Abstract:
Internal combustion diagnostic sensing devices, systems in which they are used, and methods for their use. The devices operate by detecting pulses created by the exhaust stream of internal combustion engines using a new and novel sensing device. The systems are comprised of a combination of the sensing devices and internal combustion diagnostic equipment. The devices and systems can be used for diagnostic operations on any internal combustion engine while the engine is operating.

Description:
[0001]    The invention disclosed and claimed herein deals with diagnostic devices for internal combustion engines, systems in which they are used, and methods for their use. The devices of this invention operate by detecting pulses from the exhaust stream of internal combustion engines using a new and novel sensing device. The systems of this invention are comprised of a combination of the sensing devices and internal combustion engine diagnostic equipment, such as, for example, a Snap-on R , Sun Machine, automotive engine analyzer. The devices and systems of this invention can be used for diagnostic operations on any internal combustion engine while the engine is operating.  
         BACKGROUND OF THE INVENTION  
         [0002]    Since the inception of internal combustion engines there has been a need to be able to accurately diagnose disorders in such engines. Aside from the skilled and experienced mechanic, who can detect many engine disorders by listening to the performance of the engine, there have been many commercial systems developed to diagnose such engine disorders. The most modern of these systems are based on vacuum sensors and ignition sensors. Vacuum sensors are almost impossible to use due to the complex valves and electronics used in today&#39;s engines. Many of the engine problems require time-consuming removal of spark plugs and other routines before the actual diagnostic evaluation of the engine can begin. The most common of these problems are fuel injector problems and bad valves, and other ailments in and around cylinders of engines. The diagnosis of such disorders, even with today&#39;s most sophisticated equipment, can still take hours and create costly maintenance and repair for the automobile owner.  
           [0003]    Mechanics too, would like to be able to increase the speed with which the diagnosis can be undertaken, and be able to get to the repair of the problem much more quickly.  
           [0004]    In U.S. Pat. No. 4,424,709, that issued on Jan. 10, 1984 to Meier, Jr., et al. there is disclosed a frequency domain engine defect signal analysis system that includes sensors for detecting engine operating parameters such as engine speed, engine exhaust manifold pressure, engine intake manifold vacuum, blowby gas pressure in the engine crankcase, and oil pressure, from which an evaluation can be made of the engine operating conditions that is then compared to a normal engine operation. It should be noted that this system works in a frequency domain, while the sensors of the instant invention work in a time domain and that the sensors of the instant invention do not measure or monitor, but detect an event. It should also be noted that the sensors of the instant invention display raw data directly to an engine diagnostic scope, while the devices of the Meier, et al patent all utilize processes for the data before it is taken into the diagnostic mode.  
           [0005]    The instant invention solves the problems enumerated above, and provides auto mechanics with a quick and easy means of diagnosis of internal combustion engine disorders without incurring high costs. The devices of this invention can be used by most mechanics because of the simplicity of use, the safety in using it, and the size of the device which can be held in the hand, and does not need a means to transport it. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]    [0006]FIG. 1 is a full view of a device of this invention.  
         [0007]    [0007]FIG. 2 is a filly exploded cross-sectional view of the device of FIG. 1 through line  100 - 100  of FIG. 1, showing the two major components, the insertable component, and the receiving component.  
         [0008]    [0008]FIG. 3 is a full schematic diagram of a system of this invention including in combination, a device of this invention, an internal combustion engine diagnostic apparatus, and a portion of the tube of the device and a portion of a tailpipe of an exhaust system from an automobile.  
