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EP1228362A2 - Dispositif d'etancheite de capteur de gaz et son procede de fabrication - Google Patents

Dispositif d'etancheite de capteur de gaz et son procede de fabrication

Info

Publication number
EP1228362A2
EP1228362A2 EP00989723A EP00989723A EP1228362A2 EP 1228362 A2 EP1228362 A2 EP 1228362A2 EP 00989723 A EP00989723 A EP 00989723A EP 00989723 A EP00989723 A EP 00989723A EP 1228362 A2 EP1228362 A2 EP 1228362A2
Authority
EP
European Patent Office
Prior art keywords
seal
shield
upper shield
disposed
gas sensor
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP00989723A
Other languages
German (de)
English (en)
Inventor
Richard W. Duce
Kathryn M. Mccauley
Richard C. Kuisell
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Delphi Technologies Inc
Original Assignee
Delphi Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Delphi Technologies Inc filed Critical Delphi Technologies Inc
Publication of EP1228362A2 publication Critical patent/EP1228362A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
    • G01N27/26—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating electrochemical variables; by using electrolysis or electrophoresis
    • G01N27/403—Cells and electrode assemblies
    • G01N27/406—Cells and probes with solid electrolytes
    • G01N27/407—Cells and probes with solid electrolytes for investigating or analysing gases
    • G01N27/4077—Means for protecting the electrolyte or the electrodes
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
    • G01N27/26—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating electrochemical variables; by using electrolysis or electrophoresis
    • G01N27/403—Cells and electrode assemblies
    • G01N27/406—Cells and probes with solid electrolytes
    • G01N27/407—Cells and probes with solid electrolytes for investigating or analysing gases

