U.S. patent application number 10/125236 was filed with the patent office on 2003-10-23 for particulate sensor system.
Invention is credited to Bosch, Russell H., Wang, Da Yu.
Application Number | 20030196499 10/125236 |
Document ID | / |
Family ID | 28790917 |
Filed Date | 2003-10-23 |
United States Patent
Application |
20030196499 |
Kind Code |
A1 |
Bosch, Russell H. ; et
al. |
October 23, 2003 |
PARTICULATE SENSOR SYSTEM
Abstract
Disclosed herein is a particulate sensor system, comprising a
first sensing electrode and a second sensing electrode in thermal
and electrical communication with a heater wherein the first
sensing electrode and the second sensing electrode are disposed on
the same side of an electrode substrate. Further disclosed is a
method for operating a particulate sensor system comprising
introducing a gas stream to a sensor; monitoring the resistance
between the first sensing electrode and the second sensing
electrode, and increasing the temperature of the sensor when the
resistance is greater than or equal to a first selected level.
Further disclosed is a method for operating a filter system
comprising exposing a sensor to a pre-selected number of
self-regeneration cycles, and increasing the temperature of the
filter system.
Inventors: |
Bosch, Russell H.; (Gaines,
MI) ; Wang, Da Yu; (Troy, MI) |
Correspondence
Address: |
VINCENT A. CICHOSZ
DELPHI TECHNOLOGIES, INC.
Legal Staff, Mail Code: 480-414-420
P.O. Box 5052
Troy
MI
48007-5052
US
|
Family ID: |
28790917 |
Appl. No.: |
10/125236 |
Filed: |
April 17, 2002 |
Current U.S.
Class: |
73/865.5 |
Current CPC
Class: |
G01N 15/0656
20130101 |
Class at
Publication: |
73/865.5 |
International
Class: |
G01N 015/00 |
Claims
1. A particulate sensor system, comprising: a first sensing
electrode and a second sensing electrode in thermal and electrical
communication with a heater wherein said first sensing electrode
and said second sensing electrode are disposed on a same side of an
electrode substrate.
2. The particulate sensor system of claim 1, wherein said
particulate sensor system further comprises a temperature sensor
disposed between said electrode substrate and said heater, and in
electrical communication with said heater.
3. The particulate sensor system of claim 1, wherein said electrode
substrate is non-ionically conducting.
4. The particulate sensor system of claim 1, wherein said
particulate sensor system further comprises a louvered shield
disposed around said particulate sensor system.
5. The particulate sensor system of claim 1, wherein said first
sensing electrode and said second sensing electrode are disposed on
said electrode substrate to create a width of separation between
said first sensing electrode and said second sensing electrode
wherein said width of separation is about 0.1 to about 0.5
millimeters.
6. The particulate sensor system of claim 1, wherein said
particulate sensor system further comprises a porous electrode
protective layer disposed on said first sensing electrode and said
second sensing electrode.
7. The particulate sensor system of claim 6, wherein said
particulate sensor system further comprises an isolation layer in
physical contact with said electrode protective layer.
8. The particulate sensor system of claim 7, wherein said
particulate sensor system further comprises a guard electrode
disposed on said electrode substrate and positioned between and
electrically isolated from said first sensing electrode and said
second sensing electrode.
9. The particulate sensor system of claim 8, wherein an over-layer
is disposed on said first sensing electrode and said second sensing
electrode.
10. The particulate sensor system of claim 9, wherein said
over-layer comprises a material selected from the group consisting
of dense glass, oxides, and combinations comprising at least one of
the foregoing materials.
11. The particulate sensor system of claim 10, wherein said
over-layer has a thickness of up to about 60 micrometers.
12. A method for operating a particulate sensor system comprising:
introducing a gas stream to a sensor; monitoring a resistance
between a first sensing electrode and a second sensing electrode,
wherein said first sensing electrode and said second sensing
electrode are disposed on a same side of an electrode substrate;
and increasing to a first temperature of said sensor when said
resistance is greater than or equal to a first selected level.
13. The method of claim 12, further comprising increasing said
first temperature to about 500.degree. C. to about 1,100.degree.
C.
14. The method of claim 13, further comprising increasing said
first temperature to about 500.degree. C. to about 1,000.degree.
C.
15. The method of claim 12, further comprising maintaining said
sensor at a second temperature when said resistance is at or below
a second selected level.
16. The method of claim 15, wherein said second temperature
comprises about 125.degree. C. to about 475.degree. C.
17. A method for operating a filter system comprising: exposing a
sensor to a pre-selected number of self-regeneration cycles,
wherein a self-regeneration cycle comprises: introducing a gas
stream to said sensor; monitoring a resistance between a first
sensing electrode and a second sensing electrode, wherein said
first sensing electrode and said second sensing electrode are
disposed on a same side of an electrode substrate; and increasing
to a first temperature of said electrode substrate when said
resistance is greater than or equal to a first selected level; and
increasing said filter system to a third temperature when said
sensor has been exposed to said pre-selected number of
self-regeneration cycles.
