阅读说明：本技术 气体传感器 (Gas sensor ) 是由 中江诚 今田将太 于 2018-04-16 设计创作，主要内容包括：气体传感器具备传感器元件(2),传感器元件(2)具有：有底筒状的固体电解质体(3)；设置于固体电解质体(3)的外侧面的检测电极(4A)；以及设置于固体电解质体(3)的内侧面的基准电极。传感器元件(2)的检测电极(4A)具有：在轴向(L)的前端侧(L1)的位置设置的检测电极部(41)；在轴向(L)的基端侧(L2)的位置设置的装设电极部(43)；以及在将检测电极部(41)和装设电极部(43)相连的位置设置的导体电极部(42)。在固体电解质体(3)的筒部(31)与装设电极部(43)及导体电极部(42)之间设有绝缘层(22)。(The gas sensor is provided with a sensor element (2), wherein the sensor element (2) is provided with: a solid electrolyte body (3) having a cylindrical shape with a bottom; a detection electrode (4A) provided on the outer surface of the solid electrolyte body (3); and a reference electrode provided on the inner surface of the solid electrolyte body (3). A detection electrode (4A) of a sensor element (2) has: a detection electrode unit (41) provided at a position on the front end side (L1) in the axial direction (L); an attachment electrode section (43) provided at a position on the proximal end side (L2) in the axial direction (L); and a conductor electrode portion (42) provided at a position where the detection electrode portion (41) and the mounting electrode portion (43) are connected. An insulating layer (22) is provided between the cylindrical portion (31) of the solid electrolyte body (3) and the mounting electrode portion (43) and the conductor electrode portion (42).)

1. A gas sensor (1) is provided with a sensor element (2), and the sensor element (2) is provided with:

A solid electrolyte body (3) having a cylindrical shape with a bottom, wherein the front end of the cylindrical portion (31) is closed by a curved bottom (32);

A detection electrode (4A) which is provided at least on the outer surface (301) of the cylindrical portion and is exposed to a detection gas (G) that is guided to the outside of the solid electrolyte body; and

A reference electrode (4B) which is provided at least on the inner surface (302) of the cylindrical portion and is exposed to a reference gas (G) that is guided to the inside of the solid electrolyte body;

The gas sensor is characterized in that it is,

The detection electrode has:

A detection electrode unit (41) that is provided on the entire circumference or a part of the circumference (C) around the central axis (O) of the cylindrical portion, at a position on the tip side in the axial direction (L) along the central axis (O);

An installation electrode part (43) which is arranged on the whole circumference or a part of the circumference at the position of the axial base end side and contacts with a terminal piece (71) arranged on the outer circumference of the cylinder part; and

a conductor electrode portion (42) which is provided at a position connecting the detection electrode portion and the mounting electrode portion in a part of the circumferential direction and which is formed in a narrower range in the circumferential direction than the mounting electrode portion;

An insulating layer (22) is provided between the cylindrical portion of the solid electrolyte body and the mounting electrode portion and the conductor electrode portion, and the insulating layer (22) insulates the solid electrolyte body from the mounting electrode portion and the conductor electrode portion.

2. the gas sensor according to claim 1,

The gas sensor is configured to detect an electromotive force generated between the detection electrode and the reference electrode via the solid electrolyte body, based on a difference in oxygen concentration between the reference gas in contact with the reference electrode and the detection gas in contact with the detection electrode.

3. The gas sensor according to claim 1,

A diffusion barrier layer (21) is provided on an outer surface of the cylindrical portion of the solid electrolyte body, the diffusion barrier layer (21) covering at least the entire detection electrode portion of the detection electrode to restrict diffusion of the detection gas,

the gas sensor is configured to detect a critical current generated between the detection electrode and the reference electrode via the solid electrolyte body in a state where a voltage is applied between the detection electrode and the reference electrode.

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

The insulating layer has a base end side end portion in the axial direction, which is provided closer to the base end side than the base end side end portion in the axial direction of the mounting electrode portion, is exposed on an outer side surface of the cylindrical portion, and has a tapered surface (221) whose thickness in a radial direction (R) with the center axis as a center decreases toward the base end side in the axial direction of the cylindrical portion so as to guide the terminal material mounted on the outer periphery of the cylindrical portion from the base end side in the axial direction of the cylindrical portion toward the front end side.

5. The gas sensor according to claim 4,

The angle of inclination of the tapered surface with respect to the central axis is 60 ℃ or less.

6. Gas sensor according to any one of claims 1 to 3,

An end portion (222) of the insulating layer on the base end side in the axial direction is continuously provided from an outer side surface of the cylinder portion to an end surface (311) on the base end side of the cylinder portion.

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

The minimum thickness of the insulating layer at a portion between the cylindrical portion and the mounting electrode portion and the conductor electrode portion is 4 μm or more.

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

The solid electrolyte body contains a zirconium oxide,

The reference electrode and the detection electrode contain a noble metal,

The insulating layer contains at least one of alumina, spinel, and insulating glass.

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

The gas sensor is disposed in an exhaust pipe (81) of an internal combustion engine (8) through which exhaust gas as the detection gas flows,

One catalyst (82A) or a plurality of catalysts (82A, 82B) arranged in the flow direction of the exhaust gas are arranged in the exhaust pipe,

The gas sensor is disposed on a downstream side of the at least one catalyst in a flow of the exhaust gas in the exhaust pipe.

