Patents by Inventor Shota KAGEYAMA

Shota KAGEYAMA has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11808730
    Abstract: A gas sensor element in which oxidation of electrodes and a heater occurring with continued use is suppressed is provided. The gas sensor element includes a plurality of solid electrolyte layers stacked one over another, and includes an electrochemical cell including a pair of electrodes and a portion of the plurality of solid electrolyte layers existing between the pair of electrodes; a heater part capable of heating the gas sensor element; and a gettering layer located between the plurality of solid electrolyte layers and between the plurality of solid electrolyte layers and each of the pair of electrodes, and gettering impurities in a metal component of the electrodes and the heater part during driving of the gas sensor element.
    Type: Grant
    Filed: October 31, 2019
    Date of Patent: November 7, 2023
    Assignee: NGK INSULATORS, LTD.
    Inventors: Takayuki Sekiya, Shota Kageyama, Yusuke Watanabe
  • Patent number: 11692986
    Abstract: A sensor element includes element main body including side surfaces, a detection unit, connector electrodes disposed on the rear end-side part of the side surfaces, a porous layer that covers at least front end-side part of the side surface, the porous layer having a porosity of 10% or more, and a water-penetration reduction portion. The water-penetration reduction portion is disposed on the side surface so as to divide the porous layer or to be located closer to the rear end than the porous layer. The length L of the water-penetration reduction portion is 0.5 mm or more. The water-penetration reduction portion includes, among a dense layer covering the side surface and having a porosity of less than 10% and a gap region in which the porous layer is absent, at least the dense layer. The water-penetration reduction portion reduces the capillarity of water.
    Type: Grant
    Filed: May 27, 2022
    Date of Patent: July 4, 2023
    Assignee: NGK INSULATORS, LTD.
    Inventors: Yuki Nakayama, Shota Kageyama, Yusuke Fujii, Kei Kosaka
  • Publication number: 20230057032
    Abstract: A sensor element and fabrication method thereof, the sensor element includes: a main pump cell including an inner pump electrode facing a first inner space into which a measurement gas is introduced, an external pump electrode provided on an element surface, and a solid electrolyte therebetween; an auxiliary pump cell including an auxiliary pump electrode provided facing a second inner space, the external pump electrode, and the solid electrolyte therebetween; and a measurement pump cell including a measurement electrode, the external pump electrode, and the solid electrolyte therebetween. The inner pump electrode has a porosity of 10 - 25%, the auxiliary pump electrode has a porosity of 30 - 50%, a thickness ratio of both the electrodes is 1.0 - 4.0, and current flowing to the main pump cell has a current density of 0.05 - 0.5 mA/mm2 when the measurement gas has an oxygen concentration of 20.5%.
    Type: Application
    Filed: November 7, 2022
    Publication date: February 23, 2023
    Inventors: Yusuke WATANABE, Shota KAGEYAMA, Yuki NAKAYAMA
  • Patent number: 11474089
    Abstract: A sensor element includes element main body including side surfaces, a detection unit, connector electrodes disposed on the rear end-side part of the side surfaces, a porous layer that covers at least front end-side part of the side surface, the porous layer having a porosity of 10% or more, and a water-penetration reduction portion. The water-penetration reduction portion is disposed on the side surface so as to divide the porous layer or to be located closer to the rear end than the porous layer. The length L of the water-penetration reduction portion is 0.5 mm or more. The water-penetration reduction portion includes, among a dense layer covering the side surface and having a porosity of less than 10% and a gap region in which the porous layer is absent, at least the dense layer. The water-penetration reduction portion reduces the capillarity of water.
    Type: Grant
    Filed: October 21, 2019
    Date of Patent: October 18, 2022
    Assignee: NGK INSULATORS, LTD.
    Inventors: Yuki Nakayama, Shota Kageyama, Yusuke Fujii, Kei Kosaka
  • Publication number: 20220317086
    Abstract: A gas sensor includes a sensor element and one or more hollow columnar dense bodies. The sensor element includes an element main body having a side surface, a porous layer and a water-penetration reduction portion that cover at least a front end-side part of the side surface. The water-penetration reduction portion disposed on the side surface so as to divide the porous layer or to be located closer to the rear end than the porous layer, an overlap length W that is the length of a continuous overlap between a range in which the water-penetration reduction portion is present in a longitudinal direction and a range in which inner peripheral surfaces of the one or more dense bodies are present in the longitudinal direction being 0.5 mm or more, and having a dense layer covers the side surface, the water-penetration reduction portion reduces the capillarity of water.
