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To detect an air-fuel ratio in wide range is very important to control the automotive engines with low fuel consumption and low exhaust emissions. Although the application of zirconia electrolyte for this purpose has been proposed by the authors several years ago, there remained several problems due to the contamination of gas diffusion apertures which are exposed to the exhaust gas environment. Here the behavior of ions transported in zirconia electrolyte have been analyzed to optimize the structure and characteristics, and to guarantee the long life operation of sensor. Gas contents and their reactions in combustion process under the wide range air-fuel ratio have been analyzed, and these results were reflected to the analysis of ion transportation in zirconia electrolyte. Experimental results supported the analytical results, and they showed the possibilities of long life operation of zirconia air-fuel ratio sensor utilizing ion transportation phenomena.

This paper describes the design and operation of a thick-film zirconia air-fuel ratio sensor with a heater. This sensor is composed of two zirconia plate cells, a stoichiometric cell and a lean cell, laminated on the platinum heater. It is fabricated as one body using a thick-film process. The pair of cells has a gas diffusion chamber and a slit type gas diffusion aperture. The sensing principle is based on the rate-determining diffusion of oxygen molecules at the gas diffusion aperture. By using an oxygen pumping phenomenon, air-fuel ratios of the stoichiometric and lean regions can be detected. As this sensor is heated to a high constant temperature, it has sufficient accuracy without any additional temperature compensation. Its starting time is short and response time is very quick.