US20190078488A1 - Injector for reductant delivery unit having fluid volume reduction assembly - Google Patents
Injector for reductant delivery unit having fluid volume reduction assembly Download PDFInfo
- Publication number
- US20190078488A1 US20190078488A1 US15/704,402 US201715704402A US2019078488A1 US 20190078488 A1 US20190078488 A1 US 20190078488A1 US 201715704402 A US201715704402 A US 201715704402A US 2019078488 A1 US2019078488 A1 US 2019078488A1
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- Prior art keywords
- fluid
- disposed
- filter tube
- tube
- calibration filter
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
- F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
- F01N3/2066—Selective catalytic reduction [SCR]
- F01N3/208—Control of selective catalytic reduction [SCR], e.g. dosing of reducing agent
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
- F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
- F01N3/2066—Selective catalytic reduction [SCR]
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/16—Selection of particular materials
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
- F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
- F01N3/206—Adding periodically or continuously substances to exhaust gases for promoting purification, e.g. catalytic material in liquid form, NOx reducing agents
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2896—Liquid catalyst carrier
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2610/00—Adding substances to exhaust gases
- F01N2610/02—Adding substances to exhaust gases the substance being ammonia or urea
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2610/00—Adding substances to exhaust gases
- F01N2610/14—Arrangements for the supply of substances, e.g. conduits
- F01N2610/1426—Filtration means
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2610/00—Adding substances to exhaust gases
- F01N2610/14—Arrangements for the supply of substances, e.g. conduits
- F01N2610/1433—Pumps
- F01N2610/144—Control thereof
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2610/00—Adding substances to exhaust gases
- F01N2610/14—Arrangements for the supply of substances, e.g. conduits
- F01N2610/1453—Sprayers or atomisers; Arrangement thereof in the exhaust apparatus
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
Definitions
- the present invention generally relates to a fluid injector of a reductant delivery unit (RDU), and particularly to a robust RDU fluid injector for non-purge applications.
- RDU reductant delivery unit
- One of these technologies includes a catalyst that facilitates the reactions of ammonia (NH 3 ) with the exhaust nitrogen oxides (NOx) to produce nitrogen (N 2 ) and water (H 2 O).
- This technology is referred to as Selective Catalytic Reduction (SCR).
- Ammonia is difficult to handle in its pure form in the automotive environment, therefore it is customary with these systems to use a diesel exhaust fluid (DEF) and/or liquid aqueous urea solution, typically at a 32% concentration of urea (CO(NH 2 ) 2 ).
- the solution is referred to as AUS-32, and is also known under its commercial name of AdBlue.
- the reductant solution is delivered to the hot exhaust stream typically through the use of an injector, and is transformed into ammonia prior to entry in the catalyst.
- the solution is delivered to the hot exhaust stream and is transformed into ammonia in the exhaust after undergoing thermolysis, or thermal decomposition, into ammonia and isocyanic acid (HNCO).
- the isocyanic acid then undergoes a hydrolysis with the water present in the exhaust and is transformed into ammonia and carbon dioxide (CO 2 ), the ammonia resulting from the thermolysis and the hydrolysis then undergoes a catalyzed reaction with the nitrogen oxides as described previously.
- AUS-32, or AdBlue has a freezing point of ⁇ 11 C, and system freezing is expected to occur in cold climates. Since these fluids are aqueous, volume expansion happens after the transition to the solid state upon freezing. The expanding solid can exert significant forces on any enclosed volumes, such as an injector. This expansion may cause damage to the injection unit, so different SCR strategies exist for addressing reductant expansion.
- purge SCR systems the reductant urea and/or DEF solution is purged from the RDU when the vehicle engine is turned off.
- non-purge SCR systems the reductant remains in the RDUs throughout the life of the vehicle.
- the RDU injector operates at temperatures which are above the freezing point of the reductant such that reductant in the RDU remains in the liquid state.
- the RDU injector remains filled with reductant, thereby making the RDU injector susceptible to damage from reductant expanding in freezing conditions.
- an RDU includes a fluid injector having a fluid inlet disposed at a first end of the fluid injector for receiving a reductant, and a fluid outlet disposed at a second end of the fluid injector for discharging the reductant.
- the fluid injector defines a fluid path for the reductant from the fluid inlet to the fluid outlet.
- the fluid injector further includes a tube member having an end disposed at or near the fluid inlet of the fluid injector, the tube member configured to pass reductant along the fluid path; a filter disposed in the tube member proximal to the fluid inlet of the fluid injector; and a calibration filter tube disposed in the tube member downstream of the filter, relative to a direction of flow of reductant along the fluid path from the fluid inlet to the fluid outlet of the fluid injector, the calibration filter tube having a first end portion adjacent the filter and a second end, and further including a bore defined in an axial direction through the calibration filter tube, the bore defining at least a portion of the fluid path through the fluid injector.
- An actuator unit is disposed within the fluid injector downstream of the calibration filter tube, the actuator unit engaging the second end of the calibration filter tube.
- a valve assembly is operatively coupled to the actuator unit, wherein a position of the calibration filter tube within the tube member at least partly sets an opposing opening force for the valve assembly.
- a volume reduction member has a bore though which the calibration filter tube extends, the volume reduction member occupying a space between an outer surface of the calibration filter tube and an inner surface of the tube member.
- the filter, calibration filter tube and the volume reduction member form a unitary subassembly component of the fluid injector.
- the volume reduction member is formed from compressible material, the compressible material being one of a rubber composition and closed cell foam.
- the volume reduction member includes a sidewall, the sidewall of the volume reduction member undulating in a direction along a longitudinal axis of the fluid injector.
- the fluid injector may further include a cap member including a sidewall defining an inner space into which the filter is disposed, the sidewall contacting the first end of the calibration filter tube.
- the first end portion of the calibration filter tube is disposed in the inner space of the cap member.
- the first end portion of the calibration filter tube may be attached to the sidewall of the cap member such that the calibration filter tube, the cap member, the volume reduction member and the filter form the unitary subassembly component of the fluid injector.
- the actuator unit may include a pole piece disposed in a fixed position within the fluid injector and having a bore defined axially through the pole piece, and an armature movably positioned within the fluid injector and having a pocket.
- the actuator unit may further include a coil disposed in proximity to the pole piece and the armature, and a spring disposed at least partly in the pocket of the armature.
- the calibration filter tube is disposed in the bore of the pole piece such that the second end of the calibration filter tube contacts the spring, and the spring biases the armature away from the pole piece in an absence of current passing through the coil so that the valve assembly is placed in a closed position to prevent reductant from passing through the fluid outlet.
- the calibration filter tube includes a second portion which axially extends from the first end portion of calibration filter tube, and a third portion disposed between the second portion and the second end of the calibration filter tube.
- the volume reduction member is disposed around the second portion, the third portion is disposed in the bore of the pole piece, and a downstream end of the volume reduction member is adjacent an upstream end of the pole piece, relative to the direction of flow of reductant along the fluid path.
- An outside diameter of the second portion of the calibration filter tube may be greater than an outside diameter of the third portion thereof.
- an RDU fluid injector has a fluid inlet disposed at a first end and configured to receive a fluid, and a fluid outlet disposed at a second end of the fluid injector for discharging the fluid, the fluid injector defining a fluid path for the fluid from the fluid inlet to the fluid outlet.
- a tube member has an end disposed at or near the fluid inlet of the fluid injector, the tube member configured to pass fluid along the fluid path.
- a filter is disposed in the tube member proximal to the fluid inlet of the fluid injector.
- a calibration filter tube is disposed in the tube member downstream of the filter, relative to a direction of flow of fluid along the fluid path from the fluid inlet to the fluid outlet of the fluid injector.
- the calibration filter tube has a first end portion adjacent the filter, a second end, and a bore defined in an axial direction through the calibration filter tube, the bore defining at least a portion of the fluid path through the fluid injector.
- An actuator unit is disposed within the fluid injector downstream of the calibration filter tube, the actuator unit engaging the second end of the calibration filter tube.
- a valve assembly is operatively coupled to the actuator unit, wherein a position of the calibration filter tube within the tube member sets an opposing opening force of the valve assembly.
- the fluid injector further includes a cap member having a sidewall defining an inner space into which the filter is disposed. In an example embodiment, the sidewall contacts and is attached to the first end of the calibration filter tube such that the cap member, the filter and the calibration filter tube form a single subassembly component of the fluid injector.
- FIG. 1 is a cross-sectional side view of an RDU for a non-purge SCR system according to an example embodiment
- FIG. 2 is a cross-sectional side view of a fluid injector of the RDU of FIG. 1 ;
- FIG. 3 is a magnified cross-sectional view of the inlet portion of the fluid injector of the RDU of FIG. 1 according to an example embodiment
- FIG. 4 is an exploded perspective view of components of the fluid injector of the RDU of FIG. 1 according to an example embodiment
- FIG. 5 is a magnified cross-sectional view of the outlet portion of the fluid injector of the RDU of FIG. 1 according to an example embodiment
- FIG. 6 is a magnified cross-sectional view of the inlet portion of the fluid injector of the RDU of FIG. 1 according to another example embodiment
- FIG. 7 is an exploded perspective view of components of the fluid injector of FIG. 6 ;
- FIG. 8 is a cross-sectional view of the components of FIG. 6 ;
- FIG. 9 is a magnified cross-sectional view of the inlet portion of the fluid injector of the RDU of FIG. 1 according to yet another example embodiment
- FIG. 10 is a cross-sectional view of components of the fluid injector of FIG. 9 ;
- FIG. 11 is a perspective view of a component of the fluid injector of FIG. 9 ;
- FIG. 12 is a cross-sectional view of the inlet portion of the fluid injector of the RDU of FIG. 1 according to another example embodiment
- FIG. 13 is a cross-sectional view of integrated components of the fluid injector of FIG. 12 ;
- FIG. 14 is an exploded perspective view of the components of the fluid injector of FIG. 13 ;
- FIG. 15 is a cross-sectional view of the inlet portion of the fluid injector of the RDU of FIG. 1 according to another example embodiment
- FIG. 16 is a cross-sectional view of integrated components of the fluid injector of FIG. 15 ;
- FIG. 17 is an exploded perspective view of the components of the fluid injector of FIG. 15 .
- Example embodiments are generally directed to an RDU for a non-purge SCR system in which damaging effects from a reductant, DEF and/or urea solution freezing in the RDU injector are reduced.
- FIG. 1 illustrates an RDU 10 of a non-purge SCR system according to an example embodiment.
- RDU 10 includes a solenoid fluid injector, generally indicated at 12 , that provides a metering function of fluid and provides the spray preparation of the fluid into the exhaust path of a vehicle in a dosing application.
- fluid injector 12 is constructed and arranged to be associated with an exhaust gas flow path upstream of a selective catalytic reduction (SCR) catalytic converter (not shown).
- Fluid injector 12 may be an electrically operated, solenoid fuel injector.
