U.S. patent application number 09/943824 was filed with the patent office on 2003-03-06 for exhaust port gasket with cylinder-specific electronic oxygen sensors.
This patent application is currently assigned to Dana Corporation. Invention is credited to Kozerski, Richard J., Oxenknecht, Ernest.
Application Number | 20030041589 09/943824 |
Document ID | / |
Family ID | 25480328 |
Filed Date | 2003-03-06 |
United States Patent
Application |
20030041589 |
Kind Code |
A1 |
Kozerski, Richard J. ; et
al. |
March 6, 2003 |
EXHAUST PORT GASKET WITH CYLINDER-SPECIFIC ELECTRONIC OXYGEN
SENSORS
Abstract
An exhaust port gasket is adapted for insertion between an
engine exhaust port and an exhaust pipe flange for sealing
therebetween. The gasket includes at least one primary aperture
acting as an exhaust port for accommodating flows of exhaust gases,
and includes at least one electronic oxygen sensor responsive to
oxygen levels of gases passing through the exhaust port. To the
extent that oxygen-sensing is provided at the exhaust port,
improved real time engine management may be derived from
cylinder-by-cylinder measurements of the oxygen levels by inputting
the measurements into an engine control unit module to optimize
engine performance parameters, including fuel economy and emissions
levels. In one described embodiment, a plurality of cylindrical
oxygen sensor probes are positioned in surface grooves of a spacer
layer of the exhaust gasket, and individual probe sensor wires are
collectively connected to a wire harness portion of the gasket.
Inventors: |
Kozerski, Richard J.;
(Lisle, IL) ; Oxenknecht, Ernest; (Downers Grove,
IL) |
Correspondence
Address: |
MICHAEL B. STEWART, ESQ.
RADER, FISHMAN & GRAUER PLLC
39533 WOODWARD AVE., STE 140
BLOOMFIELD HILLS
MI
48304
US
|
Assignee: |
Dana Corporation
Toledo
OH
|
Family ID: |
25480328 |
Appl. No.: |
09/943824 |
Filed: |
August 30, 2001 |
Current U.S.
Class: |
60/276 ;
60/323 |
Current CPC
Class: |
F01N 13/008 20130101;
F01N 13/1827 20130101; F02D 41/1443 20130101; F01N 13/10
20130101 |
Class at
Publication: |
60/276 ;
60/323 |
International
Class: |
F01N 003/00; F01N
007/10 |
Claims
What is claimed is:
1. An exhaust port gasket adapted for insertion between mating
surfaces of an engine exhaust port and an exhaust pipe flange for
sealing therebetween, said gasket comprising at least one port
aperture for accommodating a flow of exhaust gases therethrough,
said gasket further comprising at least one electronic oxygen
sensor responsive to oxygen levels of said exhaust gases passing
through said engine exhaust port, wherein oxygen-sensing is
provided at each exhaust port for transmittal of cylinder-specific
oxygen level data to a real-time engine management system for
optimization of engine performance parameters.
2. The exhaust port gasket of claim 1, wherein said real-time
engine management system includes optimization of fuel economy and
emissions levels.
3. The exhaust port gasket of claim 2, further comprising a sensor
connection wire integrally attached to said electronic oxygen
sensor for accommodating said transmittal of said cylinder-specific
oxygen level data to said real-time engine management system.
4. The exhaust port gasket of claim 3 wherein said exhaust port
gasket comprises at least one beaded layer and one flat spacer
layer, wherein each of said layers comprises at least one port
aperture, and wherein said apertures are concentrically registered
with each other in said respective layers, and wherein said spacer
layer comprises a surface groove adapted to receive both said
oxygen sensor and said sensor connection wire.
5. The exhaust port gasket of claim 3 wherein said exhaust port
gasket comprises a pair of beaded layers, each having at least one
bead, and one spacer layer, said spacer layer being sandwiched
between said pair of beaded layers, wherein each of said layers
comprises at least one port aperture, and wherein said apertures
are symmetrically registered with each other in said respective
layers, and wherein said spacer layer comprises a surface groove
adapted to receive both said oxygen sensor and said sensor
connection wire.
6. The exhaust port gasket of claim 5, wherein said beads of said
beaded layers are positioned symmetrically on said respective
beaded layers so as to comprise mirrored images of one another.
7. The exhaust port gasket of claim 6 comprising a plurality of
said port apertures spaced apart from one another within said
gasket, each of said ports comprising one of said oxygen sensors
responsive to said oxygen levels of said exhaust gases passing
through that one exhaust port, each sensor positioned at an edge of
its respective exhaust port.
8. The exhaust port gasket of claim 7 further comprising a harness
portion, wherein each of said sensor connection wires terminates at
an edge of said harness portion.
