMOX) catalyst member, etc.). The catalyst member 144 is configured to receive the exhaust outputted by the distributing housing 140. At least a portion of the catalyst member 144 is positioned in the catalyst member housing 142. The exhaust received by the distributing housing 140 is provided by the distributing housing 140 to the catalyst member 144 (e.g., via the catalyst member housing 142, etc.). As is explained in more detail herein, the catalyst member 144 is configured to cause decomposition of components of the exhaust using the reductant (e.g., via catalytic reactions, etc.). Specifically, reductant that has been provided into the exhaust by the injector 126 undergoes the processes of evaporation, thermolysis, and hydrolysis to form non-NOx emissions in the distributing housing 140, the catalyst member housing 142, the catalyst member 144, and / or the housing assembly 104. The catalyst member 144 is configured to assist-14-4931 -7433-5871.1Atty. Docket No. 106389-9664 in 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.

[0056] The exhaust aftertreatment system 100 also includes a sensor 146. The sensor 146 is electronically or communicatively coupled to the controller 134. The sensor 146 is configured to receive a portion of the exhaust, and the controller 134 is configured to estimate the average NOx of the exhaust to control the mixture dosed into the decomposition housing 114. In various embodiments, the sensor 146 is positioned in a first sensor housing and the first sensor housing includes holes. The portion of the first portion of the exhaust flows through the holes of the first sensor housing and the sensor 146 and controller 134 may be used to calculate mass flow rate through each hole, velocity vector at the holes, and total mass flow rate in and out of the first sensor housing to estimate the average NOx of the exhaust.

[0057] The exhaust aftertreatment system 100 also includes an exhaust sampling assembly 148. The exhaust sampling assembly 148 is configured to receive, treat, and output the exhaust provided by the catalyst member housing 142. A portion of the exhaust sampling assembly 148 is coupled to the catalyst member housing 142. In various embodiments, a portion of the exhaust sampling assembly 148 is coupled to the catalyst member 144. For example, the portion of the exhaust sampling assembly 148 may be fastened, welded, riveted, or otherwise attached to the catalyst member 144. The exhaust sampling assembly 148 is configured to receive the exhaust for sensing and direct the exhaust through the exhaust aftertreatment system 100. At least a portion of the sensor 146 extends into the exhaust sampling assembly 148.

[0058] The exhaust sampling assembly 148 includes a cover 150 and a sensor cup 152. The cover 150 directs a first portion of the exhaust from the catalyst member housing 142 to the sensor cup 152. At least a portion of the sensor 146 extends into the sensor cup 152, and the first portion of the exhaust directed into the sensor cup 152 is directed to the sensor 146 for sensing.

[0059] The exhaust sampling assembly 148 also includes an exhaust conduit 154. The sensor cup 152 is coupled to the exhaust conduit 154 such that the sensor cup 152 and a portion of the sensor 146 extends into the exhaust conduit 154. The exhaust conduit 154 is configured-15-4931 -7433-5871.1Atty. Docket No. 106389-9664 to receive and direct a second portion of the exhaust from the catalyst member 144 through the exhaust aftertreatment. Additionally, the first portion of the exhaust that is directed to the sensor cup 152 exits the sensor cup 152 into the exhaust conduit 154 to continue flow through the exhaust aftertreatment system 100. In various embodiments a portion of the second portion of the exhaust is directed into the sensor cup 152 for sensing.

[0060] The housing assembly 104 also includes an outlet housing 156 (e.g., body, etc.). The outlet housing 156 is fluidly coupled to the catalyst member housing 142 and is configured to receive exhaust from the catalyst member housing 142 and the catalyst member 144. At least a portion of the sensor 146 and at least a portion of the exhaust sampling assembly 148 is positioned in the outlet housing 156. In various embodiments, the outlet housing 156 is coupled to the catalyst member housing 142. For example, the outlet housing 156 may be fastened, welded, riveted, or otherwise attached to the catalyst member housing 142. In other embodiments, the outlet housing 156 is integrally formed with the catalyst member housing 142. The outlet housing 156 is located downstream of the catalyst member housing 142 and receives the exhaust after flowing through the catalyst member 144. In some embodiments, at least a portion of the catalyst member 144 is positioned in the outlet housing 156.

