Gas sensor and manufacturing method therefor, gas monitoring apparatus, and vehicle

Abstract

The present application relates to a gas sensor and a manufacturing method therefor, a gas monitoring apparatus, and a vehicle. The gas sensor comprises a first electrolyte substrate, a first insulating layer, and a first heterojunction layer. The first insulating layer is located on one side of the first electrolyte substrate, and the first heterojunction layer is located between the first insulating layer and the first electrolyte substrate. The first heterojunction layer comprises a first junction portion and a second junction portion that are connected within the same layer; and the first junction portion and the first insulating layer are made of the same material, and the second junction portion and the first electrolyte substrate are made of the same material.

Description

Gas sensors and their preparation methods, gas monitoring devices and vehicles

[0001] This application claims priority to Chinese Patent Application No. 202411227282.9, filed on August 30, 2024, entitled "Gas Sensor and Preparation Method Thereof, Gas Monitoring Device and Vehicle", the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application relates to the field of electronic technology, and in particular to a gas sensor and its preparation method, a gas monitoring device, and a vehicle. Background Technology

[0003] An oxygen sensor uses a ceramic sensing element to measure the oxygen concentration in a car's exhaust pipe and converts the oxygen concentration signal into an electrical signal, which is then fed back to the engine control unit (ECU) to monitor and control the air-fuel ratio. This ensures complete fuel combustion and reduces emissions of toxic and harmful substances. Based on the oxygen concentration signal from the oxygen sensor, the ECU controls the fuel injection and air intake accordingly, ensuring the engine operates at the optimal air-fuel ratio. This creates ideal conditions for the exhaust gas treatment by the three-way catalytic converter. If the fuel is too rich, the fuel quantity is reduced and the air intake is increased; if the fuel is too lean, the fuel quantity is increased and the air intake is reduced.

[0004] In some related technical solutions for oxygen sensors, a transition layer containing zirconium oxide, silicon oxide, and aluminum oxide is set between the heating element and the oxygen measuring element. However, the structure of this transition layer is only a simple mixture of zirconium oxide, aluminum oxide, and calcium oxide, which has limited effect on improving the heterojunction strength of zirconium and aluminum. Summary of the Invention

[0005] This application provides a gas sensor and its preparation method, a gas monitoring device, and a vehicle, aiming to improve the bonding strength between the first insulating layer and the first electrolyte matrix.

[0006] To achieve the above objectives, according to a first aspect of this application, a gas sensor is provided, comprising:

[0007] First electrolyte matrix;

[0008] The first insulating layer is located on one side of the first electrolyte matrix;

[0009] The first heterogeneous bonding layer is located between the first insulating layer and the first electrolyte substrate, and the first heterogeneous bonding layer includes a first bonding portion and a second bonding portion connected in the same layer. The first bonding portion is made of the same material as the first insulating layer, and the second bonding portion is made of the same material as the first electrolyte substrate.

[0010] In some embodiments, the relationship between the first joint (41) and the second joint (42) includes at least one of the first joint being disposed around at least a portion of the second joint and at least a portion of the second joint being disposed around at least a portion of the first joint.

[0011] In some embodiments, the first joint includes a first connecting portion and at least two first intersecting portions, the first connecting portion connecting the at least two first intersecting portions; the second joint includes a second connecting portion and at least two second intersecting portions, the second intersecting portions connecting the at least two second intersecting portions.

[0012] Two adjacent first intersections and first connecting parts are arranged around a second intersection, and two adjacent second intersections and second connecting parts are arranged around a first intersection.

[0013] In some embodiments, the first intersection has a first end and a second end, the first end being connected to the first connecting portion and the second end being connected to the second connecting portion;

[0014] The second cross portion has a third end and a fourth end, the third end being connected to the second connecting portion and the fourth end being connected to the first connecting portion.

[0015] In some embodiments, the first electrolyte matrix extends along a first direction, the first connecting portion and the second connecting portion are parallel to each other and both extend along the first direction, the first intersecting portion and the second intersecting portion are parallel to each other and both extend along a second direction, and the first direction intersects the second direction.

[0016] In some embodiments, the first electrolyte matrix extends along a first direction, the first connecting portion and the second connecting portion are parallel to each other and both extend along a second direction, the first intersecting portion and the second intersecting portion are parallel to each other and both extend along the first direction, and the first direction intersects the second direction.

[0017] In some embodiments, the first joint includes a plurality of first sub-joints, and the second joint includes a plurality of second sub-joints, with the plurality of first sub-joints and the plurality of second sub-joints alternately arranged around each other.

[0018] In some embodiments, at least one of the second sub-junction and the first sub-junction has a top view shape in the direction of a third direction, which is the stacking direction of the first electrolyte matrix and the first insulating layer.

[0019] In some embodiments, it also includes:

[0020] The first reinforcing layer is located between the first heterogeneous bonding layer and the first electrolyte matrix, and the first reinforcing layer and the first electrolyte matrix are made of the same material.

[0021] In some embodiments, the thickness of the first reinforcing layer along a third direction is less than the thickness of the first electrolyte substrate in the third direction, where the third direction is the stacking direction of the first electrolyte substrate and the first insulating layer.

[0022] In some embodiments, the thickness of the first reinforcing layer in the third direction is 10 micrometers to 50 micrometers.

[0023] In some embodiments, the thickness of the first heterogeneous bonding layer along a third direction is less than the thickness of the first electrolyte substrate in the third direction, where the third direction is the stacking direction of the first electrolyte substrate and the first insulating layer.

[0024] In some embodiments, the thickness of the first heterogeneous bonding layer in the third direction is 10 micrometers to 50 micrometers.

