DE-102025146243-A1 - Exhaust gas aftertreatment system with filter cartridge assembly

DE102025146243A1DE 102025146243 A1DE102025146243 A1DE 102025146243A1DE-102025146243-A1

Abstract

A filter cartridge assembly for an aftertreatment unit comprises a diesel particulate filter assembly and a diesel oxidation catalyst assembly. The diesel particulate filter assembly includes a diesel particulate filter housing and a diesel particulate filter substrate assembly. The diesel particulate filter housing comprises a first cylindrical body and a first arcuate flange extending from an edge of the first cylindrical body. The diesel oxidation catalyst assembly comprises a diesel oxidation catalyst housing and a diesel oxidation catalyst substrate assembly. The diesel oxidation catalyst housing comprises a second cylindrical body and a second arcuate flange extending from an edge of the second cylindrical body. The second arcuate flange is detachably connected to the first arcuate flange to detachably connect the diesel oxidation catalyst housing to the diesel particulate filter housing.

Inventors

Daniel J. Hill
Andrew Critchley
Paul David Thompson

Assignees

CUMMINS EMISSION SOLUTIONS INC.

Dates

Publication Date: 20260513
Application Date: 20251110
Priority Date: 20241113

Claims (20)

Filter cartridge assembly for an aftertreatment unit, the filter cartridge assembly comprising: a diesel particulate filter assembly comprising: a diesel particulate filter housing comprising: a first cylindrical body and a first arcuate flange extending from an edge of the first cylindrical body, wherein the edge of the first cylindrical body and the lateral edges of the first arcuate flange together form a first opening, and a diesel particulate filter substrate assembly arranged within the first cylindrical body; and a diesel oxidation catalyst assembly comprising: a diesel oxidation catalyst housing comprising: a second cylindrical body and a second arcuate flange extending from an edge of the second cylindrical body, the second arcuate flange being detachably connected to the first arcuate flange to detachably connect the diesel oxidation catalyst housing to the diesel particulate filter housing, the edge of the second cylindrical body and the lateral edges of the second arcuate flange together forming a second opening, and a diesel oxidation catalyst substrate assembly arranged within the second cylindrical body.
Filter cartridge assembly according to Claim 1 , wherein a first radius of curvature of the first arc-shaped flange is 102% to 108% of a second radius of curvature of the second arc-shaped flange, such that parts of the second arc-shaped flange are accommodated within the first arc-shaped flange.
Filter cartridge assembly according to Claim 1 or 2 , further comprising: a fastening element; wherein: the first arcuate flange has a first opening; the second arcuate flange has a second opening which is aligned with one of the first openings; and the fastening element is received by the first opening and the second opening to detachably connect the diesel oxidation catalyst housing to the diesel particulate filter housing.
Filter cartridge assembly according to one of the preceding claims, wherein: the diesel particulate filter assembly further comprises a first sealing assembly with a first outer diameter; and the diesel oxidation catalyst assembly further comprises a second sealing arrangement with a second outer diameter, wherein the second outer diameter is smaller than the first outer diameter.
Filter cartridge assembly according to any one of the preceding claims, wherein: the first cylindrical body comprises: a diesel particulate filter body in which the diesel particulate filter substrate assembly is arranged, and a first annular body connected to the diesel particulate filter body, the first annular body defining the edge of the first cylindrical body; and the second cylindrical body comprises: a diesel oxidation catalyst body, the diesel oxidation catalyst substrate assembly arranged within the diesel oxidation catalyst body, and a second annular body connected to the diesel oxidation catalyst body, the second annular body defining the edge of the second cylindrical body.
Filter cartridge assembly according to one of the preceding claims, wherein: the diesel particulate filter assembly further comprises a first sealing assembly with a first outer diameter, wherein the first sealing assembly is positioned on an outer surface of the diesel particulate filter body; and the diesel oxidation catalyst assembly further comprises a second sealing assembly with a second outer diameter, wherein the second outer diameter is smaller than the first outer diameter and the second sealing assembly is positioned on an outer surface of the second annular body.