Definitions

  • This invention relates to gas sensors, and, more particularly, to seals for use in gas sensors.
  • Sensors are used in a variety of applications that require qualitative and quantitative analysis of gases.
  • the direct relationship between the oxygen concentration in the exhaust gas and the air-to-fuel ratio of the fuel mixture supplied to the engine allows the oxygen sensor to provide oxygen concentration measurements for determination of optimum combustion conditions, maximization of fuel economy, and the management of exhaust emissions.
  • a conventional stoichiometric oxygen sensor typically comprises an ionically conductive solid electrolyte material, a porous electrode on the exterior surface of the electrolyte exposed to the exhaust gases with a porous protective overcoat, and an electrode on the interior surface of the sensor exposed to a known oxygen partial pressure.
  • Sensors typically used in automotive applications use a yttria stabilized zirconia based electrochemical galvanic cell with platinum electrodes, which operate in potentiometric mode to detect the relative amounts of oxygen present in the exhaust of an automobile engine. When opposite surfaces of this galvanic cell are exposed to different oxygen partial pressures, an electromotive force is developed between the electrodes on the opposite surfaces of the zirconia wall, according to the Nernst equation: RT p l
  • seals can be comprised of either a one-piece design (seal 106) or be in two parts, a seal 106 and a boot 104, to prevent water and other contaminant intrusion into the sensor 100.
  • Seals comprised of two parts are more effective at preventing contamination, but are more costly.
  • volatile hydrocarbons present in these conventional seals, tend to evaporate at high temperatures, causing the seals to shrink from the walls of the upper shield, or from the cables, allowing contaminants to enter into the sensor. What is needed in the art is a one-piece seal that prevents fluids, gases and other environmental contaminants from entering the sensor.
  • the seal comprises: a body, an upper portion having a flange, and at least one channel that extends through the body from the upper portion to a lower surface.
  • the flange has an extension that extends from the upper portion, a bend which extends from the extension along the body, and a protrusion which extends from the bend toward the body.
  • the gas sensor comprises: a sensing element, having a lower portion disposed within a subassembly, and an upper portion disposed within a wiring harness assembly comprising an upper shield disposed around a wiring harness.
  • the sensor also comprises: a seal having a body disposed in a first portion of the upper shield, and a flange wherein an edge of the upper shield is disposed between at least a portion of the flange and the body.
  • the method for producing the gas sensor comprises: disposing an upper portion of a sensing element within a wiring harness assembly comprising an upper shield disposed around a wiring harness, disposing a lower portion of the sensing element within a subassembly, disposing at least a portion of a body of a seal concentrically within the upper shield, extending a flange over an edge of the upper shield, and crimping the upper shield around the seal.
  • Figure 1 is a cross-sectional view of a prior art gas sensor design.
  • Figure 2 is a cross-sectional view of a gas sensor design in accordance with the present invention.
  • Figure 3 is an isometric view of an exemplary seal.
  • Figure 4 is a cross-sectional view of an exemplary seal taken along lines 4-4 of Figure 3.
  • Figure 5 is an isometric bottom view of an exemplary seal. DETAILED DESCRIPTION OF THE INVENTION
  • the sensor typically comprises: a wiring harness assembly having an upper shield, a seal, electrical components (e.g., edge card connectors, male and /female terminals, spring clips or adaptors, and the like, as well as combinations comprising at least one of the foregoing components), and an upper portion of a sensing element; a subassembly having a shell, a lower shield, an optional internal shield, the lower portion of a sensing element, and optionally a high temperature mat material, a ceramic insulator or similar insulate, and a talc pack, and the like.
  • the seal located within the top portion of the upper shield, protects the sensor from the intrusion of water and other contaminants.
  • the seal is a one-piece, multi-functional seal that protects the sensor from contamination and from shock loads or vibrations that may damage the sensing element, and retains the terminal support in place
  • the wiring harness assembly 12 generally includes the seal 40 and electrical components connected to the upper portion 84 of the sensing element 80 within the upper shield 20.
  • the subassembly 14 generally includes the lower portion of the sensing element 80, an internal shield 35 in a lower shield 30, insulators 90, 92. talc pack 70, and a shell 50.
  • Exemplary materials for the shields 20, 30, and 35 and for the shell 50 are stainless steels such as high chrome and/or high nickel stainless steels, and mixtures and alloys comprising at least one of the foregoing stainless steels, and the like, with all materials chosen for high temperature endurance, high- strength and corrosion resistance.
  • the lower shield 30 is securely coupled to the shell 50 such that a first end 82 of the sensing element 80 is disposed within the sensing chamber 31 to permit contact with and sensing of gas.
  • the lower shield 30 defines the sensing chamber 31 and, disposed within the lower shield 30, is an internal shield 35 for receiving the sensing element 80.
  • the lower shield 30 and the internal shield 35 incorporate a plurality of apertures 38, 39 for allowing passage of gas in and out of the sensing chamber 31 so that the gasses may be sensed by the receptive first end 82 of the sensing element 80.
  • the lower insulator 92 is Adjacent to the lower shield 30 and disposed between the shell 50 and sensing element 80 is at least a portion of the lower insulator 92.
