CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/421061, filed October 31, 2022, the entire disclosure of which is hereby incorporated by reference herein.

TECHNICAL FIELD

[0002] The present application relates generally to a reductant delivery system that includes a reductant pump for providing reductant to an exhaust aftertreatment system for an internal combustion engine.

BACKGROUND

[0003] For internal combustion engines, such as diesel engines, nitrogen oxide (NOx) compounds may be emitted in exhaust. It may be desirable to reduce NOx emissions, for example, to comply with environmental regulations. To reduce NOx emissions, reductant may be injected into the exhaust by a reductant delivery system coupled to a dosing system and within a vehicle system. The reductant facilitates conversion of a portion of the exhaust into non-NOx emissions, such as nitrogen (N2), carbon dioxide (CO2), and water (H2O), thereby reducing NOx emissions.

[0004] Reductant is stored in a tank and transported via supply lines. When stored at cold temperatures, reductant may freeze within the tank and the supply lines. A heater may be used to thaw the reductant. Heating the reductant may be a time intensive and energy consuming process because the heater typically heats an entire volume of the tank.

SUMMARY

[0005] In one embodiment, a diesel exhaust fluid system includes a reductant pump including a filter housing comprising an inlet chamber that receives reductant, a pump chamber coupled to the inlet chamber that receives reductant from the inlet chamber and delivers the reductant to a transfer channel, an outlet channel and a filter head. The reductant pump further includes a pump coupled to the filter housing that provides reductant to the transfer channel, and a filter cartridge including a top endplate, a bottom endplate, and a center tube surrounded by filter media that define a filter cartridge cavity. A cover is included above the filter cartridge and is coupled to the filter head. The reductant pump further includes a startup heater that is at least partially positioned within the filter cavity and configured to heat the reductant within the filter cartridge cavity.

[0006] In another embodiment, a diesel exhaust fluid system includes a reductant delivery system. The reductant delivery system includes a main tank that further includes a main heater disposed in a main tank volume configured to heat reductant, a lift pump configured to deliver reductant to a supply line, a temperature sensor configured to determine the temperature of the reductant in the main tank volume, and a startup tank. The startup tank further includes a startup tank body and a startup heater. The reductant delivery system further includes a reductant delivery system controller configured to receive a signal from the temperature sensor and selectively active the main lift pump.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying Figures, wherein like reference numerals refer to like elements unless otherwise indicated, in which:

[0008] FIG. l is a block schematic diagram of an example exhaust aftertreatment system;

[0009] FIG. 2 is a block schematic drawing of a reductant delivery system for an exhaust aftertreatment system, according to various embodiments;

[0010] FIG. 3 is a block schematic drawing of another reductant delivery system for an exhaust aftertreatment system, according to various embodiments; [0011] FIG. 4 is a block schematic drawing of a portion of yet another reductant delivery system for an exhaust aftertreatment system, according to various embodiments;

[0012] FIG. 5 is a block schematic drawing of a portion of yet another reductant delivery system for an exhaust aftertreatment system, according to various embodiments;

[0013] FIG. 6 is a block schematic drawing of a portion of yet another reductant delivery system for an exhaust aftertreatment system, according to various embodiments;

[0014] FIG. 7 is a block schematic drawing of a portion of yet another reductant delivery system for an exhaust aftertreatment system, according to various embodiments;

[0015] FIG. 8 is a block schematic drawing of a portion of yet another reductant delivery system for an exhaust aftertreatment system, according to various embodiments;

[0016] FIG. 9 is a block schematic drawing of yet another reductant delivery system for an exhaust aftertreatment system, according to various embodiments; and

[0017] FIG. 10 is a block schematic drawing of a portion of yet another reductant delivery system for an exhaust aftertreatment system, according to various embodiments.

[0018] It will be recognized that the Figures are schematic representations for purposes of illustration. The Figures are provided for the purpose of illustrating one or more implementations with the explicit understanding that the Figures will not be used to limit the scope or the meaning of the claims.

DETAILED DESCRIPTION

[0019] Following below are more detailed descriptions of various concepts related to, and implementations of, methods, apparatuses, and for providing a reductant delivery system including a reductant pump. The various concepts introduced above and discussed in greater detail below may be implemented in any of a number of ways, as the described concepts are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.

-J - I. Overview

[0020] Internal combustion engines (e.g., diesel internal combustion engines, etc.) produce exhaust that contains constituents, such as NOx, N2, CO2, and/or H2O. In some applications, an exhaust gas aftertreatment system is utilized to dose the exhaust gas with a reductant so as to reduce NOx emissions in the exhaust gas. The reductant must be stored inside a fluid tank (e.g., a reservoir, a DEF tank, etc.) within a reductant delivery system. The reductant delivery system pumps the reductant out of the fluid tank and delivers the reductant to the aftertreatment system.

[0021] For a reductant delivery system to provide exhaust with reductant, it is desirable for the reductant to be in a liquid form, which requires the reductant to be above a freezing temperature (e.g., less than 12°F, less than -11°C, etc.). When the reductant is stored at or below the freezing temperature, the reductant may freeze within the fluid tank. When a portion of the reductant freezes, the portion of reductant must be warmed so as to transition from a solid form to a liquid form before it can be provided to exhaust.

[0022] Various heating devices may be used to warm the reductant. However, it may be possible to more efficiently heat reductant by providing an additional tank or chamber to isolate a lesser volume of reductant for heating within the reductant delivery system.

[0023] Some implementations herein are directed to a reductant delivery system that includes a reductant pump and that is capable of quickly thawing reductant before it is provided to the reductant pump. The reductant pump includes a filter housing coupled to a pump. The filter housing includes an inlet channel, a pump chamber, a transfer channel, an outlet channel, and a filter head. Reductant within the reductant pump flows through the inlet channel and into the pump chamber. The pump pulls the reductant from the pump chamber and pushes the reductant into the transfer channel. The reductant pump further includes a filter cartridge including a top endplate, a bottom endplate, and a center tube that define a filter cartridge cavity where filter media is disposed. The reductant pump further includes a cover coupled to the filter head that defines a filter head cavity. The filter head cavity includes a startup heater to head reductant within the reductant pump. [0024] Some implementations herein are also directed to a reductant delivery system that includes a main tank, a startup tank, and a reductant delivery system controller. The startup tank includes a startup tank body and a startup heater. The startup heater warms the reductant stored in the startup tank body. The main tank includes a main tank body, a main heater, a lift pump, and a temperature sensor. The main heater warms reductant stored in the main tank body. The temperature sensor provides a signal associated with the temperature of the reductant stored in the main tank to the reductant delivery system controller. The reductant delivery system controller determines a temperature of the reductant based on the received signal. The reductant delivery system controller causes the lift pump to deliver reductant to the reductant pump based on the temperature. The reductant delivery system controller can further operate the main heater based on the temperature.

