Abstract: A shield assembly for protecting a sensing element of a gas sensor, the shield assembly includes an outer shield comprising an elongated outer wall and an inner shield comprising an inner elongated wall. The elongated outer wall includes a first end, a second end, and a tip portion disposed across the second end of the outer wall. The tip portion includes at least one elongated aperture extending therethrough and the elongated outer wall is configured to not have any openings between the first end and the second end. The inner elongated wall is disposed within the elongated outer wall. The inner elongated wall includes a first open end, a second open end, and a flange portion extending from a periphery of the first open end of the inner elongated wall.

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: 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: The sensor comprises an electrolyte disposed between a sensing electrode and a reference electrode, with a protective layer contacting the sensing electrode. At least one of the sensing electrode and the reference electrode has a porosity of about 15% or greater. The method for manufacturing the sensor comprises employing a slip. The slip is applied to the electrolyte to form the electrodes, and the electrolyte is heated to a temperature of less than about 1,500° C.

Abstract: 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.