Diesel exhaust fluid tank venting system

Description of equivalent WO 2012099963 A2

DIESEL EXHAUST FLUID TANK VENTING SYSTEM PRIORITY CLAIM

0002[0001] This application claims priority under 35 U.S.C. § 119(e) to U.S.

0003Provisional Application Serial No. 61/433,639, filed January 18, 2011, which is expressly incorporated by reference herein.

BACKGROUND

0005[0002] The present disclosure relates to systems for controlling venting of fluid vapors from a diesel exhaust fluid tank, and particularly to a multiple valve tank venting system. More particularly, the present disclosure relates to a tank-mounted tank venting control valve.

SUMMARY

0007[0003] An exhaust after-treatment system associated with a diesel engine includes a diesel exhaust fluid storage unit. The storage unit includes a diesel exhaust fluid tank and a vent system coupled to the tank and configured to regulate flow of air into the tank and fluid vapor out of the tank.

0008[0004] In illustrative embodiments, the vent system includes a tank venting control unit arranged to extend into an interior region of the tank through a single unit- mount aperture formed in the top wall of the tank. The tank venting control unit includes a fill-limit valve module located, for example, in the tank and exposed to fluid vapor extant in the tank, a breather-valve module located outside the tank and exposed to the atmosphere, and a vapor-transfer module interposed between and in fluid communication with each of the fill-limit valve and breather-valve modules.

0009[0005] In illustrative embodiments, the vapor- transfer module is formed to include separate first and second fluid-conducting passageways. The first fluid- conducting passageway conducts fluid from the fill-limit valve module to a tank filler neck via a recirculation line. The second fluid-conducting passageway is arranged to couple the fill-limit valve and breather-valve modules in fluid communication. These passageways conduct fluid to vent the interior region of the tank during certain tank conditions.

0010[0006] The first fluid-conducting passageway formed in the vapor-transfer module normally carries fluid vapor discharged from the fill-limit valve module (and the interior region of the tank) to a recirculation line coupled to a tank filler neck during normal use and refilling of the tank until the level of diesel exhaust fluid in the interior region of the tank has risen to a fill-limit valve closure level causing a buoyant fill-limit valve included in the fill-limit valve module to float upwardly on the rising fluid and close an inlet opening into the first fluid-conducting passageway. Such closure causes tank pressure to rise and forces diesel exhaust fluid up the tank filler neck to trigger a shutoff mechanism included in a fluid-dispensing pump nozzle used to discharge fluid from a diesel exhaust fluid supply into the tank filler neck.

0011[0007] The second fluid-conducting passageway formed in the vapor-transfer module conducts fluid vapor in the interior region of the tank and extant in the fill-limit valve module to an underside of a semi-permeable membrane included in the breather- valve module and configured to have a topside exposed to atmospheric air admitted into an interior chamber formed in the breather-valve module. The semi-permeable membrane is configured to provide breathing means for regulating discharge of fluid vapor through the membrane to the atmosphere and also for regulating admission of atmospheric air through the membrane into the interior region of the tank to dissipate any unwanted negative pressure (i.e., vacuum) developed in the interior region of the tank without exposing the diesel exhaust fluid in the tank to enough air to cause that diesel exhaust fluid to change from a liquid state to an unwanted crystalline state.

0012[0008] Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

0014[0009] The detailed description particularly refers to the accompanying figures in which:

0015[0010] Fig. 1 is a diagrammatic view of an illustrative exhaust after-treatment system associated with a diesel engine and comprising a diesel exhaust fluid (DEF) storage unit in accordance with the present disclosure and also showing that the system includes an exhaust pipe mating with an exhaust output port formed in the diesel engine and comprising several conduits, an upstream diesel particulate filter (FILTER), and a downstream Selective Catalytic Reduction (SCR) Converter (CONVERTER), a diesel exhaust fluid supply coupled to a fluid-dispensing pump nozzle by a hose and used to supply diesel exhaust fluid to a DEF tank included in the DEF storage unit, and DEF transfer means for injecting a metered flow of diesel exhaust fluid discharged from the DEF tank into a mixing zone provided in one of the exhaust pipe conduits located downstream of the filter and upstream of the converter;