18. The method of claim 17, further comprising increasing said
first temperature to about 500.degree. C. to about 1,100.degree.
C.
19. The method of claim 18, further comprising increasing said
first temperature to about 500.degree. C. to about 1,000.degree.
C.
20. The method of claim 17, further comprising increasing said
third temperature to about 500.degree. C. to about 1,100.degree.
C.
21. The method of claim 20, further comprising increasing said
third temperature to about 500.degree. C. to about 1,000.degree.
C.
22. The method of claim 21, further comprising increasing said
third temperature to about 500.degree. C. to about 950.degree.
C.
23. The method of claim 17, wherein said filter system is a
particulate trap.
Description
BACKGROUND OF THE INVENTION
[0001] The present disclosure relates to a self-regenerating
particulate sensor, and more particularly, to a self-regenerating
sensor capable of detecting particulates emitted from an exhaust
gas. Incomplete combustion of heavy hydrocarbon compounds, such as
heavy oils, diesel oil, and the like leads to particulate
formation. In the operation of internal combustion engines,
"smoking" of the engine leads to ambient air pollution although the
carbon monoxide and hydrocarbon emission of the exhaust gases from
the internal combustion engine itself are very low. It is,
therefore, desirable to detect the formation of particulates in the
exhaust of the engine and to provide an output signal that can then
be used to indicate the presence of particulates and further to be
used as a sensing or control signal, for example in a control loop,
to automatically adjust air, or the supply of fuel for complete
combustion and to prevent excess particulate formation.
[0002] Currently exhaust gases can be sensed by optical sensors;
however, such sensors are more suited to fixed locations, for
example smokestacks, and are not readily adaptable to automotive
use, particularly in view of the rugged and highly variable ambient
operating conditions associated with automotive use, including wide
swings in temperature, temperature gradients, shock, vibration, and
the like. It would, therefore, be desirable to provide a more
robust sensor capable of directly sensing exhaust particulates.
[0003] In the past, a sensing plate has been used for detecting
exhaust particulates, wherein the sensing plate changes the
electrical conductivity of a sensor by the formation of a carbon
bridge between electrodes. To refresh the sensor, the deposited
particulates are burned off by means of a catalyst with extra
oxygen in the engine exhaust. Such sensors, however, are not
completely practical because the strong reduction effect of the
particulates can damage the electrode and detach the electrode from
the sensing plane. Current sensors are furthermore unable to
control both the temperature surrounding the sensor and the rate of
the exhaust flow. This inability is disadvantageous as it allows
for the condensation of humidity or moisture on the sensor, which
leads to the gradual deterioration of the sensor; thus preventing
the sensor from controlling the particulate deposition process,
which in turn prevents the sensor from being a direct mechanism by
which particulates may be removed from the exhaust. A further
problem with current sensors is that they are primarily limited to
use with direct current methods of sensing conductivity. Such
methods are problematic in that the electrical properties are
highly non-liner, thereby making it difficult to control the rate
of exhaust flow.
SUMMARY OF THE INVENTION
[0004] Disclosed herein is a particulate sensor system, comprising
a first sensing electrode and a second sensing electrode in thermal
and electrical communication with a heater wherein the first
sensing electrode and the second sensing electrode are disposed on
the same side of an electrode substrate.
[0005] Further disclosed is a method for operating a particulate
sensor system comprising introducing a gas stream to a sensor;
monitoring the resistance between the first sensing electrode and
the second sensing electrode, and increasing the temperature of the
sensor when the resistance is greater than or equal to a first
selected level.
[0006] Further disclosed is a method for operating a filter system
comprising exposing a sensor to a pre-selected number of
self-regeneration cycles, and increasing the temperature of the
filter system.
[0007] The above described and other features are exemplified by
the following figures and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Referring now to the figures, which are exemplary
embodiments, and wherein the like elements are numbered alike:
[0009] FIG. 1 is a schematic showing an exemplary embodiment of the
sensor;
[0010] FIG. 2 is a flow diagram showing the circuitry of the
particulate sensor system;
[0011] FIG. 3 is a circuit diagram showing the sensing electrodes
in series with the resistor; and
[0012] FIG. 4 is a cutaway view an exemplary embodiment of a
particulate sensor.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] The present disclosure relates to a particulate sensor
system capable of self-regeneration and for use as a sensing or
control signal to automatically remove particulate matter from
exhaust emission devices. The particulate sensor system comprises a
sensor in electrical communication with a sensor circuit, which
operates to detect the level of particulate matter in the
environment surrounding the sensor. The particulate sensor system
may be calibrated to detect a specific amount of particulate
accumulation on the sensor, at which point the particulate sensor
system removes the particulates (self-regeneration) by signaling a
heater disposed in the sensor. Additionally, the particulate sensor
system may be designed such that after a predetermined number of
self-regeneration cycles, particles condensed on an exhaust system
can also be removed. It is noted that each self-regeneration cycle
can be determined based on the size dimensions of the sensor; in
general, the smaller the sensing area (e.g., the substrate surface
upon which the sensing electrodes are positioned) and the smaller
the volume at the tip of the sensor (e.g., that portion of the
sensor where the sensing electrodes are positioned), the less time
is needed for each self-regeneration cycle. Additionally, a
temperature sensor may be advantageously used to maintain the
external temperature surrounding the sensor at a point higher than
the condensation point of water but lower than the condensation
point of the particulates such that the particulates can condense
on the sensor without an accompanying condensation of water.
