WO2010100851A1 - ガスセンサの製造方法及びガスセンサ - Google Patents
ガスセンサの製造方法及びガスセンサ Download PDFInfo
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- WO2010100851A1 WO2010100851A1 PCT/JP2010/001119 JP2010001119W WO2010100851A1 WO 2010100851 A1 WO2010100851 A1 WO 2010100851A1 JP 2010001119 W JP2010001119 W JP 2010001119W WO 2010100851 A1 WO2010100851 A1 WO 2010100851A1
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- end side
- gas sensor
- welded portion
- outer cylinder
- metal shell
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/26—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating electrochemical variables; by using electrolysis or electrophoresis
- G01N27/403—Cells and electrode assemblies
- G01N27/406—Cells and probes with solid electrolytes
- G01N27/407—Cells and probes with solid electrolytes for investigating or analysing gases
- G01N27/4078—Means for sealing the sensor element in a housing
Definitions
- the present invention relates to a method for manufacturing a gas sensor including a sensor element for measuring the concentration of a specific gas contained in a gas to be measured, and the gas sensor.
- the sensor element In a gas sensor having a sensor element for measuring the concentration of a specific gas contained in a gas to be measured, the sensor element is generally held by the metal shell so that the detection part of the sensor element is exposed to the gas to be measured.
- the outer cylinder is joined to the rear end side of the metal shell.
- the metal shell and the outer cylinder are generally joined by laser welding. Specifically, the rear end portion of the metal shell is inserted into the tip of the outer cylinder, and the overlapping portion of the metal shell and the outer cylinder is temporarily fixed by caulking, and the entire circumference of the caulking portion from the outside of the outer cylinder is secured. The metal shell and the outer cylinder are joined by irradiating the laser over the entire length.
- the caulking portion is formed on the outer cylinder
- the outer peripheral surface of the metal shell from the welded portion formed by laser welding to the distal end of the outer cylinder and the outer cylinder are in order to caulk the position away from the distal end of the outer cylinder.
- a slight gap is formed between the inner peripheral surface.
- the gas sensor is flooded during use, water droplets or the like may enter the gap between the outer cylinder and the metal shell, and the welded part may be in contact with water for a long period of time. Since the interface of the welded part melted by laser welding is relatively easy to corrode, the corrosion proceeds at the interface between the welded part and the welded part when the welded part is in contact with water droplets for a long period of time. There was a problem that water intruded into the inside and caused the gas sensor to malfunction.
- the present invention has been made in view of the above-mentioned problems, and aims to improve the corrosion resistance at the welded portion between the metal shell and the outer cylinder.
- a sensor element that extends in the axial direction and has a detection part for detecting a gas to be detected on the front end side, and a cylinder part that surrounds the periphery of the sensor element while exposing the front end side and the rear end side of the sensor element
- a gas sensor manufacturing method comprising: a metal fitting; and a cylindrical outer cylinder fixed to the metal shell and surrounding a rear end side of the sensor element, wherein a front end side of the outer cylinder surrounds a cylinder portion of the metal shell.
- the outer cylinder is disposed on the metal shell so as to surround the outer cylinder, and laser welding is performed over the entire circumference of the overlapping portion between the tip of the outer cylinder and the cylinder of the metal shell, A welding process for forming a welded portion straddling the distal end portion of the outer cylinder and the cylindrical portion of the metal shell, wherein in the welding process, a plurality of shifts are made in the axial direction of the gas sensor.
- the laser welding is performed To, gas sensor method of manufacturing.
- the welding step may be performed on the cylindrical portion of the metal shell of the two adjacent welded portions among the plurality of welded portions formed by the laser welding multiple times.
- Application Example 3 The gas sensor manufacturing method according to Application Example 1 or Application Example 2, wherein, in the welding step, the laser welding is performed a plurality of times by shifting from a front end side to a rear end side of the overlapping portion.
- a sensor element that extends in the axial direction and has a detection part for detecting a gas to be detected on the front end side, and a cylinder part that surrounds the periphery of the sensor element while exposing the front end side and the rear end side of the sensor element
- a gas sensor comprising: a metal fitting; and a cylindrical outer tube fixed to the metal shell so that a rear end side surrounds the cylinder portion of the metal shell, wherein the gas sensor includes a front end portion of the outer tube and the metal shell.
- a plurality of welded portions formed over the entire circumference of the overlapping portion with the cylindrical portion and straddling the distal end portion of the outer cylinder and the cylindrical portion of the metal shell are formed at different positions in the axial direction of the gas sensor. It is characterized by that.
- the two adjacent welded portions are formed so as to partially overlap each other, and in the cross section along the axis, the two adjacent the welded portions are formed.
- the gas sensor formed so that the rear end side welding part formed in the rear end side among welding parts may overlap with the front end side welding part formed in the front end side.
- welding width in the present specification.
- the cylindrical portion of the metal shell and the tip portion of the outer cylinder are not bonded before the first laser welding, Even if an attempt is made to form a welded portion having a large depth, the welded portion may not easily have a desired shape.
- the depth of the first welded portion formed by the first laser welding is slightly smaller than the target depth to obtain a desired shape, and the second and subsequent laser welding is performed on the first welded portion. It is formed so as to be larger than the depth.
- the cylindrical portion of the metal shell and the tip of the outer tube are bonded to each other by the first weld, so that the second weld has a large depth. Even if the portion is formed, a desired shape can be obtained.
