Device for detecting air-fuel ratio of mixture over wide range from below to above stoichiometric ratio

I claim:

1. A device for detecting an air-fuel ratio of a fuel mixture by probing exhaust gases resulting from combustion of the fuel mixture, the exhaust gases including at least oxygen and combustion by-products, comprising:

a partition having a first side and a second side opposite to said first side, said partition defining on said first side an atmospheric air receiving portion communicating with the ambient atmosphere and on said second side a gas receiving portion communicating with the exhaust gases;

said partition having at least a portion formed of an oxygen ion-conductive solid electrolyte;

first electrode means exposed to said atmospheric receiving portion;

second electrode means exposed to said gas receiving portion, said first and second electrode means interposing therebetween said portion formed of said oxygen ion-conductive solid electrolyte;

means for restricting gas diffusion of the exhaust gases to said gas receiving portion;

means, including third electrode means disposed on said portion of said partition and exposed to said gas receiving portion, for applying a predetermined electric voltage across said portion, formed of said ion-conductive solid electrolyte, causing DC electric current to flow between said first and third electrode means through said portion formed of said ion-conductive solid electrolyte;

means for comparing an actual voltage between said first electrode means and said second electrode means with a target voltage to give a difference therebetween and generating a difference indicative signal;

means responsive to said difference indicative signal for controlling the polarity and intensity of said DC electric current in such a manner as to decrease said difference indicative signal toward zero; and

means for measuring said DC electric current and generating an output signal indicative of said DC electric current measured.

2. A device as claimed in claim 1, wherein said gas diffusion restricting means includes:

a first plate lying on said second side of said partition, said first plate being formed with an opening; and

a second plate lying on said first plate to close said opening, said partition, said first plate and said second plate cooperating with each other to define said gas receiving portion within said opening, said second plate being formed with a gas flow restricting hole for providing restricted flow communication between said gas receiving portion and the source of the exhaust gases.

3. A device as claimed in claim 1, wherein said gas diffusion restricting means includes:

a plate lying on said second side of said partition and having a portion spaced distant from said second side of said partition to define a clearance therebetween, said plate and said partition cooperating with each other to define said gas receiving portion within said clearance.

4. A device as claimed in claim 1, wherein said gas diffusion restricting means includes:

a porous sintered body on said second side of said partition to cooperate with said partition to define said gas receiving portion.

5. A device as claimed in claim 1, wherein said gas diffusion restricting means includes:

a porous sintered body on said second side of said partition and formed with a recess, said porous sintered body and said partition cooperating with each other to form said gas receiving portion within said recess.

6. A device as claimed in claim 1, wherein said first electrode means includes an electrode layer printed on said electrolyte.

7. A device as claimed in claim 6, wherein said electrode layer of said first electrode means is grounded.

8. A device as claimed in claim 1, wherein said second electrode means includes a pump electrode layer printed on said electrolyte and a sensor electrode layer printed on said electrolyte.

9. A device as claimed in claim 8, wherein said pump electrode layer and said second electrode layer are arranged side by side.

10. A device as claimed in claim 8, wherein said pump electrode layer is formed with an opening and said sensor electrode layer is arranged within said opening.

11. A device as claimed in claim 1, further comprising a plate lying on said first side of said partition and formed with a gutter closed at one end, said plate cooperating with said first side of said partition to define said atmospheric receiving portion within said gutter.

12. A device as claimed in claim 1, further comprising electrical heating means for heating said electrolyte.

13. A sensing element for probing exhaust gases resulting from combustion of a fuel mixture, comprising:

a partition having a first side and a second side opposite to said first side, said partition being formed of an oxygen ion-conductive solid electrolyte;

an atmospheric air receiving plate, formed of an insulator, lying on said first side of said partition and formed with a longitudinal gutter closed at one end which defines an atmospheric air receiving portion on said first side of said partition, said longitudinal gutter being open at the opposite end to allow communication with ambient atmosphere;

a base plate, formed on an insulator, lying on said ambient air receiving plate;

a heater positioned between said atmospheric air receiving plate and said base plate and in direct contact with said air receiving plate;

means cooperating with said partition for defining a gas receiving portion on said second side of said partition and in communication with the exhaust gases;

first electrode means disposed on said first side of said partition and exposed to said atmospheric air receiving portion;

second electrode means, and third electrode means disposed on said second side of said partition and exposed to said gas receiving portion; and

means for restricting gas diffusion of the exhaust gases to said gas receiving portion.

