Abstract: Disclosed herein is a ceramic part, gas sensor, and method for making the gas sensor. The ceramic part comprises: an insulating layer affixed to a substrate wherein the insulating layer comprising Al2O3 particles; and a glass comprising about 45 to about 69 mole percent SiO2, 0 to about 9 mole percent B2O3, 0 to about 26 mole percent Al2O3, 0 and 25 mole percent SrO, and about 10 to about 26 mole percent RE2O3, where RE2O3 is selected from the group consisting of Y2O3, three valent rare earth oxides, and combinations comprising at least one of the foregoing. In one embodiment of a ceramic part, a gas sensor comprises: an electrolyte layer having disposed on opposite sides thereof a first electrode and a second electrode; and an insulating layer that is in intimate contact with the second electrode, wherein the insulating layer comprises alumina and frit.

Abstract: A sensor may comprise a first electrode and a second electrode in mutual ionic communication with an electrolyte, a first socket disposed near a rear portion of a sensor element, a first lead disposed in electrical communication with the first electrode and in physical contact with the first socket and configured for electrical communication with a first terminal element, a second socket disposed near the rear portion of the sensor element, and a second lead disposed in electrical communication with the second electrode and in physical contact with the second socket and configured for electrical communication with a second terminal element. The first socket is disposed through at least one of an edge and an end of the sensor element, and the second socket is disposed through at least one of the edge and the end of the sensor element.

Abstract: A method for manufacturing a planar sensor, comprises disposing a film of a material on a substrate, wherein the material is selected from the group consisting of platinum, rhodium, palladium and mixtures and alloys comprising at least one of the foregoing materials; annealing the material; measuring a resistance value of the material; laser trimming the annealed material; heat treating the laser trimmed material; and laser trimming the heat treated material to form the sensor.

Abstract: One embodiment of a method of fabricating a sensor element for an exhaust gas sensing device, comprises disposing an electrolyte in ionic communication with a sensing electrode and a reference electrode to form the sensor element. The sensing electrode comprises an activator comprising silica and an oxide of an element. The element is selected from the group consisting of alkaline earth elements, rare earth elements, and combinations comprising at least one of the foregoing elements.

Abstract: One embodiment of an ammonia gas sensor includes: a reference electrode, an ammonia selective sensing electrode and an electrolyte disposed therebetween. The sensing electrode comprises the reaction product of a main material selected from the group consisting of vanadium, tungsten, molybdenum, vanadium oxides, tungsten oxides, molybdenum oxides, and combinations comprising at least one of the foregoing main materials, and an electrically conducting material selected from the group consisting of electrically conductive metals, electrically conductive metal oxides, and combinations comprising at least one of the foregoing.

Abstract: A sensor comprises: a pump cell comprising an inner pump electrode, an outer pump electrode, a pump cell electrolyte layer interposed between the inner pump electrode and the outer pump electrode and a cell isolation layer disposed on the inner pump electrode on a side opposite the pump cell electrolyte, wherein the outer electrode is in fluid communication with a reducing gas. A reference cell is in operable communication with the pump cell, the reference cell comprising an outer reference electrode and an inner reference electrode, and a reference cell electrolyte interposed between the outer reference electrode and the inner reference electrode.

Abstract: A hydrogen sensor and process for measuring hydrogen gas concentrations includes a pump cell and a measuring cell. The pump cell includes a first conducting electrolyte layer having a top and a bottom surface, and an electrode disposed on the top and bottom surfaces, wherein the top electrode is in communication with an unknown concentration of hydrogen gas. The measuring cell includes a second conducting electrolyte layer having a top and a bottom surface, and an electrode disposed on the top and bottom surfaces, wherein the bottom electrode is in communication with a reference gas source. A diffusion-limiting barrier is disposed between the pump cell bottom electrode and the measuring cell top electrode, wherein hydrogen diffusion through the diffusion-limiting barrier is controlled by a Knudsen diffusion mechanism at hydrogen concentrations greater than about 40%.

Abstract: Disclosed herein is a ceramic part, gas sensor, and method for making the gas sensor. The ceramic part comprises: an insulating layer affixed to a substrate wherein the insulating layer comprising Al2O3 particles; and a glass comprising about 45 to about 69 mole percent SiO2, 0 to about 9 mole percent B2O3, 0 to about 26 mole percent Al2O3, 0 and 25 mole percent SrO, and about 10 to about 26 mole percent RE2O3, where RE2O3 is selected from the group consisting of Y2O3, three valent rare earth oxides, and combinations comprising at least one of the foregoing.

Abstract: In a planar oxygen sensor having a pump cell, a reference cell, a sensor chamber and a heating device, a ground plane electrode is provided and includes a sensing portion having a first sense lead and a second sense lead and a measuring portion having a first measuring lead and a second measuring lead, wherein the first measuring lead and the second measuring lead have increased surface area relative to said sensing portion such that the resistance between the first measuring lead and the second measuring lead is reduced and wherein the first measuring lead is disposed so as to be communicated with the first sense lead and the second measuring lead is disposed so as to be communicated with the second sense lead.

