Multi-Layer Gas Sensor Structure to Reduce Thermal Cracking
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Solution Overview
Problem
Existing gas sensors with complex internal structures using ion-conductive solid electrolytes are prone to cracking due to thermal stress and require numerous manufacturing processes, affecting their accuracy and reliability.
Innovation Solution
A gas sensor design featuring a sensor element with an elongated plate shape, comprising oxygen-ion-conductive and proton-conductive solid electrolyte layers separated by an insulator layer, and incorporating oxygen and hydrogen pump cells with intracavity and extracavity electrodes, controlled by a pump control unit to measure target gases like oxygen, water vapor, and carbon dioxide with high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a complex internal structure with multiple gas chambers and reference chambers is used to enable multi-gas detection, then measurement capability is improved, but the sensor element becomes prone to cracking due to thermal stress and requires numerous manufacturing processes
Solution Approach 1:
The sensor element is divided into multiple independent detection regions along the elongated plate, with each region containing a specific solid electrolyte layer (oxygen-ion-conductive or proton-conductive) for detecting different gases. This segmentation allows each region to be optimized for its specific detection function while reducing thermal stress concentration that would occur in a fully integrated complex chamber structure.
Solution Approach 2:
The invention extracts and eliminates the complex internal gas chamber and reference chamber structures from the sensor element design. Instead of using multiple interconnected chambers, the patent uses a simplified elongated plate structure where gas detection occurs directly through the solid electrolyte layers exposed to the measurement object gas, thereby reducing structural complexity and thermal stress points.
2Adaptability or versatility
If a complex internal structure with multiple gas chambers and reference chambers is used to enable multi-gas detection, then measurement capability is improved, but the number of manufacturing processes increases
Solution Approach 1:
The sensor element is divided into multiple independent detection regions along the elongated plate, with each region containing a specific solid electrolyte layer (oxygen-ion-conductive or proton-conductive) for detecting different gases. This segmentation allows each region to be optimized for its specific detection function while reducing thermal stress concentration that would occur in a fully integrated complex chamber structure.
Solution Approach 2:
The invention extracts and eliminates the complex internal gas chamber and reference chamber structures from the sensor element design. Instead of using multiple interconnected chambers, the patent uses a simplified elongated plate structure where gas detection occurs directly through the solid electrolyte layers exposed to the measurement object gas, thereby reducing structural complexity and thermal stress points.
3Measurement precision
If an insulator layer is interposed between oxygen-ion-conductive and proton-conductive solid electrolyte layers, then measurement accuracy is improved by preventing interference, but device complexity increases
Solution Approach 1:
The insulator layer is strategically positioned only between adjacent solid electrolyte layers of different types (oxygen-ion-conductive and proton-conductive) where electrical interference could occur, rather than throughout the entire structure. This localized application of the insulator layer provides necessary electrical isolation while minimizing the overall structural complexity and maintaining manufacturing feasibility.
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 design enhances the accuracy and reliability of gas measurement by minimizing thermal stress-induced cracking and simplifying manufacturing, enabling precise concentration calculation of target gases.
Implementation Method 1
a base part in an elongated plate shape, including an oxygen-ion-conductive solid electrolyte layer
Implementation Method 2
a base part in an elongated plate shape, including an oxygen-ion-conductive solid electrolyte layer and a proton-conductive solid electrolyte layer
Implementation Method 3
an internal cavity that communicates with the gas inlet via a first diffusion-rate limiting path
Data Source
AI summary
A gas sensor includes a sensor element and a control unit for controlling the sensor element. The sensor element includes: a base part including an oxygen-ion-conductive solid electrolyte layer and a proton-conductive solid electrolyte layer, and having an insulator layer interposed between the oxygen-ion-conductive solid electrolyte layer and the proton-conductive solid electrolyte layer; an oxygen pump cell including an intracavity oxygen pump electrode disposed on the oxygen-ion-conductive solid electrolyte layer in an internal cavity; and a hydrogen pump cell including an intracavity hydrogen pump electrode disposed on the proton-conductive solid electrolyte layer in the internal cavity. The control unit includes a pump control part for controlling operation of the oxygen pump cell and the hydrogen pump cell; and a concentration calculating part for calculating a concentration of a target gas to be measured in a measurement-object gas.