Sensor with amorphous electrode

• US 6,886,403 B2
• Filed: 06/17/2003
• Issued: 05/03/2005
• Est. Priority Date: 06/17/2003
• Status: Expired due to Fees

• Current Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Anderson, Conrad H., LaBarge, William J., Ireland, Hugh W.
• Primary Examiner(s): Williams, Hezron
• Assistant Examiner(s): FRANK, RODNEY T
• Application Number:
  US10/464,713
• Publication Number:
  US 20040255669A1
• Time in Patent Office: 686 Days
• Field of Search: 733/14, 733/12, 733/05, 732/90.R, 733/17, 733/04.C
• US Class Current: 73/304.00C
• CPC Class Codes: G01F 23/363 using electromechanically actuated indicating means

Abstract

Disclosed herein are sensors, and method for making an using the same. In one embodiment, the sensor comprises: a first electrode disposed on a ceramic substrate, wherein the first electrode comprises an amorphous metal material comprising a first metal selected from the group consisting of a Group 9 metal, a Group 10 metal, a Group 11 metal, and combinations comprising at least one of the foregoing first metals, and zirconium or at least one of phosphorus and boron.

Claims

1. A fuel level sensor, comprising:

a resistive card having an arc shaped resistive path comprising a first set of spaced apart connector lines and an arc-shaped electrode overlying the first set of conductor lines; and

an arc-shaped conductive path comprising an arc-shaped continuous conductor base and a second set of spaced apart parallel conductor lines extending from the conductor base at an angle with respect to a radial line drawn from a center of the arc-shaped conductor base;

wherein the electrode comprises an amorphous metal material comprising a first metal selected from the group consisting of a Group 9 metal, a Group 10 metal, a Group 11 metal, and combinations comprising at least one of the foregoing first metals, and zirconium or at least one of phosphorus and boron.

2. The sensor of claim 1, wherein the amorphous metal material comprises zirconium and further comprising at least one of aluminum and titanium.

3. The sensor of claim 1, wherein the amorphous metal material coating is at least partially disposed over a ductile material.

4. The sensor of claim 3, wherein the ductile material is selected from the group consisting of cobalt, nickel, silver, aluminum, iron, and combinations comprising at least one of the foregoing ductile materials.

5. The sensor of claim 3, wherein the ductile material comprises less than or equal to about 0.1 wt % anions based upon the total weight of the ductile material.

6. The sensor of claim 1, wherein the first electrode comprises greater than or equal to about 50 wt % of the amorphous metal material based on the total weight of the first electrode.

7. The sensor of claim 1, wherein the first electrode comprises greater than or equal to about 75 wt % of the amorphous metal material based on the total weight of the first electrode.

8. The sensor of claim 1, wherein the first electrode comprises greater than or equal to about 85 wt % of the amorphous metal material based on the total weight of the first electrode.

9. The sensor of claim 1, wherein the first electrode comprises greater than or equal to about 95 wt % of the amorphous metal material based on the total weight of the first electrode.

10. The sensor of claim 1, wherein the amorphous metal material comprises about 10 at % to about 98 at % of the first material and less than or equal to about 45 at % of a second metal selected from the group consisting of aluminum, copper, silver, gold, and combinations comprising at least one of the foregoing second metals, and about 0.5 at % to about 30 at % of the at least one of phosphorus and boron.

11. The sensor of claim 1, wherein the amorphous metal material comprises about 20 at % to about 94 at % of the first material and less than or equal to about 45 at % of a second metal selected from the group consisting of aluminum, copper, silver, gold, and combinations comprising at least one of the foregoing second metals, and about 3 at % to about 30 at % of the at least one of phosphorus and boron.

12. The sensor of claim 1, wherein the amorphous metal material comprises about 45 at % to about 94 at % of the first material and less than or equal to about 45 at % of a second metal selected from the group consisting of aluminum, copper, silver, gold, and combinations comprising at least one of the foregoing second metals, and about 6 at % to about 30 at % of the at least one of phosphorus and boron.

13. The sensor of claim 1, wherein the first electrode further comprises layers having a layer thickness of less than or equal to about 100 micrometers, and has a total thickness of about 100 micrometers to about 500 micrometers.

14. The sensor of claim 1, wherein the electrode further comprises a bonding material selected from the group consisting of an epoxy, a metal, a catalyst, and combinations comprising at least one of the foregoing bonding materials.

15. The sensor of claim 14, wherein the bonding material is mixed with the amorphous material.

16. The sensor of claim 14, wherein the bonding material is disposed between the amorphous material and the ceramic substrate.

17. The sensor of claim 1, further comprising alternating layers of a ductile layer having a ductile layer thickness of less than or equal to about 8 micrometers and an amorphous metal material layer, and wherein the electrode has a thickness of less than or equal to about 75 micrometers.

18. The sensor of claim 17, wherein the ductile layer comprises a ductile metal selected from the group consisting of ductile nickel, ductile copper, ductile cobalt, ductile indium, ductile bismuth, ductile lead, ductile cadmium, ductile tin, and alloys and combinations comprising at least one of the foregoing ductile metals.

19. A method for detecting fuel level, comprising:

contacting a fuel level sensor with a fuel in a fuel storage vessel, wherein the fuel level sensor comprises;

a resistive card having an arc shaped resistive path comprising a first set of spaced apart connector lines and an arc-shaped electrode overlying the first set of conductor lines; and

an arc-shaped conductive path comprising an arc-shaped continuous conductor base and a second set of spaced apart parallel conductor lines extending from the conductor base at an angle with respect to the radial line drawn from a center of the arc-shaped conductor base;

wherein the electrode comprises an amorphous metal material comprising a first metal selected from the group consisting of a Group 9 metal, a Group 10 metal, a Group 11 metal, and combinations comprising at least one of the foregoing first metals, and zirconium or at least one of phosphorus and boron; and

determining the resistance between the connector lines and using the resistance to determine the level of the fuel.

20. A fuel level sensor, comprising:

a resistive card having a resistive path comprising a first set of spaced apart connector lines and an electrode overlying the first set of conductor lines; and

a conductive path comprising a continuous conductor base and a second set of spaced apart parallel conductor lines extending from the conductor base;

wherein the electrode comprises an amorphous metal material comprising a first metal selected from the group consisting of a Group 9 metal, a Group 10 metal, a Group 11 metal, and combinations comprising at least one of the foregoing first metals, and zirconium or at least one of phosphorus and boron.

21. A fuel level sensor, comprising:

a resistive card having an arc shaped resistive path comprising an arc-shaped electrode;

wherein the electrode comprises an amorphous metal material comprising a first metal selected from the group consisting of a Group 9 metal, a Group 10 metal, a Group 11 metal, and combinations comprising at least one of the foregoing first metals, and zirconium or at least one of phosphorus and boron.