Aftertreatment unit for an exhaust aftertreatment system, wherein the aftertreatment unit comprises: an aftertreatment housing defining a cavity; and the filter cartridge assembly according to one of the Claims 1 until 6 , which is received by the cavity; wherein: the diesel particulate filter assembly further comprises a first sealing assembly configured to be in contact with a first inner surface of the cavity, such that a first seal is formed between the first inner surface and the diesel particulate filter assembly; the diesel oxidation catalyst assembly further comprises a second sealing assembly configured to be in contact with a second inner surface che of the cavity is in contact, so that a second seal is formed between the second inner surface and the diesel oxidation catalyst assembly, and a first diameter of the first inner surface is larger than a second diameter of the second inner surface.
Aftertreatment unit for an exhaust aftertreatment system, wherein the aftertreatment unit comprises: an aftertreatment housing defining a cavity; the filter cartridge assembly according to one of the Claims 1 until 6 , wherein the filter cartridge assembly is arranged within the cavity; and a sampling tube connected to the aftertreatment housing, the sampling tube extending into the cavity and through the first opening and the second opening and being configured to collect exhaust gases from the area between the diesel particulate filter substrate assembly and the diesel oxidation catalyst substrate assembly.
Filter cartridge assembly according to one of the Claims 1 until 6 , further comprising: the edge of the first cylindrical body and the side edges of the first arcuate flange together define a third opening; and the edge of the second cylindrical body and the side edges of the second arcuate flange together define a fourth opening.
Filter cartridge assembly for an aftertreatment unit, the filter cartridge assembly comprising: a diesel particulate filter assembly comprising: a diesel particulate filter housing comprising: a first cylindrical body and a first arcuate flange extending from an edge of the first cylindrical body, the first arcuate flange having a first opening, and a diesel particulate filter substrate assembly arranged within the first cylindrical body; a diesel oxidation catalyst assembly comprising: a diesel oxidation catalyst housing comprising: a second cylindrical body and a second arcuate flange extending from an edge of the second cylindrical body, the second arcuate flange having a second opening aligned with one of the first openings, and a diesel oxidation catalyst substrate assembly arranged within the second cylindrical body; and a fastening element that is received by the first opening and the second opening to detachably connect the diesel oxidation catalyst housing to the diesel particulate filter housing.
Filter cartridge assembly according to Claim 10 , wherein a first radius of curvature of the first arc-shaped flange is 102% to 108% of a second radius of curvature of the second arc-shaped flange, such that parts of the second arc-shaped flange are incorporated within the first arc-shaped flange.
Aftertreatment unit for an exhaust aftertreatment system, wherein the aftertreatment unit comprises: an aftertreatment housing defining a cavity; and the filter cartridge assembly according to Claim 10 or 11 , which is received by the cavity, wherein: the diesel particulate filter assembly further comprises a first sealing assembly configured to be in contact with a first inner surface of the cavity, such that a first seal is formed between the first inner surface and the diesel particulate filter assembly, the diesel oxidation catalyst assembly further comprises a second sealing assembly configured to be in contact with a second inner surface of the cavity, such that a second seal is formed between the second inner surface and the diesel oxidation catalyst assembly, and a first diameter of the first inner surface is larger than a second diameter of the second inner surface.
Aftertreatment unit for an exhaust aftertreatment system, wherein the aftertreatment unit comprises: an aftertreatment housing defining a cavity; the filter cartridge assembly according to Claim 10 or 11 , wherein the filter cartridge assembly is arranged within the cavity; and a sampling tube connected to the aftertreatment housing, the sampling tube extending into the cavity and between the first arcuate flange and the second arcuate flange and configured to collect exhaust gases from the area between the diesel particulate filter substrate assembly and the diesel oxidation catalyst substrate assembly.
