JP3435836B2 - Gas sensor and manufacturing method thereof - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electrochemical sensor for detecting a combustible gas, particularly carbon monoxide, in the general atmosphere or in the exhaust gas of various combustion equipment that uses gas or petroleum as a fuel, and uses a catalyst. The present invention relates to a gas sensor having excellent characteristics in terms of durability, which is the biggest problem in a chemical sensor.

[0002]

2. Description of the Related Art Carbon monoxide (CO) is a colorless, tasteless and odorless gas that is slightly lighter than air but highly toxic and causes a headache when breathing for 2-3 hours even at a low concentration of about 200 PPM. 6000 PPM in the quantile
In the above, I die in breathing for several minutes.

Since it is generated from instant water heaters, bath kettles, oil and gas heating appliances and charcoal fires even in ordinary households, it is cheap, compact and reliable to be used by being built into these devices or installed indoors. There is a strong demand for a high carbon monoxide sensor.

As a conventionally proposed gas sensor, especially a carbon monoxide detection sensor, an electrode for absorbing carbon monoxide (CO) to oxidize it is provided in an electrolytic solution, and the CO concentration is determined from a current value proportional to the CO concentration. Using a detection method (constant potential electrolysis gas sensor) and a sintered body type n-type semiconductor oxide such as tin oxide (Sn02) sensitized with a trace amount of additional elements such as precious metals, these semiconductors are treated as flammable gas. A method to detect gas by utilizing the characteristic that electric conductivity changes when contacting (semiconductor type gas sensor), a pair of comparison elements in which alumina is attached to a platinum fine wire of about 20 μm and noble metal is supported It is known that there is a method (catalytic combustion type gas sensor) that detects the difference in heat generation when a combustible gas comes into contact with this element to carry out catalytic oxidation reaction by heating to a constant temperature using These are described in [Reference 1] Toyoaki Omori: "Practical Encyclopedia of Sensors": Fuji Techno System, Chapter 14, Basics of Gas Sensors (Masaki Takeshi Haruta), P11
2-130 (1986) has a detailed description.

In particular, as a gas sensor used to form an electrochemical cell, an oxygen sensor using stabilized zirconia as an electrolyte has been put to practical use for controlling exhaust gas purification of automobiles and is well known. This is a method that uses the electromotive force of an oxygen concentration cell. A gas sensor for measuring carbon monoxide and carbon dioxide at the same time as oxygen has been proposed.

[Reference 2] Japanese Patent Application Laid-Open No. 4-320955 and [Document 3] Japanese Patent Application Laid-Open No. 4-320956.

However, in the case of this method, since a concentration cell is formed, it is necessary to introduce a sample gas with a known concentration into one electrode, and although it is highly applicable as an analytical instrument, the sample gas is required each time it is measured. Can not be introduced and is not suitable for household appliances. However, this method can correct the deterioration of the electrode each time.

Further, as in the present invention, a method of forming a zirconia electrochemical cell, forming a catalyst layer on one side of an electrode and detecting carbon monoxide is [Reference 4] H.OKAMOTO, H.OBA.
YASIAND T. KUDO, Solid State Ionics, 1, 319 (1980)
Has been proposed to. The basic principle of the present invention is the same as in Reference 4. However, in Reference 4, platinum / alumina is used as the catalyst.

[0009]

All of these chemical sensors have the following drawbacks. That is, even if a constant potential electrolysis gas sensor, a semiconductor type gas sensor, and a catalytic combustion type gas sensor react indiscriminately to a reducing gas (combustible gas) in principle, even if various measures are taken, basically,
It has the property of detecting hydrogen, alcohol, etc. other than carbon monoxide (CO). That is, it has a drawback that CO selectivity is poor. Further, the sensor and the sensor system are generally expensive, and the signal processing circuit of the sensor is complicated. Further, except for the catalytic combustion type, the controllability is poor because the output of the sensor is non-linear with respect to the CO concentration.

Basically, in the case of a chemical sensor using a catalyst, there is generally a trade-off between durability and selectivity of the catalyst. In order to increase the selectivity, the operation of the chemical sensor is controlled by the activation control side of the catalytic reaction ( When used on the low temperature side, various poisonous gases are likely to be adsorbed on the surface of the catalyst, and the catalyst deteriorates rapidly and has no durability. On the contrary, if the operation is used on the diffusion control side (high temperature side), the selectivity is deteriorated. For example, in the case of a sensor using an element in which fine gold particles are supported on αFe2O3 doped with Ti4 + as a semiconductor type gas sensor, the selectivity of CO to hydrogen and alcohol is extremely excellent, but the durability of the catalyst is defective.

