Cover and sensor for diesel exhaust fluid (def) module

A cover assembly for a diesel exhaust fluid module, the cover assembly comprising:

• a cover, configured to define a top portion of the diesel exhaust fluid tank, includes at least one opening, dimensioned for passage of a lead between an exterior element and an interior of the tank, and a collar;
• a plug, configured to be press-fit into the at least one opening, include a passageway dimensioned for the lead to extend therethrough;
• and
• a sealing cap that engages an outer surface of the collar, and is sealed to the cover.

A method of making a sensor assembly for a diesel exhaust fluid module comprising:

• providing a sensor housing having a hollow opening that extends through a first end that includes a shoulder with an upstanding collar, and a second end;
• providing a junction housing having a first end with a sleeve dimensioned to surround and engage the upstanding collar of the sensor housing, and a second end defining an opening for passage of at least one electrical wire;
• providing a sensor element connected to the at least one electrical wire and arranged in a lower portion of the hollow opening;
• telescoping the sleeve of the junction housing over the upstanding collar of the sensor housing;
• and
• securing the first end of the junction to the upstanding collar of the sensor housing.

A cover assembly for a diesel exhaust fluid tank, the cover assembly comprising:

• a cover configured to define a top portion of the diesel exhaust fluid module includes an axially extending collar that defines at least one opening dimensioned to allow passage of an electrical wire into a diesel exhaust fluid tank;
• a plug that has at least one passage dimensioned to allow the electrical wire to extend into the Def tank and is configured for a press-fit into the at least one opening;
• a sealing cap that has:
• a first portion configured to engage an axially outer surface of the collar, a second portion that extends inward from the axially extending portion of the collar, and, is fastened to the cover.

A sensor assembly for a diesel exhaust fluid tank, the sensor assembly comprising:

• a sensor housing with a central opening that extends between a diesel exhaust fluid tank's base and an open end with a surrounding shoulder;
• the surrounding shoulder supports an upstanding open collar;
• a junction housing has a first end that is mated with the upstanding open collar and a second end configured for passage of an electrical conductor associated with a sensor;
• a cap having a portion that encloses a gasket in abutment with the second end of the housing and a portion that engages with the second end of the housing;
• the cap and gasket have through passages that enable an electrical conductor associated with a sensor to extend beyond the cap;
• a sensor is arranged in a lower portion of the central opening with at least one electrical conductor that extends beyond the cap;
• and,
• a thermally conductive potting compound surrounds the at least one electrical conductor between the sensor and the cap.

A diesel exhaust fluid tank cover and sensor assembly comprising:

• a cover configured for closing a diesel exhaust fluid tank;
• a sensor housing configured to receive a sensor between an open first end and a second end closed by a first sealing cap;
• a sensor positioned in a lower portion of the sensor housing toward the second end with at least one electrical lead that passes through the open first end;
• and,
• a plug, through which the at least one electrical lead passes, is positioned within an opening in the cover and secured to the cover by a second sealing cap;
• wherein the second sealing cap is sonic welded to the cover.