- a plurality of welded portions are formed in the overlapping portion at different positions in the axial direction. Therefore, the welding width can be widened and the progress of corrosion can be delayed. Therefore, it can delay that water permeates into the gas sensor.
- the gas sensor of Application Example 6 if the rear end side welded portion formed on the rear end side is formed so as to overlap the front end side welded portion formed on the front end side, the front end side of the overlapping portion Therefore, laser welding is performed by shifting from the rear end side to the rear end side, and it is possible to suppress the gap between the outer cylinder and the metal shell from being expanded. A shape can be obtained.
- the rear end side welded portion formed on the rear end side overlaps with the front end side welded portion formed on the front end side is that the gas sensor (welded portion) is visually recognized in a cross section along the axis. Sometimes, it is possible to confirm the boundary of the rear end side welded part and not to confirm the boundary of the front end side welded part at the overlapping part of the front end side welded part and the rear end side welded part.
- the depth of the front end side welded portion is slightly smaller than the target depth.
- the shape of the front end side welded portion can be a desired shape, and the rear end side welded portion is formed so that the depth of the rear end side welded portion is larger than the depth of the front end side welded portion. It can be obtained in a desired shape.
- the depth of the first welded portion is slightly smaller than the target depth.
- a desired shape can be obtained as the shape of the first welded portion, and the second welded portion can be formed in a desired shape by forming the depth of the second welded portion to be larger than the depth of the first welded portion. It can be obtained in shape.
- the “overlapping second welded portion” and the “overlapped first welded portion” are the positions of the first welded portion and the second welded portion when the gas sensor (welded portion) is viewed in a cross section along the axis. In the overlapping part, it indicates that the boundary of the second welded part can be confirmed and the boundary of the first welded part cannot be confirmed.
- the welded portion is less than half the thickness of the cylindrical portion of the metal shell, the outer cylinder and the metal shell can be reliably melted and the components of each other can be mixed together. Can be increased.
- the welded portion exceeds half the thickness of the cylindrical portion of the metal shell, the balance of the mixing ratio of the components of the outer cylinder and the metal shell is deteriorated, and the joint strength between the two may be reduced.
- FIG. 1 is a cross-sectional view showing a configuration of a gas sensor 10 as an embodiment of the present invention.
- FIG. 1 is a cross-sectional view showing a configuration of a gas sensor as one embodiment of the present invention.
- the gas sensor 10 is an oxygen sensor that detects oxygen in the exhaust gas of an internal combustion engine.
- the gas sensor 10 mainly includes an oxygen sensor element 20, a metal shell 11, an inner terminal member 30, an outer terminal member 40, and a ceramic heater 50.
- FIG. 1 shows the axis O of the gas sensor 10.
- an end portion (lower side in FIG. 1) where the solid electrolyte body 21 is disposed is referred to as a tip, and an end portion (upper side in FIG. 1) where the grommet 17 is disposed. Is called the rear end.
- the longitudinal direction FD in the figure indicates a direction parallel to the axis O (vertical direction in FIG. 1).
- the shape of the oxygen sensor element 20 is a bottomed cylindrical shape extending in the axial direction along the axis O (vertical direction in FIG. 1).
- the front end 20s (lower side in FIG. 1) of the oxygen sensor element 20 is closed, and the rear end 20k (upper side in FIG. 1) forms an opening.
- the oxygen sensor element 20 includes a solid electrolyte body 21 having oxygen ion conductivity, an outer electrode 60 formed by plating or the like on a part of the outer peripheral surface of the solid electrolyte body 21, and an inner peripheral surface of the solid electrolyte body 21.
- the inner electrode 70 formed by plating or the like is provided on the part, and the detection part 22 is provided on the tip 20s side.
- an engagement flange portion 20f that protrudes outward is provided at an intermediate portion in the axis O direction. The engagement flange portion 20f engages with a metal shell 11 described later.
- the metal shell 11 is formed in a cylindrical shape surrounding a part of the outer periphery of the oxygen sensor element 20.
- the insulator 13 is disposed in the through hole 58 of the metal shell 11 via a metal packing (not shown).
- An engagement flange portion 20f is engaged with the insulator 13 via a metal packing.
- the talc 14, the sleeve 13 b, and the metal packing 83 are disposed on the rear end side of the insulator 13, and are crimped on the rear end side of the metal shell 11, so that the oxygen sensor element 20 is placed inside the metal shell 11. Holds in an airtight state.
- a protector 15 is attached to the front end side of the metal shell 11.
- the protector 15 covers the detection part 22 of the oxygen sensor element 20 protruding from the opening on the front end side of the metal shell 11.
- the protector 15 has a double structure of an outer protector 15a and an inner protector 15b.
- the outer protector 15a and the inner protector 15b are formed with a plurality of gas permeation ports through which exhaust gas permeates. Exhaust gas is supplied to the outer electrode 60 of the oxygen sensor element 20 through the gas permeation port of the protector 15.
- the metal shell 11 includes a screw portion 11c on the tip side of the hexagonal portion 11a formed on the outer peripheral surface.
- the metal shell 11 includes a cylindrical portion 11b on the rear end side of the hexagonal portion 11a.
- a distal end portion 16a (see FIG. 2) of a cylindrical metal outer cylinder 16 is fitted into the cylindrical portion 11b, and is fixed by outer circumferential laser welding from the outside.
- the weld 100 is formed by this laser welding.
