Sensor for detecting electrically conductive and/or polarizable particles and method for adjusting such a sensor

A method of making a sensor for detecting soot particles in a combustion exhaust stream, the soot particles being electrically conductive or polarizable, the sensor comprising

• a substrate;
• a first electrode layer and a second electrode layer, the second electrode layer arranged between the substrate and the first electrode layer;
• an insulation layer disposed between the first electrode layer and the second electrode layer, and
• a first opening disposed in the first electrode layer and a second opening disposed in the insulation layer,
• wherein the first opening and the second opening are aligned to form a first passage to the second electrode layer;
• wherein the insulation layer laterally encloses the second electrode layer;
• the method comprising the steps of:
• laminating the first electrode layer, the second electrode layer, and the insulation layer to form a laminate, the insulation layer being disposed between the first electrode layer and the second electrode layer,
• subsequently forming a passage through the first electrode layer and the insulation layer, and
• ending the passage to have a bottom formed by a portion of the second electrode layer, the passage for receiving the soot particles;
• wherein the soot particles are detected by electrical conductivity between the first electrode layer and the second electrode layer;
• wherein the insulation layer comprises a heat resistance of at least 850° C. in the combustion exhaust stream.

A method of making a sensor for detecting soot particles in a combustion exhaust stream, the soot particles being electrically conductive or polarizable, the sensor comprising

• a substrate;
• a first electrode layer and a second electrode layer, the second electrode layer arranged between the substrate and the first electrode layer;
• an insulation layer disposed between the first electrode layer and the second electrode layer, and
• a first opening disposed in the first electrode layer and a second opening disposed in the insulation layer,
• wherein the first opening and the second opening are aligned to form a first passage to the second electrode layer, the first passage for receiving the soot particles;
• wherein the soot particles are detected by electrical conductivity between the first electrode layer and the second electrode layer;
• wherein the insulation layer laterally encloses the second electrode layer;
• the method comprising the steps of:
• laminating the first electrode layer, the second electrode layer, and the insulation layer to form a laminate, the insulation layer being disposed between the first electrode layer and the second electrode layer,
• wherein the insulation layer and the first electrode layer are structured by a lift-off process, an ink-jet process, a stamping process one over the other forming a passage to the second electrode layer;
• wherein the insulation layer comprises a heat resistance of at least 850° C. in the combustion exhaust stream.

A sensor for detecting soot particles in a combustion exhaust stream, the soot particles being electrically conductive or polarizable, the sensor comprising:

• a substrate;
• a first electrode layer and a second electrode layer, the second electrode layer arranged between the substrate and the first electrode layer;
• an insulation layer disposed between the first electrode layer on a side opposite to the insulation layer;
• and
• a first opening disposed in the first electrode layer and a second opening disposed in the insulation layer;
• wherein the first opening and the second opening are aligned to form a first passage to the second electrode layer, the first passage for receiving the soot particles from the combustion exhaust stream;
• wherein the soot particles are detected by electrical conductivity between the first electrode layer and the second electrode layer;
• wherein the insulation layer laterally encloses a side portion of the second electrode layer;
• and
• wherein the insulation layer comprises a heat resistance of at least 850° C. in the combustion exhaust stream.