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: A gas treatment device, comprises a substrate disposed within a shell. The substrate comprises a catalyst composition comprising a support, a catalyst, and a sufficient amount of SMSI material such that, upon exposure to a gas stream (at a gas treatment device operating temperature), less than or equal to about 35 wt % of hydrocarbons in the gas stream are burned. A method for forming a gas treatment device, comprises applying a slurry to a substrate, wherein the slurry comprises a support and a sufficient amount of SMSI material such that, upon exposure to a gas stream at a gas treatment device operating temperature, greater than or equal to about 50 wt % of hydrocarbons in the gas stream are cracked to a light fraction; applying a catalyst to the substrate; calcining the catalyst; and disposing the calcined substrate into a shell, with a retention material disposed between the shell and the calcined substrate.

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: A gas treatment device, comprises a substrate disposed within a shell. The substrate comprises a catalyst composition comprising a support, a catalyst, and a sufficient amount of SMSI material such that, upon exposure to a gas stream (at a gas treatment device operating temperature), less than or equal to about 35 wt % of hydrocarbons in the gas stream are burned.

Abstract: Disclosed herein is a gas sensor and a method of making a gas sensor comprising disposing a reference electrode on an inner surface of an electrolyte; sputtering a sensing electrode on an outer surface of the electrolyte; sputtering a zirconia layer on a side of the sensing electrode opposite the electrolyte, wherein the zirconia layer has a thickness of about 20 nanometers to about 1 micrometer, and disposing a protective layer on a side of the zirconia layer opposite the sensing electrode.

Abstract: A gas sensor comprises a first electrode and a second electrode; and an electrolyte disposed between the first electrode and the second electrode. The electrolyte is shaped into a cylinder having an axial open end portion, an axial middle portion, and an axial closed end portion. The axial closed end portion has a uniform wall thickness equal to or less than about 1.5 millimeters. A radial transition in an interior region of the electrolyte between the middle and the closed end portions forms a shoulder. Processes for sensing exhaust gas generally includes disposing the gas sensor in an exhaust stream, contacting the closed end portion of the sensor with exhaust gas, and creating an electromotive force. The sensor activates quickly due to the close proximity to a rod heater and the low thermal mass resulting from the small inner diameter and thin wall section of the closed end portion.

Abstract: Disclosed herein is a gas sensor and a method of making a gas sensor comprising disposing a reference electrode on an inner surface of an electrolyte; sputtering a sensing electrode on an outer surface of the electrolyte; sputtering a zirconia layer on a side of the sensing electrode opposite the electrolyte, wherein the zirconia layer has a thickness of about 20 nanometers to about 1 micrometer, and disposing a protective layer on a side of the zirconia layer opposite the sensing electrode.

Abstract: A method for making a sensor is disclosed. The method comprises: disposing an electrolyte between a first side of sensing electrode and a first side of reference electrode, disposing a first side of a protective layer adjacent to said a second side of said sensing electrode, applying a mixture of a metal oxide, a fugitive material, and a solvent to a second side of the protective layer, and calcining the applied mixture to form said a protective coating on the second side of the protective layer.

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 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: 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: 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 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.

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 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 using a sensing electrode having a first and second side. Using a reference electrode having a first and second side and a second electrical lead in electrical communication with the reference electrode. Disposing an electrolyte between the first side of sensing electrode and the first side of reference electrode. Disposing a first side of a protective layer adjacent to the side of sensing electrode. Mixing a metal oxide, a fugitive material, and a solvent to form a mixture. Applying the mixture to a second side of the protective layer and calcining the sensor to form the protective coating on the protective layer second side.

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.

Abstract: A preferred catalytically active solid acid material, zeolite, forms the basis of a washcoat effective for treating diesel-fueled engine exhaust to reduce emission of particulate. In a preferred method, hydrocarbon in exhaust is cracked and oxidized in the presence of a zeolite/silica washcoat mixture catalyzed with precious metal. A preferred Y-type zeolite provides acidic (cationic) sites having releasable cations which are exchanged with precious metal to form catalyzed zeolite. A preferred method of making the catalyzed zeolite/silica washcoat is provided, whereby colloidal silica is disposed as a barrier over the catalyzed washcoat, limiting exposure of catalyst to sulfur constituents in the exhaust.

Abstract: A catalyst support is formed from powders of silica, titania and vanadia and optionally a silicate-based clay by applying a wet mixture of such powders to a support substrate and drying and calcining. When impregnated with platinum or palladium, the catalyst support reduces hydrocarbon and particulate emission in diesel exhaust and also prevents formation of mutagens in the exhaust. Advantageously, the catalyst support minimizes reaction with sulfur.

Abstract: A catalyst for treatment of exhaust emissions from diesel engines includes a washcoat layer with a catalytically active metal. The washcoat layer has refractory oxide particles with catalytically active metal particles dispersed thereon, and colloidal silica disposed in a thin layer over the refractory oxide and metal particles. The refractory oxide particles and colloidal silica are each characterized by respective surface charges at a selected pH to cause the colloid to form the layer over the refractory oxide and metal particles. Preferably, the pH is selected to provide opposite and attractive surface charges between the colloidal silica and the refractory oxide particles. Preferably, the metal particles are at least one of the group consisting essentially of platinum, palladium, rhodium, ruthenium, copper and chromium.