Abstract:
An exhaust sensor includes a first sheet of ceramic that is perforated with a vent orifice and, a second sheet of ceramic that is laminated to the first sheet. A palladium circuit trace is positioned between the first sheet and the second sheet of ceramic and a fugitive ink is printed on one of the sheets that is in communication with the vent orifice and the palladium. The fugitive ink volatilizes during a firing process and created a void space that is occupied by a palladium oxide that forms at temperatures around 625-900C.
Abstract:
A sensor element includes a substrate (10) having a coating (31) on a portion of the substrate (10). The coating (31) is applied to the substrate (10) by dipping the portion of the substrate (10) into a slurry which includes a pulverized mineral and water, extracting the substrate (10) from the slurry in a direction along an axis, drying the coated substrate (10), and firing the coated substrate (10) so as to promote densification of the mineral and adhesion of the mineral to the substrate (10). The coating (31) after firing has a minimum thickness of about 100 microns at every location around the periphery of a cross section through the substrate (10) taken in a plane normal to the axis. A method for making a coated sensor element is also disclosed.
Abstract:
A sensor (10) is disclosed that comprises an electrolyte (30) disposed between and in intimate contact with a sensing electrode (20) and a reference electrode (22). A protective coating (31) is disposed on the protective layer (32) adjacent to the sensing electrode (20). The protective coating (31) comprises a mixture of a metal oxide, a zeolite, and an alumina. A method for making the sensor (10) is also disclosed.
Abstract:
An exhaust gas sensor (10) element having an electrochemical cell, a protective material (42) in fluid communication with the electrochemical cell, and a reactive inhibitive coating (28) disposed over the protective material (42). The reactive inhibitive coating (28) prevents the reaction of compounds with acides (e.g., phosphates) in the exhaust gas, which may form a dense glass layer on the outside of the gas sensor (10). The reactive inhibitive coating (28) is either an alkaline earth oxide ethoxide, and/or carbonate that is deposited on the gas sensor (10) to a thickness so as to preferably provide an excess of either the alkaline earth material.
Abstract:
One method of forming a sensor (10) comprises: disposing a reference electrode (22) and sensing electrode (20) on opposite sides of an electrolyte and a heater (62) on a side of the reference electrode (22) opposite the electrolyte to form a sensor element having a sensing end adjacent the reference electrode (22) and sensing electrode (20), dipping the sensor element in a first slurry, drying the sensor element to form a first coated sensor element, dipping the first coated sensor element into a second slurry, and drying the first coated sensor element to form a dipped sensor element.
Abstract:
An exhaust gas sensor (10) element having an electrochemical cell, a protective material (42) in fluid communication with the electrochemical cell, and a reactive inhibitive coating (28) disposed over the protective material (42). The reactive inhibitive coating (28) prevents the reaction of compounds with acides (e.g., phosphates) in the exhaust gas, which may form a dense glass layer on the outside of the gas sensor (10). The reactive inhibitive coating (28) is either an alkaline earth oxide ethoxide, and/or carbonate that is deposited on the gas sensor (10) to a thickness so as to preferably provide an excess of either the alkaline earth material.