IPC분류정보
국가/구분 |
United States(US) Patent
등록
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국제특허분류(IPC7판) |
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출원번호 |
UP-0218152
(2005-09-01)
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등록번호 |
US-7722749
(2010-06-14)
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발명자
/ 주소 |
- Wang, Da Yu
- Symons, Walter Thomas
- Farhat, Robert Jerome
- Yao, Sheng
- Kupe, Joachim
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출원인 / 주소 |
- Delphi Technologies, Inc.
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대리인 / 주소 |
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인용정보 |
피인용 횟수 :
2 인용 특허 :
2 |
초록
▼
A sensor including a species selective electrode and a reference electrode having an electrolyte layer disposed therebetween; a reference gas channel in fluid communication with the reference electrode; a heater and a temperature sensor; wherein the species selective electrode is disposed on a first
A sensor including a species selective electrode and a reference electrode having an electrolyte layer disposed therebetween; a reference gas channel in fluid communication with the reference electrode; a heater and a temperature sensor; wherein the species selective electrode is disposed on a first side of an insulating layer separating the species selective electrode from the electrolyte layer, the insulating layer having a first substantially solid area and a second area having an opening pattern extending through the insulating layer; the species selective electrode comprising a species sensing electrode portion disposed on the opening pattern of the insulating layer so as to contact the electrolyte layer through the opening pattern and a non-active electrode lead portion disposed over the first substantially solid area so that the non-active electrode lead portion is in electrical communication with the species sensing electrode portion and is free from contact with the electrolyte layer.
대표청구항
▼
The invention claimed is: 1. A sensor comprising: a species selective electrode and a reference electrode having an electrolyte layer disposed therebetween; a reference gas channel in fluid communication with the reference electrode; a heater disposed in thermal communication with the sensor; a tem
The invention claimed is: 1. A sensor comprising: a species selective electrode and a reference electrode having an electrolyte layer disposed therebetween; a reference gas channel in fluid communication with the reference electrode; a heater disposed in thermal communication with the sensor; a temperature sensor disposed in communication with the heater for maintaining the sensor at a desired operating temperature; wherein the species selective electrode is disposed on a first side of an insulating layer separating the species selective electrode from the electrolyte, the insulating layer having a first substantially solid area and a second area having an opening pattern extending through the insulating layer; the species selective electrode comprising a species sensing electrode portion comprising a first material disposed on the opening pattern of the insulating layer to extend inside at least one opening of the opening pattern so as to contact the electrolyte layer through the opening pattern and a non-active electrode lead portion comprising a second material that is different from the first material, the first material being deposited on top of the second material over the second area so that the non-active electrode lead portion is in electrical communication with the species sensing electrode portion, said non-active electrode lead portion disposed over the first substantially solid-area and the second area so as to substantially surround the periphery of at least one opening in the opening pattern while being sufficiently spaced from the periphery of each opening so as to be free from contact with the electrolyte layer; wherein both the species selective electrode and the reference electrode are in fluid communication with an exhaust atmosphere. 2. The sensor of claim 1, further comprising: an air-fuel ratio sensor. 3. The sensor of claim 1, wherein the species selective electrode is an ammonia selective electrode. 4. The sensor of claim 1, wherein the species sensing electrode portion comprises oxide powders, doped oxide powders, binary oxide materials, ternary oxide materials, vanadium oxides, V2O5, WO3, MoO3, BiVO4, BiTaO4, LiVO3, NaVO3, Na3VO4, KVO3, K3VO4, Cs3VO4, MgV2O6, Mg2V2O7, Mg2V6O17, Mg5V4O13, Mg3V2O8, CaV2O6, Ca3V2O8, SrV2O6, Sr2V2O7, Sr3V2O8, CuV2O6, Ni3V2O8, NiV2O6, CdV2O6, Cd2V2O7, Cd3V2O8, CrVO4, Co3V2O8,Pb3V2O7, CuV2O6, Cu5V2O10, AgV7O8, FeVO4, CeVO4, MnVO3, Mn2V2O7, Zn4V2O9, Zn3V2O8, Zn2V2O7, ZnV2O6, TiVO4, GdVO4, LuVO4, ErVO4, DyVO4, HoVO4, YVO4, TmVO4, YbVO4, TbVO4, SmVO4, NdVO4, AlVO4, TeVO4, SbVO4, or mixtures thereof. 