Aging treatment for exhaust gas oxygen sensor

Claim 2

In a method of making a sensing element for a solid electrolyte electrochemical exhaust gas oxygen sensor that includes sputtering a porous platinum thin film electrode onto a zirconia body and applying a protective overcoat onto the electrode, the improvement wherein the zirconia body is subsequently heated to a temperature of about 700°-900° C. for at least about 0.5 hours in a substantially pure nitrogen atmosphere without concurrent electrical treatment as a final heat treatment before exposure to exhaust gases and said heat treatment is effective to reduce rich-to-lean switching response time.

Claim 3

In a method of making an exhaust gas electrode on a sensing element for a solid electrolyte electrochemical exhaust gas oxygen sensor that includes sputtering a porous platinum thin film electrode onto a zirconia body by means of an inert gas discharge, heating the body to a temperature of about 700°-900° C. after sputtering, and then spraying a porous spinel coating at a high temperature onto at least principally active portions of the electrode, the improvement wherein the zirconia body is subsequently heated to a temperature of about 700°-900° C. in a nitrogen atmosphere having not more than about 0.1% by volume oxygen for at least one period of about 0.5-1.5 hours without concurrent electrical treatment and the subsequent heating is effective to so significantly reduce rich-to-lean switching response time that it does not substantially decrease further upon initial operation of said element in said sensor.

Claim 4

In a method of making an exhaust gas electrode on a sensing element for a solid electrolyte electrochemical exhaust gas oxygen sensor that includes sputtering a porous platinum thin film electrode onto a zirconia body by means of an inert gas discharge, heating the body to a temperature of about 700°-900° C. after sputtering, and then spraying a porous spinel coating at a high temperature onto at least principally active portions of the electrode, the improvement wherein the zirconia body is subsequently heated to a temperature of about 700°-900° C. in a nitrogen atmosphere having not more than about 0.1% by volume oxygen for at least one period of about 0.5-1.5 hours without concurrent electrical treatment and the subsequent heating is effective to so significantly reduce rich-to-lean switching response time that it does not substantially decrease further upon initial operation of said element in said sensor.

Claim 5

In a method of making an exhaust gas electrode on a sensing element for a solid electrolyte electrochemical exhaust gas oxygen sensor that includes sputtering a porous platinum thin film electrode onto a zirconia body by means of an argon discharge at a DC power of about 13-22 watts/cm 2 of target area, heating the body in air to a temperature of about 700°-900° C. after sputtering, and then flame spraying a porous spinel coating onto at least principally active portions of the electrode, the improvement wherein after the flame spraying, the zirconia body is heated to a temperature of about 700°-900° C. in a nitrogen atmosphere having less than about 0.01% by volume oxygen for at least one period of about 0.5-1.5 hours without concurrent electrical treatment and the heating is effective to reduce rich-to-lean switching response time to below about 250 milliseconds without adversely affecting sensor controllability, and switching response time does not substantially decrease further upon initial operation of said element in said sensor.

Claim 6

In a method of making an exhaust gas electrode on a sensing element for a solid electrolyte electrochemical exhaust gas oxygen sensor that includes sputtering a porous platinum thin film electrode onto a zirconia body by means of an argon discharge at a DC power of about 13-22 watts/cm 2 of target area, heating the body in air to a temperature of about 700°-900° C. after sputtering, and then flame spraying a porous spinel coating onto at least principally active portions of the electrode, the improvement wherein after the flame spraying, the zirconia body is heated to a temperature of about 700°-900° C. in a nitrogen atmosphere having less than about 0.01% by volume oxygen for at least one period of about 0.5-1.5 hours without concurrent electrical treatment and the heating is effective to reduce rich-to-lean switching response time to below about 250 milliseconds without adversely affecting sensor controllability, and switching response time does not substantially decrease further upon initial operation of said element in said sensor.