The present invention is directed to a sensor element for detecting a gas component.
Published German patent document DE 100 13 882, for example, describes a planar sensor element which is layered using silk-screen technology and contains a measuring gas space in which two annular electrodes are situated on two opposite sides. The two electrodes are parts of an electrochemical cell, which has an additional electrode and a solid electrolyte situated between the electrodes. The two electrodes situated in the measuring gas space are connected to a measuring gas located outside the sensor element via an annular diffusion barrier and a gas inlet opening. One of the two electrochemical cells is operated as a Nernst cell, in which a voltage (Nernst voltage) is formed between the electrode in the measuring gas space and the additional electrode exposed to a reference gas; the Nernst voltage is a measure of the ratio of the oxygen partial pressure at the measuring gas space electrode to that at the electrode exposed to the reference gas. The other one of the two electrochemical cells is used as a pump cell, which, by applying a voltage, is made to pump oxygen into or from the measuring gas space in such a way that an oxygen partial pressure of λ=1 is established in the measuring space.
The electrodes are situated on the measuring-side end of the sensor element, i.e., in the measuring area of the sensor element, and are connected, via leads, to contact surfaces connecting the sensor element to an analyzer circuit situated outside the sensor element. The contact surfaces are applied to the external surfaces of the sensor element on the terminal-side end of the sensor element, i.e., in a contact area. The lead area where the leads to the electrodes are situated is provided between the measuring area and the contacting area. The electrode, the lead, and the contact surface together form a conductor track.
The electrochemical cells in the measuring area of the sensor element are heated by a heating element to a temperature at which the solid electrolyte has a sufficiently high conductivity for oxygen ions.
The disadvantage of a sensor element of this type is that heat is removed from the measuring area of the sensor element via the conductor track, in particular via the electrode lead. As a result of the heat flow from the measuring area, a high-performance heating element must be used to heat the measuring area of the sensor element to the required temperature. In addition, the sensor element is also heated in the lead area and the contacting area, so that the oxygen ion conductivity of the solid electrolyte in the lead and contacting areas increases, which may impair the measuring signal. Furthermore, due to the heat flow from the measuring area, a temperature gradient is established on the electrode surface, whereby the function of the electrode and thus ultimately the measuring function of the sensor element is impaired.
Providing conductor tracks with open porosity to form three-phase boundaries on the electrodes, at which oxygen transfer between gas and solid electrolyte is possible, is also known. If the conductor track has an electrode situated in the measuring gas space and the lead of the conductor track is connected to the reference gas, it is disadvantageous that a reference gas containing a high proportion of oxygen may reach the measuring space via the interconnected pores (open porosity) of the conductor track, since this modifies the oxygen partial pressure in the electrode area and distorts the measuring signal.
The sensor element according to the present invention has the advantage over the related art that heat conduction from the measuring area along the conductor track is reduced and the electrode has a largely constant temperature over its surface.
For this purpose, the conductor track has at least one narrowing, which is configured in such a way that heat conduction along the longitudinal direction of the conductor track from the measuring area into the lead area is reduced. The narrowing is provided in a transition area between the measuring area and the lead area. The narrowing may be implemented as a constriction and/or via a recess or multiple recesses.
The conductor track has a smaller cross-section area in the area of the narrowing than in the areas adjacent to the narrowing. Areas adjacent to the narrowing are to be understood as the areas adjacent to the narrowing both in the direction of the measuring area and in the direction of the lead area. In other words, if the cross-section area were to be plotted against the length of the conductor track, the resulting function would have a minimum in the area of the narrowing. Cross-section area is to be understood as the area of the conductor track in a plane perpendicular to the heat gradient formed due to the heating of the measuring area in the conductor track. The heat gradient is usually oriented parallel to the length of the conductor track.
The cross-section area in the area of the narrowing is at most 70 percent, e.g., 50 percent of the cross-section area of the conductor track in an area adjacent to the narrowing. The area through which the heat flow from the measuring area into the lead area may take place is thus reduced.
In an example embodiment of the present invention, the narrowing is designed via at least one slot-shaped recess, which has a longer side and a shorter side, the longer side being approximately perpendicular to the length of the conductor track.
In an alternative example embodiment of the present invention, a plurality of recesses is provided in the area of the narrowing of the conductor track, whereby a netlike structure is formed in the conductor track. The recesses are advantageously offset to one another with respect to the longitudinal axis of the conductor track.
In another, alternative example embodiment, the narrowing is designed as a constriction of the conductor track, so that the width of the conductor track in the area of the constriction is smaller than the width of the conductor track in the areas adjacent to the constriction. In an example manner, the width of the conductor track in the area of the constriction is at most 70 percent, e.g., 50 percent of the width of the conductor track in the areas adjacent to the constriction.
Heat conduction from the measuring area into the lead area is effectively reduced by the above-mentioned example embodiments.