9. The exhaust port gasket of claim 8 wherein said spacer layer is
formed of a nonmetallic insulating material.
10. The exhaust port gasket of claim 9, wherein said spacer layer
comprises a vermiculite material.
11. The exhaust port gasket of claim 10 wherein said vermiculite
material is applied to a perforated metal core, and wherein said
vermiculite material is granulated for facilitating its application
to said core.
12. The exhaust port gasket of claim 11 wherein each of said
sensors defines a cylindrical body, and wherein each of said
grooves comprises a surface depth at least equal to the outside
dimension of said oxygen sensor, such that said sensor may be
substantially received within said groove.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates generally to sensing apparatus
embedded in and or applied to gasket structures, and particularly
to apparatus applied to exhaust gaskets of internal combustion
engines. More specifically, the invention relates to electronic
oxygen sensor apparatus provided within structures of exhaust
gaskets for measuring oxygen levels in gaseous exhaust media
passing through apertures of such gaskets.
[0003] 2. Description of the Prior Art
[0004] It is known to employ electronic sensors in gaskets for
sealing between engine components including, for example, the block
and cylinder head of a multi-cylinder internal combustion engine.
In one case, the gasket comprises a sealing plate having several
combustion chamber orifices, with combustion chamber sealing
elements situated on the edges of the sealing plate surrounding the
combustion chamber orifices. The gasket includes sensor elements
for cylinder-specific detection of sealing movements perpendicular
to the plane of the sealing plate, caused by pressure changes in
respective combustion chambers being measured. All of the sensor
elements are arranged outside of the combustion chamber sealing
elements, and can be piezoelectric and piezoresistive, as well as
glass fiber light guide-style sensors.
[0005] In another example, a gasket enclosed sensor system is
employed for measurement of combustion chamber parameters and
delivery of signals to points external of the engine. The gasket
includes a combustion opening substantially surrounding a
combustion chamber, and includes an access opening extending from
the combustion chamber to a point external of the engine. A
metallic sensor terminal is positioned within the access opening,
and insulating material substantially surrounds the metallic sensor
terminal.
[0006] In yet another example, a fluid sensor and associated
circuitry are used to indicate presence of oil flow in a
multi-cylinder internal combustion engine. The oil sensor includes
a heating element positioned within the oil line, directly in the
oil flow path. A comparator measures the value of signals from
upstream and downstream heat sensors, and triggers a switching
circuit when the temperature at the sensors approach one another to
indicate an adequate oil flow to the engine.
[0007] In still another example, a gasket formed in the shape of an
exhaust flange includes a load sensor comprising a pressure
sensitive electrically resistive material positioned between
electrodes and conductors extending outwardly of the perimeter of
the gasket. A seal provided between first and second layers of the
gasket, and about the load sensor, provides a seal for the
electrodes, which are positioned in a cavity to protect the sensor
from fluids.
SUMMARY OF THE INVENTION
[0008] The present invention provides an electronic oxygen sensor
for an automotive exhaust port gasket adapted for insertion between
mating surfaces of an engine exhaust port and an exhaust pipe
flange for sealing therebetween. The gasket includes at least one
primary aperture for accommodating the flow of exhaust gases, and
includes at least one electronic oxygen sensor responsive to oxygen
levels of the gases passing through said exhaust port. Where a
plurality of ports are provided in the gasket, and to the extent
that oxygen-sensing is provided at each exhaust port, a real time
quality engine management control opportunity based upon
cylinder-by-cylinder measurements of said oxygen levels is
provided. The specific cylinder-to-cylinder oxygen sensing data can
be input into an engine control unit module that includes systems
for optimization of engine performance parameters, including fuel
economy and emissions levels.
[0009] The oxygen sensor is designed to be applied to or embedded
within a spacer layer positioned between the beaded or active
layers of a multiple-layered steel exhaust port gasket. The oxygen
sensor is positioned to be particularly effective to measure
changes in oxygen levels of cylinder-specific exhaust gases passing
through the primary apertures of the gasket. In this way, a
real-time control feedback loop may be established for controlling
air-fuel mixtures for optimizing engine combustion parameters,
compared to the standard oxygen sensor placement at an exhaust
point downstream of the individual exhaust ports.
[0010] In the disclosed embodiment, the oxygen sensor system
includes a sensing element carried or formed as part of a spacer
layer of an exhaust manifold gasket.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a plan view of a spacer layer of one described
embodiment of an exhaust gasket that incorporates the oxygen sensor
system of the present invention, each sensor defined by a
cylindrical probe disposed within a surface groove provided in a
spacer layer of the gasket, and positioned to protrude slightly
into an exhaust gas port aperture.
