Method of manufacturing particulate matter detection element

Patent metadata

Field	Value
Publication number	US-11231354-B2
Application number	US-201916687737-A
Country	US
Kind code	B2
Filing date	Nov 19, 2019
Priority date	Jan 10, 2014
Publication date	Jan 25, 2022
Grant date	Jan 25, 2022

Abstract

A method of manufacturing a particulate matter detection element for detecting particulate matter in a gas to be measured includes manufacturing flat-shaped conductor layers, flat-shaped insulating layers, a laminated structure in which the conductor layers and the insulating layers are alternately laminated, and a detecting unit having the conductor layers of different polarities as a pair of detection electrodes on a cross section of the laminated structure. The conductor layers each have a constant thickness, and include conductor layer planar portions having a stripped-pattern cross section, and tapered conductor layer end edge portions each having a triangular cross section, provided on both sides of the respective conductor layer planar portions.

First claim

The invention claimed is:

1. A method of manufacturing a particulate matter detection element for measuring electrical characteristics changing with an amount of deposited particulate matter, and for detecting particulate matter in a gas to be measured, the method comprises:
a punching step of punching at least an alignment guide and a through hole, as required, in an insulating layer sheet made of an insulating material, and punching the insulating layer sheet into a predetermined outer shape;
a thick-film printing step of injecting a conductor paste made of an electrically conductive material onto the insulating layer sheet, which has been obtained in the punching step, from a thick-film printing screen in which a predetermined conductor layer pattern is formed to form a conductor layer printed film of a predetermined shape;
a laminating and pressure-bonding step of laminating and pressure-bonding the insulating layer sheets provided with the conductor layers, which have been obtained in the thick-film printing step; and
a baking step of baking and integrating a laminated structure obtained in the laminating and pressure-bonding step, wherein
simultaneously with punching the insulating layer sheet, the punching step forms a recessed sheet provided with a recess, which is in conformity with a predetermined shape of the conductor layer end edge portion, at a position corresponding to the position where the conductor layer is printed.

2. The method of manufacturing a particulate matter detection element according to claim 1 , wherein, in the laminating and pressure-bonding step, the conductor layers are laminated and pressure-bonded while being in an undried state.

3. A method of manufacturing a particulate matter detection element for measuring electrical characteristics changing with an amount of deposited particulate matter, and for detecting particulate matter in a gas to be measured, the method comprises:
a punching step of punching at least an alignment guide and a through hole, as required, in an insulating layer sheet made of an insulating material, and punching the insulating layer sheet into a predetermined outer shape;
a thick-film printing step of injecting a conductor paste made of an electrically conductive material onto the insulating layer sheet, which has been obtained in the punching step, from a thick-film printing screen in which a predetermined conductor layer pattern is formed to form a conductor layer printed film of a predetermined shape;
a laminating and pressure-bonding step of laminating and pressure-bonding the insulating layer sheets provided with the conductor layers, which have been obtained in the thick-film printing step; and
a baking step of baking and integrating a laminated structure obtained in the laminating and pressure-bonding step, wherein the thick-film printing step uses a partially reduced opening-ratio screen in which an opening ratio at a position of forming the conductor layer end edge portion in the thick-film printing screen, that is, an opening ratio for forming an end edge portion is permitted to be lower than an opening ratio at a position of forming the conductor layer planar portion, that is, an opening ratio for forming a planar portion, in conformity with a predetermined shape of a conductor layer end edge portion.

4. A method of manufacturing a particulate matter detection element for measuring electrical characteristics changing with an amount of deposited particulate matter, and for detecting particulate matter in a gas to be measured, the method comprises:
a punching step of punching at least an alignment guide and a through hole, as required, in an insulating layer sheet made of an insulating material, and punching the insulating layer sheet into a predetermined outer shape;
a thick-film printing step injecting a conductor paste made of an electrically conductive material onto the insulating layer sheet, which has been obtained in the punching step, from a thick-film printing screen in which a predetermined conductor layer pattern is formed to form a conductor layer printed film of a predetermined shape;
a laminating and pressure-bonding step of laminating and pressure-bonding the insulating layer sheets, on which the conductor layers are formed and obtained in the thick-film printing step; and
a baking step baking and integrating a laminated structure obtained in the laminating and pressure-bonding step, wherein
simultaneously with punching the insulating layer sheet, the punching step forms a recessed sheet provided with a recess, which is in conformity with a predetermined shape of the conductor layer end edge portion, at a position corresponding to the position where the conductor layer is printed, and the thick-film printing step uses a partially reduced opening-ratio screen in which an opening ratio at a position of forming the conductor layer end edge portion in the thick-film printing screen, that is, an opening ratio for forming an end edge portion is permitted to be lower than an opening ratio at a position of forming the conductor layer planar portion, that is, an opening ratio for forming a planar portion, in conformity with a predetermined shape of a conductor layer end edge portion.

Assignees

• Denso Corp

Inventors

• Koike Kazuhiko
• Imagawa Hirokatsu

Classifications

• G01N2015/0046

  in gas, e.g. smoke · CPC title

• G01N15/0606

  by collecting particles on a support · CPC title

• G01N15/0656 Primary

  using electric, e.g. electrostatic methods or magnetic methods (by investigating individual particles G01N15/1031, G01N15/12) · CPC title

• G01M15/102

  by monitoring exhaust gases · CPC title