The present invention relates to a material composition of a gas (oxygen) sensor element using a ceramic sintered body.
There is a demand for oxygen concentration detection in various gases, such as detection of oxygen concentration in exhaust gas of internal-combustion engines, detection of oxygen concentration for boiler combustion control, etc., and an oxygen sensor made from various materials is known as an oxygen concentration detecting element. An oxygen sensor using composite ceramics generated by mixing LnBa2Cu3O7-δ and Ln2BaCuO5, for example, (Ln denotes rare earth element), which are material compositions for the oxygen sensor using a ceramic sintered body, is known (Patent Document 1).
The oxygen sensor using a wire material of the ceramic sintered body as described above is a hot spot-type oxygen sensor utilizing a hot spot phenomenon that a part of the wire material is red-heated when a voltage is applied. Such an oxygen sensor may be small, light, and may have a low cost and reduced power consumption, and future practical applications are desired.
Patent Document 1: JP 2007-85816A (Japanese Patent No. 4714867)
The conventional oxygen sensor described above has a problem of durability since the wire material is easily fused as a result of hot spots generated when driving the sensor. Such fusion of the wire material may be thought of as resulting from generation of a liquid phase in local parts (particularly grain boundaries) within the hot spots.
Moreover, the characteristics of the material configuring the conventional oxygen sensor element that it easily hydrates and carbonates cause a problem that the sensor element is deteriorated due to peripheral gas components, such as water vapor or carbon dioxide gas during detection of oxygen concentration of the gas, and that durability will not be sufficient. Therefore, the conventional material composition does not allow practical application of a sensor element with improved durability.
In light of these problems, the present invention aims to provide an oxygen sensor element having high heat resistance and moisture resistance, and improved durability and reliability without losing sensor characteristics.
The present invention aims to resolve the above problems, and includes the following structure, for example, as a means for achieving the above aim. That is, the present invention is an oxygen sensor element characterized in that it is made of a ceramic sintered body and that it detects oxygen concentration based on an electric current value measured when a voltage is applied. The ceramic sintered body has a composition generated by substituting any element selected from group 2 elements in the periodic table for a part of a composition formula LnBa2Cu3O7-δ (Ln denotes rare earth element and δ is 0 to 1).
For example, it is characterized by selecting strontium (Sr) from the group 2 elements in the periodic table. It is characterized in that when the composition generated by substituting the strontium (Sr) is represented as a composition formula LnBa2-xSrxCu3O7-δ, for example, substitution quantity x should satisfy an inequality constraint 0<x≤1.5. It is also characterized in that a part of the composition represented as the composition formula LnBa2-xSrxCu3O7-δ, for example, is further substituted with calcium (Ca) and lanthanum (La). It is further characterized in that, for example, a composition represented as a composition formula Ln2BaCuO5 (Ln denotes rare earth element) is mixed together with the composition represented as the composition formula LnBa2-xSrxCu3O7-δ. Yet even further, for example, it is characterized in that the composition represented as the composition formula LnBa2-xSrxCu3O7-δ has a complex perovskite structure. It is also characterized, for example, in that the ceramic sintered body is a linear body sensor element.
Furthermore, an oxygen sensor is characterized by having any one of the oxygen sensor elements described above as an oxygen concentration detecting element. For example, it is characterized in that the oxygen sensor element is stored within a protecting tube having air holes on either end.
According to the present invention, an oxygen sensor element having high heat resistance, moisture resistance, and favorable sensor characteristics for oxygen concentration measurement, and an oxygen sensor using the element may be provided.
An embodiment according to the present invention is described in detail below with reference to accompanying drawings. The oxygen sensor element according to the embodiment is comprised of a ceramic sintered body, where the sintered body is connected to a power source, thereby electric current flowing through the sintered body, and resulting in the central portion of the sintered body generating heat. Heat-generating place (called hot spot) thereof functions as an oxygen concentration detector. Moreover, the oxygen sensor having the oxygen sensor element according to the embodiment as a sensor element detects oxygen concentration based on the electric current value of current flowing through the sintered body or sensor element.
The oxygen sensor element according to the embodiment as the oxygen concentration detector has a composition generated by substituting any one element selected from group 2 elements in the periodic table, namely beryllium (Be), magnesium (Mg), calcium (Ca), strontium (Sr), barium (Ba), and radium (Ra), for a part of the composition material LnBa2Cu3O7-δ (may be referred to as conventional composition hereafter).
In the above composition, Ln denotes rare earth element (e.g., Sc (scandium), Y (yttrium), La (lanthanum), Nd (neodymium), Sm (samarium), Eu (europium), Gd (gadolinium), Dy (dysprosium), Ho (holmium), Er (erbium), Tm (thulium), Yb (ytterbium), Lu (lutetium), etc.), and δ represents oxygen defect (0-1).