14. A sensing element as claimed in claim 13, wherein said gas receiving portion defining means includes:

a first plate, formed of an insulator, lying on said second side of said partition, said first plate being formed with an opening surrounding said second electrode means; and

said gas diffusion restricting means includes:

a second plate, formed of an insulator, lying on said first plate to close said opening, said second plate being formed with a gas flow restricting hole dimensioned to provide restricted flow communication.

15. A sensing element as claimed in claim 13, wherein said gas diffusion restricting means includes:

a plate lying on said second side of said partition and having a portion spaced distant from said second side of said partition to define a clearance therebetween, said plate and said partition cooperating with each other to define said gas receiving portion within said clearance.

16. A sensing element as claimed in claim 13, wherein said gas diffusion restricting means includes:

a porous sintered body on said second side of said partition to cooperate with said partition to define said gas receiving portion.

17. A sensing element as claimed in claim 13, wherein said gas diffusion restricting means includes:

a porous sintered body on said second side of said partition and formed with a recess, said porous sintered body and said partition cooperating with each other to form said gas receiving portion within said recess.

18. A sensing element as claimed in claim 13, wherein said first electrode means includes an electrode layer printed on said electrolyte.

19. A sensing element as claimed in claim 13, wherein said second electrode means includes a pump electrode layer printed on said electrolyte and a sensor electrode layer printed on said electrolyte.

20. A sensing element as claimed in claim 19, wherein said pump electrode layer and said sensor electrode layer are arranged side by side.

21. A sensing element as claimed in claim 19, wherein said pump electrode layer is formed with an opening and said sensor electrode layer is arranged within said opening.

22. A sensing element as claimed in claim 13, further comprising a plate lying on said first side of said partition and formed with a gutter closed at one end, said plate cooperating with said first side of said partition to define said atmospheric receiving portion with said gutter.

23. A sensing element as claimed in claim 13, further comprising electrical heating means for heating said electrolyte.

Description Submit all comments and votes

BACKGROUND OF THE INVENTION

The present invention relates to a device for detecting an air-fuel ratio of an air-fuel mixture over a wide range from below the stoichiometric ratio (rich) for the mixture to above the stoichiometric ratio (lean) for the mixture by exposing a probe or a sensing element to exhaust gases resulting from combustion of the mixture.

In automobiles, it is necessary to detect an air-fuel ratio of a mixture supplied to an internal combustion engine for controlling the supply of fuel to the engine so as to adjust the actual air-fuel ratio to a target value. Common practice to detect the air-fuel ratio is to expose an oxygen sensing element, viz., an oxygen sensor, to exhaust gases discharged by the internal combustion engine and measure oxygen partial pressure in the exhaust gases.

Japanese patent application primary publication No. 57-76450 discloses a device for detecting an air-fuel ratio of an air-fuel mixture having an air-fuel ratio above the stoichiometric ratio for the mixture by measuring an oxygen partial pressure in exhaust gases resulting from the combustion of the mixture by exposing an oxygen sensing element to the exhaust gases. This known device is further described referring to FIG. 1. As illustrated in FIG. 1, the oxygen sensing element comprises an oxygen ion-conductive solid eletrolyte 1 having a measurement electrode layer 2 on one side thereof and a reference electrode layer 3 on the other side thereof. A DC voltage is applied between the electrode layers 2 and 3 to cause an electric current I.sub.s to flow through the solid electrolyte 1 from the electrode 3 to the electrode 2. For restricting inflow of oxygen to the measurement electrode 2, a porous coating layer 4 covers the electrode 2. Another coating layer 5 covers and protects the other electrode layer 3. The inflow of the electric current I.sub.s causes oxygen ions O.sup.2- to migrate from the electrode layer 2 to the electrode layer 3. As a result, a reference oxygen partial pressure Pa develops at the reference electrode layer 3 and an oxygen partial pressure Pb, viz., an oxygen partial pressure in the exhaust gases, develops at the measurement electrode 2. An electromotive force E produced by the sensing element may be expressed by Nernst's equation as follows:

E=(RT/4F) ln(Pa/Pb) (1)

where: R is the gas constant, T the absolute temperature, and F the Faraday constant.

