Abstract: A dosing unit having a fluid path defined therethrough and including a fluid injector having an inlet tube; an inlet cup sized and shaped for receiving therein at least part of the inlet tube of the fluid injector, the inlet cup including a fluid inlet; an input tube in fluid communication with the inlet cup via the fluid inlet thereof, the input tube configured to receive fluid from a fluid source; and an insert partly disposed in the inlet tube of the fluid injector, the insert at least partly defining a fluid passage. The fluid passage is in fluid communication with the input tube and the inlet tube of the fluid injector and forms part of the fluid path of the dosing unit. The fluid passage includes a portion extending in a direction that is orthogonal to a longitudinal axis of the fluid injector.

Abstract: A fluid injector includes a fluid inlet, a fluid outlet, and a fluid path from the fluid inlet to the fluid outlet. An actuator unit is disposed within the fluid injector. A valve assembly operatively couples to the actuator unit. A spacer member is disposed between a downstream end portion of the actuator unit and a portion of the valve assembly, the spacer member constructed from a compressible, resilient material so as to compress due to expansion forces from fluid in the fluid injector freezing, and to expand when frozen fluid in the fluid injector melts. The spacer member occupies a space in the fluid path of the fluid injector.

Abstract: A fluid injector includes a calibration filter tube including a bore defined in an axial direction through the calibration filter tube, the bore defining at least a portion of a fluid path through the fluid injector, the calibration filter tube including a plurality of holes which extend from the bore to an outer surface of the calibration filter tube. A volume reduction member has a bore though which the calibration filter tube extends, the volume reduction member occupying a space between the outer surface of the calibration filter tube and an inner surface of the tube member, the volume reduction member being constructed from resilient, compressible material. Freezing or frozen fluid disposed in the calibration filter tube expands through the holes and at least partially compresses the volume reduction member, so as to reduce fluid expansion forces damaging other components of the fluid injector.

Abstract: A reductant dosing unit is disclosed, including a fluid injector having a fluid inlet and a fluid outlet. A flange is disposed proximal to the fluid outlet of the fluid injector and configured to secure to a boss associated with an exhaust path of an internal combustion engine. The flange has a largely flat body portion with a through-bore in fluid communication with the fluid outlet of the fluid injector. The flange further includes an extension which extends from the body portion toward the fluid injector and which is connected to thereto. A thermal isolator is disposed between the fluid outlet of the fluid injector and the flange. The connection between the extension of the flange and the fluid injector includes a hermetic seal, preventing exhaust gases in the exhaust path from passing between the flange extension and the fluid injector. The thermal isolator is only used as a support and thermal isolator.

Abstract: A heat shield for a reductant delivery unit (RDU), the RDU including a fluid injector with a fluid inlet and a fluid outlet, and a clamp flange for attachment to a mounting boss of a vehicle exhaust pipe. The heat shield includes a first portion which is attached to the fluid injector so as to at least partly cover the fluid outlet thereof. The first portion serves as a thermal barrier for the fluid injector and a mechanical barrier for preventing particles in the vehicle exhaust pipe from contacting the fluid injector when the RDU is attached to the vehicle exhaust pipe. The heat shield further includes a second portion which extends radially outwardly from the first portion for sealing the attachment between the clamp flange and the mounting boss of the vehicle exhaust pipe when the RDU is attached thereto.

Abstract: A reductant delivery unit (RDU) for a selective catalytic reduction system, including a housing; a fluid inlet disposed at an upper portion of the housing; a fluid return outlet; a fluid nozzle outlet disposed at a lower portion of the housing; an injector disposed within the housing and configured to receive fluid from the fluid inlet and selectively discharge the fluid from the fluid nozzle outlet; and at least one fluid passageway disposed within or around the housing. The fluid passageway provides fluid communication along a first fluid path between the fluid inlet and the fluid nozzle outlet and along a second fluid path between the fluid inlet and the fluid return outlet so that the same fluid discharged by the injector is also used as a coolant for the RDU.