In the following explanation, a ceramic sintered body is exemplified as the oxygen sensor element according to the embodiment, wherein the ceramic sintered body is made up of a composition material GdBa2-xSrxCu3O7-δ (substitution quantity x is 0<x≤1.5) generated by assigning Gd (gadolinium) as Ln of the conventional composition LnBa2Cu3O7-δ and substituting Sr (strontium) for a part of the resulting composition GdBa2Cu3O7-δ.
Results of comparatively inspecting samples manufactured using the oxygen sensor element material according to the embodiment and samples made of the conventional sensor element material are explained first. Here, green compact made from the composition described later is sintered so as to manufacture disk-shaped oxygen sensor elements (also referred to as test samples hereafter) having a diameter of approximately 16 mm and thickness of approximately 2 mm, and a moisture resistance test and a heat treatment test etc. are carried out. These samples are masses (bulk bodies) of the composition materials themselves, and are made into a form and a size that allow easy observation of change etc. in external appearance before and after the tests.
<Moisture Resistance Test Results>
Table 1 gives moisture resistance test results of the oxygen sensor element having the conventional composition and the oxygen sensor element according to the embodiment. ‘Working Example’ in Table 1 is an oxygen sensor element generated by substituting Sr (strontium) for a part of the conventional composition and assigning Gd (gadolinium) as Ln, resulting in the composition GdBa2-xCu3O7-δ (0<x≤1.5) where x=1. ‘Conventional Example’ in Table 1 is an oxygen sensor element generated by assigning Gd (gadolinium) as Ln of the conventional composition LnBa2Cu3O7-δ without substituting Sr (strontium) for a part of the composition, namely it is an oxygen sensor element where x=0.
In Table 1, x indicates that the element has degraded, and o indicates that the element has hardly degraded at all.
That is to say, in the test of leaving an element in an environment of 40° C. and 93% RH for 50 hours, the oxygen sensor element of the conventional example has degraded, while the oxygen sensor element of the working example has shown hardly any degradation. Moreover, the oxygen sensor element of the working example shows hardly any degradation even in the case of leaving the element in an environment of 40° C. and 93% RH for 500 hours.
On the other hand,
It is understood from the result of external observation that
In contrast, as illustrated in
Measurement results of x-ray diffusion (XRD) of the oxygen sensor element according to the embodiment that is carried out to consider a mechanism improving the moisture resistance of the element will be explained.
The working example of
The composition material LnBa2Cu3O7-δ of the oxygen sensor element will phase-change from orthorhombic (a≠b≠c) to tetragonal (a=b≠c) when oxygen deficiency within the crystal structure is increased.
<Heat-Resistance Test Results>
As can be understood from
In the conventional composition (x=0), since the temperature at the hot spots of the oxygen sensor element is approximately 950° C., the sintered body structure (composition) varies during sensor operation, and thus sensor characteristics may also vary. In order to examine this mechanism, differential thermal analysis (DTA) measurement of the test sample of the conventional composition and the test sample according to the embodiment is carried out. DTA measurement results are compared in
As shown in
From a two-component phase diagram of
<Sr (Strontium) Substitution Quantity>
Specimens having the composition GdBa2-xSrxCu3O7-δ, which is generated by substituting Sr (strontium) for a part of the conventional composition and assigning Gd (gadolinium) as Ln (rare earth element), are manufactured, wherein substitution quantity x is set to x=0, x=0.5, x=0.75, x=1, x=1.25, x=1.5, and x=2, and XRD measurement is carried out for each specimen.
<Sensor Characteristic Evaluation Results>
As shown in
This clearly shows that the same sensor characteristics (sensor output, response speed) as those of the test sample having the conventional composition can be obtained even with the sample of the working example generated by substituting Sr (Strontium) for a part of the conventional composition.
Inspection of a composition generated by substituting calcium (Ca) and lanthanum (La) for a part of the composition of the oxygen sensor element according to the embodiment that is represented by the composition formula GdBa2-xSrxCu3O7-δ described above is carried out. As a result, it is determined that moisture resistance of such composition generated by substituting Ca and La may be improved so as to secure sensor characteristics.
A manufacturing process for the oxygen sensor element according to the embodiment and the oxygen sensor using the element is described next.
In Step S1 of
Note that Gd (Gadolinium) is exemplified in this case as Ln (rare earth element) of the oxygen sensor element material. However, another single rare earth element may be used as Ln, or otherwise multiple rare earth elements may be mixed together, namely any one of the rare earth elements may be used. Moreover, Ln2BaCuO5 may be further added to the mixture.
In Step S2, the raw materials of the oxygen sensor element weighed and mixed together in Step S1 are ground using a ball mill Grinding may also be carried out using a solid phase method or a liquid phase method, such as with a bead mill using beads as grinding media.
In subsequent Step S3, the ground material (raw material powder) described above is heat processed (preliminary baking) at 900° C. for 5 hours in atmospheric air. Preliminary baking is a process for adjusting reactivity and grain size. Temperature for the preliminary baking may be 880 to 970° C., and is more preferably 900 to 935° C.
Processing then progresses to a granulation step. More specifically, granulated powder is made in Step S4, wherein an aqueous solution or the like of a binder resin (e.g., polyvinyl alcohol (PVA)) is added to the preliminarily baked mixture so as to make a granulated powder.