  • the lower insulator 92 is comprises a high temperature material (i.e., a material capable of withstanding the "sensor operational conditions", e.g., exhaust gas temperatures up to about 1,000°C). to provide insulation for the sensor 10.
  • a high temperature material i.e., a material capable of withstanding the "sensor operational conditions", e.g., exhaust gas temperatures up to about 1,000°C.
  • Some possible high temperature materials which are chosen for electrical insulation, thermal resistance, and mechanical support, include ceramics and metals, among others, and combinations, alloys, and composites comprising at least one of the foregoing materials in the form of fibers (random, chopped, continuous, woven, and the like), woven and non-woven mesh, among others.
  • the ceramic can include steatite, alumina, or the like, or combinations comprising at least one of the foregoing ceramics.
  • the lower insulator 92 is disposed within the shell 50.
  • the shell 50 has a body portion 52 and a threaded portion 54.
  • the body portion 52 is preferably shaped to accommodate a wrench or other tool for tightening the threaded portion 54 into a mount for an exhaust pipe or other component of an exhaust flow system, or wherever the gas sensor will be employed, thus enabling a sensor chamber 31 to be located within a flow of gasses to be measured.
  • the shell 50 can be coupled to the upper shield 20 by a crimping or other process known in the art.
  • a gasket 72 which provides a source of tension to help retain sensor 10 in operational position and serves as a seal against gas leakage.
  • a talc pack 70 which can be disposed within the shell 50 adjacent to the sensing element 80.
  • the talc pack 70 can be disposed between the upper insulator 90 and the lower insulator 92 or between the shell shoulder 56 and the insulator 90, 92.
  • the talc pack 70 holds the sensing element 80 in place by compacting talc powder around the sensing element 80.
  • the talc pack 70 serves as a leak resistant seal that can be obtained by employing an inorganic material, such as talc, mica, kaolin, and the like, as well as combinations comprising at least one of the foregoing materials, between the sensing element 80 and lower shield 30.
  • an inorganic material such as talc, mica, kaolin, and the like, as well as combinations comprising at least one of the foregoing materials, between the sensing element 80 and lower shield 30.
  • the sensing element 80 Disposed within the shell 50 and the upper shield 20 can be the sensing element 80 having contact pads 86, 88. Portions of the sensing element 80 are disposed within the upper shield 20, the shell 50 and the lower shield 30.
  • the sensing element 80 can be a planar or flat plate sensing element of a known type.
  • the sensing element 80 includes a gas constituent-responsive structure (e.g., an electrochemical cell or the like) fabricated into the sensing element in a known manner, preferably along with a heater of a known type.
  • contact pads 86, 88 Disposed at or near the second end 84 of the sensing element 80 are contact pads 86, 88, which are comprised of conventional materials known in the art.
  • the upper insulator 90 Disposed at least partially within the upper shield 20 is the upper insulator 90 which typically extends into shell 50.
  • This upper insulator can comprise any conventional design or the design set forth below.
  • the upper insulator 90 which can be comprised of the same or similar types of high temperature materials as the lower insulator 92, insulates and protects the sensor 10.
  • the upper insulator 90 which can be a cylindrical device with a passage 93 of various widths for the insertion of the sensing element 80, optionally comprises an indentation or shelf 94 that extends outward from the passage 93 within the interior of the upper portion 91 to receive the terminal(s) 62, 63 of the wiring harness assembly 12.
  • the terminal(s) 62, 63 are positioned such that they fit into, rest on or are supported by the upper insulator 90. By supporting the weight of the terminal(s) 62, 63 and the terminal support 60, the upper insulator 90 removes the weight and force from damaging the sensing element 80.
  • This embodiment is further disclosed in Patent Application Serial No. ,
  • Terminal(s) 62, 63 which provide electrical communication between the sensing element 80 and the vehicle electrical system, can hold or retain the sensing element 80 in place by utilizing a spring design, as is known in the art.
  • the terminal(s) 62, 63 are generally comprised of materials known in the art, which may include stainless steel, copper, brass, nickel, and the like, as well as combinations and alloys comprising at least one of the foregoing materials. Material and a terminal design which provides a substantial spring force under sensor operating conditions is preferred.
  • the terminals 62, 63 connect with the cable(s) or wire(s) 64, 65 entering the wiring harness assembly 12 from the vehicle electrical system.
  • the cable(s) 64, 65 can be comprised of materials that are generally those that are known in the art, including copper, brass, stainless steel, nickel, and the like, as well as combinations and alloys comprising at least one of the foregoing materials. These cables are typically encased within an insulation, such as Teflon.
  • a terminal support 60 is provided.
  • the terminal support 60 has a generally cylindrical shape optionally having a flat side, however, other designs are possible, such as multisided, and the like.
  • Located within the top of the terminal support 60 are channels or holes for receiving terminals and electrical cables. Within the channels, an indentation or pocket can be created for receiving the terminals.
  • the terminal support 60 may be formed of a material that is durable under sensor operation conditions.
  • thermoplastic thermoset
  • ceramic such as steatite, alumina, and the like
  • combinations comprising at least one of the foregoing terminal support materials, with ceramic and plastics often employed.
