Diesel Exhaust Fluid Sensor Adapter Tortuous Pathway Aeration Mitigation

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Solution Overview

Problem

Existing diesel exhaust fluid (DEF) sensors are affected by entrained air, leading to erratic or unreliable measurement results, as air bubbles can attach to sensor surfaces and disrupt readings.

Innovation Solution

A diesel exhaust fluid sensor adapter with a tortuous pathway for fluid and air flow, featuring varying stepped segments with decreasing diameters and a vent system that prevents air from reaching the sensor, allowing air to vent out and mitigate aeration within the sensor adapter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If venting apertures are provided to allow air to escape from the sensor enclosure, then air can be vented out, but micro-bubbles are driven into the enclosure and stick to critical surfaces

Engineering Contradiction:

Improveair in DEFVSAvoidmicro-bubbles attached to sensor surfaces

Core Design Contradiction:

Object-affected harmful factorsVSObject-generated harmful factors

Solution Approach 1:

The sensor enclosure is divided into multiple chambers separated by partitions. The first chamber receives aerated DEF, while the second chamber houses the sensor. This segmentation prevents air and micro-bubbles from reaching the sensor while still allowing the system to manage air venting in the first chamber.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A tortuous pathway with varying diameters acts as an intermediary between the first chamber and the second chamber. This pathway allows controlled fluid communication while blocking the direct path for air and micro-bubbles to reach the sensor.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the sensor enclosure is sealed to prevent air entry, then sensor measurement reliability is improved, but air bubbles still attach to sensor surfaces from external sources

Engineering Contradiction:

Improvesensor measurement reliabilityVSAvoidair bubbles attaching to sensor surfaces

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

3Device complexity

If a simple straight pathway is used for fluid flow through the sensor adapter, then device complexity is reduced, but air bubbles cannot be effectively separated from the fluid

Engineering Contradiction:

Improvesensor adapter structureVSAvoidentrained air in DEF

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The pathway includes curved sections and varying diameters that create a tortuous flow pattern. This curved, non-linear pathway design effectively separates air bubbles from the fluid through geometric configuration while maintaining reasonable structural simplicity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The sensor adapter effectively prevents aerated DEF from entering the sensor and allows air to vent out, resulting in accurate and reliable sensor measurements, reduced sensor errors, and decreased slosh issues.

Implementation Method 1

These larger bubbles may have relatively high buoyancy and typically rise easily in the liquid

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Implementation Method 2

these enclosures may provide venting apertures at the highest points to allow the air to escape

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Data Source

PatentUS20250146855A1Diesel exhaust fluid sensor adapter for fluid aeration mitigation

Publication Date: 2025.05.08 SHAW DEVELOPMENT LLC

AI summary

Provided is a diesel exhaust fluid (DEF) sensor adapter. The sensor adapter may include two chambers. The first chamber may include a tortuous pathway for fluid and/or air flow. The second chamber may be fluidly sealed or separated from the first chamber and may house electrical components. The tortuous pathway may include varying stepped segments having a decreasing diameter from a proximal toward a distal end. For example, a first segment at the proximal end may have a larger diameter than a second, middle segment. An entrance to a third segment from the second segment may have a greatly reduced size. The tortuous pathway may further include a vent inlet positioned at approximately the same height as the entrance but requiring an approximate 180° turn therebetween. The inlet may extend into two opposite substantially horizontal portions that each lead to a vent outlet on opposite sides of the sensor adapter. The turn from the inlet to the substantially horizontal portions may be approximately 90°. The sensor adapter and tortuous pathway may mitigate aeration of DEF. The sensor adapter may prevent aerated DEF from entering the sensor adapter and may allow air to vent out of the sensor adapter to prevent aeration of DEF within the sensor adapter.