Delphi Technologies, Inc.

Kerry Gross

Walter Thomas Symons

Kaius Kiiren Polikarpus

William J LaBarge

Da Yu Wang

Paul Casey Kikuchi

Timothy Robert Armstrong

Suresh Baskaran

Richard Frederick Beckmeyer

Craig F Habeger

Conrad H Anderson

John David Vienna

Jarrod Vincent Crum

John Gerard Darab

Disclosed herein is a ceramic part, gas sensor, and method for making the gas sensor. The ceramic part comprises: an insulating layer affixed to a substrate wherein the insulating layer comprising AlOparticles; and a glass comprising about 45 to about 69 mole percent SiO, 0 to about 9 mole percent BO, 0 to about 26 mole percent AlO, 0 and 25 mole percent SrO, and about 10 to about 26 mole percent REO, where REOis selected from the group consisting of YO, three valent rare earth oxides, and combinations comprising at least one of the foregoing. In one embodiment of a ceramic part, a gas sensor comprises: an electrolyte layer having disposed on opposite sides thereof a first electrode and a second electrode; and an insulating layer that is in intimate contact with the second electrode, wherein the insulating layer comprises alumina and frit. The method of making the gas sensor comprises: disposing a first electrode and a second electrode on opposite sides of an electrolyte layer; forming an insulating layer comprising alumina and frit; disposing the insulating layer adjacent to the second electrode to form a green sensor; and heating the green sensor to a temperature sufficient to sinter the electrolyte layer and the insulating layer.

Gas sensor having an insulating layer

A conductive co-fired body for an electrochemical cell for an exhaust sensor comprises zirconia, yttrium oxide, and alumina. The body comprises about 15 to about 30 weight % monoclinic phase zirconia. This produces an electrochemical cell having low impedance wherein the zirconia body and alumina body are co-fired. One method for manufacturing the electrochemical cell comprises combining zirconia, yttria, and alumina with solvent and dispersant to form a mixture. After, binder is added to the mixture which is then de-aired and cast onto a tape surface. The tape is dried, metallized, and laminated to an unfired alumina surface. The structure is then co-fired to form a body for said electrochemical cell.

Method of making a sensor and the product produced therefrom

The electrolyte comprises up to about 80 wt % zirconia, up to about 30 wt % stabilizer, and up to about 40 wt % dopant-zirconia. Alternatively, the electrolyte can comprise zirconia having a phase chemistry, wherein the phase chemistry, at about 25&deg; C., is about 15 wt % to about 35 wt % monoclinic, less than about 10 wt % tetragonal, balance cubic, based upon the weight of the zirconia in the electrolyte.

Gas sensor electrolyte

A method of manufacturing a ceramic body and a gas sensor is disclosed. The method comprises mixing a ceramic material and an organometallic material with a solvent to form a mixture. The organometallic material comprises both a metallic component and an organic ligand. The mixture is disposed onto a surface, dried, and removed to form the ceramic body. The sensor is made by disposing the ceramic body adjacent to an unfired electrolyte body having an electrode disposed on each side thereof to form a green sensor. The green sensor is co-fired to form the sensor.

Exhaust gas sensor and the method of manufacture thereof

The sensor is formed by disposing an electrolyte between and in intimate contact with a first electrode on the one side and a second electrode on the other side to form an assembly, heating the assembly, treating the assembly with an alkaline solution and removing the impurities to obtain optimal sensor performance. Alternatively, an electrolyte is formed, sintered, treated with alkaline solution, and then the electrodes are applied.

Method of treating an exhaust sensor and a product thereof

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New Lothrop, MI, United States of America

Kerry Gross