[0011] In particular, a drawback of the method of Document 4 in which an electrochemical cell is formed by using a solid electrolyte in which one electrode is coated with a catalyst is catalyst deterioration. Particularly in Reference 4, since a noble metal-based catalyst is used, it is deteriorated by a sulfur-based compound or a silicone-based compound unless special measures are taken. Especially, since silicone compounds are full of our living space such as cosmetics and building materials, it is necessary to take measures.

The heating required for the operation of the solid electrolyte and the activation of the catalyst layer is, but as a general means,
A means for forming a yttria-stabilized zirconia film on an alumina substrate by using an alumina substrate having a resistor pattern such as platinum printed on the back surface with electrodes is conceivable. In the case of this method, there is a concern that the zirconia layer may be cracked when the heater circuit is turned on and off due to the difference in expansion coefficient between alumina and zirconia, which is not preferable in terms of durability.

An object of the present invention is to provide a highly sensitive gas sensor which is excellent in durability of the catalyst, which has been a problem in the past, and which is small in size and consumes less power.

[0014]

In order to solve the above-mentioned conventional problems and achieve the above-mentioned object, the gas sensor of the present invention has a resistance heating heater disposed on the inner surface side of a substantially cylindrical solid electrolyte, A pair of electrodes on the outer surface of the solid electrolyte and a porous catalyst film on one of the electrodes and a non-catalytic porous film on the other
To be used. In particular, in the case of forming the catalyst layer, when using a coating body in which an oxidation catalyst is dispersed in a ceramic fiber through a binder, and on the surface, one or more precious metal elements selected from the group of platinum, palladium, and rhodium are used.
The durability is improved by means such as using a woven fabric formed by weaving fibers made of supported inorganic heat resistant fibers. Further, the porous catalyst layer film is formed thicker than the film thickness required for complete oxidation of gas, and the sensor temperature set by the resistance heater is set higher than the temperature necessary for complete oxidation of the catalyst layer. Further, the sensor temperature is initially set higher than the temperature required for complete oxidation of the catalyst layer, and a program for decreasing the sensor temperature with time is built in and used.

The basic structure of the gas sensor will be described below.
As the solid electrolyte layer, Bi2O3-MOO3, which has higher oxygen ion conductivity than stabilized zirconia or stabilized zirconia at low temperature,
An oxygen ion conductor such as CeO2-Sm2O3, or a fluoride ion conductor or a proton conductor other than the oxygen ion conductor can be molded into a cylindrical shape and used. In an electrochemical cell in which a pair of electrodes are formed on the surface using a solid electrolyte, an oxygen concentration cell is formed when an oxygen concentration between the electrodes is different, an electromotive force is generated, and an oxygen sensor element can be configured.

Further, if one of the electrodes is coated with an oxidation catalyst, a chemical reaction of CO + 1 / 2O2 → CO2 ... (1) occurs in the catalyst layer, and strictly speaking, depending on the gas diffusion rate and the catalytic oxidation reaction rate. Although different, the concentration of carbon monoxide reaching the electrode surface is reduced. Oxygen is exclusively adsorbed on the electrode coated with the oxidation catalyst, whereas carbon monoxide and oxygen are adsorbed on the bare electrode without the catalyst coating, and the chemical potential between both electrodes is absorbed here. Difference occurs, a reduction reaction occurs at the electrode on the catalyst layer side and an oxidation reaction occurs at the bare electrode side, and an oxygen concentration battery is formed to obtain an electromotive force. Even in the atmosphere or under the exhaust gas conditions of combustion equipment, the oxygen concentration is at least several percent or more, whereas carbon monoxide needs to be detected at 1000 PPM or less at most, and as in (1), Since 1 mol of carbon monoxide is 1/2 mol of oxygen, the difference in oxygen concentration on the electrode surface when evaluated as a bulk is small, and the effect of carbon monoxide concentration is dominant in the electromotive force. become. This increases the carbon monoxide concentration and increases the output. That is, it becomes a carbon monoxide detection sensor. Although this sensor is basically related to the characteristics of the catalyst, it can detect not only carbon monoxide but also combustible gas.