Technical Field

The present invention relates to a gas sensor having a sensor element whose solid electrolyte body is provided with an electrode.

Background

A gas sensor disposed in an exhaust pipe of an internal combustion engine detects gas (measurement gas) using exhaust gas flowing in the exhaust pipe as the detection gas, using an oxygen concentration difference between the detection gas and a reference gas such as the atmosphere. The gas sensor has the following uses: the air-fuel ratio sensor is used as an oxygen sensor for detecting whether the air-fuel ratio of the internal combustion engine determined from the composition of the exhaust gas is on the fuel-rich side or the fuel-lean side with respect to the theoretical air-fuel ratio, and is used as an air-fuel ratio sensor for quantitatively detecting the air-fuel ratio of the internal combustion engine determined from the exhaust gas.

the gas sensor is a bottomed cylindrical sensor element in which electrodes are disposed on the inner surface and the outer surface of a bottomed cylindrical solid electrolyte body, or a plate-shaped sensor element in which electrodes are disposed on both surfaces of a plate-shaped solid electrolyte body. When the gas sensor is used as an oxygen sensor, an electromotive force generated between a pair of electrodes sandwiching a solid electrolyte body is detected from a difference in oxygen concentration between a detection gas and a reference gas. In the case where the gas sensor is used as an air-fuel ratio sensor, a voltage is applied between the pair of electrodes, and a current flowing between the pair of electrodes through the solid electrolyte body is detected based on the oxygen concentration of the detection gas.

In many cases, a detection electrode exposed to a detection gas in a bottomed cylindrical sensor element is formed in a shape having a detection portion formed over the entire circumference of a distal end portion of a solid electrolyte body and heated to a target temperature by a heating portion of a heater, and a conductor portion led out from the detection portion to a proximal end side. In addition, it is known that an insulating layer is provided between the conductor portion and the solid electrolyte body so that oxygen transfer through the solid electrolyte body occurs only in the detection portion.

As such a sensor element, for example, there is an oxygen sensor described in patent document 1. In this oxygen sensor, an insulating layer formed of an insulator is provided between the solid electrolyte body and the conductor portion of the detection electrode, and the area of the detection electrode that functions when gas detection is performed is defined.

Disclosure of Invention

the invention provides a gas sensor, which can prevent leakage current from generating between an electrode part of a detection electrode and a reference electrode, and improve gas detection precision.

One embodiment of the present invention is a gas sensor including a sensor element including: a solid electrolyte body having a cylindrical shape with a bottom, wherein a front end portion of the cylindrical portion is closed by a curved bottom; a detection electrode provided at least on an outer surface of the cylindrical portion and exposed to a detection gas guided to an outside of the solid electrolyte body; and a reference electrode provided at least on an inner surface of the cylindrical portion and exposed to a reference gas introduced to an inside of the solid electrolyte body; the detection electrode has: a detection electrode unit provided on the entire circumference or a part of the circumference around the central axis of the tube unit at a position on the axial distal side along the central axis; a mounting electrode portion which is provided on the entire circumference or a part of the circumference at a position on the proximal end side in the axial direction and which is in contact with a terminal member mounted on the outer circumference of the cylindrical portion; and a conductor electrode portion provided at a portion in the circumferential direction at a position where the detection electrode portion and the mounting electrode portion are connected, the formation range in the circumferential direction being narrower than that of the mounting electrode portion; an insulating layer is provided between the cylindrical portion of the solid electrolyte body and the mounting electrode portion and the conductor electrode portion, and the insulating layer insulates the solid electrolyte body from the mounting electrode portion and the conductor electrode portion.

Effects of the invention

In the gas sensor, the insulating layer is provided not only between the conductor electrode portion of the detection electrode and the solid electrolyte body, but also between the electrode portion and the solid electrolyte body, which is a portion of the detection electrode where the terminal material is attached. This can prevent the following: when the proximal portion of the sensor element is heated to a high temperature of 400 ℃ or higher, the solid electrolyte body is activated, and a leak current is generated between the mounting electrode portion of the detection electrode and the reference electrode due to the movement of oxygen in the reference gas that comes into contact with the proximal portion of the sensor element.

Therefore, in the case where the gas sensor is used as an air-fuel ratio sensor, when the base end side portion of the sensor element is exposed to a high temperature environment of 400 ℃ or higher, it is also possible to make the offset current not included in the output current as the sensor output in the vicinity of the theoretical air-fuel ratio. In addition, in the case where the gas sensor is used as an oxygen sensor, when the base end side portion of the sensor element is exposed to a high temperature environment of 400 ℃ or higher, it is also possible to make the error voltage not included in the output voltage as the sensor output.

therefore, according to the gas sensor described above, it is possible to prevent a leak current from occurring between the reference electrode and the electrode portion to which the detection electrode is attached, and to improve the accuracy of gas detection.

Note that, although the parenthesized reference numerals of the respective components shown in the embodiment of the present invention indicate the correspondence with the reference numerals in the drawings of the embodiment, the respective components are not limited to the contents of the embodiment.

Drawings

the objects, features, advantages, and the like of the present invention will become more apparent from the following detailed description with reference to the accompanying drawings. The drawings of the invention are shown below.

Fig. 1 is an explanatory view showing a cross section of a gas sensor according to embodiment 1.

Fig. 2 is an explanatory diagram illustrating a state of formation of the detection electrode of the sensor element according to embodiment 1.

Fig. 3 is an explanatory view showing a cross section of the distal end portion of the sensor element according to embodiment 1.