Filter cartridge assembly according to Claim 10 or 11 , where: the first cylindrical body comprises: a diesel particulate filter body, the diesel particulate filter substrate assembly arranged within the diesel particulate filter body, and a first annular body connected to the diesel particulate filter body, wherein the first annular body defines the edge of the first cylindrical body; and the second cylindrical body comprises: a diesel oxidation catalyst body, the diesel oxidation catalyst substrate assembly arranged within the diesel oxidation catalyst body, and a second annular body connected to the diesel oxidation catalyst body, wherein the second annular body defines the edge of the second cylindrical body.
Filter cartridge assembly according to one of the Claims 10 , 11 and 14 , wherein: the diesel particulate filter assembly further comprises a first sealing assembly with a first outer diameter; and the diesel oxidation catalyst assembly further comprises a second sealing arrangement with a second outer diameter, wherein the second outer diameter is smaller than the first outer diameter.
Filter cartridge assembly for an aftertreatment unit, the filter cartridge assembly comprising: a diesel particulate filter assembly comprising: a diesel particulate filter housing comprising: a diesel particulate filter housing comprising: a first cylindrical body and a first arcuate flange extending from an edge of the first cylindrical body, a diesel particulate filter substrate assembly arranged within the first cylindrical body, and a first sealing assembly having a first outer diameter, and a diesel oxidation catalyst assembly comprising: a diesel oxidation catalyst housing comprising: a second cylindrical body and a second arcuate flange extending from an edge of the second cylindrical body, the second arcuate flange being detachably connected to the first arcuate flange to detachably connect the diesel oxidation catalyst housing to the diesel particulate filter housing, a diesel oxidation catalyst substrate assembly arranged within the second cylindrical body, and a second sealing assembly having a second Outer diameter, where the second outer diameter is smaller than the first outer diameter.
Aftertreatment unit for an exhaust aftertreatment system, wherein the aftertreatment unit comprises: an aftertreatment housing defining a cavity; and the filter cartridge assembly according to Claim 16 , which is received by the cavity; wherein: the first sealing assembly is configured to contact a first inner surface of the cavity, such that a first seal is formed between the first inner surface and the diesel particulate filter assembly, the second sealing assembly is configured to contact a second inner surface of the cavity, such that a second seal is formed between the second inner surface and the diesel oxidation catalyst assembly, and a first diameter of the first inner surface is larger than a second diameter of the second inner surface.
Filter cartridge assembly according to Claim 16 , wherein a first radius of curvature of the first arc-shaped flange is 102% to 108% of a second radius of curvature of the second arc-shaped flange, including such that parts of the second arc-shaped flange are incorporated within the first arc-shaped flange.
Aftertreatment unit for an exhaust aftertreatment system, wherein the aftertreatment unit comprises: an aftertreatment housing defining a cavity; the filter cartridge assembly according to Claim 16 , wherein the filter cartridge assembly is arranged within the cavity; and a sampling tube connected to the aftertreatment housing, the sampling tube extending into the cavity and between the first arcuate flange and the second arcuate flange and configured to collect exhaust gases from the area between the diesel particulate filter substrate assembly and the diesel oxidation catalyst substrate assembly.
Filter cartridge assembly according to Claim 1 , further comprising: a fastening element; wherein: the first arcuate flange has a first opening; the second arcuate flange has a second opening which is aligned with one of the first openings; and the fastening element is received by the first opening and the second opening in order to to detachably connect the diesel oxidation catalyst housing to the diesel particulate filter housing.

