Gas Sensor Electrode Cracking Mitigation via Graded Insulation

The patent introduces an intermediate layer between the solid electrolyte body and the insulation member. This intermediate layer has a thickness that gradually transitions from the thickness of the solid electrolyte body to the thickness of the insulation member, effectively adding a dimensional gradient that eliminates the abrupt step-like level difference. This gradual transition in the thickness dimension prevents cracking while maintaining continuous electrode conductivity.

The patent changes the thickness parameter of the intermediate layer to create a gradual transition zone. By controlling the thickness of the intermediate layer to be between the thicknesses of the solid electrolyte body and the insulation member, the patent transforms the abrupt geometric discontinuity into a continuous gradient, thereby preventing electrode cracking at the boundary.

The patent introduces an intermediate layer with graded thickness that transitions from the thinner electrolyte portion to the thicker insulation portion. This creates a dimensional bridge that distributes stress gradually across the transition zone rather than concentrating it at a sharp boundary, thereby maintaining boundary strength while preserving the optimized thin electrolyte structure for fast response.

The intermediate layer acts as a cushioning layer that absorbs and distributes mechanical stress before it can concentrate at the boundary between the electrolyte and insulation portions. By placing this stress-distributing layer in advance at the interface, the patent prevents stress concentration and potential cracking while maintaining the thin electrolyte design.

The patent merges the intermediate layer with either the solid electrolyte body or the insulation member, creating an integrated composite structure. This integration reduces the number of separate components and assembly steps, thereby simplifying the manufacturing process while still providing the stress-distributing function that prevents electrode cracking.

The patent creates a composite ceramic layer that combines the electrolyte portion and the insulation portion with an intermediate transition zone. This composite structure is manufactured as an integrated unit using co-firing or sintering processes, which simplifies production compared to assembling separate parts, while the intermediate layer within the composite provides the necessary stress distribution to prevent cracking.