Flat plate sensor with a robust package design

Abstract

The invention includes a flat plate exhaust sensor including a flat plate sensing element which is carried by a first ceramic insulator having at its upper end an upwardly extending annular ring. The annular ring defines a disc-shaped recess which is filled with a glass seal. Thus, the glass seal extends from the flat plate sensor to the annular ring of the ceramic insulator. The sensor includes an upper tubular shell which includes at the lower end a leg portion which extends inside an inner wall of a lower tubular shell. The leg portion includes a foot which is bent to match an outwardly extending sloped annular shoulder formed on an upper insulator. The upper insulator is seated on the glass seal. An intermediate gasket is formed by an active metal braze gasket between the foot and the outwardly extending sloped annular shoulder of the upper insulator. An external seal is provided by a braze ring which joins an upper end of the lower tubular shell to the upper tubular shell. The system removed the thermal expansion mismatch problems of prior art glass seal sensors.