Abstract: A heat shield for a reductant delivery unit (RDU), the RDU including a fluid injector with a fluid inlet and a fluid outlet, and a clamp flange for attachment to a mounting boss of a vehicle exhaust pipe. The heat shield includes a first portion which is attached to the fluid injector so as to at least partly cover the fluid outlet thereof. The first portion serves as a thermal barrier for the fluid injector and a mechanical barrier for preventing particles in the vehicle exhaust pipe from contacting the fluid injector when the RDU is attached to the vehicle exhaust pipe. The heat shield further includes a second portion which extends radially outwardly from the first portion for sealing the attachment between the clamp flange and the mounting boss of the vehicle exhaust pipe when the RDU is attached thereto.

Abstract: A fluid injector includes a fluid inlet, a fluid outlet, and a fluid path from the fluid inlet to the fluid outlet. An actuator unit is disposed within the fluid injector. A valve assembly operatively couples to the actuator unit. A spacer member is disposed between a downstream end portion of the actuator unit and a portion of the valve assembly, the spacer member constructed from a compressible, resilient material so as to compress due to expansion forces from fluid in the fluid injector freezing, and to expand when frozen fluid in the fluid injector melts. The spacer member occupies a space in the fluid path of the fluid injector.

Abstract: A fluid injector includes a calibration filter tube including a bore defined in an axial direction through the calibration filter tube, the bore defining at least a portion of a fluid path through the fluid injector, the calibration filter tube including a plurality of holes which extend from the bore to an outer surface of the calibration filter tube. A volume reduction member has a bore though which the calibration filter tube extends, the volume reduction member occupying a space between the outer surface of the calibration filter tube and an inner surface of the tube member, the volume reduction member being constructed from resilient, compressible material. Freezing or frozen fluid disposed in the calibration filter tube expands through the holes and at least partially compresses the volume reduction member, so as to reduce fluid expansion forces damaging other components of the fluid injector.

Abstract: A fluid injector for injecting fluid includes a body with a fluid passageway extending from an inlet to an outlet of the fluid injector; a valve seat; a valve element that is selectively engages with the valve seat; and a disc member disposed in the fluid passageway downstream of the valve seat. The disc member includes a plurality of channels defined along a first surface of the disc member, and a plurality of orifices defined through the disc, with each disc member being fluidly coupled to a plurality of channels. The channels fluidly coupled to each channel are in offset relation to each other at the orifice such that fluid flowing through the orifice forms a swirl pattern when exiting the orifice.

Abstract: A dosing unit having a fluid path defined therethrough and including a fluid injector having an inlet tube; an inlet cup sized and shaped for receiving therein at least part of the inlet tube of the fluid injector, the inlet cup including a fluid inlet; an input tube in fluid communication with the inlet cup via the fluid inlet thereof, the input tube configured to receive fluid from a fluid source; and an insert partly disposed in the inlet tube of the fluid injector, the insert at least partly defining a fluid passage. The fluid passage is in fluid communication with the input tube and the inlet tube of the fluid injector and forms part of the fluid path of the dosing unit. The fluid passage includes a portion extending in a direction that is orthogonal to a longitudinal axis of the fluid injector.

Abstract: An attachment assembly for a fluid injector includes a housing having a first end and a second end; a seat disposed within the housing; and a needle in the housing having a first end, the needle movable between a first position in which the first end of the needle provides a sealing engagement with the seat so as to prevent fluid from exiting the second end of the housing, and a second position in which the first end of the needle extends outwardly from the second end of the housing spaced apart from the seat for allowing fluid in the housing to exit through the second end; and a spring member biasing the needle towards the first position to prevent fluid in the housing from exiting the second end. The first end of the housing attaches to the fluid outlet of a fuel injector for providing an integrated injector assembly.

Abstract: A diesel dosing unit (DDU) is disclosed, having a fluid injector assembly. The fluid injector assembly includes a fluid injector and an attachment assembly attached to a downstream end of the fluid injector, the attachment assembly at least partly defining a fluid path in fluid communication with a fluid path of the fluid injector. The DDU further includes a DDU housing in which the injector assembly is disposed, the DDU housing being configured to directly attach to an exhaust pipe of a vehicle. The fluid injector assembly is dimensioned to largely match the dimensions of an existing injector of a reductant delivery unit (RDU) such that the DDU housing utilizes the housing of the existing RDU.