This electromotive force E may be measured and taken out in terms of an output Vs of the sensing element. The output Vs exibits different voltage versus .lambda. characteristics for different magnitudes of the electric current I.sub.s as shown in FIG. 2 where .lambda.=(actual air-fuel ratio)/(the stoichiometric ratio). As will be readily understood from FIG. 2, since, if the electric current I.sub.s is kept constant, the output Vs varies versus air-fuel ratio within a narrow range of .lambda., an actual air-fuel ratio within the narrow range can be detected by the sensor output Vs. This. however, is not practical for detection of air-fuel ratio over a wide range. To overcome this problem, it is proposed to keep the voltage Vs at a target value Va (see FIG. 2) and measure an electric current I.sub.s which is variable in proportion to variation in .lambda. over a wide range as shown by a fully drawn curve in FIG. 3 as long as the air-fuel ratio is above the stoichiometric ratio (.lambda.>1).

This known device, however, is not suitable for detecting an air-fuel ratio of a rich mixture (.lambda.<1) because, as will be understood from FIG. 3, the current I.sub.s increases again as the mixture becomes rich as shown by a broken line curve. This characteristic exibited by the current I.sub.s when the air-fuel ratio is below the stoichiometric ratio is derived from the fact that an equilibrium state with the exhaust gases resulting from combustion of a rich air-fuel mixture is not accomplished so that oxygen ions within the solid electrolyte are only diffused into the ambient exhaust gas environment in the form of oxygen molecules because the content of oxygen in the exhaust gases is almost zero. This explains why the migration of oxygen ions increase and thus the electric current I.sub.s increases as the air-fuel ratio shifts to the rich side beyond the stoichiometric ratio.

As a result, with the same measured magnitude in the electric current I.sub.s, a single air-fuel ratio cannot be identified because two air-fuel ratio values are present within a range near the stoichiometric ratio. Thus, it is impossible to identify the actual air-fuel ratio by relying on the measurement result of the electric current I.sub.s only. In other words, the use of this known device is confined to detecting an air-fuel ratio above the stoichiometric ratio. Besides, since both of the electrode layers 2 and 3 are exposed to the exhaust gases, the electrodes 2 and 3 are deteriorated at a fast rate. The solid electrolyte is deteriorated, too, when the sensing element is used for a long time to detect a rich air-fuel ratio because a material ZrO.sub.2 which constitutes the solid electrolyte 1 is decomposed into ions, oxygen ions of which are diffused into the exhaust gases. Thus, the output characteristic of the sensing element (I.sub.s versus A/F characteristic) varies for a time (age) and the endurability is not satisfactory.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a device, free from the above problems, for detecting an air-fuel ratio of a fuel mixture over a wide range from below the stoichiometric ratio (rich) to above the stoichiometric ratio (lean).

Another object of the present invention is to provide a device for detecting an air-fuel ratio which has a sufficiently long endurability such that it can sustain stable output characteristic for a long time even if it is used to probe exhaust gases resulting from combustion of a fuel-rich mixture.

One aspect of the present invention is to provide a device for detecting an air-fuel ratio of a fuel mixture by probing exhaust gases resulting from combustion of the fuel mixture, the exhaust gases including at least oxygen and combustion by-products, comprising:

a partition having a first side and a second side opposite to said first side, said partition defining on said first side an atmospheric air receiving portion communicating with the ambient atmosphere and on said second side a gas receiving portion communicating with a source of the exhaust gases;

said partition having at least a portion formed of an oxygen ion-conductive solid eletrolyte;

first electrode means exposed to said atmospheric air receiving portion;

second electrode means exposed to said gas receiving portion, said first and second electrode means interposing said electrolyte therebetween;

means for restricting gas diffusion of said exhaust gases to said gas receiving portion;

current providing means for providing an electric current to flow between said first and second electrode means through said electrolyte in such a manner as to cause migration of oxygen ions through said electrolyte between said atmospheric air receiving portion and said gas receiving portion so as to keep an oxygen partial pressure ratio across said electrolyte constant; and

means for detecting said electric current.

Another aspect of the present invention is to provide a sensing element for probing exhaust gases resulting from combustion of a fuel mixture, comprising:

a partition having a first side and a second side opposite to said first side, said partition defining on said first side an atmospheric air receiving portion communicating with the ambient atmosphere and on said second side a gas receiving portion communicating with a source of the exhaust gases;

said partition having at least a portion formed of an oxygen ion-conductive solid eletrolyte;

first electrode means exposed to said atmospheric air receiving portion;

second electrode means exposed to said gas receiving portion, said first and second electrode means interposed said electrolyte therebetween; and

means for restricting gas diffusion of said exhaust gases to said gas receiving portion.

