Abstract: Dosing structure (30) supplies diesel fuel to an exhaust passage of a diesel system. The dosing structure includes an electrically operated control valve (31). An inlet tube (45) is coupled with an inlet of the control valve. A first welded joint (6) is between the inlet tube and the control valve. The inlet tube is constructed and arranged to be coupled to a supply of diesel fuel for feeding fuel to the control valve. A dosing valve (32) is constructed and arranged to receive fuel from the control valve and deliver the fuel to the exhaust passage. An extension tube (33) is fluidly coupled between the control valve and the dosing valve to space the control valve from the dosing valve. A second welded joint (62) is between the extension tube and the control valve and a third welded joint (64) is between the extension tube and the dosing valve.

Abstract: A valve structure (20?) is provided for insertion into a boss (22?). The boss includes a threaded bore (46) and at least one key slot (48) therein. The valve structure includes a valve (26) constructed and arranged to control fluid flow, a fitting (24) surrounding at least a portion of the valve with the fitting having external threads (28) for mating with the threaded bore, and anti-rotate structure (34) between the valve and the fitting. The anti-rotate structure is constructed arranged such that when the fitting is rotated into threaded engagement with the boss, at least a portion of the anti-rotate structure engages a surface defining the key slot in the boss, thereby preventing rotation of the valve, with the fitting clamping on the anti-rotate structure and thus the valve.

Abstract: A reductant delivery unit for selective catalytic reduction (SCR) after-treatment for vehicles includes a fluid injector having a fluid inlet and a fluid outlet. The fluid inlet receives a source of urea solution. An injector flange is coupled directly with an end of the fluid injector and has a flange outlet in fluid communication with the fluid outlet of the fluid injector. The flange outlet is associated with an exhaust gas flow path upstream of a SCR catalytic converter with the fluid injector controlling injection of urea solution into the exhaust gas flow path. Internal surface structure that defines the flange outlet includes a conical surface joined with at least one radius surface. The radius surface is constructed and arranged to resist formation of deposits on the internal surface structure due to break down of the urea solution.

Abstract: A reductant delivery unit (10) includes a fluid injector (12) and a flange (20) coupled with the fluid injector. An exhaust boss (28) has a surface (39) defining a through-hole (40) that communicates with a vehicle's exhaust flow path. The flange is coupled to a mounting surface such that the outlet of the fluid injector communicates with the exhaust flow path so as to control injection of urea solution into the exhaust gas flow path. A gasket (32) is sandwiched between the flange and the mounting surface. The gasket has a surface (37) defining a through-hole (38) therein that communicates with the through-hole in the exhaust boss to permit the urea solution to pass from the fluid outlet to the exhaust flow path. Gasket shielding structure (44) covers the surface defining the through-hole in the gasket to prevent the urea solution from contacting the gasket.

Abstract: A reductant delivery unit for selective catalytic reduction (SCR) after-treatment for vehicles includes a solenoid operated fluid injector associated with an exhaust gas flow path upstream of a SCR catalytic converter. The fluid injector has a fluid inlet and a fluid outlet. The fluid inlet receiving a source of reducing agent and the fluid outlet communicating with the exhaust gas flow path so that the fluid injector controls injection of urea solution into the exhaust gas flow path. The fluid injector has an inlet tube for directing the reducing agent between the fluid inlet and the fluid outlet. A shield is fixed with respect to the fluid injector and surrounds at least portions of the fluid injector. A coil heater is integral with the fluid injector and is constructed and arranged, when energized, to inductively heat the inlet tube to thereby heat the reducing agent within the inlet tube.

Abstract: A reductant delivery unit having active cooling which is constructed to have sufficient structural robustness, and to improve corrosion resistance of the assembly, where an attack on the base injector is conceivable with the use of incorrect coolant media. The reductant delivery unit has an upper shield, a lower shield connected to the upper shield, and an inner sleeve. The reductant delivery unit also includes a lower sleeve connected to the inner sleeve and the lower shield. A liquid cooling cavity is formed by the connection between the inner sleeve and the lower shield, the lower sleeve and the lower shield, and the lower sleeve and the inner sleeve. Coolant flows into the liquid cooling cavity to provide a cooling function to an injector partially located within the inner sleeve, and a corrugated portion of the lower sleeve transfers heat away from at least a portion of the injector.