- fluid injector 12 includes an actuator unit having a coil 14 and a movable armature 16 .
- Components of injector 12 define a fluid path for a reductant, DEF and/or urea solution through injector 12 .
- the reductant, DEF and/or urea solution which RDU 10 is configured to inject into the exhaust path of a vehicle engine will be hereinafter referred to as “reductant” for simplicity.
- Fluid injector 12 is disposed in an interior carrier 18 of RDU 10 , as shown in FIG. 1 .
- An injector shield, generally indicated at 20 is formed by upper shield 20 A and lower shield 20 B, which surround injector 12 and are coupled to carrier 18 by folding tangs of a flange 22 of lower shield 20 B over shelf features of carrier 18 and upper shield 20 A. As a result, shield 20 and carrier 18 are fixed with respect to injector 12 .
- An inlet cup structure of RDU 10 includes a cup 26 and a fluid supply tube 28 integrally formed with cup 26 .
- Fluid supply tube 28 is in communication with a source of a reductant (not shown) that is fed into a fluid inlet 30 of injector 12 for ejection from a fluid outlet 32 thereof and into the exhaust stream of a vehicle engine (not shown).
- Fluid inlet 30 of injector 12 is in fluid communication with fluid supply tube 28 .
- Fluid outlet 32 is fluidly connected with a flange outlet 34 of an exhaust flange 36 that is coupled directly with an end of lower shield 20 B of RDU 10 .
- Injector 12 includes an injector body structure in which the components of injector 12 are disposed.
- the injector body structure includes a first injector body portion 38 in which coil 14 and armature 16 are disposed, and a valve body portion 40 in which a valve assembly of injector 12 is at least partly disposed.
- First injector body portion 38 and valve body portion 40 are fixedly connected, either directly or indirectly, to each other.
- fluid injector 12 includes a tube member 42 which is at least partly disposed within first injector body portion 38 .
- the outer surface of tube member 42 contacts the inner surface of first injector body portion 38 .
- An open end of tube member 42 is disposed within cup 26 and is in fluid communication with fluid supply tube 28 .
- An O-ring 44 is disposed within cup 26 , between an inner surface thereof and the outer surface of tube member 42 , proximal to the open end of tube member 42 .
- O-ring 44 serves to ensure that reductant exiting fluid supply tube 28 passes into the open end of tube member 42 of injector 12 .
- the actuator unit of fluid injector 12 further includes a pole piece 46 which is fixedly disposed within first injector body portion 38 .
- Coil 14 at least partly surrounds pole piece 46 and armature 16 .
- Pole piece 46 is disposed upstream of armature 16 within injector 12 .
- Pole piece 46 includes a central bore defined axially therethrough.
- Armature 16 includes a U-shaped section which defines a pocket in which at least part of a spring 50 is disposed.
- Spring 50 which is part of the actuator unit, biases movable armature 16 so that armature 16 is spaced apart from pole piece 46 when no current is passed through coil 14 .
- Spring 50 partly extends within the central bore of pole piece 46 .
- An end of spring 50 which extends within pole piece 46 contacts a spring adjustment tube 52 .
- Spring adjustment tube 52 is at least partly disposed within the central bore of pole piece 46 , upstream (relative to a direction of flow of reductant through injector 12 ) of spring 50 .
- Spring adjustment tube 52 includes a bore defined axially therethrough.
- the throughbore of spring adjustment tube 52 partly defines the fluid path for reductant in fluid injector 12 , and defines the only fluid path for reductant through pole piece 46 . Due to its engagement with spring 50 , spring adjustment tube 52 is used to calibrate the dynamic flow of reductant through fluid injector 12 .
- Armature 16 further includes one or more channels 60 ( FIGS. 1 and 2 ) defined through the armature 16 from an interior of the pocket to an upstream end portion of pin member 58 .
- Channels 60 may be equally spaced about armature 16 .
- armature 16 includes a single channel which is defined entirely around the base of the pocket formed by pocket wall 16 A.
- Channel(s) 60 allows reductant to flow from the pocket of armature 16 to the space around the upstream end of pin member 58 .
- the pocket of armature 16 and the channel(s) 60 together partly define the reductant fluid path of the fluid injector 12 and define the only part of the fluid path passing through or around armature 16 .
- the valve assembly of injector 12 includes a seal member 54 and a seat 56 .
- Seal member 54 is connected to armature 16 via a pin member 58 , which is disposed between seal member 54 and the downstream end of armature 16 .
- Seal member 54 , pin member 58 and armature 16 may combine to form an armature assembly.
- coil 14 When coil 14 is energized, coil 14 generates an electromagnetic force acting on armature 16 which overcomes the bias force from spring 50 and causes armature 16 to move towards pole piece 46 , which correspondingly moves pin member 58 so that seal member 54 is lifted off of, and disengages from, seat 56 , moving the armature assembly to an open position and thus permitting reductant to pass through fluid outlet 32 to flange outlet 34 and into the exhaust path of the vehicle engine.
- coil 14 When coil 14 is de-energized, the electromagnetic force dissipates and spring 50 biases armature 16 so that armature 16 is moved away from pole piece 46 , resulting in seal member 54 sealingly engaging with seat 56 , changing the armature assembly back to a closed position. With the armature assembly in the closed position, reductant is prevented from flowing through seat 56 and flange outlet 34 and into the exhaust path of the vehicle engine.
- RDU 10 forms part of a non-purge SCR exhaust aftertreatment system.
- reductant remains in fluid injector 12 following the vehicle engine being turned off.
- fluid injector 12 is configured so that the amount of reductant in fluid injector 12 is reduced. In other words, the total volume of the fluid path for reductant through fluid injector 12 is reduced.
- the amount of reductant in RDU 10 that may potentially freeze is reduced, thereby reducing the susceptibility of injector 12 being damaged by expansion forces from frozen reductant.
- valve body portion 40 In order to reduce the volume of the reductant fluid path in fluid injector 12 , the thickness of valve body portion 40 is increased.
- pin member 58 is constructed as a solid element such that reductant flows around the outer surface of pin member 58 , instead of therethrough.
- the spacing between the outer surface of pin 58 and the inner surface of valve body portion 40 which partly defines the fluid path for reductant through injector 12 , is narrowed. This narrowed portion of the fluid path is the only fluid path for reductant between armature 16 and seat 56 in fluid injector 12 .
- the narrowed fluid path between pin 58 and valve body portion 40 provides a sufficient reductant flow rate through fluid injector 12 for performing reductant injection during normal operation of RDU 10 while at the same time maintaining a relatively small volume of reductant within injector 12 so as to lessen the risk of injector 12 being damage from the reductant therein freezing.
- the diameter of the pocket of armature 16 is reduced, which allows for the thickness of pocket wall 16 A of armature 16 to be increased.
- the thickness of pocket wall 16 A is between 45% and 75% of the diameter of pocket, such as about 60%.
- the bore of spring adjustment tube 52 is sized for reducing the volume of the reductant fluid path in injector 12 .
- the diameter of the bore of spring adjustment tube 52 is between 12% and 22% of the outer diameter of pole piece 46 , and particularly between 16% and 19% thereof.
- FIG. 3 illustrates an upstream portion of injector 12 .
- Tube member 42 extends at least partly though injector 12 .
- the reductant fluid path through injector 12 passes through tube member 42 .
- Injector 12 includes a filter 204 disposed within tube member 42 proximal to the open end thereof.
- Filter 204 is a structurally rigid, sintered metal filter, such as a stainless steel material, in order to better withstand expansion forces from reductant freezing. Filter 204 may have a supporting outer structure for added strength. Best seen in FIG. 3 , filter 204 is disposed within a cap member 206 .
- Cap member 206 is largely cylindrically shaped having a sidewall 206 A extending circumferentially and defining an inner volume sized for receiving filter 204 therein.
- Cap member 206 is dimensioned to fit within tube member 42 , and particularly so that the outer surface of sidewall 206 A of cap member 206 contacts the inner surface of tube member 42 .
- Cap member 206 further includes annular members 206 B disposed along the axial ends of cap member 206 and extend radially inwardly from sidewall 206 A. Annular members 206 B serve to maintain filter 204 within cap member 206 in a fixed position.
- Cap member 206 is constructed of metal or like compositions.
- Injector 12 further includes a retaining ring 207 which is disposed in tube member 42 upstream of, and in contact with, cap member 206 , as shown in FIGS. 1-3 .
- Retainer ring 207 is fixed to tube member 42 along an inner surface thereof. Retainer ring 207 being fixed in position along tube member 42 serves to maintain downstream components of injector 12 in fixed positions within first injector body portion 38 .
- retainer ring 207 is welded along the inner surface of tube member 42 . Such weld connection is formed along an entire circumference of the upper edge of retainer ring 207 . It is understood, however, that other connection mechanisms may be utilized for fixing retainer ring 207 to tube member 42 .
- injector 12 further includes a volume reduction member 208 which serves to further reduce the volume of the reductant fluid path within injector 12 .
- Reduction member 208 is largely cylindrical in shape, as shown in FIG. 4 , having a top (upstream) end and a bottom (downstream) end.
- volume reduction member 208 is constructed from a metal, such as stainless steel. It is understood, though, that volume reduction member 208 may be formed from other metals or metal compositions.
- the outer surface of volume reduction member 208 is sized to contact the inner surface of tube member 42 .
- Volume reduction member 208 further includes a bore 208 A ( FIGS. 2 and 3 ) defined in the axial direction through volume rejection member 208 , from one axial (top) end to the other axial (bottom) end.
- Bore 208 A is located along the longitudinal axis of volume reduction member 208 and itself forms part of the fluid path for passing reductant through injector 12 .
- Bore 208 A forms the only fluid path for passing reductant through or around volume reduction member 208 .
- the diameter of bore 208 A is between 12% and 20% of the outer diameter of volume reduction member 208 , such as about 16%.
- volume reduction member 208 extends radially to the inner surface of tube member 42 , and because the diameter of bore 208 A is small relative to the outer diameter of volume reduction member 208 , volume reduction member 208 reduces the space or volume in which reductant may reside within injector 12 , thereby reducing the volume of the fluid path of reductant therein. Volume reduction member 208 further assists in retaining spring adjustment tube 52 in position within injector 12 such that pin adjustment tube 52 maintains a desired force on spring 50 so as to prevent a loss of calibration. Specifically, retainer ring 207 maintains the position of filter 204 and corresponding cap member 206 , which maintain the position of volume reduction member 208 , which maintains the position of spring adjustment member 52 .
- fluid injector 12 further includes a volume compensation member 210 which is disposed between the bottom (downstream) end of volume reduction member 208 and the top of pole piece 46 .
- Volume compensation member 210 is constructed from elastic material and serves to occupy the space between volume reduction member 208 and pole piece 46 so as to further lessen the volume of the reductant fluid path in injector 12 .
- Volume compensation member 210 may be in a compressed state in injector 12 when assembled, and contact the volume reduction member 208 , pole piece 46 , the inner surface of tube member 42 and the outer surface of spring adjustment member 52 .