    Type: Application
    Filed: June 13, 2022
    Publication date: October 6, 2022
    Inventors: Yuki NAKAYAMA, Shota KAGEYAMA, Yusuke FUJII, Kei KOSAKA
  • Publication number: 20220308031
    Abstract: A sensor element includes element main body including side surfaces, a detection unit, connector electrodes disposed on the rear end-side part of the side surfaces, a porous layer that covers at least front end-side part of the side surface, the porous layer having a porosity of 10% or more, and a water-penetration reduction portion. The water-penetration reduction portion is disposed on the side surface so as to divide the porous layer or to be located closer to the rear end than the porous layer. The length L of the water-penetration reduction portion is 0.5 mm or more. The water-penetration reduction portion includes, among a dense layer covering the side surface and having a porosity of less than 10% and a gap region in which the porous layer is absent, at least the dense layer. The water-penetration reduction portion reduces the capillarity of water.
    Type: Application
    Filed: May 27, 2022
    Publication date: September 29, 2022
    Inventors: Yuki NAKAYAMA, Shota KAGEYAMA, Yusuke FUJII, Kei KOSAKA
  • Patent number: 11391691
    Abstract: A gas sensor includes a sensor element and one or more hollow columnar dense bodies. The sensor element includes an element main body having a side surface, a porous layer and a water-penetration reduction portion that cover at least a front end-side part of the side surface. The water-penetration reduction portion disposed on the side surface so as to divide the porous layer or to be located closer to the rear end than the porous layer, an overlap length W that is the length of a continuous overlap between a range in which the water-penetration reduction portion is present in a longitudinal direction and a range in which inner peripheral surfaces of the one or more dense bodies are present in the longitudinal direction being 0.5 mm or more, and having a dense layer covers the side surface, the water-penetration reduction portion reduces the capillarity of water.
    Type: Grant
    Filed: October 31, 2019
    Date of Patent: July 19, 2022
    Assignee: NGK INSULATORS, LTD.
    Inventors: Yuki Nakayama, Shota Kageyama, Yusuke Fujii, Kei Kosaka
  • Patent number: 11391689
    Abstract: A gas sensor includes a sensor element and one or more hollow columnar dense bodies. The sensor element includes an element main body having a side surface, a porous layer and a water-penetration reduction portion that cover at least a front end-side part of the side surface. The water-penetration reduction portion disposed on the side surface so as to divide the porous layer an overlap length W that is the length of a continuous overlap between a range in which the water-penetration reduction portion is present in the longitudinal direction and a range in which inner peripheral surfaces of the one or more dense bodies are present in the longitudinal direction being 0.5 mm or more, the water-penetration reduction portion being a gap region in which the porous layer is absent, the water-penetration reduction portion reduces the capillarity of water.
    Type: Grant
    Filed: October 31, 2019
    Date of Patent: July 19, 2022
    Assignee: NGK INSULATORS, LTD.
    Inventors: Yuki Nakayama, Shota Kageyama, Yusuke Fujii, Kei Kosaka
  • Patent number: 11231391
    Abstract: A sensor element includes: a main pump cell constituted by an inner electrode provided to face a first inner space into which a measurement gas is introduced, an external electrode provided on an element surface, and a solid electrolyte therebetween; and a measurement pump cell constituted by a measurement electrode provided to face a second inner space communicated with the first inner space, an external electrode, and a solid electrolyte therebetween. A diffusion resistance from a gas inlet to the inner electrode is 200 to 1000 cm?1. For the first inner space and a unit electrode part of the inner electrode, a space length is 2.5 to 10 mm, a space thickness is 50 to 300 ?m, an electrode length/the space length is 0.5 to 1.0, and an electrode width/the space width is 0.5 to 1.0.
    Type: Grant
    Filed: July 24, 2019
    Date of Patent: January 25, 2022
    Assignee: NGK INSULATORS, LTD.
    Inventors: Yusuke Watanabe, Takayuki Sekiya, Shota Kageyama
  • Patent number: 10955376
    Abstract: A sensor element includes: a main pump cell constituted by an inner pump electrode facing the first inner space into which a measurement gas is introduced, an external pump electrode provided on an element surface, and a solid electrolyte located therebetween; a measurement electrode facing a second inner space communicating with the first inner space and functioning as a reduction catalyst for NOx; and a measurement pump cell constituted by the measurement electrode, the external pump electrode, and a solid electrolyte located therebetween. A diffusion resistance from the gas inlet to the inner pump electrode ranges from 200-1000 cm?1, a resistance of the main pump cell is equal to or smaller than 150?, a distance between the electrodes ranges from 0.1-0.6 mm, and the inner pump electrode which is a cermet made of an Au—Pt alloy and ZrO2 has an area ranging from 5-20 mm2.
    Type: Grant
    Filed: March 13, 2019
    Date of Patent: March 23, 2021
    Assignee: NGK INSULATORS, LTD.
