US20220259997A1 - Def system - Google Patents
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- US20220259997A1 US20220259997A1 US17/178,025 US202117178025A US2022259997A1 US 20220259997 A1 US20220259997 A1 US 20220259997A1 US 202117178025 A US202117178025 A US 202117178025A US 2022259997 A1 US2022259997 A1 US 2022259997A1
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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]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
- B01D53/86—Catalytic processes
- B01D53/90—Injecting reactants
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9404—Removing only nitrogen compounds
- B01D53/9409—Nitrogen oxides
- B01D53/9431—Processes characterised by a specific device
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9404—Removing only nitrogen compounds
- B01D53/9436—Ammonia
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9459—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts
- B01D53/9477—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts with catalysts positioned on separate bricks, e.g. exhaust systems
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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
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
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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
- F01N3/103—Oxidation catalysts for HC and CO only
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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
- F01N3/105—General auxiliary catalysts, e.g. upstream or downstream of the main catalyst
- F01N3/106—Auxiliary oxidation catalysts
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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]
- F01N3/2073—Selective catalytic reduction [SCR] with means for generating a reducing substance from the exhaust gases
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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
- F01N3/2892—Exhaust flow directors or the like, e.g. upstream of catalytic device
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2251/00—Reactants
- B01D2251/20—Reductants
- B01D2251/206—Ammonium compounds
- B01D2251/2067—Urea
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/90—Physical characteristics of catalysts
- B01D2255/904—Multiple catalysts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2257/00—Components to be removed
- B01D2257/40—Nitrogen compounds
- B01D2257/404—Nitrogen oxides other than dinitrogen oxide
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2258/00—Sources of waste gases
- B01D2258/01—Engine exhaust gases
- B01D2258/012—Diesel engines and lean burn gasoline engines
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9404—Removing only nitrogen compounds
- B01D53/9409—Nitrogen oxides
- B01D53/9413—Processes characterised by a specific catalyst
- B01D53/9418—Processes characterised by a specific catalyst for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B17/00—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups
- B05B17/04—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups operating with special methods
- B05B17/06—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups operating with special methods using ultrasonic or other kinds of vibrations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B17/00—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups
- B05B17/04—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups operating with special methods
- B05B17/06—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups operating with special methods using ultrasonic or other kinds of vibrations
- B05B17/0607—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups operating with special methods using ultrasonic or other kinds of vibrations generated by electrical means, e.g. piezoelectric transducers
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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
- F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
- F01N2240/05—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a magnetic, e.g. electromagnetic, device other than a valve
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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
- F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
- F01N2240/16—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being an electric heater, i.e. a resistance heater
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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
- F01N2410/00—By-passing, at least partially, exhaust from inlet to outlet of apparatus, to atmosphere or to other device
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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
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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
- F01N2610/10—Adding substances to exhaust gases the substance being heated, e.g. by heating tank or supply line of the added substance
- F01N2610/102—Adding substances to exhaust gases the substance being heated, e.g. by heating tank or supply line of the added substance after addition to exhaust gases, e.g. by a passively or actively heated surface in the exhaust conduit
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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
- F01N2610/1453—Sprayers or atomisers; Arrangement thereof in the exhaust apparatus
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- 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
Abstract
A DEF system for use with an internal combustion engine, the DEF system including a primary flowpath extending between a first inlet and a first outlet, where the first inlet is open to and configured to receive exhaust gasses from the internal combustion engine. The DEF system also includes a secondary flowpath including a second inlet open to the primary flowpath downstream of the first inlet and upstream of the first outlet, a second outlet open to the primary flowpath downstream of the secondary inlet and upstream of the first outlet, and an injector assembly configured to inject DEF into the secondary flowpath.
Description
- The present disclosure relates to a diesel exhaust fluid injector system for use with an internal combustion engine.
- To improve emissions, diesel internal combustion engines include some form of injection system to inject exhaust fluid (e.g., diesel exhaust fluid or DEF) into the exhaust gasses to neutralize nitrous oxides contained therein.