- the detailed configuration of the welded portion 100 between the metal outer cylinder 16 and the metal shell 11 will be described in detail later.
- the metal outer cylinder 16 is made of stainless steel such as SUS304 and has a cylindrical shape.
- the metal outer cylinder 16 is attached to the rear end side of the metal shell 11 and exposed from the rear end of the metal shell 11 and the separator. Cover around 18 and protect.
- a grommet 17 made of fluororubber is inserted into the opening on the rear end side of the metal outer cylinder 16.
- the grommet 17 is fixed by caulking on the rear end side of the metal outer cylinder 16 and seals the opening of the metal outer cylinder 16.
- a separator 18 made of insulating alumina ceramic is disposed on the tip side of the grommet 17 and inside the metal outer cylinder 16.
- Sensor output lead wires 19 and 19b and heater lead wires 12b and 12c are disposed through the grommet 17 and the separator 18.
- a through hole is formed in the center of the grommet 17 along the axis O, and a metal pipe 86 is fitted into the through hole.
- the metal pipe 86 is covered with a sheet-like filter 85 having both water repellency and air permeability. Thereby, the atmosphere outside the gas sensor 10 is introduced into the metal outer cylinder 16 through the filter 85 and is introduced into the internal space G of the oxygen sensor element 20.
- the outer terminal member 40 includes an outer fitting portion 41 made of a stainless steel plate, a separator insertion portion 42, and a connector portion 43.
- the separator insertion portion 42 is inserted into the separator 18. From this separator insertion portion 42, a separator contact portion 42d branches and protrudes.
- the outer terminal member 40 is held in the separator 18 by the separator contact portion 42 d elastically contacting the inner wall of the separator 18.
- a connector part 43 is provided at the rear end of the separator insertion part 42.
- the connector 43 grips the core wire of the sensor output lead wire 19b by caulking, and electrically connects the outer terminal member 40 and the sensor output lead wire 19b.
- An outer fitting portion 41 is provided at the tip of the separator insertion portion 42.
- the outer fitting portion 41 grips the outer periphery near the rear end of the oxygen sensor element 20 and electrically connects the outer terminal member 40 and the outer electrode 60 of the oxygen sensor element 20.
- the electromotive force generated in the outer electrode 60 is output to the outside of the gas sensor 10 through the outer terminal member 40 and the sensor output lead wire 19b.
- the inner terminal member 30 includes an insertion portion 33 made of a stainless steel plate, a separator insertion portion 32, and a connector portion 31.
- the separator insertion portion 32 is inserted into the separator 18. From this separator insertion portion 32, a separator contact portion 32d branches and protrudes.
- the inner terminal member 30 is held in the separator 18 by the separator contact portion 32 d elastically contacting the inner wall of the separator 18.
- a connector portion 31 is provided at the rear end of the separator insertion portion 32.
- the connector part 31 grips the core wire of the sensor output lead wire 19 by caulking, and electrically connects the inner terminal member 30 and the sensor output lead wire 19.
- the insertion part 33 is provided at the tip of the separator insertion part 32.
- the insertion portion 33 is inserted into the oxygen sensor element 20.
- the insertion portion 33 comes into contact with the inner electrode 70 formed on the inner peripheral surface of the oxygen sensor element 20 with a pressing force by its own elastic force. Thereby, the insertion portion 33 maintains electrical continuity with the inner electrode 70 of the oxygen sensor element 20.
- the electromotive force generated in the inner electrode 70 is output to the outside of the gas sensor 10 via the inner terminal member 30 and the sensor output lead wire 19.
- a heater pressing portion 36 is provided at the distal end of the insertion portion 33.
- the heater pressing unit 36 presses the side surface of the ceramic heater 50 against the inner peripheral surface of the oxygen sensor element 20.
- the ceramic heater 50 is disposed in the internal space G of the oxygen sensor element 20 and is maintained by the inner terminal member 30 to maintain its posture.
- the ceramic heater 50 has connecting terminals connected to the heater lead wires 12b and 12c, and heats the inner peripheral surface of the solid electrolyte body 21 by supplying electric power from the heater lead wires 12b and 12c.
- the gas sensor 10 of the embodiment has the configuration described above.
- FIG. 2 is a cross-sectional view schematically illustrating a detailed configuration of the welded portion 100 between the metal shell 11 and the metal outer cylinder 16 in the first embodiment.
- FIG. 2A shows the overall configuration of the welded portion 100
- FIG. 2B shows the front end side welded portion 110 and the rear end side welded portion 120.
- the cross-sectional view shown in FIG. 2A shows an enlarged portion of a circle X in FIG.
- the metal shell 11 is attached to the metal outer cylinder 16 so that the outer peripheral surface 11 e of the cylindrical portion 11 b of the metal shell 11 faces the inner peripheral surface 16 d of the distal end portion 16 a of the metal outer cylinder 16.
- the overlapping portion 80 is inserted to be caulked in a ring shape over the entire circumference in the circumferential direction from the outer peripheral side.
- the portion that has been crimped is hereinafter referred to as a crimped portion 90.
- laser welding is performed to join the metal shell 11 and the metal outer cylinder 16 by irradiating the laser in the circumferential direction of the metal outer cylinder 16, thereby forming the welded portion 100. Is done.
- laser welding is performed at a plurality of locations (two locations in the first embodiment) shifted in the direction of the axis O so that the positions are different along the direction of the axis O.
- the part 100 is comprised from the front end side weld part 110 and the rear end side weld part 120, as shown to Fig.2 (a).
