Abstract: An aftertreatment component for use in an exhaust aftertreatment system. The aftertreatment component comprises an aftertreatment substrate and a compressible material. The compressible material may be formed from a plastic thermoset, a rubberized material, or a metal foil which permits for the selective expansion of the substrate within the compressible material, while also reducing cost and manufacturing complexity. In various embodiments, the aftertreatment substrate and the compressible materials may be formed separately and coupled to each other, or they may be formed concurrently via coextrusion.

Abstract: An aftertreatment system comprises a SCR system, a reductant injector operatively coupled to the SCR system, and a reductant insertion assembly operatively coupled to the reductant injector. The reductant insertion assembly comprises a pump configured to pump the reductant through the reductant injector. A controller is operatively coupled to the reductant insertion assembly and configured to receive predetermined calibration values of the pump corresponding to delivery of a reductant by the pump through a calibration injector. The controller determines a desired flow rate value of the reductant into the SCR system. The controller determines an insertion time of the reductant injector for delivering the reductant through the reductant injector based on the desired flow rate value, a pump operating parameter value of the pump and the predetermined calibration values, and activates the reductant injector for the insertion time.

Abstract: A method includes: providing a SCR system comprising a SCR catalyst; heating the SCR system to a temperature greater than 500 degrees Celsius for a predetermined time so as to increase sulfur resistance of the SCR catalyst; and installing the SCR system in an aftertreatment system.

Abstract: An exhaust gas aftertreatment system includes a decomposition reactor, an injector, and a processor. The decomposition reactor includes a body, an impingement structure, and a heater. Exhaust gas is flowable through the body. The body includes an inlet and an outlet. The inlet is configured to receive the exhaust gas at a first temperature. The outlet is configured to selectively expel the exhaust gas at a second temperature greater than the first temperature. The impingement structure is disposed within the body between the inlet and the outlet. The impingement structure extends into the body and is located such that the exhaust gas flowing through the body impinges on the impingement structure. The heater is coupled to the impingement structure and configured to selectively heat the impingement structure. The injector is configured to inject reductant into the body. The processor is programmed to control the heater.

Abstract: A decomposition chamber for an aftertreatment system includes: a body including: an inlet configured to receive exhaust gas; an outlet configured to expel the exhaust gas, a thermal management chamber in fluid communication with the inlet, the thermal management chamber configured to receive a first portion of the exhaust gas from the inlet, and a main flow chamber in fluid communication with the inlet, the main flow chamber configured to receive a second portion of the exhaust gas from the inlet and to receive the first portion of the exhaust gas from the thermal management chamber; and a diffuser positioned within the main flow chamber, the diffuser including: a diffuser inlet portion including a plurality of diffuser perforations, the diffuser inlet portion configured to receive the exhaust gas from the main flow chamber, and a diffuser flange portion configured to receive the exhaust gas from the diffuser inlet portion and provide the exhaust gas to the outlet.

Abstract: A dosing lance assembly for an exhaust component includes: a housing comprising: a plate having a first channel, an endcap having a second channel, and a pipe having a first end coupled to the plate and a second end coupled to the endcap, wherein at least a portion of the pipe is airfoil-shaped; and a delivery conduit having a first end coupled to the plate and a second end coupled to the endcap, such that reductant is flowable from the first channel to the second channel.

Abstract: Various embodiments relate to a selective catalytic reduction system for treating exhaust gases of an internal combustion engine. The system includes an inlet section that receives exhaust gases from the engine. The system includes a tank storing diesel exhaust fluid (“DEF”), a pump, a valve, and an injector each in fluid communication with each other. The injector is coupled to the inlet exhaust pipe and configured to inject DEF into the exhaust gases flowing through the inlet exhaust pipe in a plurality of pulses. Each of the plurality of pulses injects a constant volume of DEF into the inlet exhaust pipe. The system further includes a controller configured to operate the pump and the valve such that a time interval between successive constant volume pulses of the plurality of pulses is varied based on a variable oxides of nitrogen content of the exhaust gases.

