Patent US4208265A successfully refreshed from Google Patents.
US4208265A
Expired / Lapsed
US
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Oxygen sensor element and process of manufacture
Assignee: Toyota Motor Corp
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Filing: 1978-04-28
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Granted: 1980-06-17
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Expires: 1998-04-28
Abstract
Abstract An oxygen sensor element is manufactured by successively forming on the outside of the output lead wire, a solid pole, a first metal electrode layer, a solid electrolyte layer, and a second metal electrode layer from inside to outside.
Inventors
- 👤 Ryuzo Hori
- 👤 Kiyoshi Uchida
- 👤 Yasuhiro Otsuka
- 👤 Shinichi Matsumoto
- 👤 Hiroshi Wakisaka
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 13:57
CPC Classifications
G; G01; G01N; G01N27/00; G01N27/26; G01N27/403; G01N27/406; G01N27/407; G01N27/4073; G01N27/4075; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002
Claims Analysis
Total Claims: 21
Claim 1
Independent Claim
155 words
Process for manufacturing an oxygen sensor element comprising the steps of: (a) forming a sinterable mass of an oxygen reference material around an output lead wire, the sinterable mass being of a material selected from the group consisting of a metal, or a mixture of a metal and its oxide, said sinterable mass containing an anti-over sintering agent; (b) sintering said mass of reference material to form a porous sintered mass of oxygen partial pressure generating material in the form of a solid pole with the lead wire embedded in the material; (c) then coating a first metal layer onto the outside surface of the solid pole so that the first metal layer electrically contacts the lead wire; (d) then coating the entire external surface of the first metal layer coated solid pole with a solid electrolyte; and (e) then coating a second metal electrode layer on the outside surface of the solid electrolyte layer.
Claim 2
Dependent Claim
155 words
Process for manufacturing an oxygen sensor element comprising the steps of: (a) forming a sinterable mass of an oxygen reference material around an output lead wire, the sinterable mass being of a material selected from the group consisting of a metal, or a mixture of a metal and its oxide, said sinterable mass containing an anti-over sintering agent; (b) sintering said mass of reference material to form a porous sintered mass of oxygen partial pressure generating material in the form of a solid pole with the lead wire embedded in the material; (c) then coating a first metal layer onto the outside surface of the solid pole so that the first metal layer electrically contacts the lead wire; (d) then coating the entire external surface of the first metal layer coated solid pole with a solid electrolyte; and (e) then coating a second metal electrode layer on the outside surface of the solid electrolyte layer.
Claim 3
Dependent Claim
22 words
A method according to claim 1 wherein said oxygen reference material consists essentially of a mixture of a metal and its oxide.
Claim 4
Dependent Claim
31 words
Process of claim 1, wherein said step of sintering comprises, sintering the solid pole on an output lead wire of a material selected from the group consisting of Pt or Pt-Rh.
Claim 5
Dependent Claim
27 words
Process of claim 1, wherein said step of sintering comprises, sintering a solid pole from a material selected from among Ni, Ni/NiO, Cu, Cu/CuO, Fe, and Fe/FeO.
Claim 6
Dependent Claim
24 words
Process of claim 4, wherein α-Al 2 O 3 is added to the material of said solid pole before sintering as anti-over sinter agent.
Claim 7
Dependent Claim
53 words
Process of claim 1, wherein said step of forming a solid electrolyte layer comprises forming the solid electrolyte layer from a material selected from among ZrO 2 (zirconia), HfO 2 , and CeO 2 , which have been stabilized with a material selected from among CaO, MgO and Y 2 O 3 .
Claim 8
Dependent Claim
35 words
Process of claim 1, wherein said first metal electrode layer and second metal electrode layer are constituted of either Pt alone or Pt containing at least one material selected from among Pd, Rh and Ag.
Claim 9
Dependent Claim
18 words
Process of claim 1, wherein said output lead wire is embedded in said lead wire prior to sintering.
Claim 10
Dependent Claim
41 words
Process of claim 1, wherein said first metal electrode layer is formed on the outside surface of said solid pole by a process selected from among: decomposition by metal salt, baking of platinum paste, chemical or electrical plating, and ion plating.
Claim 11
Dependent Claim
32 words
Process of claim 1, wherein said solid electrolyte layer is formed on the outside surface of said first metal electrode layer by a process selected from among: plasma-spraying, sintering, and hot pressing.
Claim 12
Dependent Claim
26 words
Process of claim 1, further comprising embedding an insulation tube in said solid electrolyte layer to partially cover an exposed portion of said output lead wire.
Claim 13
Dependent Claim
30 words
Process of claim 11, wherein said second metal electrode layer is formed on the outside surface of said solid electrolyte layer and on the outside surface of said insulation tube.
Claim 14
Dependent Claim
41 words
Process of claim 1, further comprising insulating an exposed portion of the wire by forming on the wire an insulation tube from a material selected from among ZrO 2 (zirconia), Al 2 O 3 (alumina) and MgO.Al 2 O 3 spinel.
Claim 15
Dependent Claim
38 words
Process of claim 1, wherein said step of forming a second metal electrode layer on the outside surface of said solid electrolyte comprises forming said electrode layer by a process selected from among: plasma-spraying, sintering and hot pressing.
Claim 16
Dependent Claim
20 words
Process of claim 1, further comprising forming a porous coating on the outside surface of said second metal electrode layer.
Claim 17
Dependent Claim
31 words
Manufacturing process of claim 15, wherein said porous coating is formed from a material selected from among stabilized ZrO 2 , Al 2 O 3 and MgO.Al 2 O 3 .
Claim 18
Dependent Claim
15 words
Manufacturing process of claim 15, comprising forming said porous coating by a process of plasma-spraying.
Claim 19
Dependent Claim
105 words
An oxygen sensor element comprising: an output lead wire, a porous sintered mass of an oxygen partial pressure generating material in the form of a solid pole formed onto one end of said output lead wire, a first metal electrode layer formed on the outer surface of said solid pole so that the first metal electrode layer electrically contacts said output lead wire, a solid electrolyte layer formed wholly around the outer surface of said first metal electrode layer and solid pole, and a second electrode layer formed on the outer surface of said solid electrolyte layer and electrically insulated from said output lead wire.
Claim 20
Dependent Claim
105 words
An oxygen sensor element comprising: an output lead wire, a porous sintered mass of an oxygen partial pressure generating material in the form of a solid pole formed onto one end of said output lead wire, a first metal electrode layer formed on the outer surface of said solid pole so that the first metal electrode layer electrically contacts said output lead wire, a solid electrolyte layer formed wholly around the outer surface of said first metal electrode layer and solid pole, and a second electrode layer formed on the outer surface of said solid electrolyte layer and electrically insulated from said output lead wire.
Claim 21
Dependent Claim
23 words
The oxygen sensor element claimed in claim 18, further comprising a protective porous coat on the outer surface of said second electrode layer.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1983-06-17 | 1983-12-17 | 1984-06-17 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-06-17 | 1987-12-17 | 1988-06-17 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-06-17 | 1991-12-17 | 1992-06-17 | $7700.00 | Window Closed / Lapsed |