- the distal end side welded portion 110 includes an outer welded portion 111 formed on the distal end portion 16 a side of the metal outer cylinder 16 and an inner side formed on the cylindrical portion 11 b side of the metal shell 11. It consists of a welded part 112.
- the rear end side welded portion 120 includes an outer welded portion 121 formed on the tip end portion 16 a side of the metal outer tube 16 and an inner welded portion 122 formed on the tube portion 11 b side of the metal shell 11.
- the welded portion 100 is laser-welded so that the front end side welded portion 110 and the inner side welded portions 112, 122 of the rear end side welded portion 120 partially overlap each other.
- Laser welding is performed, for example, by irradiating a known YAG laser.
- the range from the front end portion 16a to the cylindrical portion 11b is melted in the direction of the axis O by the laser irradiation, and the front end side welded portion 110 and the rear end side welded portion 120 straddling both are formed, whereby the overlapping portion 80 (front end portion) 16a and the cylinder part 11b) are joined.
- a gap 300 may be formed between the two.
- the gas sensor 10 gets wet during use, water droplets enter the gap 300 due to capillary action. Moisture that has entered the covered space such as the gap 300 is relatively less likely to volatilize, so there is a risk that the front end side welded portion 110 and the rear end side welded portion 120 will be in contact with the moisture staying in the gap 300 for a long period of time. is there.
- the gas sensor 10 may be used in a vehicle, and calcium chloride (CaCl 2 ) contained in a road snow removal agent is mixed with water staying in the gap 300 during vehicle running to become salt water, which promotes corrosion. Is done.
- the welding width d is along the axis O direction at the boundary between the metal outer cylinder 16 and the metallic shell 11 (the contact surface between the outer circumferential surface 11e of the metallic shell 11 and the inner circumferential surface 16d of the outer cylinder 16). It means the width of the welded part.
- laser welding is performed twice along the direction of the axis O, in other words, along the direction of progress of corrosion to form two welds (the front end side weld 110 and the rear end side weld 120).
- the welding width d is formed so as to be wider than the welding width of the welded portion formed by laser welding only once.
- the welded portion 100 formed in the overlapping portion 80 between the distal end portion 16a of the metal outer cylinder 16 and the cylindrical portion 11b of the metal shell 11 has a distal end at a position different in the axial direction.
- a side weld 110 and a rear end weld 120 are provided. Therefore, the welding width d of the front end side welded part 110 and the rear end side welded part 120 can be widened, and the progress of corrosion can be delayed. Therefore, it is possible to delay the intrusion of water into the gas sensor 10.
- the rear end side welded portion 120 is formed so as to overlap the front end side welded portion 110.
- FIG. 2B this can be seen from the fact that the boundary of the rear end side welded portion 120 can be confirmed as a solid line, whereas the boundary of the front end side welded portion 110 cannot be confirmed as a dotted line.
- the boundary of the welded portion (the front end side welded portion 110 in the first embodiment) overlapped at the overlapping portion between the front end side welded portion 110 and the rear end side welded portion 120 cannot be confirmed, but is overlapped. In order to simplify the explanation of the welded part, it is indicated by a dotted line.
- the rear end side welded part 120 formed on the rear end side is formed so as to overlap the front end side welded part 110 formed on the front end side, the rear side from the front end side of the overlapping part 80 is Laser welding is performed while being shifted to the end side, and it is possible to suppress the gap 300 between the outer cylinder 16 and the metal shell 11 from being expanded. As a result, it is possible to suppress intrusion of water droplets and a desired welded portion. 100 shapes can be obtained.
- the front end side welded portion 110 and the inner side welded portions 112 and 122 of the rear end side welded portion 120 partially overlap each other. Accordingly, since overlapping portions are formed in the inner welded portions 112 and 122, the welding strength between the metal outer cylinder 16 and the metal shell 11 can be improved.
- the front end side welded portion 110 and the rear end side welded portion 120 have thicknesses (welding depths) B1 and B2 in the radial direction of the gas sensor 10 that are at least larger than the thickness C of the metal outer cylinder 16 (
- the output at the time of laser welding is adjusted so that it is less than about half of the thickness A in the radial direction of the metal shell 11 so as to be at least twice the thickness of the metal outer cylinder 16.
- the thicknesses of the front end side welded portion 110 and the rear end side welded portion 120 in this manner, the metal outer cylinder 16 and the metal shell 11 can be reliably melted and the components of each other can be mixed, and the joint strength between the two can be increased. Can be increased.
- the thickness B2 of the rear end side welded portion 120 is formed larger than the thickness B1 of the front end side welded portion 110.
- laser welding is performed twice.
- the number of times of laser welding may be two or more, and the laser welding may be arbitrarily repeated a plurality of times depending on the thickness and material of the metal shell 11 and the metal outer tube 16. Just do it.
- FIG. 3 is a flowchart for explaining a manufacturing process of the gas sensor 10 in the first embodiment.
- FIG. 4 is an explanatory diagram for explaining in detail the welding process of the gas sensor 10 in the first embodiment.
- the process of joining the metal shell 11 and the metal outer cylinder 16 constituting the gas sensor 10 will be mainly described, and the manufacturing process of other parts of the gas sensor 10 is well known, and the description thereof will be omitted.
