Chamfered Solid Electrolyte Edge for Gas Sensor Thermal Stress
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Solution Overview
Problem
Oxygen sensors with a plate-shaped solid electrolyte body face thermal stress issues due to concentrated stress at the edges, leading to cracking and deterioration of their oxygen concentration-detecting function, particularly when exposed to high-temperature measurement gases.
Innovation Solution
A method for producing a gas sensor with a rectangular solid structure of a ceramic solid electrolyte body, where the edges are chamfered using a guide plate and cutter, heated to the glass transition point, to relax thermal stress and improve thermal shock resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the solid electrolyte body is heated to high temperature for oxygen detection, then the oxygen-detecting function is sufficient, but thermal stress concentrates at the edges causing cracking
Solution Approach 1:
The patent applies chamfering treatment specifically to the edge portions of the solid electrolyte body, creating a local structural modification at the edges while maintaining the original plate shape in the central region. This local quality change redistributes thermal stress away from the sharp edges, preventing cracking while preserving the oxygen detection function.
2Strength
If the edge portions are chamfered to relax stress concentration, then thermal shock resistance is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent replaces complex multi-step mechanical chamfering operations with a simplified single-step cutting process using a straight blade. The blade is inserted into a groove formed by V-shaped guides, automatically creating the chamfered edge geometry through a straightforward linear cutting motion rather than complex angular positioning.
3Ease of manufacture
If the solid electrolyte body is miniaturized for easy production, then manufacturing is simplified, but thermal stress concentration at edges increases
Solution Approach 1:
The patent applies chamfering treatment specifically to the edge portions of the miniaturized solid electrolyte body, creating a local structural modification that addresses stress concentration without affecting the overall miniaturized dimensions. This allows the compact sensor to maintain both small size and improved thermal shock resistance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The chamfering process enhances the thermal shock resistance of the gas sensor, preventing edge cracking and maintaining the oxygen concentration-detecting function even at high temperatures, thus improving the sensor's reliability and performance.
Implementation Method 1
The solid electrolyte body is heated to raise its temperature to the glass transition point or higher in the chamfering step
Implementation Method 2
The chamfering process enhances the thermal shock resistance of the gas sensor, preventing edge cracking and maintaining the oxygen concentration-detecting function even at high temperatures
Data Source
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AI summary
A solid electrolyte body (11) is placed on and fixed to an upper plate (120) of a press jig (116) such that a major surface (an upper surface) of the solid electrolyte body (11) faces one major surface (114a) of a guide plate (114) having a through-hole (112). The upper plate (120) is rotated by a transfer mechanism to incline the solid electrolyte body (11) in one direction, and the inclined solid electrolyte body (11) is moved toward the other major surface (114b) of the guide plate (114) such that a first edge (106a) of the solid electrolyte body (11) protrudes from the through-hole (112). Then, a cutter (118) is slid along the other major surface (114b), so that the first edge (106a) is chamfered to form a first chamfered portion (104a) .