         [0009]    [0009]FIG. 4 is a fully exploded cross-sectional view of the device of FIG. 1 through line  100 - 100  of FIG. 1, showing non-threaded components.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0010]    The invention disclosed herein deals with an internal combustion engine diagnostic device comprising an insertable component having a housing that has a front and a back. The back has centered in it a closed hub that has a wall. The closed hub is integrally connected to and surmounted on an annular flange wherein the flange is integrally connected to and surmounted on an open hub. The open hub has a wall defining an interior void space, a front, an external surface, a shouldered seat in the wall at the open hub front thereof, and a bottom in the interior void space. The open hub has threads on the external surface and has an opening from the bottom of the void space and through a portion of the closed hub to form an elongated cavity on the interior of the closed hub. The closed hub has at least two second openings leading from the cavity through the closed hub wall and exiting to the outside of the closed hub, there being located in each such second opening, an electrical lead, each electrical lead having an external end and an internal end. The external end terminates upon exiting the closed hub through one of the second openings. The internal end passes into the elongated cavity and connects electrically to a wire lead wherein each wire lead passes through the elongated cavity, through the void space, and connects electrically to a piezoelectric diaphragm, which diaphragm is seated in the shouldered seat in the wall of the housing.  
         [0011]    In addition, there is a noise reduction circuit. The noise reduction circuit is connected to and between each of the wire leads at or near the points of connection of the wire leads to the piezoelectric diaphragm. There is also a modulator disc, the modulator disc overlays the piezoelectric diaphragm and has a diameter equal to or greater than the diameter of the piezoelectric diaphragm.  
         [0012]    There is a receiving component. The receiving component is comprised of a housing having a front, a back, and a sidewall defining an interior void space. The sidewall is threaded on the interior surface, and the interior void space has a bottom, which bottom has a saucer-like concave configuration, and, centered in the saucer-like concave configuration is an elongated opening. The elongated opening passes from the saucer-like concave configuration, through the receiving housing, and exits to the exterior of the receiving component and is terminated by a tube connection.  
         [0013]    Another embodiment of this invention is an internal combustion engine diagnostic system that comprises in combination an internal combustion diagnostic device as described just above connected electrically to an engine diagnostic apparatus and, a tube that is connected to the tube connection of the internal combustion diagnostic device.  
         [0014]    Yet another embodiment of this invention is a method of diagnosing internal combustion engine disorders. The method comprises connecting the opposite end of the tube not connected to the tube connection of the internal combustion engine diagnostic device, to the tailpipe, either directly or through some other connecting device of a vehicle, and securing the tube and then using the internal combustion engine diagnostic system as described just above while the engine of the vehicle is operating.  
         [0015]    Going to still another embodiment of this invention, there is a vehicle, in which the vehicle has installed therein, a device of this invention, the device being electronically connected to any computer or other electronics located within the vehicle and with which the device is electronically compatible.  
         [0016]    Still another embodiment of this invention is a device wherein the attachment of the insertable component to the receiving component is achieved by other means and thus, there is disclosed an internal combustion engine diagnostic device which comprises in combination an insertable component comprising a housing having a front and a back. The back has centered in it a closed hub having a wall. The closed hub is integrally connected to and surmounted on an annular flange. The flange is integrally connected to and surmounted on an open hub. The open hub has a wall defining an interior void space, a front, an external surface, a shouldered seat in the wall at the open hub front thereof, and a bottom in the interior void space. The open hub has an opening from the bottom of the void space and through a portion of the closed hub to form an elongated cavity on the interior of the closed hub. The closed hub has at least two second openings leading from the cavity through the closed hub wall and exiting to the outside of the closed hub. Located in each second opening is an electrical lead, each said electrical lead having an external end and an internal end, wherein each external end terminates upon exiting the closed hub through one of the second openings. The internal end passes into the elongated cavity and connects electrically to a wire lead and each wire lead passes through the elongated cavity, through the void space, and connects electrically to a piezoelectric diaphragm, which diaphragm is seated in the shouldered seat in the wall. There is a noise reduction circuit, the noise reduction circuit is connected to and between each of the wire leads at or near the points of connection of the wire leads to the piezoelectric diaphragm.  
         [0017]    There is a modulator disc, the modulator disc overlays the piezoelectric diaphragm and has a diameter equal to or greater than the diameter of the piezoelectric diaphragm.  