- In one implementation, a DEF system for use with an internal combustion engine, the DEF system including a primary flowpath extending between a first inlet and a first outlet, where the first inlet is open to and configured to receive exhaust gasses from the internal combustion engine, a secondary flowpath including a second inlet open to the primary flowpath downstream of the first inlet and upstream of the first outlet, a second outlet open to the primary flowpath downstream of the secondary inlet and upstream of the first outlet, and an injector assembly configured to inject DEF into the secondary flowpath.
- In another implementation, a DEF system for use with an internal combustion engine configured to output a flow of exhaust gasses, the DEF system including a first flowpath configured to receive a first portion of the flow of exhaust gasses, a second flowpath parallel to the first flow path and configured to receive a second portion of the flow of exhaust gasses, and an injector assembly configured to inject DEF droplets into the second portion of the flow of exhaust gasses.
- In another implementation, a DEF system for use with an internal combustion engine, the DEF system including a first flowpath at least partially defined by a first tube having a first outer wall, where the first flowpath defines a first channel axis, the first flowpath having a first inlet open to the internal combustion engine and a first outlet downstream of the first inlet, a second flowpath at least partially defined by a second tube having a second outer wall, the second flowpath having a second inlet open to the first passageway and a second outlet open to the first passageway, where the second outlet defines an injection chamber completely encompassing the first outer wall of the first flowpath, and where the injection chamber includes a plurality of ports extending between and in fluid communication with both the first flowpath and the injection chamber, and an injector assembly configured to inject DEF into at least one of the first flowpath and the second flowpath.
- In another implementation, a DEF system for use with an internal combustion engine, the DEF system including a passageway having an inlet open to the internal combustion engine and an outlet, a mixing chamber open to the passageway, an ultrasonic DEF injection system configured to inject DEF droplets into the mixing chamber having a predetermined target diameter between 2 to 25 microns.
- Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.
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FIG. 1 is a schematic view of the DEF system. -
FIG. 2 is a cross-sectional view taken along line 2-2 ofFIG. 1 . - Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of the formation and arrangement of components set forth in the following description or illustrated in the accompanying drawings. The disclosure is capable of supporting other implementations and of being practiced or of being carried out in various ways.
- This disclosure generally relates to a diesel exhaust fluid (DEF) system configured to inject a predetermined volume of DEF into the exhaust gasses of an internal combustion engine (ICE) whereby the combined flow of intermixed DEF droplets and exhaust gasses are passed through an exhaust gas treatment element (EGTE) to undergo treatment. More specifically, the DEF system includes both a primary and secondary flowpaths oriented so that a portion of the exhaust gasses are siphoned off from the primary flowpath and directed into the secondary flowpath where they are heated and mixed with atomized DEF in a mixing chamber. More specifically, an ultrasonic injector injects a volume of DEF droplets at a predetermined target droplet diameter into the chamber to be mixed with the siphoned off exhaust gasses. By introducing the DEF droplets into the heated, secondary flow of exhaust gasses, the DEF more readily evaporates into ammonia and avoids unwanted crystallization. With the DEF introduced into the siphoned off gasses, the resulting mixture is injected back into the primary exhaust stream through an injection head having multiple ports contained therein. Finally, the fully mixed gasses flow through an exhaust gas treatment element where the gasses undergo treatment and are subsequently released into the atmosphere.