    Inventors: Yusuke Watanabe, Takayuki Sekiya, Yuki Nakayama, Shota Kageyama
  • Patent number: 10914706
    Abstract: A sensor element includes: a first inner space into which a measurement gas is introduced from outside; a second inner space communicated with the first inner space; a main pump cell constituted by an inner pump electrode facing the first inner space, an external pump electrode on a surface of the sensor element, and a solid electrolyte located therebetween; a measurement electrode facing the second inner space and functioning as a reduction catalyst for NOx; and a measurement pump cell constituted by the measurement electrode, the external pump electrode, and a solid electrolyte located therebetween. The inner pump electrode is a cermet made of an Au—Pt alloy containing Au ranging from 0.6 wt % to 1.4 wt % and ZrO2, and has a thickness ranging from 5 ?m to 30 ?m, a porosity ranging from 5% to 40%, and an area ranging from 5 mm2 to 20 mm2.
    Type: Grant
    Filed: March 13, 2019
    Date of Patent: February 9, 2021
    Assignee: NGK INSULATORS, LTD.
    Inventors: Yusuke Watanabe, Takayuki Sekiya, Yuki Nakayama, Shota Kageyama
  • Publication number: 20200200702
    Abstract: A sensor element includes: a main pump cell including an inner pump electrode facing a first inner space into which a measurement gas is introduced, an external pump electrode provided on an element surface, and a solid electrolyte therebetween; an auxiliary pump cell including an auxiliary pump electrode provided facing a second inner space, the external pump electrode, and the solid electrolyte therebetween; and a measurement pump cell including a measurement electrode, the external pump electrode, and the solid electrolyte therebetween. The inner pump electrode has a porosity of 10-25%, the auxiliary pump electrode has a porosity of 30-50%, a thickness ratio of both the electrodes is 1.0-4.0, and current flowing to the main pump cell has a current density of 0.05-0.5 mA/mm2 when the measurement gas has an oxygen concentration of 20.5%.
    Type: Application
    Filed: December 18, 2019
    Publication date: June 25, 2020
    Inventors: Yusuke WATANABE, Shota KAGEYAMA, Yuki NAKAYAMA
  • Publication number: 20200064302
    Abstract: A gas sensor element in which oxidation of electrodes and a heater occurring with continued use is suppressed is provided. The gas sensor element includes a plurality of solid electrolyte layers stacked one over another, and includes an electrochemical cell including a pair of electrodes and a portion of the plurality of solid electrolyte layers existing between the pair of electrodes; a heater part capable of heating the gas sensor element; and a gettering layer located between the plurality of solid electrolyte layers and between the plurality of solid electrolyte layers and each of the pair of electrodes, and gettering impurities in a metal component of the electrodes and the heater part during driving of the gas sensor element.
    Type: Application
    Filed: October 31, 2019
    Publication date: February 27, 2020
    Inventors: Takayuki SEKIYA, Shota KAGEYAMA, Yusuke WATANABE
  • Publication number: 20200064305
    Abstract: A gas sensor includes a sensor element and one or more hollow columnar dense bodies. The sensor element includes an element main body having a side surface, a porous layer and a water-penetration reduction portion that cover at least a front end-side part of the side surface. The water-penetration reduction portion disposed on the side surface so as to divide the porous layer or to be located closer to the rear end than the porous layer, an overlap length W that is the length of a continuous overlap between a range in which the water-penetration reduction portion is present in a longitudinal direction and a range in which inner peripheral surfaces of the one or more dense bodies are present in the longitudinal direction being 0.5 mm or more, and having a dense layer covers the side surface, the water-penetration reduction portion reduces the capillarity of water.
    Type: Application
    Filed: October 31, 2019
    Publication date: February 27, 2020
    Inventors: Yuki NAKAYAMA, Shota KAGEYAMA, Yusuke FUJII, Kei KOSAKA
  • Publication number: 20200064301
    Abstract: A gas sensor includes a sensor element and one or more hollow columnar dense bodies. The sensor element includes an element main body having a side surface, a porous layer and a water-penetration reduction portion that cover at least a front end-side part of the side surface. The water-penetration reduction portion disposed on the side surface so as to divide the porous layer an overlap length W that is the length of a continuous overlap between a range in which the water-penetration reduction portion is present in the longitudinal direction and a range in which inner peripheral surfaces of the one or more dense bodies are present in the longitudinal direction being 0.5 mm or more, the water-penetration reduction portion being a gap region in which the porous layer is absent, the water-penetration reduction portion reduces the capillarity of water.