         [0018]    There is a receiving component, the receiving component comprises a housing having a front, a back, and a sidewall defining an interior void space. The interior void space has a bottom, which bottom has a saucer-like concave configuration, and, centered in the saucer-like concave configuration is an elongated opening, which elongated opening passes from the saucer-like concave configuration, through the receiving housing, and exits to the exterior of the receiving component and is terminated and capped by a tube connection.  
         [0019]    Finally, another embodiment is a method of warning of an internal combustion engine disorder. The method comprises installing an internal combustion engine diagnostic device of this invention on or near the engine. The device is electronically connected to any computer or other electronics located within the vehicle and with which the device is electronically compatible. The computer or other electronics are capable of triggering a visible warning apparatus that is diagnosed when there is an engine disorder indicated by the internal combustion engine diagnostic device.  
         [0020]    Turning now to the Figures, and with reference to FIG. 1, which is a full view of an internal combustion engine diagnostic device which is comprised of an insertable component comprising a housing having a front and a back. The back has centered therein a closed hub having a wall, the closed hub being integrally connected to and surmounted on an annular flange. The flange is integrally connected to and surmounted on an open hub, the open hub having a wall defining an interior void space, a front, an external surface, a shouldered seat in the wall at the open hub front thereof, and a bottom in the interior void space which has an opening from the bottom of the void space and through a portion of the closed hub to form an elongated cavity on the interior of the closed hub. The closed hub has at least two second openings leading from the cavity through the closed hub wall and exiting to the outside of the closed hub, there being located in each second opening, an electrical lead, wherein each electrical lead has an external end and an internal end, wherein each external end terminates upon exiting the closed hub through one of the second openings. The internal end passes into the elongated cavity and connects electrically to a wire lead, wherein each wire lead passes through the elongated cavity, through the void space, and connects electrically to a piezoelectric diaphragm, which diaphragm is seated in the shouldered seat in the wall. There is a noise reduction circuit, the noise reduction circuit is connected to and between each of the wire leads at or near the points of connection of the wire leads to the piezoelectric diaphragm. Surmounting the piezoelectric diaphragm is a modulator disc, the modulator disc unattachedly overlays the piezoelectric diaphragm and has a diameter equal to or greater than the diameter of the piezoelectric diaphragm.  
         [0021]    There is a receiving component, the receiving component comprises a housing having a front, a back, a side wall defining an interior void space, the interior void space has a bottom, wherein the bottom has a saucer-like concave configuration, and, centered in the saucer-like concave configuration is an elongated opening. The elongated opening passes from the saucer-like concave configuration, through the receiving housing, and exits the exterior of the receiving component and is terminated by a tube connection.  
       BRIEF DESCRIPTION OF THE DRAWINGS  
       [0022]    [0022]FIG. 1 is a device  1  of this invention showing a portion of the insertable component  2 , and a full view of the receiving component  3 , along with electrical leads  4  and the tube connector  5 .  
         [0023]    [0023]FIG. 2 is an fully exploded, cross-sectional view of a device of this invention showing a full cross-sectional view of the insertable component  2  and a full cross-sectional view of the receiving component  3 .  
         [0024]    [0024]FIG. 3 is full schematic diagram of a system of this invention showing in combination a device of this invention, an internal combustion engine diagnostic apparatus, a portion of a tube connected to the tube connector of the device of this invention, and a portion of an exhaust pipe from a vehicle engine.  
         [0025]    [0025]FIG. 4 is an fully exploded, cross-sectional view of the device of this invention showing a full cross-sectional view of the insertable component  2  and a full cross-sectional view of the receiving component  3 , both without threaded surfaces.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0026]    With reference to the Figures, and regarding FIG. 1, there is shown the device  1  of this invention further showing the insertable component  2 , the receiving component  3 , the closed hub  6 , the tube connector  5 , and optionally, the attaching means  34  for the tube connector  5  to the receiving component  3 , and the leads  4 .  