- the metal shell 11 and the metal outer cylinder 16 are manufactured and the respective members are assembled. Assembling each member may use a known method, and specifically includes assembly of the oxygen sensor element 20 to the metal shell 11 and assembly of the separator 18 to the metal outer cylinder 16.
- the protector 15 is joined to the metal shell 11 by welding or the like. Thereafter, the oxygen sensor element 20 is inserted into the through hole 58 of the metal shell 11. At this time, the insulator 13 is disposed in the metal shell 11 prior to the oxygen sensor element 20. Thereafter, the talc 14 and the sleeve 13b are inserted into the through hole 58 of the metal shell 11 and crimped.
- the talc 14 crushed by caulking fills the gap between the metal shell 11 and the oxygen sensor element 20, and the oxygen sensor element 20 is held in the metal shell 11.
- the sensor output lead wires 19 and 19 b to which the inner terminal member 30 and the outer terminal member 40 are connected in advance are inserted into the separator 18 and the grommet 17.
- the heater lead wires 12 b and 12 c to which the ceramic heater 50 is connected are also arranged in the separator 18 and the grommet 17. Then, the separator 18 and the grommet 17 are disposed inside the metal outer cylinder 16.
- the metal outer cylinder 16 is disposed at a prescribed position of the metal shell 11 (step S10). Specifically, the metal outer cylinder 16 is placed on the rear end side of the metal shell 11 so that the rear end portion of the oxygen sensor element 20 is accommodated inside the metal outer cylinder 16. At this time, the ceramic heater 50 is inserted into the internal space G of the oxygen sensor element 20. Thereby, the metal outer cylinder 16 is arrange
- step S12 the distal end portion 16a of the metal outer cylinder 16 is caulked in the circumferential direction (Happomaru caulking) (step S12).
- a caulking portion 90 is formed, and the metal outer cylinder 16 is temporarily fixed to the metal shell 11.
- the separator 18 and the grommet 17 are also fixed by crimping the metal outer cylinder 16 (Happomaru caulking).
- laser welding is performed over the circumference of the metal outer cylinder 16 to join the metal shell 11 and the metal outer cylinder 16 (step S14).
- laser welding is performed twice so that the welded portion 100 including the front end side welded portion 110 and the rear end side welded portion 120 is formed at different positions along the axis O direction.
- FIG. 4A shows the first laser welding
- FIG. 4B shows the second laser welding.
- the first laser welding is performed such that the apex Q1 of the inner welded portion 112 is located at the same position in the horizontal direction with respect to the position P1 in the axis O direction.
- the front end side welding part 110 is formed.
- the apex Q2 of the inner welded portion 122 is positioned at the same position in the horizontal direction with respect to the position P2 slightly shifted from the position P1 to the rear end side in the axis O direction.
- the laser welding apparatus and the gas sensor 10 are relatively shifted along the direction of the axis O, and the second laser welding is performed. At this time, the inner welded portion 112 of the front end side welded portion 110 formed by the first laser welding and the inner welded portion 122 of the rear end side welded portion 120 formed by the second laser welding partially overlap each other. Thus, the relative positions of the laser welding apparatus and the gas sensor 10 are defined.
- the laser is irradiated from a direction substantially orthogonal to the axis O direction.
- a front end side welded portion 110 and a rear end side welded portion 120 straddling the metal shell 11 and the metal outer cylinder 16 are formed, and the metal shell 11 and the metal outer cylinder 16 are joined together, thereby completing the gas sensor 10.
- laser welding is performed a plurality of times by shifting in the axis O direction to the overlapping portion 80 between the tip portion 16a of the metal outer tube 16 and the tube portion 11b of the metal shell 11. Done. Therefore, the weld width d (see FIG. 2) of the formed front end side welded portion 110 and rear end side welded portion 120 can be increased, and the progress of corrosion can be delayed. Therefore, it is possible to delay the intrusion of water into the gas sensor 10.
- laser welding is performed such that the front end side welded portion 110 and the inner side welded portions 112 and 122 on the rear end side 120 partially overlap each other. Therefore, an overlapping portion is formed in the inner welded portion, and the welding strength between the metal outer cylinder 16 and the metal shell 11 can be improved.
- laser welding is performed by shifting the overlapping portion 80 from the front end side in the axis O direction to the rear end side. Therefore, it can suppress that the gap
- the rear end side welding in which the depth is larger than the depth of the front end side welding portion 110 (first welding portion) formed by the first laser welding. It is preferable to perform the second laser welding so as to form the portion 120 (second welded portion). Thereby, as shown in FIG. 2, a welded portion 100 in which the thickness B2 of the rear end side welded portion 120 is larger than the thickness B1 of the front end side welded portion 110 can be formed.
- the depth B1 of the front end side welded portion 110 is slightly smaller than the target depth
- the shape of the welded portion 110 can obtain a desired shape
- the rear end side welding portion 120 is formed such that the depth B2 of the rear end side welded portion 120 is larger than the depth B1 of the front end side welded portion 110, so that the rear end The side weld 120 can be obtained in a desired shape.
- the oxygen sensor element 20 corresponds to the “sensor element” in the claims
- the metal outer cylinder 16 corresponds to the “outer cylinder”.
- the front end side welded portion 110 is formed by the first laser welding and the rear end side welded portion 120 is formed by the second laser welding.
- the rear end side welded portion 120 may be formed, and the front end side welded portion 110 may be formed by the second laser welding.
- the thickness B2 of the rear end side weld 120 formed by the second laser welding is deeper than the thickness B1 of the front end weld 110 formed by the first laser welding.