Preferably the external temperature maintained by the heater is
above the temperature of water condensation, and below the burn-off
temperature of the deposited particulates.
[0014] The particulate sensor system can self-regenerate by a
signal comprising an electrical communication between at least two
sensing electrodes and a heater. A signal is transmitted from the
sensing electrodes to the heater when the electrical resistance
between the sensing electrodes drops to a predetermined threshold
amount. Such a drop in resistance is caused by particulate
condensation on the sensor. The signal activates the heater to
increase its thermal energy output, thereby causing the removal of
the particulates from the sensor. As the particulates are removed
from the sensor, the resistance gradually increases. The increasing
resistance can be employed to signal the heater to decrease its
thermal energy output, or the thermal energy output can be
maintained until the resistance reaches a selected level, or
thermal energy output may be controlled at timed intervals.
[0015] In general, the sensor comprises a sensing element and a
heating element, wherein the sensing element may comprise, but is
not limited to, at least two sensing electrodes, and optionally a
guard electrode; and, wherein the heating element may comprise, but
is not limited to, a temperature sensor, and a heater. The sensor
may include a multi-layered structure comprising the sensing
element, the temperature sensor, the heater, and a combination
comprising at least one of the foregoing, contained in a single
structure formed, e.g., by multi-layer technology.
[0016] The sensing electrodes can include metals, such as, gold,
platinum, osmium, rhodium, iridium, ruthenium, aluminum, titanium,
zirconium, and the like, as well as, oxides, cermets, alloys, and
combinations comprising at least one of the foregoing metals. In an
exemplary embodiment, the sensing electrode can comprise a
platinum/alumina cermet wherein the platinum is about 90 wt %
(weight percent) to about 98 wt % of the sensing electrode, with
about 93 wt % to about 95 wt % platinum particularly preferred,
where weight percent is based on the total dry weight of the
cermet. Each sensing electrode may be composed of the same or
different material as the other sensing electrode(s).
[0017] The sensing electrodes can be formulated in any fashion.
Preferably, however, the sensing electrodes are formed by first
preparing an ink paste by mixing an electrode forming-metal powder
(e.g., platinum, gold, osmium, rhodium, iridium, ruthenium,
aluminum, titanium, zirconium, and the like, or combinations of at
least one of the foregoing) with oxides in a sufficient amount of
solvent to attain a viscosity suitable for printing. The oxides
used to form the sensing electrodes may include those oxides that
do not promote the oxidation of particulates and that do not lower
the burn-off temperature of the particulates. Non-suitable oxides
are, e.g., copper oxide, cerium oxide, and iron oxide. The ink
paste forming the sensing electrode can then be applied to an
electrode substrate via sputtering, chemical vapor deposition,
screen printing, flame spraying, lamination, stenciling, or the
like, with screen printing particularly preferred.
[0018] The sensing electrodes are preferably disposed onto the
electrode substrate such that a constant distance of separation
between each sensing electrode is created. The width of the
distance separating the sensing electrodes can vary widely,
depending upon desired design parameters. A preferred distance
comprises a width of separation of about 0.1 to about 0.5
millimeter (mm), with about 0.1 to about 0.3 mm particularly
preferred, and about 0.1 mm especially preferred. The distance
between the sensing electrodes will allow for a suitable amount of
particulate to form between the sensing electrodes, and will also
allow for the positioning of a guard electrode between the sensing
electrodes where appropriate.
[0019] The size and geometry of the sensing electrode is preferably
selected to allow for current output sufficient to enable
reasonable signal resolution over a wide range of particulate
concentrations. Generally, a thickness of about 5 to about 25
micrometers can be employed, with a thickness of about 8 to about
20 micrometers preferred, and about 10 to about 18 micrometers
particularly preferred. The sensing electrode can be of any shape,
for example, rounded, squared, polygonal, such as square,
needle-shaped, round, oblong, interdigital, or the like.