         [0027]    Turning now to FIG. 2, wherein like numbers indicate like components as shown in FIG. 1, there is shown the insertable component  2 , the receiving component  3 , the closed hub  6 , the flange  7 , the open hub  8 , it being noted that the components  6 ,  7 , and  8  are integrally fitted together to form the housing  37 . Situated on the external surface  28  of the open hub  8  are threads  27 , which are compatible with the threads  29  located on the internal surface  26  of the void space  25  of the receiving component  3 .  
         [0028]    Located in the open hub  8  is a void space or open space  9 , and the open space  9  has a bottom  10  in which there is shown an elongated cavity  11 , and two secondary openings  12 , which run from the base  13  of the elongated cavity  11  to the outside of the closed hub  8 . Situated in the secondary openings  12 , are electrical leads  14 , each of which have an internal end  15  and an external end  16 . The internal ends  15  are electrically connected to lead wires  17 , which lead wires  17  pass through the elongated cavity  11  into the void space  9  and move through the void space  9  to electrically connect to a piezoelectric diaphragm  18 . The piezoelectric diaphragm  18  is seated in a shouldered seat  19 , which runs around the front  19  inside edge  20  of the wall  21  of the insertable component  2 .  
         [0029]    Overlaying the piezoelectric diaphragm  18  is a modulator disc  22 , wherein the diameter of the modulator disc  22  is equivalent to or greater than the diameter of the piezoelectric diaphragm  18 . The modulator disc  22  can be but is not necessarily adhered to the piezoelectric diaphragm  18 , but is compressed thereto by the receiving component  3  when the device is fully assembled.  
         [0030]    Referring now to the receiving component  3 , there is shown a housing  23 , the wall  24  of which defines a second void space  25 . The internal surface  26  of the wall  24  has threads  29  which are compatible with and receive the threads  27  of the insertable component  2 . At the bottom of the void space  25  is a saucer-like concavity  30 , the purpose of which will be discussed infra.  
         [0031]    Leading from the bottom of the saucer-like concavity  30  is an elongated opening  31  that leads through the housing  23  to exit at the back  32  of the housing  23 . The exit  33  is capped by a tube connector  5  that accommodates a tube (shown in FIG. 3).  
         [0032]    In assembling the device  1 , the lead wires  17  are electrically affixed to the bottom  35  of the piezoelectric diaphragm  18  while there is a noise reduction circuit  36  electrically attached between the lead wires  17  to form a sub-assembly. This subassembly is inserted into the void space  9  until the lead wires  17  reach into the elongated cavity  11  and touch the leads  4  secured in the secondary openings  12 . The piezoelectric diaphragm  18  is then seated in the seat  19 .  
         [0033]    The modulator disc  22  is then laid over the piezoelectric diaphragm  18 , and the receiving component  3  is then brought together with the insertable component  2  and the two components are set together tightly thereby compressing the modulator disc  22  in place and thereby completing the assembly.  
         [0034]    The saucer-like concavity  30  is centered in the bottom of the void space  25 . The saucer-like concavity  30  has a surface area at the top of the saucer-like concavity that is relative to the surface area of the top of the piezoelectric diaphragm  18 , said surface area relationship having a ratio in the range of from zero to 1:1, the ratio actually used being dependent on the type of diaphragm  18  being used, the type of modulator disc  22  and its thickness, the use of adhesive backings or not, and the size of the diaphragm  18  being used. The saucer-like concavity  30  is essentially a gas expansion chamber, which essentially allows the diffusion of the incoming exhaust impulse across the top surface of the modulator disc  22 . Thus, there is an importance to providing the proper surface area ratio between the area of the top of the saucer-like concavity  30  and the area of the top of the piezoelectric diaphragm  18 , because if the pulse provided by the exhaust stream is not properly distributed, the characteristics of the diaphragm  18  output are diminished.  