II. Overview of Exhaust Aftertreatment System

[0025] FIG. 1 depicts an exhaust aftertreatment system 100 having an example reductant delivery system 102 for an exhaust conduit system 104. The exhaust aftertreatment system 100 includes the reductant delivery system 102, a particulate filter 106 (e.g., a diesel particulate filter (DPF)), a decomposition chamber 108 (e.g., reactor, reactor pipe, conduit, etc.), and a catalyst member 110 (e.g., SCR catalyst member, etc.).

[0026] The particulate filter 106 is configured to (e.g., structured to, able to, etc.) remove particulate matter, such as soot, from exhaust flowing in the exhaust conduit system 104. The particulate filter 106 includes an inlet, where the exhaust is received, and an outlet, where the exhaust exits after having particulate matter substantially filtered from the exhaust and/or converting the particulate matter into carbon dioxide. In some implementations, the particulate filter 106 may be omitted.

[0027] The decomposition chamber 108 is configured to receive the exhaust from the particulate filter 106 and a reductant (e.g., urea, diesel exhaust fluid (DEF, etc.), Adblue®, a urea water solution (UWS), an aqueous urea solution (e.g., AUS32, etc.) from the reductant delivery system 102. When the reductant is introduced into the exhaust, reduction of emission of undesirable components (e.g., NOx, etc.) in the exhaust may be facilitated. The decomposition chamber 108 includes an inlet in fluid communication with the particulate filter 106 to receive the exhaust containing NOx emissions and an outlet for the exhaust, NOx emissions, ammonia, and/or reductant to flow to the catalyst member 110.

[0028] The doser assembly 112 is fluidly coupled to (e.g., fluidly configured to communicate with, etc.) a reductant source 114. The reductant source 114 may include multiple reductant sources 114. The reductant source 114 may be, for example, a diesel exhaust fluid tank containing Adblue®. A reductant pump 116 (e g., supply unit, etc.) is used to pressurize the reductant from the reductant source 114 for delivery to the doser assembly 112. In some embodiments, the reductant pump 116 is pressure-controlled (e.g., controlled to obtain a target pressure, etc.). The reductant pump 116 includes a reductant filter 118. The reductant filter 118 filters (e.g., strains, etc.) the reductant prior to the reductant being provided to internal components (e.g., pistons, vanes, etc.) of the reductant pump 116. For example, the reductant filter 118 may inhibit or prevent the transmission of solids (e.g., solidified reductant, contaminants, etc.) to the internal components of the reductant pump 116. In this way, the reductant filter 118 may facilitate prolonged desirable operation of the reductant pump 116. In some embodiments, the reductant pump 116 is coupled (e.g., fastened, attached, affixed, welded, etc.) to a chassis of a vehicle associated with the exhaust aftertreatment system 100.

[0029] The doser assembly 112 includes at least one injector 120. Each injector 120 is configured to dose the reductant into the exhaust (e.g., within the decomposition chamber 108, etc.) at an injection axis 119. The exhaust aftertreatment system 100 includes a mixer 121 (e.g., a swirl generating device, a vane plate, inlet plate, deflector plate, etc.). At least a portion of the mixer 121 may be located within the decomposition chamber 108. However, at least a portion of the mixer 121 may also be located in a conduit of the exhaust conduit system 104 (e.g., a conduit upstream of the decomposition chamber 108, etc.). The mixer 121 is configured to receive exhaust from the decomposition chamber 108 and reductant from the injector 120, such that the injection axis 119 extends into the mixer 121. The mixer 121 is also configured to facilitate mixing of the exhaust and the reductant. The mixer 121 is configured to facilitate swirling (e.g., tumbling, rotation, etc.) of the exhaust and mixing (e.g., combination, etc.) of the exhaust and the reductant so as to disperse the reductant within the exhaust downstream of the mixer 121. By dispersing the reductant within the exhaust (e.g., to obtain an increased uniformity index, etc.) using the mixer 121, reduction of emission of undesirable components in the exhaust is enhanced or a temperature of the exhaust may be increased.

[0030] While the injection axis 119 extends into the mixer 121, the injection axis 119 may extend into the mixer 121 at an angle relative to a central axis of the mixer 121. For example, in some embodiments, the injection axis 119 may be coincident with a central axis of the mixer

121. In other embodiments, the injection axis 119 may be perpendicular to the central axis of the mixer 121. In yet other embodiment, the injection axis 119 may be parallel to the central axis of the mixer 121.

[0031] In some embodiments, the injector 120 is not directly coupled to the mixer 121. In these embodiments, the injector 120 and the mixer 121 may each be coupled to a same component (e.g., panel, chamber, etc.). In other embodiments, the injector 120 is directly coupled to the mixer 121 . In these embodiments, the injector 120 and the mixer 121 may also each be coupled to the same component. In some embodiments, the injector 120 is not disposed within the mixer 121. In other embodiments, the injector 120 may be at least partially disposed within the mixer 121.

[0032] In some embodiments, the reductant delivery system 102 also includes an air pump

122. In these embodiments, the air pump 122 draws air from an air source 124 (e.g., air intake, etc.) and through an air filter 126 disposed upstream of the air pump 122. Additionally, the air pump 122 provides the air to the doser assembly 112 via a conduit. In these embodiments, the doser assembly 112 is configured to mix the air and the reductant into an air-reductant mixture and to provide the air-reductant mixture into the decomposition chamber 108. In other embodiments, the reductant delivery system 102 does not include the air pump 122 or the air source 124. In such embodiments, the doser assembly 112 is not configured to mix the reductant with air.

[0033] The doser assembly 112, and the reductant pump 116 are also electrically or communicatively coupled to a reductant delivery system controller 128. The reductant delivery system controller 128 controls the doser assembly 112 to dose the reductant into the decomposition chamber 108. The reductant delivery system controller 128 may also control the reductant pump 116.

[0034] The reductant delivery system controller 128 includes a processing circuit 130. The processing circuit 130 includes a processor 132 and a memory 134. The processor 132 may include a microprocessor, an application-specific integrated circuit (ASIC), a field- programmable gate array (FPGA), etc., or combinations thereof. The memory 134 may include, but is not limited to, electronic, optical, magnetic, or any other storage or transmission device capable of providing a processor, ASIC, FPGA, etc. with program instructions. This memory 134 may include a memory chip, Electrically Erasable Programmable Read-Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM), flash memory, or any other suitable memory from which the reductant delivery system controller 128 can read instructions. The instructions may include code from any suitable programming language. The memory 134 may include various modules that include instructions which are configured to be implemented by the processor 132.

[0035] In various embodiments, the reductant delivery system controller 128 is configured to communicate with a central controller 136 (e.g., engine control unit (ECU), engine control module (ECM), etc.) of an internal combustion engine having the exhaust aftertreatment system 100. In some embodiments, the central controller 136 and the reductant delivery system controller 128 are integrated into a single controller.