  • a one-piece, multifunctional fastener or seal 40 can comprise a body at least partially disposed within the upper end 22 of the upper shield 20, adjacent to the terminal support 60.
  • the seal 40 is designed to have a lip, outcropping, or flange 124 and optional bumps, projections or protrusions 140.
  • the seal 40 which can be made by conventional molding techniques known in the art, can comprise material capable of withstanding temperatures commensurate with the operation of an engine. Typical materials include fluoroelastomer, silicone, rubber, perfluoroelastomer, as well as other conventional seal materials and combinations comprising at least one of the foregoing materials.
  • This seal 40 protects the sensing element 80 by preventing the intrusion of water or other contaminants into the sensor 10.
  • the seal 40 is a one-piece unit having an upper portion 120 and a lower portion 122.
  • the upper portion 120 has a flange 124 for receiving the upper shield.
  • Located in the upper portion 120 are channels or holes 130 for receiving electrical cables (not shown).
  • the seal channels 130 extend from the upper portion 120 through the lower portion 122 and exit through the seal bottom 126.
  • Flange 124 extends outward from the upper portion 120 and along lower portion 122 creating a bend 129.
  • the bottom of flange 124 tapers inward towards the seal 40 such that a protrusion or tip 128 can contact the upper shield 20 when the seal 40 is installed therein (as shown in Figure 2).
  • the seal 40 and flange 124 preferably have a geometry and size complementary with the shield upper portion 22. Essentially, the seal 40 should, once crimped, establish a fluid tight seal between the seal 40 and the upper portion 22 of the upper shield 20 and between the seal 40 and the cables 64, 65. To further establish and maintain this fluid tight connection, the flange 124 is preferably designed such that the opening between bend 129 (and/or the protrusion) and the seal lower portion 122 is less than the thickness of shield upper portion 22 to be disposed between the bend 129 and the seal lower portion 122. As a result, the design specifications of the flange 124 are based upon obtaining the desired sealing between the flange 124 and the shield upper portion 22.
  • the flange 124 preferably comprises an upper portion, e.g., extension 131, disposed at or near the upper seal upper portion 120 which extends substantially perpendicularly from the seal 40 (e.g., angles of up to about 135° or so from the seal central axis 132 can be employed, with angles of about 30° to about 90° are preferred, and an angle of about 75° to about 90° more preferred).
  • extension 131 a bend 129 extends along lower portion 122 to form a recess 127 for receiving the shield upper portion 22.
  • the angle at which the bend 129 extends from extension 131 can be any angle less than parallel with extension 131, with angles up to about 90° preferred.
  • a protrusion 128 can extend from bend 129 toward seal lower portion 122 to form a recess 127 having a opening width which is preferably up to the thickness of the shield upper portion 22 which will be received therein, and which is more preferably smaller than the shield upper portion 22 thickness so as to form a fluid tight seal between the flange 124 and the shield upper portion 22.
  • This design enables the flange 124, to both provide a secure fitting with the upper shield 20 and to create a secondary sealing point.
  • high temperatures can cause the seal to outgas or otherwise shrink. The shrinkage draws the flange 124 closer toward the upper shield 20, thereby forming a tighter seal.
  • flange 124 is preferably disposed, continuously and concentrically around the seal body. Alternatively, if fluid tight sealing of the flange is not required, the flange 124 can be disposed intermittently around the seal body.
  • FIG. 5 one embodiment of the bottom view of the one-piece multifunctional seal 40 is illustrated.
  • the bottom 126 of the seal 40 is the other end of the channels 130 (note, four channels are shown, but any number can be employed based upon the desired number of cables and connections; typically about 3 to about 8 cables (and channels) are employed).
  • projections 140 are also disposed on the bottom 126.
  • the projections 140 are designed to contact the terminal support 60 (as shown in Figure 2), thereby holding the terminal support 60 in the desired location within the upper shield 20 and dampening vibrations or shock loads that can have an impact on the sensor.
  • the projections 140 act similar to a spring, absorbing the vibrations and thereby extending the sensor life by reducing stress and other loads, while minimizing contact between the seal 40 and the terminal support 60.
  • the projections 140 which can be employed in any quantity, are preferably spaced equidistant from each other to provide equal distribution of stresses associated with shock and vibrations.
  • These projections 140 are also preferably designed to form a sufficient air gap between the seal 40 and the terminal support 60 to substantially insulate the seal 40 from convective heat transfer from the terminal support 60. Basically due to the minimal physical contact between the terminal support 60 and the seal 40, the transfer of heat from the lower components of the sensor to the seal 40 is decreased.
  • the present seal Unlike conventional seals that either leak before 500 hours of thermal cycling between about -40°C and 200°C due to out-gassing shrinkage or that require a second sealing component (e.g., a boot), the present seal maintains fluid tight sealing after the same thermal cycling for greater than about 750 hours, and even for over about 1 ,000 hours. Furthermore, under additional testing, with the engine operating at about 1,000°C (e.g., the sensor seal being exposed to temperatures of about 250°C), the present seal has maintained fluid tight sealing for about 250 hours, with at least about 1,000 hours anticipated.
  • a second sealing component e.g., a boot

