Detection of refrigerant contaminants

• US 10,416,113 B2
• Filed: 08/20/2015
• Issued: 09/17/2019
• Est. Priority Date: 08/20/2014
• Status: Active Grant

• Current Assignee: Carrier Corporation (Carrier Global Corporation)
• Original Assignee: Carrier Corporation (Carrier Global Corporation)
• Inventors: Chen, Lei, Yang, Zhiwei, Vincitore, Antonio M., Perry, Michael L., Clough, Warren
• Primary Examiner(s): Ball, J. Christopher
• Application Number:
  US15/505,015
• Publication Number:
  US 20170269027A1
• Time in Patent Office: 1,489 Days
• CPC Class Codes: G01N 27/4045 for gases other than oxygen
• CPC Class Codes: G01N 27/4074 for detection of gases other than oxygen
• CPC Class Codes: G01N 27/4075 Composition or fabrication of the electrodes and coatings thereon, e.g. catalysts
• CPC Class Codes: G01N 27/4163 checking the operation of, or calibrating, the measuring apparatus G01N27/3274, G01N27/4175 and G01N33/0006 take precedence
• CPC Class Codes: G01N 33/0036 Specially adapted to detect a particular component all the other sub-groups of G01N33/0004 take precedence

Abstract

A gas sensor for detecting one or more contaminants in a refrigerant includes a housing having disposed therein a membrane electrode assembly comprising a sensing electrode, a counter electrode, and a solid polymer electrolyte disposed between the sensing electrode and the counter electrode. The sensing electrode comprises nanoparticles of a first catalyst comprising noble metal. The counter electrode comprises nanoparticles of a second catalyst comprising noble metal. The sensing electrode in the sensor has been preconditioned by exposure under a positive voltage bias to a preconditioning gas comprising the contaminant(s) or their precursors or derivatives.

Claims

1. A method of preconditioning for the detection of contaminants in a refrigerant sensor comprising a housing, a membrane electrode assembly disposed in the housing, the membrane electrode assembly comprising a first catalyst comprising noble metal nanoparticles that are unsupported or are supported on a non-carbon black support, a counter electrode comprising a second catalyst comprising noble metal nanoparticles, and a solid polymer electrolyte disposed between the sensing electrode and the counter electrode, a first current collector in electrical contact with the sensing electrode, a second current collector in electrical contact with the counter electrode, a first flow field in fluid communication with a first opening in the housing to direct test refrigerant to flow by or through the sensing electrode, the housing including a chamber to which the counter electrode is exposed, and an electrical circuit connecting the sensing electrode and the counter electrode, the method comprising applying a positive voltage bias to the sensing electrode and exposing the sensor to a preconditioning gas comprising the contaminant(s) or their precursors or derivatives.

2. The method of claim 1, wherein the counter electrode chamber is sealed from ambient air by a seal.

3. The method of claim 1, wherein the counter electrode chamber includes an opening in fluid communication with ambient air.

4. The method of claim 1, wherein the sensor includes a second flow field in fluid communication with the counter electrode chamber to direct air to flow by or through the counter electrode.

5. The method of claim 1, wherein either or both of the sensing electrode and the counter electrode further comprise an ionomer.

6. The method of claim 1, wherein the refrigerant is a fluorinated hydrocarbon.

7. The method of claim 6, wherein the refrigerant is R134a.

8. The method of claim 1, wherein the contaminant(s) comprise a chlorine-substituted hydrocarbon.

9. The method of claim 1, wherein the contaminant(s) comprise R40, R12, R22, R142b, R143a, R125 or R152a.

10. The method of claim 1, wherein the preconditioning gas comprises the contaminant(s) and the refrigerant.

11. The method of claim 1, wherein the preconditioning gas comprises the contaminant(s) and air.

12. The method of claim 1, wherein the preconditioning gas comprises from 0.5 vol. % to 50 vol. % of the contaminant(s) based on the total volume of preconditioning gas.

13. The method of claim 1, further comprising preconditioning the sensor by exposure to controlled humidity.

14. The method of claim 1, wherein humidity is controlled by a humidity control agent disposed in or adjacent to the counter electrode.

15. The method of claim 1, wherein the noble metal catalysts comprise platinum or an alloy of platinum with one or more of ruthenium, nickel, iron, cobalt, iridium or palladium, wherein the Pt content in atomic ratio ranges from 20% to 100%.

16. A method of testing a refrigerant for contaminant(s) using the sensor of claim 1, comprising applying a positive bias voltage to the sensing electrode relative to the counter electrode or a reference electrode, and introducing the refrigerant being tested to the first flow field, and measuring a test response voltage or current in the electrical circuit connecting the sensing electrode and the counter electrode, and further comprising, prior to introducing the test refrigerant to the first flow field, applying a positive bias voltage to the sensing electrode relative to the counter electrode or a reference electrode, introducing humidity controlled air into the sensing electrode and the counter electrode, measuring a response voltage or current in the electrical circuit connecting the sensing electrode and the counter electrode, and continuing the positive voltage bias and introduction of humidity controlled air until the a stable voltage or current response is achieved.

17. A method of testing a refrigerant for contaminant(s) using the sensor of claim 1, comprising applying a positive bias voltage to the sensing electrode relative to the counter electrode or a reference electrode, and introducing the refrigerant being tested to the first flow field, and measuring a test response voltage or current in the electrical circuit connecting the sensing electrode and the counter electrode, and, further comprising, prior to introducing the test refrigerant to the first flow field, introducing a reference refrigerant with a purity of at least 99.5 vol % to the first flow field while applying a positive bias voltage to the sensing electrode relative to the counter electrode or a reference electrode, measuring a baseline response voltage or current until a stable baseline response is achieved, and comparing the test response voltage or current to the baseline response voltage or current.

18. The method of claim 17, wherein the introduction of reference refrigerant under a positive voltage bias is continued for 1 to 60 minutes.