[0036] In some embodiments, the central controller 136 is communicable with a display device (e.g., screen, monitor, touch screen, heads up display (HUD), indicator light, etc.). The display device may be configured to change state in response to receiving information from the central controller 136. For example, the display device may be configured to change between a static state (e.g., displaying a green light, displaying a “SYSTEM OK” message, etc.) and an alarm state (e.g., displaying a blinking red light, displaying a “SERVICE NEEDED” message, etc.) based on a communication from the central controller 136. By changing state, the display device may provide an indication to a user (e.g., operator, etc.) of a status (e.g., operation, in need of service, etc.) of the reductant delivery system 102. [0037] The decomposition chamber 108 is located upstream of the catalyst member 110. As a result, the reductant is injected upstream of the catalyst member 110 such that the catalyst member 110 receives a mixture of the reductant and exhaust. The reductant droplets undergo the processes of evaporation, thermolysis, and hydrolysis to form non-NOx emissions (e.g., gaseous ammonia, etc.) within the exhaust conduit system 104.

[0038] The catalyst member 110 includes an inlet in fluid communication with the decomposition chamber 108 from which exhaust and reductant are received and an outlet in fluid communication with an end of the exhaust conduit system 104.

[0039] The exhaust aftertreatment system 100 may further include an oxidation catalyst member (e.g., a diesel oxidation catalyst (DOC)) in fluid communication with the exhaust conduit system 104 (e.g., downstream of the catalyst member 110 or upstream of the particulate fdter 106) to oxidize carbon monoxide in the exhaust.

[0040] In some implementations, the particulate filter 106 may be positioned downstream of the decomposition chamber 108. For instance, the particulate filter 106 and the catalyst member 110 may be combined into a single unit. In some implementations, the doser assembly 112 may instead be positioned downstream of a turbocharger or upstream of a turbocharger.

[0041] The exhaust aftertreatment system 100 also includes a doser mounting bracket 138 (e.g., mounting bracket, coupler, plate, etc.). The doser mounting bracket 138 couples the doser assembly 112 to a component of the exhaust aftertreatment system 100. The doser mounting bracket 138 is configured to mitigate the transfer of heat from the exhaust passing through the exhaust conduit system 104 to the doser assembly 112. In this way, the doser assembly 112 is capable of operating more efficiently and desirably than other doser assemblies which are not able to mitigate the transfer of heat. Additionally, the doser mounting bracket 138 is configured to aid in reliable installation of the doser assembly 112. This may decrease manufacturing costs associated with the exhaust aftertreatment system 100 and ensure repeated desirable installation of the doser assembly 112. [0042] In various embodiments, the doser mounting bracket 138 couples the doser assembly 112 to the decomposition chamber 108. In some embodiments, the doser mounting bracket 138 couples the doser assembly 112 to an exhaust conduit of the exhaust conduit system 104. For example, the doser mounting bracket 138 may couple the doser assembly 112 to an exhaust conduit of the exhaust conduit system 104 that is upstream of the decomposition chamber 108 or to an exhaust conduit of the exhaust conduit system 104 that is downstream of the decomposition chamber 108. In some embodiments, the doser mounting bracket 138 couples the doser assembly 112 to the particulate filter 106 and/or the catalyst member 110. The location of the doser mounting bracket 138 may be varied depending on the application of the exhaust aftertreatment system 100. For example, in some exhaust aftertreatment systems 100, the doser mounting bracket 138 may be located further upstream than in other exhaust aftertreatment systems 100. Furthermore, some exhaust aftertreatment systems 100 may include multiple doser assemblies 112 and therefore may include multiple doser mounting brackets 138.

III. Overview of Reductant Delivery System

[0043] FIG. 2 illustrates the reductant delivery system 102 according to various embodiments. The reductant delivery system 102 includes a main tank 202 (e.g., reductant tank, primary tank, etc.). The main tank 202 includes a main tank body 204. The main tank body 204 defines a main tank volume 206. The main tank body 204 is configured to store reductant within the main tank volume 206.

[0044] The main tank 202 further includes a main heater 208 (e.g., heating element, etc.). In various embodiments, a portion of the main heater 208 is coupled to the main tank body 204. For example, a portion of the main heater 208 may be fastened to the main tank body 204 (e.g., using a fastener, etc.). In other embodiments, no portion of the main heater 208 is coupled to the main tank body 204. Instead, a portion of the main heater 208 is coupled to an intermediate coupler (e.g., bracket, hanger, fitting, etc.) which is coupled to the main tank body 204. A portion of the main heater 208 is disposed in the main tank volume 206. The main heater 208 is configured to heat the reductant stored in the main tank volume 206. The main heater 208 may be an electrical heater (e.g., resistance heater, heating coil, etc.), a heat exchanger (e.g., a fluid heat exchanger, a heating fluid loop, etc.), a Peltier heater (e.g., thermoelectric heater, etc.), or another heater with similar function.

[0045] The main tank 202 further includes a temperature sensor 210. In various embodiments, the temperature sensor 210 is positioned within the main tank body 204. For example, the temperature sensor 210 may be fastened to the main tank body 204. In other embodiments, the temperature sensor 210 may be fastened to other structures positioned within the main tank body 204. The temperature sensor 210 is configured to determine the temperature of the reductant stored in the main tank volume 206. Furthermore, the temperature sensor 210 is communicatively coupled to a reductant delivery system controller 128. The temperature sensor 210 is further configured to provide a signal associated with the determined temperature of the reductant in the main tank volume 206 to the processing circuit 130 of the reductant delivery system controller 128.

[0046] As illustrated in FIG. 2, the main tank 202 further includes a lift pump 212 (e.g., rotary pump, positive displacement pump, etc.). The lift pump 212 is coupled to the main tank body 204 and is disposed within the main tank volume 206. For example, the lift pump 212 may be fastened to the bottom or a side of the main tank body 204. In some embodiments, the lift pump 212 may be coupled to the temperature sensor 210. For example, the lift pump 212 may be fastened to the pressure side of the main tank body 204 and the temperature sensor 210 may be fastened to the lift pump 212 such that the temperature sensor 210 is continuously in contact with the reductant stored in the main tank volume 206. In other embodiments, the lift pump 212 may be fastened to the bottom of the main tank body 204 and the temperature sensor 210 may be coupled to a side of the main tank body 204 (e.g. the bottom, or the side). The lift pump 212 is configured to pump warm reductant heated by the main heater 208. The reductant delivery system further includes a supply line 214. A portion of the supply line 214 is positioned within the main tank body 204. The supply line 214 is coupled to the lift pump 212.