5. The sensor of claim 4, wherein the species sensing electrode portion is doped with a material selected from the group consisting of Ce, Pb, Ag, Mn, Mo, W, Ca, Li, Na, K, Cs, Zr, Ge, Sb, Mg, Sr, Sc, Ti, Nb, Fe, Co, Ni, Cu, Rh, Pd, Ga, In, and Sn, and mixtures and combinations thereof. 6. The sensor of claim 1, wherein the species sensing electrode portion comprises an additive for creating or enhancing open porosity in the species selective sensing electrode. 7. The sensor of claim 1, wherein the species sensing electrode portion comprises an additive for creating or enhancing open porosity in the species selective sensing electrode portion selected from the group consisting of graphite, carbons, open porous glass powder, silica glass powder, regular glass powder, alkali barium borosiliate, and mixtures and combinations thereof. 8. The sensor of claim 1, wherein the non-active electrode lead portion comprises an alumina additive and optionally further comprises a material selected from the group consisting of platinum, palladium, osmium, rhodium, iridium, gold, ruthenium zirconium, yttrium, cerium, calcium, aluminum, zinc, lanthanum, strontium, cobalt, perovskite, silicon, oxides, mixtures, alloys, cermets, and mixtures and combinations comprising at least one of the foregoing. 9. The sensor of claim 1, wherein the opening pattern comprises a circular opening, a plurality of circular openings, a rectangular opening, a plurality of rectangular openings, a generally rectangular rounded end opening, a plurality of generally rectangular rounded end openings, or a combination thereof. 10. The sensor of claim 1, further comprising: a protective coating layer disposed over the species sensing electrode portion of the species selective electrode. 11. A method for forming a sensor comprising: disposing a species selective electrode and a reference electrode on opposite sides of an electrolyte layer; forming a reference gas channel in fluid communication with the reference electrode; disposing a heater in thermal communication with the sensor; disposing a temperature sensor in communication with the heater for maintaining the sensor at a desired operating temperature; disposing the species selective electrode on a first side of an insulating layer so as to separate the species selective electrode from the electrolyte layer, the insulating layer having a first substantially solid area and a second area having an opening pattern extending through the insulating layer; the species selective electrode comprising a species sensing electrode portion comprising a first material disposed on the opening pattern of the insulating layer to extend inside at least one opening of the opening pattern so as to contact the electrolyte layer through the opening pattern and a non-active electrode lead portion comprising a second material that is different from the first material; depositing the first material on top of the second material over the second area so that the non-active electrode lead portion is in electrical communication with the species sensing electrode portion, said non-active electrode lead portion disposed over the first substantially solid area and the second area so as to substantially surround the periphery of at least one opening in the opening pattern while being sufficiently spaced from the periphery of each opening so as to be free of contact with the electrolyte layer, to form a green sensor; and firing or co-firing the green sensor. 12. The method of claim 11, further comprising: disposing an air-fuel ratio sensor as part of the sensor. 13. The method of claim 11, wherein the species selective electrode is an ammonia selective electrode. 14. The method of claim 11, wherein the species sensing electrode portion comprises oxide powders, doped oxide powders, binary oxide materials, ternary oxide materials, vanadium oxides, V2O5, WO3, MoO3, BiVO4, BiTaO4, LiVO3, NaVO3, Na3VO4, KVO3, K3VO4, Cs3VO4, MgV2O6, Mg2V2O7, Mg2V6O17, Mg5V4O13, Mg3V2O8, CaV2O6, Ca3V2O8, Sr2V2O6, Sr2V2O7, Sr3V2O8, CuV2O6, Ni3V2O8, NiV2O6, CdV2O6, Cd2V2O7, Cd3V2O8, CrVO4, Co3V2O8, Pb3V2O7, CuV2O6, Cu5V2O10, AgV7O8, FeVO4, CeVO4, MnVO3, Mn2V2O7, Zn4V2O9, Zn3V2O8, Zn2V2O7, ZnV2O6, TiVO4, GdVO4, LuVO4, ErVO4, DyVO4, HoVO4, YVO4, TmVO4, YbVO4, TbVO4, SmVO4, NdVO4, AlVO4, TeVO4, SbVO4, or mixtures thereof. 15. The method of claim 14, wherein the species sensing electrode portion is doped with a material selected from the group consisting of Ce, Pb, Ag, Mn, Mo, W, Ca, Li, Na, K, Cs, Zr, Ge, Sb, Mg, Sr, Sc, Ti, Nb, Fe, Co, Ni, Cu, Rh, Pd, Ga, In, and Sn, and mixtures and combinations thereof. 16. The method of claim 11, wherein the species sensing electrode portion comprises an additive for creating or enhancing open porosity in the species selective sensing electrode. 17. The method of claim 11, wherein the species sensing electrode portion comprises an additive for creating or enhancing open porosity in the species selective sensing electrode selected from the group consisting of graphite, carbons, open porous glass powder, silica glass powder, regular glass powder, alkali barium borosiliate, and mixtures and combinations thereof. 