         [0035]    The modulator disc  22  is typically manufactured from chemical resistant materials, such as Teflon R  or similar materials (Teflon is a registered trademark of the DuPont Chemical Co., Wilmington, Del., USA for products manufactured from polytetrafluoroethylene). Similar materials that are useful in this invention are polyethylene, polypropylene, or the like, depending on the environment that the diaphragm is being used in. The adhesive used on the modulator disc  22  is an adhesive tape. The type of adhesive is not critical and is usually an adhesive tape that does not diminish the activity of the modulator disc  22  by diminishing the pulse received from the exhaust stream. One such adhesive tape is Teflon tape of about 3 to 8 mil thickness, with an acrylic adhesive on the back. It should be noted that best results are achieved by making sure that the adhesive tape uniformly rests on and is bonded to the top surface of the diaphragm  18 . As far as the inventor herein can ascertain, any adhesive tape will suffice for this application, as long as it will adhere to the diaphragm  18  surface and transmit impulses evenly across the piezoelectric diaphragm  18  surface.  
         [0036]    The housings for the components of this invention are constructed from any solid material that has sufficient strength to support the internal components. Such materials should be selected on the basis of the end use application, that is, internal or external to an internal combustion engine diagnostic apparatus, or, for example, whether or not the device of this invention is installed in a vehicle, or not. Such materials useful in this invention are for, example, polyethylene, polypropylene, polyfluorinated polymers selected from polytetrafluoroethylene, fluorinated ethylene propylene, perfluoroalkoxys, polychlorotrifluoroethylene, ethylene tetrafluoroethylene and polyvinylidene fluoride polymers, silicone polymers, nylon, synthetic resins, metals selected from aluminum, copper, and alloys of aluminum and copper.  
         [0037]    A further embodiment of this invention can be observed from FIG. 4, that is a fully exploded cross-sectional view of the device of FIG. 1 through line  100 - 100  of FIG. 1, showing non-threaded components  2  and  3 . Thus, it is contemplated within the scope of this invention to provide fastening means other than the threads described supra.  
         [0038]    The fastening of the insertable component  2  and the receiving component  3  together can be achieved by any means in which the two components are securely coupled together during use, but that can be separable for examination, replacement, cleaning, or repair. For example, a tacky gel or adhesive can be applied to the external surface  28  of the insertable component  2  that would hold the two segments together, but would allow the two segments to be separated easily by hand, or the two components can be bolted, pinned, or screwed together by the use of the openings  48 , shown on component  3  in FIG. 4. In this Figure, like numbers indicate like components as are shown in FIG. 2. The manner and means of fastening the two components is not critical as long as the two segments stay together during operation, and if desired, are separable by a simple means.  
         [0039]    It is contemplated within the scope of this invention to house the device  1  in an additional housing  38 , shown in phantom in FIG. 3, so that it may be easily handled, but moreover, the housing  38  would stabilize the assembly, and with regard to this, the housing  38  may be filled with vibration insulation or vibration dampening material (not shown), which would help prevent vibrations from the exhaust system of an internal combustion engine from interfering with the operation of the device  1 .  
         [0040]    In use, and with reference to FIG. 3, which is a schematic diagram of the apparatus  43  that is used in internal combustion diagnostic work, the device  1  is set up so that the tube connection  34  on the device  1  has attached to it, a tube  39  that is capable of withstanding the heat within an automotive exhaust pipe  40 . The opposite end  41  of the tube  39  is inserted into the open end of the exhaust pipe  40  of the vehicle, and is secured in place such as with a clip  42 , or the like. The tube  39  does not necessarily have to be directly tied to the exhaust pipe, it can be attached by some other means, such as inserted into an exhaust lead which carries the exhaust out of the vehicle and out into the atmosphere. The leads  4  are electrically connected to a commercial engine diagnostic apparatus  43  such that the apparatus  43  and the device  1  work in combination. As the exhaust system pumps exhaust out of the exhaust pipe  40 , the pulses created by the engine, in the exhaust stream, are sensed by the device  1  as the impulses are pumped into the device  1  through the tube  39 , into the void  25 , where the impulses are dispersed across the modulator disc  22  by the gas expansion capabilities of the saucer-like concavity  30  which in turn relays the pulses to the piezoelectric diaphragm  18 , which converts the pulses to electrical energy which energy is transmitted to the internal combustion engine diagnostic apparatus  43  through the leads  4  and electric wires  44  connected to the leads  4 , which in turn are electrically connected to the internal combustion engine diagnostic apparatus  43 . The results of the energy transmission are then illustrated on the scope  45  of the internal combustion engine diagnostic apparatus  43 . As shown in FIG. 3, the normal pulses  46  can be contrasted to the abnormal pulse  47  that is indicative of the presence of a disorder in a portion of the internal combustion engine.  