Fig. 4 is an explanatory diagram showing a state in which a gas sensor is disposed in an exhaust pipe of an internal combustion engine according to embodiment 1.

Fig. 5 is an explanatory view showing a cross section of a distal end portion of a sensor element used in another detection method according to embodiment 1.

Fig. 6 is an explanatory diagram showing a state of formation of the detection electrode of another sensor element according to embodiment 1.

Fig. 7 is an explanatory view showing a cross section of the tip portion of another sensor element according to embodiment 1.

Fig. 8 is a perspective view showing a state in which a terminal member is attached to a sensor element according to embodiment 2.

fig. 9 is an explanatory view showing a cross section of embodiment 2 in which a terminal member is attached to a sensor element in an enlarged manner.

Fig. 10 is an explanatory view showing a cross section of embodiment 3 with a terminal member attached to the sensor element in an enlarged manner.

Fig. 11 is a graph showing the relationship between the temperature of the sensor element and the amount of output deviation of the air-fuel ratio in test 1.

Fig. 12 is a graph showing the relationship between the thickness of the insulating layer and the amount of output deviation of the air-fuel ratio in test 2.

Fig. 13 is a graph showing the relationship between the temperature of the sensor element and the offset amount of the output voltage in test 3.

fig. 14 is a graph showing the relationship between the thickness of the insulating layer and the amount of deviation of the output voltage in test 4.

Fig. 15 is a graph showing the relationship between the inclination angle of the tapered surface and the number of defects in the insulating layer in the confirmation test 5.

Detailed Description

preferred embodiments of the gas sensor described above will be described with reference to the drawings.

< embodiment 1>

As shown in fig. 1 to 3, a gas sensor 1 of the present embodiment includes a sensor element 2, and the sensor element 2 includes a bottomed cylindrical solid electrolyte body 3, a detection electrode 4A, and a reference electrode 4B. The solid electrolyte body 3 has ion conductivity at an activation temperature, and has a cylindrical tube 31 and a curved bottom 32 that closes a distal end of the tube 31. The detection electrode 4A is an electrode that is provided on the outer surface 301 of the cylindrical portion 31 and is exposed to the detection gas G that is guided to the outside of the solid electrolyte body 3. The reference electrode 4B is provided on the inner surface 302 of the cylindrical portion 31 and the bottom portion 32, and is an electrode exposed to the reference gas a guided to the inside of the solid electrolyte body 3.

The detection electrode 4A has a detection electrode portion 41, an attachment electrode portion 43, and a conductor electrode portion 42. As shown in fig. 2, the detection electrode portion 41 is provided on the entire circumference of the circumferential direction C around the central axis O at a position on the tip side L in the axial direction L along the central axis O of the cylindrical portion 31. As shown in fig. 1 and 2, the mounting electrode portion 43 is provided at a portion in the circumferential direction C at a position on the proximal end side L2 in the axial direction L, and contacts the terminal member 71 mounted on the outer periphery of the cylindrical portion 31. As shown in fig. 2, the conductor electrode portion 42 is provided at a portion in the circumferential direction C at a position where the detection electrode portion 41 is connected to the mounting electrode portion 43, and the formation range in the circumferential direction C is narrower than that of the mounting electrode portion 43.

As shown in fig. 2 and 3, an insulating layer 22 is provided between the cylindrical portion 31 of the solid electrolyte body 3 and the mounting electrode portion 43 and the conductor electrode portion 42, and the insulating layer 22 insulates the solid electrolyte body 3 from the mounting electrode portion 43 and the conductor electrode portion 42. In fig. 2, 5, 6, and 8, the detection electrode 4A is shown with hatching, and the insulating layer 22 is shown with grid hatching at the exposed portion of the surface, for ease of understanding.

As shown in fig. 8, in the sensor element 2 and the gas sensor 1 according to embodiments 1 and 2, a direction along the central axis O of the sensor element 2 is referred to as an axial direction L, a direction around the central axis O of the sensor element 2 is referred to as a circumferential direction C, and a direction radially extending from the central axis O of the sensor element 2 is referred to as a radial direction R. In the sensor element 2 and the gas sensor 1, the side on which the bottom portion 32 of the sensor element 2 is provided is referred to as a tip side L1, and the side opposite to the tip side L1 is referred to as a base side L2.

The gas sensor 1 of the present embodiment will be described in detail below.

(internal combustion engine 8)

As shown in fig. 4, the gas sensor 1 is disposed in an exhaust pipe 81 through which exhaust gas discharged from an internal combustion engine (engine) 8 of a vehicle flows. The gas sensor 1 detects gas using exhaust gas flowing through the exhaust pipe 81 as detection gas G and using atmospheric air as reference gas a. The gas sensor 1 of the present embodiment is used as an air-fuel ratio sensor for determining an air-fuel ratio of the internal combustion engine 8 determined from the composition of the exhaust gas. The air-fuel ratio sensor can detect the air-fuel ratio quantitatively and continuously from a fuel-rich state in which the ratio of fuel to air is larger than the stoichiometric air-fuel ratio to a fuel-lean state in which the ratio of fuel to air is smaller than the stoichiometric air-fuel ratio.