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FIG. 1 illustrates a diesel exhaust fluid (DEF)system 10 for use with an internal combustion engine (ICE) 14. As shown inFIG. 1 , the ICE 14 is a diesel engine having a plurality ofcylinders 16 and anexhaust outlet 18. While the illustrated ICE 14 is a diesel engine, it is understood that the illustrated system may be fit onto a gasoline or other engine type as needed. - During operation of the ICE 14, the
cylinders 16, together, output a flow of exhaust gasses A through theexhaust outlet 18. The exhaust gasses A exiting theICE 14 generally contain particulate matter (PM) and undesirable chemicals such as nitric oxide (NOx), hydrocarbons (HC), carbon monoxide (CO), and the like. To adhere with local emission laws, one or more of these chemicals and particulates must generally be removed from the exhaust gasses or neutralized before the gasses can be released into the atmosphere. In the illustrated embodiment, the ICE 14 also includes aturbocharger 18 through which the flow of exhaust gasses A passes before exiting theexhaust outlet 18. However, in alternative embodiments, the ICE 14 may be naturally aspirated such that the flow of exhaust gasses A only passes through an exhaust manifold or header (not shown) before exiting theexhaust outlet 18. While the illustrated ICE 14 includes asingle exhaust outlet 18 feeding asingle DEF system 10, it is understood that in alternative embodiments additional exhaust outlets may be present feeding one ormore DEF systems 10. - The
DEF system 10 is configured to receive the exhaust gasses A from theoutlet 18 of the ICE 14, treat the gasses to neutralize or remove the particulates and chemicals contained therein, and release the resulting treated gasses into the atmosphere. TheDEF system 10 includes aninlet 22 coupled to and configured to receive the flow of exhaust gasses A from theexhaust outlet 18 of the ICE 14, aninjection assembly 24 for introducing DEF into theDEF system 10, one or more exhaust gas treatment elements (EGTE) 38 a, 38 b, and anoutlet 26 through which the treated exhaust gasses D are exhausted into the atmosphere. TheDEF system 10 also includes acontroller 134 in operable communication with theinjection assembly 24, EGTEs 38 a, 38 b, and the like that is configured to control, among other things, the rate and manner in which DEF is injected into the exhaust gasses and the manner in which the exhaust gasses are treated. - The
DEF system 10 also includes aprimary exhaust flowpath 30 extending between theinlet 22 and theoutlet 26 and configured to flow a first portion B of the exhaust gas flow A therethrough. Theprimary exhaust flowpath 30 includes a first EGTE 38 a, amerge site 42 downstream of the first EGTE 38 a where thesecondary exhaust flowpath 34 is introduced back into theprimary flowpath 30, and a second EGTE 38 b downstream from themerge site 42. During use, the first portion B of the exhaust gas flow is directed through the first EGTE 38 a where a first set of treatment actions occur. The first portion B is then merged with gasses from the secondary flowpath 34 (described below) to produce a second DEF/exhaust mixture F. The second DEF/exhaust mixture F is then directed through thesecond EGTE 38 b where a second set of treatment actions occur and producing the flow of treated exhaust gasses D. Finally, the treated exhaust gasses D are exhausted into the atmosphere. - The
primary exhaust flowpath 30 is at least partially formed by a length oftubing 50 through which the first portion B of exhaust gasses flows. Thetubing 50, in turn, includes an outer wall 54 at least partially forming theflowpath 30, afirst end 58, and asecond end 62 opposite thefirst end 58. In the illustrated embodiment, thefirst end 58 of thetubing 50 generally corresponds with theinlet 22 while thesecond end 62 of thetubing 50 generally corresponds with theoutlet 26. Theprimary flowpath 30 also defines a channel axis 66 extending along the length of theflowpath 30. - In the illustrated embodiment, the outer wall 54 of the
tubing 50 is substantially annular in cross-sectional shape causing theflowpath 30 to have a substantially circular cross-sectional shape with the axis 66 located at the radial center thereof. However, in alternative embodiments, other flowpath cross-sectional shapes and sizes may be present (e.g., square, rectangle, polygonal, and the like). Furthermore, while the illustratedflowpath 30 is substantially constant in cross-sectional shape, it is understood that the cross-sectional shape of theflowpath 30 may vary over the length thereof. - The first EGTE 38 a is a dual-purpose unit including a diesel oxidation catalyst (DOC)