         [0041]    The noise reduction circuit  36  is one that is compatible with the internal combustion engine diagnostic apparatus  43  and the internal combustion engine diagnostic device  1  and is used to reduce electrical noise so that electrical patterns on the scope  45  of the internal combustion engine diagnostic apparatus  43  are clear and distinctive.  
         [0042]    The advantage of the device  1  of this invention is that it makes the internal combustion engine diagnostic apparatus  43  more sensitive to changes in the internal combustion engine operation, and can be used directly with the apparatus  43  without the time consuming task of removing spark plugs or completing other routines, etc. to allow a diagnosis on the internal combustion engine. Moreover, it is a direct look at such engine operation since during normal operation of the engine, there is generated a string of pulses commensurate with the normal operation of the engine and when the engine experiences problems, this string of pulses shows distinctive changes. The device  1  of this invention detects these changes and allows them to be displayed on the scope  45  of the internal combustion engine diagnostic apparatus  43 . When the system is timed to the number one spark plug firing, it is possible to trace problems to specific cylinders.  
         [0043]    The devices  1  of this invention are safe to use, as they do not require electrical or mechanical power to operate, and output voltage levels from the piezoelectric diaphragm  18  are low.  
         [0044]    Note that it is contemplated within the scope of this invention to build the devices of this invention directly into internal combustion engine diagnostic apparatii. It is further contemplated within the scope of this invention to build devices of this invention into automotive vehicles so that the automobile will have self-diagnostic capabilities, along with pre-warning capabilities so that the owner/operator of the vehicle will know immediately when here is a problem with the engine of the vehicle.  
         [0045]    The methods and materials of construction, along with specifications are set forth in a concurrently pending U.S. patent application Ser. No. 09/870,189, filed May 30, 2001 in the name of the inventor herein, John L. Brock, and entitled NOVEL PIEZOELECTRIC TRANSDUCER ASSEMBLIES AND METHODS FOR THEIR USE, which is hereby incorporated by reference for what it teaches about piezoelectric transducer assemblies and their manufacture.  
         [0046]    The piezoelectric diaphragms that are useful in this invention range in diameter from about 0.25 inches to about 2.5 inches, the preferred size being less than about 2 inches, and the most preferred being in the range of about ¾ of an inch to about 1 ⅛ inches. The preferred thickness of the diaphragms is in the range of about 0.008 millimeters to about 0.20 millimeters, and the most preferred ranges is about 0.01 to about 0.05 millimeters and especially preferred for this invention is a range of about 0.01 to about 0.03 millimeters. The diaphragms of this invention are commercially available, and are manufactured typically from stainless steel, ceramic, brass, and polymeric films the preferred diaphragms being stainless steel, and polymeric films, and especially preferred for overall performance is stainless steel.  
         [0047]    Thin 2-layer diaphragms are the most versatile configuration of all. They may be used like single sheets (made up of 2 layers), they can be used to bend, or they can be used to extend. A 2-layer diaphragm produces curvature when one layer expands while the other layer contracts. These diaphragms are often referred to as benders, bimorphs, or flexural elements. Benders achieve large deflections relative to other piezo diaphragms.