As shown in fig. 3, in the air-fuel ratio sensor, a predetermined voltage indicating the critical current characteristic is applied between a detection electrode 4A provided on one surface of the solid electrolyte body 3 and exposed to the detection gas G and a reference electrode 4B provided on the other surface of the solid electrolyte body 3 and exposed to the reference gas a by a voltage application circuit 11. In addition, in the state where the voltage is applied, the critical current generated between the detection electrode 4A and the reference electrode 4B via the solid electrolyte body 3 is detected by the current detection circuit 12. In other words, when the oxygen concentration of the exhaust gas as the detection gas G changes, oxygen ions (O) between the detection electrode 4A and the reference electrode 4B are detected^2-) The amount and direction of movement of the fuel injector are changed, and the air-fuel ratio between the fuel-rich side and the fuel-lean side is quantitatively detected within a predetermined detection range. Further, as shown in fig. 1, a voltage application circuit 11 and a current detection circuit 12 are built in a control device 10 such as a sensor control unit.

In the air-fuel ratio sensor, by applying a voltage between the detection electrode 4A and the reference electrode 4B, when the air-fuel ratio is on the lean side, oxygen ions (O) are generated via the solid electrolyte body 3^2-) Moves from the detection electrode 4A to the reference electrode 4B. On the other hand, when the air-fuel ratio is on the fuel-rich side, the unburned gas chemically reacts at the detection electrode 4A, and then oxygen ions (O) pass through the solid electrolyte 3^2-) Moves from the reference electrode 4B to the detection electrode 4A.

As shown in fig. 5, the gas sensor 1 can also be used as an oxygen sensor that determines whether the air-fuel ratio of the internal combustion engine 8, which is determined from the composition of the exhaust gas, is ON the fuel-rich side or the fuel-lean side by a switch (ON-OFF). The oxygen sensor detects an electromotive force generated between the detection electrode 4A and the reference electrode 4B via the solid electrolyte body 3 based on a difference between the oxygen concentration of the atmosphere as the reference gas a in contact with the reference electrode 4B and the oxygen concentration of the exhaust gas as the detection gas G in contact with the detection electrode 4A by the electromotive force detection circuit 13. Further, the electromotive force detection circuit 13 is formed in the sensor control component. In addition, the oxygen sensor can also quantitatively detect the oxygen concentration of the exhaust gas from the electromotive force generated between the detection electrode 4A and the reference electrode 4B.

The gas sensor 1 is used to maintain the air-fuel ratio of the internal combustion engine 8 at a value near the theoretical air-fuel ratio at which the catalytic activity of the three-way catalyst disposed in the exhaust pipe 81 can be effectively exhibited. The gas sensor 1 may be disposed at a position on the upstream side or the downstream side of the flow of the exhaust gas with respect to the position of the three-way catalyst disposed in the exhaust pipe 81. In particular, the gas sensor 1 of the present embodiment can be used with the exhaust pipe 81 disposed at a downstream side position where the temperature of the exhaust gas is lower.

As shown in fig. 4, two catalysts 82A, 82B arranged in the flow direction of the exhaust gas are disposed in the exhaust pipe 81 of the present embodiment. The two catalysts 82A, 82B include an upstream side catalyst 82A (also referred to as S/c (start converter) catalyst) located on the upstream side, and a downstream side catalyst 82B (also referred to as U/f (under floor) catalyst) located on the downstream side of the upstream side catalyst 82A. The gas sensor 1 of the present embodiment is disposed at a position downstream of the upstream catalyst 82A in the exhaust pipe 81 in the flow of the exhaust gas, and at a position upstream of the downstream catalyst 82B in the exhaust pipe 81 in the flow of the exhaust gas. In other words, the gas sensor 1 of the present embodiment is disposed at a position between the upstream side catalyst 82A and the downstream side catalyst 82B in the direction of the flow of the exhaust gas in the exhaust pipe 81.

Further, another gas sensor 1A is disposed in the exhaust pipe 81 on the upstream side of the upstream catalyst 82A. The other gas sensor functions as an air-fuel ratio sensor. Then, the air-fuel ratio of the exhaust gas is detected using the two gas sensors 1, 1A, and the ECU (engine control unit) adjusts the opening degree of the fuel injection valve in the intake pipe by using the air-fuel ratios received from the two gas sensors 1, 1A, thereby performing air-fuel ratio control of the internal combustion engine 8.

The gas sensor 1 of the present embodiment may be disposed upstream of the upstream catalyst 82A in the exhaust pipe 81. In addition, normally, an air-fuel ratio sensor is disposed in the exhaust pipe 81 on the upstream side of the upstream-side catalyst 82A, and an oxygen sensor is disposed on the downstream side of the upstream-side catalyst 82A.

In particular, if the gas sensor 1 is disposed at a position further downstream in the exhaust pipe 81, the temperature of the exhaust gas contacting the gas sensor 1 is lower, and the condensed water easily collides with the gas sensor 1. The sensor element 2 of the present embodiment employs the solid electrolyte body 3 having a bottomed cylindrical shape (cup shape), and effectively prevents water-stained breakage due to condensed water present in the exhaust pipe 81.

(sensor element 2)

As shown in fig. 2 and 3, the solid electrolyte body 3 of the sensor element 2 is composed of stabilized zirconia or partially stabilized zirconia in which zirconia is partially substituted with a rare earth metal element or an alkaline earth metal element, and contains zirconia as a main component. The solid electrolyte body 3 can be made of yttria-stabilized zirconia or yttria-partially-stabilized zirconia. The solid electrolyte 3 has oxygen ions (O) at a predetermined activation temperature^2-) Conductive ion conductivity. The detection electrode 4A and the reference electrode 4B contain platinum as a noble metal that exhibits catalytic activity with respect to oxygen.