[0047] The reductant delivery system 102 also includes a startup tank 216 (e.g., reductant tank, secondary tank, etc.). The startup tank 216 includes a startup tank body 218. The startup tank body 218 defines a startup tank volume 220. The startup tank body 218 is configured to store reductant in the startup tank volume 220. The startup tank body 218 is coupled to the supply line 214. The lift pump 212 is configured to pump reductant from the main tank body 204 through the supply line 214. The supply line 214 is configured to deliver reductant from the main tank body 204 to the startup tank body 218. The startup tank body 218 is configured to store a startup tank volume 220 of reductant.

[0048] The startup tank 216 further includes a startup heater 222 (e.g., heating element, etc.). In various embodiments, a portion of the startup heater 222 is coupled to the startup tank body 218. For example, a portion of the startup heater 222 may be fastened to the startup tank body 218 (e.g., using a fastener, etc.). In other embodiments, no portion of the startup heater 222 is coupled to the startup tank body 218. Instead, a portion of the startup heater 222 is coupled to an intermediate coupler which is coupled to the startup tank body 218. A portion of the startup heater 222 is disposed in the startup tank volume 220. The startup heater 222 is configured to heat the reductant stored in the startup tank volume 220. The startup heater 222 may be an electrical heater, a heat exchanger, a Peltier heater, or other similar heaters.

[0049] In some embodiments, the startup tank 216 further includes a startup pump 224 (e.g., a lift pump, pressure pump, etc.). The startup pump 224 is fastened to the startup tank body 218. The startup pump 224 is positioned in the startup tank volume 220 of reductant. The reductant delivery system 102 further includes a startup supply line 226 and a reductant pump 228. The startup pump 224 is coupled to the startup supply line 226. The startup pump 224 is configured to deliver reductant from the startup tank body 218 to the startup supply line 226. A portion of the startup supply line 226 is disposed within the startup tank body 218. The startup supply line 226 is configured to deliver reductant from the startup tank body 218 to the reductant pump 228.

[0050] The reductant pump 228 is fluidly coupled to the startup tank 216 by the startup supply line 226. The reductant pump 228 includes an inlet 230 and an outlet 232. The inlet 230 is fluidly coupled to the startup tank 216 by the startup supply line 226. The inlet 230 is configured to receive reductant from the startup tank body 218. The outlet 232 is configured to receive reductant that has circulated through the reductant pump 228. [0051] The reductant delivery system 102 further includes a doser supply line 234. The outlet 232 is fluidly coupled to the doser assembly 112 by the doser supply line 234. The doser supply line 234 is configured to deliver reductant to the doser assembly 112 from the outlet 232 of the reductant pump 228.

[0052] The reductant delivery system 102 further includes a return line 236. The doser assembly 112 is fluidly coupled to the main tank 202 by the return line 236. The return line 236 is configured to deliver reductant back to the main tank volume 206 from the doser assembly 112. In some embodiments, the reductant delivery system 102 further includes a warm return line 238. The warm return line 238 is coupled to the return line 236. The reductant delivery system controller 128 is configured to control the doser assembly 112 to selectively deliver reductant to the startup tank body 218. The doser assembly 112 is configured to selectively deliver warm reductant through the warm return line 238 back to the startup tank body 218. By delivering warm reductant back to the startup tank body 218, the reductant delivery system 102 may deliver reductant from the startup tank 216 without pulling reductant from the main tank volume 206 into the startup tank volume 220.

[0053] Furthermore, the reductant delivery system controller 128 is communicatively coupled to the temperature sensor 210, the lift pump 212, the reductant pump 228, the startup pump 224, and the doser assembly 112. The reductant delivery system controller 128 is configured to receive the signal generated by the temperature sensor 210 associated with a temperature of the reductant within the main tank volume 206. The reductant delivery system controller 128 is further configured to determine the temperature of the reductant within the main tank volume 206 based on the signal. For example, the signal (e.g. resistance, infrared reading, etc.) may be sent the processing circuit 130 within the reductant delivery system controller 128. The memory 134 of the reductant delivery system controller 128 is configured to store a threshold reductant temperature. The threshold temperature may be determined by a user input or otherwise stored in the memory 134. The processor 132 of the processing circuit 130 is configured to determine the temperature of the reductant within the main tank volume 206. For example, the temperature of the reductant stored in the main tank volume 206 determined by the processor 132 can be compared to a threshold reductant temperature stored in the memory 134. For example, the temperature sensor may sense the residence between two diodes and transmit a reductant temperature value signal (e.g., temperature in °C, etc.) to the reductant delivery system controller 128. The processor 132 is configured to determine if the reductant temperature value signal is greater than or meets the threshold reductant temperature.

[0054] The reductant delivery system controller 128 is further configured to control the lift pump 212, the reductant pump 228, and the doser assembly 112 based on the determined temperature of the reductant stored within the main tank volume 206. For example, the reductant delivery system controller 128 may activate the lift pump 212 and the reductant pump 228 if the determined temperature of the reductant stored within the main tank volume 206 meets or exceeds the threshold reductant temperature. If the reductant delivery system controller 128 determines the temperature of the reductant stored within the main tank volume 206 does not meet or exceed the threshold reductant temperature, the reductant delivery system controller 128 may deactivate the lift pump 212, activate the reductant pump 228, and further be configured to activate the doser assembly 112 to return reductant to the startup tank body 218.

[0055] Additionally, the reductant delivery system controller 128 is configured to cause the lift pump 212 to deliver the reductant from the main tank volume 206 to the startup tank volume 220. For example, the reductant delivery system controller 128 may be configured to cause the lift pump 212 to deliver the reductant from the main tank volume 206 to the startup tank volume 220 based on the temperature of the reductant within the main tank volume 206. For example, the reductant delivery system controller 128 may cause the lift pump 212 to shut off if the temperature of the reductant within the main tank volume 206 is too low (e.g., the temperature of the reductant within the main tan volume is below a threshold), preventing the delivery of reductant from the main tank volume 206 to the startup tank volume 220. The reductant delivery system controller 128 is configured to prevent the delivery of reductant from the main tank volume 206 to the startup tank volume 220 so that the startup tank volume 220 remains heated to a temperature that meets or exceeds the threshold reductant temperature.

[0056] Furthermore, if the reductant delivery system controller 128 determines that the temperature of the reductant within the main tank volume 206 meets or exceeds the threshold reductant temperature, the reductant delivery system controller 128 may activate the lift pump 212 to begin delivering reductant from the main tank volume 206 to the startup tank volume 220. According to this embodiment, the reductant delivery system controller 128 may further be configured to cause reductant to continuously be delivered from the main tank volume 206 to the startup tank volume 220 to replenish the supply of warm reductant in the startup tank volume 220. For example, in this embodiment reductant from the main tank volume 206 is delivered to the startup tank volume 220 such that reductant must pass through the startup tank volume 220 before being delivered to the doser assembly 112. In other embodiments, the reductant delivery system controller 128 may be configured to activate the lift pump 212 to begin delivering reductant from the main tank volume 220 to the reductant pump 228 such that the reductant bypasses startup tank 216.