[0025] In some embodiments, the thickness of the first electrolyte matrix in the third direction is 150 micrometers to 300 micrometers.

[0026] In some embodiments, the material of the first electrolyte matrix includes zirconium oxide and additives, the additives including yttrium oxide, cerium oxide, or calcium oxide.

[0027] In some embodiments, the additive content in the first electrolyte matrix is ​​5 mol% to 10 mol%.

[0028] In some embodiments, the top view area of ​​the first bonding portion along a third direction is 20% to 80% of the top view area of ​​the first heterogeneous bonding layer in the third direction, where the third direction is the stacking direction of the first electrolyte matrix and the first insulating layer.

[0029] In some embodiments, the device further includes a heating electrode and a second insulating layer, wherein the heating electrode is located on the side of the first insulating layer away from the first heterogeneous bonding layer, and the second insulating layer is located on the side of the heating electrode away from the first insulating layer.

[0030] The gas sensor also includes:

[0031] The detection unit includes a second electrolyte substrate, a first detection electrode, and a second detection electrode. The first detection electrode is located on the side of the second electrolyte substrate away from the second insulating layer, and the second detection electrode is located on the side of the second electrolyte substrate away from the first detection electrode.

[0032] The second heterogeneous bonding layer is located between the second insulating layer and the second electrolyte substrate. The second heterogeneous bonding layer includes a third bonding portion and a fourth bonding portion connected in the same layer. The third bonding portion is made of the same material as the second insulating layer, and the fourth bonding portion is made of the same material as the second electrolyte substrate.

[0033] In some embodiments, the thickness of the second heterojunction layer along a third direction is less than the thickness of the second electrolyte substrate along a third direction, where the third direction is the stacking direction of the first electrolyte substrate and the first insulating layer, and the thickness of the second electrolyte substrate in the third direction is 150 micrometers to 300 micrometers.

[0034] In some embodiments, the sensor further includes:

[0035] The second reinforcing layer is located between the second heterogeneous bonding layer and the second electrolyte matrix, and the second reinforcing layer and the second electrolyte matrix are made of the same material.

[0036] In some embodiments, the sensor further includes:

[0037] The third electrolyte matrix is ​​located between the second heterogeneous binding layer and the second electrolyte matrix;

[0038] The standard gas channel is located on the side of the third electrolyte matrix away from the second heterogeneous binding layer;

[0039] The second detection electrode is connected to the standard gas channel.

[0040] According to a second aspect of this application, a method for preparing a gas sensor is provided, comprising:

[0041] Provide a first electrolyte matrix;

[0042] A first heterogeneous bonding layer is formed on one side of the first electrolyte matrix. The first heterogeneous bonding layer includes a first bonding portion and a second bonding portion connected in the same layer. The second bonding portion is made of the same material as the first electrolyte matrix.

[0043] A first insulating layer is formed on the side of the first heterogeneous bonding layer away from the first electrolyte matrix, and the first bonding portion is made of the same material as the first insulating layer.

[0044] In some embodiments, the step of forming a first heterogeneous bonding layer on one side of the first electrolyte matrix includes:

[0045] A second bonding portion is printed on the first electrolyte matrix;

[0046] A first bonding portion is printed on the first electrolyte substrate, and the first bonding portion is connected to the second bonding portion in the same layer.

[0047] In some embodiments, prior to the step of printing the second bonding portion on the first electrolyte substrate, the method for fabricating the gas sensor further includes:

[0048] A first reinforcing layer is printed on the first electrolyte matrix.

[0049] According to a third aspect of this application, a gas monitoring device is provided, including the gas sensor in any of the above embodiments.

[0050] According to a fourth aspect of this application, a vehicle is provided that includes the aforementioned gas monitoring device.

[0051] This application provides a gas sensor, its fabrication method, a gas monitoring device, and a vehicle. The gas sensor includes a first electrolyte substrate, a first insulating layer, and a first heterogeneous bonding layer. The first insulating layer is located on one side of the first electrolyte substrate, and the first heterogeneous bonding layer is located between the first insulating layer and the first electrolyte substrate. The first heterogeneous bonding layer includes a first bonding portion and a second bonding portion connected in the same layer. The first bonding portion is made of the same material as the first insulating layer, and the second bonding portion is made of the same material as the first electrolyte substrate. Because the first bonding portion and the second bonding portion are connected in the same layer and are independent of each other, and because the first bonding portion and the first insulating layer are made of the same material and have contacting surfaces, the bonding force between the first bonding portion and the first insulating layer is greatly improved. Similarly, because the second bonding portion and the first electrolyte substrate are made of the same material and have contacting surfaces, the bonding force between the second bonding portion and the first electrolyte substrate is greatly improved. Therefore, the first heterogeneous bonding layer can significantly improve the bonding strength between the first insulating layer and the first electrolyte substrate. Attached Figure Description

[0052] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0053] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings, wherein the same reference numerals in the following description denote the same parts.

[0054] Figure 1 is a three-dimensional structural diagram of a gas sensor provided in some embodiments of this application;

[0055] Figure 2 is an exploded structural diagram of a gas sensor provided in some embodiments of this application;

[0056] Figure 3 is a schematic diagram of the structure of the first heterogeneous bonding layer at position A in Figure 2 provided in some embodiments of this application;

[0057] Figure 4 is a cross-sectional view of the first insulating layer, the first heterogeneous bonding layer and the first reinforcing layer in Figure 2 provided in some embodiments of this application along the first direction and the third direction;

[0058] Figure 5 is a schematic diagram of the exploded structure of a gas sensor provided in some embodiments of this application;

[0059] Figure 6 is a schematic diagram of the connection structure of the first joint and the second joint provided in some embodiments of this application;

[0060] Figure 7 is a schematic flowchart of a method for preparing a gas sensor according to some embodiments of this application. Specific Implementation

[0061] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the protection scope of this application.