element 70 and a diesel particular filter (DPF)element 74. Generally speaking, theDOC 70 is a flow-through filter that contains precious metals configured to reduce the CO, HC, and PM levels within the exhaust gasses. TheDPF 74, in contrast, is a wall-flow filter configured to remove any remaining soot that theDOC 70 was unable to oxidize. - The second EGTE 38 b is also a dual-purpose unit including a selective catalytic reduction (SCR)
element 78 and an ammonia oxidation catalyst (AOC)element 82. Generally speaking, theSCR 78 is formed from ceramic materials and is configured to react with the DEF introduced into the exhaust stream to convert Nitrogen Oxides (NOx) into diatomic Nitrogen (N2) and water. The AOC 82, in contrast, is configured to oxidize any remaining ammonia left over from the previous reactions before the gasses leave the system via theoutlet 26. - While the illustrated
DEF system 10 includes two dual-purpose EGTEs 38 a, 38 b placed in series to produce a four-step exhaust gas treatment process (seeFIG. 1 ), it is understood that in alternative embodiments more or fewer types and styles of EGTEs may be used depending on which exhaust treatment capabilities theDEF system 10 is intended to carry out and the exact type of fuel being used by the ICE 14. Furthermore, the packaging of the EGTEs within thefirst flowpath 30 may also be varied. For example, one or more single purpose EGTEs may be mounted in series or parallel to each other. In other embodiments, one or more multi-purpose EGTEs may be used. In still other embodiments, a combination of single and multi-purpose EGTEs may be mounted in series or parallel with each other. - The
DEF system 10 also includes asecondary exhaust flowpath 34. Thesecondary exhaust flowpath 34 branches off from theprimary exhaust flowpath 30 running parallel to at least a portion thereof. Thesecondary exhaust flowpath 34 includes a secondary inlet 86 open to theprimary exhaust flowpath 30, amixing chamber 90, theinjection assembly 24, aheating unit 94, and asecondary outlet 98 open to theprimary exhaust flowpath 30 at a location downstream from where the secondary inlet 86 is open to theprimary exhaust flowpath 30. During use, a second portion C of the exhaust gas flow are siphoned away from the first portion B of the exhaust gas flow and directed into thesecondary exhaust flowpath 34 via the secondary inlet 86. As the second portion B flows through thesecondary exhaust flowpath 34, the second portion C is heated and mixed with a predetermined volume of DEF droplets to produce a first DEF/Exhaust mixture E. The first mixture E is then blended back into the first portion B of the exhaust gas flow (e.g., via the secondary outlet 98) to produce a second DEF/Exhaust mixture F. - In the illustrated embodiment, the
secondary inlet 34 is positioned downstream from theinlet 22 and upstream of the first EGTE 38 a and configured to siphon a pre-determined proportion of the exhaust gas flow A therefrom. However, in alternative embodiments where more than oneexhaust outlet 18 is present in the ICE 14, thesecondary inlet 34 may be attached to a secondary exhaust outlet of the ICE 14, different from the exhaust outlet to which theprimary flowpath 30 is attached, directly. - Similar to the
primary exhaust flowpath 30, thesecondary exhaust flowpath 34 is at least partially formed by a length oftubing 102 through which the second portion C of exhaust gasses flows. Thetubing 102, in turn, includes anouter wall 106, afirst end 110, and asecond end 114 opposite thefirst end 110. In the illustrated embodiment, thefirst end 110 of thetubing 102 corresponds with the secondary inlet 86 while thesecond end 114 corresponds with thesecondary outlet 98. Thesecondary flowpath 34 also defines asecondary channel axis 118 extending along the length thereof. - In the illustrated embodiment, the
outer wall 106 of thesecondary exhaust flowpath 34 is substantially annular in cross-sectional shape causing thesecondary flowpath 34 to have a substantially circular cross-sectional shape with the axis at the center thereof. However, in alternative embodiments, the different cross-sectional flowpath shapes may be present. - The mixing
chamber 90 of thesecondary flowpath 34 includes a sub-volume within theflowpath 34 where the DEF is introduced into and mixed together with the second portion C of the exhaust flow. In the illustrated embodiment, the mixingchamber 90 is an enlarged chamber or volume positioned in theflowpath 34 between the secondary inlet 86 and thesecondary outlet 98. Although not shown, the mixingchamber 90 may include baffles, fins, and the like to help control the flow of exhaust gasses and DEF droplets and promote mixing therein. While the illustrated mixingchamber 90 includes a substantially rectangular chamber spliced into the length oftubing 102, it is understood that in alternative embodiments different sizes and shapes of mixingchamber 90 may be present such as, but not limited to, a length of enlarged tubing (e.g., tubing having a similar but larger cross-sectional shape), a spherical chamber, polygonal chamber, and the like. - As shown in