- FIG. 5 illustrates a downstream end portion of fluid injector 12 .
- seat 56 includes a bore defined axially through seat 56 .
- the length of the throughbore of seat 56 is reduced so as to further reduce the volume of the reductant fluid path through seat 56 , and particularly the sac volume below the sealing band of seat 56 which engages with seal member 54 .
- fluid injector 12 includes a plurality of orifice discs 212 disposed in a stacked arrangement.
- the orifice disc stack is disposed against the downstream end of seat 56 .
- the disc stack includes a first disc 212 A having one or more orifices that are configured for providing the desired spray pattern of reductant exiting injector 12 . It is understood that the dimension and locations of the orifices of first disc 212 A may vary and be dependent upon the reductant dosing requirements of the particular vehicle engine.
- the disc stack further includes a second disc 212 B which is disposed downstream of first disc 212 A and includes orifices through which the reductant spray passes.
- Second disc 212 B has a larger thickness than the thickness of first disc 212 A and being disposed against first disc 212 A, and supports first disc 212 A so as to prevent the thinner first disc 212 A from deforming due to expansion forces from frozen reductant upstream of first disc 212 A.
- fluid injector 12 and particularly the components thereof, are configured to reduce the volume of the reductant fluid path in injector 12 .
- the ratio of the volume of the fluid path in fluid injector 12 to a volume of the components of injector 12 is between 0.08 and 0.30, and particularly between 0.12 and 0.20, such as about 0.15.
- volume amounts are calculated between orthogonal planes relative to the longitudinal axis of fluid injector 12 —from a first plane along the open end of tube member 42 (i.e., fluid inlet 30 ) and a second plane along the lowermost (downstream) surface of second disc 212 B (i.e., fluid outlet 32 ). It is understood that the particular ratio of volume of the reductant path to injector component volume within fluid injector 12 may vary depending upon a number of cost and performance related factors, and may be any value between about 0.08 and about 0.30.
- Providing a fluid injector having a reduced ratio of reductant fluid path volume to injector component volume to fall within the above range advantageously results in less reductant in injector 12 which reduces the susceptibility of RDU 10 being damaged if the reductant in injector 12 freezes.
- fluid injector 12 includes a volume reduction member 308 which has many of the characteristics of volume reduction member 208 discussed above with respect to FIGS. 1-5 . Similar to volume reduction member 208 , volume reduction member 308 is constructed from stainless steel or like composition, is disposed in tube member 42 of fluid injector 12 between volume compensation member 210 and filter 204 . However, volume reduction member 308 includes a first portion 308 A and a second portion 308 B. As shown in FIG. 7 , each of first portion 308 A and second portion 308 B has a cylindrical shape, with the outer diameter of first portion 308 A being less than the outer diameter of second portion 308 B.
- first portion 308 A is less than the diameter of second portion 308 B by the thickness of sidewall 306 A of cap member 306 , as will be explained in greater detail below.
- Volume reduction member 308 includes top (upstream) and bottom (downstream) end portions which form the axial ends of first portion 308 A and second portion 308 B, respectively.
- the outer surface of second portion 308 B is sized to contact the inner surface of tube member 42 .
- volume reduction member 308 includes an angled annular surface or skirt 308 D, which extends in the axial direction between the outer surface of first portion 308 A and the outer surface of second portion 308 B and serves as the physical interface therebetween.
- the angle of angled surface 308 D, relative to the longitudinal axis of volume reduction member 308 and/or injector 12 is an acute angle.
- the angle of angled surface 308 D is orthogonal to the longitudinal axis of volume reduction member 308 and/or injector 12 .
- Volume reduction member 308 further includes a bore 308 C defined in the axial direction through volume rejection member 308 , from one axial (top) end to the other axial (bottom) end. Bore 308 C is located along the longitudinal axis of volume reduction member 308 and itself forms part of the reductant fluid path for passing reductant through injector 12 , and the only reductant fluid path through or around volume reduction member 308 . In an example embodiment, the diameter of the bore 308 C is between 12% and 20% of the outer diameter of volume reduction member 308 , such as about 16%.
- volume reduction member 308 extends to the inner surface of tube member 42 and because the diameter of bore 308 C is relatively small relative to the outer diameter of volume reduction member 308 , volume reduction member 308 occupies a volume within injector 12 which reduces the space or volume of the reductant fluid path through injector 12 , thereby reducing the amount of reductant in injector 12 that could freeze and potentially damage injector 12 .
- Cap member 306 includes a number of the same characteristics of cap member 206 described above with respect to FIGS. 1-5 . As shown in FIG. 7 , cap member 306 is largely cylindrically shaped having a sidewall 306 A extending circumferentially and defining an inner volume sized for receiving filter 204 therein. Cap member 306 is dimensioned to fit within tube member 42 , and particularly so that the outer surface of sidewall 306 A of cap member 306 contacts the inner surface of tube member 42 . Cap member 306 further includes an annular member 306 B disposed along the axial (upstream) end of cap member 306 and extending radially inwardly from sidewall 306 A. Annular member 306 B serves to maintain filter 204 within cap member 306 in a fixed position. Like cap member 206 , cap member 306 is constructed of metal or like compositions and provides structural support to filter 204 .
- cap member 306 is engaged with and secured to volume reduction member 308 .
- filter 204 , cap member 306 and volume reduction member 308 form a single, unitary and integrated component, as shown in FIG. 8 .
- Having a single, unitary component formed from filter 204 , cap member 306 and volume reduction member 308 advantageously allows for a simpler and less complex process for assembling injector 12 during manufacture thereof.
- cap member 306 fits over and engages with or otherwise attaches to at least a part of first portion 308 A of volume reduction member 308 , as shown in FIGS. 6 and 8 .
- cap member 306 forms a press fit engagement with first portion 308 A.
- cap member 306 is welded to first portion 308 A, such as a fillet weld between bottom surface 306 C of cap member 306 and the radially outer surface of first portion 308 A.
- the angled surface 308 D provides sufficient spacing for securing cap member 306 to first portion 308 A. It is understood that cap member 306 may be secured to first portion 308 A of volume reduction member 308 via other mechanisms.
- the outer diameter of sidewall 306 A is the same or nearly the same as the outer diameter of second portion 308 A. See FIGS. 6 and 8 .
- volume reduction member 308 is constructed from metal, such as stainless steel, according to an example embodiment.
- a part of second portion 308 B is constructed from plastic or like compositions. Specifically, as illustrated in FIGS. 9-11 , first portion 308 A and a first part 308 B- 1 of second portion 308 B are formed as a single metal member, and a second part 308 B- 2 of second portion 308 B is plastic overmolded around the first part thereof.
- FIG. 11 shows the metal first portion 308 A and first part 308 B- 1 of second portion 308 B.
- First part 308 B- 1 of second portion 308 B includes intermediate section 308 B- 3 which extends away from first portion 308 A in an axial (downstream) direction, and distal section 308 B- 4 which is attached to intermediate section 308 B- 3 and extends in the axial (downstream) direction therefrom, as shown in FIG. 10 .
- Distal section 308 B- 4 extends in a radial direction further from a longitudinal axis of volume reduction member 308 (and/or injector 12 ) than the radial extension of intermediate section 308 B- 3 so as to form a ledge.
- Second part 308 B- 2 of second portion 308 B is formed around the ledge formed by intermediate section 308 B- 3 and distal section 308 B- 4 so as to form volume reduction member 308 as a single, unitary and integrated component.
- volume reduction member 308 is connected to cap member 306 so as to result in volume reduction member 308 , filter 204 and cap member 306 forming a single assembly component for use in assembling injector 12 .
- the single assembly component (filter 204 , cap member 306 and volume reduction member 308 ) is inserted within tube member 42 under pressure while contacting volume compensator 212 .
- cap member 306 is welded to tube member 42 all along the intersection thereof along the top portion of tube member 42 .
- the weld connection is a fillet weld.
- FIG. 12 illustrates fluid injector 12 according to another example embodiment.
- fluid injector 12 includes filter 204 and cap member 306 in which filter 204 is disposed, as described above.
- fluid injector 12 includes calibration filter tube 402 and volume reduction member 408 .
- Calibration filter tube 402 includes a bore 402 A which is axially defined through calibration filter tube 402 . At one (upstream) end of calibration filter tube 402 , bore 402 A is in fluid communication with filter 204 for receiving reductant therefrom. At the other (downstream) end of calibration filter tube 402 , bore 402 A provides reductant to armature 16 .
- calibration filter tube 402 forms part of the fluid path for reductant through fluid injector 12 , and forms the only such fluid path from filter 204 to armature 16 .
- the diameter of bore 402 A of calibration filter tube 402 being small relative to the inner diameter of tube member 42 , the volume of the fluid path for reductant through injector 12 is reduced so as to lessen the adverse impact of reductant freezing therein.
- calibration filter tube 402 further includes first end portion 402 B which is disposed at least partly within cap member 306 and contacts filter 204 .
- First end portion 402 B is largely disc-shaped, having a sidewall 402 C which contacts the inner surface of sidewall 306 A of cap member 306 .
- first end portion 402 B of calibration fluid member 402 is attached to cap member 306 so that cap member 306 , filter 204 and calibration filter tube 402 form a single, unitary and integrated subassembly component for facilitating simplified assembly of fluid injector 12 .
- cap member 306 engages with first end portion 402 B, and particularly forms a press fit engagement therewith.
- cap member 306 is welded to first end portion 402 B, such as a fillet weld connection between the axial end of sidewall 306 A of cap member 306 and the outer surface of sidewall 402 C of first portion 402 A. It is understood that, alternatively or additionally, cap member 306 may be secured to first end portion 402 B of calibration filter tube 402 using other techniques.
- Calibration filter tube 402 further includes elongated second portion 402 D which extends in an axial direction from first portion 402 A, as shown in FIGS. 12-14 .
- Second portion 402 D is sized to extend into pole piece 46 so that a second end 402 E, opposite first end portion 402 B, engages with spring 50 ( FIG. 12 ).
- Second portion 402 D is largely cylindrically shaped, with bore 402 A disposed therein.
- Calibration filter tube 402 further includes annular tab 402 F which extends radially outwardly from the outer surface of second portion 402 D.
- Tab 402 F extends slightly outwardly from the outer surface of, and is positioned along, second portion 402 D of calibration filter tube 402 so as to contact the inner surface of pole piece 46 defining the central bore thereof. This contact between tab 402 F and the central bore of pole piece 46 results in calibration filter tube 402 forming a press fit attachment with pole piece 46 .
- calibration filter tube 402 contacts and engages with spring 50 . Due to the engagement between calibration filter tube 402 and spring 50 , and the engagement between armature 16 and spring 50 , calibration filter tube 402 is used to calibrate the dynamic flow of reductant through fluid injector 12 . Specifically, with cap member 306 , filter 204 and calibration filter tube 402 being formed as a single, unitary and integrated subassembly component, positioning calibration filter tube 402 in the desired position within tube member 42 , prior to welding cap member 306 thereto, is simplified for providing the desired calibrated force for spring 50 .
