Abstract: A high temperature electrical connector suitable for use in a high temperature gas sensor. The electrical connector incorporates a ceramic connector body having a pair of opposing ceramic body portions which each house a plurality of conductive terminals. The body portions are in pivoting engagement and fixed in a connector body retainer which also enables their pivoting, hinged movement. The pivoting engagement permits the ceramic body portions and terminals to hinge open to receive a gas sensor with a low insertion force and a hinge closed to provide the desired contact force. The ceramic body portions may also include a taper section in a pivot portion with a taper angle that may be varied to control the pivoting, hinged movement of the electrical connector.

Abstract: An ablating device is used to form a pattern into a sensing element pad of a soot sensor, with the pattern establishing two finger paths without electrical connection between them. The pattern can be formed through a protective layer on the sensing element pad before the sensing element pad is fired.

Abstract: A sensing system, including: a sensing assembly, the sensing assembly having: a trim resistor; and a controller removably secured to the sensing assembly, the controller being configured to determine a resistance value of the trim resistor; a database in operable communication with the controller, the database having a plurality of resistance values, each identifying a pair of compensation values; a microprocessor receiving the resistance value of the trim resistor, a first signal and a second signal, the resistance value of the trim resistor being used to define a selected pair of compensation values from the database, one of the selected pair of compensation values is used to adjust the first signal and the other one of the selected pair of compensation values is used to adjust the second signal.

Abstract: A soot sensor, comprising: a sensing element configured to provide a signal indicative of an amount of soot detected by the sensing element, the sensing element terminating at a tip portion; a shield disposed about the sensing element, the shield comprising an elongated body having a solid side wall terminating at a distal end portion, and a single opening disposed completely across the distal end portion, the single opening having a peripheral edge defined by the distal end portion of the side wall; and an inner area defined by the shield, the area being in fluid communication with the single opening and the tip portion being completely recessed within the area at a distance from the single opening and a peripheral edge of the tip portion being at least a predetermined distance from the solid side wall, the predetermined distance preventing soot from completely blocking the single opening.

Abstract: Soot sensing systems and soot sensors are provided. In one exemplary embodiment, a soot sensor includes a non-conductive substrate and a first electrode disposed on the non-conductive substrate. The soot sensor further includes a second electrode disposed on the non-conductive substrate and spaced away from the first electrode. The soot sensor further includes a first protective layer disposed over at least a portion of the first electrode. The soot sensor further includes a second protective layer disposed over at least a portion of the second electrode. Further, an electrical parameter between the first and second electrodes is indicative of an amount of soot disposed on the non-conductive substrate between the first and second electrodes.

Abstract: A sensing system, comprising: a sensing assembly, the sensing assembly having: a trim resistor integrally formed with the sensing assembly, the trim resistor having a resistance value; a first sensing element for providing a first signal in response to a first sensed condition; a second sensing element for providing a second signal in response to a second sensed condition; and a controller removably secured to the sensing assembly and receiving the first signal and the second signal, the controller being configured to determine the resistance value of the trim resistor; a database associated with the controller, the database having a plurality of resistance values, each resistance value in the database identifies a pair of compensation values; a microprocessor associated with the controller, the microprocessor receiving the resistance value of the trim resistor, the first signal and the second signal, the resistance value of the trim resistor being used to define a selected pair of compensation values from th

Abstract: A shield assembly for a gas sensor and a method for securing the shield assembly to the gas sensor are provided. The shield assembly includes an outer shield and an inner shield. The outer shield includes an outer wall defining a cavity therein and a tip portion located at one end of the outer wall. The outer wall includes a plurality of apertures extending therethrough. The inner shield is disposed within the cavity of the outer shield. The inner shield includes an inner-wall defining an inner cavity therein. The inner wall is in a facing spaced relationship with respect to the outer wall. The inner shield further includes an engagement portion, a tip engaging portion, and a plurality of inner shield apertures. The plurality of inner shield apertures and the plurality of apertures of the outer wall provide fluid communication to the inner cavity through the outer shield and the inner shield.

Abstract: A method for manufacturing a planar sensor, comprises disposing a film of a material on a substrate, wherein the material is selected from the group consisting of platinum, rhodium, palladium and mixtures and alloys comprising at least one of the foregoing materials; annealing the material; measuring a resistance value of the material; laser trimming the annealed material; heat treating the laser trimmed material; and laser trimming the heat treated material to form the sensor.

Abstract: An electrical connection is made by connecting a metal element to a second element to which the electrical connection is desired to be made by means of a conductive material disposed onto one or both of the metal element and the second element so as to contact and disperse about or through the metal element thereby providing both an electrical and a mechanical connection. The metal element may be a strip or pad with openings or knurls formed such as by stamping, a wire that is flattened and knurled, or a mesh material such as a wire mesh. In a preferred embodiment, the conductive material is a metal capable of withstanding harsh, high temperature environments, such as a noble metal. In another preferred embodiment, the second element is a ceramic element, preferably with a noble metal conductive pad thereon, to which the metal element is attached.

Abstract: A trim resistor assembly includes a trimmable resistor element embedded within a polymeric housing. The trimmable resistor element includes trimmable resistive film disposed on a nonconductive substrate. Lead wires are connected to contact pads on the substrate. The resistor element and wires are pre-assembled and placed within a mold defining a cavity. The mold includes a pedestal that covers a central region of the substrate that includes the trimmable resistive film. A polymeric material is injected into the cavity to form an integrally molded body that is the polymeric housing. In addition to the trim resistor element and the bare end sections of the wires, the section of the wires that are adjacent the end sections and include the polymeric sheath are also embedded in the housing to strengthen and seal the joint. The pedestal forms an opening in the housing that exposes the resistive film to provide access for trimming the resistance to a desired value.