Generally, it is necessary to heat the sensor element due to the characteristics of the solid electrolyte. This is achieved by the heating means provided in the sensor. That is, since this sensor is equipped with a resistance heater on the inner surface side of the cylindrical solid electrolyte, this is done. Further, if necessary, temperature control may be carried out in combination with temperature detection means such as a thermistor for the purpose of accurate temperature control. As the material used for the resistance heater, various metals and alloy wires such as nickel-based, iron-chromium-based and noble metal-based can be used. Platinum wire is desirable in terms of durability and controllability.

The electrode formed on the surface of the solid electrolyte is platinum,
Gold, silver, or the like can be used, but platinum is generally preferred from the viewpoints of oxygen adsorption characteristics to the electrodes relating to the response of the sensor, diffusion characteristics of ions into the electrolyte, and heat stability.

As the electrode forming method at this time, various methods such as a paste method, a sputtering method, a vacuum vapor deposition method and an electroless plating method can be applied. In addition to basic performance such as sensor responsiveness, electrode characteristics are deeply related to durability, and are important.
Of these methods, electroless plating is particularly preferable because the electrodes are stable and can be atomized and dispersed. Also, in the paste method, excellent characteristics can be obtained by using a paste in which the electrode material is sufficiently atomized.

[0020]

The operation of the sensor in the general atmosphere or in the exhaust gas passage of the combustion device will be described. It is assumed that the sensor element has already been heated to a constant temperature by the resistance heating element arranged on the inner surface side of the cylindrical solid electrolyte. When air containing no combustible gas such as carbon monoxide is sent to the electrode on the solid electrolyte, there is no difference in gas concentration and no electromotive force is generated. Next, when air containing carbon monoxide is sent, carbon monoxide is oxidized in the catalyst layer and does not reach the electrode side where the catalyst layer is formed, so that it occurs between the electrodes on the solid electrolyte. Electricity is generated.

The output of the electromotive force between the electrodes of the solid electrolyte is amplified to extract a signal related to the concentration of carbon monoxide in the air. This increases with increasing carbon monoxide concentration. In the exhaust gas of the combustion equipment, the exhaust conditions change in actual use in relation to combustion control. That is, although the exhaust temperature and the exhaust gas composition (oxygen concentration, nitrogen gas concentration, carbon dioxide concentration, water vapor concentration), etc. change greatly over time,
Since these do not react in the catalyst layer, they are not related to the sensor output, and a stable output related to only combustible gas such as carbon monoxide is obtained.

In the present invention, particularly in the formation of the catalyst layer, a coating body in which an oxidation catalyst is dispersed in a ceramic fiber through a binder is used. In addition, one or more precious metal elements selected from the group of platinum, palladium and rhodium on the surface.
By using a woven fabric formed by weaving fibers made of supported inorganic heat resistant fibers, compared with the catalyst layer formed by conventional thick film printing, etc. The catalyst is used in a certain state. That is,
In contrast to the conventional catalyst layer having a thickness of about 50 μm, the present invention uses the catalyst layer with a thickness of at least 500 μm. Since the internal catalyst layer is used, the life is extremely long.

Over time, the capacity of the resistance heater decreases with deterioration, and the catalyst layer temperature decreases. However, catalytically, the catalyst layer temperature is lower than the catalyst activation temperature due to the capacity of the solid electrolyte. On the other hand, since the catalyst is used in the diffusion control region on the much higher temperature side, the catalytic ability, on the contrary, hardly changes with time.

Further, by setting the sensor temperature to the high temperature side at the initial stage, the sensor output is slightly lowered to be used by slightly generating the oxidation catalytic reaction of carbon monoxide on the electrode surface not covered with the catalyst layer. Therefore, the sensor sensitivity can be improved conversely through a control program that decreases the capacity of the resistance heating heater with time. This is a kind of fail-safe function and is advantageously used in the durability of the sensor.

[0025]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a perspective view of an embodiment of the present invention. In FIG. 1, 1 is a resistance heater, 2 is a cylindrical solid electrolyte, 3 and 4 are a pair of electrodes, and a porous catalyst layer 5 is formed on 4 electrodes on one side. For the resistance heater of No. 1, various heat resistance resistance heating wires, noble metal coil wires, etc. are used, but the appearance thereof is omitted in FIG. 1.