[0057] FIG. 3 illustrates another embodiment of the reductant delivery system 102. , FIG. 3 shows the reductant delivery system 102 including the main tank 202, the startup tank 216, and the reductant pump 228 according to some embodiments. The startup tank 216 is positioned within the main tank body 204. The startup tank 216 defines the startup tank volume 220 positioned within the main tank volume 206. According to some embodiments the startup heater 222 and the main heater 208 may be combined to be a single heater. In other embodiments, the startup heater 222 may be fastened to the main heater 208. The main heater 208 may be fastened to the main tank body 204 and fastened to the startup tank body 218. The main heater 208 extend from the main tank body 204 through the main tank volume 206 and into the startup tank body 218. Thus a portion of the main heater 208 may be positioned in the startup tank volume 220. Instead, in another embodiment, the heater positioned within the startup volume 220 may be a separate startup heater 222. For example, the separate startup heater may be fastened to the startup tank body 218. The startup heater may extend into the startup tank volume 220. The startup heater is configured to heat the reductant stored within the startup tank body 218.

[0058] The startup tank volume 220 is fluidly coupled to the main tank volume 206. The startup tank 216 is configured to encapsulate the startup tank volume 220 of reductant within the main tank volume 206. For example, the startup tank 216 may include thermally insulated walls (e.g., walls that include insulation, etc.) to concentrate the transmission of heat from at least one of the startup heater 222, the main heater 208, and a combined single heater such that the reductant stored in the startup tank volume 220 may be heated more quickly. The startup tank volume 220 is less than the main tank volume 206 to allow for faster heating of the stored reductant.

[0059] Furthermore, in some embodiments, the startup tank 216 is isolated from the main tank volume 206. For example, the startup tank volume 220 may be fluidly coupled (e g., by a transfer tube) to the main tank volume 206. Instead, in other embodiments, the startup tank body 218 may include openings for reductant to flow into the startup volume 220 from the main tank volume 206.

[0060] As shown in FIG. 3 the main tank 202 includes the lift pump 212. According to some embodiments the lift pump 212 is fastened to the main tank body 204 and may also be fastened to the startup tank body 218. According to other embodiments, a portion of the lift pump 212 may be positioned within the startup tank volume 220. According to some embodiments, the lift pump 212 is configured to selectively deliver reductant from the main tank volume 206 and the startup tank volume 220 to the supply line 214. For example, the reductant delivery system controller 128 may be configured to activate the lift pump 212 based on the temperature signal received from the temperature sensor 210. The lift pump 212 may be activated to deliver reductant only from the startup volume 220 if the reductant delivery system controller 128 determines that the temperature of the reductant in the main tank volume 206 does not meet or exceed the threshold reductant temperature. Otherwise, the lift pump 212 may be activated to deliver reductant from the main tank volume 206 if the reductant delivery system controller 128 determines that the temperature of the reductant in the main tank volume 206 meets or exceeds the threshold reductant temperature. According to another embodiment, the reductant delivery system controller may activate the lift pump 212 to pull reductant from both the startup tank volume 220 and the main tank volume 206 at the same time.

[0061] According to yet another embodiment, the lift pump 212 may be positioned only in the main tank volume 206. For example, in some embodiments the lift pump 212 is coupled to the main tank body 204 such that the lift pump is only positioned within the main tank volume 206. In other embodiments, a portion of the lift pump 212 may be positioned inside the main tank volume 206 and another portion of the lift pump 212 may be positioned outside of the main tank volume 206. In yet another embodiment, the lift pump 212 may be positioned outside of the main tank volume 206. The lift pump 212 is configured to only pull reductant from the main tank volume 206 when activated by the reductant delivery system controller 128.

[0062] Furthermore, according to this embodiment the startup pump 224 is positioned only within the startup tank volume 220. In other embodiments, the startup pump 224 may be positioned outside of the startup tank volume 220. For example, a portion of the startup pump 224 may be positioned within the startup tank volume 220 and another portion of the startup pump 224 may be positioned outside of the startup tank volume 220. In yet another embodiment, the startup pump 224 may be positioned outside of the startup tank volume 220. The startup pump 224 is configured to only pull reductant from the startup tank volume 220 when activated by the reductant delivery system controller 128. For example, the reductant delivery system controller can activate the startup pump 224 when the temperature of the reductant stored within the main tank volume 206 does not meet or exceed the threshold reductant temperature. Instead, the reductant delivery system controller 128 can turn off (e.g., deactivate, etc.) the startup pump 224 and activate (e.g., turn on, etc.) the lift pump 212 when the reductant within the main tank volume 206 meets or exceeds the threshold reductant temperature. According to yet another embodiment, the reductant delivery system controller 128 can activate the startup pump 224 and the lift pump 212 at the same time. Furthermore, in some embodiments, the lift pump 212 and the startup pump 224 may be a single pump.

[0063] The lift pump 212 and the startup pump 224 are fluidly coupled to the reductant pump 228 by the supply line 214. According to some embodiments, the lift pump 212 and the startup pump 224 are configured to pump reductant into the supply line 214 from the main tank volume 206 and the startup tank volume 220. The supply line 214 is configured to deliver reductant from the main tank volume 206 and the startup tank volume 220 to the inlet 230 of the reductant pump 228. Furthermore, the doser assembly 112 is fluidly coupled to the main tank body 204 and the startup tank body 218 by the return line 236. The return line 236 is configured to selectively return reductant back to the main tank volume 206. The reductant delivery system 102 may include an optional warm line 302. The optional warm line 302 is coupled to the return line 236. The optional warm line is also coupled to the main tank body 204 and the startup tank body 218. A portion of the optional warm line 302 is positioned in the main tank volume 206 and extends such that another portion of the optional warm line 302 is positioned within the startup tank volume 220 The optional warm line 302 is configured to return reductant to the startup tank volume 220 when the reductant stored in the main tank volume 206 does not meet or exceed the threshold reductant temperature, as determined by the reductant delivery system controller 128. For example, upon determining the main tank volume 206 does not meets or exceed the threshold reductant temperature, the reductant delivery system controller 128 is configured to activate the doser assembly 112 to deliver warm reductant through the optional warm line 302 back to the startup tank volume 220.

[0064] FIGS. 4-6 illustrate the startup tank 216 and the reductant pump 228 as incorporated into various reductant delivery systems 102 as previously shown. The embodiment of FIG. 4 depicts a detailed cross-sectional view of the reductant pump 228 that may be included in the system illustrated in FIG. 2. The reductant pump 228 is fluidly coupled to the startup tank 216 by the startup supply line 226. In various embodiments, the startup tank 216 may be positioned near the reductant pump 228 such that the length of the startup supply line 226 is shortened.

