阅读说明：本技术 气体传感器 (Gas sensor ) 是由 中山裕葵 荫山翔太 藤井雄介 小坂圭 于 2019-01-22 设计创作，主要内容包括：气体传感器10具备：传感器元件20、压粉体45a、45b、以及绝缘子44a～44c。传感器元件20具备：元件主体60、上侧连接器电极71、多孔质层80、以及第一水侵入抑制部91。第一水侵入抑制部91按照沿着元件主体60的长度方向将多孔质层80分割或位于比多孔质层80更靠后端侧的位置的方式配设于第一面60a,并且位于比上侧连接器电极71更靠前端侧的位置,其前后方向上的存在范围和绝缘子44b的内周面44b1的前后方向上的存在范围的连续重复部分的长度、亦即重复距离W为0.5mm以上。第一水侵入抑制部91至少具有：气孔率小于10％的第一致密层92和不存在多孔质层80的第一间隙区域93中的第一致密层92,抑制水沿着长度方向的毛细现象。(The gas sensor 10 includes: sensor element 20, dust compacts 45a and 45b, and insulators 44a to 44 c. The sensor element 20 includes: the element body 60, the upper side connector electrode 71, the porous layer 80, and the first water intrusion prevention section 91. The first water intrusion prevention part 91 is disposed on the first surface 60a so as to divide the porous layer 80 along the longitudinal direction of the element main body 60 or to be located on the rear end side of the porous layer 80, and is located on the front end side of the upper connector electrode 71, and the overlapping distance W, which is the length of the continuous overlapping portion of the existing range in the front-rear direction of the upper connector electrode and the existing range in the front-rear direction of the inner peripheral surface 44b1 of the insulator 44b, is 0.5mm or more. The first water intrusion prevention portion 91 includes at least: the first dense layer 92 having a porosity of less than 10% and the first dense layer 92 in the first gap region 93 where the porous layer 80 is not present suppress the capillary phenomenon of water along the longitudinal direction.)

1. A gas sensor is provided with:

a sensor element;

a metal cylindrical body having a through hole through which the sensor element penetrates in an axial direction;

1 or more green compacts arranged in the through hole and filled between an inner peripheral surface of the through hole and the sensor element; and the number of the first and second groups,

1 or more hollow columnar dense bodies having a porosity of less than 10% and disposed in the through-hole, and having the sensor element inserted therein, and pressing the green compact in the axial direction,

wherein the content of the first and second substances,

the sensor element is provided with:

an elongated element body having: two ends along the length direction, namely a front end and a rear end, and more than 1 side surface along the length direction;

a detection unit having a plurality of electrodes arranged on the distal end side of the element main body and detecting a concentration of a specific gas in the measurement gas;

a connector electrode provided with 1 or more on the rear end side of any one of the 1 or more side surfaces, for electrically conducting with the outside;

a porous layer having a porosity of 10% or more, the porous layer covering at least the distal end side of the side surface on which the connector electrode is disposed; and

a water intrusion prevention section that is disposed on the side surface so as to divide the porous layer along the longitudinal direction or to be located on the rear end side of the porous layer, and that is located on the front end side of the connector electrode; a repetition distance W, which is a length of a continuous overlapping portion of an existing range of the water intrusion prevention portion in the longitudinal direction and an existing range of the inner peripheral surface of the 1 or more dense bodies in the longitudinal direction, is 0.5mm or more; and the water intrusion prevention section has at least: and a dense layer which covers the side face and has a porosity of less than 10%, and the dense layer is adjacent to the dense layer and is in an interstitial region where the porous layer does not exist, and a capillary phenomenon of water along the length direction is suppressed.

2. The gas sensor according to claim 1,

the length Le of the dense layer in the length direction is 0.5mm or more.

3. The gas sensor according to claim 1 or 2,

a length Le in the longitudinal direction of the dense layer is 20mm or less.

4. A gas sensor according to any one of claims 1 to 3,

the length Lg of the gap region in the longitudinal direction is 1mm or less.

5. The gas sensor according to claim 4,

the water intrusion suppressing portion does not have the gap region.

6. The gas sensor according to any one of claims 1 to 5,

the sensor element includes an outer lead portion disposed on the side surface on which the connector electrode is disposed and electrically connecting any one of the plurality of electrodes to the connector electrode,

the porous layer covers at least a part of the outer lead portion.

7. The gas sensor according to any one of claims 1 to 6,

the porous layer covers at least a region from the distal end of the side surface on which the connector electrode is disposed to an end of the connector electrode on the distal end side, except for a region where the water intrusion prevention portion is present,

the water intrusion prevention section is disposed on the side surface so as to divide the porous layer along the longitudinal direction.

8. The gas sensor according to any one of claims 1 to 7,

the element body has a rectangular parallelepiped shape with 4 of the side faces along the length direction,

the number of the connector electrodes is 1 or more on a first side surface and a second side surface opposed to each other among the 4 side surfaces,

the porous layer covers the first side surface and the second side surface respectively,

the water intrusion suppressing portions are disposed on the first side surface and the second side surface, respectively.

Technical Field

The present invention relates to a gas sensor.

Background

Conventionally, there is known a gas sensor including a sensor element for detecting a concentration of a specific gas such as NOx in a measurement gas such as an exhaust gas of an automobile (for example, patent documents 1 and 2). The sensor element of patent document 1 includes: a laminate obtained by laminating oxygen ion conductive solid electrolyte layers. Further, the sensor element includes: and an outer pump electrode, an outer pump electrode lead, a connector electrode, and a porous protective layer, which are disposed on the upper surface of the laminate. The outer pump electrode, the outer pump electrode lead wire, and the connector electrode are connected in this order and electrically connected to the outside. The porous protection layer covers the outer pump electrode and the outer pump electrode with the lead wires, and protects them. Patent document 2 describes a structure of a gas sensor including such a sensor element. The gas sensor of patent document 2 includes an element sealing body that fixes a sensor element. The element sealing body is provided with: a cylindrical metal shell and an inner cylinder, the sensor element penetrating through the inside of the metal shell and the inner cylinder; and a plurality of supports and a plurality of green compacts, which are disposed inside the metal shell and the inner cylinder and through which the sensor element passes.

Disclosure of Invention

However, when a porous layer exists on the surface of the sensor element as in the porous protection layer of patent document 1, moisture in the exhaust gas may migrate through the porous layer due to capillary action. As a result, moisture reaches the connector electrode, and the connector electrode may be rusted or corroded by water or a component such as sulfuric acid dissolved in water, or a short circuit may occur between the connector electrodes.

The present invention has been made to solve the above problems, and a main object thereof is to suppress moisture from reaching a connector electrode.

In order to achieve the above main object, the present invention adopts the following means.

The gas sensor of the present invention includes: a sensor element; a metal cylindrical body having a through hole through which the sensor element penetrates in an axial direction; 1 or more green compacts arranged in the through hole and filled between an inner peripheral surface of the through hole and the sensor element; and 1 or more hollow columnar dense bodies having a porosity of less than 10%, disposed in the through-hole, and having the sensor element inserted therein, and pressing the green compact in the axial direction,

the sensor element is provided with:

an elongated element body having: two ends along the length direction, namely a front end and a rear end, and more than 1 side surface along the length direction;

a detection unit having a plurality of electrodes arranged on the distal end side of the element main body and detecting a concentration of a specific gas in the measurement gas;

a connector electrode provided with 1 or more on the rear end side of any one of the 1 or more side surfaces, for electrically conducting with the outside;

a porous layer having a porosity of 10% or more, the porous layer covering at least the distal end side of the side surface on which the connector electrode is disposed; and

a water intrusion prevention section that is disposed on the side surface so as to divide the porous layer along the longitudinal direction or to be located on the rear end side of the porous layer, and that is located on the front end side of the connector electrode; a repetition distance W, which is a length of a continuous overlapping portion of an existing range of the water intrusion prevention portion in the longitudinal direction and an existing range of the inner peripheral surface of the 1 or more dense bodies in the longitudinal direction, is 0.5mm or more; and the water intrusion prevention section has at least: and a dense layer which covers the side face and has a porosity of less than 10%, and the dense layer is adjacent to the dense layer and is in an interstitial region where the porous layer does not exist, and a capillary phenomenon of water along the length direction is suppressed.