[0012] FIG. 2 is an enlarged perspective break-away view of a
portion of the gasket of the present invention to reveal details of
a groove provided in the surface of an exhaust gasket spacer layer,
showing an oxygen sensor probe positioned in the groove and cut
open to reveal the cylindrical nature of the probe.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] Referring initially to FIG. 1, one described embodiment of
an exhaust gasket 10 is shown, including a plurality of spaced
cylinder head exhaust ports 12, 14, 16, and 18. The described
gasket 10 is a multi-layer steel (MLS) gasket, although this
invention is not limited only to so-called MLS gaskets. The gasket
10 also includes a plurality of similarly spaced bolt apertures 20.
A plurality of oxygen sensors 22, 24, 26, and 28 are adapted to
interface the edges of each of the cylinder head exhaust ports 12,
14, 16, and 18, respectively.
[0014] Each of the oxygen sensors 22, 24, 26, and 28 has an
integral connection to one of the individual sensor connection
wires 30, 32, 34, and 36, respectively. All respective sensor
connection wires converge together at, and are attached to, a wire
harness portion 38 of the gasket 10. The ends 40 of the sensor
connection wires collectively terminate along an edge 42 of the
harness portion 38 as shown, and are adapted to be engaged by an
electrical harness clip (not shown) that is secured rigidly to the
wire harness portion 38 for facilitating transmittal of electrical
data to an electronic engine control unit (ECU) not shown. It is
envisioned that the ECU will read the relevant oxygen sensor data,
and make adjustments to time-responsive engine controls in response
to cylinder-specific levels of oxygen indicated.
[0015] Referring now to FIG. 2, a fragmentary portion of one of the
cylinder head exhaust ports, i.e. port 14, is depicted on an
enlarged scale to show details of one representative individual
oxygen sensor 24, and its associated sensor connection wire 32. A
spacer layer 46 is adapted to be positioned against at least one
beaded metallic layer 48 as shown, and is ideally positioned
between two of such beaded layers. The beaded layer 48 has at least
one resilient beaded 44, adapted for assuring positive sealing, as
will be appreciated by those skills in the art. Two of such beaded
layers 48 are preferably employed, the layers 48 sandwiching the
spacer layer 46. Ideally, the beads 44 are positioned symmetrically
on the layers 48 so as to form mirrored images of one another.
[0016] The spacer layer 46 includes an elongated groove 50 in the
surface of the layer 46. The groove 50 has a surface depth equal to
the outside dimension of the oxygen sensor 24. The groove may be
machined or stamped into the layer 46, as the layer is of carbon
steel metal.
[0017] The beaded layers 48 in the embodiment described herein are
formed of spring steel, e.g. stainless steel. The spacer layer 46,
sandwiched between layers 48, is also formed of steel, but since
without resilient beads may be formed of a lesser quality steel,
such as plain carbon steel. Alternatively, the spacer layer 46 may
be formed of an insulating nonmetallic material resistant to high
temperatures. For example, granulated vermiculite provides one such
alternative material for the manufacture of the layer 46, wherein
the vermiculite would be applied to a clinched or perforated metal
core. The resultant composite layer 46 would offer superior heat
insulating properties, in addition to readily accommodating
formation of the grooves 50 in the surface of the layer 46.
[0018] Each sensor is formed in the nature of a probe, and includes
an interior cylindrical wall 52 and an exterior cylindrical wall
54. The sensor body is formed of a ceramic; the interior and
exterior cylindrical walls 52, 54 thereof are coated in accordance
with principles of oxygen sensing art, and may include a
composition of zirconium oxide. Typically, when the sensor reaches
its operating temperature, typically around 300.degree. C., a
voltage is generated which has a value that is a function of the
amount of oxygen present in the gases being measured. To the extent
that oxygen sensor art is well established, however, the precise
methods of sensing are beyond the scope of this invention.
[0019] In the described embodiment, the manner of affixation of the
oxygen sensors and the sensor connection wires to the layer 46 is
such that the sensors and wires are fully disposed within their
respective grooves 50. A bonding agent, such as an epoxy or high
temperature adhesive, may also be used to assure reliable
affixation of the sensors 22, 24, 26, 28 in their grooves during
manufacture of the gasket. Of course, the same or similar
affixation technique would be applied to the sensor connection
wires 30, 32, 34, and 36.
[0020] It is to be understood that the above description is
intended to be illustrative and not limiting. Many embodiments will
be apparent to those of skill in the art upon reading the above
description. For example, a gasket within the sensor elements and
wires molded into the body of the gasket material would fall within
the broader scope of this invention. Therefore, the scope of the
invention should be determined, not with reference to the above
description, but instead with reference to the appended claims,
along with the full scope of equivalents to which such claims are
entitled.
* * * * *