Description

CROSS-REFERENCE TO RELATED REGISTRATION This application claims precedence over the preliminary application submitted on 13 November 2024. US application no. 63/719,743 , the entire content of which is hereby incorporated into this application by reference. TECHNICAL AREA The present application relates generally to systems and methods for filtering exhaust gases in an exhaust aftertreatment system of an internal combustion engine. STATE OF THE ART Nitrogen oxide compounds ( NOx ) are emitted in the exhaust gases of combustion engines, such as diesel engines. It is desirable to reduce NOx emissions, for example, to comply with environmental regulations. To reduce NOx emissions, a reducing agent can be metered into the exhaust gases via a dosing system and within an aftertreatment system. The reducing agent facilitates the conversion of some of the exhaust gases into non- NOx emissions such as nitrogen ( N2 ), carbon dioxide ( CO2 ), and water ( H2O ), thereby reducing NOx emissions. In some applications, it is desirable to capture particles such as soot in the exhaust gases of an internal combustion engine and treat them with an aftertreatment system to convert a portion of the exhaust gases into non-hydrocarbon emissions, for example, by converting carbon monoxide (CO) to carbon dioxide ( CO₂ ) and/or converting unburned hydrocarbons to water ( H₂O ) and carbon dioxide ( CO₂ ). By capturing the particles and converting a portion of the exhaust gases into non-hydrocarbon emissions, the aftertreatment system can reduce the amount of particles and hydrocarbon emissions at the system outlet. The aftertreatment system may include a filter cartridge assembly containing a diesel oxidation catalyst (DOC) configured to facilitate at least some of the conversion of the exhaust gases into non-hydrocarbon emissions, and a diesel particulate filter (DPF) configured to facilitate the capture of particles in the exhaust gases. SUMMARY During operation of the internal combustion engine, the service life of the diesel oxidation catalyst, at which it no longer effectively converts the portion of the exhaust gases into non-hydrocarbon emissions, may be reached sooner than the service life of the diesel particulate filter, at which it no longer effectively captures the particles in the exhaust gases. For example, if the internal combustion engine uses certain fuels (e.g., B100, toxic fuels, biodiesel, etc.), the diesel oxidation catalyst may become toxic and cease to function effectively before the diesel particulate filter reaches the end of its service life. Consequently, the filter cartridge assembly may need to be replaced with a different one while the diesel particulate filter still has some of its filter life remaining. Certain embodiments of the present disclosure can overcome this problem. In one embodiment, a filter cartridge assembly for an aftertreatment unit comprises a diesel particulate filter assembly and a diesel oxidation catalyst assembly. The diesel particulate filter assembly comprises a diesel particulate filter housing and a diesel particulate filter substrate assembly. The diesel particulate filter housing comprises a first cylindrical body and a first arcuate flange extending from an edge of the first cylindrical body. The edge of the first cylindrical body and the lateral edges of the first arcuate flange together define a first opening. The diesel particulate filter substrate assembly is arranged within the first cylindrical body. The diesel oxidation catalyst assembly comprises a diesel oxidation catalyst housing and a diesel oxidation catalyst substrate assembly. The diesel oxidation catalyst housing comprises a second cylindrical body and a second arcuate flange extending from an edge of the second cylindrical body. The second arcuate flange is detachably connected to the first arcuate flange to detachably connect the diesel oxidation catalyst housing to the diesel particulate filter housing. The edge of the second cylindrical body and the lateral edges of the second arcuate flange together form a second opening. The diesel oxidation catalyst substrate assembly is located inside the second cylindrical body. In a further embodiment, a filter cartridge assembly for an aftertreatment unit comprises a diesel particulate filter assembly, a diesel oxidation catalyst assembly, and a Fastening element. The diesel particulate filter assembly comprises a diesel particulate filter housing and a diesel particulate filter substrate assembly. The diesel particulate filter housing comprises a first cylindrical body and a first arcuate flange extending from an edge of the first cylindrical body. The first arcuate flange has a first opening. The diesel particulate filter substrate assembly is arranged within the first cylindrical body. The diesel oxidation catalyst assembly comprises a diesel oxidation catalyst housing and a diesel oxidation catalyst substrate assembly. The diesel oxidation catalyst housing compr