Compact electrochemical cell for gas detection
First Claim
1. An electrochemical cell for gas detection comprising an impervious nonconductive cell body having an electrolyte cavity and a separate sensor cavity formed therein, said electrolyte cavity being at least partially filled with a liquid electrolyte, said sensor cavity having a plurality of sensor elements stacked therein including a counter electrode positioned at an inner end of said sensor cavity, a gas diffusion sensing electrode containing a catalytic material and positioned at an outer end of said sensor cavity and spaced from said counter electrode, an electrolyte mat positioned between and contacting said counter and sensing electrodes, and a reference electrode disposed within said electrolyte mat and spaced from said counter and sensing electrodes, said reference electrode formed of a non-porous, conductive material coated with a layer of a catalytic material, and with said counter electrode being a porous, hydrophilic, conductive structure containing a catalytic material, with said catalytic material of said sensing, counter and reference electrodes oxidizing or reducing a particular gas or particular gases coming in contact therewith, said sensing electrode closing off the outer end of said sensor cavity and sealing said counter electrode, reference electrode and electrolyte mat within said sensor cavity, said cell including wick means for wicking liquid electrolyte from said electrolyte cavity to said electrolyte mat, and including means for making electrical contact with said counter, reference and sensing electrodes, wherein said counter and reference electrodes are submerged within said sensor cavity by said sensing electrode and any gas contacting said counter and reference electrodes passes through said sensing electrode and is dissolved in said electrolyte.
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Abstract
An electrochemical cell for use in gas detection includes a cell body having an electrolyte cavity and a separate sensor cavity. The sensor cavity holds stacked sensor elements including a counter electrode, electrolyte mat, reference electrode and sensing electrode. A wick draws the electrolyte from the electrolyte cavity to the electrolyte mat. The sensing electrode closes off the sensor cavity and seals the counter and reference electrodes therein. The only gas which contacts the counter and reference electrodes is that which passes through the sensing electrode or is generated by the counter electrode and becomes dissolved in the electrolyte.
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Citations
35 Claims
- 1. An electrochemical cell for gas detection comprising an impervious nonconductive cell body having an electrolyte cavity and a separate sensor cavity formed therein, said electrolyte cavity being at least partially filled with a liquid electrolyte, said sensor cavity having a plurality of sensor elements stacked therein including a counter electrode positioned at an inner end of said sensor cavity, a gas diffusion sensing electrode containing a catalytic material and positioned at an outer end of said sensor cavity and spaced from said counter electrode, an electrolyte mat positioned between and contacting said counter and sensing electrodes, and a reference electrode disposed within said electrolyte mat and spaced from said counter and sensing electrodes, said reference electrode formed of a non-porous, conductive material coated with a layer of a catalytic material, and with said counter electrode being a porous, hydrophilic, conductive structure containing a catalytic material, with said catalytic material of said sensing, counter and reference electrodes oxidizing or reducing a particular gas or particular gases coming in contact therewith, said sensing electrode closing off the outer end of said sensor cavity and sealing said counter electrode, reference electrode and electrolyte mat within said sensor cavity, said cell including wick means for wicking liquid electrolyte from said electrolyte cavity to said electrolyte mat, and including means for making electrical contact with said counter, reference and sensing electrodes, wherein said counter and reference electrodes are submerged within said sensor cavity by said sensing electrode and any gas contacting said counter and reference electrodes passes through said sensing electrode and is dissolved in said electrolyte.