In the gas sensor, a connector electrode is disposed on the rear end side of any one of 1 or more side surfaces of the element main body, and a porous layer covering at least the front end side of the side surface is disposed. The sensor element further includes a water intrusion suppressing portion that is disposed on a side surface of the sensor element so as to divide the porous layer along the longitudinal direction or to be located on a rear end side of the porous layer and is located on a front end side of the connector electrode. Therefore, when the front end side of the element main body, which is the side where the plurality of electrodes of the detection section are present, is exposed to the gas to be measured, even if the moisture in the gas to be measured moves to the rear end side of the element main body within the porous layer due to the capillary phenomenon, the moisture reaches the water intrusion prevention section before reaching the connector electrode. The water intrusion prevention section has at least the dense layer and the dense layer in the gap region, and unlike the porous layer, water is less likely to generate a capillary phenomenon in the longitudinal direction of the element main body, and therefore, water is less likely to pass through the inside of the water intrusion prevention section. In the gas sensor of the present invention, the overlapping distance W, which is the length of the continuous overlapping portion between the range of existence of the water intrusion prevention portion and the range of existence of the inner peripheral surface of 1 or more dense bodies in the longitudinal direction of the sensor element, is 0.5mm or more. Here, the compressed powder and the dense body are present between the cylindrical body and the sensor element, and the porosity of the dense body is less than 10%, so that it is difficult for moisture to pass through the inside of the dense body, but the compressed powder has water absorption, so that moisture can move not only in the porous layer but also in the inside of the compressed powder. Therefore, when the repetition distance W is 0mm, for example, when the water intrusion prevention section is disposed only at the same position as the green compact in the longitudinal direction of the sensor element, the water may pass through the interior of the green compact and move to the rear end side while bypassing the water intrusion prevention section. However, in the gas sensor of the present invention, since the repeat distance W is 0.5mm or more, there is a region in which the water migration inside the powder compact is suppressed and the water intrusion suppressing portion is bypassed over a sufficient length, the water migration due to the bypass can be sufficiently suppressed. Thus, the water intrusion prevention section prevents the water that has migrated through the porous layer from passing through the water intrusion prevention section, and also prevents the water from migrating through the green compact while bypassing the water intrusion prevention section. Therefore, in the gas sensor, the moisture can be prevented from moving to the rear end side of the sensor element than the water intrusion prevention section and reaching the connector electrode. Here, the length L in the longitudinal direction of the water intrusion prevention portion is always a value equal to or greater than the repetition distance W, and therefore, the length L is also equal to or greater than 0.5 mm. In this case, the repetition distance W may be 5mm or more. The repetition distance W may be 20mm or less. The porosity of the dense layer may be 8% or less, or may be 5% or less.

In the gas sensor of the present invention, the length Le of the dense layer in the longitudinal direction may be 0.5mm or more. In this way, the water intrusion prevention portion can sufficiently prevent the water from passing through the water intrusion prevention portion in the longitudinal direction only by the portion of the dense layer in the water intrusion prevention portion.

In the gas sensor according to the present invention, the length Le of the dense layer in the longitudinal direction may be 20mm or less. In this manner, for example, in the case where the element body and the dense layer are manufactured by forming the unfired element body and the unfired dense layer and then firing them, it is possible to suppress the occurrence of warpage in the sensor element due to the difference in shrinkage rate between the unfired element body and the unfired dense layer at the time of firing.

In the gas sensor according to the present invention, a length Le of the dense layer in the longitudinal direction may be 30% or less of a length of the element main body in the longitudinal direction. In this manner, for example, in the case where the unfired element main body and the unfired dense layer are formed and then fired to produce the element main body and the dense layer, it is possible to suppress occurrence of warpage in the sensor element due to a difference in shrinkage rate between the element main body and the dense layer at the time of firing.

In the gas sensor according to the present invention, a length Lg of the gap region in the longitudinal direction may be 1mm or less. In this way, since the length Lg of the gap region is small, the exposed portion of the side surface of the element main body (the portion not covered with the porous layer and not covered with the dense layer) can be reduced.

In the gas sensor according to the present invention, the water intrusion prevention unit may not include the gap region. In other words, the length Lg of the gap region of the water intrusion prevention portion in the longitudinal direction may be 0 mm. In this way, the exposed portion of the side surface of the element main body (the portion not covered with the porous layer and not covered with the dense layer) can be further reduced.

In the gas sensor according to the present invention, the sensor element may include an outer lead portion disposed on the side surface on which the connector electrode is disposed, the outer lead portion electrically connecting any one of the plurality of electrodes to the connector electrode, and the porous layer may cover at least a part of the outer lead portion. In this way, at least a part of the outer lead portion can be protected by the porous layer. In addition, when the outer lead portion is protected by the porous layer, the porous layer is likely to exist at a position close to the connector electrode, and therefore, the significance of applying the present invention is significant.

In this case, the porous layer may cover the entire outer lead portion, or the porous layer may cover all portions of the outer lead portion where the water intrusion prevention portion is not present. The gas sensor of the present invention may further include an outer electrode which is one of the plurality of electrodes included in the detection unit, is electrically connected to the connector electrode through the outer lead portion, and is disposed on the side surface on which the connector electrode is disposed. In this case, the porous layer may coat the outer electrode.

In the gas sensor according to the present invention, the porous layer may cover at least a region from the distal end of the side surface on which the connector electrode is disposed to an end portion on the distal end side of the connector electrode, except for a region where the water intrusion prevention section is present, and the water intrusion prevention section may be disposed on the side surface so as to divide the porous layer along the longitudinal direction.

In the gas sensor according to the present invention, the element body may have a rectangular parallelepiped shape and 4 side surfaces along the longitudinal direction, the connector electrodes may be provided in 1 or more number on a first side surface and a second side surface of the 4 side surfaces that face each other, the porous layer may cover the first side surface and the second side surface, and the water intrusion prevention portions may be provided on the first side surface and the second side surface, respectively. In this case, the element main body may be a laminate obtained by laminating a plurality of layers, and the first side surface and the second side surface may be upper and lower surfaces of the element main body with the laminating direction being a vertical direction.

Drawings

Fig. 1 is a longitudinal sectional view showing a state in which the gas sensor 10 is attached to the pipe 58.

Fig. 2 is a perspective view of the sensor element 20.

Fig. 3 is a sectional view a-a of fig. 2.

Fig. 4 is a plan view of the sensor element 20.

Fig. 5 is a bottom view of the sensor element 20.

Fig. 6 is an explanatory diagram showing a positional relationship between the insulator 44b and the water intrusion prevention section 90.

Fig. 7 is an explanatory diagram showing the arrangement of the water intrusion prevention unit 90 when the repetition distance W is 0 mm.

Fig. 8 is an explanatory view of the gas sensor 10 of experimental example 1A.

Fig. 9 is an explanatory view of the gas sensor 10 of experimental example 2A.

Fig. 10 is an explanatory view of the gas sensor 10 of experimental example 3A.

Fig. 11 is an explanatory diagram of the gas sensor 10 of experimental examples 4A and 6A.

Fig. 12 is an explanatory view of the gas sensor 10 of experimental example 5A.

Fig. 13 is a graph showing the time change of the intrusion distance in the liquid intrusion test in experimental examples 2A and 8A.

