# US 11,441,993 B2 · Method and system for exhaust particulate matter sensing

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- Number: US 11,441,993 B2
- Document ID: US11441993B2
- Status: Granted
- Kind: B2
- Application number: 16/431,496
- Filed: 2019-06-04
- Published: 2019-10-24
- Granted: 2022-09-13
- Earliest claimed: 2016-08-22
- Assignees: Ford Global Technologies, LLC
- Applicants: Ford Global Technologies, LLC
- Inventors: Xiaogang Zhang
- Web page: https://patentgrep.com/patent/US11441993B2

## CPC

- G01N 15/0656: {using electric, e.g. electrostatic methods or magnetic methods (by investigating individual particles G01N15/1031, G01N15/12)}
- F01N 11/007: {the diagnostic devices measuring oxygen or air concentration downstream of the exhaust apparatus}
- G01M 15/102: {by monitoring exhaust gases}
- G01N 15/0606: {by collecting particles on a support}
- F01N 2560/05: the means being a particulate sensor
- G01N 2015/0046: {in gas, e.g. smoke}
- Y02T 10/40: Engine management systems
- G01N: INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES (measuring or testing apparatus or processes other than immunoassay, involving enzymes or microorganisms C12M, C12Q)
- F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16)
- G01M: TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

Methods and systems are provided for sensing particulate matter by a particulate matter (PM) sensor positioned upstream, or downstream, of a diesel particulate filter in an exhaust system. The PM sensor may include first and second conductive matrixes each having a three dimensional shape. The first matrix functions as a positive electrode, and the second functions as a negative electrode. Each matrix defines extensions and/or passages passing respectively through, and/or near, each other to form multiple soot capturing gaps. A first of the multiple soot capturing gaps is oriented orthogonal to a second of the multiple soot capturing gaps.

## Claims

### Claim 1

A particulate matter sensor, comprising
a first conductive matrix having a three-dimensional shape defined by an x-dimension, a y-dimension, and a z-dimension to be charged to a first voltage to function as a positive electrode;
a second conductive matrix having a three-dimensional shape defined by the x-dimension, the y-dimension, and the z-dimension to be charged to a second voltage to function as a negative electrode; and
one of the first and second matrixes defining extensions and/or passages, and the other of the first and second matrixes defining extensions and/or passages, the extensions and/or the passages passing respectively through and/or spaced from each other forming multiple soot capturing gaps defined by a local shortest distance from the first matrix to the second matrix, and wherein a first of the multiple soot capturing gaps is oriented orthogonal to a second of the multiple soot capturing gaps; and
wherein a change in voltage of the first and/or second matrix is effected by soot forming in the soot capturing gaps and is determinable as a soot concentration level in an exhaust stream from an engine.

### Claim 2 (depends on 1)

The particulate matter sensor of claim 1, wherein the orientation of the first soot capturing gap is transverse to a flow direction of the exhaust stream, and the orientation of the second soot capturing gap is in parallel with the exhaust stream.

### Claim 3 (depends on 1)

The particulate matter sensor of claim 1, wherein the extensions of the first conductive matrix include a first set of electrically conductive comb-like tines, and the extensions of the second conductive matrix include a second set of electrically conductive comb-like tines interdigitated with the first set of electrically conductive comb-like tines.

### Claim 4 (depends on 3)

The particulate matter sensor of claim 3, wherein:
a first group of the interdigitated comb-like tines is selected in alternating order from the first matrix and the second matrix and arranged substantially orthogonal with a general flow direction of the exhaust stream, and a second group of the interdigitated comb-like tines is selected in alternating order from the second matrix and the first matrix and arranged substantially parallel with the first group of the interdigitated comb-like tines; and
the first soot capturing gap is oriented substantially transverse to the general flow direction from the first matrix to the second matrix within the first group of interdigitated comb-like tines, and the second soot capturing gap is oriented substantially in line with the general flow direction from the first matrix to the second matrix and from the first group of interdigitated comb-like tines to the second group of interdigitated comb-like tines forming respective bridges of alternate polarity in a first direction substantially transverse to the general flow direction and in a second direction substantially parallel with the general flow direction.

### Claim 5 (depends on 1)

The particulate matter sensor of claim 1, wherein a passage from the first conductive matrix includes a hole, and wherein an extension from the second conductive matrix extends into the hole.

### Claim 6 (depends on 1)

The particulate matter sensor of claim 1, wherein extensions from the first conductive matrix and extensions from the second conductive matrix each define corrugated profiles, and wherein the respective corrugated profiles are interwoven to form the multiple soot capturing gaps.

### Claim 7

A particulate matter (PM) sensor for use in an engine exhaust comprising:
a positive electrode having multiple extensions and/or multiple passages; and
a negative electrode having multiple extensions and/or multiple passages;
wherein the passages and the extensions pass respectively through and/or spaced from each other forming multiple soot capturing gaps between the positive electrode and the negative electrode, each soot capturing gap having an orientation defined by a local shortest distance between the positive electrode and the negative electrode, wherein a first portion of the soot capturing gaps are orientated substantially orthogonally to a second portion of soot capturing electrodes.

### Claim 8 (depends on 7)

The PM sensor of claim 7, wherein the positive electrode includes, or is electrically coupled with, a main positive electrode fixed to a substrate, and wherein the negative electrode includes, or is electrically coupled with, a main negative electrode fixed to the substrate.

### Claim 9 (depends on 7)

The PM sensor of claim 7, wherein the positive electrode and the negative electrode are located in a boxlike housing.

### Claim 10 (depends on 7)

The PM sensor of claim 7, wherein each gap from the first portion of the soot capturing gaps is orientated substantially transverse to a flow direction of the engine exhaust, and wherein each gap from the second portion of the soot capturing gaps is orientated substantially in line with the engine exhaust.

### Claim 11 (depends on 7)

The PM sensor of claim 7, wherein the positive electrode includes a first set of extensions, and the negative electrode includes a second set of extensions, interdigitated with the first set of extensions.

### Claim 12 (depends on 7)

The PM sensor of claim 7, wherein extensions from the positive electrode and extensions from the negative electrode each define corrugated profiles, and wherein the respective corrugated profiles are interwoven to form the multiple soot capturing gaps.

### Claim 13 (depends on 7)

The PM sensor of claim 7, further comprising a third portion of the soot capturing gaps orientated substantially orthogonally to the first portion and to the second portion of soot capturing gaps.