Gas Sensor Electrolyte Extension Tapering
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Solution Overview
Problem
Existing gas sensor elements with zirconia filling portions and alumina sheets face issues with conductor layer cracking or breakage due to the structure of the zirconia filling portion protruding beyond the through hole, leading to stress concentration and potential damage at the edge of the alumina sheet.
Innovation Solution
A gas sensor element design featuring a composite ceramic layer with a plate-shaped insulating portion and a solid electrolyte portion, where the first insulating surface is flush with the first electrolyte surface, and an extension portion of the electrolyte portion overlaps the insulating portion, reducing stress concentration and preventing conductor layer cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the zirconia filling portion protrudes from the through hole with a larger size than the opening area, then the electrolyte portion can be securely positioned, but the conductor layer may be cracked or broken at the edge of the insulating portion
Solution Approach 1:
The invention transitions from a two-dimensional planar structure to a three-dimensional stepped structure by adding an extension portion that protrudes from the through hole. This vertical dimensionality change allows the electrolyte portion to extend beyond the insulating portion's opening area, providing secure positioning while the stepped configuration prevents stress concentration on the conductor layer by creating a gradual transition zone.
Solution Approach 2:
The invention applies curvature by forming the outer peripheral surface of the extension portion as an inclined surface that gradually tapers toward the opening area of the through hole. This curved, inclined configuration eliminates sharp edges and corners that would cause stress concentration, thereby preventing cracking of the conductor layer while maintaining secure positioning of the electrolyte portion.
2Quantity of substance
If the zirconia filling portion is made larger than the through hole opening, then the electrolyte can be adequately contained, but stress concentration occurs at the boundary causing conductor layer breakage
Solution Approach 1:
The invention eliminates stress concentration by replacing sharp boundaries with a curved inclined surface. The outer peripheral surface of the extension portion is formed as an inclined surface that gradually tapers, creating a smooth transition zone that distributes mechanical stress evenly rather than concentrating it at sharp edges or corners.
Solution Approach 2:
The invention changes the geometric parameters of the electrolyte portion by creating an extension portion with varying cross-sectional area. The inclined surface configuration gradually reduces the dimensions of the extension portion from its base at the through hole opening toward its tip, transforming a abrupt dimensional change into a gradual parameter transition that reduces stress concentration.
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 design enhances the durability of the gas sensor element by preventing conductor layer cracking and breakage, ensuring reliable operation and maintaining detection performance.
Implementation Method 1
a plate-shaped electrolyte portion that contains a solid electrolyte ceramic and is disposed in the through hole
Data Source
AI summary
A gas sensor element including a composite ceramic layer including a plate-shaped insulating portion containing an insulating ceramic and having a through hole formed therein and a plate-shaped electrolyte portion containing a solid electrolyte ceramic and disposed in the through hole; and a first conductor layer extending continuously from a first insulating surface on one side of the insulating portion to a first electrolyte surface of the electrolyte portion facing the same direction as the one side of the insulating portion. The first insulating surface is flush with the first electrolyte surface. The electrolyte portion has, on its first electrolyte surface side, an extension portion extending outward from the through hole so as to overlap the first insulating surface. Further, the thickness of the extension portion decreases toward the outer circumference of the extension portion. Also disclosed is a method of manufacturing the gas sensor element.