In subsequent Step S5, a pressing pressure is applied to the granulated powder using a uniaxial press method, for example, and molded, so as to manufacture a plate member (press-molded body) having a thickness of 300 μm, for example. Molding may be carried out by a hydrostatic pressing method, hot pressing method, doctor blade method, printing method, or thin film method.
Dicing is carried out in Step S6. Dicing entails cutting the molded plate member into a predetermined product size and shape (e.g., 0.3×0.3×7 mm linear shape). The smaller the size of the oxygen sensor element, the more excellent in electric power saving, and thus the product size may be different from the size mentioned above.
In Step S7, de-binding the oxygen sensor element that has been diced in such a manner as described above is performed, and the resulting oxygen sensor element is baked in atmospheric air at, for example, 920° C. for 10 hours. Note that while the firing temperature may be 900 to 1000° C., the firing temperature may be changed according to composition since optimum temperature varies according to composition. An annealing step may be carried out hereafter.
In Step S8, both ends of the resulting oxygen sensor element are dipped and coated in sliver (Ag), and dried at 150° C. for 10 minutes, thereby forming electrodes. In Step S9, a silver (Ag) wire having a diameter of 0.1 mm, for example, is attached through a joining method such as wire bonding to the electrodes formed in Step S8 and then dried at 150° C. for 10 minutes. The terminal electrodes formed in this manner are then baked at 670° C. for 20 minutes, for example, in Step S10.
Material of the electrodes and the wire described above may be of a material other than silver (Ag), such as gold (Au), platinum (Pt), nickel (Ni), tin (Sn), copper (Cu), resin electrode, etc. Moreover, dipping the electrodes may also use a printing method or a film adhering method such as sputtering. Furthermore, electrical characteristics of the oxygen sensor element manufactured through the steps described above may also be evaluated using a four-terminal method, for example, as a final step in
<Oxygen Sensor>
The oxygen sensor using the oxygen sensor element according to the embodiment has heat-generating place (hot spots) in the central portion of the oxygen sensor element, which will be oxygen concentration detectors. For example, an oxygen sensor 1 shown in
Silver (Ag) wires attached to either end of the oxygen sensor element 5 are electrically connected to the respective conductive caps 2a and 2b using a lead-free solder and arranged such that the longitudinal direction of the oxygen sensor element 5 is the same as the axial direction of the glass tube 4 so the oxygen sensor element 5 does not touch the glass tube 4. Moreover, gas (oxygen) to be measured flows smoothly into the glass tube 4 via air holes 3a and 3b, which are provided on end surface sides of the conductive caps 2a and 3b, respectively, resulting in the oxygen sensor element 5 exposed to that gas, thereby allowing accurate measurement of oxygen concentration in the ambient atmosphere.
The outer dimensions (size) of the oxygen sensor 1 include, for example, a glass tube diameter of 5.2 mm, glass tube length of 20 mm, and air hole diameter of 2.5 mm, thereby making the oxygen sensor element having the dimensions given above (0.3×0.3×7 mm) exchangeable via the air holes of the glass tube.
Note that the protecting member of the oxygen sensor element 5 may be a ceramic case, a resin case, or the like aside from the glass tube described above. Moreover, the connection between the silver (Ag) wires attached to the oxygen sensor element 5 and the respective conductive caps 2a and 2b may be carried out through lead soldering, welding, caulking, etc.
Furthermore, while omitted from the drawing, the oxygen sensor, which uses the oxygen sensor element according to the embodiment, has a configuration for measuring oxygen concentration in the atmosphere to be measured based on the electric current measured with an ammeter since a current flows through the oxygen sensor element according to peripheral oxygen concentration when a predetermined voltage is applied to the oxygen sensor by a power source.
As described above, the oxygen sensor element according to the embodiment has a composition represented as the composition formula LnBa2-xSrxCu3O7-δ (Ln denotes rare earth element and substitution quantity x is 0<x≤1.5), which is generated by substituting any one element selected from group 2 elements in the periodic table, such as strontium (Sr), for a part of the conventional composition represented as the composition formula LnBa2Cu3O7-δ.
Use of such a composition raises the liquid phase melting point of SrO—CuO higher than that of the liquid phase of BaO—CuO, making it difficult for the liquid phase to generate when driving the oxygen sensor. This allows provision of an oxygen sensor element that improves heat resistance and moisture resistance of the oxygen sensor element and has high durability and reliability without losing sensor characteristics.
In addition, while an example of substituting Sr (strontium) for a part of the conventional composition is given in the embodiment described above, it may be assumed that even substitution with any one element selected from group 2 elements in the periodic table, such as beryllium (Be), magnesium (Mg), calcium (Ca), barium (Ba), and radium (Ra), gives the same results as in the case of Sr substitution.
Number | Date | Country | Kind |
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2018-015923 | Jan 2018 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2019/003263 | 1/30/2019 | WO | 00 |