[0020] The optional guard electrode is most preferably included in
the sensor when an alternating current (AC) method is used to
detect conductivity (complex impedance). The AC method is ideally
employed where a sensor more sensitive than that obtained using a
DC method is desired. The differing sensitivity created by AC or DC
methods is a result of the way in which the particulates are
detected. For example, sensing, and hence, quantification, of
particulate accumulation by the DC method, requires that the
particulates be in direct physical contact (bridging) with other
deposited particulates. Therefore, particulate sensing is limited
to those deposited particulates in direct contact with other
deposited particulates. Such direct contact occurs only when a
sufficient amount of particulates deposit on the surface between
the two electrodes. When particulate deposition is insufficient,
and there is not enough direct particle contacts to form a direct
conducting bridge between the electrodes, there is no DC current
flow, and the sensor cannot detect the presence of deposited
particulates. The AC method, however, can detect a greater range of
particulates as AC can conduct current among the non-contacting
particulates through capacitance effect, and hence, can sense
non-bridged particulates. In this way, a full range (e.g., up to
about 100%) of particulate concentrations can be measured using an
AC method as compared to a range of about 15-25% detected when
using a DC method (numbers are based on the commonly known
percolation theory). In general, the higher the AC frequency, the
more sensitive the sensor.
[0021] The AC guard electrode is preferably disposed along the
length of the electrode substrate, and is preferably positioned
between the sensing electrodes up to the area wherein the deposited
particulates can be detected. The guard electrode can eliminate any
stray capacitance between the sensing electrodes from the
background measurement data and thereby improve the signal to noise
ratio. The use of AC detection can also protect the two measurement
electrodes from direct exposure to the exhaust gas. Under the AC
method, the sensing electrodes can be covered with an over-layer,
preferably a thin over-layer, (e.g., a thickness of up to about 60
micrometers), of a dense glass (glazing materials), oxides (e.g.,
alumina), or combinations comprising at least one of the foregoing.
The over-layer can protect the sensing electrodes against reduction
of the particulates when they are burned off. Typically, when the
particulates are burned off, oxygen is consumed, thereby creating a
reducing atmosphere locally. This reducing atmosphere, in turn, can
reduce the weak oxide bonding between the sensing electrodes and
the substrate, and can de-bond the sensing electrodes from the
substrate. An over-layer, however, can protect the sensing
electrodes, and the AC frequency current can still flow through the
over-layer to engage the deposited particulates. The over-layer can
be done with doctor-bladed cast tape, or with commercial glazing
products. Preferably, the over-layer comprises a dense glass or
oxide to hinder the reducing atmosphere from penetrating underneath
the sensing electrodes where the sensing electrodes contact the
substrate.
[0022] Both the heater and the temperature sensor, forming in whole
or in part, the heating element, can comprise various materials.
Possible materials include platinum, gold, palladium, and the like;
and alloys, oxides, and combinations comprising at least one of the
foregoing materials, with platinum/alumina, platinum/palladium,
platinum, and palladium preferred. The heater and temperature
sensor can be applied to the sensor in any fashion, such as by
sputtering, chemical vapor deposition, screen printing, flame
spraying, lamination, and stenciling among others where screen
printing is particularly preferred. Furthermore, the heater can
comprise a thickness of about 3 to about 50 micrometers, with about
5 to about 30 micrometers preferred, and about 10 to about 20
micrometers more preferred.
[0023] The sensor may further comprise various substrates useful in
electrically isolating and protecting the sensing element and the
heating element from the temperature surrounding the sensor and/or
from the thermal reduction of the condensed particulates during the
self-regeneration cycles. The substrates include, but are not
limited to, an electrode protective layer, an electrode substrate,
an isolation layer, an insulating temperature substrate, a heater
substrate, insulating substrates, wherein the number of insulating
substrates is sufficient to prevent disruptive ionic or electrical
communication between the heating element and the sensing electrode
(e.g., preferably about 2 to about 3 insulating substrates), and
combinations comprising at least one of the foregoing.
[0024] The substrates can comprise non-ionically conducting,
electrically insulating materials. Possible electrically insulating
materials include oxides, such as alumina, zirconia, yttria,
lanthanum oxide, silica, and combinations comprising at least one
of the foregoing, or any like material capable of inhibiting
electrical communication and providing physical protection, wherein
alumina is particularly preferred. In order to hinder electrical
communication between the components of the sensor, the substrates
are preferably composed of a high purity oxide; e.g., less than
about 10.0 wt % impurities, with less than about 8.0 wt %
preferred, and less than about 5.0 wt % more preferred, wherein the
weight percent of the impurities is based on the total weight of
the substrate. Although the composition of the individual
substrates can vary, preferably they comprise a material having
substantially similar coefficients of thermal expansion, shrinkage
characteristics, and chemical compatibility in order to minimize,
if not eliminate, delamination and other processing problems.
Alkaline (e.g., sodium, potassium, lithium, and the like) oxides
should be avoided as they can be easily reduced to form impurities
in the heater, temperature sensor, and the sensing electrodes.
[0025] In general, each of the substrates can be of sufficient size
to support the entire length of the sensing electrodes, the
temperature sensor, and/or the heater. The thickness of each
substrate can be determined based on the desired thermal response
time of the self-regeneration cycle, where shorter thermal response
times require a smaller thickness. Preferably, the thickness of
each substrate can be up to about 200 micrometers thick, with a
thickness of about 50 to about 180 micrometers more preferred, and
about 140 to about 160 micrometers especially preferred. The
substrates can be formed using ceramic tape casting methods, and
the like.
