Delphi Technologies, Inc.

Eric P Clyde

William J LaBarge

Paul Casey Kikuchi

Richard Frederick Beckmeyer

Marsha E Nottingham

Da Yu Wang

Kailash Chandra Jain

Walter Thomas Symons

Kaius Kiiren Polikarpus

Carlos Augusto Valdes

Earl Wayne Lankheet

Richard Eugene Fouts

James D Ward

Kenneth M Rahmoeller

An exhaust sensor comprises a sensing electrode and a reference electrode each in contact with an electrolyte. At least one of the sensing electrode and the reference electrode are formed by depositing an electrode precursor material on an electrolyte precursor material and sintering the combination at a sufficient temperature for a sufficient time to achieve densification of the electrolyte, wherein the electrode precursor material comprises an alkali salt. Electrode patterns having enhanced perimeter ratios are also disclosed. The resulting exhaust sensor is capable of providing a usable output at a reduced operating temperature.

Low-temperature activity exhaust sensor

In one embodiment, a protective coating for an electrode of a sensor is described, the protective coating comprising an annealed catalyst, said annealed catalyst comprising at least one metal that has been subjected to thermal energy that is at least equivalent to or greater than that received from calcining the at least one metal for 24 hours at a temperature of 930 degrees C in air. In another embodiment, the annealed catalyst will comprise at least one metal that has been subjected to thermal energy that is equal to or less than that received from calcining the at least one metal for 24 hours at 1030 degrees C in air. In one exemplary embodiment, the annealed catalyst will comprise at least one metal that has been subjected to thermal energy that is equal to that received from calcining the at least one metal for 24 hours at 980 degrees C in air.

Catalyst anneal for durable stoichiometric shift corrected protective coating for oxygen sensors

A two-step chemical treatment method for chemically conditioning a sensor element comprising an electrolyte in ionic communication with a first electrode and a second electrode is described. The method comprises treating at least a portion of a sensor element with a first solution comprising an inorganic base, a carbonate salt and an acid salt; heating the sensor element; treating at least a portion of the sensor element with a second solution comprising an inorganic base and a carbonate salt; and drying the sensor element. The gas sensors comprising the two-step treated sensor elements have reduced lean shift, green effect, sensor output amplitude drop, and the light-off time is improved.

Methods of making gas sensors and sensors formed therefrom

In one embodiment, a method of making a sensor comprises: forming a slurry comprising a metal oxide, a binder, an acetate, and a reducing material, applying the slurry to at least a portion of a sensing element comprising two electrodes with an electrolyte disposed therebetween, and calcining the slurry to form a protective coating. In one embodiment, a gas sensor, comprises: a sensing element comprising a sensing electrode and a reference electrode having an electrolyte disposed therebetween, and a protective coating disposed over the sensing electrode, wherein the protective coating comprises aluminum oxide, an alpha alumina and about 2 wt % to about 15 wt % solid solution, based upon the total weight of the protective coating.

Disclosed herein is a method for producing a gas sensor, comprising disposing a reference electrode on a side of an electrolyte, disposing a measuring electrode on a side of the electrolyte opposite the reference electrode, disposing a first protective coating on a side of the measuring electrode opposite the electrolyte, treating the sensor with an aqueous salt solution comprising chloride and carbonate salts comprising elements selected from the group consisting of Group IA and IIA elements of the Periodic Table to form a treated sensor comprising the chloride and the carbonate salt mixture, drying the treated sensor, and disposing a second protective coating on a side of the first protective coating opposite the measuring electrode.

Co-fired oxygen sensor elements

A method for making a sensor is disclosed. The method comprises: disposing an electrolyte between a first side of sensing electrode and a first side of reference electrode, disposing a first side of a protective layer adjacent to said a second side of said sensing electrode, applying a mixture of a metal oxide, a fugitive material, and a solvent to a second side of the protective layer, and calcining the applied mixture to form said a protective coating on the second side of the protective layer.

Coating for gas sensors

An exhaust gas sensor element having an electrochemical cell, a protective material in fluid communication with the electrochemical cell, and a reactive inhibitive coating disposed over the protective material. The reactive inhibitive coating prevents the reaction of compounds with acids(e.g., phosphates) in the exhaust gas, which may form a dense glass layer on the outside of the gas sensor. The reactive inhibitive coating is either an alkaline earth oxide ethoxide, and/or carbonate that is deposited on the gas sensor to a thickness so as to preferably provide an excess of either the alkaline earth material.

Sensor coating inhibiting glass formation

A sensor is disclosed that comprises an electrolyte disposed between and in intimate contact with a sensing electrode and a reference electrode. A protective coating is disposed on the protective layer adjacent to the sensing electrode. The protective coating comprises a mixture of a metal oxide, a zeolite, and an alumina. A method for making the sensor is also disclosed.

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Bay City, MI, United States of America

Eric P Clyde