Landscapes

  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Molecular Biology (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • General Health & Medical Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Measuring Oxygen Concentration In Cells (AREA)
  • Investigating Or Analyzing Materials By The Use Of Fluid Adsorption Or Reactions (AREA)

Abstract

L'invention concerne un dispositif d'étanchéité (40) de capteur de gaz qui comprend un corps (122), une partie supérieure comprenant un rebord (124), et au moins un canal (130). Le rebord (124) présente une extension (131) s'étendant de la partie supérieure, un coude (129) s'étendant à partir de l'extension (131) le long du corps (122), et une protubérance (128) s'étendant à partir du coude (129) en direction du corps (122). Le canal (130) s'étend à travers le corps (122) à partir de la partie supérieure vers une surface inférieure (126). L'invention concerne également un procédé d'utilisation du dispositif d'étanchéité (40) de capteur de gaz à l'intérieur d'un capteur (10).
EP00989723A 1999-10-27 2000-10-26 Dispositif d'etancheite de capteur de gaz et son procede de fabrication Withdrawn EP1228362A2 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US16188099P 1999-10-27 1999-10-27
US161880P 1999-10-27
PCT/US2000/041614 WO2001035087A2 (fr) 1999-10-27 2000-10-26 Dispositif d'etancheite de capteur de gaz et son procede de fabrication

Publications (1)

Publication Number Publication Date
EP1228362A2 true EP1228362A2 (fr) 2002-08-07

Family

ID=22583167

Family Applications (1)

Application Number Title Priority Date Filing Date
EP00989723A Withdrawn EP1228362A2 (fr) 1999-10-27 2000-10-26 Dispositif d'etancheite de capteur de gaz et son procede de fabrication

Country Status (4)

Country Link
EP (1) EP1228362A2 (fr)
JP (1) JP2004521311A (fr)
KR (1) KR20020060720A (fr)
WO (1) WO2001035087A2 (fr)

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005029057A1 (fr) 2003-09-17 2005-03-31 Ngk Spark Plug Co., Ltd. Detecteur et procede de production de ce detecteur
WO2005031334A1 (fr) * 2003-09-29 2005-04-07 Ngk Spark Plug Co., Ltd. Detecteur de gaz
EP1544609A1 (fr) 2003-12-15 2005-06-22 Hitachi, Ltd. Capteur d'oxygène
JP5095915B2 (ja) * 2004-10-27 2012-12-12 日立オートモティブシステムズ株式会社 酸素センサ
KR100674014B1 (ko) * 2005-03-30 2007-01-25 한국델파이주식회사 차량의 엔진제어용 산소센서
KR101525684B1 (ko) * 2013-10-28 2015-06-03 주식회사 현대케피코 산소센서 터미널
CN111016826B (zh) * 2019-12-31 2025-08-01 欧托凯勃汽车线束（太仓）有限公司 一种硅胶线密封保护件
JP7725400B2 (ja) * 2022-03-18 2025-08-19 日本碍子株式会社 ガスセンサおよびガスセンサにおける濃度補正方法
JP7756599B2 (ja) * 2022-06-02 2025-10-20 日本特殊陶業株式会社 ガスセンサ及びガスセンサの製造方法

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4217179A (en) * 1978-07-17 1980-08-12 National Research Development Corporation Determination of lithium, sensor therefor and method of making said sensor
JPH0754852Y2 (ja) * 1990-10-03 1995-12-18 日本碍子株式会社 酸素センサ
US6315880B1 (en) * 1997-10-16 2001-11-13 Mary R. Reidmeyer Chemical plating method, electrolytic cell and automotive oxygen sensor using it

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
None *
See also references of WO0135087A3 *

Also Published As

Publication number Publication date
WO2001035087A3 (fr) 2001-12-13
JP2004521311A (ja) 2004-07-15
WO2001035087A2 (fr) 2001-05-17
KR20020060720A (ko) 2002-07-18

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