Exhaust sensor including a composite tile sensing element and methods of making the same

摘要

An exhaust sensor having a substrate including first and second portions, the first portion comprising a dielectric material, the second portion comprising an electrolyte material and a transition zone interposed between the first and second portions. The transition zone includes an increasing concentration of the dielectric material in the direction of the first portion of the substrate and an increasing concentration of the electrolyte material in a direction towards the second portion of the substrate. The invention also includes a method of making such an exhaust sensor substrate including the steps of co-depositing first and second amenable compositions, the first composition comprising a dielectric material and the second composition comprising an electrolyte material. The co-deposited compositions are fired together to form the substrate having first, second and transition portions as described above. The two compositions may be co-deposited as a slurry and spread over a substrate using a partition doctor blade to form a very thin tape of a dielectric material and an electrolyte material. The two compositions may be co-deposited by feeding the compositions side by side through a compaction press to form a single tape having a first dielectric portion and a second electrolyte portion.