The bottom 32 of the solid electrolyte body 3 is formed in a hemispherical shape, and the cylindrical portion 31 of the solid electrolyte body 3 is formed in a cylindrical shape. An opening 33 through which the reference gas a can flow into the solid electrolyte body 3 is formed at a position opposite to the bottom portion 32 in the axial direction L of the solid electrolyte body 3. The outer diameter of each portion in the axial direction L of the cylindrical portion 31 is appropriately changed in consideration of attachment to the housing 61.

a protective layer 21 made of a ceramic porous body is provided at the distal end portion of the sensor element 2 so as to cover at least the entire detection electrode portion 41 of the detection electrode 4A. The protective layer 21 in the air-fuel ratio sensor of the present embodiment has a function as a diffusion barrier layer, and restricts diffusion of the exhaust gas as the detection gas G. When a predetermined voltage is applied between the detection electrode 4A and the reference electrode 4B, the flow rate of the detection gas G passing through the protective layer 21 is restricted, and a sensor output corresponding to the oxygen concentration in the detection gas G is obtained. The protective layer 21 also has a function of preventing poisoning and wetting of the detection electrode 4A. Further, a porous layer for preventing poisoning and wetting of the detection electrode 4A may be provided outside the protective layer 21 as a diffusion barrier layer.

In addition, in the case where the gas sensor 1 is used as an oxygen sensor, the protective layer 21 mainly has a function of preventing poisoning and water staining of the detection electrode 4A. In this case, the protective layer 21 may be formed of a plurality of layers having different porosities, different compositions, and the like of the porous body.

As shown in fig. 1 and 3, the reference electrode 4B is provided on the entire inner surface 302 of the solid electrolyte body 3. The inner terminal 72 is mounted on the proximal end side L2 of the inner surface 302 of the solid electrolyte body 3 in contact with the proximal end side L2 of the reference electrode 4B. Since the gas sensor 1 of the present embodiment is used as an air-fuel ratio sensor, the reference electrode 4B and the inner terminal member 72 are on the positive side and the detection electrode 4A and the terminal member 71 are on the negative side in accordance with the voltage applied between the reference electrode 4B and the detection electrode 4A.

The reference electrode 4B can be locally electrically polarized in the same manner as the detection electrode 4A, and includes a detection electrode portion located on the distal end side L1, a mounting electrode portion located on the proximal end side L2, and a conductor electrode portion connecting the detection electrode portion and the mounting electrode portion.

The detection electrode portion 41 of the detection electrode 4A is a portion of the detection electrode 4A where gas detection such as detection of an air-fuel ratio is substantially performed. In other words, only the detection electrode portion 41 of the detection electrode 4A is directly provided on the outer surface 301 of the solid electrolyte body 3 without interposing the insulating layer 22 therebetween. In the sensor element 2, the area of the detection electrode portion 41 is defined in order to stabilize the accuracy of gas detection, in other words, in order to reduce variations in the output of the gas sensor 1. The detection electrode portion 41 is heated to a target temperature by a heater 5, and the heater 5 is disposed inside the solid electrolyte body 3 of the sensor element 2.

the conductor electrode portion 42 of the detection electrode 4A is formed at one location in the circumferential direction C of the solid electrolyte body 3. The conductor electrode portion 42 is formed parallel to the central axis O and the axial direction L of the cylindrical portion 31 of the solid electrolyte body 3. In other words, both ends of the conductor electrode portion 42 in the circumferential direction C are parallel to the axial direction L.

The mounting electrode portion 43 of the detection electrode 4A is formed toward the circumferential direction C at a position on the base end side L2 of the outer surface 301 of the solid electrolyte body 3. The mounting electrode portion 43 of the present embodiment is formed only in a part of the outer surface 301 of the solid electrolyte body 3 in the circumferential direction C.

As shown in fig. 3, the insulating layer 22 provided on the outer surface 301 of the sensor element 2 is not provided between the cylindrical portion 31 and the detection electrode portion 41. The insulating layer 22 is provided on the entire bottom portion 32, the entire portion between the cylindrical portion 31 and the conductor electrode portion 42, and the entire portion between the cylindrical portion 31 and the mounting electrode portion 43. The mounting electrode portion 43 of the present embodiment is not provided to the base end position of the outer side surface 301 of the sensor element 2. The mounting electrode portion 43 may be provided to the base end position of the outer side surface 301 of the sensor element 2.

in the present embodiment, the insulating layer 22 is not provided at the formation position of the detection electrode portion 41, and the insulating layer 22 is provided at the bottom portion 32 and the proximal end side of the detection electrode portion 41. The detection electrode 4A is continuously provided from the detection electrode portion 41 to the outer surface of the insulating layer 22 provided on the bottom portion 32. This enables the electrode 4A to be easily formed. The bottom electrode portion 411 provided on the outer surface of the insulating layer 22 of the bottom portion 32 does not function as a hole-making oxygen ion (O) due to the presence of the insulating layer 22^2-) The conductive electrodes function.

As shown in fig. 6, the mounting electrode portion 43 of the detection electrode 4A may be formed over the entire circumference in the circumferential direction C. The detection electrode portion 41 of the detection electrode 4A does not necessarily have to be formed over the entire circumference of the circumferential direction C. As shown in fig. 6 and 7, the insulating layer 22 may be provided only on the proximal end side of the detection electrode portion 41, and may not be provided on the outer surface 301 of the bottom portion 32.