FIG. 2 is a perspective view of an embodiment of the present invention.
The difference from FIG. 1 is that a porous film 6 is formed on the surface of the electrode 3. The porous film 6 is a coating formed of a material having no catalytic activity for the oxidation reaction. Various poisonous substances serve as a resistance that diffuses to the electrode 3, and prevents the electrode 3 from being deteriorated. Silicon as a porous film with no catalytic activity,
A film made of an oxide or a complex oxide of various typical elements such as aluminum is desirable. It can be prepared by using an organic metal salt such as naphthenate and octylate, forming a paste together with a solvent and a binder such as methylcellulose, applying the paste onto the electrode surface, and baking.
The decomposed portion of the organic substance becomes voids, and porosity is obtained.
By itself, by disposing heat-resistant fibers such as glass wool and silica / alumina fibers on the outer periphery of the electrode when the gas sensor element is mounted, this acts as a physical filter medium for poisoning components of the catalyst, and is therefore used as a substitute. You can also

The characteristics of the electrode material are important in terms of responsiveness as a gas sensor. It is desirable to form a film in which platinum is atomized and dispersed. In order to improve the activity of the electrochemical reaction on the electrode surface, the characteristics are improved by etching the outer surface of the cylindrical solid electrolyte to form a concave surface. FIG. 3 is a development view of the outer surface of the cylindrical solid electrolyte. The outer surface of the solid electrolyte 2 By forming the electrode on the concave pattern 7 by a post-processing method using a laser or the like, the electrochemical characteristics relating to the responsiveness as a gas sensor are improved.

As a method for forming an electrode on the outer surface of a cylindrical solid electrolyte of the present invention, an electrode pattern is formed on a conventionally known film by printing, vapor deposition, sputtering or the like, and this is formed on the solid electrolyte. Transfer to
Although a method of forming electrodes can be adopted, in the case of the present invention, since a complicated pattern is not required, the solid electrolyte is rotated by a jig by using a cylindrical shape, and as shown in FIG. It is possible to manufacture the electrodes in a form like roller printing. High productivity and low cost.

Further, as shown in FIG. 5, the electrodes 3 and 4 and the porous catalyst film layer 5 can also be formed by spraying the material fine powder onto the electrode surface by a method such as plasma spraying. From the viewpoint of catalytic activity, fine catalyst particles are desirable as the temporary particle diameter of the coating forming the catalyst layer,
By using this to granulate in advance and coarsen the secondary particle size, the supply of particles during the thermal spraying process becomes smoother, and a catalyst film having excellent catalytic activity and high porosity can be formed. Further, in the case of this method, it is possible to form a film having a considerably large film thickness. That is, in the case of conventional printing,
At most, the film is several tens of microns, but in this method mm
A thick film of level can be formed. Generally, it is not desirable to use different materials by bonding them on the heating surface, but such a problem is solved because the catalyst layer of the present invention is porous and the voids absorb the difference in thermal expansion coefficient.

With respect to the porous catalyst film layer, in particular, several kinds of catalyst elements having different compositions are fed and applied,
The catalyst layer can be formed by changing the composition from the surface to the inside of the catalyst layer. In this case, the composition can be changed from low activity to high activity from the surface side of the catalyst layer toward the electrode side. As a result, when deterioration progresses from the surface of the catalyst layer, the inside of the catalyst layer, which has high activity, is used as the deterioration progresses, rather the catalytic activity rises and the gas sensor performance can be improved over time.

FIG. 6 shows a conceptual cross-sectional view of an embodiment of a porous catalyst film whose catalytic activity is improved with time. The composite oxide composed of manganese dioxide and cupric oxide exhibits a high oxidation catalytic activity, but exhibits the maximum activity when the compounding ratio of manganese dioxide and cupric oxide is 7/3. Therefore, when forming a film by plasma spraying, the composition ratio should be 7/3 at the beginning of film formation, and the amount of cupric oxide supplied should be reduced toward the surface so that the surface becomes zero. 6
The porous catalyst film can be formed. Since manganese dioxide alone has a high catalytic activity, only the upper layer of the surface of the catalyst layer is used for the oxidation catalytic reaction in the initial stage, and if the surface catalytic activity decreases over time due to poisoning, etc. , The interiors with higher catalytic activity are used one after another. This is an idea to achieve a long life as a sensor against deterioration of the catalyst. Although the example of the mixture of manganese dioxide and cupric oxide is described, the oxidizing activity can be changed as shown in FIG. 6 by changing the catalyst composition in the same manner even if the kind of the catalyst is arbitrarily changed. .