Detailed Description

Next, embodiments of the present invention will be described with reference to the drawings. Fig. 1 is a longitudinal sectional view showing a state in which a gas sensor 10 according to an embodiment of the present invention is attached to a pipe 58. Fig. 2 is a perspective view of the sensor element 20 viewed from the upper right front. Fig. 3 is a sectional view a-a of fig. 2. Fig. 4 is a plan view of the sensor element 20. Fig. 5 is a bottom view of the sensor element 20. In the present embodiment, as shown in fig. 2 and 3, the longitudinal direction of the element main body 60 of the sensor element 20 is defined as the front-rear direction (longitudinal direction), the stacking direction (thickness direction) of the element main body 60 is defined as the up-down direction, and the direction perpendicular to the front-rear direction and the up-down direction is defined as the left-right direction (width direction).

As shown in fig. 1, the gas sensor 10 includes: assembly 15, nut 47, outer cylinder 48, connector 50, lead 55, and rubber plug 57. The assembly 15 includes: a sensor element 20, a protective cover 30, and an element sealing body 40. The gas sensor 10 is attached to a pipe 58 such as an exhaust pipe of a vehicle, for example, and is used for detecting NOx or O contained in exhaust gas as a measurement gas₂And the concentration of the specific gas (specific gas concentration) is measured. In the present embodiment, the gas sensor 10 measures the NOx concentration as the specific gas concentration. The front end side of both ends (front end and rear end) of the sensor element 20 in the longitudinal direction is exposed to the gas to be measured.

As shown in fig. 1, the protective cover 30 includes: a bottomed cylindrical inner protection cover 31 that covers the distal end side of the sensor element 20; and a bottomed cylindrical outer protective cover 32 covering the inner protective cover 31. A plurality of holes for allowing the gas to be measured to flow are formed in the inner protective cover 31 and the outer protective cover 32, respectively. An element chamber 33 is formed as a space surrounded by the inner protective cover 31, and the fifth surface 60e (front end surface) of the sensor element 20 is disposed in the element chamber 33.

The element sealing body 40 is a member for sealing and fixing the sensor element 20. The element sealing body 40 includes: a cylindrical body 41 having a metallic shell 42 and an inner cylinder 43, insulators 44a to 44c (an example of a dense body), dust compacts 45a and 45b, and a metal ring 46. The sensor element 20 is located on the central axis of the element sealing body 40, and penetrates the element sealing body 40 in the vertical direction.

The metallic shell 42 is a cylindrical metallic member. The metal shell 42 is formed as a thick portion 42a having a smaller inner diameter on the front side than on the rear side. A protective cover 30 is attached to the same side (front side) of the metal shell 42 as the front end of the sensor element 20. The rear end of the metallic shell 42 is welded to the flange 43a of the inner tube 43. A part of the inner peripheral surface of the thick portion 42a forms a bottom surface 42b as a stepped surface. The bottom surface 42b presses the insulator 44a so as not to protrude forward. The metal shell 42 has a through hole penetrating the metal shell 42 in the axial direction (in this case, the front-rear direction), and the sensor element 20 penetrates the through hole.

The inner tube 43 is a tubular metal member and has a flange portion 43a at the tip. The inner cylinder 43 and the main fitting 42 are coaxially welded and fixed. Further, the inner tube 43 is formed with a reduced diameter portion 43c for pressing the powder compact 45b in the central axis direction of the inner tube 43, and a reduced diameter portion 43d for pressing the insulators 44a to 44c and the powder compacts 45a and 45b downward in fig. 1 via the metal ring 46. The inner tube 43 has a through hole penetrating the inner tube 43 in the axial direction (here, the front-rear direction), and the sensor element 20 penetrates the through hole. The through hole of the metallic shell 42 and the through hole of the inner cylinder 43 communicate with each other in the axial direction, and these constitute the through hole of the cylindrical body 41.

The insulators 44a to 44c and the green compacts 45a and 45b are disposed between the inner circumferential surface of the through hole of the tubular body 41 and the sensor element 20. The insulators 44a to 44c function as supports for the green compacts 45a and 45 b. Examples of the material of the insulators 44a to 44c include ceramics such as alumina, steatite, zirconia, spinel, cordierite, and mullite; or glass. The insulators 44a to 44c are dense members, and have a porosity of, for example, less than 1%. The insulators 44a to 44c each have a through hole penetrating therethrough in the axial direction (in this case, the front-rear direction), and the sensor element 20 penetrates through the through hole. In the present embodiment, the through-holes of the insulators 44a to 44c have a rectangular cross section perpendicular to the axial direction, corresponding to the shape of the sensor element 20. The green compacts 45a and 45b are obtained by molding powder, for example, and function as sealing materials. The material of the green compacts 45a and 45b may be alumina powder, ceramic powder such as boron nitride, or the like, in addition to talc, and the green compacts 45a and 45b may include at least one of these. The average particle diameter of the particles constituting the green compacts 45a and 45b may be 150 to 300. mu.m. The green compact 45a is filled between the insulators 44a and 44b, and is sandwiched and pressed by the insulators 44a and 44b from both sides (front and rear) in the axial direction. The green compact 45b is filled between the insulators 44b and 44c, and is sandwiched and pressed by the insulators 44b and 44c from both sides (front and rear) in the axial direction. The insulators 44a to 44c and the dust compacts 45a and 45b are sandwiched by the reduced diameter portion 43d and the metal ring 46 and the bottom surface 42b of the thick portion 42a of the metallic shell 42 and pressed from front to back. The powder compacts 45a and 45b are compressed between the cylindrical body 41 and the sensor element 20 by the pressing force from the diameter reducing portions 43c and 43d, and the powder compacts 45a and 45b seal the element chamber 33 in the protective cover 30 and the space 49 in the outer cylinder 48 and fix the sensor element 20.

The nut 47 is fixed to the outside of the metal shell 42 coaxially with the metal shell 42. An external thread portion is formed on the outer peripheral surface of the nut 47. The male screw portion is inserted into a fixing member 59, and the fixing member 59 is welded to the pipe 58 and has a female screw portion on an inner peripheral surface. Thus, the gas sensor 10 can be fixed to the pipe 58 in a state where the distal end side of the sensor element 20 or the part of the protective cover 30 in the gas sensor 10 protrudes into the pipe 58.

The outer cylinder 48 is a cylindrical metal member that covers the inner cylinder 43, the rear end side of the sensor element 20, and the connector 50. The upper portion of the metal shell 42 is inserted into the outer cylinder 48. The lower end of the outer cylinder 48 is welded to the metallic shell 42. A plurality of lead wires 55 connected to the connector 50 are led out from the upper end of the outer tube 48. The connector 50 is electrically connected in contact with an upper side connector electrode 71 and a lower side connector electrode 72 disposed on the surface of the sensor element 20 on the rear end side. The lead wires 55 are electrically connected to the electrodes 64 to 68 and the heater 69 inside the sensor element 20 via the connector 50. The gap between the outer tube 48 and the lead 55 is sealed by a rubber stopper 57. The space 49 in the outer cylinder 48 is filled with the reference gas. A sixth surface 60f (rear end surface) of the sensor element 20 is disposed in the space 49.