[0026] Any number of the substrates can be porous, dense, or both
porous and dense. The porosity or the diameter of the pores can be
controlled to limit the various sizes of particulates that can
reach the sensing electrodes, and to limit the size of particulates
that can penetrate and trap within the porous layer. In general,
larger-sized particulates (e.g., particles having a diameter along
the major axis equal to or greater than about 5 micrometers)
interfere with current conduction more than do smaller-sized
particulates (e.g., particles having a diameter along the major
axis less than about 5 micrometers). Therefore, where more precise
conductance measurements are desired, it is especially desirable to
exclude the larger particulates from accumulating onto or between
the sensing electrodes. Such exclusion can be achieved by
controlling the size and/or the number of pores on the substrate,
and/or by controlling the internal tortuousness of the substrate.
Here, tortuousness is defined as the effective path length through
the connected pores per standard thickness of the layer.
[0027] Pore size can be controlled by the size of the fugitive
materials used, e.g., by controlling the size of carbon black or
graphite, where fugitive materials are those materials that burn
off at high temperatures leaving behind pores with controlled
sizes. Tortuousness depends on the texture of the substrate-forming
oxide powder used to form the substrate. Texture, in turn, can be
controlled by firing the substrate-forming oxide powder at a high
temperature to coarsen the substrate-forming powder, and then
sieving the substrate-forming metal powder to the right size range
for slurry making.
[0028] Preferably, where the substrate comprises the electrode
protective layer, there is a space gap (e.g., about 10 to about 50
micrometers) between the electrode protective layer and the sensing
electrodes to allow for the free deposition of particulates after
penetrating the porous electrode protective layer. Applying a
fugitive layer between the sensing electrode area and the porous
layer, which can be burned off during the firing stage, can create
the space gap. Screen printing can be used to deposit such
layers.
[0029] The sensor may further comprise various leads responsible
for electrically communicating the sensor with the sensor circuit.
One end of each sensing electrode, one end of the temperature
sensor, and one end of the heater preferably has a connecting point
to which one end of at least one lead may be attached. Preferably,
each sensing electrode is electrically connected with at least one
lead extending from one end of each sensing electrode to via holes
formed on the isolation layer; the temperature sensor is
electrically connected with at least one lead extending from one
end of temperature sensor to via holes formed on the insulating
temperature substrate; and the heater is electrically connected
with at least one lead extending from one end of the heater to via
holes formed on the heater substrate. The via holes formed on the
above substrates serve to provide a mechanism for electrically
connecting the leads to a top contact pad and a bottom contact pad
positioned on the exterior of the sensor. The contact pads provide
a contact point between the sensor and the sensor circuit. In a
preferred embodiment, the via holes are formed at the end portion
of the sensor where the opposite end of the sensor is the tip.
[0030] The via holes, top contact pad, and bottom contact pad
comprise electrically conductive materials. A general method for
forming the via-holed substrate is described in U.S. Pat. No.
6,300,576. For example, each via hole is formed by penetrating the
substrate to form a through-hole as the via hole at the position
for wiring, filling the through-hole with a conducting paste, and
curing the conducting paste while the substrate is shaped and cured
under heat in a heating/pressing step. The conducting paste can be
prepared as a paste using conducting particles, a thermosetting
resin solution, and, if necessary, a solvent. The thermosetting
resin can be selected from resins that can be cured simultaneously
in the step of heating/pressing the substrate. An epoxy resin,
thermosetting polybutadiene resin, phenol resin, or polyimide resin
is preferably used.
[0031] For the conducting particles, a conducting particle-forming
powder of a metal material that is stable and has a low specific
resistance and low mutual contact resistance is preferably used.
For example, a powder of gold, silver, copper, platinum, palladium,
lead, tin, nickel, and combinations comprising at least one of the
foregoing is preferably used.
[0032] After acquiring the components of the sensor, the sensor is
preferably constructed according to thick film multilayer
technology such that the thickness of the sensor allows for good
thermal response time toward the thermal cycle of sensor
regeneration. A preferable thickness is about 0.1 to about 3.0
millimeter (mm), with about 0.15 to about 2.5 mm particularly
preferred, and about 0.3 to about 1.22 mm especially preferred. To
increase the thermal mechanical strength (thermal shock) of the
sensor, the tip of the sensor is preferably as small as possible,
yet large enough for ease of manufacturing. Therefore, the tip of
the device can comprise a length of about 0.5 to about 4.5 mm, with
about 1.0 to about 4.0 mm preferred, and about 1.0 to about 2.0 mm
more preferred. To accommodate the top and bottom contact pads at
the end portion of the device where thermal shock is of no concern,
the width of the sensor can be about 4 to about 8.5 mm, with about
4.5 to about 8.0 mm preferred, and about 5.0 to about 6.0 mm more
preferred.