Although examples of manganese dioxide and cupric oxide have been described above, of the pair of electrodes formed on the outer surface of the cylindrical solid electrolyte of the present invention, the porosity formed on one of the electrodes. Various oxidation catalysts can be applied as the high quality catalyst film. From the viewpoint of the idea of extending the life of the present invention and the balance of cost, an oxidation catalyst composed of an oxide of a transition element or a composite oxide is desirable. Especially, manganese, iron, copper,
Oxides selected from the group of cobalt, nickel and silver have high oxidative activity. As for the catalyst, if these are contained as the main components, a sufficient effect is recognized, and the presence of a coexisting compound which does not become a catalyst poison is irrelevant. Further, the white metal element is an excellent oxidation catalyst, but when it is used in the present invention, it is necessary to reduce the amount of the white metal element and devise a constitution for exhibiting the maximum activity. Such an example is shown below.

The logic of extending the life of the gas sensor of the present invention is as follows.
It is very simple and basically uses a large amount of catalyst with high activity. In the prior art, in this respect, the catalyst film formation is attempted within the range of thin film and thick film technologies, and it is presumed that this has hit the wall of the catalyst life.

The present invention intends to solve the problem of prolonging the service life of the gas sensor by using an overwhelmingly large amount of catalyst in view of the common sense of the conventional gas sensor.

As a method for extending the life of the catalyst, an example of forming a thick film of the catalyst layer will be shown in addition to the above-described examples of plasma spraying and the like.

In FIG. 7, an oxidation catalyst 9 is contained in a heat-resistant ceramic fiber 8 through a binder on one electrode 4 of a pair of electrodes formed on the outer surface of a cylindrical solid electrolyte 2. The conceptual diagram of the cross section which formed the film 5 made to show is shown. Briefly, it is a ceramic paper containing a catalyst. This is roughly manufactured by the following steps. The heat resistance of the ceramic wool, such as silica-alumina fibers or glass fibers from the state of being suspended and dispersed in water together with a binder such as a catalyst powder and a dispersing agent (surfactant) and roller b Darushirika or alumina sol, filtered papermaking As a result, the above-mentioned catalyst-containing ceramic paper is obtained. It is produced by winding this on an electrode using an inorganic adhesive such as colloidal silica or alumina sol, and curing by heating. The thickness of the ceramic paper is at least 0.5mm
It can be produced with a film thickness of several mm to about 10 mm as described above, and can be widely produced in combination with the setting of the amount of catalyst to be contained (basis weight) and the setting of porosity.

Inorganic heat-resistant long fibers are used in FIG. 8 to woven them into a cloth (in this case, an example of plain weave is shown), and a fiber woven cloth in which a catalyst is supported on the surface of the fiber ceramic fiber. A conceptual diagram is shown. About 10 to 2000 fibers of about 10 μm are used as a yarn. Alumina fiber, heat resistant glass fiber, SiC fiber, S
i-Ti-CO fiber or the like can be used for this purpose.

A silica or alumina washcoat treatment was performed on a fiber of about 10 μm to a thickness of about 5 μm to improve the specific surface area, and a precious metal such as platinum, palladium or rhodium was mainly carried to form a catalyst. . The catalyst body produced in this manner has high activity, but the amount of precious metal used is extremely small.

A woven cloth or thread carrying the above catalyst is wound around one electrode of a pair of electrodes formed on the outer surface of a cylindrical solid electrolyte to form a porous catalyst coating layer. At this time, the density of the woven cloth and the thickness of the coating layer can be set arbitrarily. A part may be fixed with an inorganic adhesive.

With yttria-stabilized (8Y) zirconia,
2mm on the outer surface using a cylindrical solid electrolyte with an outer diameter of # 1.2mm, an inner diameter of 0.6mm and a length of 7mm
Width is about 5 μm after applying paste in a ring shape on both ends and baking.
A platinum electrode having a film thickness of was formed. A large number of samples with lead wires attached thereto were made as prototypes, and the following tests were carried out by changing the type and configuration of the catalyst to be treated.

The catalyst was placed in a test tank heated to 500 ° C., 500 ppm of carbon monoxide-containing air was blown, and the sensor output was evaluated. Representative examples are shown below.

