Abstract: A vehicle includes an exhaust aftertreatment system for use with an automotive internal combustion engine. The aftertreatment system includes one or more aftertreatment devices for removing or reducing effluents from exhaust gases produced by the combustion engine. The aftertreatment devices includes a selective catalytic reduction unit that can be heated by a power source. An electrical connection system is configured to interconnect the power source and one or more electrical components to transfer and deliver electrical power to the one or more electrical components.

Abstract: An exhaust component assembly includes a heat shield formed from a composite material and a mounting structure that attaches the heat shield to an outer housing of an exhaust component. The mounting structure comprises an insulator located between an outer surface of the outer housing an inner surface of the heat shield. A method of assembling the composite heat shield to the outer housing of the exhaust component assembly is also disclosed.

Abstract: A vehicle includes an exhaust aftertreatment system for use with an automotive internal combustion engine. The system includes a reagent mixer configured to deliver a reagent for mixing with exhaust gases produced by the engine. The reagent mixer includes a flow-redirection housing defining an mixing chamber and a manifold coupled downstream of the flow-redirection housing. A doser is mounted to the flow-redirection housing and is configured to inject the reagent toward the mixing chamber.

Abstract: An exhaust component assembly includes a heat shield and a mounting structure to attach the heat shield to an outer housing of an exhaust component. The mounting structure comprises a primary insulator located between an outer surface of the outer housing and an inner surface of the heat shield and at least one secondary insulator positioned adjacent to the primary insulator. A method of assembling the heat shield to the outer housing of the exhaust component assembly is also disclosed.

Abstract: An exhaust system includes a first exhaust after-treatment system receiving exhaust gases generated by an engine, a second exhaust after-treatment system downstream of the first exhaust after-treatment system, and at least one bypass connecting an engine outlet to an inlet to the second exhaust after-treatment system. A turbocharger is associated with the bypass and a bypass valve is located upstream of the turbocharger. The bypass valve is moveable between an open position to bypass exhaust gas flow to the first exhaust after-treatment system, a closed position to direct all exhaust gas flow to the first exhaust after-treatment system, and a partially open position where one portion of exhaust gas flow is directed into the first exhaust after-treatment system and a remaining portion of exhaust gas flow is directed into the turbocharger. A controller controls movement of the bypass valve between the open, closed, and partially open positions.

Abstract: A vehicle exhaust system includes a mixer housing that has a doser opening and defines an internal mixing chamber. A doser injects fluid into the mixer housing through the doser opening. A flow passage has an inlet end positioned adjacent the doser opening and an outlet end open to the mixing chamber. At least one heating device associated with the flow passage.

Abstract: An exhaust component assembly includes a housing having at least one mount area configured to be attached to another exhaust component. A primary heat shield is attached to the housing and includes at least one open area at the mount area. A secondary heat shield positioned adjacent to the primary heat shield to at least partially cover the mount area. A method of assembling the primary and secondary heat shields to the housing of the exhaust component assembly is also disclosed.

Abstract: An exhaust system includes a first exhaust after-treatment system receiving exhaust gases generated by an engine, a second exhaust after-treatment system downstream of the first exhaust after-treatment system, and at least one bypass connecting an engine outlet to an inlet to the second exhaust after-treatment system. A turbocharger is associated with the bypass and a bypass valve is located upstream of the turbocharger. The bypass valve is moveable between an open position to bypass exhaust gas flow to the first exhaust after-treatment system, a closed position to direct all exhaust gas flow to the first exhaust after-treatment system, and a partially open position where one portion of exhaust gas flow is directed into the first exhaust after-treatment system and a remaining portion of exhaust gas flow is directed into the turbocharger. A controller controls movement of the bypass valve between the open, closed, and partially open positions.

Abstract: A vehicle exhaust system includes a mixer housing that has a doser opening and defines an internal mixing chamber. A doser injects fluid into the mixer housing through the doser opening. A flow passage has an inlet end positioned adjacent the doser opening and an outlet end open to the mixing chamber. At least one heating device associated with the flow passage.

