Oxygen sensing element and process of manufacturing the same

Claim 2

A process of manufacturing an oxygen sensing element having a solid electrolyte body made of an oxygen-ion conductive solid electrolyte material, and a measuring electrode and a reference electrode formed on the solid electrolyte body in communication with a measurement gas and a reference gas having a predetermined oxygen concentration, respectively, such that an electromotive force is induced between the measuring and reference electrodes based on a difference in oxygen concentration between the measurement gas and the reference gas, said method comprising the steps of: preparing an unfired formed body of said solid electrolyte body using said oxygen-ion conductive solid electrolyte material mixed with a sintering aid; firing said unfired formed body into said solid electrolyte body at a temperature within a range which is defined by a permissible lowest sintering point of said unfired formed body and a point which is 60° C. above said permissible lowest sintering point; and chemically treating the fired surface of said solid electrolyte body under a condition whereby the oxygen-ion conductive solid electrolyte material is not deteriorated and the strength of the solid electrolyte body is not reduced; said chemical treatment being carried out to such an extent that an amount of the sintering aid left on the surface of said solid electrolyte body is smaller than that left within an interior structure of the solid electrolyte body, as viewed in a transverse cross sectional plane of the solid electrolyte body.

Claim 3

A process according to claim 1, wherein said step of chemically treating the fired surface of said solid electrolyte body comprises exposing said fired surface to a solution containing no more than 10% of acid.

Claim 4

A process according to claim 1, wherein said solid electrolyte material consists of zirconia fully or partially stabilized by a stabilizing agent.

Claim 5

An oxygen sensing element having an oxygen-ion conductive solid electrolyte body, a measuring electrode formed on the solid electrolyte body in communication with a measurement gas, and a reference electrode formed on the solid electrolyte body in communication with a reference gas having a predetermined oxygen concentration, such that an electromotive force is induced between the measuring and reference electrodes based on a difference in oxygen concentration between the measurement gas and the reference gas; wherein said oxygen-ion conductive solid electrolyte body is formed by a process comprising: preparing an unfired formed body of the solid electrolyte body from an oxygen-ion conductive solid electrolyte material mixed with a sintering aid; firing said unfired formed body into said solid electrolyte body at a firing temperature selected within a range which is defined by a lower limit equal to a permissible lowest sintering point of said unfired formed body and an upper limit which is 60° C. above the permissible lowest sintering point; and chemically treating the fired surface of said solid electrolyte body under a condition whereby the oxygen-ion conductive solid electrolyte material is not deteriorated and the strength of the solid electrolyte body is not reduced; said chemical treatment being carried out to such an extent that an amount of the sintering aid left on the surface of said solid electrolyte body is smaller than that left within an interior structure of the solid electrolyte body, as viewed in a transverse cross sectional plane of the solid electrolyte body.

Claim 6

An oxygen sensing element having an oxygen-ion conductive solid electrolyte body, a measuring electrode formed on the solid electrolyte body in communication with a measurement gas, and a reference electrode formed on the solid electrolyte body in communication with a reference gas having a predetermined oxygen concentration, such that an electromotive force is induced between the measuring and reference electrodes based on a difference in oxygen concentration between the measurement gas and the reference gas; wherein said oxygen-ion conductive solid electrolyte body is formed by a process comprising: preparing an unfired formed body of the solid electrolyte body from an oxygen-ion conductive solid electrolyte material mixed with a sintering aid; firing said unfired formed body into said solid electrolyte body at a firing temperature selected within a range which is defined by a lower limit equal to a permissible lowest sintering point of said unfired formed body and an upper limit which is 60° C. above the permissible lowest sintering point; and chemically treating the fired surface of said solid electrolyte body under a condition whereby the oxygen-ion conductive solid electrolyte material is not deteriorated and the strength of the solid electrolyte body is not reduced; said chemical treatment being carried out to such an extent that an amount of the sintering aid left on the surface of said solid electrolyte body is smaller than that left within an interior structure of the solid electrolyte body, as viewed in a transverse cross sectional plane of the solid electrolyte body.

Claim 7

An oxygen sensing element according to claim 4, wherein said solid electrolyte material consists of ziconium fully or partially stabilized by a stabilizing agent.

Claim 8

An oxygen sensing element according to claim 4, wherein said sintering aid comprises SiO 2 .

Claim 9

An oxygen sensing element according to claim 4, wherein said step of chemically treating the fired surface of said solid electrolyte body comprises exposing said fired surface to a solution containing no more than 10% of acid.

Claim 10

An oxygen sensing element according to claim 4, wherein said step of chemically treating the fired surface of said solid electrolyte body is performed at a temperature of not greater than 80° C.