As shown in fig. 3, the detection electrode 4A is formed by plating an electrode material on the outer surface 301 of the solid electrolyte body 3, and the reference electrode 4B is formed by plating an electrode material on the inner surface 302 of the solid electrolyte body 3. The insulating layer 22 is formed by applying a paste of an insulating material to the outer surface 301 of the solid electrolyte body 3 and sintering the paste together with the solid electrolyte body 3. In forming the insulating layer 22, the portion of the solid electrolyte body 3 on the outer surface 301 where the detection electrode portion 41 is formed is covered with a tape member or the like. In this state, the paste is applied and the tape member and the like are peeled off, so that the insulating layer 22 can be prevented from being formed in the covered portion. The insulating layer 22 is made of a material containing aluminum oxide (Al)₂O₃) Spinel (MgAl)₂O₄) And at least one insulating material selected from insulating glass. This insulating material is generally used for the gas sensor 1, and has a high specific resistance, so that a sufficient insulating effect can be obtained.

the insulating layer 22 of the present embodiment is formed on the outer surface 301 of the solid electrolyte body 3 so as to have a thickness as uniform as possible. The minimum thickness of the insulating layer 22 at the positions between the cylindrical portion 31 and the conductor electrode portion 42 and between the cylindrical portion 31 and the mounting electrode portion 43 is 4 μm or more. The minimum thickness means the thickness of the portion having the smallest thickness. If the minimum thickness of the insulating layer 22 is less than 4 μm, a sufficient insulating effect may not be obtained. From the viewpoint of manufacturing, the thickness of the insulating layer 22 can be set to, for example, 10 μm or less.

(Heater 5)

As shown in fig. 3, a heater 5 for heating the solid electrolyte body 3 is disposed inside the solid electrolyte body 3 of the sensor element 2. The heater 5 includes ceramic substrates 51A and 51B and a heating element 52 including a conductor provided on the substrate 51B. A heat generating portion 521 having a minimum cross-sectional area and generating heat by joule heat when the heat generating element 5 is energized is formed at the distal end portion of the heat generating element 52.

The heat generating portion 521 is formed in a serpentine shape in the axial direction L at the distal end portion of the heat generating element 52. The heat generating portion 521 is disposed at a position facing the inner peripheral side of the detection electrode portion 41 of the detection electrode 4A, and heats the solid electrolyte body 3, the reference electrode 4B, and the detection electrode 4A so that the detection electrode portion 41 reaches a target temperature. The heater 5 is formed by winding a sheet-like base material 51B provided with a heating element 52 around a base material 51A as a mandrel.

(other structures of the gas sensor 1)

As shown in fig. 1, the gas sensor 1 includes, in addition to the sensor element 2 and the heater 5: a case 61 that holds the sensor element 2, a tip side cover 62 provided at a portion of the tip side L1 of the case 61, a base end side cover 63 provided at a portion of the base end side L2 of the case 61, a terminal piece 71 provided at an outer side surface 301 of a portion of the base end side L2 of the sensor element 2, an inner terminal piece 72 provided at an inner side surface 302 of a portion of the base end side L2 of the sensor element 2, and the like.

(case 61)

As shown in fig. 1, in order to hold the sensor element 2, an insertion hole 611 penetrating in the axial direction L is formed in the housing 61. The insertion hole 611 includes a small-diameter hole 612 located on a distal end side L1 in the axial direction L, and a large-diameter hole 613 located on a proximal end side L2 in the axial direction L and having a larger diameter than the small-diameter hole 612. The sensor element 2 is inserted into the small-diameter hole portion 612 and the large-diameter hole portion 613 of the insertion hole 611, and is held by a seal 64 such as a sleeve or a talc powder disposed in a gap between the sensor element 2 and the large-diameter hole portion 613.

The flange portion 34, which is the portion of the sensor element 2 having the largest outer diameter, is locked to the end of the small-diameter hole portion 612, thereby preventing the sensor element 2 from coming out of the insertion hole 611 toward the distal end side L1. A caulking portion 615 bent inward is formed at a portion of the housing 61 on the proximal end side L2 in the axial direction L. The seal 64 is compressed in the axial direction L between the caulking portion 615 and the flange portion 34, and the sensor element 2 is held by the housing 61. The portion of the sensor element 2 on the distal end side L1, in particular, the portion where the inner detection unit 41 and the conductor electrode unit 42 are formed, is disposed so as to protrude from the housing 61 toward the distal end side L1 in the axial direction L.

(front cover 62 and base cover 63)

As shown in fig. 1, a front end side cover 62 for protecting the sensor element 2 is attached to a portion of the front end side L1 in the axial direction L of the housing 61 so as to cover a portion of the sensor element 2 protruding from the housing 61 in the front end direction L1. The front end cover 62 is disposed in the exhaust pipe 81. The front end side cover 62 is formed with a gas passage hole 621 through which the detection gas G passes. The front end side cover 62 may have a double structure or a single structure. The exhaust gas as the detection gas G flowing from the gas passage hole 621 of the front end side cover 62 into the front end side cover 62 passes through the protective layer 21 of the sensor element 2 and is guided to the detection electrode 4A.