As shown in fig. 2 to 5, the sensor element 20 includes: the element body 60, the detection section 63, the heater 69, the upper side connector electrode 71, the lower side connector electrode 72, the porous layer 80, and the water intrusion prevention section 90. The element body 60 has a plurality of (6 in fig. 3) stacked zirconium oxide (ZrO) layers₂) A laminate obtained by forming a plasma-conductive solid electrolyte layer. The element body 60 has an elongated rectangular parallelepiped shape with its longitudinal direction extending in the front-rear direction, and has first to sixth surfaces 60a to 60f as outer surfaces of the element body. The first to fourth surfaces 60a to 60d are surfaces along the longitudinal direction of the element body 60, and correspond to side surfaces of the element body 60. The fifth surface 60e is a front end surface of the element main body 60, and the sixth surface 60f is a rear end surface of the element main body 60. For the dimensions of the element main body 60, for example, the length may be 25mm to 100mm, the width may be 2mm to 10mm, and the thickness may be 0.5mm to 5 mm. A gas-to-be-measured inlet 61 and a reference gas inlet 62 are formed in the element main body 60, the gas-to-be-measured inlet 61 being open at a fifth surface 60e to introduce the gas to be measured into the element main body, and the reference gas inlet 62 being open at a sixth surface 60f to introduce the reference gas (here, the atmosphere) serving as a detection reference for the specific gas concentration into the element main body.

The detection unit 63 detects the concentration of a specific gas in a gas to be measured. The detection unit 63 includes: a plurality of electrodes disposed on the front end side of the element main body 60. In the present embodiment, the detection unit 63 includes: an outer electrode 64 disposed on the first surface 60 a; and an inner main pump electrode 65, an inner auxiliary pump electrode 66, a measurement electrode 67, and a reference electrode 68 disposed inside the element body 60. The inner main pump electrode 65 and the inner auxiliary pump electrode 66 are disposed on the inner circumferential surface of the space inside the element body 60, and have a tunnel-like structure.

The principle of the detection unit 63 detecting the concentration of the specific gas in the measurement target gas is well known, and therefore, a detailed description thereof will be omitted, but the detection unit 63 detects the concentration of the specific gas as follows, for example. The detection unit 63 draws out or draws in oxygen in the gas to be measured around the inner main pump electrode 65 to the outside (the element chamber 33) based on the voltage applied between the outer electrode 64 and the inner main pump electrode 65. The detection unit 63 draws out or draws in oxygen in the gas to be measured around the inner auxiliary pump electrode 66 to the outside (the element chamber 33) based on the voltage applied between the outer electrode 64 and the inner auxiliary pump electrode 66. Thereby, the gas to be measured whose oxygen concentration is adjusted to a predetermined value reaches the periphery of the measurement electrode 67. The measurement electrode 67 functions as a NOx reduction catalyst, and reduces the specific gas (NOx) in the gas to be measured that has reached. Then, the detection unit 63 generates, as an electric signal, an electromotive force generated between the measurement electrode 67 and the reference electrode 68 in accordance with the oxygen concentration after reduction, or a current flowing between the measurement electrode 67 and the outer electrode 64 based on the electromotive force. The electric signal generated by the detection unit 63 in this manner is a signal indicating a value corresponding to the concentration of the specific gas in the gas to be measured (a value from which the concentration of the specific gas can be derived), and corresponds to the detection value detected by the detection unit 63.

The heater 69 is a resistor disposed inside the element main body 60. The heater 69 generates heat by supplying power from the outside, thereby heating the element main body 60. The heater 69 heats and maintains the temperature of the solid electrolyte layer forming the element body 60, and can adjust the temperature (for example, 800 ℃) for activating the solid electrolyte layer.

The upper side connector electrode 71 and the lower side connector electrode 72 are: and electrodes disposed on the rear end side of any one of the side surfaces of the element body 60 and electrically connected to the outside. Both the upper side connector electrode 71 and the lower side connector electrode 72 are exposed without being covered with the porous layer 80. In the present embodiment, 4 upper connector electrodes 71a to 71d are arranged in the left-right direction on the rear end side of the first surface 60a as the upper connector electrodes 71. As the lower-side connector electrode 72, 4 lower-side connector electrodes 72a to 72d are arranged in the left-right direction on the rear end side of the second surface 60b (lower surface) facing the first surface 60a (upper surface). The connector electrodes 71a to 71d and 72a to 72d are electrically connected to any one of the electrodes 64 to 68 of the detection section 63 and the heater 69. In the present embodiment, the upper-side connector electrode 71a is electrically connected to the measurement electrode 67, the upper-side connector electrode 71b is electrically connected to the outer electrode 64, the upper-side connector electrode 71c is electrically connected to the inner auxiliary pump electrode 66, the upper-side connector electrode 71d is electrically connected to the inner main pump electrode 65, the lower-side connector electrodes 72a to 72c are electrically connected to the heater 69, and the lower-side connector electrode 72d is electrically connected to the reference electrode 68. The upper-side connector electrode 71b and the outer electrode 64 are electrically connected to each other by an outer lead 75 provided on the first surface 60a (see fig. 3 and 4). The other connector electrodes are electrically connected to the corresponding electrodes or heaters 69 via lead wires, through holes, or the like provided in the element body 60.

The porous layer 80 is: and a porous body covering at least the tip side of the first surface 60a and the second surface 60b, which are the side surfaces of the element main body 60 on which the upper side connector electrode 71 and the lower side connector electrode 72 are arranged. In the present embodiment, the porous layer 80 includes: an inner porous layer 81 covering the first surface 60a and the second surface 60b, respectively; and an outer porous layer 85 disposed outside the inner porous layer 81.

The inner porous layer 81 includes: a first inner porous layer 83 covering the first surface 60a, and a second inner porous layer 84 covering the second surface 60 b. The first inner porous layer 83 covers the entire region from the front end to the rear end of the first surface 60a on which the upper side connector electrodes 71a to 71d are disposed, except for the region where the first water intrusion prevention portion 91 and the upper side connector electrodes 71 are present (see fig. 2 to 4). The left-right width of the first inner porous layer 83 is the same as the left-right width of the first surface 60a, and the first inner porous layer 83 covers the entire first surface 60a from the left end to the right end in the first surface 60 a. Due to the presence of the first water intrusion prevention part 91, the first inner porous layer 83 is divided into: a front end portion 83a located on the front end side of the first water intrusion prevention section 91 in the longitudinal direction, and a rear end portion 83b located on the rear end side of the first water intrusion prevention section 91. The first inner porous layer 83 covers at least a part of each of the outer electrode 64 and the outer lead 75. In the present embodiment, as shown in fig. 3 and 4, the first inner porous layer 83 entirely covers the outer electrode 64, and entirely covers the outer lead 75 where the first water intrusion prevention part 91 is not present. The first inner porous layer 83 functions as a protective layer, for example, to protect the outer electrode 64 and the outer lead 75 from components such as sulfuric acid in the gas to be measured, and to suppress corrosion thereof.

The second inner porous layer 84 covers the entire region from the front end to the rear end of the second surface 60b on which the lower-side connector electrodes 72a to 72d are disposed, except for the region where the second water intrusion prevention portion 94 and the lower-side connector electrode 72 are present (see fig. 2, 3, and 5). The second inner porous layer 84 has the same lateral width as the second surface 60b, and the second inner porous layer 84 covers the entire second surface 60b from the left end to the right end of the second surface 60 b. Due to the presence of the second water intrusion prevention portion 94, the second inner porous layer 84 is divided into: a front end portion 84a located on the front end side of the second water intrusion prevention part 94 in the longitudinal direction, and a rear end portion 84b located on the rear end side of the second water intrusion prevention part 94.

The outer porous layer 85 covers the first to fifth surfaces 60a to 60 e. The first surface 60a and the second surface 60b are covered with the inner porous layer 81 and the outer porous layer 85. The outer porous layer 85 has a length in the front-rear direction shorter than that of the inner porous layer 81, and covers only the front end of the element body 60 and the region near the front end, unlike the inner porous layer 81. Thus, the outer porous layer 85 covers the peripheral portions of the electrodes 64 to 68 of the detection unit 63 in the element main body 60, in other words, the portions of the element main body 60 that are disposed in the element chamber 33 and exposed to the gas to be measured. Thus, the outer porous layer 85 functions as a protective layer, and prevents the adhesion of moisture or the like in the gas to be measured and the occurrence of cracks in the device main body 60.