- 15. An electrochemical cell for gas detection comprising an impervious, nonconductive cell body having an electrolyte cavity extending into said cell body from a rear surface thereof and a sensor cavity extending into said cell body from a front surface thereof, a dividing wall separating said sensor cavity and electrolyte cavity, means for closing off said electrolyte cavity at said rear surface, said electrolyte cavity being at least partially filled with a liquid electrolyte, said sensor cavity having a counter electrode at an inner end thereof and adjacent said dividing wall, an electrolyte mat adjacent said counter electrode, a gas diffusion sensing electrode containing a catalytic material and positioned adjacent said electrolyte mat and spaced from said counter electrode, a reference electrode disposed within said electrolyte mat and spaced from said counter and sensing electrodes, with said reference electrode formed of a non-porous, conductive material coated with a layer of a catalytic material, and with said counter electrode being a porous, hydrophilic, conductive structure containing a catalytic material, with said catalytic material of said sensing, counter and reference electrodes oxidizing or reducing a particular gas or particular gases coming in contact therewith, said sensing electrode closing off said sensor cavity at said front surface and sealing said counter electrode, reference electrode and electrolyte mat therein, said cell including a wick which extends between said electrolyte mat and the electrolyte in said electrolyte cavity and passes through said counter electrode and dividing wall, and including means for making electrical contact with said counter, reference and sensing electrodes, wherein said counter and reference electrodes are submerged within said sensor cavity by said sensing electrode and any gas contacting said counter and reference electrodes passes through said sensing electrode and is dissolved in said electrolyte.
- 21. An electrochemical cell for gas detection comprising an impervious nonconductive cell body having an electrolyte cavity and a separate sensor cavity formed therein, said electrolyte cavity being at least partially filled with a liquid electrolyte, said sensor cavity having a plurality of sensor elements stacked therein including a counter electrode positioned at an inner end of said sensor cavity, a gas diffusion sensing electrode containing a catalytic material and positioned at an outer end of said sensor cavity and spaced from said counter electrode, an electrolyte mat positioned between and contacting said counter and sensing electrodes, and a reference electrode disposed within said electrolyte mat and spaced from said counter and sensing electrodes, said reference electrode formed of a non-porous, conductive material coated with a layer of catalytic material, and with said counter electrode being a porous, hydrophilic, conductive structure containing a catalytic material, with said catalytic material of said sensing, counter and reference electrodes oxidizing or reducing a particular gas or particular gases coming in contact therewith, said sensing electrode closing off the outer end of said sensor cavity and sealing said counter electrode, reference electrode and electrolyte mat within said sensor cavity, said cell including wick means for wicking liquid electrolyte from said electrolyte cavity to said electrolyte mat, and including means for making electrical contact with said counter, reference and sensing electrodes, wherein said counter and reference electrodes are submerged within said sensor cavity by said sensing electrode and any gas contacting said counter and reference electrodes passes through said sensing electrode and is dissolved in said electrolyte, and further including a wire ring positioned behind and in contact with said counter electrode and terminating in a counter electrode lead wire which extends through said cell body and through said electrolyte cavity to a counter electrode connector at an outer portion of said cell and forms the means for making electrical contact with said counter electrode.
- 24. An electrochemical cell for gas detection comprising an impervious nonconductive cell body having an electrolyte cavity and a separate sensor cavity formed therein, said electrolyte cavity being at least partially filled with a liquid electrolyte, said sensor cavity having a plurality of sensor elements stacked therein including a counter electrode positioned at an inner end of said sensor cavity, a gas diffusion sensing electrode containing a catalytic material and positioned at an outer end of said sensor cavity and spaced from said counter electrode, an electrolyte mat positioned between and contacting said counter and sensing electrodes, and a reference electrode disposed within said electrolyte mat and spaced from said counter and sensing electrodes, with said reference electrode being a metal wire formed into one or more spaced loops and coated with a layer of a catalytic material, and with said counter electrode being a porous, hydrophilic, conductive structure containing a catalytic material, with said catalytic material of said sensing, counter and reference electrodes oxidizing or reducing a particular gas or particular gases coming in contact therewith, said sensing electrode closing off the outer end of said sensor cavity and sealing said counter electrode, reference electrode and electrolyte mat within said sensor cavity, said cell including wick means for wicking liquid electrolyte from said electrolyte cavity to said electrolyte mat, and including means for making electrical contact with said counter, reference and sensing electrodes, wherein said counter and reference electrodes are submerged within said sensor cavity by said sensing electrode and any gas contacting said counter and reference electrode passes through said sensing electrode and is dissolved in said electrolyte.