FIG. 1 , theinjection system 24 is configured to introduce a predetermined volume of DEF droplets into thesecondary flowpath 34 at a predetermined target droplet diameter. More specifically, theinjection system 24 includes a DEF reservoir ortank 122, aDEF supply module 126, and a DEF atomizer 130. TheDEF tank 122 is configured to store a volume of liquid DEF or other treatment liquids therein. As shown inFIG. 1 , thetank 122 may include aDEF level sensor 124, atemperature sensor 128, and aheater 132 to keep the liquid DEF from freezing while being stored. - The
DEF supply module 126 generally contains a series of valves and pumps and is configured to draw DEF from theDEF reservoir 122 and supply a predetermined volume of DEF to the DEF atomizer 130. TheDEF supply module 126 is in operable communication with the DEF controller 134 (described below) which instructs themodule 126 at which flow rate and pressure to provide DEF to the atomizer 130. In some embodiments, thesupply module 126 may also include a filter (not shown) or other elements configured to prepare the DEF for atomization and introduction into the exhaust flow. - The DEF atomizer 130 is configured to receive a pre-determined volume of DEF from the
supply module 126 and atomize the DEF into droplets having a predetermined target droplet diameter for subsequent introduction into the second portion C of the exhaust flow. For the purposes of this application, the “target” diameter is the diameter of droplet the atomizer 130 is attempting to produce although it is understood that a distribution of droplet diameters generally centered on the target diameter (e.g., both larger and smaller) may actually result. - In the illustrated embodiment, the atomizer 130 is an ultrasonic device using ultrasonic waves to shape and form the droplets as they are introduced into the
secondary flowpath 34. During use, the atomizer 130 may adjust the frequency and amplitude of the ultrasonic waves interacting with the liquid DEF to control the droplet characteristics of the DEF being introduced into thesecondary flowpath 34. Such adjustable characteristics may include target droplet diameter, average droplet diameter, droplet diameter distribution, and the like. - In the illustrated embodiment, the atomizer 130 is configured to produce DEF droplets having a target diameter or average droplet diameter between 2-30 microns. In alternative embodiments the atomizer 130 may be configured to produce droplets between 2-25 microns in diameter. In still other embodiments, the atomizer 130 may be configured to produce droplets between 2-15 microns in diameter. In still other embodiments, the atomizer 130 may be configured to produce droplets between 10-15 microns in diameter. In still other embodiments, the atomizer 130 may be configured to produce droplets between 3-6 microns in diameter. In still other embodiments, the atomizer 130 may be configured to produce droplets between 3-9 microns in diameter. Generally speaking, the target or average droplet diameters produced by the ultrasonic atomizer 130 are smaller than the DEF droplets produced by traditional mechanical injectors which typically produce droplets having a target diameter or average diameter between 40-60 microns. By producing DEF droplets having a smaller target diameter, the DEF is able to more quickly and easily vaporize into ammonia (NH3) during use and avoid crystallization. Furthermore, DEF droplets of a smaller diameter also allow for the vaporization into ammonia to occur at a lower temperature within the exhaust gas flow.
- The
heating unit 94 is configured to heat the gasses and droplets contained within thesecondary flowpath 34. More specifically, theheating unit 94 is configured to elevate the relative temperature within the mixing chamber 90 (e.g., the temperature of the second portion C of the exhaust gasses and/or the DEF droplets contained therein) to promote the vaporization of the DEF into ammonia as it mixes with the second portion C of the exhaust gasses. In the illustrated embodiment, theheating unit 94 includes an electric coil or element positioned within mixingchamber 90 of thesecondary flowpath 34. - In the illustrated embodiment, the
heating unit 94 is in operable communication with thecontroller 134 and able to actively adjust the target temperatures withinsecondary flowpath 34. Such targets may include, but are not limited to, a predetermined ambient temperature within the mixingchamber 90, a target temperature increase over the initial temperature of the exhaust gasses leaving theICE 14, a target DEF droplet temperature, a target temperature at a particular location within the DEF system 10 (e.g., at thesecondary outlet 98, within the mixingchamber 90, at themerge site 42, at thesecond EGTE 38 b, and the like). - While the illustrated