Abstract: Methods, apparatuses, and systems for estimating exhaust air mass-flow in an aftertreatment system. An embodiment includes a selective catalytic reduction (SCR) system including at least one catalyst, a differential pressure (dP) sensor operatively coupled to the SCR system, a temperature sensor, and a controller. The dP sensor is configured to measure a value of a differential pressure across the SCR system, determine a first output value from the dP sensor, and a first temperature output value from the temperature sensor. The first output value is indicative of the value of the differential pressure across the SCR system. The first temperature output value is indicative of a temperature of the SCR system. The controller is further configured to estimate an exhaust air mass-flow output from the aftertreatment system using the first output value from the dP sensor and the first temperature output value from the temperature sensor.

Abstract: An exhaust aftertreatment system includes a catalyst, an exhaust conduit system, a first sensor, a second sensor, a reductant pump, a dosing module, and a reductant delivery system controller. The exhaust conduit system is coupled to the catalyst. The first sensor is coupled to the exhaust conduit system upstream of the catalyst and configured to obtain a current first measurement upstream of the catalyst. The second sensor is coupled to the exhaust conduit system downstream of the catalyst and configured to obtain a current second measurement downstream of the catalyst. The reductant pump is configured to draw reductant from a reductant source. The dosing module is fluidly coupled to the reductant pump and configured to selectively provide the reductant from the reductant pump into the exhaust conduit system upstream of the catalyst. The reductant delivery system controller is communicable with the first sensor, the second sensor, the reductant pump, and the dosing module.

Abstract: A sensor table mounting system includes an insulating blanket assembly and a senor table. The insulating blanket assembly is configured to surround an external housing surface of an exhaust aftertreatment component housing. The insulating blanket assembly includes an inner blanket surface, an outer blanket surface, and a first restraint. The outer blanket surface is opposite the inner blanket surface. The first restraint includes a first restraint first end that is fixed to the outer blanket surface. The sensor table includes a platform, a first standoff, a second standoff, a first footing, and a second footing. The first footing is offset from the platform by the first standoff and configured to be coupled to the first restraint. The second footing is offset from the platform by the second standoff and configured to be coupled to the first restraint.

Abstract: A lance injector assembly for an aftertreatment system comprises a shaft configured to extend into an exhaust conduit of the aftertreatment system, the shaft being hollow so as to define a cavity. A supply line is disposed within the cavity defined by the shaft. The supply line is configured to receive a liquid reductant, and an outlet of the supply line is fluidly coupled to an opening defined in the shaft. A heating element is located in the cavity and configured to selectively heat the liquid reductant flowing through the supply line to generate gaseous reductant to be expelled from the outlet of the supply line.

Abstract: A lance injector assembly for an exhaust component is provided. The lance injector assembly includes a lance and a poppet valve. The lance includes a lance housing, a supply passage fluidly coupled to a reductant source and terminating at a nozzle orifice, and a return passage fluidly coupled to the reductant source. The poppet valve is positioned downstream of the nozzle orifice and includes a poppet movable between a closed position and an open position. When operating in a recirculation mode, the poppet is in the closed position to permit a full portion of reductant supplied to the lance from the reductant source to return to the reductant source. When operating in an injection mode, the poppet is in the open position to permit a first portion of reductant to flow from the nozzle orifice and a second portion of reductant to return to the reductant source.

Abstract: A mixing assembly for an exhaust aftertreatment system includes: a mixing body including upstream and downstream mixing body openings, the upstream mixing body opening configured to receive exhaust gas; an upstream plate coupled to the mixing body, the upstream plate including a plurality of upstream plate openings, each of the plurality of upstream plate openings configured to receive a flow percentage that is less than 50% of a total flow of the exhaust gas; a downstream plate coupled to the mixing body downstream from the upstream plate in a direction of exhaust gas flow, the downstream plate including a downstream plate opening; and a swirl plate positioned between the upstream plate and the downstream plate and defining a swirl collection region and a swirl concentration region, the swirl collection region positioned over the plurality of upstream plate openings and the swirl collection region positioned over the downstream plate opening.

