Gas Sensor Element with Width Transition Slit for Soot Prevention

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Solution Overview

Problem

Conventional gas sensors face inaccuracies in detecting gas concentrations due to solids, such as soot, adhering to the gas introduction portion, which limits the amount of gas measured and results in incorrect detected values.

Innovation Solution

A sensor element with width transition slits, where the entrance slit width is larger than the exit, and a heater to burn off adhering solids, combined with inner and outer pump electrodes and measurement electrodes to manage oxygen and decompose gas components, ensuring accurate gas concentration measurement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a conventional gas sensor with a slit-shaped gas introduction portion is used, then the structure is simple and easy to manufacture, but solids such as soot adhere to the entrance of the slit, limiting the amount of gas introduced and causing inaccurate detection

Engineering Contradiction:
Improvegas concentration detection accuracyVSAvoidslit structure complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent applies asymmetry by designing the slit as a width transition slit where the slit width varies along its length. Specifically, the slit has a larger width at the entrance side and a smaller width at the exit side, creating an asymmetric geometry that prevents solid particles from adhering at the entrance while still allowing gas to flow through. This asymmetric design resolves the contradiction by maintaining detection accuracy without requiring complex additional components.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The patent applies local quality by creating different slit widths at different locations along the slit. The entrance portion has a larger width to prevent solid adhesion, while the exit portion has a smaller width. This local variation in geometric quality allows the single slit structure to simultaneously achieve both particle prevention and gas flow functions, resolving the contradiction between measurement precision and device complexity.

Inventive Principle:
Principle #3Local quality

2Object-affected harmful factors

If the temperature at the slit entrance is increased to burn off solids, then solids can be removed effectively, but the temperature is already insufficient for combustion at the entrance (400-600°C)

Engineering Contradiction:
Improvesolid particle adhesionVSAvoidtemperature at slit entrance
Core Design Contradiction:
Object-affected harmful factorsVSTemperature

Solution Approach 1:

The patent converts the harmful effect of solid particle adhesion into a beneficial design feature by using the width transition slit geometry. Instead of trying to raise the temperature to burn off solids, the design allows solids to naturally fall into the narrower exit portion where they can be thermally processed, while the larger entrance width prevents adhesion in the first place. This resolves the contradiction by eliminating the need for temperature increase.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent applies parameter changes by modifying the geometric parameters of the slit (width variation along its length) rather than changing the temperature parameter. The width transition from larger at the entrance to smaller at the exit creates a design that inherently prevents solid adhesion without requiring temperature changes, thus resolving the contradiction between removing harmful solids and maintaining insufficient temperature conditions.

Inventive Principle:
Principle #35Parameter changes

3Reliability

If a width transition slit with larger entrance width is used, then solids do not adhere at the entrance, but the slit structure becomes more complex to manufacture

Engineering Contradiction:
Improvegas introduction reliabilityVSAvoidslit fabrication ease
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies segmentation by dividing the slit into distinct regions with different width characteristics - a larger width region at the entrance and a smaller width region at the exit. This segmented approach to the slit geometry allows each region to perform its specific function (preventing adhesion at the entrance, allowing flow at the exit) while maintaining manufacturability through the clear zonal division.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent applies inversion by reversing the conventional approach of having a uniform or tapered slit. Instead of tapering from large to small, the design uses a width transition that is optimized for the specific function of preventing solid adhesion at the entrance while maintaining gas flow. This inverted design philosophy resolves the contradiction by prioritizing functional reliability over conventional manufacturing simplicity.

Inventive Principle:
Principle #13The other way round (Inversion)

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

Prevents inaccuracies in gas concentration detection by effectively removing solids and maintaining a high temperature within the slits to burn off adhering particles, ensuring accurate measurement of gas concentrations.

Implementation Method 1

a heater configured to heat the base

Methodology Applied
Scientific EffectHeating: Heating

Implementation Method 2

the solids adhering inside the width transition slit burn and disappear

Methodology Applied
Scientific EffectCombustion: Combustion

Implementation Method 3

inner and outer pump electrodes respectively disposed inside and outside the base and configured to pump out oxygen contained in a gas to be measured introduced into the internal space from the internal space to an external space

Methodology Applied
Scientific EffectElectrical pumping:

Implementation Method 4

inner and outer measurement electrodes respectively disposed inside and outside the base and configured to decompose a predetermined gas component contained in the gas to be measured after the oxygen is pumped out by the inner and outer pump electrodes and to pump out oxygen generated by the decomposition

Methodology Applied
Scientific EffectDecomposition: Decomposition (biological)

Data Source

PatentUS10775341B2Sensor element, manufacturing method therefor, and gas sensor
Publication Date: 2020.09.15 NGK INSULATORS LTD
  • US10775341B2 patent drawing
  • US10775341B2 patent drawing
  • US10775341B2 patent drawing

AI summary

In a sensor element 101, oxygen contained in a gas to be measured introduced into a first internal space 20 through a first diffusion control part 11 is pumped out by applying voltage between an inner pump electrode 22 and an outer pump electrode 23. After the oxygen is pumped out, NOx in the gas to be measured generates oxygen by being reduced by a measurement electrode 44. This oxygen is pumped by applying voltage between the measurement electrode 44 and the outer pump electrode 23. On the basis of current generated according to the amount of oxygen thus pumped, the NOx gas concentration is calculated. A slit width of the first diffusion control part 11 on an entrance side is larger than a slit width on an exit side.