heating unit 94 is shown positioned within and heating the volume of the mixingchamber 90, it is understood that in alternative embodiments theheating unit 94 may be positioned anywhere along the secondary exhaust flowpath 34 (e.g., at the secondary inlet 86, within thetubing 102, at thesecondary outlet 98, and the like). In still other embodiments,additional heating units 94 may be present at multiple locations. In still other embodiments, theheating unit 94 may be incorporated into or work together with the atomizer 130 so that the DEF itself is heated directly either prior to or as the DEF is being atomized. In still other embodiments, a combination ofheating units 94 in thesecondary flowpath 34 and atomizer 130 may be present. - While the atomizer 130,
supply module 126,tank 122,heating unit 94, andcontroller 134 are illustrated as separate elements, it is understood that in alternative embodiments, the atomizer 130,supply module 126,DEF tank 122,heating unit 94, andcontroller 134 may all be integrated together as a single unit or into a number of sub-units. - The
secondary outlet 98 is positioned downstream of the first EGTE 38 a and upstream of thesecond EGTE 38 b. During use the secondary outlet is configured to evenly blend the first DEF/exhaust mixture E of thesecondary flowpath 34 with the second portion B of the exhaust flowpath to produce the second DEF/exhaust mixture F (seeFIGS. 1 and 2 ). - As shown in
FIG. 2 , thesecondary outlet 98 includes amultipoint DEF injector 142. TheDEF injector 142, in turn, includes anoutlet chamber 146 fed by thesecondary flowpath 34 and completely encompassing theprimary flowpath 30 generally perpendicular to the channel axis 66. Themultipoint DEF injector 142 also includes a plurality of nozzles orports 150 extending between and in fluid communication with both theoutlet chamber 146 and theprimary flowpath 30. - In the illustrated embodiment, the
outlet chamber 146 completely encompasses (e.g., extends 360 degrees around) and is at least partially defined by the outer wall 54 of thetubing 50 forming theprimary flowpath 30. More specifically, theoutlet chamber 146 has a substantially rectangular-toroid shape oriented perpendicular to the channel axis 66 with the outer wall 54 of thetubing 50 forming the inner wall of thechamber 146. While the illustratedoutlet chamber 146 is substantially equal in cross-sectional shape about the entire periphery of the outer wall 54, in alternative embodiments the size and shape of thechamber 146 may vary to promote an even flow rate of gasses to all areas about the periphery of theflowpath 30. In still other embodiments, baffles or fins may be present to promote the flow of gasses to all areas of thechamber 146. - As shown in
FIG. 2 , eachport 150 of themultipoint DEF injector 142 includes an aperture formed into the outer wall 54 of thetubing 50. In the illustrated embodiment, theports 150 are spaced evenly about the entire periphery of the outer wall 54, however, in alternative embodiments different patterns or layouts ofports 150 may be used to promote more even mixing of the two flows. Furthermore, while the illustratedports 150 include apertures formed into the outer wall 54, in alternative embodiments the nozzles may include elongated structures extending radially inwardly into theprimary flowpath 30. In such embodiments, theelongated ports 150 may terminate at varying radial distances into theflowpath 30 to promote more even blending of the flows. - The
controller 134 of theDEF system 10 is in operable communication with the atomizer 130, thesupply module 126, thetank 122, theheating unit 94, and one or more sensors 138 a-e and configured to control the operation of theDEF system 10 to produce the desired exhaust treatment results. More specifically, thecontroller 134 is configured to monitor the operation of theICE 14 andDEF system 10 via the one or more sensors 138 a-e, enter the data into one or more operating algorithms, and output signals to the atomizer 130,supply module 126, andheating unit 94 to dictate, among other things, the target diameter of the DEF droplets being introduced into thesecondary flowpath 34, the volume of DEF droplets being introduced into thesecondary flowpath 34, and the target temperatures of thesecondary flowpath 34 at one or more locations. In some embodiments, thecontroller 134 may also control (via a valve in the secondary flowpath 34) the proportion of the exhaust flow A that is siphoned off into the secondary flowpath 34 (e.g., the relative flow of the second portion C relative to the first portion B). To make such determinations thecontroller 134 may at least partially consider any one of or combination of: user inputs and operating modes, the operating temperature of the first or second EGTEs 38 a, 38 b, the current operating temperature in the mixingchamber 90, the rate of exhaust flow into theDEF system 10, the NOx level in the exhaust flow A entering theDEF system 10, the NOx level at the entrance to thesecond EGTE 38 b, the NOx level at the exit of thesecond EGTE 38 b, the volume of DEF remaining in thereservoir 122, the ambient temperature, the operating conditions of theICE 14, and the like. - During use, the