0016[0011] Fig. 2 is an exploded perspective assembly view of a DEF tank venting control unit in accordance with the present disclosure that is adapted to be mounted in a single unit-mount aperture formed in a top wall of the DEF tank and is configured to vent fluid vapor in a controlled manner either to a tank filler neck via a recirculation line or to the atmosphere and showing that the DEF tank venting control unit comprises (from left to right and bottom to top) a float, a closure adapted to be mounted to an upper end of the float, a body formed to include a sleeve sized to extend into an interior region of the DEF tank through the single unit-mount aperture, a large-diameter first vapor-discharge tube coupled to an upper right portion of the sleeve, a small-diameter second vapor-discharge tube coupled to an upper left portion of the sleeve, a round semi-permeable membrane located above the body, a membrane- support frame, and a round vent cap located above the membrane- support frame and configured to mate with a top end of the body;

0017[0012] Fig. 3 is a perspective view of an illustrative DEF tank venting control unit in accordance with the present disclosure after the components shown in Fig. 2 have been assembled;

0018[0013] Fig. 4 is an enlarged top view of a tank breather unit comprising the round semi-permeable membrane and the membrane-support frame shown in Fig. 2:

0019[0014] Figs. 5-7 show operation of a fill-limit vent valve comprising a lower portion of the body and the closure shown in Fig. 2 to close a vapor-outlet port formed in the body and located above the closure during refilling of the DEF tank with more diesel exhaust fluid so as to create pressure conditions in the DEF tank and nozzle shut-off conditions in the tank filler neck to trigger a shutoff mechanism in a fluid-dispensing pump nozzle so as to shut off the flow of diesel exhaust fluid into the DEF tank from the diesel exhaust fluid supply at the proper time when the tank is full;

0020[0015] Fig. 5 is a diagrammatic view showing a DEF storage unit in accordance with the present disclosure along with a DEF delivery system located to the right of the DEF storage unit and a DEF transfer system located under the DEF storage unit and showing (in section) the DEF tank venting control unit of Fig. 2 mounted in a unit- mount aperture formed in the top wall of the DEF tank and that the DEF delivery system is disabled and no diesel exhaust fluid is flowing into the interior region of the DEF tank through the tank filler neck and also showing that the DEF tank venting control unit includes a fill-limit valve module located inside the interior region of the DEF tank, a breather- valve module located outside the DEF tank, and a vapor-transfer module located between the fill-limit valve module and the breather- valve module and formed to include (1) a first fluid-conducting passageway for conducting fluid vapor from the interior region of the DEF tank to a vapor-recirculation line coupled to the tank filler neck and (2) a separate second fluid-conducing passageway for conducting fluid vapor from the interior region of the DEF tank to the underside of the semi-permeable membrane included in the tank-breather unit in the breather-valve module and for conducting any fluid (e.g., atmospheric air) that has passed from the atmosphere and through the semi-permeable membrane into the fill-limit valve module for delivery into the interior region of the DEF tank;

0021[0016] Fig. 6 is a diagrammatic view similar to Fig. 5 showing diesel exhaust fluid flowing from the diesel exhaust fluid supply into the interior region of the DEF tank when the DEF delivery system is enabled and the fluid-dispensing pump nozzle is on;

0022[0017] Fig. 7 is a diagrammatic view similar to Figs. 5 and 6 showing that the level of diesel exhaust fluid in the DEF tank has risen to a fill-limit vent valve closure level to raise the float valve buoyantly in the diesel exhaust fluid to cause the closure to close the vapor-outlet port associated with the first fluid-conducting passageway formed in the vapor-transfer module and thereby block flow of pressurized fluid vapor from the interior region of the DEF tank to the tank filler neck through a recirculation line coupled to each of the vapor-transfer module and the tank filler neck;

0023[0018] Fig. 8 is a DEF tank venting control unit in accordance with a second embodiment of the present disclosure;

0024[0019] Fig. 9 is an exploded perspective assembly view of components that can be assembled to produce the DEF tank venting control unit of Fig. 8;

0025[0020] Fig. 10 is an enlarged top view of a tank breather unit comprising the round semi-permeable membrane and the membrane-support frame shown in Fig. 9:

