Method for controlling an internal combustion engine having an exhaust system component including a self-healing ceramic material

Patent metadata

Field	Value
Publication number	US-10648388-B2
Application number	US-201414915329-A
Country	US
Kind code	B2
Filing date	Aug 20, 2014
Priority date	Sep 6, 2013
Publication date	May 12, 2020
Grant date	May 12, 2020

Abstract

An object of the present invention is to provide an exhaust system component having excellent properties to be located in an exhaust flow path from an internal combustion engine, particularly, an exhaust system component having an extended use-life. The exhaust system component of the present invention for an internal combustion engine has a self-healing ceramic material and an electric heater for heating the self-healing ceramic material. In particular, the exhaust system component of the present invention is an oxygen sensor having a detection element and an electric heater, wherein the detection element has a solid electrolyte layer, a reference-side electrode layer, an exhaust-side electrode layer, and a diffusion layer and/or a trap layer each composed of a self-healing ceramic material.

First claim

The invention claimed is:

1. A method for controlling an internal combustion engine having an exhaust system component and a combustion chamber, wherein the exhaust system component comprises a self-healing ceramic material, and an electric heater for heating the self-healing ceramic material, the method comprises:
determining a change in an electrical conductivity of the self-healing ceramic material;
determining a cracking of the self-healing ceramic material based on the change in the electrical conductivity of the self-healing ceramic material; and
heating the self-healing ceramic material by the electric heater in response to combustion not being performed in the combustion chamber to put the self-healing ceramic material in a high-temperature oxidizing condition;
wherein the self-healing ceramic material comprises fine particles and the fine particles are oxidized under the high-temperature oxidizing condition so as to fill a crack in the self-healing ceramic material,
wherein electric current flow or gas diffusion takes place through the self-healing ceramic material,
wherein the exhaust system component is an electrically heated catalyst having the following configuration:
(a) an electrically conductive catalyst-supporting substrate having a binding material composed of the self-healing ceramic material and electrically conductive particles bound to each other by the binding material, and
(b) the electric heater that is an electrode put into contact with the electrically conductive catalyst-supporting substrate to flow an electric current to the electrically conductive catalyst-supporting substrate, and
wherein the self-healing ceramic material has a ceramic matrix, and fine metal or semimetal carbide particles having a particle diameter of 1 um or less and being dispersed in the ceramic material, and
wherein the electrically conductive particles have a particle diameter of 5 um or more.

2. The method according to claim 1 , wherein the electrically conductive catalyst-supporting substrate is a honeycomb substrate.

3. The method according to claim 1 , wherein the electrically conductive particles are silicon carbide particles.

4. The method according to claim 1 , wherein:
the internal combustion engine further has an electric motor, and
the self-healing ceramic material is heated by the electric heater, when the electric motor works and combustion is not performed in the combustion chamber.

5. The method according to claim 1 , wherein the heating of the self-healing ceramic material by the electric heater is to a temperature of 550 degrees Celsius or more.

Assignees

• Toyota Motor Co Ltd

Inventors

• Takeuchi Naoki
• Kumagai Noriaki
• Hayashita Go
• Tabata Masakazu
• Ito Hirokazu
• Sugimoto Kazuhiro
• Murata Hiroki

Classifications

• F01N3/2828 Primary

  Ceramic multi-channel monoliths, e.g. honeycombs · CPC title

• F01N3/2013

  using electric or magnetic heating means · CPC title

• F01N13/16 Primary

  Selection of particular materials · CPC title

• F01N2330/06

  Ceramic, e.g. monoliths · CPC title

• G01N27/4077

  Means for protecting the electrolyte or the electrodes · CPC title