Gas Sensor Reference Electrode Lead Through Hole Design
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Solution Overview
Problem
The existing gas sensor design is prone to breakage of the reference electrode lead due to the formation of steps between the insulating member and the insulating porous layer, leading to potential electrical discontinuities and reduced reliability.
Innovation Solution
Incorporating a through hole in the insulating porous layer between the reference electrode lead and the reference electrode, with an electrically conductive member extending through this hole to connect them, thereby avoiding the need for the reference electrode lead to span the step and reducing the risk of breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the reference electrode lead is formed to extend over and across the step between the insulating member and the insulating porous layer, then the reference electrode can be electrically connected to the reference electrode lead, but the reference electrode lead becomes more likely to break at the step
Solution Approach 1:
The reference electrode lead is positioned in the thickness direction (vertical dimension) of the insulating porous layer rather than extending horizontally across the step. The lead passes through the porous layer via a through hole, changing the connection path from a horizontal surface extension to a vertical penetration, thereby avoiding the step and preventing breakage while maintaining electrical connectivity.
2Ease of manufacture
If the reference electrode lead is formed on the surface of the insulating member extending over the step, then electrical connection is achieved, but a step is formed on the reference electrode lead increasing breakage risk
Solution Approach 1:
The reference electrode lead is extracted from the surface configuration and repositioned within the thickness of the insulating porous layer. By removing the lead from the problematic surface step region and placing it inside the porous layer structure, the design eliminates the step formation on the lead while preserving the electrical connection function.
3Device complexity
If the through hole is positioned such that its projection overlaps the detection electrode, then the reference electrode lead connection is simplified, but unevenness in thickness of the stacked layers occurs
Solution Approach 1:
The through hole is positioned in a specific location within the insulating porous layer where it does not overlap with the detection electrode projection. This localized positioning strategy allows the lead connection to be simplified while avoiding the detection electrode area, thereby preventing thickness unevenness in the stacked layers. The solution applies local quality by making the through hole position specific rather than universal.
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
This configuration enhances the electrical connectivity and durability of the reference electrode lead, preventing breakage and maintaining the sensor's accuracy in detecting gas concentrations by eliminating unevenness and potential electrical discontinuities.
Implementation Method 1
An electrically conductive member formed of a material having electrical conductivity is disposed in (inside) the through hole so as to extend from an opening of the through hole at one end thereof to an opening of the through hole at the other end thereof, thereby electrically connecting the reference electrode lead and the reference electrode through the electrically conductive member
Data Source
AI summary
A gas sensor for detecting the concentration of a detection target gas in an atmosphere of interest is disposed on an electrically insulating member. The gas sensor includes an insulating porous layer formed of an electrically insulating porous material, a reference electrode, a solid electrolyte body, a detection electrode that are stacked in this order on the electrically insulating member, and a reference electrode lead disposed between the insulating member and the insulating porous layer. The insulating porous layer defines a through hole in a region sandwiched between the reference electrode lead and the reference electrode. An electrically conductive member formed of a material having electrical conductivity is disposed in the through hole so as to extend from an opening of the through hole at one end thereof to an opening of the through hole at the other end thereof.