[0065] Furthermore, according to some embodiments, the startup pump 224 is configured to purge (e.g., empty reductant, not store reductant when system is off, etc.) the startup supply line 226 to prevent reductant from sitting stagnant in the line and freezing. For example, the startup pump may be configured to pull reductant from the startup supply line 226 back to the startup tank volume 220. Purging the startup supply line 226 may decrease the time needed to thaw the reductant in the reductant delivery system 102. The startup tank 216 includes the startup tank body 218 that defines the startup tank volume 220. The startup tank includes the startup pump 224 positioned within the startup tank volume 220. The startup pump 224 is configured to pump reductant from the startup tank volume 220 into the startup supply line 226. The startup supply line 226 is configured to deliver reductant from the startup tank body to the inlet 230 of the reductant pump 228. [0066] Furthermore, the reductant pump 228 includes a reductant pump body 402. The reductant pump body 402 includes a filter housing 404. The inlet 230 is configured to deliver reductant from startup supply line 226 to the reductant pump body 402. The filter housing 404 includes a filter head 406. The reductant pump 228 further includes a filter cartridge 408. The filter cartridge 408 is positioned in the filter housing 404. The filter cartridge 408 includes a top endplate 410, a bottom endplate 412, and a center tube 414. The top endplate 410 is coupled to the filter head 406. The bottom endplate 412 is positioned opposite of the top endplate 410. The center tube 414 is coupled to the top endplate 410 and the bottom endplate 412. The filter cartridge 408 further includes a filter cartridge cavity 416. Collectively, the top endplate 410, the bottom endplate 412, and the center tube 414 define the filter cartridge cavity 416. The filter cartridge cavity 416 includes filter media 418. The filter media 418 is configured to catch debris or other particles (pebbles, dust, etc.) within the reductant to aid proper function and longevity of the reductant pump 228. The filter cartridge 408 is configured to be removable and replaceable. For example, a new filter cartridge 408 may be placed in the filter cartridge cavity 416 after a period of time to ensure proper filtration of the reductant.

[0067] As shown in FIG. 4, the reductant pump 228 further includes a cover 420, and a filter head cavity 422. The cover 420 is coupled to the filter head 406 to define the filter head cavity 422. The cover 420 is positioned over the filter cartridge 408. The filter head cavity 422 extends between the cover 420 and the bottom endplate 412.

[0068] FIG. 5 illustrates the reductant pump 228 according to another exemplary embodiment. The embodiment of the reductant pump 228 as shown in Fig. 5 further includes a startup heater 502. The startup heater 502 is fastened to the filter head 406. A portion of the startup heater 502 is positioned within the filter cartridge cavity 416. For example, the startup heater 502 may be positioned within the center tube 414 of the filter cartridge 408. The startup heater 502 is configured to radiate heat outward through the filter media 418 and into the filter head cavity 422. As the heat radiates outward from the startup heater 502, the reductant within the filter head cavity 422 may be heated as it travels through the filter media 418 and up the center tube 414. [0069] FIG. 6 illustrates the reductant pump 228 according to another embodiment. The reductant pump 228 includes a reductant tank body 602 and an additional startup volume 604. The additional startup volume 604 is positioned within the filter head cavity 422. The additional startup volume 604 is heated by the startup heater 502. The additional startup volume 604 may store a small amount of reductant compared to the main tank volume 206. For example, the additional startup volume 604 may be a minimum of 0.5% of the main tank volume 206 and a maximum of 8% of the main tank volume 206. The reductant in the additional startup tank 216 may be heated more quickly than the reductant stored in the main tank volume 206 such that the engine may be started more quickly in cold temperatures (e.g., below freezing, etc.). Furthermore, the additional startup volume 604 may be positioned within the filter head cavity 422 and pulled through the filter media 418. The filter media 418 is configured to catch any debris residing in the reductant to prevent any damage to the reductant delivery system 102. The reductant then travels up the center tube414 and out of the outlet 232 of the reductant pump 228. According to this embodiment, the reductant pump 228 is integrated with the startup tank 216 such that the reductant pump can store reductant in the additional startup volume 604. The startup tank 216 being integrated with the reductant pump 228 such that the reductant pump 228 is configured to store the additional startup volume 604 reduces the amount of space and touch points within the reductant delivery system 102.

[0070] FIG. 7 illustrates a cross-sectional top down view of a reductant pump 228. The reductant pump 228 of the reductant delivery system 102 includes a reductant pump body 700, an inlet 230, an inlet channel 702, and a filter channel 704. The inlet channel 702 is coupled to the supply line 214 and the inlet 230. The inlet 230 is also coupled to the filter channel 704. The inlet channel 702 is configured to receive reductant from the supply line 214 and deliver the reductant through the inlet 230 to the filter channel 704. A portion of the filter channel 704 is positioned within the reductant pump body 700 and another portion of the filter channel 704 is positioned within the filter housing 404. The filter channel 704 includes a first filter 706. The first filter 706 (e.g., a 190 micron filter, etc.) is configured to filter out large debris from the reductant as it flows into the reductant pump body 700 and the filter housing 404. [0071] The filter housing 404 further includes a pump chamber 708. The pump chamber 708 includes a pump inlet channel 710, a pump plate suction check valve 712, a pump plate 714, and a pump 716. The filter channel 704 is configured to deliver reductant to the pump chamber 708. The filter channel 704 is coupled to the pump inlet channel 710. A portion of the pump inlet channel 710 is positioned in the filter housing 404 and another portion of the pump inlet channel 710 is positioned within the pump chamber 708. The pump inlet channel 710 is configured to receive reductant from the filter channel 704 and deliver the reductant to the pump plate suction check valve 712. The pump plate suction check valve 712 is coupled to the pump plate 714. The pump plate suction check valve 712 (e.g., a one-way valve, etc.) is configured to allow reductant to flow through the pump plate 714 and prevent the flow of reductant back through the pump plate suction check valve 712 and back into the pump inlet channel 710.

[0072] The reductant pump 228 further includes a first plate channel 718, a diaphragm 720, and a second plate channel 722. The first plate channel 718 is configured to receive reductant from the pump plate suction check valve 712. The pump 716 is configured to draw reductant through the first plate channel 718 and push the reductant down through the second plate channel 722. The pump plate suction check valve 712 is fluidly coupled to the first plate channel 718. A portion of the first plate channel 718 is disposed within the pump plate 714.

[0073] The diaphragm 720 is coupled to the pump plate 714. The diaphragm 720 is configured to operate between a first position and a second position. When in the first position, the diaphragm 720 is configured to receive reductant from the first plate channel 718 and deliver reductant to the second plate channel 722. A portion of the second plate channel 722 is disposed within the pump plate 714. When in the second position, the diaphragm 720 is configured to prevent the flow of reductant from the first plate channel 718 to the second plate channel 722. The diaphragm 720 is configured to create suction to pull the reductant through the pump plate 714 via the first plate channel 718.