[0033] Referring to the drawings, FIG. 1 shows an exploded view of
a typical sensor 100. The sensor is a multi-layered device having a
plurality of electrically insulating layers or substrates, e.g., 4,
7, 23, 8, and 9 interspersed between the operative electrically
conductive elements of the sensor. The sensor includes an electrode
substrate 4 with a first sensing electrode 131 and a second sensing
electrode 132 wherein each is capable of being mounted on or fixed
to the same side of the electrode substrate 4. An optional guard
electrode 2 may be included. This guard electrode is capable of
being mounted or fixed between the sensing electrodes and
electrically connected to a ground (not shown). An electrode
protective layer 1 is mounted or fixed over the sensing electrodes
131 and 132 and the guard electrode 2. This entire construction
forms an electrode sensor element 115. A temperature sensor 5 is
mounted on an insulating temperature substrate 8 to form a
temperature sensor element 120, and a heater 6 is mounted on a
heater substrate 9 to form a heater element 125. A plurality of
insulating substrates 23 is mounted between the temperature sensor
element 120 and the electrode sensor element 115 to electrically
isolate the first sensing electrode 131 and the second sensing
electrode 132 from the temperature sensor 5 and the heater 6. The
first sensing electrode 131 is electrically communicated with one
end of a first measuring lead 18, which extends from the first
sensing electrode 131 and is electrically communicated to via holes
110 formed on the isolation layer 7. The second sensing electrode
132 is electrically communicated with one end of a second measuring
lead 19, which extends from the second sensing electrode 132 and is
electrically communicated to via holes 110 formed on the isolation
layer 7. Guard electrode 2 is disposed across the electrode
substrate 4 wherein one end of the guard electrode 2 is
electrically communicated with via holes 110 formed on the
isolation layer 7.
[0034] Electrode protective layer 1 and electrode substrate 4 are
non-movably associated with the first sensing electrode 131, the
second sensing electrode 132, and guard electrode 2 to secure the
first sensing electrode 131, the second sensing electrode 132, and
the guard electrode 2 to the sensor 100. A dense reduction
protection over-layer on top of electrodes 131 and 132 (not shown
in FIG. 1) can be introduced when an AC measurement method is used.
Such security is preferred as particulates condense on the sensor
to create a strong reduction effect of the particulate matter,
which can otherwise damage the sensing electrodes. Electrode
substrate 4 is also non-movably associated with guard electrode 2
so as to secure guard electrode 2 in the sensor 100.
[0035] In accordance with a first embodiment, temperature sensor 5
comprises a first temperature sensor end 126 and a second
temperature sensor end 127. One end of a first temperature sensing
lead 25 is electrically communicated with the first temperature
sensor end 126 and extends to and is connected with via holes 110
formed on the insulating temperature substrate 8. One end of a
second temperature sensing lead 26 is electrically communicated
with the second temperature sensor end 127 and extends to and is
communicated with via holes 110 formed on the insulating
temperature substrate 8. Preferably, the insulating temperature
substrate 8 is non-movably associated with the temperature sensor 5
and the heater 6 so as to electrically isolate the temperature
sensor 5 from the heater 6.
[0036] Also in accordance with a first embodiment, heater 6
includes a first heater end 128 and a second heater end 129. One
end of a first heater element lead 21 is electrically communicated
with the first heater end 128 and extends to and is connected with
via holes 110 formed on the insulating temperature substrate 8 and
the heater substrate 9. One end of a second heater element lead 22
is electrically communicated with the second heater end 129 and
extends to and is communicated with via holes 110 formed on the
insulating temperature substrate 8 and the heater substrate 9. In
addition, sensor 100 preferably includes a heater substrate 9
non-movably associated with heater 6 so as to electrically isolate
heater 6 from a second contact pad 29.
[0037] In accordance with a first embodiment, the first measuring
lead 18, second measuring lead 19, and the guard electrode 2 are
electrically communicated with a first contact pad 28, wherein the
first contact pad 28 comprises a first ground terminal 13, a first
resistance measurement terminal 14, and a second power terminal 15.
In an exemplary embodiment, the first measuring lead 18 is
preferably electrically communicated with the first ground terminal
13, the second measuring lead 19 is preferably electrically
communicated with the second power terminal 15, and the guard
electrode 2 is electrically communicated with the first resistance
measurement terminal 14.
[0038] Also in accordance with an exemplary embodiment, the first
heater element lead 21 is preferably electrically communicated with
the first temperature sensing lead 25 such that the temperature
sensor can serve as an alkaline impurity getter. By removing the
alkaline impurities condensed on the heater, the temperature sensor
serves to prolong the usability of both the heater and the sensing
electrodes. While not damaging the temperature sensor since the
accumulated alkaline impurity does not change the temperature
sensor's total resistive characteristics to any significant degree.
