Abstract: 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.

Abstract: 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° 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.

Abstract: 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.

Abstract: 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.

Abstract: The sensor comprises an electrode ink composition comprising a noble metal, and organo-metallic materials or combinations thereof. A solid electrolyte is disposed between a sensing electrode, exposed to a sensing gas such as an exhaust gas and a reference electrode, exposed to a reference gas.

Abstract: 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.

Abstract: 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° C.

Abstract: 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.