    Type: Application
    Filed: October 31, 2019
    Publication date: February 27, 2020
    Inventors: Yuki NAKAYAMA, Shota KAGEYAMA, Yusuke FUJII, Kei KOSAKA
  • Publication number: 20200049679
    Abstract: A sensor element includes element main body including side surfaces, a detection unit, connector electrodes disposed on the rear end-side part of the side surfaces, a porous layer that covers at least front end-side part of the side surface, the porous layer having a porosity of 10% or more, and a water-penetration reduction portion. The water-penetration reduction portion is disposed on the side surface so as to divide the porous layer or to be located closer to the rear end than the porous layer. The length L of the water-penetration reduction portion is 0.5 mm or more. The water-penetration reduction portion includes, among a dense layer covering the side surface and having a porosity of less than 10% and a gap region in which the porous layer is absent, at least the dense layer. The water-penetration reduction portion reduces the capillarity of water.
    Type: Application
    Filed: October 21, 2019
    Publication date: February 13, 2020
    Inventors: Yuki NAKAYAMA, Shota KAGEYAMA, Yusuke FUJII, Kei KOSAKA
  • Publication number: 20200041442
    Abstract: A sensor element includes: a main pump cell constituted by an inner electrode provided to face a first inner space into which a measurement gas is introduced, an external electrode provided on an element surface, and a solid electrolyte therebetween; and a measurement pump cell constituted by a measurement electrode provided to face a second inner space communicated with the first inner space, an external electrode, and a solid electrolyte therebetween. A diffusion resistance from a gas inlet to the inner electrode is 200 to 1000 cm?1. For the first inner space and a unit electrode part of the inner electrode, a space length is 2.5 to 10 mm, a space thickness is 50 to 300 ?m, an electrode length/the space length is 0.5 to 1.0, and an electrode width/the space width is 0.5 to 1.0.
    Type: Application
    Filed: July 24, 2019
    Publication date: February 6, 2020
    Inventors: Yusuke WATANABE, Takayuki SEKIYA, Shota KAGEYAMA
  • Publication number: 20190285572
    Abstract: A sensor element includes: a main pump cell constituted by an inner pump electrode facing the first inner space into which a measurement gas is introduced, an external pump electrode provided on an element surface, and a solid electrolyte located therebetween; a measurement electrode facing a second inner space communicating with the first inner space and functioning as a reduction catalyst for NOx; and a measurement pump cell constituted by the measurement electrode, the external pump electrode, and a solid electrolyte located therebetween. A diffusion resistance from the gas inlet to the inner pump electrode ranges from 200-1000 cm?1, a resistance of the main pump cell is equal to or smaller than 150?, a distance between the electrodes ranges from 0.1-0 6 mm, and the inner pump electrode which is a cermet made of an Au—Pt alloy and ZrO2 has an area ranging from 5-20 mm2.
    Type: Application
    Filed: March 13, 2019
    Publication date: September 19, 2019
    Inventors: Yusuke WATANABE, Takayuki SEKIYA, Yuki NAKAYAMA, Shota KAGEYAMA
  • Publication number: 20190285574
    Abstract: A sensor element includes: a first inner space into which a measurement gas is introduced from outside; a second inner space communicated with the first inner space; a main pump cell constituted by an inner pump electrode facing the first inner space, an external pump electrode on a surface of the sensor element, and a solid electrolyte located therebetween; a measurement electrode facing the second inner space and functioning as a reduction catalyst for NOx; and a measurement pump cell constituted by the measurement electrode, the external pump electrode, and a solid electrolyte located therebetween. The inner pump electrode is a cermet made of an Au—Pt alloy containing Au ranging from 0.6 wt % to 1.4 wt % and ZrO2, and has a thickness ranging from 5 ?m to 30 ?m, a porosity ranging from 5% to 40%, and an area ranging from 5 mm2 to 20 mm2.
    Type: Application
    Filed: March 13, 2019
    Publication date: September 19, 2019
    Inventors: Yusuke WATANABE, Takayuki SEKIYA, Yuki NAKAYAMA, Shota KAGEYAMA
  • Patent number: 9804118
    Abstract: In a sensor element, a reference gas regulation pump cell pumps in oxygen to the periphery of a reference electrode in which a reference gas is introduced, by the flow of a control current Ip3 between the reference electrode and an outer pump electrode located in a region exposed to a measurement-object gas. An average current density of the reference electrode under the flow of the control current Ip3 is higher than 0 ?A/mm2 and lower than 400 ?A/mm2. The average current density is preferably not higher than 170 ?A/mm2. An average value of the control current Ip3 is preferably higher than 1 ?A. The outer pump electrode as a measurement-object gas side electrode of the reference gas regulation pump cell may be provided on an outer surface of a layered body (or more specifically, on a second solid electrolyte layer).
    Type: Grant
    Filed: March 30, 2015
    Date of Patent: October 31, 2017
    Assignee: NGK Insulators, Ltd.
    Inventors: Takayuki Sekiya, Naoya Saito, Shota Kageyama