Denso Corporation

Hirofumi Noda

Takashi Araki

Hirokazu Yamada

Takehito Kimata

Yuto Tamei

Keiji Kanao

Takashi Kojima

Masato Ozawa

Satoshi Hino

Koichi Yoshida

Kaneo Buma

Kazutoshi Kodama

Kouichi Hirano

A sensor device is equipped with a housing having an element cover retaining a sensor element such that a detection section of the sensor element is positioned at the tip end of the sensor element. The element cover includes an inner cover provided with inner side holes and an inner tip face hole respectively provided therein, and an outer cover provided with outer side holes in a side thereof, with the tip position of the outer side holes located closer to the tip end than is the tip position of the inner cover. Between the outer surface of the inner cover and the inner surface of the outer cover there is a large clearance section at the tip end and a small clearance section at the base end, providing a flow path that is shaped for connecting the large clearance section and the small clearance section without a step.

Sensor device detecting specific component in gas

A sensor device includes an element cover at the tip end of a housing, retaining a sensor element. An outer cover is provided with outer side holes, with the tip position of the outer side holes being farther toward the tip end than is the tip position of an inner cover, and a first flow passage having a gas flow direction that is at right angles to the axial direction is formed at the inner side of the outer cover. An inner side hole in the inner cover is open to a second flow passage provided between the side surfaces of the inner cover and the outer cover, and a detection surface of the sensor element is located on an extension line in an extension direction of a guide member which extends obliquely into the interior of the inner cover from the tip-position edge of the inner side hole.

Sensor device

A gas sensor is provided which includes a hollow metallic housing, a sensor device installed in the housing, and a seal disposed in the housing to hermetically isolate between the housing and the sensor device. The housing has an inner shoulder formed on an inner periphery thereof. The seal is retained on the inner shoulder. The seal is made up of a powder body and a glass body. The powder body is made of inorganic powder and mounted on the inner shoulder. The glass body is arranged on the powder body and has a varying coefficient of thermal expansion which alleviates a difference in thermal expansion between the sensor device and the housing, thereby ensuring the stability of hermetic sealing ability of the seal in high-temperature environments.

Gas sensor

The gas sensor is equipped with a sensor device, a plurality of electrode springs contacting with electrodes and of the sensor device, an insulator retaining the electrode springs, and a plurality of leads connected to the respective electrode springs. Each of the electrode springs includes a retained portion retained by the insulator and a contact portion which is bent and inclined from the retained portion toward a front end side of the sensor device in the lengthwise direction. The contact portion is elastically deformed in contact with the electrode. Each of the electrode springs also includes a bent portion between the contact portion and the retained portion. The bent portion constitutes a base end of the contact portion and is oriented toward the base end side of the gas sensor in the lengthwise direction, thereby enabling the length of the sensor device to be decreased and improving the heat resistance of the electrode springs.

The gas sensor includes a sensor element, a first insulator inside which the sensor element is inserted, a second insulator disposed on a proximal side of the first insulator so as to cover a proximal side of the sensor element, and a contact member held by the second insulator and sandwiching the sensor element. A proximal end portion of the first insulator and a distal end portion of the second insulator abut on each other in an axial direction. Each the proximal end portion and the distal end portion is provided with a positioning structure. The positioning structure is configured to restrict a relative movement between the first and second insulators in a sandwiching direction in which the sensor element is sandwiched by the contact member and in an orthogonal direction perpendicular to the sandwiching direction and in the axial direction.

The gas sensor includes a sensor element having electrode pads formed in its electrode forming surfaces at the proximal end portion thereof, an insert-holding insulator insert-holding the sensor element, a housing insert-holding the insert-holding insulator, and a terminal unit. The proximal end portion of the sensor element is held by the terminal unit which includes a pair of proximal end insulators formed with metal terminals at their inner surfaces, and a spring member pressing the proximal end insulators in a direction that they approach each other. Each of the proximal end insulators includes an insulator contact portion in contact with one of the electrode forming surfaces. The insulator contact portion is located closer to the proximal end of the sensor element than a terminal contact portion at which the metal terminal contacts a corresponding one of the electrode pads.

Gas sensor and method of manufacturing same

An improved structure of a gas sensor designed to withstand physical impact which may result in damage such as cracks to a sensor element built in the gas sensor. Specifically, the gas sensor includes a buffer provided by a clearance between an air cover a porcelain insulator. The clearance is in a range of 1 to 2.5 mm at a minimum. The gas sensor may alternatively have a harder portion in the air cover which has a Vickers hardness of 200 to 400. The gas sensor may alternatively have a rigidity enhancer in the air cover which works to provides an increased rigidity to the air cover.

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Kariya, Japan

Hirofumi Noda