The porous layer 80 is made of a ceramic porous material such as an alumina porous material, a zirconia porous material, a spinel porous material, a cordierite porous material, a titania porous material, or a magnesia porous material. In the present embodiment, the porous layer 80 is made of an alumina porous body. The thickness of each of the first inner porous layer 83 and the second inner porous layer 84 may be, for example, 5 μm to 40 μm. The thickness of the outer porous layer 85 may be, for example, 40 to 800 μm. The porosity of the porous layer 80 is 10% or more. The porous layer 80 covers the outer electrode 64 and the gas introduction port 61, but the gas to be measured can pass through the porous layer 80 as long as the porosity is 10% or more. The porosity of the inner porous layer 81 may be 10% to 50%. The porosity of the outer porous layer 85 may be 10% to 85%. The porosity of the outer porous layer 85 may be higher than the porosity of the inner porous layer 81.

The porosity of the inner porous layer 81 is a value derived using an image (SEM image) obtained by observation using a Scanning Electron Microscope (SEM). First, the sensor element 20 is cut along the thickness direction of the inner porous layer 81 so that the cross section of the inner porous layer 81 becomes an observation surface, and the cut cross section is filled with resin and polished to prepare an observation sample. Next, the observation surface of the observation sample was photographed with the SEM magnification set to 10000 times from 1000 times, and an SEM image of the inner porous layer 81 was obtained. Then, the obtained image is subjected to image analysis, and a threshold value is determined by a discriminant analysis method (profound binarization) based on the luminance distribution of the luminance data of the pixels in the image. Then, each pixel in the image is binarized into an object portion and a pore portion based on the determined threshold value, and the area of the object portion and the area of the pore portion are calculated. Then, the ratio of the area of the pore portion to the total area (the total area of the object portion and the pore portion) was derived as the porosity (unit:%). The porosity of the outer porous layer 85 and the porosities of the first dense layer 92 and the second dense layer 95, which will be described later, are also derived in the same manner.

The water intrusion prevention section 90 suppresses a capillary phenomenon of water along the longitudinal direction of the element main body 60. In the present embodiment, the water intrusion prevention unit 90 includes a first water intrusion prevention unit 91 and a second water intrusion prevention unit 94. The first water intrusion prevention portion 91 is disposed on the first surface 60a on which the upper side connector electrode 71 and the first inner porous layer 83 are disposed. As described above, the first water intrusion prevention part 91 is disposed on the first surface 60a so as to divide the first inner porous layer 83 into front and rear parts along the longitudinal direction. The first water intrusion prevention section 91 is disposed on the front end side of the element body 60 with respect to the upper side connector electrode 71, that is, in front of the upper side connector electrode 71. The first water intrusion prevention unit 91 is disposed rearward of the outer electrode 64. The first water intrusion prevention section 91 is disposed rearward of any of the plurality of electrodes 64 to 68 of the detection section 63 including the outer electrode 64 (see fig. 3). When moisture moves to the rear side in the distal end portion 83a due to capillary phenomenon, the first water intrusion prevention portion 91 prevents the moisture from passing through the first water intrusion prevention portion 91, thereby functioning to prevent the moisture from reaching the upper side connector electrode 71. The first water intrusion prevention part 91 includes a first dense layer 92 and a first gap region 93. The first dense layer 92 is a dense layer having a porosity of less than 10%. The left-right width of the first dense layer 92 is the same as the left-right width of the first surface 60a, and the first dense layer 92 covers the entire first surface 60a from the left end to the right end of the first surface 60 a. The first dense layer 92 is adjacent to the rear end of the front end side portion 83 a. As shown in fig. 4, first dense layer 92 covers a part of outer lead 75. The first gap region 93 is a region on the first surface 60a, and is a region where the porous layer 80 and the first dense layer 92 are not present. The first gap region 93 is formed as a region between the rear end of the first dense layer 92 and the front end of the rear end side portion 83 b. The outer lead 75 is exposed at a portion where the first gap region 93 exists.

The second water intrusion prevention portion 94 is disposed on the second surface 60b on which the lower side connector electrode 72 and the second inner porous layer 84 are disposed. As described above, the second water intrusion prevention part 94 is disposed on the second surface 60b so as to divide the second inner porous layer 84 into front and rear parts along the longitudinal direction. The second water intrusion prevention portion 94 is disposed on the front end side of the element body 60 with respect to the lower side connector electrode 72, that is, in front of the lower side connector electrode 72. The second water intrusion prevention unit 94 is disposed rearward of the outer electrode 64. The second water intrusion prevention section 94 is disposed rearward of any of the plurality of electrodes 64 to 68 of the detection section 63 including the outer electrode 64 (see fig. 3). When the moisture moves to the rear side in the distal end side portion 84a due to the capillary phenomenon, the second water intrusion prevention portion 94 acts to prevent the moisture from passing through the second water intrusion prevention portion 94 and to prevent the moisture from reaching the lower side connector electrode 72. The second water intrusion suppression part 94 includes a second dense layer 95 and a second gap region 96. The second dense layer 95 is a dense layer having a porosity of less than 10%. The second dense layer 95 has the same lateral width as the second surface 60b, and the second dense layer 95 covers the entire second surface 60b from the left end to the right end of the second surface 60 b. The second dense layer 95 adjoins the rear end of the front end side portion 84 a. The second gap region 96 is a region on the second face 60b, and is a region where the porous layer 80 and the second dense layer 95 are not present. The second gap region 96 is formed as a region between the rear end of the second dense layer 95 and the front end of the rear end side portion 84 b.

The length L (see fig. 4 and 5) of each of the first water intrusion prevention part 91 and the second water intrusion prevention part 94 in the longitudinal direction is 0.5mm or more. When the length L is 0.5mm or more, the passage of water through the first water intrusion prevention part 91 and the second water intrusion prevention part 94 can be sufficiently suppressed. The length L may be 5mm or more. The length L may be 25mm or less, or 20mm or less. The length L of the first water intrusion prevention part 91 and the length L of the second water intrusion prevention part 94 are the same in the present embodiment, but they may be different.

Although the first dense layer 92 and the second dense layer 95 are different from the porous layer 80 in that the porosity is less than 10%, ceramics made of the materials exemplified in the above-described porous layer 80 may be used. In the present embodiment, both first dense layer 92 and second dense layer 95 are alumina ceramics. The thickness of each of the first dense layer 92 and the second dense layer 95 may be, for example, 5 μm to 40 μm. The thickness of the first dense layer 92 is preferably equal to or greater than the thickness of the first inner porous layer 83. Similarly, the thickness of the second dense layer 95 is preferably equal to or greater than the thickness of the second inner porous layer 84. The porosity of each of the first dense layer 92 and the second dense layer 95 is preferably 8% or less, and more preferably 5% or less. As the porosity decreases, the first dense layer 92 and the second dense layer 95 can further suppress the capillary phenomenon of water along the longitudinal direction of the element main body 60.

The length Le (see fig. 4 and 5) of each of the first dense layer 92 and the second dense layer 95 in the longitudinal direction is preferably 0.5mm or more. Thus, the first and second water intrusion prevention sections 91 and 94 can sufficiently prevent the water from passing through the first and second water intrusion prevention sections 91 and 94 in the longitudinal direction only by the portions of the first and second dense layers 92 and 95, respectively. The length Le may be 5mm or more. Note that, the length Le of the first dense layer 92 and the length Le of the second dense layer 95 are the same in the present embodiment, but they may be different.