18. The method of claim 11, wherein the non-active electrode lead portion comprises an alumina additive and optionally further comprises a material selected from the group consisting of platinum, palladium, osmium, rhodium, iridium, gold, ruthenium zirconium, yttrium, cerium, calcium, aluminum, zinc, lanthanum, strontium, cobalt, perovskite, silicon, oxides, mixtures, alloys, cermets, and mixtures and combinations comprising at least one of the foregoing. 19. The method of claim 11, wherein the opening pattern comprises a circular opening, a plurality of circular openings, a rectangular opening, a plurality of rectangular openings, a generally rectangular rounded end opening, a plurality of generally rectangular rounded end openings, or a combination thereof. 20. The method of claim 11, further comprising: disposing a protective coating layer over the species sensing electrode portion of the species selective electrode. 21. An exhaust gas treatment system comprising: a sensor comprising a species selective electrode and a reference electrode having an electrolyte layer disposed therebetween; a reference gas channel in fluid communication with the reference electrode; a heater disposed in thermal communication with the sensor; a temperature sensor disposed in communication with the heater for maintaining the sensor at a desired operating temperature; wherein the species selective electrode is disposed on a first side of an insulating layer separating the species selective electrode from the electrolyte layer, the insulating layer having a first substantially solid area and a second area having an opening pattern extending through the insulating layer; the species selective electrode comprising a species sensing electrode portion comprising a first material disposed on the opening pattern of the insulating layer to extend inside at least one opening of the opening pattern so as to contact the electrolyte layer through the opening pattern and a non-active electrode lead portion comprising a second material that is different from the first material, the first material being deposited on top of the second material over the second area, so that the non-active electrode lead portion is in electrical communication with the species sensing electrode portion, said non-active electrode material disposed over the first substantially solid area and the second area so as to substantially surround the periphery of at least one opening in the opening pattern while being sufficiently spaced from the periphery of each opening so as to be free from contact with the electrolyte layer; the species selective sensing element being disposed downstream of an exhaust catalyst for sensing a concentration of reductant in a catalyst treated exhaust gas; a controller in communication the species selective sensing element, an engine, and a reductant supply, for controlling the amount of reductant delivered to the exhaust gas exiting the catalyst. 22. The system of claim 21, wherein the species selective electrode is an ammonia selective electrode. 23. The system of claim 21, wherein the exhaust catalyst is a selective catalyst reactor or a urea based selective catalyst reactor. 24. The system of claim 21, wherein the reductant supply is a nitrogen-containing reductant, ammonia, or ammonia prepared from urea. 25. The system of claim 21, wherein the exhaust gas comprises a diesel engine exhaust gas. 26. The sensor of claim 1, wherein the non-active electrode lead portion is disposed over the first substantially solid-area and the second area so as to entirely surround the periphery of at least one opening in the opening pattern. 27. A sensor comprising: a species selective electrode and an electrolyte layer; wherein the species selective electrode is disposed on a first side of an insulating layer separating the species selective electrode from the electrolyte, the insulating layer having a first substantially solid area and a second area having an opening extending through the insulating layer; the species selective electrode comprising a species sensing electrode portion comprising a first material disposed on the insulating layer to extend inside the opening so as to contact the electrolyte layer through the opening, and a non-active electrode lead portion comprising a second material that is different from the first material, the first material being deposited on top of the second material over the second area so that the non-active electrode lead portion is in electrical communication with the species sensing electrode portion, said non-active electrode lead portion disposed over the first substantially solid area and the second area so as to substantially surround the periphery of the opening while being sufficiently spaced from the periphery of the opening so as to be free from contact with the electrolyte layer.
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