Abstract: A system includes: a NOx sensor; and a controller configured to: increase an amount of O2 in a chamber of the NOx sensor; interpret one or more values of a parameter indicative an amount of O2 and/or NOx measured by the NOx sensor; determine if the one or more values of the parameter exceed a threshold value; and indicate a failure of the NOx sensor responsive to the one or more values of the parameter do not exceed the threshold value.

Abstract: An apparatus comprises a housing including a housing first portion having a first joint portion configured to overlap a second joint portion of a housing second portion so as to form a housing joint. A primary clamp is positioned at a primary location of the housing joint which abuts at least a portion of the first and the second joint portion. A mounting bracket is positioned on and contacts the primary clamp. A plurality of secondary clamps are positioned at secondary locations, each of which is different than the primary location, of the housing joint. A band is operatively coupled to the mounting bracket by positioning around and contacting each of the plurality of secondary clamps. The band is tightened to urge the mounting bracket and thereby the primary clamp, and the plurality of secondary clamps towards the housing joint to secure the housing joint.

Abstract: A process for detecting reductant deposits includes accessing data indicative of signal output from a radiofrequency sensor positioned proximate a decomposition reactor tube; comparing the data indicative of signal output from the radiofrequency sensor to a deposit formation threshold; and activating a deposit mitigation process responsive to the data indicative of signal output from the radiofrequency sensor exceeding the deposit formation threshold.

Abstract: An aftertreatment system comprises a SCR system, a first filter, and a second filter disposed downstream of the first filter and a bypass conduit providing a flow path bypassing the second filter. A valve is operatively coupled to the bypass conduit and is moveable between a closed position in which the exhaust gas flows through the second filter, and an open position in which at least a portion of the exhaust gas flows through the bypass conduit. A controller is operatively coupled to the valve configured to adjust the valve based on a first filtration efficiency of the first filter to cause the exhaust gas expelled into the environment from the aftertreatment to have a particulate matter count meeting particulate matter emission standards.

Abstract: An aftertreatment system (100) includes a decomposition chamber (108), a reductant pump (120), a first dosing module (110), a second dosing module (112), and a controller (133). The first dosing module (110) is coupled to the decomposition chamber (108) and configured to receive reductant from the reductant pump (120). The second dosing module (112) is coupled to the decomposition chamber (108) and configured to receive reductant from the reductant pump (120) independent of the first dosing module (110). The controller (133) is communicatively coupled to the first dosing module (110) and the second dosing module (112). The controller (133) is configured to independently control a first volumetric flow rate of reductant provided from the first dosing module (110) into the decomposition chamber (108) and a second volumetric flow rate of reductant provided from the second dosing module (112) into the decomposition chamber (108).

Abstract: An aftertreatment component includes an aftertreatment housing. The aftertreatment housing has a first surface positioned so as to be directly impinged by diesel exhaust fluid injected into the aftertreatment housing. The first surface is a polished surface.

Abstract: A doser mounting bracket for coupling a doser to an exhaust gas aftertreatment system component having a sidewall and an exhaust gas aftertreatment system component opening includes a lower surface, an engagement wall, a central structure, an upper surface, and an attachment structure. The lower surface is configured to be held in a position opposing the sidewall. The engagement wall extends from the lower surface. The central structure has an opening that extends therethrough and includes a centering structure that extends from the lower surface and is configured to be received within the exhaust gas aftertreatment system component opening. The attachment structure extends from the upper surface and is configured to be coupled to the doser. The engagement wall is configured to separate the lower surface from the sidewall when the engagement wall interfaces with the sidewall such that a pocket is formed between the engagement wall, the centering structure, and the lower surface.