[0062] This paper uses Cartesian coordinates to represent directions, where "Y" represents the first direction, "X" represents the second direction, and "Z" represents the third direction. The first, second, and third directions intersect each other, that is, X, Y, and Z intersect each other, for example, they can be perpendicular to each other or form a certain angle.

[0063] Please refer to Figures 1-4. Figure 1 is a three-dimensional structural diagram of a gas sensor provided in some embodiments of this application. Figure 2 is an exploded structural diagram of a gas sensor provided in some embodiments of this application. Figure 3 is a structural schematic diagram of the first heterogeneous bonding layer at position A in Figure 2 provided in some embodiments of this application. Figure 4 is a cross-sectional view of the first insulating layer, the first heterogeneous bonding layer and the first reinforcing layer in Figure 2 provided in some embodiments of this application along the first direction and the third direction.

[0064] The gas sensor 100 includes a first electrolyte substrate 1, a first insulating layer 3, and a first heterogeneous bonding layer 4. The first insulating layer 3 is located on one side of the first electrolyte substrate 1, and the first heterogeneous bonding layer 4 is located between the first insulating layer 3 and the first electrolyte substrate 1. The first heterogeneous bonding layer 4 includes a first bonding portion 41 and a second bonding portion 42 connected in the same layer. The first bonding portion 41 is made of the same material as the first insulating layer 3, and the second bonding portion 42 is made of the same material as the first electrolyte substrate 1. Since the first bonding portion 41 and the second bonding portion 42 are connected in the same layer and are independent of each other, and the first bonding portion 41 and the first insulating layer 3 are made of the same material and have contacting surfaces, the bonding force between the first bonding portion 41 and the first insulating layer 3 is greatly improved. Since the second bonding portion 42 and the first electrolyte substrate 1 are made of the same material and have contacting surfaces, the bonding force between the second bonding portion 42 and the first electrolyte substrate 1 is greatly improved. Therefore, the first heterogeneous bonding layer 4 can greatly improve the bonding strength between the first insulating layer 3 and the first electrolyte substrate 1.

[0065] The material of the first electrolyte matrix 1 may include zirconium oxide and additives, including yttrium oxide, cerium oxide, or calcium oxide, wherein zirconium oxide may be a high-density material to provide greater hardness. The material of the first insulating layer 3 may include aluminum oxide or aluminum nitride, wherein aluminum oxide or aluminum nitride may be a high-density material to provide greater hardness.

[0066] In some embodiments, the additive content in the first electrolyte matrix 1 is 5 mol% to 10 mol%, which can make the first electrolyte matrix 1 have a tetragonal crystal form, good conductivity, and moderate cost.

[0067] The thickness of the first heterojunction layer 4 along the third direction Z can be less than the thickness of the first electrolyte substrate 1 along the third direction Z, where the third direction Z is the stacking direction of the first electrolyte substrate 1 and the first insulating layer 3. Setting the thickness of the first heterojunction layer 4 to be less than the thickness of the first electrolyte substrate 1 can reduce the number of printing operations for the first heterojunction layer 4, thereby reducing costs, and can also reduce the impact of the first heterojunction layer 4 on the heat transfer efficiency along the third direction Z.

[0068] In some embodiments, the thickness of the first electrolyte substrate 1 along the third direction Z is 150 micrometers to 300 micrometers. The thickness of the first heterojunction layer 4 along the third direction Z is 10 micrometers to 50 micrometers. A thickness greater than or equal to 10 micrometers can improve the bonding strength between the first insulating layer 3 and the first electrolyte substrate 1, while a thickness less than or equal to 50 micrometers can not only reduce costs but also reduce the impact of the first heterojunction layer 4 on the heat transfer efficiency in the third direction Z.

[0069] The gas sensor 100 may include a heating unit and a detection unit. The heating unit may include a first insulating layer 3 and a second insulating layer 5, and a heating electrode 2 located between the first insulating layer 3 and the second insulating layer 5. The detection unit may include a first detection electrode 6, a second detection electrode 7, and a solid electrolyte layer located between the first detection electrode 6 and the second detection electrode 7.

[0070] In some embodiments, the thickness of the first insulating layer 3 along the third direction Z is 10 micrometers to 50 micrometers, and the thickness of the second insulating layer 5 along the third direction Z is 10 micrometers to 50 micrometers. The thickness of the detection unit along the third direction Z is 10 micrometers to 20 micrometers.

[0071] As shown in Figure 2, the first electrolyte substrate 1 can serve as a carrier to support other structures. The first heterogeneous bonding layer 4, the first insulating layer 3, the heating electrode 2, and the second insulating layer 5 are sequentially stacked on the first electrolyte substrate 1. The solid electrolyte layer in the detection unit is the second electrolyte substrate 8, wherein the second detection electrode 7 is located on the side of the second electrolyte substrate 8 away from the first detection electrode 6. The first insulating layer 3 and the second insulating layer 5 can be made of the same material, and the first electrolyte substrate 1 and the second electrolyte substrate 8 can also be made of the same material.

[0072] The gas sensor 100 may further include a second heterogeneous bonding layer 9, which is located between the second insulating layer 5 and the second electrolyte substrate 8. The second heterogeneous bonding layer 9 includes a third bonding portion and a fourth bonding portion connected in the same layer. The third bonding portion is made of the same material as the second insulating layer 5, and the fourth bonding portion is made of the same material as the second electrolyte substrate 8, thus greatly improving the bonding strength between the second insulating layer 5 and the second electrolyte substrate 8.