- Calibration filter tube 402 is formed from a metal composition, such as stainless steel.
- injector 12 further includes volume reduction member 408 which is disposed around second portion 402 D of calibration filter tube 402 .
- Volume reduction member 408 has a cylindrical shape, with a central bore defined axially through volume reduction member 408 .
- the central bore of volume reduction member 408 is sized for receiving calibration filter tube 402 therein.
- the outer radial surface of volume reduction member 408 contacts the inner surface of tube member 42 .
- One axial (upstream) end of volume reduction member 408 is disposed adjacent and contacts first end portion 402 B of calibration filter tube 42 , and the other axial (downstream) end of volume reduction member 408 is disposed against and contacts the upstream end of pole piece 46 .
- volume reduction member 408 occupies the space between second portion 402 D of calibration filter tube 402 and tube member 42 that is upstream of pole piece 46 and downstream of first end portion 402 B of calibration filter tube 402 .
- volume reduction member 408 is attached to calibration filter tube 402 such that volume reduction member 408 forms the single, unitary and integrated subassembly component with cap member 306 , filter 204 and calibration filter tube 402 .
- volume reduction member 408 is constructed from a resilient and compressible material, and is compressible in at least the axial direction along fluid injector 12 .
- Volume reduction member 408 being compressible in the axial direction allows for the single assembly component (cap member 306 , filter 204 and calibration filter tube 402 ) to be adjustably positioned within tube member 42 relative to pole piece 46 so that the opening and closing force of the valve assembly of fluid injector 12 may be easily calibrated as desired.
- volume reduction member 408 is constructed from closed cell foam. It is understood, though, that volume reduction member 408 may be constructed from other compressible material. If constructed from closed cell foam, volume reduction member 408 is compressible in both axial (longitudinal) and radial (lateral) directions. In an example embodiment, volume reduction member 408 is in a compressed state in fluid injector 12 .
- FIGS. 15-17 illustrate fluid injector 12 according to another example embodiment.
- fluid injector 12 includes filter 204 and cap member 306 in which filter 204 is disposed, as described above.
- fluid injector 12 includes calibration filter tube 502 .
- Calibration filter tube 502 has many features of calibration filter tube 402 described above with respect to FIGS. 12-14 .
- Calibration filter tube 502 includes a bore 502 A which is axially defined through calibration filter tube 502 . At one (upstream) end of calibration filter tube 502 , bore 502 A is in fluid communication with filter 204 for receiving reductant therefrom. At the other (downstream) end of calibration filter tube 502 , bore 502 A provides reductant to armature 16 . In this way, calibration filter tube 502 forms part of the fluid path for reductant through fluid injector 12 , and forms the only such fluid path from filter 204 to armature 16 . With the diameter of bore 502 A of calibration filter tube 502 being small relative to the inner diameter of tube member 42 , the volume of the fluid path for reductant through injector 12 is reduced so as to lessen the adverse impact of reductant freezing therein.
- calibration filter tube 502 further includes first end portion 502 B which is disposed at least partly within cap member 306 and contacts filter 204 .
- First end portion 502 B is largely disc-shaped, having a sidewall 502 C which contacts the inner surface of sidewall 306 A of cap member 306 .
- first end portion 502 B of calibration fluid member 502 is attached to cap member 306 so that cap member 306 , filter 204 and calibration filter tube 502 form a single, unitary and integrated subassembly component for facilitating simplified assembly of fluid injector 12 .
- cap member 306 engages with first end portion 502 B, and particularly forms a press fit engagement therewith.
- cap member 306 is welded to first end portion 502 B, such as a fillet weld connection between the axial end of sidewall 306 A of cap member 306 and the outer surface of sidewall 502 C of first portion 502 B. It is understood that, additionally or alternatively, cap member 306 may be secured to first end portion 502 B of calibration filter tube 502 using other techniques.
- Calibration filter tube 502 further includes an elongated second portion 502 D which extends in an axial direction from first portion 502 A, and an elongated third portion 502 E which extends in the axial direction from second portion 502 D, as shown in FIGS. 15-17 .
- Third portion 502 E is sized to extend into pole piece 46 so that a second end 502 F of calibration filter tube 502 , opposite first end portion 502 B, engages with spring 50 ( FIG. 12 ).
- Second portion 502 D and third portion 502 E are largely cylindrically shaped, with bore 502 A disposed therein.
- the outer diameter of second portion 502 D is larger than the outer diameter of third portion 502 E.
- the outer diameter of third portion 502 E is sized for being received in the central bore of pole piece 46 .
- Calibration filter tube 502 further includes annular tab 502 G ( FIG. 17 ) which extends radially outwardly from the outer surface of third portion 502 E.
- Tab 502 G extends slightly outwardly from the outer surface of, and is axially positioned along, third portion 502 E of calibration filter tube 502 so as to contact the inner surface of pole piece 46 defining the central bore thereof. This contact between tab 502 G and the central bore of pole piece 46 results in calibration filter tube 502 forming a press fit engagement with pole piece 46 .
- Calibration filter tube 502 is formed from a metal composition, such as stainless steel.
- calibration filter tube 502 contacts and engages with spring 50 . Due to the engagement between calibration filter tube 502 and spring 50 , and the engagement between spring 50 and armature 16 , calibration filter tube 502 is used to calibrate the dynamic flow of reductant through fluid injector 12 .
- cap member 306 , filter 204 and calibration filter tube 502 being formed as a single, unitary and integrated subassembly component, positioning of calibration filter tube 502 in the desired position within tube member 42 , prior to welding cap member 306 thereto, is simplified for providing the desired calibrated force for spring 50 for setting the opposed opening and closing force for the valve assembly of fluid injector 12 .
- injector 12 further includes volume reduction member 508 which is disposed around second portion 502 D of calibration filter tube 502 .
- Volume reduction member 508 has a generally cylindrical shape, with a central bore defined axially through volume reduction member 508 .
- the central bore of volume reduction member 508 is sized for receiving second portion 502 D of calibration filter tube 502 therein.
- the outer radial surface of volume reduction member 508 contacts the inner surface of tube member 42 .
- One axial (upstream) end of volume reduction member 508 is disposed adjacent and contacts first end portion 502 B of calibration filter tube 42
- the other axial (downstream) end of volume reduction member 508 is disposed against and contacts the upstream end of pole piece 46 .
- volume reduction member 508 occupies the space between second portion 502 D of calibration filter tube 502 and tube member 42 that is upstream of pole piece 46 and downstream of first end portion 502 B of calibration filter tube 502 .
- volume reduction member 508 is constructed from compressible material, such as being compressible in at least the axial direction along fluid injector 12 .
- Volume reduction member 508 being compressible in at least the axial direction allows for the single assembly component (cap member 306 , filter 204 and calibration filter tube 502 ) to be adjustably positioned within tube member 42 relative to pole piece 46 so that the valve assembly of fluid injector 12 may be calibrated as desired.
- volume reduction member 508 is in a compressed state in fluid injector 12 .
- volume reduction member 508 includes a sidewall 508 A which extends between two axial ends.
- a downstream axial end wall 508 B of volume reduction member 508 extends radially inwardly from sidewall 508 A and contacts the outer surface of third portion 502 E of calibration filter tube 502 .
- the upstream axial end of volume reduction member 508 may be open and contact a downstream surface of first portion 502 B of calibration filter tube 502 .
- volume reduction member 508 undulates in an axial direction, as shown in FIGS. 15-17 , alternating between sidewall peaks and valleys in a wave-like pattern relative to a longitudinal axis of volume reduction member 508 and/or injector 12 . Having an undulating sidewall 508 A facilitates sidewall 508 A being compressible or otherwise partly collapsible in both axial (longitudinal) and radial (lateral) directions.
- volume reduction member 508 is constructed from a compressible, resilient material, such as a rubber composition or other like material. Volume reduction member 508 may be in a compressed state within fluid injector 12 .
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Abstract
Description
- The present application is related to U.S. patent application Ser. No. ______, filed ______, and titled, “INJECTOR FOR REDUCTANT DELIVERY UNIT HAVING REDUCED FLUID VOLUME” (attorney docket no. 2017P03658US); U.S. patent application Ser. No. ______, filed ______, and titled, “SEAL MEMBER FOR REDUCTANT DELIVERY UNIT” (attorney docket no. 2017P03660US); and U.S. patent application Ser. No. ______, filed ______, and titled, “INJECTOR FOR REDUCTANT DELIVERY UNIT HAVING FLUID VOLUME REDUCTION ASSEMBLY” (attorney docket no. 2017P03659US). The content of the above applications are hereby incorporated by reference herein in their entirety.
- The present invention generally relates to a fluid injector of a reductant delivery unit (RDU), and particularly to a robust RDU fluid injector for non-purge applications.
- Emissions regulations in Europe and North America are driving the implementation of new exhaust aftertreatment systems, particularly for lean-burn technologies such as compression-ignition (diesel) engines, and stratified-charge spark-ignited engines (usually with direct injection) that are operating under lean and ultra-lean conditions. Lean-burn engines exhibit high levels of nitrogen oxide emissions (NOx) that are difficult to treat in oxygen-rich exhaust environments characteristic of lean-burn combustion. Exhaust aftertreatment technologies are currently being developed that treat NOx under these conditions.
- One of these technologies includes a catalyst that facilitates the reactions of ammonia (NH3) with the exhaust nitrogen oxides (NOx) to produce nitrogen (N2) and water (H2O). This technology is referred to as Selective Catalytic Reduction (SCR). Ammonia is difficult to handle in its pure form in the automotive environment, therefore it is customary with these systems to use a diesel exhaust fluid (DEF) and/or liquid aqueous urea solution, typically at a 32% concentration of urea (CO(NH2)2). The solution is referred to as AUS-32, and is also known under its commercial name of AdBlue. The reductant solution is delivered to the hot exhaust stream typically through the use of an injector, and is transformed into ammonia prior to entry in the catalyst. More specifically, the solution is delivered to the hot exhaust stream and is transformed into ammonia in the exhaust after undergoing thermolysis, or thermal decomposition, into ammonia and isocyanic acid (HNCO). The isocyanic acid then undergoes a hydrolysis with the water present in the exhaust and is transformed into ammonia and carbon dioxide (CO2), the ammonia resulting from the thermolysis and the hydrolysis then undergoes a catalyzed reaction with the nitrogen oxides as described previously.
- AUS-32, or AdBlue, has a freezing point of −11 C, and system freezing is expected to occur in cold climates. Since these fluids are aqueous, volume expansion happens after the transition to the solid state upon freezing. The expanding solid can exert significant forces on any enclosed volumes, such as an injector. This expansion may cause damage to the injection unit, so different SCR strategies exist for addressing reductant expansion.