The electrical communication between heater 6 and temperature
sensor 5 comprises connecting a first temperature sensing lead 25
with the first heater element lead 21, such that the lead from the
temperature sensor is electrically connected to the negative
polarity lead of the heater. The electrical connection may be made
by way of via holes 110 formed on the insulating temperature
substrate 8.
[0039] Furthermore, in a first embodiment, the second temperature
sensing lead 26 and second heater element lead 22 are electrically
connected to a second contact pad 29. The second contact pad 29
comprises a second ground terminal 10, a second resistance
measurement terminal 11, and a first power terminal 12.
[0040] In an exemplary embodiment, the second heater element lead
22 can be electrically communicated with the first power terminal
12; the second temperature sensing lead 26 can be electrically
communicated with the second resistance measurement terminal 11;
and the first temperature sensing lead 25 can be electrically
communicated with the first heater element lead 21, wherein the
first heater element lead 21 can also be electrically communicated
with the second ground terminal 10.
[0041] A second embodiment of the particulate sensor system 70 is
shown in FIG. 2, which depicts the sensor 100 in relation to a
sensor circuit 80. As schematically shown in FIG. 2, the first
ground terminal 13, the first resistance measurement terminal 14,
and the second power terminal 15 are electrically communicated to
form the AC/DC (alternating current/direct current) impedance
measurement circuit 30. The AC/DC impedance measurement circuit 30
can be a series circuit comprising a resistor, the sensing
electrodes, the guard electrode, and a measuring device.
[0042] FIG. 3 depicts an exemplary embodiment of the AC/DC
impedance measurement circuit 30. As shown in FIG. 3, the first
measuring lead 18 is electrically communicated to a first lead 31.
Such a communication may be made by way of via holes formed in the
isolation layer wherein a first ground terminal may mediate the
electrical communication. The first lead 31 extends from the
electrical communication with the first measuring lead 18 to a
ground potential 35. Additionally, a second lead 32 is electrically
communicated to the second measuring lead 19. Such a communication
may be made by way of via holes formed in the isolation layer
wherein a first resistance measurement terminal may mediate the
electrical communication. The second lead 32 extends from the
electrical communication with the second measuring lead 19 to a
resistor 33. The resistor 33, in turn, is electrically communicated
to a positive/negative terminal 36, and to a measuring device 34.
The measuring device 34 can be any device capable of reading the
resistance, such as a voltmeter, or an ohmmeter.
[0043] In another embodiment of the AC/DC impedance measurement
circuit, the guard electrode can be electrically communicated to
the resistor by way of the first resistance measurement terminal.
Such a connection can be affected by via holes formed in the
isolation layer.
[0044] FIG. 2 further depicts a sensor refreshment decision circuit
40 in electrical connection with the AC/DC impedance measurement
circuit 30 and a heater power control circuit 50. In a preferred
embodiment, once the resistance between the first measuring lead 18
and the second measuring lead 19 of the sensing electrodes 3
decreases to a threshold resistance level with design parameters,
as determined by the measuring device (not shown) in the AC/DC
impedance measurement circuit 30, the sensor refreshment decision
circuit 50 emits a signal to the heater power control circuit 50
which, in turn, transmits a signal to the heater 6 to increase its
thermal energy output. Such a transmittal by the heater power
control circuit 50 to the heater 6 is preferably a result of the
electrical communication between the first power terminal 12 and
the second heater element lead 22 as affected by via holes 110
formed in the heater substrate 9. The thermal output by the heater
6 is increased to a level sufficient to burn off particulates
deposited on and/or between the sensing electrodes 3. Suitable
burn-off temperatures may include heating the sensor up to about
500.degree. C. to up to about 1,100.degree. C., with up to about
500.degree. C. to up to about 1,000.degree. C. preferred, and up to
about 500.degree. C. to up to about 950.degree. C. more preferred.
As the particulates are burned off, the resistance between the
sensing electrodes 3 rises proportionately until a second
predetermined resistance is reached, at which point, the heater
power control circuit 50 signals to the heater 9 to reduce its
thermal energy output.
[0045] In an exemplary embodiment, the particulate sensor system
may be calibrated such that after a predetermined number of
self-regeneration cycles, (e.g., after the sensing electrodes have
signaled the heater to burn off particulates condensed on the
sensor), an additional electrical signal may be sent from the
particulate sensor system to an additional heater located in an
environment rich in exhaust soot condensation, such that the
additional heater may burn off the exhaust particulate condensation
or may signal the engine to adjust fuel ratios (exhaust
temperature) to assist in burning off the condensation. The
temperature at which the exhaust soot can typically be burned off
is about 500.degree. C. to about 1,100.degree. C.