The length Lg of each of the first gap region 93 and the second gap region 96 in the longitudinal direction is preferably 1mm or less. As described above, the length Lg is small, and thus the exposed portion of the side surface (here, the first surface 60a and the second surface 60b) of the element main body 60, that is, the portion not covered with any one of the porous layer 80, the first dense layer 92, and the second dense layer 95 can be reduced. In particular, in the present embodiment, the outer lead 75 is disposed on the first surface 60a, and the outer lead 75 is exposed at a portion where the first gap region 93 exists. Therefore, by reducing the length Lg of the first gap region 93, the portion of the outer lead 75 that is not protected by the porous layer 80 or the first dense layer 92 can be reduced.

Fig. 6 is an explanatory diagram showing a positional relationship between the water intrusion prevention section 90 and the insulators 44a to 44c and the green compacts 45a and 45b, and is a longitudinal sectional view of the gas sensor 10 in which illustration of components not related to the explanation is omitted. The first water intrusion prevention portion 91 is disposed: the overlapping distance W, which is the length of the continuous overlapping portion of the range of presence of the first water intrusion prevention portion 91 along the longitudinal direction of the sensor element 20 (in this case, the front-rear direction) and the range of presence of the inner peripheral surface 44b1 of the insulator 44b along the longitudinal direction of the sensor element 20, is 0.5mm or more. The inner peripheral surface 44b1 of the insulator 44b is a surface of the insulator 44b facing the first water intrusion prevention part 91, in other words, a surface exposed to the first water intrusion prevention part 91, and is an upper surface of the inner peripheral surface of the insulator 44b having a quadrangular cross section. The value of the repeat distance W determined by the positional relationship of the inner peripheral surface 44b1 and the first water intrusion suppressing portion 91 corresponds to the length in the front-rear direction of the continuous portion of the first water intrusion suppressing portion 91 that is not in contact with the dust bodies 45a, 45 b. As shown in fig. 6, in the present embodiment, the first water intrusion prevention unit 91 is disposed such that: and is included in the front-rear direction in the inner peripheral surface 44b1 of the insulator 44 b. More specifically, it is configured to: the region from the front end to the rear end of the first water intrusion prevention part 91 (the range in which the first water intrusion prevention part 91 is present in the front-rear direction) is included inside the region from the front end to the rear end of the inner peripheral surface 44b1 of the insulator 44b (the range in which the inner peripheral surface 44b1 is present in the front-rear direction). By setting the positional relationship as described above, the repetition distance W becomes equal to or longer than the length L, and as described above, the length L is 0.5mm or longer, and therefore the repetition distance W is also 0.5mm or longer for the first water intrusion prevention portion 91. In the present embodiment, the range in which the inner peripheral surface 44b1 is present in the front-rear direction coincides with the range in which the insulator 44b is present in the front-rear direction. Therefore, the length of the continuously overlapping portion of the range in which the first water intrusion prevention portion 91 is present along the longitudinal direction of the sensor element 20 and the range in which the insulator 44b is present along the longitudinal direction of the sensor element 20 is the same as the aforementioned overlapping distance W.

Similarly, the second water intrusion prevention unit 94 is also arranged to: the overlapping distance W, which is the length of the continuous overlapping portion of the range of the second water intrusion prevention portion 94 along the longitudinal direction of the sensor element 20 (in this case, the front-rear direction) and the range of the insulator 44b inner peripheral surface 44b2 along the longitudinal direction of the sensor element 20, is 0.5mm or more. The inner peripheral surface 44b2 of the insulator 44b is a surface of the insulator 44b facing the second water intrusion prevention part 94, in other words, a surface exposed to the second water intrusion prevention part 94, and is a surface of the insulator 44b located on the lower side of the cross-sectional quadrangular inner peripheral surface. The value of the repeat distance W determined by the positional relationship of the inner peripheral surface 44b2 and the second water intrusion suppression portion 94 corresponds to the length in the front-rear direction of the continuous portion of the second water intrusion suppression portion 94 that is not in contact with the dust bodies 45a, 45 b. As shown in fig. 6, in the present embodiment, the second water intrusion prevention unit 94 is arranged to: and is included in the front-rear direction in the inner peripheral surface 44b2 of the insulator 44 b. More specifically, it is configured to: the region from the front end to the rear end of the second water intrusion prevention part 94 (the range in which the second water intrusion prevention part 94 exists in the front-rear direction) is included inside the region from the front end to the rear end of the inner peripheral surface 44b2 of the insulator 44b (the range in which the inner peripheral surface 44b2 exists in the front-rear direction). By setting the above positional relationship, the second water intrusion prevention unit 94 holds the repetition distance W as the length L, and as described above, the length L is 0.5mm or more, and therefore the repetition distance W is also 0.5mm or more. In the present embodiment, the range in which the inner peripheral surface 44b2 is present in the front-rear direction coincides with the range in which the insulator 44b is present in the front-rear direction. Therefore, the length of the continuously overlapping portion of the range in which the second water intrusion prevention portion 94 is present along the longitudinal direction of the sensor element 20 and the range in which the insulator 44b is present along the longitudinal direction of the sensor element 20 is the same as the above-described overlapping distance W.

The repetition distance W of the first water intrusion prevention unit 91 and the repetition distance W of the second water intrusion prevention unit 94 are the same in the present embodiment, but they may be different. In the first and second water intrusion prevention portions 91 and 94, the repetition distances W may be 5mm or more, and 20mm or less, respectively.

In fig. 6, the inner peripheral surface 44b1 and the first dense layer 92 of the first water intrusion prevention section 91 are in contact with each other, but may be vertically separated from each other. By separating the two, contact between the two is suppressed when, for example, thermal expansion of the two occurs or vibration of the gas sensor 10 occurs, and at least one of the insulator 44b and the sensor element 20 can be suppressed from being damaged. The distance separating the inner peripheral surface 44b1 from the first dense layer 92 at normal temperature (e.g., 20 ℃) may be 50 μm or more. This can suppress the movement of moisture in the gap between the inner peripheral surface 44b1 and the first dense layer 92 due to capillary action. The separation distance is preferably 100 μm or more. The separation distance may be 500 μm or less. Similarly, the inner peripheral surface 44b2 and the second dense layer 95 of the second water intrusion prevention part 94 are in contact with each other in fig. 6, but they may be vertically separated from each other by a distance that satisfies any one or more of the numerical ranges described above.

A method for manufacturing the gas sensor 10 configured as described above will be described below. First, a method of manufacturing the sensor element 20 will be described. In manufacturing the sensor element 20, first, a plurality of (6 in this case) unfired ceramic green sheets corresponding to the element body 60 are prepared. Each green sheet is provided with a notch, a through hole, a groove, or the like by punching treatment or the like as necessary, and an electrode or a wiring pattern is screen-printed. Note that, as for the unfired porous layer which becomes the first inner porous layer 83 and the second inner porous layer 84 after firing and the unfired dense layer which becomes the first dense layer 92 and the second dense layer 95 after firing, the unfired porous layers are also formed on the surfaces corresponding to the first surface 60a and the second surface 60b in the green sheet by screen printing. Thereafter, a plurality of green sheets are stacked. The stacked plurality of green sheets are an unfired device body which becomes a device body after firing, and are provided with an unfired porous layer and an unfired dense layer. Then, the unfired element body is fired to obtain the element body 60 including the first inner porous layer 83, the second inner porous layer 84, the first dense layer 92, and the second dense layer 95. Next, the outer porous layer 85 was formed by plasma spraying, thereby obtaining the sensor element 20. As the method for producing the porous layer 80, the first dense layer 92, and the second dense layer 95, a gel injection molding method, dipping, or the like may be used in addition to screen printing and plasma spraying.

