# US 7,607,339 B2 · Ceramic laminate body, gas sensor element and related manufacturing method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,607,339 B2 - Document ID: US7607339B2 - Status: Granted - Kind: B2 - Application number: 11/706,396 - Filed: 2007-02-15 - Published: 2007-09-20 - Granted: 2009-10-27 - Earliest claimed: 2006-03-15 - Assignees: Denso Corporation - Inventors: Makoto Nakae; Shoichiro Emmei; Kiyomi Kobayashi - Web page: https://patentgrep.com/patent/US7607339B2 ## CPC - C04B 37/005: {consisting of glass or ceramic material} - C04B 2237/064: based on alumina or aluminates - C04B 2237/343: Alumina or aluminates - C04B 2237/348: Zirconia, hafnia, zirconates or hafnates - C04B 2237/592: whereby the interlayer is not continuous, e.g. not the whole surface of the smallest substrate is covered by the interlayer - C04B 2237/62: Forming laminates or joined articles comprising holes, channels or other types of openings - C04B 2237/64: Forming laminates or joined articles comprising grooves or cuts - C04B 2237/708: of one or more of the interlayers - G01N 33/0009: {General constructional details of gas analysers, e.g. portable test equipment (devices for withdrawing samples in the gaseous state G01N1/22)} - Y10T 428/166: Glass, ceramic, or metal sections [e.g., floor or wall tile, etc.] - Y10T 428/24926: including ceramic, glass, porcelain or quartz layer - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - 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) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A ceramic laminate body, a gas sensor element employing such a ceramic laminate body and related manufacturing method are disclosed as including first and second ceramic sheets, made of material compositions different from each other, and an intermediate bonding layer, bonding the first and second ceramic sheets to each other so as to form a closed hollow space between the first and second ceramic sheets. The intermediate bonding layer has a multilayer structure including first and second unit intermediate layers laminated on each other such that innermost end portions of the first and second unit intermediate layers are displaced from each other to adapt a difference in degreasing contraction rates of associated component parts. ## Claims ### Claim 1 A gas sensor element comprising: a first ceramic sheet including a solid electrolyte body; a second ceramic sheet being made of material compositions different from those of the first ceramic sheet and including a chamber forming layer having one surface facing the solid electrolyte body and formed with a recessed portion defining a reference gas chamber; an intermediate bonding layer that bonds the first and second ceramic sheets to each other so as to form a closed hollow space between the first and second ceramic sheets and is formed only in an area between the solid electrolyte body and the chamber forming layer; wherein the intermediate bonding layer has a multilayer structure including first and second unit intermediate layers laminated on each other such that an innermost end portion of one of the first and second unit intermediate layers protrudes inward in the closed hollow space and is laterally offset from an innermost end portion of the other of the first and second unit intermediate layers, and wherein the first unit intermediate layer is formed on the solid electrolyte body and the second unit intermediate layer is formed on the chamber forming layer such that the first unit intermediate layer has the innermost end portion protruding toward the reference gas chamber to a further extent than the innermost end portion of the second unit intermediate layer, whereby the innermost end portions of the first and second unit intermediate layers define a stepped shape in cross section and the innermost end portions do not extend inward of a periphery of the reference gas chamber; a reference gas detecting electrode formed on one surface of the solid electrolyte body in face-to-face relation with the reference gas chamber; a measuring gas detecting electrode formed on the other surface of the solid electrolyte body and exposed in a measuring gas chamber; a diffusion resistance layer stacked on the other surface of the solid electrolyte body so as to define the measuring gas chamber in an area around the measuring gas detecting electrode and operative to permeate measuring gas to the measuring gas chamber; and a shielding layer laminated on the diffusion resistance layer. ### Claim 2 (depends on 1) The gas sensor element according to claim 1, wherein: the first and second unit intermediate layers, forming the intermediate bonding layer, have a thickness ranging from 5 to 100 μm. ### Claim 3 (depends on 1) The gas sensor element according to claim 1, wherein: the innermost end portion of the one of the first and second unit intermediate layers is displaced from the innermost end portion of the other of the first and second unit intermediate layers by a displacement value greater than a thickness of the one of the first and second unit intermediate layers. ### Claim 4 (depends on 1) The gas sensor element according to claim 1, wherein: the one of the first and second unit intermediate layers is made of alumina in major proportions and the other of the first and second unit intermediate layers is made of zirconia in major proportions. ### Claim 5 (depends on 1) The gas sensor element according to claim 1, wherein: the first and second unit intermediate layers have inward end portions, exposed to the closed hollow space, which have substantially arc-shaped configurations in cross section, respectively. ### Claim 6 (depends on 5) The gas sensor element according to claim 5, wherein: the arc-shaped configurations of the first and second unit intermediate layers are aligned on the same orientations. ### Claim 7 (depends on 5) The gas sensor element according to claim 5, wherein: the arc-shaped configurations of the first and second unit intermediate layers are aligned on the opposite orientations. ### Claim 8 (depends on 1) The gas sensor element according to claim 1, wherein: the first and second unit intermediate layers have different degreasing contraction factors. ### Claim 9 (depends on 8) The gas sensor element according to claim 8, wherein: the first unit intermediate layer comprises a hardened adhesive paste and the second unit intermediate layer comprises a hardened ceramic paste. ### Claim 10 (depends on 1) The gas sensor element according to claim 1, wherein: the intermediate bonding layer further includes a third unit intermediate layer interposed between the second unit intermediate layer and the second ceramic sheet. ### Claim 11 (depends on 10) The gas sensor element according to claim 10, wherein: the third unit intermediate layer has an innermost end portion protruding further inward to the closed hollow space than the innermost end portion of the second unit intermediate layer by a displacement value greater than a thickness of the third unit intermediate layer. ### Claim 12 (depends on 10) The gas sensor element according to claim 10, wherein: the third unit intermediate layer has an innermost end portion exposed to the closed hollow space and is displaced outward from the innermost end portion of the second unit intermediate layer by a displacement value greater than a thickness of the third unit intermediate layer. ### Claim 13 (depends on 1) The gas sensor element according to claim 1, wherein: the second ceramic sheet has a recessed portion to define a part of the closed hollow space. ### Claim 14 (depends on 1) The gas sensor element according to claim 1, wherein: the innermost end portions of the first and second unit intermediate layers are displaced from each other by a displacement value expressed by t≦L1 where “t” represents a thickness of one of the first and second unit intermediate layers and “L1” represents the displacement value between the innermost end portions of the first and second unit intermediate layers.