Still another aspect of the present invention is to provide a method for detecting an air-fuel ratio of a fuel-rich mixture which is below the stoichiometric ratio for the mixture by probing exhaust gases resulting from combustion of the fuel-rich mixture, the exhaust gases including combustible by-products, said method comprising the steps of:

providing a sensing element comprising a partition having a first side and a second side opposite to said first side, said partition defining on said first side an atmospheric air receiving portion communicating with the ambient atmosphere and on said second side a gas receiving portion communicating with a source of the exhaust gases, said partition having at least a portion formed of an oxygen ion-conductive solid eletrolyte, first electrode means exposed to said atmospheric air receiving portion, second electrode means exposed to said gas receiving portion, said first and second electrode means interposing said electrolyte therebetween, and means for restricting gas diffusion of said exhaust gases to said gas receiving portion;

causing an electric current to flow between said first and second electrode means through said electrolyte in such a manner as to cause migration of oxygen ions through said electrolyte between said atmospheric air receiving portion and said gas receiving portion so as to keep an oxygen partial pressure ratio across said electrolyte constant; and

detecting said electric current.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional diagram showing a known oxygen sensing element discussed above;

FIG. 2 is a graph showing the relationship between the output voltage and the air-fuel ratio;

FIG. 3 is a graph showing the relationship between the inflow current and the airfuel ratio;

FIG. 4 is an exploded perspective view of a first embodiment of a sensing element according to the present invention;

FIG. 5 is a cross sectional diagram of the sensing element;

FIG. 6 is a block diagram of a device, according to the present invention, for detecting an air-fuel ratio using the sensing element shown in FIG. 4;

FIG. 7 is a graph showing the relationship between the pump current and the oxgen partial pressure within the exhaust gases;

FIG. 8 is a graph showing the relationship between the measured voltage and the air-fuel ratio;

FIG. 9 is the detailed circuit diagram of the device shown in FIG. 6;

FIG. 10 is an exploded perspective view of a second embodiment of a sensing element according to the present invention;

FIG. 11 is a longitudinal cross sectional diagram of the sensing element shown in FIG. 10; and

FIG. 12 is a similar cross sectional diagram to FIG. 5 showing a third embodiment of a sensing element according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 4 to 12 of the accompanying drawings, the present invention is further described.

Referring to FIGS. 4 and 5, a first embodiment of a sensing element (oxygen sensor) of a device for detecting an air-fuel ratio of a fuel mixture is illustrated. The sensing element comprises a partition 14 having a first side 14a and a second side 14b. The partition 14 defines on the first side 14a an atmospheric air receiving portion 13 communicating with the ambient atmosphere and on the second side 14b a gas receiving portion 19 communicating with a source of exhaust gases, such as an exhaust pipe of an automotive internal combustion engine, as best seen in FIG. 5. In this embodiment, the partition 14 is formed of an oxygen ion-conductive solid electrolyte. If desired, the partition 14 may be partly formed of the oxygen ion-conductive solid electrolyte such that that portion of the partition which is interposed between first electrode means 15 and second electrode means 16, 17 is formed of the oxygen ion-conductive solid electrolyte and the balance portion formed of another heat resistive material. The first electrode means includes a thin electrode layer 15 printed on the first side 14a of the partition 14 and exposed to the atmospheric air receiving portion 13, while the second electrode means includes a thin pump electrode layer 16 and a thin sensor electrode layer 17 which are arranged side by side.

Referring to FIG. 4, there is shown a base plate 10 with an electrical heater 11 for heating the partition 14 of the oxygen ion-conductive solid electrolyte. Lying on the base plate 10 is an atmospheric air receiving plate 12 formed with a channel-like gutter 12a closed at one end. Lying on the atmospheric air receiving plate 12 is the partition 14 having printed on the first side thereof 14a the reference electrode layer 15 and on the opposite second side thereof 14b the pump and sensor electrode layers 16 and 17. The heater 11 has leads 22 and 23, and the electrode layers 15, 16 and 17 has leads 24, 25 and 26 connected as shown in FIG. 6. For restricting gas diffusion of the exhaust gases to the second electrode means 16 and 17, a plate 18 is laid on the second side 14b of the partition or solid electrolyte 14, which plate 18 is formed with a window-like opening 18a defining the side boundary of the gas receiving portion 19, and another plate 20 is laid on the plate 18, which plate 20 is formed with a small hole 21 for restricting gas flow communication between the gas receiving portion 19 and the ambient exhaust gas environment.

