Sensor element and gas sensor

Patent metadata

Field	Value
Publication number	US-11867659-B2
Application number	US-202016853207-A
Country	US
Kind code	B2
Filing date	Apr 20, 2020
Priority date	Apr 23, 2019
Publication date	Jan 9, 2024
Grant date	Jan 9, 2024

Abstract

A sensor element ( 10 ) including: a measurement chamber ( 150 ); a pump cell ( 110 ) including a solid electrolyte ( 111 ), an inner electrode ( 113 ) exposed to the measurement chamber, and an outer electrode ( 112 ), the pump cell being configured to adjust an oxygen concentration in the measurement chamber; a diffusion resistance portion ( 151 ); and a detection cell ( 120 ) configured to measure a concentration of a specific gas in the measurement target gas after the adjustment of the oxygen concentration. The outer electrode is covered by a porous layer ( 114 ) and is disposed in a hollow space ( 10 G) surrounded by a gas non-permeable dense layer 115, 118 . The hollow space is in communication with an air introduction hole ( 10 h ) that is open on a rear side relative to the diffusion resistance portion. The outer electrode is exposed via the porous layer to air introduced through the air introduction hole.

First claim

The invention claimed is:

1. A sensor element of a stacked type extending in a direction of an axial line thereof, the sensor element comprising:
a measurement chamber;
a pump cell including a solid electrolyte, an inner electrode formed on a surface of the solid electrolyte and exposed to the measurement chamber, and an outer electrode formed on another surface of the solid electrolyte and disposed outside the measurement chamber, the pump cell being configured to adjust an oxygen concentration in the measurement chamber by pumping out and pumping in oxygen in a measurement target gas introduced into the measurement chamber;
a diffusion resistance portion disposed between outside and the measurement chamber and configured to adjust a diffusion rate of the measurement target gas introduced into the measurement chamber; and
a detection cell configured to measure a concentration of a specific gas in the measurement target gas after the adjustment of the oxygen concentration, wherein
the outer electrode is covered by a porous layer and is disposed in a hollow space surrounded by a first dense layer that has a gas non-permeable property and that prevents the outer electrode from coming into contact with the measurement target gas,
the hollow space is in communication with an air introduction hole that is open on a rear side relative to the diffusion resistance portion, and the outer electrode is exposed via the porous layer to air introduced through the air introduction hole, and
when viewed in a stacking direction, a heater is stacked on a side of the sensor element opposite to the first dense layer based on the solid electrolyte,
when viewed in the stacking direction, the first dense layer, the solid electrolyte, the diffusion resistance portion, and the heater are stacked in this order,
at least a part of the heater and the detection cell are contacted without a gap therebetween,
the porous layer is disposed in an opening of a second dense layer, the second dense layer being disposed between the first dense layer and a composite layer that includes the solid electrolyte and an insulating layer, and
side surfaces of the outer electrode are in direct physical contact with and embedded in the solid electrolyte.

2. The sensor element according to claim 1 , wherein
when viewed in a cross section along the stacking direction and perpendicular to the direction of the axial line, and when a cross-sectional area of the hollow space is defined as W1 and a cross-sectional area of the air introduction hole is defined as W2,
a relationship of (1.5×W1)≥W2≥(0.3×W1) is satisfied.

3. The sensor element according to claim 1 , wherein
the air introduction hole penetrates the first dense layer and is open on a front side relative to a rear end of the sensor element.

4. The sensor element according to claim 1 , wherein
the outer electrode contains a noble metal and a component of the solid electrolyte,
when a cross section of the outer electrode is observed, the outer electrode includes a noble metal region composed of the noble metal, a solid electrolyte region composed of the component of the solid electrolyte, and a coexistence region in which the noble metal and the component of the solid electrolyte coexist, and
the coexistence region is present along a boundary between the noble metal region and the solid electrolyte region.

5. The sensor element according to claim 1 , wherein a width of the opening of the second dense layer is wider than a width of the hollow space along a width direction of the sensor element.

6. A gas sensor comprising:
the sensor element according to claim 1 ; and
a metal shell configured to hold the sensor element.

Assignees

• Ngk Spark Plug Co
• Niterra Co Ltd

Inventors

• Furuta Hitoshi
• Kamada Kentaro
• Kojima Akinori
• Yamahara Satoshi
• Hara Akihiro

Classifications

• G01N27/409 Primary

  Oxygen concentration cells · CPC title

• G01N27/406

  Cells and probes with solid electrolytes · CPC title

• G01N27/4071

  using sensor elements of laminated structure · CPC title

• G01N27/4072 Primary

  characterized by the diffusion barrier · CPC title

• G01N27/41

  Oxygen pumping cells · CPC title