0026[0021] Fig. 11 is a sectional view of a DEF storage unit showing portions of the fill-limit valve module, vapor-transfer module, and breather- valve module included in the DEF tank venting control unit of Fig. 8 while the fill-limit valve remains in an opened position; and

0027[0022] Fig. 12 is a view similar to Fig. 11 after the fill-limit valve of Fig. 11 has been moved to assume a closed position. DETAILED DESCRIPTION

0028[0023] A diesel exhaust fluid (DEF) storage unit 10 in accordance with the present disclosure is used to supply a metered amount of diesel exhaust fluid 12 to a mixing zone 14 in an exhaust pipe 16 coupled to a diesel engine 18 as suggested diagrammatically in Fig. 1. In mixing zone 14, diesel exhaust fluid 12 mixes with an exhaust product (i.e., ΝΟχ) 20 flowing through exhaust pipe 16 away from diesel engine 18 to produce a mixture 22 that reacts with a suitable catalyst 24 provided in a downstream Selective Catalytic Reduction (SCR) converter 26 to cause water and nitrogen to be discharged from a downstream end 28 of exhaust pipe 16 so as to minimize ΝΟχ emissions downstream from diesel engine 18.

0029[0024] Diesel exhaust fluid 12 is a mixture of ionized water and urea. Diesel exhaust fluid 12 is discharged as a liquid into mixing zone 14 formed in exhaust pipe 16 to produce a ΝΟχ/DEF mixture 22 that is admitted into a downstream SCR converter 26 as suggested in Fig. 1. Liquid urea in diesel exhaust fluid 12 crystallizes when exposed to a sufficient amount of air so DEF storage unit 10 is a substantially sealed system designed in accordance with the present disclosure to store and maintain diesel exhaust fluid 12 in a liquid state until it is discharged from DEF tank 30 and delivered in metered amounts to mixing zone 14 in exhaust pipe 16.

0030[0025] DEF storage unit 10 includes a diesel exhaust fluid (DEF) tank 30 and a

0031DEF tank venting control unit 40 formed to include, in series, a fill-limit valve module 41, a vapor-transfer module 42, and a breather-valve module 43 as shown diagrammatically in Fig. 1 and illustratively in Figs. 2 and 5-7. DEF tank venting control unit 40 is mounted in a single unit-mount aperture 35 formed in DEF tank 30 as suggested in Figs. 1 and 5.

0032[0026] Fill-limit valve module 41 is located substantially inside DEF tank 30 as suggested in Fig. 5. Fill-limit value module 41 provides means for controlling flow of fluid vapor 12V (e.g. ammonia gas) from an interior region 32 formed in DEF tank 30 to a recirculation line 34 coupled in fluid communication to vapor-transfer module 42 and a tank filler neck 36 coupled to DEF tank 30 to control shutoff of a fluid-dispensing pump nozzle 54 included in a diesel exhaust fluid (DEF) delivery system 50 during a tank- refilling activity after DEF tank 30 is full.

0033[0027] Breather-valve module 43 is located substantially outside DEF tank 30 as suggested in Fig. 5. Breather-valve module 43 includes a semi-permeable membrane 72 configured to provide breathing means for regulating flow of air from atmosphere 11 into interior region 32 of DEF tank 30 through vapor-transfer and fill-limit valve modules 42, 41 to maintain a selected positive vapor pressure in interior region 32 without exposing diesel exhaust fluid 12 to enough air to change from a normal liquid state to an unwanted crystalline state and also for regulating discharge of fluid vapor 12V from interior region 32 of DEF tank to atmosphere 11 through fill-limit valve and vapor-transfer modules 41,

003442 to block development of a vapor pressure in interior region 32 in excess of a selected maximum pressure.

0035[0028] Vapor-transfer module 42 is interposed between fill-limit valve and breather- valve modules 41, 43 as suggested diagrammatically in Fig. 1 and illustratively in Fig. 5 and is formed to include first fluid-conducting passageway 421 and, for example, four second fluid-conducting passageways 422A-D as suggested in Fig. 2. Vapor-transfer module 42 is configured to conduct fluid vapor 12V from fill-limit valve module 41 through a first fluid-conducting passageway 421 to recirculation line 34 and to conduct air and fuel vapor 12V through a second fluid-conducting passageway 422A between fill- limit valve module 41 and breather-valve module 43.

