Gas Sensor Element Manufacturing Pressing Green Body Components

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Solution Overview

Problem

Conventional gas sensors experience variations in gas detection performance due to cracks in the second solid electrolyte member, leading to reduced yield and inconsistent electric potential between electrodes.

Innovation Solution

A manufacturing method that involves pressing the green reinforcement member and electrode protection member to eliminate gaps between them, ensuring enhanced adhesion and preventing thermal shrinkage-induced cracks during firing, thereby maintaining consistent electric potential and reducing performance variations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the green electrode protection member is inserted into the insertion hole of the green reinforcement member without pressing, then the assembly process is simple, but gaps form between the components during firing causing cracks in the solid electrolyte member

Engineering Contradiction:

Improveassembly process simplicityVSAvoidgap elimination between components

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The green electrode protection member is pressed into the insertion hole of the green reinforcement member before firing to eliminate gaps. This preliminary action ensures proper fit and prevents crack formation during the subsequent firing process, while maintaining manufacturing efficiency.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the green electrode protection member is pressed into the insertion hole to eliminate gaps, then adhesion between components is enhanced and cracks are prevented, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveadhesion between reinforcement member and electrode protection memberVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Pressing the green electrode protection member into the insertion hole changes the physical state and density of the green body components, ensuring tight fit and eliminating gaps. This parameter change enhances adhesion and prevents cracks during firing, improving reliability without significantly complicating the manufacturing process.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If gaps exist between the green reinforcement member and green electrode protection member, then the assembly process is faster, but thermal shrinkage during firing causes cracks in the solid electrolyte member

Engineering Contradiction:

Improveassembly speedVSAvoidcrack resistance of solid electrolyte member

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The pressing operation is performed as a preliminary step before firing to eliminate gaps between the green reinforcement member and green electrode protection member. This ensures that during the thermal shrinkage phase of firing, no gaps exist to cause stress concentration and crack formation, thereby maintaining strength while preserving assembly efficiency.

Inventive Principle:

Principle #10Preliminary action

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 method enhances the adhesion between the reinforcement and electrode protection members, preventing cracks in the solid electrolyte member and ensuring consistent gas detection performance across gas sensors, allowing for high-yield production.

Implementation Method 1

pressing at least one of the green reinforcement member (112) and the green electrode protection member (113a) so as to form a green protection layer (111)

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

the laminate is subjected to resin removal firing, and then main firing, whereby the gas sensor element 300 and the heater 200 are obtained

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 3

a gap G between the green reinforcement member (112) and the green electrode protection member (113a)... stress is likely to concentrate on a portion around the gap G in the second green solid electrolyte member during firing

Methodology Applied

Scientific EffectThermal shrinkage: Thermal Contraction

Data Source

PatentUS8080143B2Gas sensor element, method for manufacturing the same, and gas sensor

Publication Date: 2011.12.20 NITERRA CO LTD

AI summary

A method for manufacturing a gas sensor element (300), which includes a plate-like second solid electrolyte member (109), a fourth electrode (110) formed on the second solid electrolyte member (109), and a protection layer (111) including a reinforcement member (112) having an insertion hole (112a), and a porous electrode protection member (113a) provided in the insertion hole (112) and adapted to protect the fourth electrode (110) from becoming poisoned. The method includes a pressing step of, after disposing a green electrode protection member (113a) in the insertion hole (112a) of a green reinforcement member (112), pressing at least one of the green reinforcement member (112) and the green electrode protection member (113a) so as to form a green protection layer (111); a laminate-forming step of arranging the green protection layer (111) and a green solid electrolyte member (113a) in layers so as to form a laminate which will become the gas sensor element (300) after being fired; and a firing step of firing the laminate.