- There are two known SCR system strategies in the marketplace: purge systems and non-purge systems. In purge SCR systems, the reductant urea and/or DEF solution is purged from the RDU when the vehicle engine is turned off. In non-purge SCR systems, the reductant remains in the RDUs throughout the life of the vehicle. During normal operation of a non-purge SCR system, the RDU injector operates at temperatures which are above the freezing point of the reductant such that reductant in the RDU remains in the liquid state. When the vehicle engine is turned off in the non-purge SCR system, however, the RDU injector remains filled with reductant, thereby making the RDU injector susceptible to damage from reductant expanding in freezing conditions.
- Example embodiments overcome shortcomings found in existing RDU fluid injectors and provide an improved fluid injector for non-purge SCR systems in which the adverse effects from the RDU being in temperatures that are below the freezing point of reductant are reduced. According to an example embodiment, an RDU includes a fluid injector having a fluid inlet disposed at a first end of the fluid injector for receiving a reductant, and a fluid outlet disposed at a second end of the fluid injector for discharging the reductant. The fluid injector defines a fluid path for the reductant from the fluid inlet to the fluid outlet. The fluid injector further includes a tube member having an end disposed at or near the fluid inlet of the fluid injector, the tube member configured to pass reductant along the fluid path; a filter disposed in the tube member proximal to the fluid inlet of the fluid injector; and a calibration filter tube disposed in the tube member downstream of the filter, relative to a direction of flow of reductant along the fluid path from the fluid inlet to the fluid outlet of the fluid injector, the calibration filter tube having a first end portion adjacent the filter and a second end, and further including a bore defined in an axial direction through the calibration filter tube, the bore defining at least a portion of the fluid path through the fluid injector. An actuator unit is disposed within the fluid injector downstream of the calibration filter tube, the actuator unit engaging the second end of the calibration filter tube. A valve assembly is operatively coupled to the actuator unit, wherein a position of the calibration filter tube within the tube member at least partly sets an opposing opening force for the valve assembly. A volume reduction member has a bore though which the calibration filter tube extends, the volume reduction member occupying a space between an outer surface of the calibration filter tube and an inner surface of the tube member. In an example embodiment, the filter, calibration filter tube and the volume reduction member form a unitary subassembly component of the fluid injector.
- In an example embodiment, the volume reduction member is formed from compressible material, the compressible material being one of a rubber composition and closed cell foam.
- In an example embodiment, the volume reduction member includes a sidewall, the sidewall of the volume reduction member undulating in a direction along a longitudinal axis of the fluid injector.
- The fluid injector may further include a cap member including a sidewall defining an inner space into which the filter is disposed, the sidewall contacting the first end of the calibration filter tube. The first end portion of the calibration filter tube is disposed in the inner space of the cap member. The first end portion of the calibration filter tube may be attached to the sidewall of the cap member such that the calibration filter tube, the cap member, the volume reduction member and the filter form the unitary subassembly component of the fluid injector.
- The actuator unit may include a pole piece disposed in a fixed position within the fluid injector and having a bore defined axially through the pole piece, and an armature movably positioned within the fluid injector and having a pocket. The actuator unit may further include a coil disposed in proximity to the pole piece and the armature, and a spring disposed at least partly in the pocket of the armature. In an example embodiment, the calibration filter tube is disposed in the bore of the pole piece such that the second end of the calibration filter tube contacts the spring, and the spring biases the armature away from the pole piece in an absence of current passing through the coil so that the valve assembly is placed in a closed position to prevent reductant from passing through the fluid outlet.
- The calibration filter tube includes a second portion which axially extends from the first end portion of calibration filter tube, and a third portion disposed between the second portion and the second end of the calibration filter tube. The volume reduction member is disposed around the second portion, the third portion is disposed in the bore of the pole piece, and a downstream end of the volume reduction member is adjacent an upstream end of the pole piece, relative to the direction of flow of reductant along the fluid path.
- An outside diameter of the second portion of the calibration filter tube may be greater than an outside diameter of the third portion thereof.
- In another example embodiment, an RDU fluid injector has a fluid inlet disposed at a first end and configured to receive a fluid, and a fluid outlet disposed at a second end of the fluid injector for discharging the fluid, the fluid injector defining a fluid path for the fluid from the fluid inlet to the fluid outlet. A tube member has an end disposed at or near the fluid inlet of the fluid injector, the tube member configured to pass fluid along the fluid path. A filter is disposed in the tube member proximal to the fluid inlet of the fluid injector. A calibration filter tube is disposed in the tube member downstream of the filter, relative to a direction of flow of fluid along the fluid path from the fluid inlet to the fluid outlet of the fluid injector. The calibration filter tube has a first end portion adjacent the filter, a second end, and a bore defined in an axial direction through the calibration filter tube, the bore defining at least a portion of the fluid path through the fluid injector. An actuator unit is disposed within the fluid injector downstream of the calibration filter tube, the actuator unit engaging the second end of the calibration filter tube. A valve assembly is operatively coupled to the actuator unit, wherein a position of the calibration filter tube within the tube member sets an opposing opening force of the valve assembly. The fluid injector further includes a cap member having a sidewall defining an inner space into which the filter is disposed. In an example embodiment, the sidewall contacts and is attached to the first end of the calibration filter tube such that the cap member, the filter and the calibration filter tube form a single subassembly component of the fluid injector.
- Aspects of the invention will be explained in detail below with reference to an exemplary embodiment in conjunction with the drawings, in which:
-
FIG. 1 is a cross-sectional side view of an RDU for a non-purge SCR system according to an example embodiment; -
FIG. 2 is a cross-sectional side view of a fluid injector of the RDU ofFIG. 1 ; -
FIG. 3 is a magnified cross-sectional view of the inlet portion of the fluid injector of the RDU ofFIG. 1 according to an example embodiment; -
FIG. 4 is an exploded perspective view of components of the fluid injector of the RDU ofFIG. 1 according to an example embodiment; -
FIG. 5 is a magnified cross-sectional view of the outlet portion of the fluid injector of the RDU ofFIG. 1 according to an example embodiment; -
FIG. 6 is a magnified cross-sectional view of the inlet portion of the fluid injector of the RDU ofFIG. 1 according to another example embodiment; -
FIG. 7 is an exploded perspective view of components of the fluid injector ofFIG. 6 ; -
FIG. 8 is a cross-sectional view of the components ofFIG. 6 ; -
FIG. 9 is a magnified cross-sectional view of the inlet portion of the fluid injector of the RDU ofFIG. 1 according to yet another example embodiment; -
FIG. 10 is a cross-sectional view of components of the fluid injector ofFIG. 9 ; -
FIG. 11 is a perspective view of a component of the fluid injector ofFIG. 9 ; -
FIG. 12 is a cross-sectional view of the inlet portion of the fluid injector of the RDU ofFIG. 1 according to another example embodiment; -
FIG. 13 is a cross-sectional view of integrated components of the fluid injector ofFIG. 12 ; -
FIG. 14 is an exploded perspective view of the components of the fluid injector ofFIG. 13 ; -
FIG. 15 is a cross-sectional view of the inlet portion of the fluid injector of the RDU ofFIG. 1 according to another example embodiment; -
FIG. 16 is a cross-sectional view of integrated components of the fluid injector ofFIG. 15 ; -
FIG. 17 is an exploded perspective view of the components of the fluid injector ofFIG. 15 . - The following description of the example embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
- Example embodiments are generally directed to an RDU for a non-purge SCR system in which damaging effects from a reductant, DEF and/or urea solution freezing in the RDU injector are reduced.
-
FIG. 1 illustrates anRDU 10 of a non-purge SCR system according to an example embodiment.RDU 10 includes a solenoid fluid injector, generally indicated at 12, that provides a metering function of fluid and provides the spray preparation of the fluid into the exhaust path of a vehicle in a dosing application. Thus,fluid injector 12 is constructed and arranged to be associated with an exhaust gas flow path upstream of a selective catalytic reduction (SCR) catalytic converter (not shown).Fluid injector 12 may be an electrically operated, solenoid fuel injector. As shown inFIGS. 1 and 2 ,fluid injector 12 includes an actuator unit having acoil 14 and amovable armature 16. Components ofinjector 12 define a fluid path for a reductant, DEF and/or urea solution throughinjector 12. The reductant, DEF and/or urea solution whichRDU 10 is configured to inject into the exhaust path of a vehicle engine will be hereinafter referred to as “reductant” for simplicity. -
Fluid injector 12 is disposed in aninterior carrier 18 ofRDU 10, as shown inFIG. 1 . An injector shield, generally indicated at 20, is formed byupper shield 20A andlower shield 20B, which surroundinjector 12 and are coupled tocarrier 18 by folding tangs of aflange 22 oflower shield 20B over shelf features ofcarrier 18 andupper shield 20A. As a result,shield 20 andcarrier 18 are fixed with respect toinjector 12. - An inlet cup structure of
RDU 10, generally indicated at 24 inFIG. 1 , includes acup 26 and afluid supply tube 28 integrally formed withcup 26.Fluid supply tube 28 is in communication with a source of a reductant (not shown) that is fed into afluid inlet 30 ofinjector 12 for ejection from afluid outlet 32 thereof and into the exhaust stream of a vehicle engine (not shown).Fluid inlet 30 ofinjector 12 is in fluid communication withfluid supply tube 28.Fluid outlet 32 is fluidly connected with aflange outlet 34 of anexhaust flange 36 that is coupled directly with an end oflower shield 20B ofRDU 10. -
Injector 12 includes an injector body structure in which the components ofinjector 12 are disposed. The injector body structure includes a firstinjector body portion 38 in whichcoil 14 andarmature 16 are disposed, and avalve body portion 40 in which a valve assembly ofinjector 12 is at least partly disposed. Firstinjector body portion 38 andvalve body portion 40 are fixedly connected, either directly or indirectly, to each other. - Referring to
FIGS. 1-3 ,fluid injector 12 includes atube member 42 which is at least partly disposed within firstinjector body portion 38. The outer surface oftube member 42 contacts the inner surface of firstinjector body portion 38. An open end oftube member 42 is disposed withincup 26 and is in fluid communication withfluid supply tube 28. An O-ring 44 is disposed withincup 26, between an inner surface thereof and the outer surface oftube member 42, proximal to the open end oftube member 42. O-ring 44 serves to ensure that reductant exitingfluid supply tube 28 passes into the open end oftube member 42 ofinjector 12. - The actuator unit of