(1) Untreated: Output 0 (2) ZnO / CuO = 1/1: Organometallic salt thermal decomposition: Output about 5
mV (3) MnO2 / CuO = 7/3: Pyrolysis of organic metal salt: Output approx. 2 mV (4) LaCoO3 powder / silica-alumina ceramic fiber: Output approx. 2 mV (5) Pt 0.1 wt% in silica cloth: Output approx. 3 mV (6) In Au / α-Fe2O3-Ti4 + / silica-alumina ceramic fiber: Output approx. 5 mV (7) MnO2 / Fe2O3 / CuO = 1/1/1 / Silica-alumina ceramic fiber: output approx. 5 mV (8) Rh 0.1 wt% silica cloth: Output about 4 mV FIG. 9 shows the results of evaluating the relationship between the sensor output and the carbon monoxide concentration for the above (7). As shown in FIG. 9, extremely good concentration dependence was confirmed.

When a general oxidation catalyst is used, if the operating temperature of the gas sensor of the present invention is set to 450 ° C. or higher, if the thickness of the porous catalyst layer is several μm, it will be about 500 PPM of carbon monoxide. Although sensor output can be obtained, in this case, deterioration of the catalyst is unavoidable, which is a practical bottleneck. In the present invention, since the thickness of the catalyst layer is 100 to 1000 times as it is while the structure penetrates the catalyst layer (air can diffuse to the electrode), the oxidation capacity of carbon monoxide has a sufficient margin. . In the oxidation reaction, since the temperature is higher than the temperature required for complete oxidation, only the surface layer of the catalyst layer is used for the reaction, and deterioration is limited to the surface layer. Even if the surface layer is deteriorated, the function of the gas sensor is not hindered because the inside is in a sufficiently active state. Therefore, it can be used as a gas sensor for a long period of time with extremely high reliability. In addition, the temperature of the sensor is set to a high temperature in the initial stage, the oxidation reaction of carbon monoxide on the electrode surface without the catalyst coating is carried out a little, and the apparent sensor output is set to a low state. The catalyst activity can be improved from the initial level by programming it with a microcomputer or the like so as to lower it. This raises the reliability of the sensor against deterioration with time, which is one of the fatal problems of the chemical sensor. As already described, by adopting a sufficiently thick catalyst coating layer, it is possible to improve the catalytic activity from the surface of the catalyst layer toward the inside. The reliability of the gas sensor is remarkably improved by the above method.

[0044]

As described above, according to the gas sensor of the present invention, the following effects can be obtained.

(1) Regarding detection of carbon monoxide, a highly sensitive and small gas sensor can be obtained. It is highly stable and suitable for installation in combustion equipment. Further, since it has a cylindrical shape and has a resistance heater inside, it is highly reliable even with respect to repeated thermal on / off, which is symmetrical in terms of temperature distribution and the like. In addition, the overall power consumption is low.

(2) It is extremely strong against deterioration of the catalyst layer, which is generally a problem in chemical sensors, and can be used with high reliability for a long period of time. The life of conventional gas sensors is about 1/10 to 1/3 of the life of the equipment in terms of reliability of the catalyst, so it was unbalanced and difficult to install in equipment. It can be used as a safety sensor with high reliability.

(3) It is an extremely practical sensor that is inexpensive in terms of sensor manufacturing and has high mass productivity.

[Brief description of drawings]

FIG. 1 is a partially cutaway perspective view showing a gas sensor according to an embodiment of the present invention.

FIG. 2 is a partially cutaway perspective view showing a second gas sensor according to an embodiment of the present invention.

FIG. 3 is a development view of an outer surface of a cylindrical solid electrolyte of a third gas sensor according to an embodiment of the present invention, showing an etching pattern of an electrode forming portion.

FIG. 4 is a perspective view showing an embodiment relating to a method for manufacturing a gas sensor of the present invention.

FIG. 5 is a perspective view showing an embodiment relating to a second manufacturing method of the gas sensor of the present invention.

FIG. 6 is a conceptual diagram of a cross section of a gas sensor according to an embodiment of the present invention.

FIG. 7 is a conceptual diagram of a cross section centered on a catalyst coating in which an oxidation catalyst is dispersed in a ceramic fiber of a gas sensor according to an embodiment of the present invention.

FIG. 8 (a) is a conceptual diagram of a woven fabric in which a noble metal element is carried by precoating silica alumina or the like on a woven fabric of heat-resistant fibers of a gas sensor according to one embodiment of the present invention (b) The same woven fabric Conceptual diagram of fiber cross section

FIG. 9 is a graph showing the relationship between carbon monoxide concentration and sensor output according to one embodiment of the present invention.