[0074] The pump chamber 708 further includes a pressure check valve 724, an outlet chamber 726, and an outlet channel 728. The pressure check valve 724 is fluidly coupled to the second plate channel 722. The pressure check valve 724 is configured to receive reductant from the second plate channel 722. Furthermore, the pressure check valve 724 is configured to prevent the flow of reductant back through the second plate channel 722. From the pressure check valve 724, the reductant flows into the filter head cavity 422 where it is heated by the startup heater 502. The reductant then flows upward through the center tube 414. The outlet chamber 726 is coupled to the center tube 414 and coupled to the outlet 232. The outlet channel 728 is coupled to the outlet 232. The center tube 414 is configured to deliver filtered reductant from the filter head cavity 422 to the outlet chamber 726. The outlet chamber 726 is configured to deliver reductant from the center tube 414 to the outlet channel 728 through the outlet 232.

[0075] FIG. 8 illustrates a cross sectional front view of the reductant pump 228 according to one exemplary embodiment. The reductant pump 228 includes a pump motor 802 (e.g., electric motor, servo motor, etc.), a piston 804, and a transfer channel 806. The pump motor 802 is positioned within the pump chamber 708. According to some embodiments, the pump motor 802 is coupled to the pump plate 714. The pump motor 802 is coupled to the piston 804 and coupled to the diaphragm. The piston 804 is also coupled to the diaphragm 720.

[0076] The diaphragm 720 is configured to pull reduction up through the pump plate 714 through the first plate channel 718. The diaphragm 720 is further configured to pump the reductant back down through the pump plate 714 via the second plate channel 722. The pump motor 802 is configured to reposition the piston 804. The piston 804 is configured to move the diaphragm 720 from the first position to the second position. For example, the pump motor 802 repositions the piston 804. For example, the piston 804 may be repositioned vertically such that the piston 804 is moved to a higher position, pulling the diaphragm 720 upward. The upward movement of the diaphragm 720 pulls reductant through the first plate channel 718. Furthermore, the pump motor 802 repositions the piston 804 a second time such that the piston 804 is moved vertically to a lower position. The downward movement of the piston 804 pushes the diaphragm 720 downward. The downward movement of the diaphragm pushes reductant through the second plate channel 722. The transfer channel 806 is coupled to the second plate channel 722. A portion of the transfer channel 806 is positioned within the pump chamber 708 and another portion of the transfer channel 806 is positioned in the filter head cavity 422. The second plate channel 722 is configured to deliver reductant from the first plate channel 718 to the transfer channel 806. The transfer channel 806 is configured to deliver reductant from the second plate channel 722 to the filter head cavity 422.

[0077] FIG. 9 illustrates a reductant delivery system 102 according to another exemplary embodiment. The reductant delivery system 102 includes the main tank 202, the main tank body 204 configured to store the main tank volume 206 of reductant for a diesel engine. The main tank 202 includes the main heater 208 disposed within the main tank volume 206. According to some embodiments, the main heater 208 includes a main heater housing 902. The main heater housing 902 is positioned around the main heater 208. The main heater housing 902 is configured to prevent direct contact of the main heater 208 with the reductant stored in the main tank volume 206.

[0078] According to other embodiments, the main heater 208 is sealed (e.g., liquid resistant, etc.). For example, the main heater 208 may be sealed such that the main heater 208 is configured to directly contact the reductant in the main tank volume 206. Furthermore, the main tank 202 includes the lift pump 212 configured to pump reductant from the main tank volume 206 to the reductant pump 228 via the supply line 214. In some embodiments, the main tank lift pump 212 is positioned on the pressure side of the main tank 202.

[0079] The temperature sensor 210 is configured to determine a temperature of the reductant stored within the main tank volume 206. The temperature sensor 210 is further configured to communicate the temperature of the reductant in the main tank volume 206 to the reductant delivery system controller 128. The reductant delivery system controller 128 includes the memory 134 configured to store a threshold reductant temperature value. In some embodiments, the threshold reductant temperature value may be a user defined value. In other embodiments, the threshold reductant temperature value may be hard coded in the memory 134. The reductant delivery system controller 128 is configured to receive the temperature of the reductant stored in the main tank volume 206 from the temperature sensor 210. The reductant delivery system controller 128 is further configured to determine if the temperature of the reductant stored in the main tank volume 206 meets or exceeds the threshold reductant temperature value for the reductant delivery system 102. [0080] The reductant delivery system 102 further includes a first selection valve 904. The first selection valve 904 is communicatively coupled to the reductant delivery system controller 128. The reductant delivery system controller 128 is also communicatively coupled to the temperature sensor 210. The first selection valve 904 is fluidly coupled to the supply line 214 and fluidly coupled to the reductant pump 228. The supply line 214 is configured to deliver reductant from the main tank volume 206 to the first selection valve 904 (e.g., a main tank selection valve, etc.). The first selection valve 904 is configured to prevent or allow the passing of reductant in the supply line 214 from the main tank volume 206. In response to the reductant delivery system controller 128 determining that the reductant stored the main tank volume 206meets or exceeds the threshold reductant temperature value, the reductant delivery system controller 128 is configured to open the first selection valve 904 to allow reductant to flow from the main tank volume 206 towards the reductant pump 228. In response to the reductant delivery system controller 128 determining that the reductant stored in the main tank volume 206 is less than the threshold reductant temperature value, the reductant delivery system controller 128 is configured to close the first selection valve 904.

[0081] According to some embodiments the reductant delivery system 102 further includes a suction side accumulator 906. The suction side accumulator 906 is fluidly coupled to the first selection valve 904 by the supply line 214. The suction side accumulator 906 is also fluidly coupled to the reductant pump 228. When the first selection valve 904 is in an open position, the suction side accumulator 906 is configured to deliver a dose of reductant to the reductant pump 228 such that the reductant pump 228 does not overflow. The suction side accumulator 906 is further configured to prevent backward flow of reductant away from the reductant pump 228 and back into the main tank volume 206. 228.

[0082] Furthermore, the reductant delivery system controller 128 is communicatively coupled to the integrated reductant pump 228. In response to the reductant delivery system controller 128 closing the first selection valve 904, the reductant delivery system controller 128 is further configured to communicate to the reductant pump 228 that the first selection valve 904 is in a closed position. When the first selection valve 904 is in a closed position, the reductant pump 228 is configured to pull reductant only from the additional startup volume 604 positioned within the filter head cavity 422.

[0083] According to this exemplary embodiment, the filter head cavity 422 is configured to have larger horizontal and vertical dimensions to store the additional startup volume 604. Instead, in other embodiments, the filter head cavity 422 is configured to only have a larger vertical dimension or only a larger horizontal dimension to store the additional startup volume 604.