Abstract: A vehicle exhaust system includes an outer housing defining an internal cavity surrounding an axis, an inlet baffle configured to direct engine exhaust gas into the internal cavity, an injector that is configured to spray a fluid into the internal cavity to mix with engine exhaust gas, and an inner wall spaced radially inward of an inner surface of the outer housing to define a gap. The inner wall has an impingement side facing the axis and a non-impingement side facing the gap. At least one heating element is associated with the non-impingement side to actively heat the inner wall to reduce spray deposit formation on the impingement side.

Abstract: An exhaust component assembly includes a heat shield and a mounting structure to attach the heat shield to an outer housing of an exhaust component. The mounting structure includes a primary insulator located between an outer surface of the outer housing and an inner surface of the heat shield, and at least one secondary insulator positioned adjacent the primary insulator. The primary insulator comprises a sheet of material including at least one encapsulated insulating cavity.

Abstract: A vehicle exhaust system includes an outer housing defining an internal cavity surrounding an axis, an inlet baffle configured to direct engine exhaust gas into the internal cavity, and an injector that is configured to spray a fluid into the internal cavity to mix with engine exhaust gas. An inner wall is spaced radially inward of an inner surface of the outer housing to define a gap. The inner wall has an impingement side facing the axis and a non-impingement side facing the gap. At least one heat transfer element is positioned within the gap and in is contact with at least one of the inner surface of the outer housing and the non-impingement side of the inner wall to transfer heat through the inner wall to the impingement side to reduce spray deposit formation.

Abstract: An exhaust component assembly includes a housing having at least one mount area configured to be attached to another exhaust component. A primary heat shield is attached to the housing and includes at least one open area at the mount area. A secondary heat shield positioned adjacent to the primary heat shield to at least partially cover the mount area. A method of assembling the primary and secondary heat shields to the housing of the exhaust component assembly is also disclosed.

Abstract: An exhaust component assembly includes a heat shield formed from a composite material and a mounting structure that attaches the heat shield to an outer housing of an exhaust component. The mounting structure comprises an insulator located between an outer surface of the outer housing an inner surface of the heat shield. A method of assembling the composite heat shield to the outer housing of the exhaust component assembly is also disclosed.

Abstract: An exhaust component assembly includes a heat shield and a mounting structure to attach the heat shield to an outer housing of an exhaust component. The mounting structure comprises a primary insulator located between an outer surface of the outer housing and an inner surface of the heat shield and at least one secondary insulator positioned adjacent to the primary insulator. A method of assembling the heat shield to the outer housing of the exhaust component assembly is also disclosed.

Abstract: A vehicle exhaust system includes an outer housing defining an internal cavity surrounding an axis, an inlet baffle configured to direct engine exhaust gas into the internal cavity, an injector that is configured to spray a fluid into the internal cavity to mix with engine exhaust gas, and an inner wall spaced radially inward of an inner surface of the outer housing to define a gap. The inner wall has an impingement side facing the axis and a non-impingement side facing the gap. At least one heating element is associated with the non-impingement side to actively heat the inner wall to reduce spray deposit formation on the impingement side.

Abstract: An exhaust component assembly includes a heat shield and a mounting structure to attach the heat shield to an outer housing of an exhaust component. The mounting structure includes a primary insulator located between an outer surface of the outer housing and an inner surface of the heat shield, and at least one secondary insulator positioned adjacent the primary insulator. The primary insulator comprises a sheet of material including at least one encapsulated insulating cavity.

Abstract: A vehicle exhaust system includes an outer housing defining an internal cavity surrounding an axis, an inlet baffle configured to direct engine exhaust gas into the internal cavity, and an injector that is configured to spray a fluid into the internal cavity to mix with engine exhaust gas. An inner wall is spaced radially inward of an inner surface of the outer housing to define a gap. The inner wall has an impingement side facing the axis and a non-impingement side facing the gap. At least one heat transfer element is positioned within the gap and in is contact with at least one of the inner surface of the outer housing and the non-impingement side of the inner wall to transfer heat through the inner wall to the impingement side to reduce spray deposit formation.