[0061] The exhaust aftertreatment system 100 also includes a downstream exhaust conduit 158 (e.g., line, pipe, etc.). The downstream exhaust conduit 158 is fluidly coupled to the outlet housing 156 and is configured to receive the exhaust from the outlet housing 156. In some embodiments, the downstream exhaust conduit 158 is coupled to the outlet housing 156. In other embodiments, the downstream exhaust conduit 158 is integrally formed with the outlet housing 156.

[0062] While the exhaust aftertreatment system 100 has been shown and described in the context of use with a diesel internal combustion engine, it is understood that the exhaust aftertreatment system 100 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.-16-4931 -7433-5871.1Atty. Docket No. 106389-9664III. Example Exhaust Sampling Assemblies

[0063] Figures 2-6, 10, and 13 illustrate an example of the exhaust sampling assembly 148 according to various embodiments.

[0064] The exhaust sampling assembly 148 includes an end flange 202 positioned in the catalyst member housing 142. At least a portion of the end flange 202 is coupled to the catalyst member 144. The end flange 202 is configured to direct the exhaust from the catalyst member 144 through the exhaust sampling assembly 148.

[0065] As shown in Figures 5 and 6, the end flange 202 includes a central opening 204 that extends in a longitudinal direction through the end flange 202. The central opening 204 directs a first portion of the exhaust from the catalyst member 144 through the exhaust sampling assembly 148. As is shown in Figure 4, the central opening 204 is centered on an opening axis JI .

[0066] The end flange 202 also includes a plurality of apertures 206 arrayed around the central opening 204. The apertures 206 extend in the longitudinal direction through the end flange 202. The apertures 206 direct a second portion of the exhaust from the catalyst member 144 through the exhaust sampling assembly 148.

[0067] The exhaust sampling assembly 148 includes an exhaust conduit 154 that has an exhaust conduit inlet end 208 that is coupled to the end flange 202 along the central opening 204, such that the first portion of the exhaust flows through the central opening 204 and into the exhaust conduit 154. The opening axis JI extends through the exhaust conduit inlet end 208. The exhaust conduit 154 also includes a first sensor opening 210. As is shown in Figure 4, the first sensor opening 210 is centered on a sensor opening axis J2. As is shown in Figure 4, a portion of the exhaust conduit 154 is centered on a center axis J3. The portion of the exhaust conduit 154 that is coupled to the end flange 202 is centered on the center axis J3. In various embodiments, the exhaust conduit 154 is configured such that portions of the exhaust conduit 154 are not centered on the center axis J3. The exhaust conduit 154 has a conduit area. The-17-4931 -7433-5871.1Atty. Docket No. 106389-9664 conduit area is defined as a cross sectional area of the exhaust conduit 154, with the cross section having an equal radius to a radius of the exhaust conduit 154.

[0068] The exhaust sampling assembly 148 also includes a cover 150. The end flange 202 has a transverse surface 212. A portion of the transverse surface 212 is coupled to the exhaust conduit 154. Additionally, the central opening 204 and the apertures 206 are disposed along the transverse surface 212, and the center axis J3 extends through the transverse surface 212. The cover 150 is coupled to the transverse surface 212 and to an outer circumferential surface 213 of the exhaust conduit 154. The outer circumferential surface 213 is defined as a surface that forms a boundary of the exhaust conduit 154 and is located away from a center of the exhaust conduit 154. The configuration of the cover 150, the end flange 202, and the exhaust conduit 154 forms a sampling chamber 214. The sampling chamber 214 is formed between an inner surface 215 of the cover 150, the transverse surface 212, and the outer circumferential surface 213 of the exhaust conduit 154. The inner surface 215 is defined as a surface located on an interior of the cover 150 that defines a boundary of the interior of the cover 150. At least a portion of the exhaust conduit 154 is positioned within a space created by the inner surface 215. The second portion of the exhaust flows through the apertures 206 and into the sampling chamber 214. The cover 150 includes a second sensor opening 216. The second sensor opening 216 is aligned with the first sensor opening 210, such that the second sensor opening 216 is centered on the sensor opening axis J2.