fluid injector 12 further includes apole piece 46 which is fixedly disposed within firstinjector body portion 38.Coil 14 at least partly surroundspole piece 46 andarmature 16.Pole piece 46 is disposed upstream ofarmature 16 withininjector 12.Pole piece 46 includes a central bore defined axially therethrough. -
Armature 16 includes a U-shaped section which defines a pocket in which at least part of aspring 50 is disposed.Spring 50, which is part of the actuator unit, biasesmovable armature 16 so thatarmature 16 is spaced apart frompole piece 46 when no current is passed throughcoil 14.Spring 50 partly extends within the central bore ofpole piece 46. An end ofspring 50 which extends withinpole piece 46 contacts aspring adjustment tube 52.Spring adjustment tube 52 is at least partly disposed within the central bore ofpole piece 46, upstream (relative to a direction of flow of reductant through injector 12) ofspring 50.Spring adjustment tube 52 includes a bore defined axially therethrough. The throughbore ofspring adjustment tube 52 partly defines the fluid path for reductant influid injector 12, and defines the only fluid path for reductant throughpole piece 46. Due to its engagement withspring 50,spring adjustment tube 52 is used to calibrate the dynamic flow of reductant throughfluid injector 12. -
Armature 16 further includes one or more channels 60 (FIGS. 1 and 2 ) defined through thearmature 16 from an interior of the pocket to an upstream end portion ofpin member 58.Channels 60 may be equally spaced aboutarmature 16. In an example embodiment,armature 16 includes a single channel which is defined entirely around the base of the pocket formed bypocket wall 16A. Channel(s) 60 allows reductant to flow from the pocket ofarmature 16 to the space around the upstream end ofpin member 58. The pocket ofarmature 16 and the channel(s) 60 together partly define the reductant fluid path of thefluid injector 12 and define the only part of the fluid path passing through or aroundarmature 16. - Referring to
FIGS. 1, 2 and 5 , the valve assembly ofinjector 12 includes aseal member 54 and aseat 56.Seal member 54 is connected to armature 16 via apin member 58, which is disposed betweenseal member 54 and the downstream end ofarmature 16.Seal member 54,pin member 58 andarmature 16 may combine to form an armature assembly. Whencoil 14 is energized,coil 14 generates an electromagnetic force acting onarmature 16 which overcomes the bias force fromspring 50 and causes armature 16 to move towardspole piece 46, which correspondingly movespin member 58 so thatseal member 54 is lifted off of, and disengages from,seat 56, moving the armature assembly to an open position and thus permitting reductant to pass throughfluid outlet 32 toflange outlet 34 and into the exhaust path of the vehicle engine. Whencoil 14 is de-energized, the electromagnetic force dissipates andspring 50 biases armature 16 so thatarmature 16 is moved away frompole piece 46, resulting inseal member 54 sealingly engaging withseat 56, changing the armature assembly back to a closed position. With the armature assembly in the closed position, reductant is prevented from flowing throughseat 56 andflange outlet 34 and into the exhaust path of the vehicle engine. - As mentioned above,
RDU 10 forms part of a non-purge SCR exhaust aftertreatment system. As a result, reductant remains influid injector 12 following the vehicle engine being turned off. In example embodiments,fluid injector 12 is configured so that the amount of reductant influid injector 12 is reduced. In other words, the total volume of the fluid path for reductant throughfluid injector 12 is reduced. By having less space for reductant ininjector 12, the amount of reductant inRDU 10 that may potentially freeze is reduced, thereby reducing the susceptibility ofinjector 12 being damaged by expansion forces from frozen reductant. - In order to reduce the volume of the reductant fluid path in
fluid injector 12, the thickness ofvalve body portion 40 is increased. In addition,pin member 58 is constructed as a solid element such that reductant flows around the outer surface ofpin member 58, instead of therethrough. The spacing between the outer surface ofpin 58 and the inner surface ofvalve body portion 40, which partly defines the fluid path for reductant throughinjector 12, is narrowed. This narrowed portion of the fluid path is the only fluid path for reductant betweenarmature 16 andseat 56 influid injector 12. The narrowed fluid path betweenpin 58 andvalve body portion 40 provides a sufficient reductant flow rate throughfluid injector 12 for performing reductant injection during normal operation ofRDU 10 while at the same time maintaining a relatively small volume of reductant withininjector 12 so as to lessen the risk ofinjector 12 being damage from the reductant therein freezing. - Further, the diameter of the pocket of
armature 16, in which spring 50 is at least partly disposed, is reduced, which allows for the thickness ofpocket wall 16A ofarmature 16 to be increased. In an example embodiment, the thickness ofpocket wall 16A is between 45% and 75% of the diameter of pocket, such as about 60%. The increase in thickness ofpocket wall 16A, as well as the increased thickness ofvalve body portion 40 andpin member 50 being a solid pin, result in the components ofinjector 12 being strengthened and thus more resistant to reductant freezing forces. - Still further, the bore of
spring adjustment tube 52 is sized for reducing the volume of the reductant fluid path ininjector 12. In an example embodiment, the diameter of the bore ofspring adjustment tube 52 is between 12% and 22% of the outer diameter ofpole piece 46, and particularly between 16% and 19% thereof. -
FIG. 3 illustrates an upstream portion ofinjector 12.Tube member 42 extends at least partly thoughinjector 12. The reductant fluid path throughinjector 12 passes throughtube member 42.Injector 12 includes afilter 204 disposed withintube member 42 proximal to the open end thereof.Filter 204 is a structurally rigid, sintered metal filter, such as a stainless steel material, in order to better withstand expansion forces from reductant freezing.Filter 204 may have a supporting outer structure for added strength. Best seen inFIG. 3 ,filter 204 is disposed within acap member 206.Cap member 206 is largely cylindrically shaped having asidewall 206A extending circumferentially and defining an inner volume sized for receivingfilter 204 therein.Cap member 206 is dimensioned to fit withintube member 42, and particularly so that the outer surface ofsidewall 206A ofcap member 206 contacts the inner surface oftube member 42.Cap member 206 further includesannular members 206B disposed along the axial ends ofcap member 206 and extend radially inwardly fromsidewall 206A.Annular members 206B serve to maintainfilter 204 withincap member 206 in a fixed position.Cap member 206 is constructed of metal or like compositions. -
Injector 12 further includes a retainingring 207 which is disposed intube member 42 upstream of, and in contact with,cap member 206, as shown inFIGS. 1-3 .Retainer ring 207 is fixed totube member 42 along an inner surface thereof.Retainer ring 207 being fixed in position alongtube member 42 serves to maintain downstream components ofinjector 12 in fixed positions within firstinjector body portion 38. In an example embodiment,retainer ring 207 is welded along the inner surface oftube member 42. Such weld connection is formed along an entire circumference of the upper edge ofretainer ring 207. It is understood, however, that other connection mechanisms may be utilized for fixingretainer ring 207 totube member 42. - Referring to
FIGS. 1-4 ,injector 12 further includes avolume reduction member 208 which serves to further reduce the volume of the reductant fluid path withininjector 12.Reduction member 208 is largely cylindrical in shape, as shown inFIG. 4 , having a top (upstream) end and a bottom (downstream) end. In an embodiment,volume reduction member 208 is constructed from a metal, such as stainless steel. It is understood, though, thatvolume reduction member 208 may be formed from other metals or metal compositions. The outer surface ofvolume reduction member 208 is sized to contact the inner surface oftube member 42. -
Volume reduction member 208 further includes abore 208A (FIGS. 2 and 3 ) defined in the axial direction throughvolume rejection member 208, from one axial (top) end to the other axial (bottom) end.Bore 208A is located along the longitudinal axis ofvolume reduction member 208 and itself forms part of the fluid path for passing reductant throughinjector 12.Bore 208A forms the only fluid path for passing reductant through or aroundvolume reduction member 208. In an example embodiment, the diameter ofbore 208A is between 12% and 20% of the outer diameter ofvolume reduction member 208, such as about 16%. Becausevolume reduction member 208 extends radially to the inner surface oftube member 42, and because the diameter ofbore 208A is small relative to the outer diameter ofvolume reduction member 208,volume reduction member 208 reduces the space or volume in which reductant may reside withininjector 12, thereby reducing the volume of the fluid path of reductant therein.Volume reduction member 208 further assists in retainingspring adjustment tube 52 in position withininjector 12 such thatpin adjustment tube 52 maintains a desired force onspring 50 so as to prevent a loss of calibration. Specifically,retainer ring 207 maintains the position offilter 204 andcorresponding cap member 206, which maintain the position ofvolume reduction member 208, which maintains the position ofspring adjustment member 52. - With reference to
FIGS. 1-4 ,fluid injector 12 further includes avolume compensation member 210 which is disposed between the bottom (downstream) end ofvolume reduction member 208 and the top ofpole piece 46.Volume compensation member 210 is constructed from elastic material and serves to occupy the space betweenvolume reduction member 208 andpole piece 46 so as to further lessen the volume of the reductant fluid path ininjector 12.Volume compensation member 210 may be in a compressed state ininjector 12 when assembled, and contact thevolume reduction member 208,pole piece 46, the inner surface oftube member 42 and the outer surface ofspring adjustment member 52. -
FIG. 5 illustrates a downstream end portion offluid injector 12. As can be seen,seat 56 includes a bore defined axially throughseat 56. In an example embodiment, the length of the throughbore ofseat 56 is reduced so as to further reduce the volume of the reductant fluid path throughseat 56, and particularly the sac volume below the sealing band ofseat 56 which engages withseal member 54. - According to an example embodiment,
fluid injector 12 includes a plurality of orifice discs 212 disposed in a stacked arrangement. The orifice disc stack is disposed against the downstream end ofseat 56. In the example embodiment illustrated inFIG. 5 , the disc stack includes afirst disc 212A having one or more orifices that are configured for providing the desired spray pattern ofreductant exiting injector 12. It is understood that the dimension and locations of the orifices offirst disc 212A may vary and be dependent upon the reductant dosing requirements of the particular vehicle engine. The disc stack further includes asecond disc 212B which is disposed downstream offirst disc 212A and includes orifices through which the reductant spray passes.Second disc 212B has a larger thickness than the thickness offirst disc 212A and being disposed againstfirst disc 212A, and supportsfirst disc 212A so as to prevent the thinnerfirst disc 212A from deforming due to expansion forces from frozen reductant upstream offirst disc 212A. - As discussed above,
fluid injector 12, and particularly the components thereof, are configured to reduce the volume of the reductant fluid path ininjector 12. In example embodiments, the ratio of the volume of the fluid path influid injector 12 to a volume of the components of injector 12 (including but not necessarily limited tocoil 14,armature 16,pole piece 46,spring adjustment tube 52,volume reduction member 208,volume compensation member 210,filter 204, retainingring 207,spring 50,pin member 58,seal member 54,seat 56, firstinjector body portion 20A and valve body portion 40) is between 0.08 and 0.30, and particularly between 0.12 and 0.20, such as about 0.15. These volume amounts are calculated between orthogonal planes relative to the longitudinal axis offluid injector 12—from a first plane along the open end of tube member 42 (i.e., fluid inlet 30) and a second plane along the lowermost (downstream) surface ofsecond disc 212B (i.e., fluid outlet 32). It is understood that the particular ratio of volume of the reductant path to injector component volume withinfluid injector 12 may vary depending upon a number of cost and performance related factors, and may be any value between about 0.08 and about 0.30. Providing a fluid injector having a reduced ratio of reductant fluid path volume to injector component volume to fall within the above range advantageously results in less reductant ininjector 12 which reduces the susceptibility ofRDU 10 being damaged if the reductant ininjector 12 freezes. - In another example embodiment, shown in
