Patent Application
20070084438
The present invention relates to throttles for an internal combustion engine, and more particularly, to an electromechanical default system to allow air to bypass a closed throttle plate in response to an ETC fault signal.
An electronic throttle control system (ETC) for controlling the amount of air to an engine is well known. The throttle valve plate of the throttle body pivots in response to signals received from the engine control unit (ECU) and thereby acts to regulate the amount of air delivered to the intake manifold. Throttle position sensors maintain the correct throttle position over the range of expected engine torque loads.
Prior art throttle plates are typically designed to default to a slightly open position (e.g., by about 10-20 degrees depending on the particular application) when in the engine-off condition or upon receiving an ETC fault signal. This is because there exists the possibility of the throttle plate becoming stuck in the fully closed position due to winter-time ice or carbon build-up in this area. Also, should the ETC malfunction, some air must be able to reach the intake manifold to allow the car a “limp home” condition for needed repairs. Thus, the prior art typically provides an ETC throttle system with a throttle plate that defaults to an open position in engine-off and ETC failure conditions. However, one serious drawback to a throttle open default position is that hydrocarbons remaining in the intake manifold are allowed to evaporate and escape into the atmosphere. Present day emissions regulations require throttle designs which substantially restrict the escape of hydrocarbons which would otherwise occur through an open throttle plate during engine-off or ETC failure conditions. Therefore, there exists a need for an ETC throttle body that gives the engine a limp home condition yet restricts the escape of evaporated hydrocarbons during engine-off and ETC failure conditions.
The present invention provides a throttle body having a default closed position for the throttle plate when in an engine-off condition to substantially prevent the escape of hydrocarbons into the atmosphere, and further includes an air bypass channel that opens in response to an ETC failure condition (with engine on) to allow the automobile a limp home condition.
More particularly, the throttle body is provided with a bypass air channel extending from the inlet end of the throttle bore to the outlet end radially outwardly of the main throttle bore wherein the throttle plate is located. The bypass is normally closed and will open only in response to receiving a signal that the ETC has malfunctioned with the engine running.
Any desired and appropriate mechanism may be used for the closing and subsequent opening of the bypass. For example, and not by way of limitation, the mechanism could be an electromechanical valve such as a poppet valve or a solenoid valve; a wax plug or other material that falls away upon application of an electric charge or change in air or mechanical pressure.
The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
As seen in
ETC 10 includes a main throttle bore 12 having an inlet end 12a and an outlet end 12b which connects to the air intake manifold of the engine. Outside air is thus delivered through throttle main bore 12 to the engine's air intake manifold and mixes with fuel to power the engine in a well known manner. A throttle plate 14 is pivotally secured within main bore 12 and is movable through connection of an actuator 16 which may be a DC brush motor, for example. Actuator 16 responds to signals received from the ECU to pivot throttle plate 14 between a fully closed position as seen best in
When in the fully closed position, throttle plate 14 essentially seals throttle bore 12 such that no air is allowed therethrough and the engine is thus not running. Conversely, the fully open position of the throttle plate allows the maximum amount of air through the throttle bore 12 to power the engine. Positions between fully open and fully closed are dictated by the ECU which moves the throttle plate 14 via actuator 16 based on the engine load condition.
As explained in the Background section hereof, many prior art throttle bodies are designed to default to a slightly open position rather than a fully closed position. This is because of the fear that the throttle plate may get stuck in the fully closed position, and also to allow some air to reach the engine in case the ETC actuator fails, thereby allowing a limp home condition for needed repairs. Unfortunately, this open throttle position also allows the intake manifold to be exposed to the ambient leading to the evaporation and escape of hydrocarbons into the environment when the engine is not running. Present day federal emissions regulations require these emissions be eliminated or at least significantly reduced from previously seen levels.
The present invention addresses the above noted concerns by having the throttle plate 14 default to the fully closed position when the engine is not running and/or the ETC actuator 16 fails. With the throttle plate 14 fully closed (
In particular, the invention provides a throttle air bypass channel 20 having an inlet end 20a and outlet end 20b extending between and adjacent the throttle main bore inlet end 12a and outlet end 12b, respectively, and radially outwardly of main throttle bore 12. As such, when channel 20 is unobstructed and open, air may bypass main throttle bore 12 (and thus also closed throttle plate 14) by flowing from channel inlet end 20a to outlet end 20b and thereby reach the engine intake manifold.
A removable obstruction is positioned in channel 20 such that channel 20 is normally closed. The obstruction is automatically removed (and thus channel 20 is opened) upon the occurrence of a fault being detected in the ETC. As used herein, the terms “removable” and “removed” are meant to indicate a condition where the obstruction is no longer blocking or sealing off channel 20 and may or may not involve actual physical separation of the obstruction from the throttle body. It is furthermore understood that all necessary components and connections, according to the selected obstruction type, are included to allow the obstruction to receive and respond to an ETC fault signal.
In the embodiment of the invention shown in
While the invention has been described by reference to various specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. For example, although the invention has been described and shown with a poppet valve as the removable obstruction, it is understood that any device capable of normally obstructing and then automatically opening channel 20 in response to receiving an ETC fault signal would be suitable. A few possible examples include a plug of material (e.g., wax or a fusible metal alloy) that, under normal operating conditions, maintains the channel 20 plugged and closed, yet automatically opens the channel 20 upon receiving an ETC fault signal (e.g., by reducing in size, disintegrating, or otherwise moving away from the closed position in channel 20).
Accordingly, it is intended that the invention not be limited to the described embodiments, but will have the full scope defined by the language of the following claims.