Next, the gas sensor 10 assembled with the sensor element 20 is manufactured. First, the sensor element 20 is inserted in the axial direction inside the through hole of the cylindrical body 41, and the insulator 44a, the dust 45a, the insulator 44b, the dust 45b, the insulator 44c, and the metal ring 46 are arranged in this order between the inner circumferential surface of the cylindrical body 41 and the sensor element 20. Next, the metal ring 46 is pressed to compress the green compacts 45a and 45b, and in this state, the reduced diameter portions 43c and 43d are formed, thereby producing the element sealing body 40 and sealing the space between the inner peripheral surface of the cylindrical body 41 and the sensor element 20. Thereafter, the protective cover 30 is welded to the element sealing body 40, and the nut 47 is attached to obtain the assembly 15. Then, the lead 55 passing through the rubber stopper 57 and the connector 50 connected thereto are prepared, and the connector 50 is connected to the rear end side of the sensor element 20. Thereafter, the outer cylinder 48 is welded and fixed to the metallic shell 42, thereby obtaining the gas sensor 10.

Here, when the element body 60, the first dense layer 92, and the second dense layer 95 are produced by forming the unfired element body and the unfired dense layer and then firing them as described above, the length Le of the first dense layer 92 and the second dense layer 95 is preferably 20mm or less. The shrinkage rates of the unfired element body and the unfired dense layer at the time of firing may be different, and if the length Le is too long, the sensor element 20 may be warped by firing. If the length Le is 20mm or less, the warpage of the sensor element 20 during firing can be suppressed. The length Le of the first dense layer 92 and the second dense layer 95 is preferably 30% or less of the length in the longitudinal direction of the element main body 60. By satisfying this condition, the warping of the sensor element 20 during firing can be suppressed.

Next, an example of use of the gas sensor 10 configured as described above will be described below. In a state where the gas sensor 10 is attached to the pipe 58 as shown in fig. 1, when the gas to be measured flows through the pipe 58, the gas to be measured flows through the protection cover 30 and flows into the element chamber 33, and the distal end side of the sensor element 20 is exposed to the gas to be measured. When the gas to be measured passes through the porous layer 80, reaches the outer electrode 64, and reaches the inside of the sensor element 20 from the gas to be measured inlet 61, the detection unit 63 generates an electric signal corresponding to the NOx concentration in the gas to be measured as described above. The electric signal is taken out via the upper-side connector electrode 71 and the lower-side connector electrode 72, and the NOx concentration is detected based on the electric signal.

At this time, the gas to be measured may contain moisture, and this moisture may move in the porous layer 80 due to a capillary phenomenon. When the moisture reaches the exposed upper and lower connector electrodes 71 and 72, the upper and lower connector electrodes 71 and 72 may rust or corrode due to components such as water and sulfuric acid dissolved in water; or short circuit between adjacent electrodes of the upper-side connector electrode 71 and the lower-side connector electrode 72. However, in the present embodiment, even if the moisture in the gas to be measured moves to the rear end side of the element main body 60 within the porous layer 80 (particularly within the first inner porous layer 83 and within the second inner porous layer 84) due to the capillary phenomenon, the moisture reaches the first water intrusion prevention part 91 or the second water intrusion prevention part 94 before reaching the upper-side connector electrode 71 and the lower-side connector electrode 72. The first water intrusion prevention unit 91 further includes: the first dense layer 92 having a porosity of less than 10% and the first gap region 93, which is a space where no porous layer exists, are less likely to generate a capillary phenomenon in which water flows along the longitudinal direction of the element main body 60. Further, the length L in the longitudinal direction of the first water intrusion prevention part 91 is 0.5mm or more, and therefore, the passage of moisture through the first water intrusion prevention part 91 can be sufficiently suppressed. Thus, the first water intrusion prevention section 91 can prevent the moisture from passing through the inside of the first water intrusion prevention section 91 from the distal end side portion 83a side.

Further, when the overlapping distance W between the first water intrusion prevention section 91 and the insulator 44b is 0.5mm or more, it is possible to sufficiently prevent the moisture from passing through the interiors of the pressure powders 45a and 45b, bypassing the first water intrusion prevention section 91, and moving to the rear end side of the sensor element 20. For example, as a comparative example, the following is considered: as shown in fig. 7, the first water intrusion suppressing member 91 and the second water intrusion suppressing member 94 are disposed only at the same positions as the dust 45a in the longitudinal direction of the sensor element 20, and the repetition distance W is 0 mm. In fig. 7, the first water intrusion prevention unit 91 includes only the first dense layer 92, and the second water intrusion prevention unit 94 includes only the second dense layer 95. In this case, although the moisture cannot pass through the inside of the first water intrusion prevention portion 91, the dust body 45a has water absorption property, and therefore, the moisture can move inside the dust body 45 a. Therefore, the moisture may pass through the inside of the pressure powder 45a, and may bypass the first water intrusion prevention portion 91 and move to the rear end side of the first water intrusion prevention portion 91 (see thick arrows in fig. 7). In contrast, in the sensor element 20 of the present embodiment, the first water intrusion prevention section 91 is disposed as shown in fig. 6, and the repetition distance W is 0.5mm or more. In the portion (overlap portion) of the overlap distance W, the first water intrusion prevention portion 91 does not contact the dust compact 45a, and the insulator 44b is dense, so that the moisture hardly passes through the inside of the insulator 44b, and thus the moisture hardly detours as shown in fig. 7. Further, since the repetition distance W is 0.5mm or more, there is a region in which the water is suppressed from bypassing the first water intrusion suppression portion 91 over a sufficient length, the movement of water due to bypassing can be sufficiently suppressed.

Thus, the first water intrusion prevention section 91 prevents the moisture moving in the porous layer 80 (particularly the distal end side portion 83a) from passing through the first water intrusion prevention section 91, and also prevents the moisture from moving around the first water intrusion prevention section 91 via the green compacts 45a and 45 b. Therefore, in the gas sensor 10, the moisture can be suppressed from moving to the rear end side of the sensor element 20 with respect to the first water intrusion suppression portion 91 and reaching the upper side connector electrode 71. Therefore, in the sensor element 20, the occurrence of the above-described problem caused by the adhesion of water to the upper-side connector electrode 71 is suppressed.

Similarly, the overlapping distance W between the second water intrusion prevention part 94 and the insulator 44b is 0.5mm or more, so that the second water intrusion prevention part 94 prevents the moisture moving in the porous layer 80 (particularly the front end side portion 84a) from passing through the second water intrusion prevention part 94 and also prevents the moisture from moving around the second water intrusion prevention part 94 via the green compacts 45a and 45 b. Therefore, in the gas sensor 10, the moisture can be suppressed from moving to the rear end side of the sensor element 20 with respect to the second water intrusion suppression portion 94 and reaching the lower side connector electrode 72. Therefore, in the sensor element 20, the occurrence of the above-described problem caused by the adhesion of water to the lower-side connector electrode 72 is suppressed.

Here, the correspondence relationship between the components of the present embodiment and the components of the present invention is clarified. The sensor element 20 of the present embodiment corresponds to the sensor element of the present invention, the cylindrical body 41 corresponds to a cylindrical body, the dust bodies 45a and 45b correspond to dust bodies, the insulators 44a to 44c correspond to dense bodies, the element main body 60 corresponds to an element main body, the detection section 63 corresponds to a detection section, the connector electrodes 71a to 71d and 72a to 72d correspond to connector electrodes, respectively, the first surface 60a and the second surface 60b correspond to side surfaces on which the connector electrodes are arranged, the porous layer 80 corresponds to a porous layer, and the first water intrusion suppression section 91 and the second water intrusion suppression section 94 correspond to a water intrusion suppression section, respectively. The outer lead 75 corresponds to an outer lead portion, the outer electrode 64 corresponds to an outer electrode, the first surface 60a corresponds to a first side surface, and the second surface 60b corresponds to a second side surface.