0036[0029] DEF tank venting control unit 40 is arranged to extend into interior region

003732 of DEF tank 30 through a single unit-mount aperture 35 formed in a top wall 37 of DEF tank 30 as suggested in Figs. 1 and 5. Fill-limit valve module 41 of DEF tank venting control unit 40 is located substantially in interior region 32 of DEF tank 30 and is exposed to diesel exhaust fluid 12 and fluid vapor 12V extant in interior region 32 as suggested in Fig. 5. Breather-valve module 43 of unit 40 is located outside of interior region 32 in an illustrative embodiment and is formed to include an interior chamber 43C in fluid communication with atmosphere 11 as suggested in Fig. 5.

0038[0030] Breather-valve module 43 includes a semi-permeable membrane 72 arranged to communicate fluidly with each of second fluid-conducting passageway 422A formed in vapor-transfer module 42 and interior chamber 43C formed in breather- valve module 43. Semi-permeable membrane 72 is configured to (1) block flow of liquid fluid 12 from second fluid-conducting passageway 422A into interior chamber 43C, (2) allow some fluid vapor 12V to pass from second fluid-conducting passageway 422A to atmosphere 11 through interior chamber 43C as long as a positive pressure is maintained in interior region 32 of DEF tank 30, and (3) allow some air to pass from atmosphere 11 into interior region 32 of DEF tank 30 in sequence through interior chamber 43C, second fluid-conducting passageway 422A, and the fill-limit valve module 41 to dissipate any unwanted negative pressure (i.e., vacuum) that might develop in interior region 32 of DEF tank 30 owing to exposure of DEF tank 30 to various external environmental conditions such as, for example, cool evening temperatures and without causing crystallization of the liquid diesel exhaust fluid 12 stored in DEF tank 30.

0039[0031] Tank venting control unit 40 includes (in an illustrative first embodiment) a body 60 and a fill-limit vent valve 62 comprising a float 64 and a closure 66 coupled to an upper portion of float 64 and arranged to move up and down on liquid diesel exhaust fluid 12 admitted into a float chamber 68 formed in a lower portion 60L of body 60 to receive float 64 therein as suggested in Figs. 2 and 5. A middle portion 60M of body 60 is formed to include first and second fluid-conducting passageways 421, 422A as suggested in Figs. 2 and 5. An upper portion 60U of body 60 is formed to include interior chamber 43C as suggested in Figs. 2 and 5. In an illustrative embodiment, body 60 includes a sleeve 600 defining lower, middle, and upper portions 60L, 60M, and 60U of body 60, a first vapor- discharge tube 601 coupled to middle portion 60M and formed to include a portion of first fluid-conducting passageway 421 therein, and a second fluid-discharge tube 602 coupled to upper portion 60U and formed to include a fluid-conducting passageway 603 placed in fluid communication with each of atmosphere 11 and interior chamber 43C as also suggested in Figs. 2 and 5.

0040[0032] Tank venting control unit 40 also includes a tank breather unit 70 comprising a semi-permeable membrane 72 and a membrane- support frame 74 as shown, for example, in Figs. 2, 4, and 5. In an illustrative embodiment shown in Fig. 4, tank breather unit 70 is included in breather- valve module 43 and is coupled to a membrane housing formed to include interior chamber 43C and defined by upper portion 60U in body 60 to cause semi-permeable membrane 72 to form a vapor-flow partition having an underside 72U in fluid communication with fluid vapor 12V extant in vapor-transfer module 42 (and specifically in second fluid-conducting passageway 422A) and having a topside 72T in fluid communication with atmospheric air extant in interior chamber 43C of breather- valve module 43. A vent cap 76 is coupled to a top end of upper portion 60U in body 60 and arranged to cooperate with tank breather unit 70 to form interior chamber 43C therebetween as suggested in Fig. 5.

