Filter Assembly with Integral Gasket for Reductant Storage
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Solution Overview
Problem
Existing reductant storage systems for internal combustion engines, such as those using diesel exhaust fluid (DEF), face contamination issues due to the accumulation of dirt and debris, which can reduce the efficacy of the liquid reducing agent and cause wear or damage to sensors and injection systems.
Innovation Solution
A filter assembly with a filtering material and a gasket, where the gasket includes a proximal flange with a larger diameter than the opening, providing a sealing surface and a distal portion with a larger diameter than the intermediate portion, securely attached to the filtering material, is integrated into the reductant storage system to prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a filter is provided in a filling port, then contaminants are prevented during filling, but the filling rate is reduced and contaminants can still enter via other locations
Solution Approach 1:
The filter assembly is divided into multiple functional segments: a filter element for contamination removal, a gasket for sealing, and a flange for mounting. This segmentation allows the filter to be integrated into the filling port without blocking the entire opening, maintaining filling rate while providing effective filtration.
Solution Approach 2:
The filter assembly acts as an intermediary component between the filling port and the reductant storage tank. It provides a sealed interface that allows reductant to be filled while preventing contaminant entry, resolving the contradiction between filling efficiency and contamination protection.
2Reliability
If a filter assembly with larger diameter components is used, then contaminant prevention is improved, but the storage container opening size must be increased
Solution Approach 1:
The filter assembly components are nested within each other: the filter element is positioned within the gasket, which is in turn positioned within the flange. This nested configuration allows the filter assembly to be inserted through a relatively small opening while providing a larger sealing surface area for effective contamination prevention.
Solution Approach 2:
The filter assembly extends in the axial dimension rather than requiring a larger radial opening. The flange provides a large sealing surface area in the radial direction while the entire assembly can be inserted through a smaller opening, utilizing the axial dimension to resolve the size contradiction.
3Reliability
If the gasket diameter is larger than the opening, then sealing effectiveness is improved, but the filter assembly complexity increases
Solution Approach 1:
The gasket is integrally formed with the filter element, merging the sealing function and filtration function into a single component. This integration provides effective sealing with a large gasket diameter while reducing overall assembly complexity by eliminating the need for separate gasket and filter components.
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 filter assembly effectively prevents contaminants from entering the reductant storage system, ensuring the quality of the reductant and protecting sensitive equipment, while allowing for a larger header assembly without redesigning the storage container, thus maintaining the system's efficiency and longevity.
Implementation Method 1
a filter assembly that extends through the opening and includes a filtering material
Implementation Method 2
a gasket that includes a proximal flange...including a sealing surface in sealing contact with the storage container
Data Source
AI summary
A reductant storage system for an internal combustion engine system includes a storage container having a bottom wall, a top wall opposite the bottom wall, an opening extending through the top wall, and a reservoir formed by a hollow interior of the storage container and a filter assembly. The filter assembly extends through the opening and include a filtering material and a gasket integrally formed with the filtering material. The gasket includes a proximal flange that is larger than the opening and including a sealing surface in sealing contact with the storage container.