Abstract: The poison resistant sensor comprises a sensing electrode (4) having a first and second side; a reference electrode (7) having a first and second side; an electrolyte (1) disposed between and in intimate contact with the first side of the sensing electrode and the first side of the reference electrode; a first side of a protective layer (3) disposed adjacent to the second side of the sensing electrode; and a protective coating (17), comprising alpha alumina and gamma alumina, disposed in physical contact with the second side of the protective layer.

Abstract: An exhaust gas sensor includes a first electrode, a second electrode, and an electrolyte disposed between the first electrode and the second electrode. The electrolyte includes a first portion disposed at least in partial physical contact and in ionic communication with a second portion. The first portion has a first portion grain size which is different than a second portion grain size. Further, a method for manufacturing a gas sensor includes forming a multiple portion electrolyte. The electrolyte is formed with a first portion having one grain size, and a second portion at least in partial physical contact and in ionic contact with the first portion, the second portion having a second portion grain size different from the first portion grain size. The electrolyte may be fired before or after application of an electrode in ionic contact with the first portion and a second electrode in ionic contact with said second portion.

Abstract: An exhaust gas sensor includes a first electrode, a second electrode, and an electrolyte disposed between the first electrode and the second electrode. The electrolyte includes a first portion disposed at least in partial physical contact and in ionic communication with a second portion. The first portion has a first portion grain size which is different than a second portion grain size. Further, a method for manufacturing a gas sensor includes forming a multiple portion electrolyte. The electrolyte is formed with a first portion having one grain size, and a second portion at least in partial physical contact and in ionic contact with the first portion, the second portion having a second portion grain size different from the first portion grain size. The electrolyte may be fired before or after application of an electrode in ionic contact with the first portion and a second electrode in ionic contact with said second portion.

Abstract: A resistor seal composition useful in resistor spark plugs, comprises glass, at least one metal oxide, at least one filler material, and a branched or straight chained zirconium carboxylate. The glass comprises a strontium borate glass and/or a borosilicate glass. Metal oxides include aluminum oxide, zinc oxide, and zirconium oxide. Filler materials include silicon dioxide and mullite.

Abstract: This invention provides a very low cost effective method to alter the association of precious metal catalysts with specific support oxides in mixed oxide systems. The invention includes two discoveries: 1) that the isoelectric points for the three normally-used gasoline catalyst components are significantly different and the surface charges present have significant magnitude to promote attraction and repulsion of ions or charged radicals; and 2) ammine-chloride or ammine-nitrate salts both dissociate into positively charged precious metal radicals and are stable over a very wide pH range. The pH of the impregnation solution is controlled such that the surface charge of the oxide is opposite to the charge on the precious metal radical if the metal is to be supported on that oxide, and to control the pH such that all charges on the oxide to be avoided are the same as the precious metal radical.

Abstract: A ceramic catalytic converter is made by first creating an electrode by cutting space apart holes through an electrode block, threading an electrode wire through each hole in the block and performing wire cutting electrical discharge machining to form a cutting surface with a plurality of cell walls converging at rounded corners. The electrode is used to cut an extrusion die, a feedhole is provided in the die (preferably connected to a corner of the cell), and ceramic material is extruded through the extrusion die to form an extruded substrate having a plurality of open cells defined by adjacent walls converging in a rounded corner to form the ceramic catalytic converter. The rounded corner cell walls allows a more uniform deposit of washcoat and precious metals and reduces the amount of precious metals necessary in the ceramic catalytic converter.

Abstract: The invention includes a ceramic catalytic converter substrate having cell walls with rounded corners. The cell walls have a honeycomb or hexagonal shape with rounded corners. The cell walls may be manufactured with very thin walls from 0.003-0.005 inches. There is provided increased structural strength of the substrate due to rounded corners of cell walls into honeycomb or hexagonal shaped walls. The rounded corners of the cell walls also substantially increases the strength of the substrate. The honeycomb shape of the substrate uniformly dissipates any force applied to the substrate. The rounded corner cell walls allows a more uniform deposit of washcoat and precious metals and reduces the amount of precious metals necessary which coat the substrate along with reducing additional backpressure of the exhaust system caused by the washcoat which normally forms fillets in corners of squared-celled substrates.