controller 134 receives information from one or more sensors 138 a-outputting signals representative of various operating conditions within theICE 14 andDEF system 10. Such sensors may include, but are not limited to, exhaustgas temperature sensors 138 a, exhaustgas pressure sensors 138 b, EGTEoperating temperature sensors 138 c, exhaust gas flow sensors 138 d, NOxlevel sensors 138 e, and the like. Such sensors 138 a-e may be stand-alone units, combined into multi-purpose units, or virtually produced using software. - During operation of the
ICE 14, the operation of thecylinders 16 produces a flow of exhaust gasses A that are discharged through anexhaust outlet 18. After leaving theexhaust outlet 18, the flow of exhaust gasses A enters theDEF system 10 via theinlet 22 where a portion is siphoned off through the secondary inlet 86. This results in a first portion B of the exhaust flow continuing along theprimary flowpath 30 and a second portion C of the exhaust flow flowing along thesecondary flowpath 34. The relative proportion of the exhaust gasses that are siphoned off may be determined by thecontroller 134. - After separation, the second portion C of the exhaust flow continues along the
secondary flowpath 34 and into the mixingchamber 90. Inside the mixingchamber 90, the second portion C is heated via theheating unit 94 and mixed with a volume of DEF droplets to form the first DEF/exhaust mixture E. The increased temperature from theheating unit 94 and smaller droplet diameter produced by the atomizer 130 promotes the vaporization of the DEF into ammonia. The target diameter of the droplets and volume of droplets distributed is controlled by thecontroller 134. - The first DEF/exhaust mixture E then exits the mixing
chamber 90 and flows into theoutlet chamber 146 of themultipoint DEF injector 142 where it merges with the first portion B of the exhaust flow via the plurality ofports 150 to produce the second DEF/exhaust mixture F. As stated above, the relative location of theports 150 help evenly distribute the introduction of the first DEF/exhaust mixture E into the first portion B to produce an even mix. - Looking now to the primary flowpath A, the first portion B of the exhaust flow flows along the
primary flowpath 30 where it is directed into the first EGTE 38 a to undergo a first treatment stage. As descried above, as the first portion B flows through the first EGTE 38 a, theDOC element 70 oxidizes and reduces the levels of PM, HC, and CO contained within the exhaust gasses while theDPF element 74 acts as a filter capturing any remaining soot that theDOC element 70 was unable to oxidize. - After undergoing the first stage of treatment, the first portion B of the exhaust flow then enters the
merge site 42 whereby the first DEF/exhaust mixture E is re-mixed with the first portion B to produce the second DEF/exhaust mixture F (described above). The resulting mixture F is then directed into thesecond EGTE 38 b where it undergoes a second treatment stage to produce the flow of treated exhaust gasses D. As described above, while flowing through thesecond EGTE 38 b, theSCR element 78 reacts with the DEF contained within the mixture F to convert NOx into elemental nitrogen and water while theAOC element 82 neutralizes any remaining ammonia. The resulting treated gasses D are then exhausted into the atmosphere.
Claims (20)
1) diesel exhaust fluid (DEF) system for use with an internal combustion engine, the DEF system comprising:
a primary flowpath extending between a first inlet and a first outlet, wherein the first inlet is open to and configured to receive exhaust gasses from the internal combustion engine;
a secondary flowpath including:
a second inlet open to the primary flowpath downstream of the first inlet and upstream of the first outlet,
a second outlet open to the primary flowpath downstream of the secondary inlet and upstream of the first outlet; and
an injector assembly configured to inject DEF into the secondary flowpath; and
a first exhaust gas treatment element, and wherein the first exhaust gas treatment element is in fluid communication with the primary flowpath and positioned downstream of the second inlet and upstream of the second outlet.
2) The DEF system of claim 1 , wherein the injector assembly is configured to output DEF droplets between 2-25 microns in diameter.
3) The DEF system of claim 1 , wherein the injector assembly includes an ultrasonic atomizer.