[0073] In some embodiments, the thickness of the second heterojunction layer 9 along the third direction Z is less than the thickness of the second electrolyte substrate 8 along the third direction Z, where the third direction Z is the stacking direction of the first electrolyte substrate 1 and the first insulating layer 3, and the thickness of the second electrolyte substrate 8 in the third direction Y is 150 micrometers to 300 micrometers. Setting the thickness of the second heterojunction layer 9 to be less than the thickness of the second electrolyte substrate 8 can reduce the number of printing operations required for the second heterojunction layer 9, thereby reducing costs, and can also reduce the impact of the second heterojunction layer 9 on the heat transfer efficiency in the third direction Z.

[0074] For example, the thickness of the second heterogeneous bonding layer 9 along the third direction Z is 10 micrometers to 50 micrometers. A thickness greater than or equal to 10 micrometers can improve the bonding strength between the second insulating layer 5 and the second electrolyte substrate 8. A thickness less than or equal to 50 micrometers can not only reduce costs, but also reduce the impact of the second heterogeneous bonding layer 9 on the heat transfer efficiency in the third direction Z.

[0075] The gas sensor 100 may also include an electrode protection layer 10 for protecting the second detection electrode 7.

[0076] The gas sensor 100 may further include a standard gas channel 11, which may be located on the side of the second electrolyte substrate 8 near the first detection electrode 6 and in contact with the first detection electrode 6. Therefore, the first detection electrode 6 can detect the oxygen content of the standard gas, while the second detection electrode 7 is used to detect the oxygen content of the gas to be detected (e.g., exhaust gas from an exhaust pipe). Because the oxygen concentrations on both sides of the second electrolyte substrate 8 are different, a potential difference can be generated between the first detection electrode 6 and the second detection electrode 7, allowing the gas sensor 100 to output a voltage signal, thereby regulating the air-fuel ratio.

[0077] In some embodiments, the first electrolyte substrate can serve as the solid electrolyte layer in the detection unit, and the first insulating layer is the insulating layer in the heating unit that is close to the first electrolyte substrate. In this case, the first heterogeneous bonding layer can improve the bonding strength between the first insulating layer and the solid electrolyte layer in the detection unit.

[0078] Please refer to Figure 5, which is a schematic diagram of the exploded structure of a gas sensor provided in some embodiments of this application. For ease of understanding and brief description, the same structures as those in the above embodiments will continue to use the same reference numerals, and the same structures will not be described in detail. This embodiment will only describe the different structures in detail.

[0079] The gas sensor 200 may further include a first reinforcing layer 12, which is located between the first heterogeneous bonding layer 4 and the first electrolyte substrate 1, and the first reinforcing layer 12 and the first electrolyte substrate 1 are made of the same material. Therefore, during the bonding process, the first reinforcing layer 12 can wet the first heterogeneous bonding layer 4 and the first electrolyte substrate 1, thereby enhancing the bonding strength between the first heterogeneous bonding layer 4 and the first electrolyte substrate 1.

[0080] The gas sensor 100 may further include a second reinforcing layer 13, which is located between the second heterogeneous bonding layer 9 and the second electrolyte substrate 8, and the second reinforcing layer 13 and the second electrolyte substrate 8 are made of the same material. Therefore, during the bonding process, the second reinforcing layer 13 can wet the second heterogeneous bonding layer 9 and the second electrolyte substrate 8, thereby strengthening the second heterogeneous bonding layer 9 and the second electrolyte substrate 8.

[0081] In some embodiments, the first reinforcing layer 12 and the second reinforcing layer 13 can effectively wet the first electrolyte substrate 1 and the second electrolyte substrate 8 during the screen printing process, allowing the two electrolyte substrates to make better contact during the pressing process, thereby promoting the improvement of the sintering bond strength between the electrolyte substrates. In addition, since the reinforcing layer and the electrolyte substrate are made of the same material, they can promote the bonding between the electrolyte substrates during the sintering process, thereby increasing the density of the electrolyte substrate bonding area.

[0082] The top view areas of the first electrolyte substrate 1, the first reinforcing layer 12, the second reinforcing layer 13, and the second electrolyte substrate 8 are equal and larger than the top view areas of other film layers (including the heating unit). Therefore, the first reinforcing layer 12 and the second reinforcing layer 13 can contact each other during the sintering process. The "top view" refers to the top view along the third direction Z, which is the stacking direction of the first electrolyte substrate 1 and the first insulating layer 3.

[0083] In some embodiments, the thickness of the first reinforcing layer 12 along the third direction Z is less than the thickness of the first electrolyte substrate 1 in the third direction Z. Therefore, while using the first reinforcing layer 12 to enhance the bonding strength between the first heterogeneous bonding layer 4 and the first electrolyte substrate 1, the heat transfer efficiency in the third direction Z can be controlled within an acceptable range, and the printing cost can be reduced.

[0084] In some embodiments, the thickness of the first reinforcing layer 12 in the third direction Z is 10 micrometers to 50 micrometers. This can ensure that the first reinforcing layer 12 enhances the bonding strength between the first heterogeneous bonding layer 4 and the first electrolyte substrate 1, reduce the impact of the first reinforcing layer 12 on the heat transfer efficiency in the third direction Z, and reduce printing costs.

[0085] The gas sensor 100 may further include a third electrolyte substrate 14, which is located between the second heterojunction layer 9 and the second electrolyte substrate 8. In some embodiments, the third electrolyte substrate 14 may be located between the second reinforcing layer 13 and the second electrolyte substrate 8. A standard gas channel 11 is located on the side of the third electrolyte substrate 14 away from the second heterojunction layer 9, so that the standard gas channel 11 can be screen-printed on the surface of the third electrolyte substrate 14, thereby reducing the difficulty of the screen-printing process. The material of the third electrolyte substrate 14 may be the same as the material of the first electrolyte substrate 1.