0041[0033] Fill-limit vent valve 64 includes a base 641, an closure support 642 coupled to an upper end of base 641, and a closure retainer 643 coupled to an upper end of closure support 642 as shown, for example, in Fig. 2. Fill-limit vent valve 64 also includes a pair of valve retainers 644 coupled to a lower end of base 641 and a pair of valve guides 645 also coupled to the lower end of base 641 as suggested in Fig. 2. [0034] Closure 66 is an annular disk made of a suitable sealing material as shown, for example, in Fig. 2. Closure retainer 643 is an upstanding post in an illustrative embodiment that is arranged to extend upwardly through a center hole formed in closure 66 as suggested in Figs. 2 and 5 so as to retain closure 66 in a stationary position on a closure-support plate 646 included in closure support 642 of fill-limit vent valve 64.

0042[0035] Lower portion 601 of body 60L is formed to include a float chamber 68 sized to receive a fill-limit valve 62 therein as suggested in Fig. 5. Lower portion 60L is also formed to include first and second vent apertures 611 and 612 located near top wall 37 of DEF tank 30 and arranged to allow fuel vapor 12V and air to flow therethrough between interior region 32 of DEF tank and float chamber 60 of lower portion with fluid access to first and second fluid-conducting passageways 421, 422A formed in vapor- transfer module 42 as suggested in Figs. 2 and 5.

0043[0036] Lower portion 60L is also formed to include a retainer-receiver slot 644S for each of the valve retainers 644 included in fill-limit vent valve 64 and a guide-received slot 645S for each of valve guides 645 as suggested in Figs. 2 and 3. Each valve retainer 644 provides means for retaining float 64 in float chamber 68 while allowing up-and-down movement of float 64 in float chamber 68 during rise and fall of diesel exhaust fluid 12 in interior region of DEF tank 30 as suggested in Figs. 5-7. Each valve guide 645 is constrained to move up-and-down in a companion guide-receiver slot 645S to block rotation of fill-limit vent valve 62 about a central vertical axis during up-and-down movement of fill-limit vent valve 62 along that central vertical axis as suggested Figs. 5-7.

0044[0037] A mount fixture 71 is coupled to an exterior portion of vapor-transfer module 42 as suggested in Figs. 2 and 3. Mount fixture 71 is configured to mate with top wall 37 of DEF tank 30 in any suitable manner to maintain lower portion 60L of body 60 in a suspended position in interior region 32 of DEF tank 30 as suggested in Figs. 5-7. In that suspended position, float 64 is exposed to diesel exhaust fluid 12 extant in interior region 32. Fluid vapor 12V extant in interior region 32 can flow into float chamber 68 formed in lower portion 60L of body 60 through first and second vent apertures 611, 612 formed in lower portion 60L. In an illustrative embodiment, mount fixture 71 is ring- shaped and is positioned to lie between vent apertures 611, 612 and first fluid-discharge tube 601 as suggested in Fig. 3.

0045[0038] An illustrative interior configuration of vapor-transfer module 42 is shown in Figs. 2 and 5. Vapor- transfer module includes an endless outer wall 60M arranged to extend between fill-limit valve module 41 and breather-valve module 43 as suggested in Figs. 2 and 5. Interior tube 420 and fins 421, 422, 423, and 424 cooperate to form four separate second fluid-conducting passageways 422A, B, C, and D as suggested in Fig. 2. Each of fins 421-424 extends from interior tube 420 in a radially outward direction in uniform circumferentially spaced-apart relation to one another to mate with endless outer wall 60M included in sleeve 600 as suggested in Fig. 2. Although only one of the second fluid-conducting passageways 422A is shown in Figs. 5-7, the other three second fluid- conducting passageways 422 B-D also lie in fluid communication with float chamber 68 and underside 72V of semi-permeable membrane 72 as suggested in Fig. 2.

0046[0039] Membrane-support frame 74 includes a mount ring 740 and cross-shaped retainer 741 coupled at outer ends thereof to mount right 74 as shown, for example, in Fig. 2. Cross-shaped retainer 741 is arranged to lie in confronting and mating relation to the topside 72T of semi-permeable membrane 72 as suggested in Figs. 2 and 4. The underside 72U of semi-permeable membrane 72 is arranged to lie in confronting and mating relation to upwardly facing edges of interior tube 420 and fins 421-424 as suggested in Fig. 2.