[0069] In various embodiments, as shown in Figures 3 and 4, the cover 150 includes an upstream end 218 and a chamber end 220. The upstream end 218 is coupled to the transverse surface 212 such that the second portion of the exhaust flows into the sampling chamber 214 through the upstream end 218. The upstream end 218 defines an upstream end area that is the entirety of the area of the upstream end 218. The chamber end 220 is positioned between the second sensor opening 216 and the upstream end 218. The second portion of the exhaust flows out of the sampling chamber 214 and through the first sensor opening 210 through the chamber end 220. The chamber end 220 defines a chamber end area that is the entirety of the area of the chamber end 220. In various embodiments, the chamber end area is less than the upstream end-18-4931 -7433-5871.1Atty. Docket No. 106389-9664 area. This configuration allows for high velocity flow stream through the sampling chamber 214 and to the sensor 146, resulting in more desirable results from the sensor 146.

[0070] In various embodiments, the cover 150 also includes a concentrating wall 222 that extends from the upstream end 218. The concentrating wall 222 is positioned between the transverse surface 212 and the second sensor opening 216. The concentrating wall 222 may be coupled to the transverse surface 212 such that the sampling chamber 214 is formed with an inner surface 223 of the concentrating wall 222. The inner surface 223 is defined as a surface located on an interior of the concentrating wall 222 that defines a boundary of the interior of the concentrating wall 222. In some embodiments, the concentrating wall 222 extends from the upstream end 218 to the chamber end 220. In various embodiments, a distance between the opening axis JI and the concentrating wall 222 decreases at greater distances from the end flange 202. This configuration allows for high velocity flow stream through the sampling chamber 214 and to the sensor 146 and directs the exhaust to the sensor 146 for more desirable sensing results.

[0071] The exhaust conduit 154 has a conduit diameter. In various embodiments, as is shown in Figure 4, the cover 150 and the exhaust conduit 154 are configured such that the first sensor opening 210 and the second sensor opening 216 are separated by a distance DI in a direction orthogonal to the center axis J3 and intersecting the center axis. In various embodiments, the distance DI is between 2% and 7%, inclusive of the conduit diameter. This configuration allows for control of the flow of exhaust being sampled and helps maintain required metrics for desirable results from the sensor 146.

[0072] As shown in Figures 8-15, the cover 150 can be a variety of shapes and configurations. The shape of the cover 150 can be adjusted depending on the configuration of the exhaust aftertreatment system 100 and available space in the exhaust aftertreatment system 100. As shown in Figures 13-15, the cover 150 may be symmetrical. For example, the upstream end 218 of the cover 150 may be circular. The center axis J3 lies on a first plane Pl. The first plane Pl is orthogonal to the sensor opening axis J2 and intersects the end flange 202. In various embodiments, the cover 150 has mirror symmetry across the first plane Pl. In other-19-4931 -7433-5871.1Atty. Docket No. 106389-9664 words, the cover 150 is symmetric with respect to the first plane Pl. The first plane Pl divides the cover 150 into a first half and a second half such that the first half of the cover 150 is a mirror image of the second half of the cover 150. The first half and the second half of the cover 150 are reflections of each other across the first plane Pl. In various embodiments, the conduit area is at most 70% of the upstream area. This configuration allows for a large sampling of flow.