[0084] Furthermore, the reductant delivery system includes a pressure side accumulator (e.g., a nitrogen bladder, etc.) 908. The pressure side accumulator is coupled to the outlet channel 728 of the reductant pump 228. For example, according to some embodiments, the pressure side accumulator 908 may be a nitrogen bladder pressure accumulator. The nitrogen bladder pressure accumulator 908 is configured to receive reductant from the reductant pump 228. The nitrogen bladder pressure accumulator 908 may include a rubber or elastomeric bladder filled with nitrogen gas that can be surrounded by reductant. The pressure from the nitrogen gas inside the bladder may be exceeded by the volume of reductant introduced into the pressure side accumulator 908. Once enough reductant has entered the pressure side accumulator 908 to sufficiently reach a maximum pressure, the nitrogen within the bladder expands forcing the reductant out of the pressure side accumulator 908 and through the doser supply line 234. The doser supply line 234 is configured to deliver the reductant to the doser assembly 112. Instead, in other embodiments, the reductant delivery system 102 may include one of a suction side accumulator 906 and a pressure side accumulator 908.

[0085] The doser assembly 112 is coupled to the return line 236 configured to return reductant to the reductant delivery system 102 form the aftertreatment system 100. The reductant delivery system 102 further includes a second selection valve 910. The second selection valve 910 is coupled to the return line 236 and the optional warm line 302. The second selection valve 910 is communicatively coupled to the reductant delivery system controller 128. The reductant delivery system controller 128 is configured to receive a signal from the temperature sensor 210 associated with the reductant temperature of the main tank volume 206. In response to the reductant delivery system controller 128 determining the temperature of the reductant in the main tank volume meets or exceeds threshold reductant temperature value, the reductant delivery system controller 128 is configured to open the second selection valve 910. When in an open position the second selection valve is configured to deliver reductant from the doser assembly 112 back to the main tank volume 206. In response to the reductant delivery system controller 128 determining the temperature of the reductant stored in the main tank volume 206 does not meet or exceed the threshold reductant temperature value, the reductant delivery system controller 128 is configured to close the second selection valve. When in a closed position the second selection valve 910 is configured to deliver reductant through the optional warm line 302 the reductant pump 228. For example, the reductant pump 228 stores the warm reductant in the additional startup volume 604.

[0086] According to one exemplary embodiment, FIG. 10 illustrates the main tank 202 of the reductant delivery system 102. The main tank 202 includes the main tank body 204 that defines the main tank volume 206. The main tank 202 further includes a main tank filling tube 912, a heating element 914, and a heating pot 916. The main tank filling tube 912 is coupled to the main tank body 204. A portion of the main tank filling tube 912 is positioned within the main tank volume 206. The main tank filling tube 912 is configured to open and close to allow a user to add reductant to the main tank volume 206.

[0087] The heating element 914 is coupled to the heating pot 916. The heating element 914 and the heating pot 916 are positioned within the main tank volume 206. The heating pot 916 is configured to store a freeze resistant liquid that can be heated and circulated through the heating element 914. The heating element 914 is configured to heat reductant stored within the main tank volume 206. According to other embodiments, the main tank 202 includes a main heater 208, such as a heating rod or a Positive Temperature Coefficient (PTC) heater, as previously described.

[0088] The main tank 202 further includes a temperature sensor 918 and a level sensor 920. The temperature sensor 918 and the level sensor 920 are positioned within the main tank volume 206. The level sensor 920 is fastened to the main tank body 204 and communicatively coupled to the reductant delivery system controller 128. The temperature sensor 918 is coupled to the level sensor 920 and communicatively coupled to the reductant delivery system controller 128 (as shown in previous embodiments). The temperature sensor 918 is configured to determine a temperature of the reductant in the main tank volume 206. The temperature sensor 918 is further configured to communicate a temperature signal to the reductant delivery system controller 128. The level sensor 920 is configured to determine a level of reductant stored within the main tank volume 206. The level sensor is further configured to communicate a level signal to the reductant delivery system controller 128. For example, according to some embodiments, the reductant delivery system controller 128 may use the level determined by the level sensor 920 to indicate to the user that the reductant level within the main tank volume 206 is below a level threshold.

[0089] Furthermore, the main tank 202 includes a main tank delivery pump 922 (e.g., a lift pump), and a suction tube 924. According to this embodiment, the main tank delivery pump 922 is coupled to the exterior side of the main tank body 204. Instead, in other embodiments, the main tank delivery pump 922 may be positioned on the interior side of the main tank body 204 or positioned within the main tank volume 206 as previously described. The main tank delivery pump 922 is coupled to the suction tube 924. The suction tube 924 is configured to deliver reductant from the main tank volume 206 up to the main tank delivery pump 922. The main tank delivery pump 922 is fluidly coupled to the supply line 214 (e.g., a feed line). The main tank delivery pump 922 is configured to pull reductant from the main tank volume 206 up the suction tube 924. The main tank delivery pump 922 is further configured to push reductant through the supply line 214 to deliver reductant to the reductant pump 228 as previously described.

IV. Configuration of Example Embodiments

[0090] While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed but rather as descriptions of features specific to particular implementations. Certain features described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

[0091] As utilized herein, the terms “substantially,” “generally,” “approximately,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.

[0092] The term “coupled” and the like, as used herein, mean the joining of two components directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two components or the two components and any additional intermediate components being integrally formed as a single unitary body with one another, with the two components, or with the two components and any additional intermediate components being attached to one another.

[0093] The terms “fluidly coupled to” and the like, as used herein, mean the two components or objects have a pathway formed between the two components or objects in which a fluid, such as air, exhaust, liquid reductant, gaseous reductant, aqueous reductant, gaseous ammonia, etc., may flow, either with or without intervening components or objects. Examples of fluid couplings or configurations for enabling fluid communication may include piping, channels, or any other suitable components for enabling the flow of a fluid from one component or object to another.

[0094] It is important to note that the construction and arrangement of the various systems shown in the various example implementations is illustrative only and not restrictive in character. All changes and modifications that come within the spirit and/or scope of the described implementations are desired to be protected. It should be understood that some features may not be necessary, and implementations lacking the various features may be contemplated as within the scope of the disclosure, the scope being defined by the claims that follow. When the language “a portion” is used, the item can include a portion and/or the entire item unless specifically stated to the contrary.

[0095] Also, the term “or” is used, in the context of a list of elements, in its inclusive sense (and not in its exclusive sense) so that when used to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, Z, X and Y, X and Z, Y and Z, or X, Y, and Z (i.e., any combination of X, Y, and Z). Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present, unless otherwise indicated.

[0096] Additionally, the use of ranges of values (e.g., W1 to W2, etc.) herein are inclusive of their maximum values and minimum values (e.g., W1 to W2 includes W1 and includes W2, etc.), unless otherwise indicated. Furthermore, a range of values (e.g., W1 to W2, etc.) does not necessarily require the inclusion of intermediate values within the range of values (e.g., W1 to W2 can include only W1 and W2, etc.), unless otherwise indicated.