A base end cover 63 is attached to a portion of the base end side L2 of the housing 61 in the axial direction L. The base end side cover 63 is disposed outside the exhaust pipe 81. An introduction hole 631 is formed in a part of the base end cover 63, and the introduction hole 631 is used to introduce atmospheric air as the reference gas a into the base end cover 63. The introduction hole 631 is provided with a filter 632 that passes gas without passing liquid. The reference gas a introduced from the introduction hole 631 into the base end side cover 63 passes through the gap in the base end side cover 63 and is guided to the reference electrode 4B on the inner surface 302 of the sensor element 2.

As shown in fig. 1, a terminal member 71 that comes into contact with the mounting electrode portion 43 of the detection electrode 4A is mounted on the outer surface 301 of the base end side L2 of the sensor element 2. Further, the inner terminal piece 72 that contacts the portion of the reference electrode 4B on the base end side L2 is attached to the inner surface 302 of the portion of the sensor element 2 on the base end side L2. A lead wire 65 is attached to the terminal 71 and the inner terminal 72, and the lead wire 65 electrically connects the detection electrode 4A and the reference electrode 4B of the sensor element 2 to the external control device 10. The lead wire 65 is held by a bush 66 disposed in the proximal end side cover 63.

(Effect)

In the gas sensor 1 of the present embodiment, the insulating layer 22 is provided not only between the conductor electrode portion 42 of the detection electrode 4A and the cylindrical portion 31 of the solid electrolyte body 3, but also between the mounting electrode portion 43, which is a portion of the detection electrode 4A where the terminal material 71 is mounted, and the cylindrical portion 31 of the solid electrolyte body 3. Thus, when the portion of the base end side L2 of the sensor element 2 is heated to a high temperature of 400 ℃.

Therefore, in the case where the gas sensor 1 is used as an air-fuel ratio sensor, when the portion of the base end side L2 of the sensor element 2 is exposed to a high-temperature environment of 400 ℃ or more, it is also possible to make: in the vicinity of the stoichiometric air-fuel ratio, the output current as the sensor output does not contain a compensation current. In addition, even when the gas sensor 1 is used as an oxygen sensor, when the portion of the base end side L2 of the sensor element 2 is exposed to a high temperature environment of 400 ℃.

In the sensor element 2 including the solid electrolyte body 3 having a cylindrical bottom, when the temperature of the exhaust gas becomes high, the entire sensor element 2 tends to become high in temperature. At this time, it is found that a minute leakage current flows between the reference electrode 4B and the detection electrode 4A. In the conventional gas sensor 1, the influence of a minute leakage current on the detection accuracy of the gas sensor 1 is not so much problematic. However, from the viewpoint of further promoting emission reduction and low fuel consumption in recent years, the influence of a minute leakage current on the detection accuracy of the gas sensor 1, particularly, the case where an ideal point (a point at which the air-fuel ratio of the exhaust gas is detected as the stoichiometric air-fuel ratio) is shifted by a minute leakage current becomes a problem. The gas sensor 1 of the present embodiment is intended to solve such a problem newly generated in recent years.

the insulating layer 22 of the present embodiment defines the formation area of the detection electrode portion 41, and is used not only to suppress variations in sensor output of the gas sensor 1 but also to eliminate leakage current caused by movement of oxygen in the reference gas a such as air in the solid electrolyte body 3.

In the gas sensor 1, the solid electrolyte body 3 in the portion of the detection electrode portion 41 including the detection electrode 4A on the leading end side L1 of the sensor element 2 is heated to a temperature at which the ion conduction of oxygen is activated. The portion of the sensor element 2 on the base end side L2 is not usually heated to a temperature at which the solid electrolyte body 3 is activated.

However, depending on the combustion mode of the internal combustion engine 8, the following may occur: the temperature of the exhaust gas becomes high, and the solid electrolyte body 3 in the portion of the base end side L2 of the sensor element 2 is heated to the activation temperature. In this case, since oxygen in the reference gas a exists around the detection electrode 4A and the reference electrode 4B, the oxygen may be ionized and pass through the solid electrolyte body 3 from the detection electrode 4A to the reference electrode 4B. That is, in the portion of the solid electrolyte body 3 on the base end side L2 where the off gas as the detection gas G does not reach, an electric current is generated by conduction of oxygen ions. This current flows not based on the change in the composition of the detection gas G, and becomes a leakage current that causes an error in the detection of the air-fuel ratio or the like.

When the gas sensor 1 is used as an air-fuel ratio sensor, by applying a voltage between the detection electrode 4A and the reference electrode 4B so that the reference electrode 4B is on the positive side, ionized oxygen may pass through the solid electrolyte body 3 from the detection electrode 4A to the reference electrode 4B, thereby generating a leakage current. In addition, when the gas sensor 1 is used as an oxygen sensor, the oxygen concentration of the reference gas a in contact with the detection electrode 4A and the terminal member 71 and the oxygen concentration of the reference gas a in contact with the reference electrode 4B and the inner terminal member 72 are slightly different from each other, and therefore ionized oxygen may pass through the solid electrolyte body 3, and a leakage current may occur.

In the gas sensor 1 of the present embodiment, the occurrence of such a leakage current can be prevented by the arrangement of the insulating layer 22. Therefore, according to the gas sensor 1 of the present embodiment, it is possible to prevent a leak current from occurring between the mounting electrode portion 43 of the detection electrode 4A and the reference electrode 4B, and to improve the accuracy of gas detection.

< embodiment 2>

In the sensor element 2 of the present embodiment, the formation of the insulating layer 22 provided between the conductive electrode portion 42 and the mounting electrode portion 43 of the detection electrode 4A and the cylindrical portion 31 of the solid electrolyte body 3 was examined.