In a particularly advantageous manner, the conductor track is additionally used for shielding electrodes terminated with a high resistance, such as a reference electrode. For this purpose, the conductor track is situated in such a way that it absorbs fault currents and/or shields against electrical interference that may come from the heater. A wide conductor track is required for effective shielding. However, making a conductor track wider also increases its cross-section area. Large cross-section areas result in an undesirably high heat conduction. Therefore, according to the present invention, recesses are provided to implement a wide conductor track having a relatively small cross-section area. Width b of the conductor track is to be understood as the dimension of the conductor track perpendicularly to its length and parallel to the major surface of the sensor element. Width b identifies the distance between the boundaries of the conductor track in that direction and is therefore the same for a conductor track of a given external contour regardless of whether or not it has recesses. In contrast, cross-section area A is reduced by the introduction of recesses. Since the recesses have only a slight effect on the quality of the shielding, the shielding of the conductor track having recesses (for the same width b) is comparable to that of a conductor track without recesses. However, since cross-section area A is considerably reduced by the introduction of the recesses, the heat conduction of a conductor track having recesses is considerably lower than that of a conductor track without recesses. The ratio A/b≦0.1 mm, e.g., A/b≦0.02 mm, is advantageously met in the recess area, which helps achieve good shielding with low heat conduction.
The ratio b/c≦0.8, e.g., b/c≦0.5, is also advantageously met, b again being the (total) width of the conductor track, with c being the sum of widths of the individual sections of the conductor track, which are interrupted by the recess(es). The height of the conductor track, i.e., the dimension of the conductor track in the direction perpendicular to the major surface of the sensor element, is advantageously in the range of 4 μm to 20 μm, e.g., in the range of 5 μm to 10 μm.
It is also advantageous that a gas diffusion diminishes along the conductor track according to the present invention having a narrowing. Reference gas may penetrate into the measuring gas space through a conductor track having an open porosity, which results in distortion of the measuring signal. The cross section of the conductor track is reduced and thus the gas flow through the conductor track is limited by the narrowing. In a particularly advantageous manner, the conductor track includes an area in which the gas diffusion per unit of surface area is considerably further limited or even totally suppressed, for example, by a structure having closed pores or no pores being provided in this area. Using this measure, a gas having high oxygen content may be effectively prevented from reaching the measuring gas space from the terminal-side end section of the sensor element via the conductor track. Normally the conductor track contains a metallic portion, for example, platinum, and a ceramic portion, for example, yttrium oxide-stabilized zirconium oxide. By reducing the ceramic portion, the proportion of pores is reduced or an area having a closed porosity is provided. The conductor track area in which the gas diffusion is substantially limited or totally suppressed is advantageously provided directly next to the measuring gas space and is short compared to the total length of the conductor track.
In an alternative example embodiment of the present invention, which may be implemented independently from the above-mentioned measures, the electrode situated entirely in the measuring space has a first and a second electrode section, the first electrode section being electrically contacted by the electrode lead in the transition area between the measuring area and the lead area, and the second electrode section and the first electrode section being electrically connected only on their sides facing away from the lead area. In such a system, the heat may flow from the second electrode section to the lead of the conductor track only via the first electrode section. This reduces the heat flow, in particular from the second electrode section into the lead, without impairing the measuring function of the electrode (for example, by reducing the surface area of the electrode).
Sensor element 10 has a heated measuring area 11 and a lead area 12. The area between measuring area 11 and lead area 12 is referred to as transition area 13. The heating of measuring area 11 by a heating element 51 is described in more detail below (see
On one side of first solid electrolyte layer 21 forming an external surface of sensor element 10, there is a first conductor track 31, which includes a first electrode 31a and a first lead 31b to first electrode 31a. First conductor track 31 is covered by a porous protective layer 46. Furthermore, an electrically insulating insulation layer 45 is provided between first lead 31b and first solid electrolyte layer 21.
A second conductor track 32, which includes a second lead 32b and a second electrode 32a situated in measuring gas space 41, is applied between first and second solid electrolyte layers 21, 22. Second electrode 32a is applied to first solid electrolyte layer 21 opposite first electrode 31a. A third conductor track 33, which includes a third electrode 33a and a third lead 33b, is situated on the side of second solid electrolyte layer 22 facing first solid electrolyte layer 21. Third electrode 33a is situated in measuring space 41 opposite second electrode 32a. Second electrode 32a is electrically connected to third lead 33b via a lead-through 39. Lead-through 39 may also be provided laterally next to the sectional plane depicted in
Next to second electrode 32a, a fourth conductor track 34 having fourth electrode 34a and a fourth lead 34b is situated on first solid electrolyte layer 21. Fourth electrode 34a is exposed to a reference gas. The reference gas may be present in porous fourth conductor track 34 and/or in a porous insulation layer 44, which is provided in lead area 12 between third conductor track 33 and fourth conductor track 34.
Each of electrodes 31a, 32a, 33a, 34a is connected to contact surfaces (not shown) provided on the side of sensor element 10 facing away from measuring area 11 via leads 31b, 33b, 34b. Each of the contact surfaces is connected to contacting elements, which conduct the measuring signals to an external electronic system (also not shown). Since lead 32b of second electrode 32a is electrically connected to third lead 33b via lead-through 39, second and third electrodes 32a, 33a have a shared lead 33b in some areas.
A heating element 51, which includes a heater 51a and a heater lead 51b, is situated between second solid electrolyte layer 22 and a third solid electrolyte layer 23. Heating element 51 is embedded into a heater insulation 52, which electrically insulates heating element 51 from the surrounding solid electrolyte layers 22, 23. Heating element 51 and heater insulation 52 are laterally surrounded by a heater sealing frame 53.
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The fifth and sixth embodiments of the present invention according to
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Number | Date | Country | Kind |
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10 2004 013 545.2 | Mar 2004 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2005/050560 | 2/9/2005 | WO | 00 | 8/4/2008 |