Abstract: A selective catalytic reduction solution having urea, water and gas bubbles contained within the solution. In particular, the solution has a urea content that is present in an amount greater than 31% (m/m) mass fraction of material and gas bubbles in the solution in an amount between about 7% to about 9% of the volume of solution when the solution is at a pressure of about 1 bar absolute. When the selective catalytic reduction solution is pressurized to a range between 6 bar and 7.5 bar, the gas bubbles are in a range between about 1.33% to about 1.07% of the solution when the solution is pressurized. The presence of the gas bubbles provides an expansion volume for the urea solution, if the urea solution begins freezing due to cold temperatures.

Abstract: A fluid injector includes a fluid inlet, a fluid outlet, a fluid path from the fluid inlet to the fluid outlet; a tube; a filter disposed in the tube proximal to the fluid inlet; and a calibration filter tube disposed downstream of the filter. The calibration filter tube includes a first end portion adjacent the filter and an axial throughbore, the throughbore defining at least a portion of the fluid path through the fluid injector. An actuator unit is disposed within the fluid injector and engages a second end of the calibration filter tube. A valve assembly operatively couples to the actuator unit. A position of the calibration filter tube within the tube sets an opening force of the valve assembly. A cap member has a sidewall defining an inner space receiving the filter, and the sidewall contacts and attaches to the first end of the calibration filter tube.

Abstract: A fluid injector for injecting fluid includes a body with a fluid passageway extending from an inlet to an outlet of the fluid injector; a valve seat; a valve element that is selectively engages with the valve seat; and a disc member disposed in the fluid passageway downstream of the valve seat. The disc member includes a plurality of channels defined along a first surface of the disc member, and a plurality of orifices defined through the disc, with each disc member being fluidly coupled to a plurality of channels. The channels fluidly coupled to each channel are in offset relation to each other at the orifice such that fluid flowing through the orifice forms a swirl pattern when exiting the orifice.

Abstract: A reductant dosing unit is disclosed, including a fluid injector having a fluid inlet and a fluid outlet. A flange is disposed proximal to the fluid outlet of the fluid injector and configured to secure to a boss associated with an exhaust path of an internal combustion engine. The flange has a largely flat body portion with a through-bore in fluid communication with the fluid outlet of the fluid injector. The flange further includes an extension which extends from the body portion toward the fluid injector and which is connected to thereto. A thermal isolator is disposed between the fluid outlet of the fluid injector and the flange. The connection between the extension of the flange and the fluid injector includes a hermetic seal, preventing exhaust gases in the exhaust path from passing between the flange extension and the fluid injector. The thermal isolator is only used as a support and thermal isolator.

Abstract: A reductant delivery unit (RDU) for a selective catalytic reduction system, including a housing; a fluid inlet disposed at an upper portion of the housing; a fluid return outlet; a fluid nozzle outlet disposed at a lower portion of the housing; an injector disposed within the housing and configured to receive fluid from the fluid inlet and selectively discharge the fluid from the fluid nozzle outlet; and at least one fluid passageway disposed within or around the housing. The fluid passageway provides fluid communication along a first fluid path between the fluid inlet and the fluid nozzle outlet and along a second fluid path between the fluid inlet and the fluid return outlet so that the same fluid discharged by the injector is also used as a coolant for the RDU.

Abstract: A dosing unit for a diesel exhaust treatment system eliminates heat from the exhaust stream using an electrically operated fluid injector inside a cavity, sized and shaped to receive the electrically operated injector therein and surround the fluid injector in the cavity with engine coolant flowing through the cavity. Continuous welds aid heat transfer between the components.

Abstract: A selective catalytic reduction solution having urea, water and gas bubbles contained within the solution. In particular, the solution has a urea content that is present in an amount greater than 31% (m/m) mass fraction of material and gas bubbles in the solution in an amount between about 7% to about 9% of the volume of solution when the solution is at a pressure of about 1 bar absolute. When the selective catalytic reduction solution is pressurized to a range between 6 bar and 7.5 bar, the gas bubbles are in a range between about 1.33% to about 1.07% of the solution when the solution is pressurized. The presence of the gas bubbles provides an expansion volume for the urea solution, if the urea solution begins freezing due to cold temperatures.