[0086] Referring to Figure 3, in some embodiments, at least a portion of the first bonding portion 41 is disposed around at least a portion of the second bonding portion 42, and / or at least a portion of the second bonding portion 42 is disposed around at least a portion of the first bonding portion 41. This can increase the contact area between the first bonding portion 41 and the second bonding portion 42, improve the bonding strength between them, and reduce delamination or breakage, thereby facilitating the bonding between the first insulating layer 3 and the first electrolyte substrate 1.

[0087] As shown in Figure 3, the first joint 41 includes a first connecting portion 411 and at least two first intersecting portions 412, with the first connecting portion 411 connecting the at least two first intersecting portions 412; the second joint 42 includes a second connecting portion 421 and at least two second intersecting portions 422, with the second intersecting portions 422 connecting the at least two second intersecting portions 422. Two adjacent first intersecting portions 412 and first connecting portions 411 are arranged around a second intersecting portion 422, and two adjacent second intersecting portions 422 and second connecting portions 421 are arranged around a first intersecting portion 412.

[0088] As shown in Figure 3, the first electrolyte substrate 1 extends along the first direction Y. The first connecting portion 411 and the second connecting portion 421 are arranged opposite to each other in the second direction X and both extend along the first direction Y. The first intersecting portion 412 and the second intersecting portion 422 are alternately arranged along the first direction Y and both extend along the second direction X, and the first direction Y intersects the second direction X. In one embodiment, the first direction Y and the second direction X can be perpendicular to each other and both are perpendicular to the third direction Z.

[0089] Figure 4 shows the cross-sectional structure of the first insulating layer 3, the first heterogeneous bonding layer 4, and the first reinforcing layer 12, wherein the first cross portion 412 and the second cross portion 422 are arranged alternately along the first direction Y.

[0090] In other embodiments, the first electrolyte substrate 1 extends along the first direction Y, the first connecting portion 411 and the second connecting portion 421 are arranged opposite to each other in the first direction Y and both extend along the second direction X, the first intersecting portion 412 and the second intersecting portion 422 are alternately arranged along the second direction X and both extend along the first direction Y, and the first direction Y intersects the second direction X.

[0091] In some embodiments, as shown in FIG3, the first cross portion 412 has a first end 412A and a second end 412B. The first end 412A is connected to the first connecting portion 411, and the second end 412B is connected to the second connecting portion 421. The second cross portion 422 has a third end 422A and a fourth end 422B. The third end 422A is connected to the second connecting portion 421, and the fourth end 422B is connected to the first connecting portion 411. This cross-composite structure can effectively mitigate the problem of inconsistent sintering shrinkage rates between the first insulating layer 3 and the first electrolyte substrate 1, and increase the contact area between the first bonding portion 41 and the second bonding portion 42, thereby improving the bonding force between the two. As a result, the gas sensor 100 has excellent sealing performance and bending strength.

[0092] In some embodiments, the top view area of ​​the first joint portion 41 along the third direction Z is 20% to 80% of the top view area of ​​the first heterogeneous bonding layer 4 along the third direction Z. When the first joint portion 41 and the second joint portion 42 include a first connecting portion 411 and a second connecting portion 421, the area ratio of the first joint portion 41 is 20% to 80%, which can allow the first joint portion 41 and the second joint portion 42 to have an intersection to form an intersecting structure, thereby increasing the contact area between the two and improving the bonding force.

[0093] The first heterogeneous bonding layer 4 provided in this application has a cross-tooth structure, and the second bonding part 42 and the first bonding part 41 form an S-shaped contact, which increases the contact area between the second bonding part 42 and the first bonding part 41, making the first bonding part 41 and the second bonding part 42 more tightly engaged, so that the second bonding part 42 and the first bonding part 41 are less likely to crack and delaminate due to stress accumulation.

[0094] Please refer to Figure 6, which is a schematic diagram of the connection structure of the first joint and the second joint provided in some embodiments of this application.

[0095] The first joint 41 includes a plurality of first sub-joints 410, and the second joint 42 includes a plurality of second sub-joints 420. The plurality of first sub-joints 410 and the plurality of second sub-joints 420 are alternately arranged around each other, which can also increase the contact area between the first joint 41 and the second joint 42.

[0096] In a specific example, the first heterogeneous bonding layer 4 consists of a first sub-bonding portion 410, a second sub-bonding portion 420, a first sub-bonding portion 410 and a second sub-bonding portion 420 from the inside out. Alternatively, the first heterogeneous bonding layer 4 can also consist of a second sub-bonding portion 420, a first sub-bonding portion 410, a second sub-bonding portion 420 and a first sub-bonding portion 410 from the inside out.

[0097] In some embodiments, the top view of the first sub-joint portion 410 and / or the second sub-joint portion 420 along the third direction Z is a U-shape. As shown in FIG6, the top view of one first sub-joint portion 410 is rectangular, the top view of the other first sub-joint portion 410 is U-shaped, and the top view of both second sub-joint portions 420 is U-shaped.

[0098] Please refer to Figure 7, which is a schematic flowchart of a gas sensor fabrication method provided in some embodiments of this application. This gas sensor fabrication method can be used to fabricate the gas sensor 200 described above. Therefore, referring to Figure 5, the fabrication method of the gas sensor 200 includes the following steps S1-S4.

[0099] Step S1: Provide the first electrolyte matrix 1.

[0100] In some embodiments, after providing the first electrolyte substrate 1, a first reinforcing layer 12 can be printed on the first electrolyte substrate 1 using a screen printing method. The thickness of the first reinforcing layer 12 can be 20 micrometers.

