Gas Sensor Lead Portion Stacking for Accuracy and Strength
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Solution Overview
Problem
The existing gas sensor elements face challenges in maintaining strength and measurement accuracy due to the generation of gaps between lead portions during the sintering process, which affects the accuracy of gas detection and the overall performance of the sensor.
Innovation Solution
The gas sensor element design involves strategically positioning the lead portions to increase their widthwise separation distances and prevent overlap, ensuring they are spaced apart in the width direction without overlapping in the stacking direction, which helps in suppressing gap generation and maintaining the sensor's strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the lead portions are disposed at edge portions to increase widthwise distance, then measurement accuracy is improved, but the second and third lead portions cannot be connected to a common electrode pad
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement to a three-dimensional stacked arrangement. The second lead portion and third lead portion are disposed at different positions in the stacking direction, allowing them to connect to a common electrode pad while maintaining sufficient widthwise separation for accurate measurement. This spatial dimensionality change resolves the contradiction between measurement accuracy and manufacturing ease.
2Ease of manufacture
If the second lead portion and third lead portion are disposed to overlap in stacking direction, then connection to common electrode pad is facilitated, but gaps are generated during sintering reducing sensor strength
Solution Approach 1:
The patent applies local quality by making the lead portions have different thicknesses. The second lead portion has a smaller thickness than the third lead portion, allowing them to be disposed at different positions in the stacking direction. This local differentiation prevents overlap and gap formation during sintering while still enabling connection to the common electrode pad, thus maintaining sensor strength.
3Measurement precision
If the lead portions are separated by large distance in width direction, then sensing accuracy is improved, but the structural integrity may be compromised
Solution Approach 1:
The patent uses the stacking direction (third dimension) to achieve lead portion separation. By disposing the second and third lead portions at different positions in the stacking direction rather than increasing widthwise distance, the patent maintains both sensing accuracy and structural integrity without compromising the element's mechanical strength.
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 accuracy of gas sensing and detection while maintaining the structural integrity of the gas sensor element by preventing gap formation between the solid electrolyte bodies and insulating layers, thus improving measurement accuracy and sensor strength.
Implementation Method 1
a first cell (20) including a first solid electrolyte body (28) and first and second lead portions (24, 26) electrically connected to a pair of electrode portions
Data Source
AI summary
In a cross section of the gas sensor element which is perpendicular to its lengthwise direction and through which all first to fourth lead portions penetrate, when the cross section is bisected into two regions with respect to the width direction of the gas sensor element, the first lead portion and the fourth lead portion are disposed in one of the regions and the second lead portion and the third lead portion are disposed in the other region, and the second lead portion and the third lead portion are disposed so as to be spaced apart from each other in the width direction with no overlap as viewed in a stacking direction.