Gas Sensor Electrolyte Holding Structure
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Solution Overview
Problem
Existing gas sensor elements face instability in holding the solid electrolyte body within the placement hole due to the low strength of surface alumina layers, leading to potential displacement and reduced effectiveness in detecting gas concentrations in exhaust pipes.
Innovation Solution
The gas sensor element incorporates a solid electrolyte body with a holding plate and insulators, where the boundary portion between the placement hole and the solid electrolyte body is sandwiched between high-rigidity first and second sandwiching portions, ensuring stable placement and enhanced rigidity across the measurement and reference gas chambers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If surface alumina layers are used to hold the solid electrolyte body, then the structure is simple and easy to manufacture, but the holding strength is insufficient leading to displacement
Solution Approach 1:
The patent employs a composite structure combining alumina layers with additional holding structures (such as protrusions, recesses, or bonding layers) to achieve both sufficient holding strength and structural simplicity. This composite approach allows the weak alumina material to be reinforced without completely redesigning the entire holding mechanism.
2Reliability
If the solid electrolyte body is held in the placement hole, then the structure is compact, but the solid electrolyte body may displace due to insufficient holding strength
Solution Approach 1:
The patent incorporates preliminary holding structures (such as positioning protrusions, guiding features, or pre-bonded layers) that are formed during manufacturing to prevent displacement before it occurs. These features are built into the placement hole or solid electrolyte body in advance to ensure stable positioning during operation.
3Reliability
If insulators are added to sandwich the boundary portion, then placement stability is improved, but the device complexity increases
Solution Approach 1:
The patent designs the insulator layers to serve multiple functions: providing electrical insulation, reinforcing the holding structure, and preventing displacement of the solid electrolyte body. By making the insulators multi-functional, the patent improves placement stability without proportionally increasing device complexity.
Data Source
AI summary
A gas sensor element has an electrolyte layer, a first insulator, a second insulator, a measurement gas chamber, and a reference gas chamber. The electrolyte layer includes a holding plate and a solid electrolyte body. The first insulator is laminated on one side of the electrolyte layer, and the second insulator is laminated on the other side of the electrolyte layer. At least a part of the boundary portion between the placement hole and the solid electrolyte body is sandwiched between a first sandwiching portion of the first insulator and a second sandwiching portion of the second insulator.