Sensor Element Conductor Track Angular Orientation
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Solution Overview
Problem
Existing sensor elements with sintered or sinterable ceramic structures face issues with sintering distortion and thermal conductivity, leading to potential crushing of conductor tracks due to overlapping edges with the reference gas channel during production.
Innovation Solution
The conductor tracks are designed to extend at an angle away from the sensor element's end region, overlapping with the reference gas channel to distribute the cutting effect over a wider area, and the use of conductive bushings with a perpendicular leadthrough and specific material compositions to minimize the impact on the sensor's breaking strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conductor tracks are designed to completely or partially overlap with the reference gas channel, then sintering distortion is reduced and thermal conductivity is optimized, but the edge of the reference channel can crush the conductor tracks during production
Solution Approach 1:
The conductor track is extended into the third dimension by forming it at an angle (α between 2° and 25°) relative to the sensor element surface, rather than lying flat. This angular extension creates a gradual transition zone that distributes the mechanical stress from the reference gas channel edge over a larger volume, preventing crushing while maintaining the overlapping configuration for thermal and sintering benefits
2Reliability
If the reference gas channel is left unfilled to improve reference air access, then gas permeability is improved, but the cutting effect of the channel edge on conductor tracks is exacerbated
Solution Approach 1:
The conductor track is designed with an angular extension (α between 2° and 25°) that creates a gradual transition zone. This three-dimensional configuration distributes the mechanical stress from the unfilled reference gas channel edge over a larger volume, preventing crushing while maintaining excellent reference gas access through the unfilled channel
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 reduces the squeezing of conductor tracks during production and maintains the sensor's breaking strength while optimizing heat conduction and access to reference air, enhancing the overall functionality and reliability of the sensor element.
Implementation Method 1
the respective conductor track extends at its end facing away from the first end region of the sensor element at an angle α of not more than 25°, in particular not more than 14°, at an angle of 20° to the outside of the sensor element
Implementation Method 2
to optimize the heat conduction inside the sensor element during operation, it is attractive to design the conductor tracks completely or partially (for example, at least 10% of the width) overlapping with the reference gas channel
Implementation Method 3
The invention relates in particular to a sintered or sinterable ceramic sensor element which is produced, for example, by bringing together, in particular stacking, individual, optionally printed, ceramic green sheets
Implementation Method 4
The sensor element further comprises an electrical resistance heater and a cermet electrode as functional elements in a first end region of the sensor element
Data Source
Figure 1
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AI summary
A sensor element for detecting a physical property of a gas includes: a solid electrolyte film; a first end area and a second end area situated diametrically opposite in the longitudinal direction; a functional element in the first end area in the interior which is electrically conductively connected to a contact surface situated in the second end area on the outer surface, the electrically conductive connection having a strip conductor running essentially in the longitudinal direction in the interior of the sensor element; and a reference gas channel running essentially in the longitudinal direction of the sensor element communicating with a reference gas outside of the sensor element via a reference gas opening, the strip conductor and the reference gas channel being situated in such a way that at least a partial overlap occurs between them.