FIGS. 6-8 ,fluid injector 12 includes avolume reduction member 308 which has many of the characteristics ofvolume reduction member 208 discussed above with respect toFIGS. 1-5 . Similar tovolume reduction member 208,volume reduction member 308 is constructed from stainless steel or like composition, is disposed intube member 42 offluid injector 12 betweenvolume compensation member 210 andfilter 204. However,volume reduction member 308 includes afirst portion 308A and asecond portion 308B. As shown inFIG. 7 , each offirst portion 308A andsecond portion 308B has a cylindrical shape, with the outer diameter offirst portion 308A being less than the outer diameter ofsecond portion 308B. The outer diameter offirst portion 308A is less than the diameter ofsecond portion 308B by the thickness ofsidewall 306A ofcap member 306, as will be explained in greater detail below.Volume reduction member 308 includes top (upstream) and bottom (downstream) end portions which form the axial ends offirst portion 308A andsecond portion 308B, respectively. The outer surface ofsecond portion 308B is sized to contact the inner surface oftube member 42. - As mentioned, the outer diameter of
first portion 308A ofvolume reduction member 308 is less than the outer diameter ofsecond portion 308B thereof. As shown inFIGS. 6-8 ,volume reduction member 308 includes an angled annular surface orskirt 308D, which extends in the axial direction between the outer surface offirst portion 308A and the outer surface ofsecond portion 308B and serves as the physical interface therebetween. The angle ofangled surface 308D, relative to the longitudinal axis ofvolume reduction member 308 and/orinjector 12, is an acute angle. Alternatively, the angle ofangled surface 308D is orthogonal to the longitudinal axis ofvolume reduction member 308 and/orinjector 12. -
Volume reduction member 308 further includes abore 308C defined in the axial direction throughvolume rejection member 308, from one axial (top) end to the other axial (bottom) end.Bore 308C is located along the longitudinal axis ofvolume reduction member 308 and itself forms part of the reductant fluid path for passing reductant throughinjector 12, and the only reductant fluid path through or aroundvolume reduction member 308. In an example embodiment, the diameter of thebore 308C is between 12% and 20% of the outer diameter ofvolume reduction member 308, such as about 16%. Becausevolume reduction member 308 extends to the inner surface oftube member 42 and because the diameter ofbore 308C is relatively small relative to the outer diameter ofvolume reduction member 308,volume reduction member 308 occupies a volume withininjector 12 which reduces the space or volume of the reductant fluid path throughinjector 12, thereby reducing the amount of reductant ininjector 12 that could freeze and potentially damageinjector 12. -
Cap member 306 includes a number of the same characteristics ofcap member 206 described above with respect toFIGS. 1-5 . As shown inFIG. 7 ,cap member 306 is largely cylindrically shaped having asidewall 306A extending circumferentially and defining an inner volume sized for receivingfilter 204 therein.Cap member 306 is dimensioned to fit withintube member 42, and particularly so that the outer surface ofsidewall 306A ofcap member 306 contacts the inner surface oftube member 42.Cap member 306 further includes anannular member 306B disposed along the axial (upstream) end ofcap member 306 and extending radially inwardly fromsidewall 306A.Annular member 306B serves to maintainfilter 204 withincap member 306 in a fixed position. Likecap member 206,cap member 306 is constructed of metal or like compositions and provides structural support to filter 204. - In example embodiments,
cap member 306 is engaged with and secured tovolume reduction member 308. In this way,filter 204,cap member 306 andvolume reduction member 308 form a single, unitary and integrated component, as shown inFIG. 8 . Having a single, unitary component formed fromfilter 204,cap member 306 andvolume reduction member 308 advantageously allows for a simpler and less complex process for assemblinginjector 12 during manufacture thereof. - In the example embodiments,
cap member 306 fits over and engages with or otherwise attaches to at least a part offirst portion 308A ofvolume reduction member 308, as shown inFIGS. 6 and 8 . In one example embodiment,cap member 306 forms a press fit engagement withfirst portion 308A. In another example embodiment,cap member 306 is welded tofirst portion 308A, such as a fillet weld betweenbottom surface 306C ofcap member 306 and the radially outer surface offirst portion 308A. In each such embodiment, theangled surface 308D provides sufficient spacing for securingcap member 306 tofirst portion 308A. It is understood thatcap member 306 may be secured tofirst portion 308A ofvolume reduction member 308 via other mechanisms. - With
cap member 306 fitting overfirst portion 308A ofvolume reduction member 308, the outer diameter ofsidewall 306A is the same or nearly the same as the outer diameter ofsecond portion 308A. SeeFIGS. 6 and 8 . - As discussed above,
volume reduction member 308 is constructed from metal, such as stainless steel, according to an example embodiment. In another example embodiment, a part ofsecond portion 308B is constructed from plastic or like compositions. Specifically, as illustrated inFIGS. 9-11 ,first portion 308A and afirst part 308B-1 ofsecond portion 308B are formed as a single metal member, and asecond part 308B-2 ofsecond portion 308B is plastic overmolded around the first part thereof.FIG. 11 shows the metalfirst portion 308A andfirst part 308B-1 ofsecond portion 308B.First part 308B-1 ofsecond portion 308B includesintermediate section 308B-3 which extends away fromfirst portion 308A in an axial (downstream) direction, anddistal section 308B-4 which is attached tointermediate section 308B-3 and extends in the axial (downstream) direction therefrom, as shown inFIG. 10 .Distal section 308B-4 extends in a radial direction further from a longitudinal axis of volume reduction member 308 (and/or injector 12) than the radial extension ofintermediate section 308B-3 so as to form a ledge.Second part 308B-2 ofsecond portion 308B, made of overmolded plastic or other like compositions, is formed around the ledge formed byintermediate section 308B-3 anddistal section 308B-4 so as to formvolume reduction member 308 as a single, unitary and integrated component. As discussed above,volume reduction member 308 is connected to capmember 306 so as to result involume reduction member 308,filter 204 andcap member 306 forming a single assembly component for use in assemblinginjector 12. - During assembly of
injector 12, the single assembly component (filter 204,cap member 306 and volume reduction member 308) is inserted withintube member 42 under pressure while contacting volume compensator 212. Following insertion and while still under pressure,cap member 306 is welded totube member 42 all along the intersection thereof along the top portion oftube member 42. In an embodiment, the weld connection is a fillet weld. -
FIG. 12 illustratesfluid injector 12 according to another example embodiment. In this embodiment,fluid injector 12 includesfilter 204 andcap member 306 in which filter 204 is disposed, as described above. In addition,fluid injector 12 includescalibration filter tube 402 andvolume reduction member 408.Calibration filter tube 402 includes abore 402A which is axially defined throughcalibration filter tube 402. At one (upstream) end ofcalibration filter tube 402, bore 402A is in fluid communication withfilter 204 for receiving reductant therefrom. At the other (downstream) end ofcalibration filter tube 402, bore 402A provides reductant toarmature 16. In this way,calibration filter tube 402 forms part of the fluid path for reductant throughfluid injector 12, and forms the only such fluid path fromfilter 204 toarmature 16. With the diameter ofbore 402A ofcalibration filter tube 402 being small relative to the inner diameter oftube member 42, the volume of the fluid path for reductant throughinjector 12 is reduced so as to lessen the adverse impact of reductant freezing therein. - As shown in
FIGS. 12-14 ,calibration filter tube 402 further includesfirst end portion 402B which is disposed at least partly withincap member 306 and contacts filter 204.First end portion 402B is largely disc-shaped, having asidewall 402C which contacts the inner surface ofsidewall 306A ofcap member 306. In an example embodiment,first end portion 402B ofcalibration fluid member 402 is attached to capmember 306 so thatcap member 306,filter 204 andcalibration filter tube 402 form a single, unitary and integrated subassembly component for facilitating simplified assembly offluid injector 12. In one example embodiment,cap member 306 engages withfirst end portion 402B, and particularly forms a press fit engagement therewith. In another example embodiment,cap member 306 is welded tofirst end portion 402B, such as a fillet weld connection between the axial end ofsidewall 306A ofcap member 306 and the outer surface ofsidewall 402C offirst portion 402A. It is understood that, alternatively or additionally,cap member 306 may be secured tofirst end portion 402B ofcalibration filter tube 402 using other techniques. -
Calibration filter tube 402 further includes elongatedsecond portion 402D which extends in an axial direction fromfirst portion 402A, as shown inFIGS. 12-14 .Second portion 402D is sized to extend intopole piece 46 so that asecond end 402E, oppositefirst end portion 402B, engages with spring 50 (FIG. 12 ).Second portion 402D is largely cylindrically shaped, withbore 402A disposed therein.Calibration filter tube 402 further includesannular tab 402F which extends radially outwardly from the outer surface ofsecond portion 402D.Tab 402F extends slightly outwardly from the outer surface of, and is positioned along,second portion 402D ofcalibration filter tube 402 so as to contact the inner surface ofpole piece 46 defining the central bore thereof. This contact betweentab 402F and the central bore ofpole piece 46 results incalibration filter tube 402 forming a press fit attachment withpole piece 46. - As mentioned,
second end 402E ofcalibration filter tube 402 contacts and engages withspring 50. Due to the engagement betweencalibration filter tube 402 andspring 50, and the engagement betweenarmature 16 andspring 50,calibration filter tube 402 is used to calibrate the dynamic flow of reductant throughfluid injector 12. Specifically, withcap member 306,filter 204 andcalibration filter tube 402 being formed as a single, unitary and integrated subassembly component, positioningcalibration filter tube 402 in the desired position withintube member 42, prior towelding cap member 306 thereto, is simplified for providing the desired calibrated force forspring 50. -
Calibration filter tube 402 is formed from a metal composition, such as stainless steel. - With continued reference to
FIGS. 12-14 ,injector 12 further includesvolume reduction member 408 which is disposed aroundsecond portion 402D ofcalibration filter tube 402.Volume reduction member 408 has a cylindrical shape, with a central bore defined axially throughvolume reduction member 408. The central bore ofvolume reduction member 408 is sized for receivingcalibration filter tube 402 therein. As shown inFIG. 12 , the outer radial surface ofvolume reduction member 408 contacts the inner surface oftube member 42. One axial (upstream) end ofvolume reduction member 408 is disposed adjacent and contactsfirst end portion 402B ofcalibration filter tube 42, and the other axial (downstream) end ofvolume reduction member 408 is disposed against and contacts the upstream end ofpole piece 46. In this way,volume reduction member 408 occupies the space betweensecond portion 402D ofcalibration filter tube 402 andtube member 42 that is upstream ofpole piece 46 and downstream offirst end portion 402B ofcalibration filter tube 402. In an example embodiment,volume reduction member 408 is attached tocalibration filter tube 402 such thatvolume reduction member 408 forms the single, unitary and integrated subassembly component withcap member 306,filter 204 andcalibration filter tube 402. - In an example embodiment,
