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: 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.

Abstract: Disclosed herein is a sensing element comprising: a sensing electrode; a reference electrode; an electrolyte disposed between and in ionic communication with the sensing electrode and the reference electrode; a heater circuit disposed on a support layer adjacent to the reference electrode; and a vent disposed adjacent to and in fluid communication with the heater circuit, and in fluid communication with a gas.

Abstract: A gas sensing element and method of making are provided. The gas sensing element can comprise calcined inorganic oxides that sequester contaminants in an exhaust stream. The calcined inorganic oxides provide sensors with improved performance, thereby eliminating post-sinter chemical and/or electrical conditioning.

Abstract: A gas sensor system includes an ammonia-sensing cell for generating a signal upon exposure to an unknown gas comprising ammonia, an A/F cell for generating a signal upon exposure to hydrocarbons in the gas, a heater in thermal communication with the cells and a housing in which the cells and the heater are mounted. The housing permits an unknown gas to flow therethrough for contact with the cells, and there is a sensor control circuit in communication with the cells. The sensor control circuit is configured to utilize the signals from the cells to generate an ammonia concentration signal indicating the concentration of ammonia in the unknown gas. Ammonia may be sensed in an unknown gas by heating such cells to selected working temperatures, exposing them to an unknown gas, obtaining signals from the cells, and using the cell signals to determine the ammonia content.

Abstract: One method of forming a sensor comprises: disposing a reference electrode and sensing electrode on opposite sides of an electrolyte and a heater on a side of the reference electrode opposite the electrolyte to form a sensor element having a sensing end adjacent the reference electrode and sensing electrode, 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: A method of making a sensor element comprises: combining coarse aluminium oxide with fine aluminium oxide and a binder to form a mixture, milling the mixture to form a base slurry, mixing a supported catalyst with the base slurry and a fugitive material to form a final slurry, applying the slurry to a sensor element precursor over at porous protective layer at least in an area opposite a sensing electrode, and calcining the sensor element precursor to form a calcined sensor element with a catalyzed coating over at least a portion of the porous protective layer. The coarse aluminium oxide has a coarse agglomerate size and the fine aluminium oxide has a fine particle size less than the coarse agglomerate size.

Abstract: A method of treating a gas sensor comprising: disposing the gas sensor in a basic agent solution comprising a basic agent selected from the group consisting of Group IA of the Periodic Table of Elements, Group IIA of the Periodic Table of Elements, and combinations comprising at least one of the foregoing metals, wherein the gas sensor comprises an electrolyte disposed between and in ionic communication with a first electrode and a second electrode; disposing the gas sensor in an acidic agent solution; wetting at least a portion of a porous protective layer of the gas sensor with an alkaline-carbonate solution; and heating the gas sensor.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: One embodiment of a method for producing a gas sensor, comprises: disposing said gas sensor in a basic agent solution comprising a basic agent comprises a hydroxide of a metal selected from the group consisting of Group IA of the Periodic Table of Elements; Group IIA of the Periodic Table of Elements, and combinations comprising at least one of the foregoing basic agents, wherein said gas sensor comprises an electrolyte disposed between and in ionic communication with a first electrode and a second electrode; and disposing said gas sensor in an acidic agent solution.

Abstract: Disclosed herein is a gas sensor having a small amount of lead oxide incorporated into an inner electrode and an outer electrode, and a method for depositing the lead oxide. The lead oxide is applied in an amount sufficient to effectuate consistent performance during sensor break-in. Lead oxide is transferred to the electrodes of the sensor element during the fabrication process by exposing the sensor element to glass having a known lead content during a heating step. Lead oxide from the glass is vaporized and deposited on the electrodes in the form of lead oxide. The deposited lead oxide is incorporated into the electrodes of the sensor element. The lead oxide reduces performance irregularities thereby improving performance during the initial use of the gas sensor.

Abstract: A method of treating a gas sensor comprising: disposing the gas sensor in a basic agent solution comprising a basic agent selected from the group consisting of Group IA of the Periodic Table of Elements, Group IIA of the Periodic Table of Elements, and combinations comprising at least one of the foregoing metals, wherein the gas sensor comprises an electrolyte disposed between and in ionic communication with a first electrode and a second electrode; disposing the gas sensor in an acidic agent solution; wetting at least a portion of a porous protective layer of the gas sensor with an alkaline-carbonate solution; and heating the gas sensor.

Abstract: 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.

Abstract: A method and system for controlling the temperature of an oxygen sensor is provided wherein the method includes obtaining an oxygen sensor, a heating device, heating control device and a signal generator, wherein the oxygen sensor includes a reference cell and wherein the heating device is communicated with the oxygen sensor and the heating control device, introducing a fixed frequency sinusoidal signal to the reference cell through a voltage divider resistor so as to create a response signal, wherein the response signal is responsive to the temperature of the reference cell, buffering the response signal so as to create a buffered signal, applying the buffered signal to a high pass filter so as to create a filtered signal having a filtered signal magnitude, wherein the filtered signal magnitude is inversely proportional to the temperature of the reference cell, measuring the filtered signal so as to create a temperature signal responsive to the filtered signal magnitude and communicating the temperature sign

Abstract: One embodiment of a method for producing a gas sensor, comprises: disposing said gas sensor in a basic agent solution comprising a basic agent comprises a hydroxide of a metal selected from the group consisting of Group IA of the Periodic Table of Elements; Group IIA of the Periodic Table of Elements, and combinations comprising at least one of the foregoing basic agents, wherein said gas sensor comprises an electrolyte disposed between and in ionic communication with a first electrode and a second electrode; and disposing said gas sensor in an acidic agent solution.

Abstract: 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.

Abstract: A method for making a sensor is disclosed, comprising mixing a metal oxide with a polymer to create a composition. The composition is applied to at least a portion of the sensing element comprising two electrodes with an electrolyte disposed therebetween, and calcined to form a protective coating. A gas sensor created in accordance with the above-referenced method is also disclosed.

Abstract: A sensor comprising an electrochemical cell (sensing electrode, reference electrode, and electrolyte disposed therebetween) has a protective silica coating at least on a side of the sensing electrode opposite the electrolyte. This protective silica coating can be an aerogel which is optionally also disposed on a side of the reference electrode opposite the electrolyte.