[0073] The cover 150 can be a variety of different shapes. Shape selection of the cover 150 may be dependent on space restrictions of the exhaust aftertreatment system 100, budgets, etc. The cover may be asymmetrical, as shown in Figures 7-9. For example, the upstream end 218 of the cover 150 may have a first portion 224, a second portion 226, and a third portion 228. The second portion 226 is positioned circumferentially between the first portion 224 and the third portion 228. The first portion 224 has a first radius of curvature and the second portion 226 has a second radius of curvature that is less than the first radius of curvature. The third portion 228 has a third radius of curvature that is less than or equal to the first radius of curvature. The upstream end 218 is configured such that the first portion 224 is centered on an axis parallel to the sensor opening axis J2. In various embodiments, the conduit area is at most 70% of the upstream area. This configuration allows for a large sampling of flow.

[0074] As is shown in Figures 10-12, the upstream end 218 of the cover 150 may be semicircular with endpoints that lie on the first plane Pl . In various embodiments with the upstream end 218 being semi-circular, the apertures 206 have equal diameters. In various embodiments with the upstream end 218 being semi-circular, the apertures 206 have diameters that are larger than diameters of apertures 206 in the exhaust sampling assembly 148 where the cover 150 is symmetrical or asymmetrical. These configurations allow for more flow to be properly sampled although the cover 150 takes up less space.

[0075] The apertures 206 may have varying diameters such that the flow of exhaust through the exhaust sampling assembly 148 and to the sensor 146 is collected at high velocity flow stream for efficient sensing. As is shown in Figures 5 and 6, the apertures 206 include a first aperture 230 having a first diameter, a second aperture 232 having a second diameter less-20-4931 -7433-5871.1Atty. Docket No. 106389-9664 than the first diameter, and a third aperture 234 having a third diameter less than the first diameter. The second aperture 232 is disposed circumferentially between the first aperture 230 and the third aperture 234. In various embodiments, the third diameter is also less than the second diameter. In various embodiments, the second diameter is between 50% and 75%, inclusive, of the first diameter and the third diameter is between 25% and 60%, inclusive, of the first diameter.

[0076] The exhaust sampling assembly 148 includes a reference axis 14. The reference axis J4 is parallel to the sensor opening axis J2 and extends along the transverse surface 212. The apertures 206 are configured such that the first aperture 230 has a first aperture center that is angled from the reference axis J4 along the transverse surface 212 by a first angle in a first rotational direction. In various embodiments, the first angle is at most 90 degrees. The second aperture 232 has a second aperture center that is angled from the reference axis J4 along the transverse surface 212 by a second angle in the first rotational direction. The second angle is greater than the first angle. The third aperture 234 has a third aperture center that is angled from the reference axis J4 along the transverse surface 212 by a third angle in the first rotational direction. The third angle is greater than the second angle.

[0077] As shown in Figure 5, the apertures 206 may further include a fourth aperture 236. The fourth aperture 236 has a fourth diameter that is greater than or equal to the third diameter and less than the first diameter. The fourth aperture 236 is angled from the reference axis 14 along the transverse surface 212 by a fourth angle in the first rotational direction. The fourth angle is greater than the third angle and greater than 180 degrees. The apertures 206 may further include a fifth aperture 238. The fifth aperture 238 has a fifth diameter equal to the first diameter. The fifth aperture 238 is angled from the reference axis J4 along the transverse surface 212 by a fifth angle in the first rotational direction. The fifth angle is greater than the fourth angle. In various embodiments, the first angle is equal to an angle from the fifth angle to the reference axis J4 along the transverse surface 212 in the first rotational direction. In other words, the first aperture 230 and the fifth aperture 238 have mirror symmetry across the reference axis J4.-21-4931 -7433-5871.1Atty. Docket No. 106389-9664

[0078] This configuration of the apertures 206 according to the embodiments discussed allows for a velocity profile to be properly maintained for sensing, where more flow is collected from the apertures 206 closer to the first sensor opening 210 than from the apertures 206 further away. Additionally, smaller diameters for a portion of the apertures 206 further away from the first sensor opening 210 increases velocity of flow through the portion of the apertures 206, allowing for the velocity profile to not be impacted as the exhaust flows towards the first sensor opening 210 for sensing. The different diameters of the apertures 206 ensures that all of the apertures 206 are utilized for sensing, and reduces recirculation and backpressure.