- FIGS. 5 and 6 are cross-sectional views schematically illustrating the detailed configuration of the welded portion between the metal shell 11 and the metal outer cylinder 16 in a modified example.
- the cross-sectional views shown in FIG. 5 and FIG. 6 show the vicinity of the welded portion in an enlarged manner, similarly to FIG.
- parts having the same configuration as in the first embodiment will be described using the same reference numerals.
- the rear end side welding portion 120a is formed by the first laser welding, and the front end side welding slightly shifted from the first laser welding to the front end side in the axis O direction by the second laser welding.
- a portion 110a is formed.
- the front end side welding part 110a is formed so that it may overlap with the rear end side welding part 120a.
- the boundary of the front end side welded portion 110a can be confirmed as a solid line, whereas the boundary of the rear end side welded portion 120a is as indicated by a dotted line. It can be seen from the fact that it cannot be confirmed.
- Each of the front end side welded portion 110a and the rear end side welded portion 120a that are laser-welded is the outer welded portion 111a, 121a that is the front end side of the metal outer tube 16, and the inner side weld that is the cylindrical portion side of the metal shell 11.
- Parts 112a and 122a, and the inner welded portions 112a and 122a of the front end side welded portion 110a and the rear end side welded portion 120a are adjacent to each other, in other words, the inner welded portion 112a and the outer welded portion of the welded portion 110a.
- Laser welding is performed so that a boundary portion 113a with 111a and a boundary portion 123a between the inner welded portion 122a and the outer welded portion 121a of the welded portion 120a are in contact with each other.
- the front end side welded portion 110 a (second welded portion) has a thickness B ⁇ b> 2 a of the rear end side welded portion 120 a (first welded portion) formed by the first laser welding.
- the thickness B1a is formed deep.
- Each of the front end side welded portion 110b and the rear end side welded portion 120b which are laser-welded is an outer welded portion 111b, 121b which is the front end side of the metal outer tube 16, and an inner welded portion 112b which is the cylindrical portion side of the metal shell 11.
- 122b, and the inner welded portions 112b and 122b of the front end side welded portion 110b and the rear end side welded portion 120b are formed at positions separated in the axis O direction, that is, the inner welded portion 112b and the inner welded portion.
- Laser welding is performed so that 122b does not overlap.
- the outer welded portion 111b and the outer welded portion 121b partially overlap, but may not overlap.
- the overall welding width is larger than the welding width of the weld formed by laser welding only once by performing laser welding as described above.
- the integrated width of the weld width of the front end side welds 110a and 110b and the weld width of the rear end side welds 120a and 120b can be increased. Therefore, the penetration of water into the gas sensor 10 can be delayed as in the first embodiment.