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26. An electrochemical cell for gas detection comprising an impervious nonconductive cell body having an electrolyte cavity and a separate sensor cavity formed therein, said electrolyte cavity being at least partially filled with a liquid electrolyte, said sensor cavity having a plurality of sensor elements stacked therein including a counter electrode positioned at an inner end of said sensor cavity, a gas diffusion sensing electrode containing a catalytic material and positioned at an outer end of said sensor cavity and spaced from said counter electrode, an electrolyte mat positioned between and contacting said counter and sensing electrodes, and a reference electrode disposed within said electrolyte mat and spaced from said counter and sensing electrodes, said reference electrode formed of a non-porous, conductive material coated with a layer of a catalytic material, and with said counter electrode being a porous, hydrophilic, conductive structure containing a catalytic material, with said catalytic material of said sensing, counter and reference electrodes oxidizing or reducing a particular gas or particular gases coming in contact therewith, said sensing electrode closing off the outer end of said sensor cavity and sealing said counter electrode, reference electrode and electrolyte mat within said sensor cavity, said cell including wick means for wicking liquid electrolyte from said electrolyte cavity to said electrolyte mat, and including means for making electrical contact with said counter, reference and sensing electrodes, wherein said counter and reference electrodes are submerged within said sensor cavity by said sensing electrode and any gas contacting said counter and reference electrodes passes through said sensing electrode and is dissolved in said electrolyte, and further including a reference electrode lead wire connected to said reference electrode and which extends through said electrolyte mat, counter electrode, cell body and electrolyte cavity to a reference electrode connector at an outer portion of said cell and forms the means for making electrical contact with said reference electrode.
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27. An electrochemical cell for gas detection comprising an impervious nonconductive cell body having an electrolyte cavity and a separate sensor cavity formed therein, said electrolyte cavity being at least partially filled with a liquid electrolyte, said sensor cavity having a plurality of sensor elements stacked therein including a counter electrode positioned at an inner end of said sensor cavity, a gas diffusion sensing electrode containing a catalytic material and positioned at an outer end of said sensor cavity and spaced from said counter electrode, an electrolyte mat positioned between and contacting said counter and sensing electrodes, and a reference electrode disposed within said electrolyte mat and spaced from said counter and sensing electrodes, said reference electrode formed of a non-porous, conductive material coated with a layer of a catalytic material, and with said counter electrode being a porous, hydrophilic, conductive structure containing a catalytic material, with said catalytic material of said sensing, counter and reference electrodes oxidizing or reducing a particular gas or particular gases coming in contact therewith, said sensing electrode closing off the outer end of said sensor cavity and sealing said counter electrode, reference electrode and electrolyte mat within said sensor cavity, said cell including wick means for wicking liquid electrolyte from said electrolyte cavity to said electrolyte mat, and including means for making electrical contact with said counter, reference and sensing electrodes, wherein said counter and reference electrodes are submerged within said sensor cavity by said sensing electrode and any gas contacting said counter and reference electrodes passes through said sensing electrode and is dissolved in said electrolyte, with said sensing electrode having a conductive outer surface, said cell including a conductive ring in contact with the outer surface of said sensing electrode and electrically connected to a sensing electrode terminal at an outer portion of said cell, and including a planar sensor contact in contact with said conductive ring and extending to said sensing electrode terminal, said sensor contact having an enlarged portion spaced from and covering said sensing electrode, with said enlarged portion having a plurality of holes therethrough to permit gas flow to said sensing electrode.
