Gas concentration detector

• US 5,830,339 A
• Filed: 10/25/1996
• Issued: 11/03/1998
• Est. Priority Date: 10/27/1995
• Status: Expired due to Term

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Watanabe, Isao, Shibata, Masahiro, Imamura, Shinichiro, Sugiyama, Tomio, Nakano, Syuichi
• Primary Examiner(s): TUNG, TA HSUNG
• Application Number:
  US08/736,911
• Time in Patent Office: 739 Days
• Field of Search: 204/421-429
• US Class Current: 204/426
• CPC Class Codes: G01N 27/4071 using sensor elements of laminated structure

Abstract

A gas concentration detector comprises a plate sensor element including a sensing action and a signal output section. A flange section is formed between the sensing section and the signal output section so as to protrude in the lateral direction thereof. A cylindrical housing has an inside space for receiving the sensor element. Powder is disposed in the inside space of the cylindrical housing at a predetermined position adjacent to the flange section so that the sensor element is airtightly fixed to the housing by applying a pressing force on the powder. Furthermore, a cross-sectional area of the signal output section is larger than a cross-sectional area of the sensing section.

Claims

1. A gas concentration detector comprising:

a plate sensor element including a sensing section, an elongated signal output section, and a flange section positioned between said sensing section and said signal output section, said flange section being formed by a protruding side face of said plate sensor element;

a cylindrical housing having an inside space for receiving said plate sensor element; and

powder disposed in said inside space of said cylindrical housing at a predetermined position adjacent to said flange section of said sensor element, so that said sensor element is surrounded by said powder in an air tight fashion along an entire periphery thereof and fixed to said housing by applying a pressing force on said powder, wherein

a cross-sectional area of said signal output section is larger than a cross-sectional area of said sensing section, when the cross-sectional area is defined by each outer periphery of said signal output section and said sensing section taken along a plane normal to a longitudinal axis of said sensor element,

said flange section is provided at only a portion of said entire periphery of said plate sensor, and

said flange section is supported by said cylindrical housing with no intervening powder.

2. The gas concentration detector in accordance with claim 1, wherein said flange section has upper and lower surfaces, and at least one of said upper and lower surfaces is tapered.

3. The gas concentration detector in accordance with claim 1, wherein said cylindrical housing has an inclined support surface on an inside surface thereof, and said flange section has a tapered portion supported by said inclined support surface, so that said flange section is brought into contact with said inclined support surface along an outermost periphery of said tapered portion.

4. The gas concentration detector in accordance with claim 1, wherein a washer is interposed between said cylindrical housing and said sensor element.

5. The gas concentration detector in accordance with claim 1, wherein said sensor element comprises a plate solid electrolyte made of oxygen ion conductive metallic oxide, and a pair of electrodes provided on said solid electrolyte.

6. The gas concentration detector in accordance with claim 1, wherein said sensor element comprises a sensor section comprising a pair of electrodes provided on a plate solid electrolyte made of oxygen ion conductive metallic oxide, and said solid electrolyte is bonded on a substrate made of electrical insulating metallic oxide.

7. The gas concentration detector in accordance with claim 6, wherein said substrate made of electrical insulating metallic oxide has said flange section protruding in the lateral direction, while said solid electrolyte has no flange.

8. The gas concentration detector in accordance with claim 1, wherein said sensor element has a two-cell structure comprising a pump cell and a sensor cell which are stacked.

9. The gas concentration detector in accordance with claim 8, wherein each of said pump cell and said sensor cell of said sensor element comprises a sensor section comprising a pair of electrodes provided on a plate solid electrolyte made of oxygen ion conductive metallic oxide, and said solid electrolyte is bonded on a substrate made of electrical insulating metallic oxide.

10. The gas concentration detector in accordance with claim 1, wherein said sensor element comprises a heater element.

11. The gas concentration detector in accordance with claim 1, wherein said plate sensor element has a polygonal cross section.

12. The gas concentration detector in accordance with claim 11, wherein said polygonal cross section of said plate sensor element is a quadrangular cross section.

13. The gas concentration detector in accordance with claim 1, wherein said flange section protrudes in parallel with a longer side of a cross section of said plate sensor element when said cross section is taken along a plane normal to said axis of said plate sensor element.

14. A gas concentration detector comprising:

a sensor element including a sensing section, a signal output section, and a flange section positioned between said sensing section and said signal output section;

said sensor element having at least one flush side face extending in a longitudinal direction of said sensor element from an end of said sensing section to an opposite end of said signal output section;

a cylindrical housing having an inside space for accommodating said sensor element; and

powder filled in a predetermined space enclosed by at least an inside wall of said cylindrical housing and a flange surface adjacent to said signal output section, so that said sensor element is surrounded in an air tight fashion by said powder along an entire periphery thereof and fixed to said housing via said powder when a pressing force is applied on said powder, wherein

a cross-sectional area of said signal output section is larger than a cross-sectional area of said sensing section when said cross-sectional areas are taken along a plane normal to the axis of said sensor element,

said flange section is not provided on said flush side face of said sensor element, and

said flange section is supported by said cylindrical housing with no intervening powder.

15. The gas concentration detector in accordance with claim 14, wherein said flange section has another flange surface adjacent to said sensing section, said another flange surface is held by said housing with no intervening powder.

16. The gas concentration detector in accordance with claim 14, wherein at least one electrode for detecting gas concentration is disposed on said flush side face of said sensor element.

17. The gas concentration detector in accordance with claim 14, wherein a signal lead for outputting a sensor signal is disposed along said flush side face of said sensor element.

18. A gas concentration detector comprising:

a rectangular sensor element having a rectangular cross section, including a sensing portion and a signal output portion;

opposite side faces of said rectangular sensor element being formed into flange portions located between said sensing portion and said output portion;

other opposite side faces of said rectangular sensor element being formed into parallel flush surfaces each extending in a longitudinal direction of said rectangular sensor element from an end of said sensing portion to an opposite end of said signal output portion;

a cylindrical housing having an inside space for accommodating said rectangular sensor element; and

powder filled in a predetermined space enclosed by at least an inside wall of said cylindrical housing and flange surfaces adjacent to said signal output portion, so that said rectangular sensor element is surrounded in an air tight fashion by said powder along an entire periphery thereof and fixed to said cylindrical housing via said powder when a pressing force is applied on said powder, wherein

a rectangular cross section of said signal output portion is larger than a rectangular cross section of said sensing portion when said cross sections are taken along a plane normal to the axis of said sensor element,

said flange portions are not provided on said parallel flush surfaces of said rectangular sensor element, and

said flange portions are supported by said cylindrical housing with no intervening powder.

19. The gas concentration detector in accordance with claim 18, wherein said flush surfaces correspond to longer sides of said rectangular cross section of said sensor element, while said flange surfaces correspond to shorter sides of said rectangular cross section of said sensor element.