[0101] Step S2: A first heterogeneous bonding layer 4 is formed on one side of the first electrolyte substrate 1. The first heterogeneous bonding layer 4 includes a first bonding portion 41 and a second bonding portion 42 connected in the same layer. The second bonding portion 42 is made of the same material as the first electrolyte substrate 1.

[0102] For a specific example, refer to Figure 3. The second bonding portion 42 of the first heterogeneous bonding layer 4 is printed on the first reinforcing layer 12, and then the first bonding portion 41 of the first heterogeneous bonding layer 4 is printed on the first reinforcing layer 12, so that the second bonding portion 42 and the first bonding portion 41 are distributed in a cross pattern, and the edges of the second bonding portion 42 and the first bonding portion 41 are in contact with each other.

[0103] Step S3: A first insulating layer 3 is formed on the side of the first heterogeneous bonding layer 4 away from the first electrolyte substrate 1, and the first bonding portion 41 is made of the same material as the first insulating layer 3.

[0104] For a specific example, the first insulating layer 3 can be printed on the surface of the first heterogeneous bonding layer 4.

[0105] Step S4: A heating electrode 2 is formed on the side of the first insulating layer 3 away from the first electrolyte substrate 1.

[0106] In a specific example, heating electrodes 2 and second insulating layers 5 are sequentially printed on the first insulating layer 3.

[0107] The method for preparing the gas sensor 200 may also include the following steps.

[0108] 1) Provide a second electrolyte substrate 8, and print a first detection electrode 6 and a second detection electrode 7 on both sides of the second electrolyte substrate 8 by screen printing, and print an electrode protective layer 10 on the end of the second detection electrode 7.

[0109] 2) A third electrolyte substrate 14 is provided. A second reinforcing layer 13 is screen-printed on one side of the third electrolyte substrate 14. Then, a fourth bonding portion of the second heterogeneous bonding layer 9 is printed on the second reinforcing layer 13. Subsequently, a third bonding portion of the second heterogeneous bonding layer 9 is printed on the second reinforcing layer 13, such that the fourth and third bonding portions are distributed in a cross pattern and their edges are in contact with each other. Then, a standard gas channel 11 is screen-printed on the other side of the third electrolyte substrate 14.

[0110] 3) The side of the third electrolyte substrate 14 with the printing paste is stacked with the side of the first electrolyte substrate 1 with the printing paste, so that the first insulating layer 3 and the second insulating layer 5 are symmetrically distributed on both sides of the heating electrode 2, the first heterogeneous bonding layer 4 and the second heterogeneous bonding layer 9 are symmetrically distributed on both sides of the heating electrode 2, and the first reinforcing layer 12 and the second reinforcing layer 13 are symmetrically distributed on both sides of the heating electrode 2.

[0111] 4) The side of the second electrolyte substrate 8 with the first detection electrode 6 printed on it is stacked with the side of the third electrolyte substrate 14 without printing paste to form a blank composed of three layers of electrolyte substrate.

[0112] 5) Place the billet in a sintering furnace at 1450℃ and sinter for 2 hours, firing once.

[0113] In this application, the first heterogeneous bonding layer 4 is a cross-composite structure formed by the second bonding portion 42 and the first bonding portion 41. This cross-composite structure allows the second bonding portion 42 and the first bonding portion 41 to form a tooth-like bond, enabling the heterogeneous materials to interlock during sintering, thereby promoting the bonding of heterogeneous co-firing and reducing cracks or delamination caused by poor bonding during heterogeneous sintering. The heating electrode 2 can rapidly heat up the gas sensor 200. During the rapid heating of the gas sensor 200, the bonding of heterogeneous materials is prone to fatigue cracks due to the difference in thermal expansion coefficients caused by the accumulation of thermal stress. The existence of the cross-composite structure in this application can make the bonding between the second bonding portion 42 and the first bonding portion 41 tighter, thereby avoiding thermal stress cracks and facilitating the bonding between the first insulating layer 3 and the first electrolyte substrate 1.

[0114] Referring to Table 1, Examples 1-6 and Comparative Examples 1-3 were designed. The above-described preparation method is used as Example 1, where the prepared gas sensor 200 includes a reinforcing layer (including a first reinforcing layer 12 and a second reinforcing layer 13) and a heterogeneous bonding layer (including a first heterogeneous bonding layer 4 and a second heterogeneous bonding layer 9). The thickness of the first heterogeneous bonding layer 4 is 20 micrometers, and the thickness of the second heterogeneous bonding layer 9 is equal to the thickness of the first heterogeneous bonding layer 4. The area ratio of the first bonding portion 41 in the first heterogeneous bonding layer 4 is 50%, and the area ratio of the third bonding portion in the second heterogeneous bonding layer 9 is equal to the area ratio of the first bonding portion 41 in the first heterogeneous bonding layer 4. The thickness of the first reinforcing layer 12 is 20 micrometers, and the thickness of the second reinforcing layer 13 is equal to the thickness of the first reinforcing layer 12.

[0115] Example 2

[0116] The gas sensor was prepared using the above preparation method, but no reinforcement layer was prepared (i.e., the thickness of the first reinforcement layer 12 and the second reinforcement layer 13 is 0), otherwise the same.

[0117] Example 3

[0118] The gas sensor prepared using the above preparation method differs from that in Example 1 in that the area ratio of the first bonding portion 41 in the first heterogeneous bonding layer 4 is 20%, and the area ratio of the third bonding portion in the second heterogeneous bonding layer 9 is 20%.

[0119] Example 4

[0120] The gas sensor prepared using the above preparation method differs from that in Example 1 in that the area ratio of the first bonding portion 41 in the first heterogeneous bonding layer 4 is 80%, and the area ratio of the third bonding portion in the second heterogeneous bonding layer 9 is 80%.

