Thick Film Materials for Planar NOx (Nitrogen Oxide) Sensors

Ferro offers thick-film materials including platinum conductor pastes or inks and high temperature co-fireable ceramic tapes for use in planar NOx (Nitrogen Oxide) sensors.

Thick Film Materials for Planar NOx Sensors

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As emissions regulations for diesel-fueled vehicles continue to become more stringent, automotive engineers are faced with designing vehicles that release fewer pollutants into the atmosphere.


EFFECTIVE NOx SENSOR CONSTRUCTION

Multiple layers of HTCC green tapes are implemented, and printed layers are formed using the screen-print technique to produce buried, insulated platinum heaters. All layers are co-fired at temperatures up to ~1550°C, using a correct product mix and prolonged firing regimes to ensure complete burn-out of the thick sensor build and to minimize blistering and warp. 

Successful processing and firing of multilayer cofired structures used in NOx sensors requires knowledge of dimensional stability during layer build and printing, shrinkage during firing, and the necessary firing regime to ensure that flat, blister-free parts are produced.

The same manufacturing principles employed in the fabrication of oxygen sensors apply to the fabrication of NOx sensors, however, the product mix may be different and there may not be a need for a reference air channel as the measurement of NOx is not necessarily used to control Air Fuel Ratio (AFR).

Ferro has extensive experience in enabling the flat parts of planar NOx sensors to be constructed, even when using a combination of tapes and pastes.

We provide a range of materials that is suitable for the manufacture of the heater/electrode combination found in planar nitrogen oxide (NOx) sensors. The sensitive layer applied to the electrode is normally proprietary, however, Ferro offers paste-making services using customer-specified powders.


Thick Film Materials for HTCC NOx Sensor Systems
THICK FILM MATERIALS FOR NOx (NITROGEN OXIDE) SENSORS

Our materials for sensor fabrication include platinum and zirconia pastes or inks.  All Ferro materials for use in nitrogen oxide (NOx) sensor fabrication are manufactured to be lead-free, cadmium-free and phthalate-free. All of our HTCC inks and tapes used in planar NOx sensors are formulated to be RoHs and REACH compliant.

Ferro can also modify existing pastes and tapes to meet specific requirements or manufacture tapes and pastes from customer-supplied powders. 
Lot sizes range from a few hundred grams to the high volumes required by the automotive industry.

 

THICK FILM MATERIALS FOR FOR PLANAR  NOx (NITROGEN OXIDE) SENSORS
NOX (Nitrogen Oxide) Sensor Construction


HIGH-TEMPERATURE CO-FIRED CERAMIC (HTCC) TAPES AND INK MATERIALS FOR PLANAR NITROGEN OXIDE (NOx) SENSORS

 

COMPONENT  SENSOR 
COMPONENT 
FERRO PRODUCT  PRODUCT INFORMATION 
  Porous
Overcoat ink
4569 Porous Zirconia
Dielectric Paste 
Porous zirconia paste used as a protective coating on
sensor electrode 
  Diffusion
Control ink 
4999-Q8 Porous Dielectric Paste Used to control the rate of gas diffusion at the
electrode surface 
  Platinum ink  5570 Platinum
Conductive Paste
Conductive platinum paste used as a gas sensor
electrode 
  Insulation ink  4530-B Alumina Dielectric Paste Dielectric insulation ink used as the platinum heater
from the rest of the ceramic body 
  PtRh ink  5724 Platinum-Rhodium Conductive Paste Used as gas sensor electrode 
  Pt ink  5570 Platinum
Conductive Paste
Used as gas sensor electrode 
  Terminal ink  5571 Platinum
Conductive Paste
Platinum conductor used as a terminal pad for
external contact 
  Heater ink  5574-A Platinum
Conductive Paste 
Platinum “resistor” for heater track to heat the
sensor to its operating temperature 
  Via fill ink  5575 Platinum Conductive Via Fill
Platinum via fill conductor used to interconnect
platinum layers through the zirconia ceramic body 
  Fugitive tape
or ink 
4443 Fugitive Paste Fugitive paste used for making cavities in the fired
ceramic body 
  Zirconia tape  42022-CWM Zirconia Ceramic Tape Zirconica tape used as electrolyte as well as body of
the NOx sensor 
  Glue ink  4431 Dielectric Paste Glue ink used to facilitate lamination of the different
tape layers in the sensor


ELECTRONIC MATERIALS VALUE ADDED SERVICES

VALUE ADDED SERVICES

Ferro has over 20 years of history in designing and manufacturing thick film materials and products formulated specifically for high temperature co-fired ceramics (HTCC) applications. 
Successful processing and firing of multilayer co-fired structures utilized in NOx sensors requires knowledge of dimensional stability during layer build and printing, shrinkage during firing, and the necessary firing regime to ensure that flat, blister-free parts are produced.  Our customers can leverage our prototype-building equipment and expertise in these processing aspects.  

We also provide training at our own facilities or on-site at our customers’ locations, with comprehensive programs that cover most aspects of sensor manufacturing including materials, equipment, prototype building, testing and evaluation processes.