[0079] The exhaust sampling assembly 148 also includes the sensor cup 152 coupled to an inner surface 239 of the exhaust conduit 154 around the first sensor opening 210. The inner surface 239 is defined as a surface located on an interior of the exhaust conduit 154 that defines a boundary of the interior of the exhaust conduit 154. The inner surface 239 is opposite of the outer circumferential surface 213. At least a portion of the sensor cup 152 is positioned within a space created by the inner surface 239. The sensor cup 152 includes an outlet 240. In various embodiments, the outlet 240 is a plurality of openings. The outlet 240 has an outlet area that is defined by the total area of the outlet 240 by which exhaust can flow through. The configuration of the exhaust sampling assembly 148 allows exhaust to be flowable through the apertures 206 to the sampling chamber 214, from the sampling chamber 214 into the sensor cup 152, and out of the sensor cup 152 into the exhaust conduit 154 via the outlet 240. In various embodiments, the sensor cup 152 also includes a rain guard 242. The rain guard 242 functions to direct flow that exits from the outlet 240 back into the exhaust conduit 154. Additionally, the rain guard 242 aids in preventing the occurrence of water ingress.

[0080] The exhaust aftertreatment system 100 includes the sensor 146 coupled to the cover 150 along the second sensor opening 216 such that a portion of the sensor 146 extends into the sensor cup 152 through the first sensor opening 210. The configuration allows for exhaust to flow to the sensor 146 via the first sensor opening 210 for sensing and sampling.

[0081] Figure 16 illustrates a perspective view of the sensor cup 152. In various embodiments, the sensor cup 152 has a sensor cup first opening 244 and / or a sensor cup second-22-4931 -7433-5871.1Atty. Docket No. 106389-9664 opening 246. The sensor cup first opening 244 is disposed on the sensor cup 152 along a sensor cup plane. The sensor cup first opening 244 is opposite of the outlet 240, such that a first distance from the transverse surface 212 to the sensor cup first opening 244 is less than a second distance from the transverse surface 212 to the outlet 240. The sensor cup first opening 244 functions as a drain hole to prevent water ingress from occurring.

[0082] The sensor cup second opening 246 is disposed along a bottom surface 248 of the sensor cup 152. The sensor opening axis J2 does not intersect the sensor cup plane and extends through the bottom surface 248. In various embodiments, the sensor cup second opening 246 is centered on the sensor opening axis J2. In various embodiments, a center of the sensor cup second opening 246 is positioned on a center of the bottom surface 248. The sensor cup second opening 246 allows for exhaust in the exhaust conduit 154 to enter the sensor cup 152 and provide the sensor 146 with more flow for sensing. Additionally, the sensor cup second opening 246 can function as a drain hole if water ingress occurs. The sensor cup second opening 246 has a sensor cup second area which is the entirety of the area defined by the sensor cup second opening 246. In various embodiments, the second cup second area is between 30% and 50%, inclusive, of the outlet area of the outlet 240.IV. Configuration of Example Embodiments

[0083] While the exhaust sampling assembly 148 in the exhaust aftertreatment system 100 has been shown and described in the context of use with a diesel internal combustion engine, it is understood that the exhaust aftertreatment system 100 may be used with other internal combustion engines, such as gasoline internal combustion engines, hybrid internal combustion engines, propane internal combustion engines, and other similar internal combustion engines.

[0084] As utilized herein, an area is measured along a plane (e.g., a two-dimensional plane, etc.) unless otherwise indicated. This area may change in a direction that is not disposed along the plane (e.g., along a direction that is orthogonal to the plane, etc.) unless otherwise indicated.

[0085] 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-23-4931 -7433-5871.1Atty. Docket No. 106389-9664 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.

[0086] 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 in the scope of the appended claims.

[0087] 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.

