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 with a sensing electrode, a reference electrode; and an electrolyte disposed between and in ionic communication with the sensing electrode and the reference electrode. A protective layer is disposed adjacent to the sensing electrode. A plurality of vias is disposed in the protective layer adjacent to the electrolyte and in fluid communication with the sensing electrode and a gas to be sensed. The vias have a diameter of about 50 micrometers to about 250 micrometers.

Abstract: A planar temperature sensing element is provided with first and second layers disposed over the temperature-sensing device. The second layer comprises an inorganic binder, a first ceramic material, and a second ceramic material. The inorganic binder is selected from the group consisting of M3+ phosphates, M4+ phosphates, M3+ nitrates, M4+ nitrates, and combinations comprising at least one of the foregoing. The first ceramic material is selected from the group consisting of aluminosilicate, M3+ aluminates, M4+ aluminates, M3+ hexaluminates, M4+ hexaluminates, and combinations comprising at least one of the foregoing. The second ceramic material comprises a phosphate-containing material.

Abstract: 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.

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 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.