According to the sensor element 20 of the present embodiment described in detail above, since the first water intrusion suppressing portions 91 are arranged on any one side surface (here, the first surface 60a) of the 1 or more side surfaces of the element main body 60, it is possible to suppress the moisture from moving to the rear end side of the sensor element 20 than the first water intrusion suppressing portions 91 and reaching the upper side connector electrodes 71a to 71 d. Similarly, in the sensor element 20, the second water intrusion prevention section 94 is arranged on any one side surface (here, the second surface 60b) of the 1 or more side surfaces of the element main body 60, and therefore, it is also possible to prevent the moisture from moving to the rear end side of the sensor element 20 than the second water intrusion prevention section 94 and reaching the lower side connector electrodes 72a to 72 d.

Further, the length Le of the first dense layer 92 and the second dense layer 95 is 0.5mm or more, and therefore, in the first water intrusion prevention section 91 and the second water intrusion prevention section 94, the passage of water through the water intrusion prevention section 90 in the longitudinal direction can be sufficiently suppressed only by the portions of the first dense layer 92 and the second dense layer 95. Further, the length Le of the first dense layer 92 and the second dense layer 95 is 20mm or less, and thus warpage of the sensor element 20 due to a difference in the shrinkage rate between the unfired element body and the unfired dense layer at the time of firing can be suppressed. Further, the length Le of the first dense layer 92 and the second dense layer 95 is 30% or less of the length of the element main body 60 in the longitudinal direction, and thus warpage of the sensor element 20 can be suppressed.

Since the length Lg of the first and second gap regions 93 and 96 is 1mm or less and is thus small, the exposed portions of the side surfaces (here, the first and second surfaces 60a and 60b) of the element main body 60 (the portions not covered with the porous layer 80 and the first and second dense layers 92 and 95) can be reduced.

The sensor element 20 includes an outer lead 75, and the outer lead 75 is disposed on a side surface (here, the first surface 60a) on which the upper connector electrode 71 is disposed, and electrically connects any one of the plurality of electrodes of the detection section 63 (here, the outer electrode 64) to the upper connector electrode 71 b. The porous layer 80 (particularly, the first inner porous layer 83) covers at least a part of the outer lead 75. Therefore, at least a part of the outer lead 75 can be protected by the porous layer 80. In the case where the outer lead 75 is protected by the porous layer 80, the porous layer (here, the first inner porous layer 83) is likely to exist at a position close to the lower connector electrode 72b, and therefore, it is important to suppress the moisture from reaching the lower connector electrode 72b through the first inner porous layer 83 by the first water intrusion suppression portion 91.

The present invention is not limited to the above embodiments, and can be implemented in various forms as long as the technical scope of the present invention is maintained.

For example, although the first water intrusion prevention unit 91 includes the first dense layer 92 and the first gap region 93 in the above embodiment, the first water intrusion prevention unit 91 may include at least the first dense layer 92. That is, the first water intrusion prevention part 91 may not include the first gap region 93. In other words, the length Lg of the first water intrusion prevention part 91 may be 0 mm. By not providing the first water intrusion prevention part 91 with the first gap region 93, the exposed portion of the first surface 60a (the portion not covered with the porous layer 80 and the first dense layer 92) can be further reduced. The same applies to the second water intrusion prevention unit 94.

In the above embodiment, the first water intrusion prevention section 91 divides the first inner porous layer 83 into the front end side portion 83a and the rear end side portion 83b along the longitudinal direction, but is not limited thereto. The first water intrusion prevention part 91 may be located further to the rear end side than the porous layer 80. For example, in the above embodiment, the first inner porous layer 83 may not include the rear end side portion 83 b. In this case, a portion provided with the rear end side portion 83b in fig. 4 is also included in a part of the first gap region 93. The second water intrusion prevention section 94 may be located on the rear end side of the porous layer 80 without dividing the second inner porous layer 84 in the same manner.

In the above embodiment, the first dense layer 92 is disposed adjacent to the front of the first gap region 93, but the first dense layer 92 may be disposed adjacent to the rear of the first gap region 93. The same applies to the second water intrusion prevention unit 94.

In the above-described embodiment, the gas sensor 10 includes 3 insulators (insulators 44a to 44c) and 2 green compacts ( green compacts 45a and 45b), but the number of the insulators and the green compacts is not limited to this, and may be 1 or more. In the above-described embodiment, the insulators 44a to 44c are given as examples of the dense body, but the dense body is not limited thereto. One or more of the insulators 44a to 44c may be dense bodies having a porosity of less than 10%. In the case of a dense body having a porosity of less than 10%, the water is less likely to pass through the inside, and therefore, the movement of the water by bypassing the water intrusion prevention portion 90 can be sufficiently suppressed. The porosity of the compact may be less than 5%. The porosity of the dense body is a value derived using SEM in the same manner as the porosity of the inner porous layer 81.

In the above-described embodiment, the first water intrusion prevention part 91 and the second water intrusion prevention part 94 are respectively disposed at positions overlapping with the insulator 44b in the front-rear direction, but the present invention is not limited thereto. For example, the first water intrusion prevention part 91 and the second water intrusion prevention part 94 may be disposed at positions overlapping with the insulator 44a or the insulator 44c in the front-rear direction. However, if the first water intrusion prevention section 91 overlaps only the insulator (insulator 44a in this case) on the leading end side among the plurality of insulators included in the gas sensor 10, there is a possibility that the moisture in the gas state in the gas to be measured may move to the rear end side of the sensor element 20 with respect to the first water intrusion prevention section 91 through the gap between the first water intrusion prevention section 91 and the insulator 44 a. Further, when the first water intrusion prevention section 91 overlaps only the insulator on the rearmost end side (insulator 44c in this case) among the plurality of insulators included in the gas sensor 10, the first water intrusion prevention section 91 and the upper side connector electrode 71 are relatively close to each other. In this case, the first water intrusion prevention section 91 can prevent the moisture of the liquid from moving to the upper side connector electrode 71 due to the capillary phenomenon, but a part of the moisture of the liquid may be vaporized on the front side of the first water intrusion prevention section 91, pass through the gap between the first water intrusion prevention section 91 and the insulator 44c, move to the rear end side of the sensor element 20 than the first water intrusion prevention section 91, and reach the upper side connector electrode 71. Therefore, when the number of insulators provided in the gas sensor 10 is 2 or more, the first water intrusion prevention portion 91 preferably overlaps with the insulator other than the insulator on the most distal end side. When the number of insulators included in the gas sensor 10 is 3 or more, the first water intrusion prevention portion 91 preferably overlaps with other insulators except for the insulator on the foremost end side and the insulator on the rearmost end side.

In the above embodiment, the sensor element 20 may not include the second inner porous layer 84, and the second surface 60b may not be covered with the porous layer 80. In this case, the sensor element 20 may not include the second water intrusion prevention unit 94. The water intrusion prevention portion may be provided on at least 1 of the side surfaces (the first surface 60a and the second surface 60b in the embodiment) on which the connector electrode and the porous protection layer are provided, among the side surfaces (the first surface 60a to the fourth surface 60d in the embodiment) provided on the element main body. In this way, the water can be prevented from reaching the connector electrode at least at the side surface where the water intrusion prevention portion is disposed.

In the above-described embodiment, the first inner porous layer 83 covers the region from the front end to the rear end of the first surface 60a except for the region where the first water intrusion prevention portion 91 and the upper connector electrode 71 are present, but the present invention is not limited to this. For example, the first inner porous layer 83 may cover a region from the front end of the first surface 60a to the end on the front end side of the upper connector electrodes 71a to 71d, except for a region where the first water intrusion prevention portion 91 is present. Alternatively, the first inner porous layer 83 may cover at least a region of the first surface 60a from the front end to the rear of the first water intrusion prevention part 91 except for a region where the first water intrusion prevention part 91 exists. The same applies to the second inner porous layer 84.

In the above embodiment, the element main body 60 has a rectangular parallelepiped shape, but is not limited thereto. For example, the element body 60 may be cylindrical or cylindrical. In this case, the element main body 60 has 1 side.