Delphi Technologies, Inc.

Gm Global Technolgoy Operations, Inc.

Richard Eugene Fouts

William J LaBarge

Richard Frederick Beckmeyer

Raymond Leo Bloink

Kaius Kiiren Polikarpus

Paul Casey Kikuchi

Eric P Clyde

Robert P Johnston

Lora Younkman

Darrell H Eldridge

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.

Methods of making gas sensors and sensors formed therefrom

The method of making a wide range oxygen sensor of the present invention enables ease of handling and processing, particularly in a mass production environment. This process comprises forming planar composite elements of the sensor where the elements are individually laminated. These laminated composites are easily handled and readily stacked. Furthermore, electrodes and electrode leads can be readily deposited on the laminated composites, across the intersection of the various materials forming the composite. After deposition of the electrodes, leads, and a heater, the elements are stacked accordingly and laminated to produce the oxygen sensor.

Method for making a wide range sensor element

An exhaust gas sensor includes a first electrode, a second electrode, and an electrolyte disposed between the first electrode and the second electrode. The electrolyte includes a first portion disposed at least in partial physical contact and in ionic communication with a second portion. The first portion has a first portion grain size which is different than a second portion grain size. Further, a method for manufacturing a gas sensor includes forming a multiple portion electrolyte. The electrolyte is formed with a first portion having one grain size, and a second portion at least in partial physical contact and in ionic contact with the first portion, the second portion having a second portion grain size different from the first portion grain size. The electrolyte may be fired before or after application of an electrode in ionic contact with the first portion and a second electrode in ionic contact with said second portion.

Gas sensor

A method of making a hollow-shaped green ceramic article by pressure slip casting in a slip casting mold having a porous mold part with porosity channels opening at the surface of the mold cavity. A slip composition is formed having solid phase components with an average particle size distribution less than the cross-sectional dimension of mold porosity channels, and also having a flocculating agent to cause agglomeration of the solid phase particles into floccules larger than the porosity channel dimension. The molding cavity is filled with the slip composition, and the same is then hydrostatically pressurized while withdrawing slip filtrate from the mold cavity via the mold porosity channels for a time sufficient to deposit to a desired thickness a layer of solids. Excess slip is then removed from the molding cavity to provide an exposed interior surface on the deposit layer. Air under pressure is then applied to the exposed interior surface of the deposit layer, preferably while also withdrawing slip filtrate via the mold porosity channels from the mold cavity surface-deposit layer interface. The slip casted green ceramic hollow article is removed from the mold only after sufficient water has been removed in situ from within the material of the green ceramic article to enable the same to be self-supporting.

Pressure slip casting process for making hollow-shaped ceramics

Growing community of inventors

Grand Blanc, MI, United States of America

Richard Eugene Fouts