# US 11,029,277 B2 · Gas sensor

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- Number: US 11,029,277 B2
- Document ID: US11029277B2
- Status: Granted
- Kind: B2
- Application number: 16/601,859
- Filed: 2019-10-15
- Published: 2020-02-06
- Granted: 2021-06-08
- Earliest claimed: 2017-04-18
- Assignees: Denso Corporation
- Applicants: Denso Corporation
- Inventors: Akira Saito
- Web page: https://patentgrep.com/patent/US11029277B2

## CPC

- F02D 41/1494: {Control of sensor heater}
- G01N 27/4073: {Composition or fabrication of the solid electrolyte}
- F02D 41/1454: {the characteristics being an oxygen content or concentration or the air-fuel ratio}
- F02D 41/1495: {Detection of abnormalities in the air/fuel ratio feedback system}
- G01N 27/4067: {Means for heating or controlling the temperature of the solid electrolyte}
- G01N 27/4077: {Means for protecting the electrolyte or the electrodes}
- F02D: CONTROLLING COMBUSTION ENGINES (vehicle fittings, acting on a single sub-unit only, for automatically controlling vehicle speed B60K31/00; conjoint control of vehicle sub-units of different type or different function, road vehicle drive control systems for purposes other than the control of a single sub-unit B60W)
- G01N: INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES (measuring or testing apparatus or processes other than immunoassay, involving enzymes or microorganisms C12M, C12Q)

## Abstract

A gas sensor includes: a sensor element including a bottomed tubular solid electrolyte, a detection electrode, and a reference electrode; and a heater for heating the solid electrolyte. The reference electrode includes an inner detection section on an entire periphery in a circumferential direction at an endmost position on a tip side on the reference electrode, an inner connecting section on an entire periphery in the circumferential direction at an endmost position on a base end side on the reference electrode, and an inner lead section on a part in the circumferential direction at a position where the inner detection section is connected to the inner connecting section. A formation region in the circumferential direction of the inner lead section is reduced stepwise from the inner detection section toward the inner connecting section.

## Claims

### Claim 1

A gas sensor comprising:
a sensor element including a solid electrolyte that has ionic conductivity and in which a tip portion of a tube having a tubular shape is blocked by a bottom having a curved surface, a detection electrode that is provided on an outer surface of the solid electrolyte and is exposed to detection gas, and a reference electrode that is provided on an inner surface of the solid electrolyte and is exposed to reference gas; and
a heater that has a tip portion including a heating section for heating the solid electrolyte and is arranged inside the solid electrolyte for a tip of the tip portion to contact with the inner surface of the bottom, wherein:
the reference electrode includes
an inner detection section that is provided on an entire periphery in a circumferential direction around a center axis of the tube at a position that is an endmost position on a tip side on the reference electrode and faces the heating section,
an inner connecting section that is provided on an entire periphery or a part in the circumferential direction of the tube at an endmost position on a base end side on the reference electrode and is connected to an inner terminal metal fitting, and
an inner lead section that is provided on a part in the circumferential direction of the tube at a position where the inner detection section is connected to the inner connecting section and that is formed in a formation region in the circumferential direction smaller than a formation region in the circumferential direction of the inner connecting section;
the formation region in the circumferential direction of the inner lead section is reduced stepwise or reduced to form a tapered shape from the inner detection section toward the inner connecting section; and
a rate (S1−S2)/S1 has a relationship of 0.3≤(S1−S2)/S1≤0.7, where S1 represents a surface area of an entire portion of the inner surface of the solid electrolyte and S2 represents a surface area of a part of the entire portion of the inner surface of the solid electrolyte on which the reference electrode is formed, the rate (S1−S2)/S1 being a rate of a surface area of a part of the entire portion of the inner surface of the solid electrolyte on which a reduction of the reference electrode is made.

### Claim 2 (depends on 1)

The gas sensor according to claim 1, wherein:
the inner detection section is provided so as to be continuous with an entire periphery at a position on the tip side of the inner surface of the tube and an entire portion of the inner surface of the bottom; and
the tip of the tip portion of the heater is in contact with the inner detection section on the inner surface of the bottom.

### Claim 3 (depends on 1)

The gas sensor according to claim 1, wherein the inner lead section is formed parallel to the center axis.

### Claim 4 (depends on 1)

The gas sensor according to claim 1, wherein the reference electrode has an average thickness in the range of 0.4 to 1.6 μm.

### Claim 5 (depends on 1)

The gas sensor according to claim 1, wherein:
the gas sensor is arranged in an exhaust pipe in which exhaust gas discharged from an internal combustion engine flows;
the gas sensor is used to detect, by using the exhaust gas as the detection gas, an electromotive force generated between the detection electrode and the reference electrode through the solid electrolyte and determine whether an air-fuel ratio of the internal combustion engine is on a rich side on which a ratio of fuel to air is greater than a theoretical air-fuel ratio or on a lean side on which the ratio of fuel to air is greater smaller than the theoretical air-fuel ratio; and
the gas sensor is used to detect, on the basis of the electromotive force, an air-fuel ratio at which an excess air ratio λ is in the range of 0.97 to 1.00, where the excess air ratio λ is 1.00 when the theoretical air-fuel ratio is 14.5, the excess air ratio λ being a value obtained by dividing an air mass flow supplied to the internal combustion engine by a minimum air mass flow theoretically required for complete combustion of fuel.

### Claim 6 (depends on 1)

The gas sensor according to claim 1, wherein the inner lead section of the reference electrode is formed so that the formation region in the circumferential direction is reduced in at least three steps from the inner detection section of the reference electrode toward the inner connecting section of the reference electrode in an axial direction of the sensor element.