Reference Electrode Layout for Peel-Resistant Gas Sensors
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Solution Overview
Problem
Conventional gas sensors face issues with peeling of the reference electrode, leading to reduced detection accuracy and potential failure in gas concentration measurement.
Innovation Solution
The gas sensor design includes a laminate structure where a portion of the reference electrode is sandwiched between two solid electrolyte layers, with a defined ratio of the sandwiched area to the exposed area being 0.3 or more, to prevent peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the reference electrode is fully exposed in the reference gas chamber, then detection function is improved, but peeling occurs leading to reduced reliability
Solution Approach 1:
The reference electrode is divided into two functional segments: an exposed portion for detection function and a sandwiched portion for mechanical stability. The sandwiched portion is embedded between the first and second layers, while the exposed portion remains in the reference gas chamber for electrochemical detection.
Solution Approach 2:
Different portions of the reference electrode have different functional properties. The sandwiched portion provides mechanical anchoring and peeling prevention, while the exposed portion provides electrochemical detection function. This local differentiation resolves the contradiction between stability and functionality.
2Reliability
If the reference electrode is sandwiched between layers, then peeling is suppressed, but detection area may be reduced
Solution Approach 1:
The electrode is segmented into sandwiched and exposed portions, allowing each segment to fulfill its specific function without compromising the other. The sandwiched portion ensures stability while the exposed portion maintains detection capability.
Solution Approach 2:
The invention changes the geometric parameter by defining a minimum ratio (0.3 or more) between the sandwiched area and exposed area. This parameter control ensures that sufficient electrode surface remains exposed for detection while maintaining adequate sandwiched area for stability.
Data Source
AI summary
A gas sensor includes: a laminate formed of a plurality of layers including at least one layer of a solid electrolyte; a reference gas chamber formed in the laminate and containing a reference gas; and a reference electrode partially exposed in the reference gas chamber. A portion which is not exposed in the reference gas chamber, of the reference electrode is sandwiched between, among the layers, a first layer and a second layer adjacent to the first layer. When an area of the portion sandwiched between the first layer and the second layer, of the reference electrode is defined as a first area, and an area of a portion exposed in the reference gas chamber, of the reference electrode is defined as a second area, a ratio of the first area to the second area is 0.3 or more.