Abstract: A sensor may comprise a first electrode and a second electrode in mutual ionic communication with an electrolyte, a first socket disposed near a rear portion of a sensor element, a first lead disposed in electrical communication with the first electrode and in physical contact with the first socket and configured for electrical communication with a first terminal element, a second socket disposed near the rear portion of the sensor element, and a second lead disposed in electrical communication with the second electrode and in physical contact with the second socket and configured for electrical communication with a second terminal element. The first socket is disposed through at least one of an edge and an end of the sensor element, and the second socket is disposed through at least one of the edge and the end of the sensor element.

Abstract: Disclosed herein is an impact absorber for an exhaust sensor. The impact absorber comprises a collar of deformable material disposed around a housing of the exhaust sensor. The collar extends radially outward from the housing. The collar may be formed from a material selected to degrade at exhaust temperature, or the collar may be formed from a material that provides radiation shielding to a portion of the sensor after installation. The collar may be disposed around a sealing gasket. A wall may be disposed around at least a portion of a perimeter of the collar, the wall being spaced apart from a plurality of facets formed on the housing to form a recess for receiving a socket wrench tool.

Abstract: A sensor may comprise a first electrode and a second electrode in mutual ionic communication with an electrolyte, a first socket disposed near a rear portion of a sensor element, a first lead disposed in electrical communication with the first electrode and in physical contact with the first socket and configured for electrical communication with a first terminal element, a second socket disposed near the rear portion of the sensor element, and a second lead disposed in electrical communication with the second electrode and in physical contact with the second socket and configured for electrical communication with a second terminal element. The first socket is disposed through at least one of an edge and an end of the sensor element, and the second socket is disposed through at least one of the edge and the end of the sensor element.

Abstract: A method for manufacturing a planar sensor, comprises disposing a film of a material on a substrate, wherein the material is selected from the group consisting of platinum, rhodium, palladium and mixtures and alloys comprising at least one of the foregoing materials; annealing the material; measuring a resistance value of the material; laser trimming the annealed material; heat treating the laser trimmed material; and laser trimming the heat treated material to form the sensor.

Abstract: Disclosed herein is an impact absorber for an exhaust sensor. The impact absorber comprises a collar of deformable material disposed around a housing of the exhaust sensor. The collar extends radially outward from the housing. The collar may be formed from a material selected to degrade at exhaust temperature, or the collar may be formed from a material that provides radiation shielding to a portion of the sensor after installation. The collar may be disposed around a sealing gasket. A wall may be disposed around at least a portion of a perimeter of the collar, the wall being spaced apart from a plurality of facets formed on the housing to form a recess for receiving a socket wrench tool.

Abstract: Provided for herein is a temperature sensor and methods of making and using the same. In one embodiment, the temperature sensor comprises: a cover plate disposed at a first end of a substrate to form an interface portion; a sensing element disposed between the cover plate and the substrate to form an assembly; wherein the cover plate and substrate have relative dimensions so as to form a ledge at the first end; and wherein the cover plate is attached to the substrate at the ledge. In anther embodiment, the temperature sensor comprises: a cover plate disposed at a first end of a substrate to form an interface portion, a sensing element disposed between the cover plate and the substrate to form an assembly, and a seal disposed to inhibit fluid communication between the sensing element a gas to be temperature sensed, wherein fluid communication is retained between the sensing element and an external environment.

Abstract: An independently housed trim resistor including a trim resistor having a resistive element and a plurality of conductive pads, wherein the plurality of conductive pads are disposed so as to be communicated with the resistive element, a plurality of lead wires, wherein the plurality of lead wires are disposed so as to be communicated with and terminated at the plurality of conductive pads and a resistor housing, the resistor housing having a housing body and a housing top, wherein the housing body defines a resistor cavity for containing the trim resistor and wherein the housing top includes a trim opening disposed so as to allow communication with the resistive element and a method for fabricating an independently housed trim resistor including obtaining a first lead wire, a second lead wire and a trim resistor, wherein the trim resistor includes a resistive element and a plurality of conductive pads, obtaining a resistor housing having a housing top and a housing body, wherein the housing body defines a resi

Abstract: Provided for herein is a temperature sensor and methods of making and using the same. In one embodiment, the temperature sensor comprises: a cover plate disposed at a first end of a substrate to form an interface portion; a sensing element disposed between the cover plate and the substrate to form an assembly; wherein the cover plate and substrate have relative dimensions so as to form a ledge at the first end; and wherein the cover plate is attached to the substrate at the ledge.

Abstract: An exhaust gas sensor is provided and formed by attaching the sensor's upper shield and shell. The attachment is attained by bending a protruding segment or lip over a terminal end portion of the lower shield. This produces a single sealing surface and eliminates the requirement of a conventional crimp which places high compressive forces on the sensing element.

Abstract: A method for manufacturing a planar temperature sensor including disposing a thick amount of a material having a temperature coefficient of resistance of greater than about 800 parts per million and a natural resistance of above about 5 micro-ohm-centimeters on a substrate, measuring a resistance value of said material, and setting a laser trimming device to ablate material consistent with achieving an inputted resistance value.