[0046] In an exemplary embodiment the particulate sensor system
further comprises a temperature sensing circuit that can
continuously control the temperature surrounding the particulate
sensor 100. As shown in FIG. 2, the second temperature sensing lead
26 of the temperature sensor 5 is electrically communicated with
the second ground terminal 10; the second ground terminal 10 is
electrically communicated with the heater power control circuit 50
by way of the temperature sensing circuit 60. The heater power
control circuit 50 sends a signal back through the temperature
sensing circuit 60 to the heater 6 by way of the electrical
communication between the first power terminal 12 and the second
heater element lead 22. Preferably the heater 6 is activated by the
heater power control circuit 50 when the temperature falls below or
at the condensation temperature of water, and is deactivated at a
point just lower than the condensation point of the particulates.
Suitable deactivation points include, but are not limited to,
temperatures of about 125.degree. C. to about 475.degree. C., with
about 150.degree. C. to about 450.degree. C. preferred, and about
175.degree. C. to about 425.degree. C. more preferred.
[0047] The particulate sensor system is preferably powered by a
battery or other power generating device. The power supplied by the
battery to the particulate sensor system depends on the current
method employed (e.g., AC or DC) and on the degree of sensitivity
required. In general, the higher the voltage, or the higher the
frequency, the lower the particulate concentration the particulate
sensor system can detect. Consequently, for a DC method, the
voltage (V) used is preferably about 0.1 V to about 700 V, where
0.1 to about 500V is more preferred. For an AC method, the
frequency used is preferably about 50 kilohertz (kHz) to about 400
kHz, where 100 kHz to about 300 kHz is more preferred.
[0048] An exemplary application of the disclosed particulate sensor
system is as a signaling device to regenerate filter systems
commonly employed to control the amount of pollutants released from
the exhaust of diesels and other internal combustion engines. An
especially preferred filter system is a particulate sensor system.
The particulate sensor system can be calibrated such that upon
reaching a specified number of self-regeneration cycles, a control
device sends a signal to the particulate sensor system to
regenerate itself. Upon receiving the appropriate signal, a heater
disposed within the particulate trap can be activated to burn off
the particulate deposited on the particulate trap, or more air can
be added to the exhaust to burn off the particulates, or to
increase the exhaust temperature to ignite the regeneration of the
particulate trap.
[0049] FIG. 4 depicts another embodiment of the particulate sensor.
FIG. 4 shows the sensor 100 installed in suitable sockets of metal.
As shown in FIG. 4, the sensor can additionally comprise a louvered
shield 130. The louvered shield 130 protects an exposed portion of
the sensor 100 and has perforations so as to allow flow of the
exhaust gases around the sensor. By appropriate design of the
louver shield, the amount and velocity of the gas can be regulated
to increase the temperature of the sensor. The louvered shield can
be exposed to the harsh exhaust gases and therefore is preferably
formed from a suitable material such as a stainless steel.
Additionally, the louvered shield can be used to control the
penetration of small-size particulates. Particulates with sizes
greater than about 1 micrometers are more easily sensed by the
resistive measurement device. Controlling the louvered shield
offers the possibility of sensing the concentration of those
particulates smaller than the controlled cut-off size.
[0050] As further shown in FIG. 4, introduction of the sensor 100
into the gas stream, the particulate content of which is to be
determined, is preferably done by securing the sensor elements
themselves in suitable sockets made of metal. The sockets can
comprise embedding the sensor 100 in ceramic insulators 140 which
in turn are covered by a shell 145. The socket can, directly, form
one terminal connection, for example the chassis or ground
connection to the ground potential of the power supply source. The
other terminal is brought out to a connecting cap. Sockets used in
general connection with spark plugs, and shaped similarly thereto,
and having spark plug-type threads, are suitable; other socket
constructions, for example as used in connection with
oxygen-exhaust gas sensors, are also suitable.
[0051] The particulate sensor system disclosed herein has several
improvements over a sensor that does not comprise a sensor in
electrical communication with an external circuit as disclosed
herein. The particulate sensor system provides a regenerative
on-site mechanism for monitoring and controlling the level of
particulate matter contained in the emission of gases, particularly
those gases generated in automobiles. The time for the particulate
matter condensation onto the sensor and the cleaning of the sensor
is monitored and is related to the level of particulate from the
engine. The signal for cleaning the sensor can be used to control
the engine smoke, engine diagnostics, and particulate trap
regeneration. Also, the system of the present disclosure has a
relatively small thermal mass that improves the thermal response
time of the regeneration of the sensor. The use of an AC resistance
measurement method allows for the detection of lower soot
concentrations as compared to a DC method. The possible use of a
fully dense protection layer on top of the sensing electrodes for
the AC method fully protects the electrodes from the reduction
power of the soot regeneration, and still allows for the electrodes
to sense condensed particulates by the complex impedance
measurement.
[0052] The pore size controlled porous layers allows the soot
measurement to be biased toward smaller sizes of particulate. The
controlled shield louvers can decrease the ratio of the gas speeds
inside and outside of the louver. In so doing, the larger
particulates can be excluded from entering the sensor shield.
[0053] While the invention has been described with reference to an
exemplary embodiment, it will be understood by those skilled in the
art that various changes can be made and equivalents can be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications can be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the appended
claims.
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