# US 2014/0190829 A1 · Gas sensor

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- Number: US 2014/0190829 A1
- Document ID: US20140190829A1
- Status: Published application
- Kind: A1
- Application number: 14/234,242
- Filed: 2012-10-26
- Published: 2014-07-10
- Earliest claimed: 2011-11-04
- Assignees: Ngk Spark Plug Co., Ltd.
- Applicants: Ngk Spark Plug Co., Ltd.
- Inventors: Daiki Tabuchi; Hidekazu Kato; Yasuhiro Fujita; Mitsuru Sugihara; Takayoshi Atsumi
- Web page: https://patentgrep.com/patent/US20140190829A1

## CPC

- G01N 27/4077: {Means for protecting the electrolyte or the electrodes}
- 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 metal shell, a gas sensor element held in the metal shell, a metal portion arranged between a flange portion of the gas sensor element and a seat portion of the metal shell and a porous thermal spray layer formed on the gas sensor element. When viewed in cross section along the direction of an axis of the gas sensor, a corner of the metal portion axially overlaps in position with or radially outwardly protrudes from an outer surface of a part of the thermal spray layer located on a side surface of the flange portion and is brought into contact with the seat portion. A rear end-facing surface of the metal portion is brought into contact with an outer surface of the thermal spray layer at a position radially inside the side surface of the flange portion.

## Claims

### Claim 1

A gas sensor, comprising:
a gas sensor element extending in an axis direction of the gas sensor and including a bottomed cylindrical element body and an outer electrode, the element body being exposed to a gas under measurement at a front end side thereof and opened at a rear end side thereof and having a radially outwardly protruding flange portion, the outer electrode being formed on an outer surface of a front end portion of the element body located front of the flange portion;
a cylindrical metal shell radially outwardly surrounding the gas sensor element and having, on an inner surface thereof, a seat portion tapered and inclined toward the front end side so as to face a front end-facing surface of the flange portion; and
an annular metal portion arranged between the front end-facing surface of the flange portion and the seat portion,
wherein the gas sensor further comprises a porous thermal spray layer formed on a region from the front end portion of the element body via the front end-facing surface to at least a side surface of the flange portion so as to cover the outer electrode; and
wherein, when viewed in cross section along the axis direction, a corner connecting a radially outer side surface of the metal portion and a front end-facing surface of the metal portion is formed so as to axially overlap in position with or radially outwardly protrude from an outer surface of a part of the thermal spray layer located on the side surface of the flange portion and is brought into contact with the seat portion, and a rear end-facing surface of the metal portion is brought into contact with an outer surface of a part of the thermal spray layer located on the front end-facing surface of the flange portion at a position radially inside the side surface of the flange portion.

### Claim 2 (depends on 1)

The gas sensor according to claim 1, wherein the side surface of the flange portion and the front-facing surface of the flange portion are connected by a curved surface or a plain surface.

### Claim 3 (depends on 1)

The gas sensor according to claim 1, wherein, in a region radially outside the contact of the metal portion and the outer surface of the thermal stray layer, an angle formed between the rear end-facing surface of the metal portion and the axis direction is larger than an angle formed between the outer surface of the thermal spray layer and the axis direction.

### Claim 4 (depends on 1)

The gas sensor according to claim 1, wherein the metal portion is reduced in thickness toward the radially outside.

### Claim 5 (depends on 1)

The gas sensor according to claim 1, wherein the gas sensor further comprises a protector portion formed integral with the metal portion so as to extend from the metal portion toward the front end side and accommodate therein the gas sensor element.