4) The DEF system of claim 1 , further comprising a heating unit configured to heat exhaust gasses contained within the secondary flowpath.
5) The DEF system of claim 1 , wherein the injector assembly is configured to output DEF droplets having a target diameter, and wherein the target diameter is adjustable.
6) The DEF system of claim 1 , further comprising a first second exhaust gas treatment element in fluid communication with the primary flowpath and positioned downstream of the second outlet.
7) The DEF system of claim 6 , wherein the first second exhaust gas treatment element is at least one of a selective catalytic reduction unit and an ammonia oxidation catalyst unit.
8) The DEF system of claim 1 , wherein the first exhaust gas treatment element is at least one of a diesel particular filter and a diesel oxidation catalyst.
9) A diesel exhaust fluid (DEF) system for use with an internal combustion engine configured to output a flow of exhaust gasses, the DEF system comprising:
a first flowpath configured to receive a first portion of the flow of exhaust gasses;
a second flowpath parallel to the first flow path and configured to receive a second portion of the flow of exhaust gasses;
an injector assembly configured to inject DEF droplets into the second portion of the flow of exhaust gasses, and wherein the injector assembly is configured to inject DEF droplets having a target diameter, and wherein the target diameter is adjustable.
10) (canceled)
11) The DEF system of claim 9 , further comprising a heating unit configured to heat the second portion of the flow of exhaust gasses and the DEF.
12) A diesel exhaust fluid (DEF) system for use with an internal combustion engine, the DEF system comprising:
a first flowpath at least partially defined by a first tube having a first outer wall, wherein the first flowpath defines a first channel axis, the first flowpath having a first inlet open to the internal combustion engine and a first outlet downstream of the first inlet;
a second flowpath at least partially defined by a second tube having a second outer wall, the second flowpath having a second inlet open to the first passageway and a second outlet open to the first passageway,
wherein the second outlet defines an injection chamber completely encompassing the first outer wall of the first flowpath, and wherein the injection chamber includes a plurality of ports extending between and in fluid communication with both the first flowpath and the injection chamber, and wherein each port is formed into the first outer wall and directed radially toward the first channel axis; and
an injector assembly configured to inject DEF into at least one of the first flowpath and the second flowpath.
13) The DEF system of claim 12 , wherein the second flowpath includes a mixing chamber downstream of the second inlet and upstream of the second outlet.
14) The DEF system of claim 12 , further comprising a heating unit configured to heat the DEF contained within the second flowpath.
15) The DEF system of claim 12 , wherein the injector assembly includes an ultrasonic injector assembly.
16) The DEF system of claim 12 , wherein the ports are positioned equally along the second outer wall.
17) The DEF injection system of claim 12 , further comprising a first exhaust gas treatment element open to the first flowpath and positioned downstream of the second outlet.
18) The DEF system of claim 17 , further comprising a second exhaust gas treatment element open to the first flowpath and positioned upstream of the second outlet.
19) A diesel exhaust fluid (DEF) system for use with an internal combustion engine, the DEF system comprising:
a passageway having an inlet open to the internal combustion engine and an outlet;
a mixing chamber open to the passageway;
an ultrasonic DEF injection system configured to inject DEF droplets into the mixing chamber having a predetermined target diameter between 2 to 25 microns.
20) The DEF system of claim 19 , wherein the target diameter is variable.
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US17/178,025 US11421573B1 (en) | 2021-02-17 | 2021-02-17 | DEF system |
DE102022102471.7A DE102022102471A1 (en) | 2021-02-17 | 2022-02-02 | DEF system |
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US17/178,025 US11421573B1 (en) | 2021-02-17 | 2021-02-17 | DEF system |
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CN105019988B (en) | 2015-08-03 | 2019-07-26 | 包头北大工道发动机技术有限公司 | Vehicle-mounted urea solution metering ultrasonic atomization feedway |
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- 2021-02-17 US US17/178,025 patent/US11421573B1/en active Active
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US6173568B1 (en) * | 1997-09-16 | 2001-01-16 | Siemens Aktiengesellschaft | Method and device for operating an internal combustion engine operating with an excess of air |
US20040124259A1 (en) * | 2002-09-13 | 2004-07-01 | The Ohio State University | Liquid atomization system for automotive applications |
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