0047[0040] An illustrative exhaust after-treatment system 100 is shown

0048diagrammatically in Fig. 1. System 100 is associated with diesel engine 10 and comprises DEF storage unit 10.

0049[0041] Exhaust pipe 16 is configured to mate with and receive exhaust product 22 discharged from diesel engine 18 through an exhaust output part 18P formed in diesel engine 18 as suggested in Fig. 1. Exhaust pipe 16 comprises, in series, an upstream conduit 161, a diesel particulate filter 25, a midstream conduit 162, a selective catalytic reduction (SCR) converter 26, and a downstream conduit 163 as suggested in Fig. 5. Exhaust product 20 discharged from diesel engine 18 and flowing through upstream exhaust conduit 161 comprises nitrogen oxides (NO_x) and particulate matter (PM). The particulate matter is trapped in diesel particulate trap 25. Owing to operation of converter 26 and metered discharge of diesel exhaust fluid 12 into mixing zone 14 in midstream conduit 162, filtered exhaust product 21 flowing away from diesel particulate trap 25 through midstream conduit 162 is converted in SCR converter 26 to water and nitrogen for discharge from exhaust pipe 16 through downstream conduit 163 as suggested in Fig. 1.

0050[0042] Diesel exhaust fluid (DEF) transfer means 110 is provided for injecting a metered flow of diesel exhaust fluid 12 discharged from DEF tank 30 into the mixing zone 14 formed in midstream conduit 162 of filler neck 16 as suggested in Fig. 1. In illustrative embodiments, DEF transfer means comprises, in series, a discharge conduit 111, a fluid pump 112, a fluid meter 113, and a fluid-discharge nozzle 114 coupled in fluid

0051communication to mixing zone 14 as suggested in Fig. 1. In illustrative embodiments, the diesel exhaust fluid 12 discharged into mixing zone 14 hydrolyzes into ammonia gas (NH₃) which mixes with flowing exhaust product 20 to produce a mixture 22 that flows into SCR converter 26. Ammonia (NH₃) and Nitrogen Oxides (NO_x) react with the catalyst 24 provide in SCR converter 26 to form nitrogen and water.

0052[0043] During tank refilling activity (before shutoff), fluid-dispensing pump nozzle 54 is on and dispenses liquid diesel exhaust fluid 12 into interior region 32 of DEF tank 30 as suggested in Fig. 6. Fluid level rises in interior region 32 to displace air and fuel vapor exhaust in interior region 32. Fuel vapor 12V exits interior region 32 through first and second vent apertures formed in body 60 and flows through float chamber 68 and first fluid-conducting passageway 421 to recirculation line 34 and tank filler neck 36.

0053[0044] As suggested in Fig. 7 (at shutoff), float 64 has risen in float chamber 68 to cause closure 66 to close the aperture opening into first fluid-conducting passageway 421. This closure increases pressure in interior region 32 of DEF tank 30 and provides shutoff for DEF delivery system 50 in a normal way.

0054[0045] A breathing operation begins in breather-valve module 43 (after shutoff) using semi-permeable membrane 72 in breather valve unit 70. Semi-permeable membrane 72 restricts discharge of fluid vapor 12V and liquid diesel exhaust fluid 12 to atmosphere 11 through chamber 43C but allows DEF tank 30 to breath so as to minimize unwanted high-pressure and negative-pressure conditions that might otherwise develop in DEF tank 30 under certain operating conditions. Air and fluid vapor 12V are able to flow between atmosphere 11 and interior region 32 of DEF tank 30 in accordance with predetermined flow criteria established by design of semi-permeable membrane 72 via the second fluid- conducting passageways 422A-D during normal operating conditions of system 100.

0055[0046] A DEF tank venting control unit 140 in accordance with a second embodiment of the present disclosure is shown in Figs. 8-12. Unit 140 includes a semipermeable membrane 72 as suggested in Fig. 9.

0056[0047] One difference between the embodiments shown in Figs. 8-12 and in

0057Figs. 1-7 is that tank venting control unit 140 shown in Figs. 8-12 includes means 100 for blocking fluid communication between first fluid-conducting passageway 421 and semi-permeable membrane 72 as suggested in Figs. 11 and 12. In an illustrative embodiment, a wall is located in vapor-transfer module 42 to provide means 100.