[0088] 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, etc., may flow, either with or without intervening components or objects. Examples of fluid couplings or configurations for enabling-24-4931 -7433-5871.1Atty. Docket No. 106389-9664 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.

[0089] 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 in 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 in 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.

[0090] 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.

[0091] 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 in the range of values (e.g., W1 to W2 can include only W1 and W2, etc ), unless otherwise indicated.-25-4931 -7433-5871.1

Claims

Atty. Docket No. 106389-9664WHAT IS CLAIMED IS:

1. An exhaust sampling assembly comprising: an end flange comprising: a central opening, and a plurality of apertures arrayed around the central opening and extending in a longitudinal direction through the end flange; an exhaust conduit having an exhaust conduit inlet end coupled to the end flange along the central opening of the end flange, the exhaust conduit comprising a first sensor opening; a cover coupled to a transverse surface of the end flange and to an outer circumferential surface of the exhaust conduit, such that a sampling chamber is formed between an inner surface of the cover, the transverse surface of the end flange, and the outer circumferential surface of the exhaust conduit, the cover comprising a second sensor opening aligned with the first sensor opening of the exhaust conduit; and a sensor cup coupled to an inner surface of the exhaust conduit around the first sensor opening, the sensor cup comprising an outlet; wherein the exhaust sampling assembly is configured such that exhaust is flowable through the apertures of the end flange to the sampling chamber, from the sampling chamber into the sensor cup, and out of the sensor cup via the outlet into the exhaust conduit.

2. The exhaust sampling assembly according to claim 1, wherein the cover comprises: an upstream end coupled to the transverse surface of the end flange and having an upstream end area, and a chamber end between the second sensor opening and the upstream end having a chamber end area less than the upstream end area.

3. The exhaust sampling assembly according to claim 1, wherein: the central opening is centered on an opening axis;-26-4931 -7433-5871.1Atty. Docket No. 106389-9664 the cover comprises a concentrating wall extending from an upstream end of the cover, the concentrating wall coupled to the transverse surface of the end flange, an inner surface of the concentrating wall forming the sampling chamber; and a distance between the opening axis and the concentrating wall decreases at greater distances from the end flange.

4. The exhaust sampling assembly according to claim 1, wherein: a portion of the exhaust conduit is centered on a center axis; the first sensor opening is centered on a sensor opening axis; the center axis lies on a first plane, the first plane orthogonal to the sensor opening axis and intersecting the end flange; the cover comprises an upstream end coupled to the transverse surface of the end flange; the upstream end is circular; and the cover has mirror symmetry across the first plane.

5. The exhaust sampling assembly according to claim 1, wherein: the cover comprises an upstream end coupled to the transverse surface of the end flange; the upstream end comprises: a first portion having a first radius of curvature, a second portion having a second radius of curvature less than the first radius of curvature, and a third portion having a third radius of curvature less than or equal to the first radius of curvature, the second portion positioned circumferentially between the first portion and the third portion; the first sensor opening is centered on a sensor opening axis; and the upstream end is configured such that the first portion is centered on an axis parallel to the sensor opening axis.-27-4931 -7433-5871.1Atty. Docket No. 106389-96646. The exhaust sampling assembly according to claim 4 or claim 5, wherein: the upstream end has an upstream end area; and the exhaust conduit has a conduit area that is at most 70% of the upstream end area.

7. The exhaust sampling assembly according to claim 1, wherein: the cover comprises an upstream end coupled to the transverse surface of the end flange; a portion of the exhaust conduit is centered on a center axis; the first sensor opening is centered on a sensor opening axis; the center axis lies on a first plane that is orthogonal to the sensor opening axis and intersects the end flange; and the upstream end is semi-circular and has endpoints that lie on the first plane.

8. The exhaust sampling assembly according to claim 1, wherein: the first sensor opening is centered on a sensor opening axis; the cover comprises: an upstream end coupled to the transverse surface of the end flange and having an upstream end area, and a chamber end defined by the second sensor opening having a chamber end area less than the chamber end area; and the upstream end comprises: a first portion having a first radius of curvature, a second portion having a second radius of curvature less than the first radius of curvature, and a third portion having a third radius of curvature less than or equal to the first radius of curvature, the second portion positioned circumferentially between the first portion and the third portion, the upstream end configured such that the first portion is centered on an axis parallel to the sensor opening axis.