As shown in fig. 8 and 9, the end portion on the base end side L2 in the axial direction L of the insulating layer 22 is provided closer to the base end side L2 than the end portion on the base end side L2 in the axial direction L of the mounting electrode portion 43. The end of the insulating layer 22 on the base end side L2 constitutes the outermost shell portion of the outer surface 301 of the tube portion 31 and is exposed on the outer surface 301 of the tube portion 31. The end portion on the base end side L2 of the insulating layer 22 has a tapered surface 221, and the thickness of the tapered surface 221 in the radial direction R about the center axis O decreases toward the base end side L2 of the cylinder portion 31. The tapered surface 221 is a surface that guides the attachment of the terminal member 71 attached to the outer periphery of the tube portion 31 from the base end side L2 toward the tip end side L1 of the tube portion 31. The insulating layer 22 is usually provided on the outer surface 301 of the solid electrolyte body 3 so as to have a uniform thickness except for the end on the base end side L2.

In the present embodiment, when the terminal 71 is mounted on the solid electrolyte body 3, the terminal 71 can be brought into contact with the tapered surface 221 of the end portion of the base end side L2 of the insulating layer 22. Also, the terminal member 71 can be slid on the tapered surface 221. Thus, even if the terminal 71 comes into contact with the end of the base end side L2 of the insulating layer 22, the end of the base end side L2 is less likely to be peeled off or chipped.

In the present embodiment, the entire tapered surface 221 of the end portion of the base end side L2 of the insulating layer 22 is exposed. In addition, the mounting electrode portion 43 may be provided on the surface of the tapered surface 221 at the position of the tip side L1. In this case, only the surface of the tapered surface 221 at the base end side L2 is exposed. The tapered surface 221 constitutes the outermost shell portion of the outer surface 301 of the tube portion 31, and thus becomes a surface that comes into contact with the terminal member 71 when the terminal member 71 is mounted on the solid electrolyte body 3.

As shown in fig. 9, the inclination angle θ of the tapered surface 221 with respect to the axial direction L parallel to the central axis O is 60 ° or less. If the inclination angle θ of the tapered surface 221 exceeds 60 °, peeling, chipping, or the like may occur at the end of the base end side L2 of the insulating layer 22. If the inclination angle θ of the tapered surface 221 becomes smaller, the length in the axial direction L of the end portion of the base end side L2 of the insulating layer 22 becomes larger. Therefore, from the viewpoint of manufacturing, the inclination angle θ of the tapered surface 221 can be set to, for example, 15 ° or more.

instead of forming the tapered surface 221 at the end of the base end side L2 of the insulating layer 22, a curved surface may be formed at the corner of the base end side L2 of the insulating layer 22. In this case, peeling, chipping, or the like of the insulating layer 22 can be made less likely to occur.

Other structures, operational effects, and the like of the gas sensor 1 of the present embodiment are the same as those of the embodiment 1. In this embodiment, the same reference numerals as those in embodiment 1 denote the same components as those in embodiment 1.

< embodiment 3>

In the sensor element 2 of the present embodiment, the formation of the insulating layer 22 provided between the conductor electrode portion 42 and the mounting electrode portion 43 of the detection electrode 4A and the cylindrical portion 31 of the solid electrolyte body 3 was also examined.

As shown in fig. 10, the end 222 of the insulating layer 22 on the base end side L2 in the axial direction L is provided continuously from the outer surface 301 of the cylindrical portion 31 to the end surface 311 of the base end side L2 of the cylindrical portion 31. The corner 223 of the insulating layer 22 at the corner of the base end side L2 of the cylindrical portion 31 is preferably formed in a curved shape or the like. The end 222 of the insulating layer 22 does not need to be provided on the entire end surface 311 of the base end side L2 of the tube portion 31. The end 222 of the insulating layer 22 is provided at a position on the outer circumferential side of the end face 311 on the base end side L2 of the tube portion 31, and is not provided at a position on the center side of the end face 311 on the base end side L2 of the tube portion 31.

When the paste of the insulating material for forming the insulating layer 22 is applied to the outer surface 301 of the cylindrical portion 31 of the solid electrolyte body 3 by the roll transfer method, the paste can be applied to the end surface 311 of the base end side L2 of the cylindrical portion 31. Thereafter, the paste can be sintered together with the solid electrolyte 3 to form the insulating layer 22 from the paste.

In the present embodiment, as in the case of embodiment 2, even if the terminal member 71 comes into contact with the corner 223 of the base end side L2 of the insulating layer 22, the corner 223 of the base end side L2 is less likely to be peeled off or chipped. Other structures, operational effects, and the like of the gas sensor 1 of the present embodiment are the same as those of the embodiment 1. In this embodiment, the same reference numerals as those in embodiment 1 denote the same components as those in embodiment 1.

The present invention is not limited to the embodiments, and various embodiments can be further configured without departing from the scope of the present invention.

< confirmation test 1>

In this test, the relationship between the temperature of the sensor element 2 and the error generated in the sensor output of the gas sensor 1 serving as the air-fuel ratio sensor was confirmed for the gas sensor 1 (test article) of embodiment 1 in which the insulating layer 22 was provided in the sensor element 2, and for the gas sensor (comparative article) in which the insulating layer 22 was not provided in the sensor element 2. Fig. 11 shows how much error is generated in the sensor output of the gas sensor 1 when the temperature [ ° c ] of the sensor element 2 is appropriately changed.