Dual-Passage Fluid Coupler for Accurate Crankcase Pressure Sensing
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Solution Overview
Problem
Existing PCV system couplers face challenges in accurately measuring crankcase pressure without causing a pressure drop, and they are prone to water vapor intrusion, which can lead to sensor malfunctions due to condensation or icing.
Innovation Solution
The dual-passage, quick-connect fluid coupler design features a main connector body with parallel-flow internal fluid chambers, a dedicated sensor compartment, and a distinct blow-by fluid passage that isolate the crankcase pressure sensor from the main blow-by passage, preventing water vapor intrusion and maintaining accurate pressure readings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is placed directly in the main blow-by passage to measure pressure, then pressure measurement accuracy is improved, but water vapor intrusion and sensor malfunction risk increase
Solution Approach 1:
The passage is segmented into a main blow-by passage and a separate auxiliary passage. The sensor is placed in the auxiliary passage, which is fluidly connected to the main passage through a communication opening. This segmentation allows the sensor to measure pressure accurately without being directly exposed to water vapor in the main passage.
Solution Approach 2:
The auxiliary passage acts as an intermediary between the sensor and the main blow-by passage. It transmits pressure information from the main passage to the sensor while isolating the sensor from direct contact with water vapor and other harmful substances in the main passage.
2Reliability
If the sensor is isolated from the main blow-by passage to prevent water vapor intrusion, then sensor reliability is improved, but pressure measurement accuracy may deteriorate due to pressure drop
Solution Approach 1:
The communication opening is positioned upstream from the sensor in the auxiliary passage. This preliminary positioning ensures that pressure is transmitted to the sensor before any potential pressure drop can occur in the auxiliary passage, maintaining accurate pressure measurement while keeping the sensor isolated from water vapor.
3Object-affected harmful factors
If a complex sealing structure is added to prevent water vapor intrusion, then sensor protection is improved, but device complexity increases
Solution Approach 1:
Instead of adding complex sealing structures within the main passage, the solution moves the sensor to a separate auxiliary passage (a different spatial dimension). The communication opening provides the necessary fluid connection while the physical separation in another dimension naturally prevents water vapor intrusion without requiring additional sealing components.
Data Source
AI summary
Presented are dual-passage fluid couplers with integrated fluid sensors, methods for using/making such fluid couplers, and motor vehicles equipped with such fluid couplers. A quick-connect (QC) fluid coupler includes a sensor assembly with a sensor housing containing a sensing device that monitors fluid flow, and a main connector body with opposing inlet and outlet ends having respective inlet and outlet ports. The main connector body contains a sensor chamber attaching thereto the sensor housing, and a primary fluid chamber that extends from the inlet end to the outlet end of the main connector body and fluidly connects the inlet and outlet ports. Interposed between the primary and sensor chambers is a secondary fluid chamber that is fluidly connected to the sensor chamber via a sensor port and to the primary fluid chamber via a bleed port upstream from the sensor port and a merge channel downstream from the sensor port.