The base plate 10, atmospheric air receiving plate 12 and plates 18, 20 are formed of a heat resistive insulator, such as alumina and mullite or a heat resistive alloy. The solid electrolyte 14 is formed of a sintered body obtained by solidifying at least one selected from C.sub.2 O, MgO, Y.sub.2 O.sub.2, YB.sub.2 O.sub.3 into an oxide such as ZrO.sub.2, HrO.sub.2, ThO.sub.2, Bi.sub.2 O.sub.3.

Each of the electrodes 15, 16 and 17 includes platinum or gold as a main constituent thereof. The pump electrode 16 and the reference electrode 15 serve as electrodes which allows electric current to pass through the solid electrolyte 14 to cause the migration of oxygen ion within the solid electrolyte 14 so as to keep an oxygen partial pressure ratio, viz., a ratio between oxygen partial pressure at one side of the solid electrolyte and oxygen partial pressure at the other side thereof, constant. The sensor electrode 17 and the reference electrode 15 serve as electrodes for measuring an electric voltage developed across the solid electrolyte 14 due to the oxygen partial pressure ratio.

Referring to FIG. 6, the electrode layers 15, 16 and 17 are circuited with a detecting circuit 30. The circuit 30 comprises a source of electric voltage 31 which generates a target electric voltage-Va, a differential amplifier 32, a pump electric current supply unit 33, a resistor 34 and a pump electric current detecting unit 35 which detects the pump electric current by measuring the electric voltage across the resistor 34.

The differential amplifier 32 functions to compare a potential Vs of the reference electrode 15 of the sensing element relative to the sensor electrode 17 with the target electric voltage-Va, and calculate the difference therebetween .DELTA.V (.DELTA.V=Vs-(-Va)). The pump electric voltage supply unit 33 regulates an outflow of the pump electric current Ip from the pump electrode 16 of the sensing element (or an inflow thereto) so as to reduce the output .DELTA.V of the differential amplifier 32 toward zero. That is, when the output .DELTA.V is positive, Ip is increased, whereas when the output .DELTA.V is negative, Ip is decreased.

The pump electric current detecting unit 35 detects the pump electric current Ip by measuring a difference in electric potential across the resistor 34 in terms of the electric voltage Vi (Vi<Ip). The direction of flow of the pump electric current Ip as indicated by the fully drawn arrow in FIG. 6 is regarded as the positive direction and in this case the electric voltage Vi detected becomes positive, whereas when the direction of the pump electric current is negative as indicated by a broken arrow, the electric voltage Vi becomes negative.

The operation of this embodiment is described.

Although any value is set as the target electric voltage -Va generated by the source of electric voltage 31 as long as it corresponds to a value which may be taken by the electric voltage Vs generated at the sensor electrode 17, it is preferrable for the purpose of accurately converging the electric voltage Vs to the target value that the target electric voltage should take a value at which a tangent in variation in the electric voltage Vs versus variation in oxygen concentration within the gas receiving portion 19 is the largest, that is, a middle value between the upper and lower limits between which the electric voltage rapidly changes versus variation in the oxygen concentration.

If -500 mV is set as the target value -Va, the pump electric current supply unit or circuit 33 controls the supply of the pump electric current Ip in such a manner as to accomplish the relationship; Vs=-500 mV. Assuming that the temperature T is 1000.degree. K., the oxygen partial pressures Pa and Pg within the atmospheric air receiving portion 13 of the sensing element and the gas receiving portion 19 thereof shall satisfy the following relationship which has been obtained by using the Nernst's equation;

Pg/Pa.apprxeq.10.sup.-10.

Substituting Pa.apprxeq.0.206 atm, Pg.apprxeq.0.206.times.10.sup.-10 atm.

Assuming the oxygen partial pressure within the exhasut gases is Px, the quantity Q of oxygen O.sub.2 entering the gas receiving portion 19 past the small hole 21 can be expressed as Q=D (Px-Pg), where D is the diffusion coefficient. Since Pg=0,

Q.apprxeq.D Px (1).

Since the quantity of oxygen ion O.sup.2- migrating within the solid electrolyte 14 is as high as this quantity Q, the following relation Ip.varies.Q holds. Thus,

Ip=K.sub.1 Px (2)

K.sub.1 : a constant.

The pump electric current Ip therefor varies in proportion to the oxygen partial pressure (oxygen concentration) within the exhaust gases as shown in FIG. 7.

Since the oxygen concentration is closely related to the air-fuel ratio when the air-fuel ratio (A/F) of the mixture fed to the internal combustion engine is on the lean side (.lambda.>1), it is apparent that