Asymmetric Gas Sensor Gap Design for Thermal Shock Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Gas sensor elements with reduced gap height tend to crack during manufacturing and lack thermal shock resistance, especially when exposed to temperature changes, due to insufficient strength.
Innovation Solution
A gas sensor element with a laminated structure featuring a gap between ceramic layers, where the cross-sectional shape of the gap is defined by specific ratios of distances H1 and H2, and a height within the range of 10 μm to 100 μm, enhancing thermal shock resistance and air passage while reducing thickness and preventing cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the height of the gap is decreased to reduce the size of the gas sensor, then the thickness of the gas sensor element is reduced and power consumption is decreased, but the gas sensor element cracks during manufacturing and lacks sufficient strength
Solution Approach 1:
The gap cross-section is designed with an asymmetric shape where the distance from the straight line AB to the end point C (H1) and to the end point D (H2) satisfy a specific ratio relationship (0.15 ≤ H1/H2 ≤ 0.67). This asymmetric configuration optimizes stress distribution within the gap, preventing crack formation while maintaining reduced thickness for low power consumption.
Solution Approach 2:
The invention changes the geometric parameters of the gap cross-section by defining specific relationships between H1 and H2 distances. By controlling the ratio H1/H2 within a predetermined range, the structural strength is optimized to prevent cracking during manufacturing and under thermal shock conditions, while maintaining the reduced gap height for compact design.
2Use of energy by stationary object
If the height of the gap is decreased to reduce power consumption, then the gas sensor element becomes thinner, but it cracks due to thermal shock from rapid temperature changes
Solution Approach 1:
The asymmetric gap cross-section with controlled H1/H2 ratio creates an optimized stress distribution pattern that specifically addresses thermal shock resistance. This asymmetric geometry allows the structure to better withstand rapid temperature changes without cracking, enabling reliable operation in high-temperature environments while maintaining low power consumption through reduced gap height.
Solution Approach 2:
By changing the geometric parameters of the gap cross-section and establishing the specific ratio relationship between H1 and H2, the invention optimizes the structural response to thermal stress. This parameter optimization ensures the gas sensor element can endure rapid temperature cycling without failure, maintaining reliability while operating at reduced power levels.
3Device complexity
If the gap height is reduced to decrease the thickness of the gas sensor element, then the size is reduced, but the gas sensor element lacks sufficient strength in the manufacturing stage
Solution Approach 1:
The asymmetric gap cross-section design with specific H1/H2 ratio optimizes the structural integrity during the manufacturing process. This asymmetric configuration provides enhanced strength and crack resistance during handling and assembly operations, making the reduced-thickness sensor element easier to manufacture despite its compact size.
Solution Approach 2:
By optimizing the geometric parameters of the gap cross-section and establishing the predetermined ratio relationship between H1 and H2, the invention enhances the manufacturability of thin gas sensor elements. The parameter optimization ensures sufficient strength during manufacturing stages while maintaining the compact size required for low power consumption applications.
Data Source
AI summary
A cross-sectional shape of a gap of a gas sensor element has an end point A which is one of contact points at which the cross-sectional shape is in single-point contact with a virtual straight line parallel to a lamination direction, the one contact point being closest to one side of the laminated structure, an end point B which is one of the contact points closest to another side of the laminated structure, an end point C having the greatest separation from a straight line AB toward a solid electrolyte ceramic layer, and an end point D having the greatest separation from the straight line AB toward another ceramic layer. The distance H1 between the straight line AB and the end point C and the distance H2 between the straight line AB and the end point D satisfy 0.25≦H1/H2<1.00 or 1.00<H1/H2≦4.00.