volume reduction member 408 is constructed from a resilient and compressible material, and is compressible in at least the axial direction alongfluid injector 12.Volume reduction member 408 being compressible in the axial direction allows for the single assembly component (cap member 306,filter 204 and calibration filter tube 402) to be adjustably positioned withintube member 42 relative topole piece 46 so that the opening and closing force of the valve assembly offluid injector 12 may be easily calibrated as desired. In one embodiment,volume reduction member 408 is constructed from closed cell foam. It is understood, though, thatvolume reduction member 408 may be constructed from other compressible material. If constructed from closed cell foam,volume reduction member 408 is compressible in both axial (longitudinal) and radial (lateral) directions. In an example embodiment,volume reduction member 408 is in a compressed state influid injector 12. -
FIGS. 15-17 illustratefluid injector 12 according to another example embodiment. In this embodiment,fluid injector 12 includesfilter 204 andcap member 306 in which filter 204 is disposed, as described above. In addition,fluid injector 12 includescalibration filter tube 502.Calibration filter tube 502 has many features ofcalibration filter tube 402 described above with respect toFIGS. 12-14 . -
Calibration filter tube 502 includes abore 502A which is axially defined throughcalibration filter tube 502. At one (upstream) end ofcalibration filter tube 502, bore 502A is in fluid communication withfilter 204 for receiving reductant therefrom. At the other (downstream) end ofcalibration filter tube 502, bore 502A provides reductant toarmature 16. In this way,calibration filter tube 502 forms part of the fluid path for reductant throughfluid injector 12, and forms the only such fluid path fromfilter 204 toarmature 16. With the diameter ofbore 502A ofcalibration filter tube 502 being small relative to the inner diameter oftube member 42, the volume of the fluid path for reductant throughinjector 12 is reduced so as to lessen the adverse impact of reductant freezing therein. - As shown in
FIGS. 15-17 ,calibration filter tube 502 further includesfirst end portion 502B which is disposed at least partly withincap member 306 and contacts filter 204.First end portion 502B is largely disc-shaped, having asidewall 502C which contacts the inner surface ofsidewall 306A ofcap member 306. In an example embodiment,first end portion 502B ofcalibration fluid member 502 is attached to capmember 306 so thatcap member 306,filter 204 andcalibration filter tube 502 form a single, unitary and integrated subassembly component for facilitating simplified assembly offluid injector 12. In one example embodiment,cap member 306 engages withfirst end portion 502B, and particularly forms a press fit engagement therewith. In another example embodiment,cap member 306 is welded tofirst end portion 502B, such as a fillet weld connection between the axial end ofsidewall 306A ofcap member 306 and the outer surface ofsidewall 502C offirst portion 502B. It is understood that, additionally or alternatively,cap member 306 may be secured tofirst end portion 502B ofcalibration filter tube 502 using other techniques. -
Calibration filter tube 502 further includes an elongatedsecond portion 502D which extends in an axial direction fromfirst portion 502A, and an elongatedthird portion 502E which extends in the axial direction fromsecond portion 502D, as shown inFIGS. 15-17 .Third portion 502E is sized to extend intopole piece 46 so that asecond end 502F ofcalibration filter tube 502, oppositefirst end portion 502B, engages with spring 50 (FIG. 12 ).Second portion 502D andthird portion 502E are largely cylindrically shaped, withbore 502A disposed therein. - In an example embodiment, the outer diameter of
second portion 502D is larger than the outer diameter ofthird portion 502E. The outer diameter ofthird portion 502E is sized for being received in the central bore ofpole piece 46. -
Calibration filter tube 502 further includesannular tab 502G (FIG. 17 ) which extends radially outwardly from the outer surface ofthird portion 502E.Tab 502G extends slightly outwardly from the outer surface of, and is axially positioned along,third portion 502E ofcalibration filter tube 502 so as to contact the inner surface ofpole piece 46 defining the central bore thereof. This contact betweentab 502G and the central bore ofpole piece 46 results incalibration filter tube 502 forming a press fit engagement withpole piece 46. -
Calibration filter tube 502 is formed from a metal composition, such as stainless steel. - As mentioned,
second end 502F ofcalibration filter tube 502 contacts and engages withspring 50. Due to the engagement betweencalibration filter tube 502 andspring 50, and the engagement betweenspring 50 andarmature 16,calibration filter tube 502 is used to calibrate the dynamic flow of reductant throughfluid injector 12. Specifically, withcap member 306,filter 204 andcalibration filter tube 502 being formed as a single, unitary and integrated subassembly component, positioning ofcalibration filter tube 502 in the desired position withintube member 42, prior towelding cap member 306 thereto, is simplified for providing the desired calibrated force forspring 50 for setting the opposed opening and closing force for the valve assembly offluid injector 12. - With continued reference to
FIGS. 15-17 ,injector 12 further includesvolume reduction member 508 which is disposed aroundsecond portion 502D ofcalibration filter tube 502.Volume reduction member 508 has a generally cylindrical shape, with a central bore defined axially throughvolume reduction member 508. The central bore ofvolume reduction member 508 is sized for receivingsecond portion 502D ofcalibration filter tube 502 therein. As shown inFIG. 12 , the outer radial surface ofvolume reduction member 508 contacts the inner surface oftube member 42. One axial (upstream) end ofvolume reduction member 508 is disposed adjacent and contactsfirst end portion 502B ofcalibration filter tube 42, and the other axial (downstream) end ofvolume reduction member 508 is disposed against and contacts the upstream end ofpole piece 46. In this way,volume reduction member 508 occupies the space betweensecond portion 502D ofcalibration filter tube 502 andtube member 42 that is upstream ofpole piece 46 and downstream offirst end portion 502B ofcalibration filter tube 502. - In an example embodiment,
volume reduction member 508 is constructed from compressible material, such as being compressible in at least the axial direction alongfluid injector 12.Volume reduction member 508 being compressible in at least the axial direction allows for the single assembly component (cap member 306,filter 204 and calibration filter tube 502) to be adjustably positioned withintube member 42 relative topole piece 46 so that the valve assembly offluid injector 12 may be calibrated as desired. In an example embodiment,volume reduction member 508 is in a compressed state influid injector 12. - As shown in
FIGS. 15-17 ,volume reduction member 508 includes asidewall 508A which extends between two axial ends. A downstreamaxial end wall 508B ofvolume reduction member 508 extends radially inwardly fromsidewall 508A and contacts the outer surface ofthird portion 502E ofcalibration filter tube 502. The upstream axial end ofvolume reduction member 508 may be open and contact a downstream surface offirst portion 502B ofcalibration filter tube 502. -
Sidewall 508A ofvolume reduction member 508 undulates in an axial direction, as shown inFIGS. 15-17 , alternating between sidewall peaks and valleys in a wave-like pattern relative to a longitudinal axis ofvolume reduction member 508 and/orinjector 12. Having an undulatingsidewall 508A facilitatessidewall 508A being compressible or otherwise partly collapsible in both axial (longitudinal) and radial (lateral) directions. In an example embodiment,volume reduction member 508 is constructed from a compressible, resilient material, such as a rubber composition or other like material.Volume reduction member 508 may be in a compressed state withinfluid injector 12. - The example embodiments have been described herein in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the invention are possible in light of the above teachings. The description above is merely exemplary in nature and, thus, variations may be made thereto without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (20)
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
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US15/704,402 US20190078488A1 (en) | 2017-09-14 | 2017-09-14 | Injector for reductant delivery unit having fluid volume reduction assembly |
FR1871037A FR3071011B1 (en) | 2017-09-14 | 2018-09-13 | FLUID VOLUME REDUCTION INJECTOR |
JP2018172920A JP6661720B2 (en) | 2017-09-14 | 2018-09-14 | Injector for reducing agent supply unit with fluid volume reduction assembly |
KR1020180110531A KR102127048B1 (en) | 2017-09-14 | 2018-09-14 | Injector for reductant delivery unit having fluid volume reduction assembly |
CN201811074587.5A CN109505684B (en) | 2017-09-14 | 2018-09-14 | Injector for a reductant delivery unit having a fluid volume reduction assembly |
DE102018215678.6A DE102018215678A1 (en) | 2017-09-14 | 2018-09-14 | Injection valve for a reducing agent delivery unit with fluid volume reduction arrangement |
Applications Claiming Priority (1)
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US15/704,402 US20190078488A1 (en) | 2017-09-14 | 2017-09-14 | Injector for reductant delivery unit having fluid volume reduction assembly |
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US20190078488A1 true US20190078488A1 (en) | 2019-03-14 |
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US15/704,402 Abandoned US20190078488A1 (en) | 2017-09-14 | 2017-09-14 | Injector for reductant delivery unit having fluid volume reduction assembly |
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US (1) | US20190078488A1 (en) |
JP (1) | JP6661720B2 (en) |
KR (1) | KR102127048B1 (en) |
CN (1) | CN109505684B (en) |
DE (1) | DE102018215678A1 (en) |
FR (1) | FR3071011B1 (en) |
Cited By (4)
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US20190078485A1 (en) * | 2017-09-14 | 2019-03-14 | Continental Automotive Systems, Inc. | Injector for reductant delivery unit having reduced fluid volume |
US20190078486A1 (en) * | 2017-09-14 | 2019-03-14 | Continental Automotive Systems, Inc. | Injector for reductant delivery unit having fluid volume reduction assembly |
US10947880B2 (en) * | 2018-02-01 | 2021-03-16 | Continental Powertrain USA, LLC | Injector for reductant delivery unit having fluid volume reduction assembly |
US10975821B2 (en) | 2015-09-15 | 2021-04-13 | Vitesco Technologies GmbH | Injection device for metering a fluid and motor vehicle having such an injection device |
Families Citing this family (1)
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US11344826B2 (en) * | 2019-04-03 | 2022-05-31 | Caterpillar Inc. | Machine fluid system having filter protector for sock filter in manifold tube assembly |
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- 2018-09-14 KR KR1020180110531A patent/KR102127048B1/en active IP Right Grant
- 2018-09-14 JP JP2018172920A patent/JP6661720B2/en active Active
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Cited By (6)
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US10947880B2 (en) * | 2018-02-01 | 2021-03-16 | Continental Powertrain USA, LLC | Injector for reductant delivery unit having fluid volume reduction assembly |
Also Published As
Publication number | Publication date |
---|---|
JP6661720B2 (en) | 2020-03-11 |
CN109505684A (en) | 2019-03-22 |
DE102018215678A1 (en) | 2019-03-14 |
KR102127048B1 (en) | 2020-06-25 |
FR3071011B1 (en) | 2021-10-22 |
KR20190030632A (en) | 2019-03-22 |
FR3071011A1 (en) | 2019-03-15 |
CN109505684B (en) | 2021-06-01 |
JP2019056374A (en) | 2019-04-11 |
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