- the present invention is not limited to these embodiments, and various configurations can be taken without departing from the spirit of the present invention.
- the bottomed cylindrical oxygen sensor element 20 is used, but a long plate sensor element may be used.
- 1st Example and the modification demonstrated the oxygen sensor 10 you may use for a NOx sensor, a H2 sensor, a temperature sensor, etc.
- outer side welded part 112, 112a, 112b ... inner side welded part 113a, 123a ... boundary part 121, 121a, 121b ... outer side welded part 122, 12 a, 122b ... inside the welded portion 300 ... gap
Abstract
Description
軸線方向に延び、先端側に被検出ガスを検出するための検知部を有するセンサ素子と、該センサ素子の先端側及び後端側を露出させつつ前記センサ素子の周囲を囲む筒部を有する主体金具と、前記主体金具に固定され、前記センサ素子の後端側を囲む筒状の外筒とを有するガスセンサの製造方法であって、前記外筒の先端側が前記主体金具の筒部の周囲を囲むように、前記外筒を前記主体金具に配置する外筒配置工程と、前記外筒の先端部と前記主体金具の筒部との重なり部に、全周に亘って、レーザ溶接を行い、前記外筒の先端部と前記主体金具の筒部とに跨る溶接部を形成する溶接工程と、を備えるガスセンサの製造方法であって、前記溶接工程において、前記ガスセンサの軸線方向にずらして、複数回、前記レーザ溶接を行うことを特徴とする、ガスセンサの製造方法。
適用例1のガスセンサの製造方法であって、前記溶接工程は、複数回の前記レーザ溶接によって形成される複数の前記溶接部のうち、隣り合う2つの前記溶接部の前記主体金具の筒部に形成される各内側溶接部が、一部分重複するようにレーザ溶接を行う、ガスセンサの製造方法。
適用例1又は適用例2のガスセンサの製造方法であって、前記溶接工程では、前記重なり部の先端側から後端側にずらして、複数回、前記レーザ溶接を行う、ガスセンサの製造方法。
適用例1乃至適用例3のいずれか一項に記載のガスセンサの製造方法であって、前記溶接工程では、1回目の前記レーザ溶接により形成された第1溶接部の深さよりも深さが大きくなる第2溶接部を形成するように、2回目以降の前記レーザ溶接を行う、ガスセンサの製造方法。
軸線方向に延び、先端側に被検出ガスを検出するための検知部を有するセンサ素子と、前記センサ素子の先端側及び後端側を露出させつつ前記センサ素子の周囲を囲む筒部を有する主体金具と、後端側が前記主体金具の筒部の周囲を囲むように前記主体金具に固定される筒状の外筒と、を備えるガスセンサであって、前記外筒の先端部と前記主体金具の筒部との重なり部に全周に亘って形成された、前記外筒の先端部と前記主体金具の筒部とに跨る溶接部が、前記ガスセンサの軸線方向に異なる位置に複数形成されていることを特徴とする。
適用例5のガスセンサであって、前記複数の前記溶接部のうち、隣り合う2つの前記溶接部が一部分重複するように形成されており、前記軸線に沿った断面にて、隣り合う2つの前記溶接部のうち、後端側に形成される後端側溶接部が、先端側に形成される先端側溶接部に対して重なるように形成されている、ガスセンサ。
適用例6のガスセンサであって、前記後端側溶接部の深さは、前記先端側溶接部の深さよりも大きい、ガスセンサ。
適用例5のガスセンサであって、複数の溶接部のうち、隣り合う2つの前記溶接部の前記主体金具の筒部に形成される内側溶接部が一部分重複するように形成されている。
適用例5のガスセンサであって、前記溶接部のうち、重なった第2溶接部の深さは、重ねられた第1溶接部の深さよりも大きい、ガスセンサ。
適用例5乃至適用例9のいずれか一項に記載のガスセンサにおいて、前記溶接部は、前記主体金具の前記筒部の厚みの半分以下の部位に設けられる、ガスセンサ。
なお、「後端側に形成される後端側溶接部が、先端側に形成される先端側溶接部に対して重なる」とは、ガスセンサ(溶接部)を軸線に沿った断面にて視認したときに、先端側溶接部と後端側溶接部の重複部において、後端側溶接部の境界の確認ができると共に、先端側溶接部の境界が確認できないことを指す。
なお、「重なった第2溶接部」及び「重ねられた第1溶接部」は、ガスセンサ(溶接部)を軸線に沿った断面にて視認したときに、第1溶接部と第2溶接部の重複部において、第2溶接部の境界の確認ができると共に、第1溶接部の境界が確認できないことを指す。
A1.ガスセンサの構成:
図1は、本発明の一実施例としてのガスセンサの構成を示す断面図である。ガスセンサ10は、内燃機関の排気ガス中の酸素を検出する酸素センサである。ガスセンサ10は、酸素センサ素子20と、主体金具11と、内側端子部材30と、外側端子部材40と、セラミックヒータ50と、を主に備える。
図2は、第1実施例における主体金具11と金属外筒16との溶接部100の詳細構成について模式的に説明する断面図である。図2(a)は、溶接部100の全体的な構成について示しており、図2(b)は、先端側溶接部110、後端側溶接部120について示している。図2(a)に示す断面図は、図1の円Xの部分を拡大して示している。図2(a)に示すように、主体金具11の筒部11bの外周面11eが金属外筒16の先端部16aの内周面16dに対向するように、主体金具11が金属外筒16に挿入され重なり部80を形成し、重なり部80が、外周側から周方向に一周に亘ってリング状に加締められる。加締められている部分を、以降、加締め部90と呼ぶ。更に、加締め部90において、金属外筒16の周方向に一周に亘ってレーザを照射することにより、主体金具11と金属外筒16とを接合するレーザ溶接が施され、溶接部100が形成される。第1実施例では、レーザ溶接は、軸線Oの方向に沿って異なる位置となるように、軸線Oの方向にずれて複数箇所(第1実施例では2箇所)に施されているので、溶接部100は、図2(a)に示すように、先端側溶接部110、後端側溶接部120とから構成されている。
図3および図4を参照して、ガスセンサの製造方法について説明する。図3は、第1実施例におけるガスセンサ10の製造工程を説明するフローチャートである。図4は、第1実施例における、ガスセンサ10の溶接工程について詳細に説明する説明図である。図3では、ガスセンサ10を構成する主体金具11と金属外筒16との接合の過程を中心に説明し、ガスセンサ10のその他の部位の製造過程については公知であるため説明を省略する。
第1実施例では、先端側溶接部110、後端側溶接部120の内側溶接部112、122が一部分重複するようにレーザ溶接を行っているが、内側溶接部112、122は重複していなくても良い。また、第1実施例では、1回目のレーザ溶接にて先端側溶接部110が形成され、2回目のレーザ溶接にて後端側溶接部120が形成されているが、1回目のレーザ溶接にて後端側溶接部120が形成され、2回目のレーザ溶接にて先端側溶接部110が形成されていてもよい。さらに、第1実施例では、2回目のレーザ溶接にて形成された後端側溶接部120の厚みB2が、1回目のレーザ溶接にて形成された先端側溶接部110の厚みB1よりも深く形成されているが、先端側溶接部110の厚みと後端側溶接部120の厚みとが略同等であってもよい。