[0121] Example 5

[0122] The gas sensor prepared using the above method differs from Example 1 in that the thickness of the first heterogeneous bonding layer 4 and the second heterogeneous bonding layer 9 is 10 micrometers.

[0123] Example 6

[0124] The gas sensor prepared using the above method differs from Example 1 in that the thickness of the first heterogeneous bonding layer 4 and the second heterogeneous bonding layer 9 is 50 micrometers.

[0125] Comparative Example 1

[0126] The gas sensor was prepared using the above method, but the reinforcing layer and heterogeneous bonding layer were not prepared; otherwise, they were the same.

[0127] Comparative Example 2

[0128] The gas sensor was prepared using the above method, but without the preparation of the heterogeneous bonding layer; otherwise, the process was the same.

[0129] Comparative Example 3

[0130] The preparation process described in CN102235994B is adopted, in which the transition layer is simply a mixture of zirconium oxide, aluminum oxide and calcium oxide.

[0131] Table 1

[0132] Performance tests were conducted on the above embodiments and comparative examples. The performance test methods are as follows:

[0133] 1. Bending strength test: The bending strength test is conducted in accordance with GB / T6569-2006 Test Method for Bending Strength of Fine Ceramics.

[0134] 2. Thermal shock resistance test: Apply 12V DC power to the heater of the product to make the product heat up rapidly, maintain the temperature for 1 minute, then turn off the power and let the product cool down naturally for 1 minute. This is one hot and cold cycle, and one record is made for one cycle.

[0135] The test results are shown in Table 2 below. As can be seen from the data in Table 2, the gas sensor 200 prepared using the method of this application shows significant improvements in crack yield, flexural strength, and thermal shock resistance compared to the product in the comparative example. Furthermore, a comparison of Example 1 and Example 2 shows that the product with the reinforcing layer performs better than the product without the reinforcing layer.

[0136] Table 2

[0137] This application provides a gas monitoring device, which includes the gas sensor described above. The gas monitoring device has all the beneficial effects of the gas sensor described above, which will not be repeated here.

[0138] This application provides a vehicle that includes the aforementioned gas monitoring device, and the vehicle possesses all the beneficial effects of the aforementioned gas monitoring device, which will not be elaborated further here. This gas monitoring device can be applied to vehicle exhaust gas monitoring.

[0139] The vehicle may be a gasoline-powered vehicle, a plug-in hybrid electric vehicle, or a new energy vehicle, etc., and this disclosure does not make any specific restrictions.

[0140] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0141] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0142] The embodiments, implementation methods, and related technical features of this application can be combined and substituted for each other without conflict.

[0143] The above are merely preferred embodiments of this application and are not intended to limit this application in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of this application without departing from the scope of the technical solution of this application shall still fall within the scope of the technical solution of this application.

Claims

1. A gas sensor, characterized in that, include: First electrolyte matrix (1); The first insulating layer (3) is located on one side of the first electrolyte matrix (1); The first heterogeneous bonding layer (4) is located between the first insulating layer (3) and the first electrolyte substrate (1), and the first heterogeneous bonding layer (4) includes a first bonding portion (41) and a second bonding portion (42) connected in the same layer. The first bonding portion (41) is made of the same material as the first insulating layer (3), and the second bonding portion (42) is made of the same material as the first electrolyte substrate (1).

2. The gas sensor according to claim 1, characterized in that, The relationship between the first joint (41) and the second joint (42) includes at least one of the following: at least a portion of the first joint (41) is disposed around at least a portion of the second joint (42) and at least a portion of the second joint (42) is disposed around at least a portion of the first joint (42).

3. The gas sensor according to claim 2, characterized in that, The first connecting portion (41) includes a first connecting portion (411) and at least two first intersecting portions (412), wherein the first connecting portion (411) connects the at least two first intersecting portions (412); the second connecting portion (42) includes a second connecting portion (421) and at least two second intersecting portions (422), wherein the second intersecting portions (422) connect the at least two second intersecting portions (422). Two adjacent first intersections (412) and first connecting portions (411) are arranged around a second intersection (422), and two adjacent second intersections (422) and second connecting portions (421) are arranged around a first intersection (412).

4. The gas sensor according to claim 3, characterized in that, The first intersection (412) has a first end (412A) and a second end (412B), the first end (412A) being connected to the first connecting part (411), and the second end (412B) being connected to the second connecting part (421). The second cross portion (422) has a third end (422A) and a fourth end (422B), the third end (422A) being connected to the second connecting portion (421) and the fourth end (422B) being connected to the first connecting portion (411).

5. The gas sensor according to claim 3 or 4, characterized in that, The first electrolyte substrate (1) extends along the first direction (Y), the first connecting portion (411) and the second connecting portion (421) are disposed opposite to each other in the second direction (X) and both extend along the first direction (Y), and the first direction (Y) intersects the second direction (X); The first intersection and the second intersection are alternately arranged along the first direction and both extend along the second direction.

6. The gas sensor according to any one of claims 3-5, characterized in that, The first electrolyte substrate (1) extends along a first direction (Y), the first connecting portion (411) and the second connecting portion (412) are disposed opposite to each other in the first direction (Y) and both extend along a second direction (X), and the first direction (Y) intersects with the second direction (X); The first intersection (412) and the second intersection (422) are alternately arranged along the second direction (X) and both extend along the first direction (Y).

7. The gas sensor according to any one of claims 2-6, characterized in that, The first joint (41) includes a plurality of first sub-joints (410), and the second joint (42) includes a plurality of second sub-joints (420). The plurality of first sub-joints (410) and the plurality of second sub-joints (420) are alternately arranged around each other.