[Explanation of symbols] 1 Resistance heating heater 2 Cylindrical solid electrolyte 3, 4 pairs of electrodes 5 Porous catalyst coating layer

Claims (12)

(57) [Claims] 1. A resistance heater is provided on the inner surface side of a substantially cylindrical solid electrolyte, and a porous catalyst film is provided on one of the pair of electrodes and the electrode on the outer surface of the solid electrolyte and the other is provided with catalytic performance. A gas sensor formed by forming a porous coating without 2. A resistance heater is arranged on the inner surface side of a substantially cylindrical solid electrolyte, and a part of the outer surface of the solid electrolyte is etched corresponding to a pair of electrode patterns, and a pair of electrodes and A gas sensor comprising a porous catalyst film formed on one of the electrodes and a porous film formed on the other. 3. A method for manufacturing a gas sensor, which comprises rotating a substantially cylindrical solid electrolyte and printing a pattern on the outer periphery of a pair of electrodes and a coating layer formed on the surface of the electrodes using a paste. 4. A method of manufacturing a gas sensor, wherein a substantially cylindrical solid electrolyte is rotated to form a pattern on the outer periphery of a pair of electrodes and a coating layer formed thereon by plasma spraying. 5. A resistance heating heater is arranged on the inner surface side of a substantially cylindrical solid electrolyte, and a pair of electrodes and a porous catalyst film are formed on one of the electrodes on the outer surface of the solid electrolyte to form a porous catalyst. A gas sensor in which a coating is formed by grading the internal composition of the coating from the outer surface side toward the electrode side so as to improve the catalytic activity. 6. A yttrium-stabilized zirconia is used as a solid electrolyte, a platinum wire coil is used as a resistance heater, a material containing platinum as a main component is used as a pair of electrode materials, and an organic metal salt of a typical element is used as a porous film. the gas sensor of claim 1, wherein an organic metal salt of a transition element as the porous catalyst film made using a film formed by pyrolysis. 7. A pair of electrodes are formed on the outer surface of a cylindrical solid electrolyte using yttrium-stabilized zirconia as a solid electrolyte, and the pair of electrodes is bonded to a ceramic fiber as a coating for coating one electrode. A gas sensor in which the other electrode is coated with porous glass by using a coating body in which an oxidation catalyst is dispersed via an agent. 8. A silica / alumina fiber as the ceramic fiber, silica or an alumina compound as a binder, and manganese, copper, iron, cobalt as an oxidation catalyst,
One or more oxides selected from the group of nickel and silver,
Alternatively, the gas sensor according to claim 7, which comprises a composite oxide. 9. A silica / alumina fiber as the ceramic fiber, silica or an alumina compound as a binder, and an iron oxide doped with titanium ions carrying gold in the form of fine particles as an oxidation catalyst.
7. The gas sensor according to 7 . 10. A pair of electrodes are formed on the outer surface of a cylindrical solid electrolyte using yttrium-stabilized zirconia as the solid electrolyte, and platinum is provided on the surface as a coating for coating one electrode of the pair of electrodes. , A palladium, rhodium, a gas sensor formed by forming a woven fabric layer formed by weaving fibers made of inorganic heat-resistant fibers carrying one or more precious metal elements selected from the group, and coating the other electrode with porous glass. . 11. A resistance heating heater is arranged on the inner surface side of a substantially cylindrical solid electrolyte, and a pair of electrodes and a porous catalyst film on one of the electrodes and a porous film on the other are formed on the outer surface of the solid electrolyte. Then, the porous catalyst layer film is formed thicker than the film thickness required for complete oxidation of gas, and the sensor temperature set by the resistance heater is set higher than the temperature required for complete oxidation of the catalyst layer. 12. A resistance heating heater is arranged on the inner surface side of a substantially cylindrical solid electrolyte, and a pair of electrodes and a porous catalyst film on one of the electrodes and a porous film on the other are formed on the outer surface of the solid electrolyte. Then, the porous catalyst layer film is formed thicker than the film thickness required for complete oxidation of gas, and the sensor temperature set by the resistance heater is initially set higher than the temperature required for complete oxidation of the catalyst layer. A gas sensor with a built-in program that lowers the sensor temperature over time.