Abstract: A gas sensor is disclosed comprising an oxygen pump cell having at least one exterior pump electrode and at least one interior pump electrode disposed on opposite sides of a first solid electrolyte layer. An emf cell having a first and second emf electrodes and first and second reference gas electrodes are disposed on opposite sides of a second solid electrolyte layer. At least one insulating layer is in contact with the first and second emf electrodes. At least one via hole is disposed through the first solid electrolyte layer. At least one air channel is disposed through at least one insulating layer. An air vent is disposed in at least one insulating layer in contact with the first and second reference gas electrodes. A heater is disposed in thermal communication with the sensor. And at least five electrical leads are in electrical communication with said sensor. A method of using a gas sensor is also disclosed.

Abstract: A gas sensor, comprising an oxygen pump cell with a first pump electrode and a second pump electrode disposed on opposite sides of a first solid electrolyte layer and a second pump electrode. The sensor also comprises an emf cell with an emf electrode and a reference gas electrode disposed on opposite sides of a second solid electrolyte layer. The emf electrode is disposed in fluid communication to the second pump electrode. A via hole is disposed through the first solid electrolyte layer, such that the first pump electrode is in fluid communication with the second pump electrode. A protective insulating layer, having a passage for gas to be sensed, is disposed in contact with the first pump electrode. A first insulating layer, having a conduit, is disposed in contact with the emf electrode. A second insulating layer, having an air channel, is disposed in contact with the reference gas electrode. A heater is disposed in thermal communication with the emf cell.

Abstract: Disclosed herein is a planar exhaust gas sensor for sensing the partial pressure of a gas in an exhaust. The sensing element has a modified, non-rectangular overall geometry. A terminal end of the element, onto which external sensor circuits can be attached, has a larger width than a sensor end of the element, in which is located the sensing cell. The reduced size of the sensor end of the element relative allows for more rapid attainment of operating temperature and lower energy consumption.

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 hydrogen sensor and process for measuring hydrogen gas concentrations includes a pump cell and a measuring cell. The pump cell includes a first conducting electrolyte layer having a top and a bottom surface, and an electrode disposed on the top and bottom surfaces, wherein the top electrode is in communication with an unknown concentration of hydrogen gas. The measuring cell includes a second conducting electrolyte layer having a top and a bottom surface, and an electrode disposed on the top and bottom surfaces, wherein the bottom electrode is in communication with a reference gas source. A diffusion-limiting barrier is disposed between the pump cell bottom electrode and the measuring cell top electrode, wherein hydrogen diffusion through the diffusion-limiting barrier is controlled by a Knudsen diffusion mechanism at hydrogen concentrations greater than about 40%.

Abstract: A heater for a gas sensor has a first thermistor element and a second thermistor element arranged in an electrically parallel configuration. Each thermistor element may be deposited onto a substrate such that the first thermistor element extends about a perimeter of the substrate and the second thermistor element extends across a portion of the substrate intermediate the perimeter of the substrate. The thermistor elements are preferably fabricated of materials having differing thermal coefficients of resistivity. A method of heating the gas sensor includes disposing the two thermistor elements in an electrically parallel configuration over a surface of the substrate and passing an electric current through the elements.

Abstract: One embodiment of a method of fabricating a sensor element for an exhaust gas sensing device, comprises disposing an electrolyte in ionic communication with a sensing electrode and a reference electrode to form the sensor element. The sensing electrode comprises an activator comprising silica and an oxide of an element. The element is selected from the group consisting of alkaline earth elements, rare earth elements, and combinations comprising at least one of the foregoing elements.

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 heater pattern for a heater of a gas sensor in which a temperature profile is manipulated utilizes a thermistor element arranged in an electrically serial configuration and disposed on a substrate. The thermistor element is arranged so as to define an edge pattern extending about a perimeter of the substrate and a center pattern serially connected to the edge pattern. The center pattern extends over a portion of the substrate that is intermediate the perimeter of the substrate. In a preferred embodiment, the thermistor element is screen printed onto the substrate to a thickness of about 5 microns to about 50 microns, and preferably to a thickness of about 10 microns to about 40 microns. The edge and center patterns are furthermore preferably formed of materials having differing coefficients of thermal resistivity, e.g., platinum and platinum/palladium blends.

Abstract: A gas sensor, comprising an oxygen pump cell with a first pump electrode and a second pump electrode disposed on opposite sides of a first solid electrolyte layer and a second pump electrode. The sensor also comprises an emf cell with an emf electrode and a reference gas electrode disposed on opposite sides of a second solid electrolyte layer. The emf electrode is disposed in fluid communication to the second pump electrode. A via hole is disposed through the first solid electrolyte layer, such that the first pump electrode is in fluid communication with the second pump electrode. A protective insulating layer, having a passage for gas to be sensed, is disposed in contact with the first pump electrode. A first insulating layer, having a conduit, is disposed in contact with the emf electrode. A second insulating layer, having an air channel, is disposed in contact with the reference gas electrode. A heater is disposed in thermal communication with the emf cell.

Abstract: A gas sensor is disclosed comprising an oxygen pump cell having at least one exterior pump electrode and at least one interior pump electrode disposed on opposite sides of a first solid electrolyte layer. An emf cell having a first and second emf electrodes and first and second reference gas electrodes are disposed on opposite sides of a second solid electrolyte layer. At least one insulating layer is in contact with the first and second emf electrodes. At least one via hole is disposed through the first solid electrolyte layer. At least one air channel is disposed through at least one insulating layer. An air vent is disposed in at least one insulating layer in contact with the first and second reference gas electrodes. A heater is disposed in thermal communication with the sensor. And at least five electrical leads are in electrical communication with said sensor. A method of using a gas sensor is also disclosed.