Abstract: A reductant delivery unit for selective catalytic reduction (SCR) after-treatment for vehicles includes a solenoid operated fluid injector associated with an exhaust gas flow path upstream of a SCR catalytic converter. The fluid injector has a fluid inlet and a fluid outlet. The fluid inlet receiving a source of reducing agent and the fluid outlet communicating with the exhaust gas flow path so that the fluid injector controls injection of urea solution into the exhaust gas flow path. The fluid injector has an inlet tube for directing the reducing agent between the fluid inlet and the fluid outlet. A shield is fixed with respect to the fluid injector and surrounds at least portions of the fluid injector. A coil heater is integral with the fluid injector and is constructed and arranged, when energized, to inductively heat the inlet tube to thereby heat the reducing agent within the inlet tube.

Abstract: A sealing device which is used as part of an injector in a reductant delivery unit (RDU), where the RDU is part of a selective catalytic reduction (SCR) system for injecting diesel exhaust fluid (DEF) into an exhaust system, used for controlling exhaust emissions. This invention improves the purging efficiency of the RDU, in addition to improving the sealing performance of the unit by reducing the fluid volume to be evacuated from the injector, and provides an additional sealing barrier to reduce the sealing load of the existing sealing elements. An additional sealing device having a ring seal and a stopper element (also referred to as a “plug”) is pressed into the upper valve body of the injector, which results in a reduced fluid volume that is left behind after a purging event, due to the reduced initial volume at the beginning of the purge.

Abstract: A reductant delivery unit for selective catalytic reduction (SCR) after-treatment for vehicles includes a fluid injector having a fluid inlet and a fluid outlet. The fluid inlet receives a source of urea solution. An injector flange is coupled directly with an end of the fluid injector and has a flange outlet in fluid communication with the fluid outlet of the fluid injector. The flange outlet is associated with an exhaust gas flow path upstream of a SCR catalytic converter with the fluid injector controlling injection of urea solution into the exhaust gas flow path. Internal surface structure that defines the flange outlet includes a conical surface joined with at least one radius surface. The radius surface is constructed and arranged to resist formation of deposits on the internal surface structure due to break down of the urea solution.

Abstract: A reductant delivery unit (RDU) delivers supplied reductant (aqueous urea solution) to the engine exhaust system. The delivered reductant is transformed into ammonia which then reacts with the exhaust oxides of nitrogen in a catalytic environment to produce nitrogen and H20. The reductant must be metered to coincide with the amount of NOx present in the exhaust, and also present sufficient spray quality of the delivered fluid to promote good mixing of the ammonia with the exhaust gas. The RDU is a liquid-cooled, making the RDU suitable for very high temperature environment applications.

Abstract: A compact fuel pressure regulator (10) includes a housing (12) with an interior (13) communicating and inlet opening (16) and an outlet opening (20). The housing defines a valve seat surface (26) in the interior. A cover (22) is provided at an end of the housing and is disposed in the interior. The cover includes a through-hole (24) therein that communicates the outlet opening with the interior. A valve structure (28) is movable within the interior to control fuel flow between the inlet opening and outlet opening. A spring (30) is engaged between the valve structure and the cover so that when pressure of fuel at the inlet opening is greater than a force of the spring, the fuel pushes the valve structure against the bias of the spring and away from the valve seat surface so that fuel flows around a periphery of the valve structure to the outlet opening.

Abstract: A reductant delivery unit (10) includes a fluid injector (12) and a flange (20) coupled with the fluid injector. An exhaust boss (28) has a surface (39) defining a through-hole (40) that communicates with a vehicle's exhaust flow path. The flange is coupled to a mounting surface such that the outlet of the fluid injector communicates with the exhaust flow path so as to control injection of urea solution into the exhaust gas flow path. A gasket (32) is sandwiched between the flange and the mounting surface. The gasket has a surface (37) defining a through-hole (38) therein that communicates with the through-hole in the exhaust boss to permit the urea solution to pass from the fluid outlet to the exhaust flow path. Gasket shielding structure (44) covers the surface defining the through-hole in the gasket to prevent the urea solution from contacting the gasket.