8. The gas sensor according to claim 7, characterized in that, At least one of the second sub-junction (410) and the first sub-junction (420) has a top view shape along a third direction (Z) that is a U-shape, where the third direction (Z) is the stacking direction of the first electrolyte substrate (1) and the first insulating layer (3).

9. The gas sensor according to any one of claims 1-8, characterized in that, Also includes: The first reinforcing layer (12) is located between the first heterogeneous bonding layer (4) and the first electrolyte substrate (1), and the first reinforcing layer (12) and the first electrolyte substrate (1) are made of the same material.

10. The gas sensor according to claim 9, characterized in that, The thickness of the first reinforcing layer (12) along the third direction (Z) is less than the thickness of the first electrolyte substrate (1) in the third direction (Z), which is the stacking direction of the first electrolyte substrate (1) and the first insulating layer (3).

11. The gas sensor according to claim 10, characterized in that, The thickness of the first reinforcing layer (12) in the third direction (Z) is 10 micrometers to 50 micrometers.

12. The gas sensor according to any one of claims 1-11, characterized in that, The thickness of the first heterogeneous bonding layer (4) along the third direction (Z) is less than the thickness of the first electrolyte substrate (1) in the third direction, which is the stacking direction of the first electrolyte substrate (1) and the first insulating layer (3).

13. The gas sensor according to claim 12, characterized in that, The thickness of the first heterogeneous bonding layer (4) in the third direction (X) is 10 micrometers to 50 micrometers.

14. The gas sensor according to claim 12, characterized in that, The thickness of the first electrolyte matrix (1) in the third direction (Z) is 150 micrometers to 300 micrometers.

15. The gas sensor according to claim 1, characterized in that, The material of the first electrolyte matrix (1) includes zirconium oxide and additives, the additives including yttrium oxide, cerium oxide or calcium oxide.

16. The gas sensor according to claim 15, characterized in that, In the first electrolyte matrix (1), the content of the additive is 5 mol% to 10 mol%.

17. The gas sensor according to any one of claims 1-16, characterized in that, The top view area of ​​the first bonding portion (41) along the third direction (Z) is 20% to 80% of the top view area of ​​the first heterogeneous bonding layer (4) along the third direction (Z), where the third direction (Z) is the stacking direction of the first electrolyte substrate (1) and the first insulating layer (3).

18. The gas sensor according to any one of claims 1-17, characterized in that, It also includes a heating electrode (2) and a second insulating layer (5), wherein the heating electrode (2) is located on the side of the first insulating layer (3) away from the first heterogeneous bonding layer (4), and the second insulating layer (5) is located on the side of the heating electrode (2) away from the first insulating layer (3); The gas sensor also includes: The detection unit includes a second electrolyte substrate (8), a first detection electrode (6), and a second detection electrode (7). The first detection electrode (6) is located on the side of the second electrolyte substrate (8) away from the second insulating layer (5), and the second detection electrode (7) is located on the side of the second electrolyte substrate (8) away from the first detection electrode (6). The second heterogeneous bonding layer (9) is located between the second insulating layer (5) and the second electrolyte substrate (8). The second heterogeneous bonding layer (8) includes a third bonding portion and a fourth bonding portion connected in the same layer. The third bonding portion is made of the same material as the second insulating layer (5), and the fourth bonding portion is made of the same material as the second electrolyte substrate (8).

19. The gas sensor according to claim 18, characterized in that, The thickness of the second heterojunction layer (9) along the third direction (Z) is less than the thickness of the second electrolyte substrate (8) along the third direction (Z), where the third direction (Z) is the stacking direction of the first electrolyte substrate (1) and the first insulating layer (3), and the thickness of the second electrolyte substrate (8) in the third direction (Z) is 150 micrometers to 300 micrometers.

20. The gas sensor according to claim 18, characterized in that, The sensor also includes: The second reinforcing layer (13) is located between the second heterogeneous bonding layer (9) and the second electrolyte matrix (8), and the second reinforcing layer (13) and the second electrolyte matrix (8) are made of the same material.

21. The gas sensor according to claim 18, characterized in that, The sensor also includes: The third electrolyte matrix (14) is located between the second heterogeneous bonding layer (9) and the second electrolyte matrix (8); A standard gas channel (11) is located on the side of the third electrolyte matrix (14) away from the second heterogeneous binding layer (9); The second detection electrode (7) is connected to the standard gas channel (11).

22. A method for preparing a gas sensor, characterized in that, include: Provide a first electrolyte matrix; A first heterogeneous bonding layer is formed on one side of the first electrolyte matrix. The first heterogeneous bonding layer includes a first bonding portion and a second bonding portion connected in the same layer. The second bonding portion is made of the same material as the first electrolyte matrix. A first insulating layer is formed on the side of the first heterogeneous bonding layer away from the first electrolyte matrix, and the first bonding portion is made of the same material as the first insulating layer.

23. The method for preparing a gas sensor according to claim 22, characterized in that, The step of forming a first heterogeneous binding layer on one side of the first electrolyte matrix includes: A second bonding portion is printed on the first electrolyte substrate; A first bonding portion is printed on the first electrolyte substrate, and the first bonding portion is connected to the second bonding portion in the same layer.

24. The method for preparing a gas sensor according to claim 23, characterized in that, Prior to the step of printing the second bonding portion on the first electrolyte substrate, the method for fabricating the gas sensor further includes: A first reinforcing layer is printed on the first electrolyte substrate.

25. A gas monitoring device, characterized in that, Including the gas sensor according to any one of claims 1 to 21.

26. A vehicle, characterized in that, Includes the gas monitoring device as described in claim 25.

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