11…主体金具
12b…ヒータリード線
13…インシュレータ
13b…スリーブ
14…タルク
15…プロテクタ
15a…外側プロテクタ
15b…内側プロテクタ
16…金属外筒
17…グロメット
18…セパレータ
19、19b…センサ出力リード線
20…酸素センサ素子
30…内側端子部材
40…外側端子部材
50…セラミックヒータ
85…フィルタ
86…金属パイプ
90…加締め部
100、100a,100b…溶接部
110、110a、110b、…先端側溶接部
120、120a、120b…後端側溶接部
111、111a、111b…外側溶接部
112、112a、112b…内側溶接部
113a、123a…境界部分
121,121a、121b…外側溶接部
122、122a、122b…内側溶接部
300…間隙
Claims (10)
- 軸線方向に延び、先端側に被検出ガスを検出するための検知部を有するセンサ素子と、該センサ素子の先端側及び後端側を露出させつつ前記センサ素子の周囲を囲む筒部を有する主体金具と、前記主体金具に固定され、前記センサ素子の後端側を囲む筒状の外筒とを有するガスセンサの製造方法であって、
前記外筒の先端部が前記主体金具の筒部の周囲を囲むように、前記外筒を前記主体金具に配置する外筒配置工程と、
前記外筒の先端部と前記主体金具の筒部との重なり部に、全周に亘ってレーザ溶接を行い、前記外筒の先端部と前記主体金具の筒部とに跨る溶接部を形成する溶接工程と、を備え、
前記溶接工程において、前記ガスセンサの軸線方向にずらして、複数回、前記レーザ溶接を行うことを特徴とする、
ガスセンサの製造方法。 - 請求項1記載のガスセンサの製造方法であって、
前記溶接工程は、複数回の前記レーザ溶接によって形成される複数の前記溶接部のうち、隣り合う2つの前記溶接部の前記主体金具の筒部に形成される各内側溶接部が、一部分重複するようにレーザ溶接を行う、
ガスセンサの製造方法。 - 請求項1又は請求項2記載のガスセンサの製造方法であって、
前記溶接工程では、前記重なり部の先端側から後端側にずらして、複数回、前記レーザ溶接を行う、
ガスセンサの製造方法。 - 請求項1乃至請求項3のいずれか一項に記載のガスセンサの製造方法であって、
前記溶接工程では、1回目の前記レーザ溶接により形成された第1溶接部の深さよりも深さが大きくなる第2溶接部を形成するように、2回目以降の前記レーザ溶接を行う、
ガスセンサの製造方法。 - 軸船方向に延び、先端側に被検出ガスを検出するための検知部を有するセンサ素子と、
前記センサ素子の先端側及び後端側を露出させつつ前記センサ素子の周囲を囲む筒部を有する主体金具と、
後端側が前記主体金具の筒部の周囲を囲むように前記主体金具に固定される筒状の外筒と、を備えるガスセンサであって、
前記外筒の先端部と前記主体金具の筒部との重なり部に全周に亘って形成された、前記外筒の先端部と前記主体金具の筒部とに跨る溶接部が、前記ガスセンサの軸線方向に異なる位置に複数形成されていることを特徴とする、
ガスセンサ。 - 請求項5記載のガスセンサであって、
前記複数の前記溶接部のうち、隣り合う2つの前記溶接部が一部分重複するように形成されており、
前記軸線に沿った断面にて、該隣り合う2つの前記溶接部のうち、後端側に形成される後端側溶接部が、先端側に形成される先端側溶接部に対して重なるように形成されている、
ガスセンサ。 - 請求項6記載のガスセンサであって、
前記後端側溶接部の深さは、前記先端側溶接部の深さよりも大きい、
ガスセンサ。 - 請求項5記載のガスセンサであって、
複数の前記溶接部のうち、隣り合う2つの前記溶接部の前記主体金具の筒部に形成される内側溶接部が一部分重複するように形成されている、
ガスセンサ。 - 請求項5記載のガスセンサであって、
前記溶接部のうち、重ねられた第1溶接部の深さは、重なった第2溶接部の深さよりも大きい、
ガスセンサ。 - 請求項5乃至請求項9のいずれか一項に記載のガスセンサにおいて、
前記溶接部は、前記主体金具の前記筒部の厚みの半分以下の部位に設けられる、
ガスセンサ。
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CN2010800037985A CN102265148A (zh) | 2009-03-02 | 2010-02-22 | 气体传感器的制造方法及气体传感器 |
DE112010000950.3T DE112010000950B4 (de) | 2009-03-02 | 2010-02-22 | Verfahren zur Herstellung eines Gassensors, sowie Gassensor |
US13/133,281 US20110239739A1 (en) | 2009-03-02 | 2010-02-22 | Method of manufacturing gas sensor, and gas sensor |
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DE102011079234A1 (de) | 2011-07-15 | 2013-01-17 | Robert Bosch Gmbh | Verfahren zum Festlegen eines Doppelrohrs an einem Grundkörper sowie Messfühler mit entsprechend festgelegtem Doppelrohr |
WO2013080513A1 (ja) * | 2011-11-29 | 2013-06-06 | 日本特殊陶業株式会社 | ガスセンサ |
JP2014006035A (ja) * | 2012-06-27 | 2014-01-16 | Ngk Spark Plug Co Ltd | グロープラグ |
WO2014119342A1 (ja) * | 2013-02-01 | 2014-08-07 | オリンパス株式会社 | 部材接合方法、部材接合構造、および継手管 |
WO2022249924A1 (ja) * | 2021-05-24 | 2022-12-01 | 株式会社デンソー | ガスセンサ |
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JP5204284B2 (ja) * | 2010-11-12 | 2013-06-05 | 日本特殊陶業株式会社 | ガスセンサ |
US20160053899A1 (en) * | 2014-08-20 | 2016-02-25 | Swagelok Company | Valve with welded diaphragm to assist opening force |
JP6542707B2 (ja) * | 2016-04-21 | 2019-07-10 | 日本特殊陶業株式会社 | ガスセンサ |
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US20110239739A1 (en) | 2011-10-06 |
DE112010000950T5 (de) | 2012-07-26 |
CN102265148A (zh) | 2011-11-30 |
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