Abstract: A valve structure (20?) is provided for insertion into a boss (22?). The boss includes a threaded bore (46) and at least one key slot (48) therein. The valve structure includes a valve (26) constructed and arranged to control fluid flow, a fitting (24) surrounding at least a portion of the valve with the fitting having external threads (28) for mating with the threaded bore, and anti-rotate structure (34) between the valve and the fitting. The anti-rotate structure is constructed arranged such that when the fitting is rotated into threaded engagement with the boss, at least a portion of the anti-rotate structure engages a surface defining the key slot in the boss, thereby preventing rotation of the valve, with the fitting clamping on the anti-rotate structure and thus the valve.

Abstract: Dosing structure (30) supplies diesel fuel to an exhaust passage of a diesel system. The dosing structure includes an electrically operated control valve (31). An inlet tube (45) is coupled with an inlet of the control valve. A first welded joint (6) is between the inlet tube and the control valve. The inlet tube is constructed and arranged to be coupled to a supply of diesel fuel for feeding fuel to the control valve. A dosing valve (32) is constructed and arranged to receive fuel from the control valve and deliver the fuel to the exhaust passage. An extension tube (33) is fluidly coupled between the control valve and the dosing valve to space the control valve from the dosing valve. A second welded joint (62) is between the extension tube and the control valve and a third welded joint (64) is between the extension tube and the dosing valve.

Abstract: A fuel rail cup is provided with a lead-in volume of one-third a receiving volume of the fuel rail cup that allows insertion of an O-ring mounted on a fuel injector inlet to be inserted at 20 pound-force or less. A method of inserting the fuel injector inlet with an O-ring surrounding the fuel injector inlet into a receiving volume of a fuel rail cup is also provided.

Abstract: A fuel rail cup is provided with a lead-in volume of one-third a receiving volume of the fuel rail cup that allows insertion of an O-ring mounted on a fuel injector inlet to be inserted at 20 pound-force or less. A method of inserting the fuel injector inlet with an O-ring surrounding the fuel injector inlet into a receiving volume of a fuel rail cup is also provided.

Abstract: A mounting arrangement includes a fuel injector, a fuel injector cup, and a fastener. The fuel injector includes a body that defines an interior fuel passage that extends between an inlet and an outlet. The body of the fuel injector also includes first and second exterior grooves. The first exterior groove receives a compliant seal, and the second exterior groove is located between the first groove and the outlet. The fuel injector cup includes an end that defines an aperture through which passes along an axis the inlet of the fuel injector. The fuel injector cup also includes inner and outer surfaces. The inner surface contiguously engages the compliant seal, and the outer surface includes a shoulder that faces generally opposite the end of the fuel injector cup. The fastener includes first and second portions.

Abstract: A a clip for mounting an elongated fuel rail with respect to an internal combustion engine. The fuel rail extends along a longitudinal axis and includes a mounting portion at an intermediate positon along the longitudinal axis, and the internal combustion engine includes a recess. The clip comprises a first portion adapted to engage the fuel rail, and a second portion adapted to be slidably received in the recess along a generally transverse axis with respect to the longitudinal axis. The first portion partially surrounds the longitudinal axis and is adapted to engage the mounting portion so as to prevent relative displacement along the longitudinal axis. The second portion is adapted to be releasably retained with respect to the recess.

Abstract: A mounting arrangement includes a fuel injector, a fuel injector cup, and a fastener. The fuel injector includes a body that defines an interior fuel passage that extends between an inlet and an outlet. The body of the fuel injector also includes first and second exterior grooves. The first exterior groove receives a compliant seal, and the second exterior groove is located between the first groove and the outlet. The fuel injector cup includes an end that defines an aperture through which passes along an axis the inlet of the fuel injector. The fuel injector cup also includes inner and outer surfaces. The inner surface contiguously engages the compliant seal, and the outer surface includes a shoulder that faces generally opposite the end of the fuel injector cup. The fastener includes first and second portions.

Abstract: A a clip for mounting an elongated fuel rail with respect to an internal combustion engine. The fuel rail extends along a longitudinal axis and includes a mounting portion at an intermediate positon along the longitudinal axis, and the internal combustion engine includes a recess. The clip comprises a first portion adapted to engage the fuel rail, and a second portion adapted to be slidably received in the recess along a generally transverse axis with respect to the longitudinal axis. The first portion partially surrounds the longitudinal axis and is adapted to engage the mounting portion so as to prevent relative displacement along the longitudinal axis. The second portion is adapted to be releasably retained with respect to the recess.