Electrochemical sensors having nonporous working electrode

• US 20030075442A1
• Filed: 10/22/2001
• Published: 04/24/2003
• Est. Priority Date: 10/22/2001
• Status: Active Grant

• Current Assignee: PerkinElmer LAS, Inc. (Perkinelmer Incorporated)
• Original Assignee: PerkinElmer LAS, Inc. (Perkinelmer Incorporated)
• Inventors: Dalmia, Avinash, Prohaska, Otto J.
• Granted Patent: US 6,908,537 B2
• Time in Patent Office: Days
• US Class Current: 204/426
• CPC Class Codes: G01N 27/4045 for gases other than oxygen
• CPC Class Codes: G01N 27/4074 for detection of gases other than oxygen

Abstract

The invention relates to an electrochemical gas sensor having a substrate, substrate surface for depositing electrodes thereon, counter and sensing electrodes for measuring current flow, an electrolyte for providing an electrical connection between the electrodes, and an electrode surface having minimal porosity, pore size, and thickness for deterring flooding.

Claims

1. An electrochemical sensor, comprising:

a substrate having a surface;

a first electrode deposited on said surface;

a second electrode spaced apart from said first electrode and deposited on said surface for detecting a gas;

an electrolyte in electrical contact with said first electrode and said second electrode for carrying a flow of current; and

said second electrode having a porosity of less than 5%, a pore size less than 0.12 micrometers at said pore size'"'"'s greatest measurement, and a thickness less than 1 micrometer for controlling flooding.

2. The electrochemical sensor according to claim 1, wherein said porosity is less than 2%.

3. The electrochemical sensor according to claim 1, wherein said pore size is less than 0.05 micrometers at said pore size'"'"'s greatest measurement.

4. The electrochemical sensor according to claim 1, wherein said thickness is less than 0.2 micrometers for deterring flooding.

5. The electrochemical sensor according to claim 1, wherein said porosity is less than 1%.

6. The electrochemical sensor according to claim 1, wherein said pore size is less than 0.01 micrometers at said pore size'"'"'s greatest measurement.

7. The electrochemical sensor according to claim 1, wherein said thickness is less than 0.1 micrometers for deterring flooding.

8. The electrochemical sensor according to claim 1, wherein said second electrode has negligible porosity.

9. The electrochemical sensor according to claim 1, wherein said second electrode is nonporous.

10. The electrochemical sensor according to claim 1, wherein said first electrode is sputter coated.

11. The electrochemical sensor according to claim 1, wherein said first electrode is vapor deposited.

12. The electrochemical sensor according to claim 1, wherein said second electrode is sputter coated.

13. The electrochemical sensor according to claim 1, wherein said second electrode is vapor deposited.

14. The electrochemical sensor according to claim 1, further including an acidic solution for hydrating said electrolyte.

15. The electrochemical sensor according to claim 1, further including a reservoir for containing a solution to hydrate said electrolyte.

16. The electrochemical sensor according to claim 1, wherein said substrate has a pore less than 0.12 micrometers at its greatest measurement.

17. The electrochemical sensor according to claim 1, wherein said substrate has a pore less than 0.05 micrometers at its greatest measurement.

18. The electrochemical sensor according to claim 1, wherein said substrate has a pore less than 0.01 micrometers at its greatest measurement.

19. The electrochemical sensor according to claim 1, wherein said surface of said substrate has negligible porosity.

20. The electrochemical sensor according to claim 1, wherein said surface of said substrate is generally flat.

21. The electrochemical sensor according to claim 1, wherein said surface of said substrate has a porosity of less than 5%.

22. The electrochemical sensor according to claim 1, wherein said surface of said substrate has a porosity of less than 2%

23. The electrochemical sensor according to claim 1, wherein said surface of said substrate has a porosity of less than 1%.

24. An electrochemical sensor operational below 0°

C., comprising;

a substrate having a surface;

a first electrode deposited on said;

a second electrode spaced apart from said first electrode and deposited on said surface for detecting a gas;

an electrolyte in electrical contact with said first electrode and said second electrode for carrying a flow of current; and

an acidic solution for hydrating said electrolyte.

25. The electrochemical sensor according to claim 24, wherein said acidic solution is 30% acidic.

26. The electrochemical sensor according to claim 24, wherein said acidic solution is 50% acidic.