9. An exhaust aftertreatment system comprising:-28-4931 -7433-5871.1Atty. Docket No. 106389-9664 a sensor; and the exhaust sampling assembly according to claim 1; wherein the sensor is coupled to the cover along the second sensor opening such that a portion of the sensor extends into the sensor cup within the exhaust conduit through the first sensor opening.

10. The exhaust sampling assembly according to claim 1, wherein: a portion of the exhaust conduit is centered on a center axis and has a conduit diameter; and the cover and the exhaust conduit are configured such that the first sensor opening and the second sensor opening are separated by a distance in a direction orthogonal to the center axis and intersecting the center axis, the distance between 2% and 7%, inclusive, of the conduit diameter.

11. The exhaust sampling assembly according to claim 1, wherein: the apertures of the end flange comprise: a first aperture having a first diameter, a second aperture having a second diameter less than the first diameter, and a third aperture having a third diameter less than the first diameter; and the second aperture is disposed circumferentially between the first aperture and the third aperture.

12. The exhaust sampling assembly according to claim 11, wherein: a portion of the exhaust conduit is centered on a center axis; the first sensor opening is centered on a sensor opening axis; the center axis extends through the transverse surface of the end flange; a reference axis parallel to the sensor opening axis extends along the transverse surface; the first aperture has a first aperture center that is angled from the reference axis along the transverse surface by a first angle in a first rotational direction;-29-4931 -7433-5871.1Atty. Docket No. 106389-9664 the second aperture has a second aperture center that is angled from the reference axis along the transverse surface by a second angle in the first rotational direction, the second angle greater than the first angle; and the third aperture has a third aperture center that is angled from the reference axis along the transverse surface by a third angle in the first rotational direction, the third angle greater than the second angle.

13. The exhaust sampling assembly according to claim 12, wherein: the apertures comprise a fourth aperture having a fourth diameter greater than or equal to the third diameter and less than the first diameter; and the fourth aperture has a fourth aperture center that is angled from the reference axis along the transverse surface of the end flange by a fourth angle in the first rotational direction, the fourth angle greater than the third angle, the fourth angle greater than 180 degrees.

14. The exhaust sampling assembly according to claim 13, wherein: the apertures comprise a fifth aperture having a fifth diameter equal to the first diameter; and the fifth aperture has a fifth aperture center that is angled from the reference axis along the transverse surface of the end flange by a fifth angle in the first rotational direction, the fifth angle greater than the fourth angle.

15. The exhaust sampling assembly according to claim 14, wherein the first angle is equal to an angle from the fifth angle to the reference axis along the transverse surface in the first rotational direction.

16. The exhaust sampling assembly according to claim 11, wherein: the second diameter is between 50% and 75%, inclusive of the first diameter; and the third diameter is between 25% and 60%, inclusive of the first diameter.

17. The exhaust sampling assembly according to claim 1, wherein:-30-4931 -7433-5871.1Atty. Docket No. 106389-9664 the first sensor opening is centered on a sensor opening axis; the sensor cup has at least one of a sensor cup first opening or a sensor cup second opening; the sensor cup first opening is disposed on the sensor cup along a sensor cup plane, the sensor cup first opening opposite of the outlet of the sensor cup; the sensor cup second opening is disposed on the sensor cup along a bottom surface of the sensor cup; and the sensor opening axis does not intersect the sensor cup plane and extends through the bottom surface, the sensor cup second opening centered on the sensor opening axis.

18. The exhaust sampling assembly according to claim 17, wherein: the outlet of the sensor cup has an outlet area; and the sensor cup second opening has a sensor cup second area that is between 30% and 50%, inclusive of the outlet area.-31-4931 -7433-5871.1

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