Oxygen sensor

• US 4,588,494 A
• Filed: 03/08/1985
• Issued: 05/13/1986
• Est. Priority Date: 03/16/1984
• Status: Expired due to Term

• Current Assignee: NGK Insulators Limited
• Original Assignee: NGK Insulators Limited
• Inventors: Murase, Takao, Kato, Nobuhide
• Primary Examiner(s): NOT, DEFINED
• Application Number:
  US06/709,802
• Time in Patent Office: 431 Days
• Field of Search: 204/425, 204/426, 204/1 S, 204/428, 338/34, 339/217 S
• US Class Current: 204/426
• CPC Class Codes: G01N 27/4062 Electrical connectors associated therewith
• CPC Class Codes: G01N 27/407 for investigating or analysing gases G01N27/411 takes precedence
• CPC Class Codes: G01N 27/4071 using sensor elements of laminated structure
• CPC Class Codes: G01N 27/4077 Means for protecting the electrolyte or the electrodes

Abstract

An oxygen sensor including an elongate planar oxygen sensing element which has an oxygen detecting portion adjacent to one longitudinal end thereof. The detecting portion is exposed to a measurement gas to determine an oxygen concentration of the measurement gas. The sensing element is electrically connected to at least one external device through conductor members. An electrical terminal portion is formed on the sensing element, adjacent to the other longitudinal end thereof. The terminal portion has at least one pair of electrical contacts which are disposed adjacent to corresponding connectors for direct contact therewith.

Claims

1. An oxygen sensor including an elongate planar oxygen sensing element having a first longitudinal end and a second longitudinal end, wherein an oxygen detecting portion is adjacent to said first longitudinal end, said detecting portion being exposed to a measurement gas to determine an oxygen concentration of said measurement gas, said sensing element being electrically connected to at least one external device through at least one conductor member, wherein the improvement comprises:

a protective covering having a first longitudinal end and a second longitudinal end, said protective covering accommodating therein said sensing element;

a rubber plug having a first end and a second end, whereby said second end is press-fitted into said first longitudinal end of said protective covering, said at least one conductor member extending through said rubber plug;

an electrical insulating member disposed between and retained by said second longitudinal end of said sensing element and said second end of said rubber plug;

electrical terminal means formed on said sensing element, adjacent to said second longitudinal end thereof, said electrical terminal means including at least one pair of electrical contacts disposed in said electrical insulating member; and

connector means disposed adjacent to said electrical terminal means, and including connectors which are electrically connected to said conductor members and are fixedly supported in said electrical insulating member, said connectors being held in direct electrical contact with said at least one pair of electrical contacts.

2. The oxygen sensor of claim 1, wherein said electrical terminal means of said sensing element consists of a plug, and said connector means consists of a receptacle into which said plug is inserted to achieve pressed contact between said at least one pair of electrical contacts and said connectors.

3. The oxygen sensor of claim 1, wherein said electrical terminal means of said sensing element consists of a receptacle, and said connector means consists of a plug which is inserted into said receptacle to achieve pressed contact between said connectors and at least one pair of electrical contacts.

4. The oxygen sensor of claim 1, wherein said at least one pair of electrical contacts consists of an output signal and an earth contact, said conductor members including said protective covering, said output signal contact being connected to said external device through a corresponding one of said connectors and through one of said conductor members, said earth contact being grounded through a corresponding one of said connectors and through said protective covering.

5. The oxygen sensor of claim 1, wherein said at least one pair of electrical contacts of said electrical terminal means comprises end portions having at least one pair of electrical leads formed on said sensing element, said end portions of the electrical leads being exposed adjacent to said second longitudinal end of the sensing element.

6. The oxygen sensor of claim 5, wherein said at least one pair of electrical leads comprises a pair of leads connected to a pair of electrodes disposed in said oxygen detecting portion of the sensing element, one of said pair of electrodes being exposed to said measurement gas.

7. The oxygen sensor of claim 6, wherein said conductor members comprise said protective covering, the exposed end portion of the electrical lead connected to said one electrode being grounded through a corresponding one of said connectors and through said protective covering.

8. The oxygen sensor of claim 6, wherein the exposed end portions of said pair of leads are formed on one of opposite surfaces of said sensing element perpendicular to the direction of thickness thereof.

9. The oxygen sensor of claim 5, wherein said sensing element comprises an electrical heater incorporated therein to heat said oxygen detecting portion thereof, said at least one pair of electrical leads comprising a pair of leads connected to said electrical heater to apply power thereto.

10. The oxygen sensor of claim 1, wherein said sensing element comprises an electrical heater incorporated therein to heat said oxygen detecting portion thereof.

11. The oxygen sensor of claim 1, wherein said at least one pair of electrical contacts are exposed adjacent to said second longitudinal end of said planar sensing element, each of said electrical contacts being raised above a surface of the planar sensing element.

12. The oxygen sensor of claim 11, further comprising an electrically insulating member in which said connectors are fixedly supported for electrical contact with said at least one pair of electrical contacts.

13. The oxygen sensor of claim 12, wherein an end portion of said sensing element on the side of said second longitudinal end thereof is inserted into said insulating member for electrical contact of said electrical contacts with said connectors supported in said insulating member.

14. Th oxygen sensor of claim 12, wherein each of said connectors includes a contact lug which is resiliently held in pressed contact with a corresponding one of said electrical contacts.

15. The oxygen sensor of claim 11, wherein said at least one pair of electrical contacts comprises a first pair of electrical contacts electrically connected to a pair of electrodes disposed in said oxygen detecting portion of the sensing element, and a second pair of electrical contacts electrically connected to an electrical heater incorporated in said sensing element to heat said oxygen detecting portion.

16. The oxygen sensor of claim 15, wherein said first pair of electrical contacts consists of end portions of electrical leads extending from each of said pair of electrodes, and said second pair of electrical contacts consists of end portions of electrical leads extending from said electrical heater, each of said end portions of the electrical leads being raised above a surface of the sensing element.

17. The oxygen sensor of claim 16, wherein the end portions of said electrical leads of said pair of electrodes are found on a first surface of opposite surfaces of the sensing element perpendicular to the direction of thickness thereof, and the end portions of said electrical leads of said electrical heater are formed on a second surface of the opposite surfaces of the sensing element.

18. The oxygen sensor of claim 16, wherein the end portions of said electrical leads of said pair of electrodes are formed substantially in the same plane perpendicular to the direction of thickness of said sensing element.

19. The oxygen sensor of claim 16, wherein the end portions of said electrical leads of said electrical heater are formed substantially in the same plane perpendicular to the direction of thickness of said sensing element.

20. The oxygen sensor of claim 16, wherein the end portions of said electrical leads of said pair of electrodes are formed in different planes perpendicular to the direction of thickness of the sensing element.

21. The oxygen sensor of claim 1, wherein said oxygen detecting portion of the sensing element comprises a solid electrolyte material consisting essentially of zirconia ceramics, and is operated to determine the oxygen concentration of said measurement gas according to the principle of an oxygen concentration cell.

22. The oxygen sensor of claim 1, wherein said oxygen detecting portion of the sensing element comprises an oxide semiconductor, having an electrical resistance which varies as a function of an oxygen partial pressure of said measurement gas.