- 28. An electrochemical cell for gas detection comprising an impervious, nonconductive cell body having an electrolyte cavity extending into said cell body from a rear surface thereof and a sensor cavity extending into said cell body from a front surface thereof, a dividing wall separating said sensor cavity and electrolyte cavity, means for closing off said electrolyte cavity at said rear surface, said electrolyte cavity being at least partially filled with a liquid electrolyte, said sensor cavity having a counter electrode at an inner end thereof and adjacent said dividing wall, an electrolyte mat adjacent said counter electrode, a gas diffusion sensing electrode containing a catalytic material and positioned adjacent said electrolyte mat and spaced from said counter electrode, a reference electrode disposed within said electrolyte mat and spaced from said counter and sensing electrodes, with said reference electrode formed of a non-porous, conductive material coated with a layer of a catalytic material, and with said counter electrode being a porous, hydrophilic, conductive structure containing a catalytic material, with said catalytic material of said sensing, counter and reference electrodes oxidizing or reducing a particular gas or particular gases coming in contact therewith, said sensing electrode closing off said sensor cavity at said front surface and sealing said counter electrode, reference electrode and electrolyte mat therein, said cell including a wick which extends between said electrolyte mat and the electrolyte in said electrolyte cavity and passes through said counter electrode and dividing wall, and including means for making electrical contact with said counter, reference and sensing electrodes, wherein said counter and reference electrodes are submerged within said sensor cavity by said sensing electrode and any gas contacting said counter and reference electrodes passes through said sensing electrode and is dissolved in said electrolyte, and further including a wire ring positioned behind and in contact with said counter electrode and terminating in a counter electrode lead wire which extends through said dividing wall and through said electrolyte cavity to a counter electrode connector at a rear portion of said cell and forms the means for making electrical contact with said counter electrode.
- 33. An electrochemical cell for gas detection comprising an impervious, nonconductive cell body having an electrolyte cavity extending into said cell body from a rear surface thereof and a sensor cavity extending into said cell body from a front surface thereof, a dividing wall separating said sensor cavity and electrolyte cavity, means for closing off said electrolyte cavity at said rear surface, said electrolyte cavity being at least partially filled with a liquid electrolyte, said sensor cavity having a counter electrode at an inner end thereof and adjacent said dividing wall, an electrolyte mat adjacent said counter electrode, a gas diffusion sensing electrode containing a catalytic material and positioned adjacent said electrolyte mat and spaced from said counter electrode, a reference electrode disposed within said electrolyte mat and spaced from said counter and sensing electrodes, with said reference electrode being a metal wire formed into one or more spaced loops coated with a layer of a catalytic material, and with said counter electrode being a porous, hydrophilic, conductive structure containing a catalytic material, with said catalytic material of said sensing, counter and reference electrodes oxidizing or reducing a particular gas or particular gases coming in contact therewith, said sensing electrode closing off said sensor cavity at said front surface and sealing said counter electrode, reference electrode and electrolyte mat therein, said cell including a wick which extends between said electrolyte mat and the electrolyte in said electrolyte cavity and passes through said counter electrode and dividing wall, and including means for making electrical contact with said counter, reference and sensing electrodes, wherein said counter and reference electrodes are submerged within said sensor cavity by said sensing electrode and any gas contacting said counter and reference electrodes passes through said sensing electrode and is dissolved in said electrolyte.
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35. An electrochemical cell for gas detection comprising an impervious, nonconductive cell body having an electrolyte cavity extending into said cell body from a rear surface thereof and a sensor cavity extending into said cell body from a front surface thereof, a dividing wall separating said sensor cavity and electrolyte cavity, means for closing off said electrolyte cavity at said rear surface, said electrolyte cavity being at least partially filled with a liquid electrolyte, said sensor cavity having a counter electrode at an inner end thereof and adjacent said dividing wall, an electrolyte mat adjacent said counter electrode, a gas diffusion sensing electrode containing a catalytic material and positioned adjacent said electrolyte mat and spaced from said counter electrode, a reference electrode disposed within said electrolyte mat and spaced from said counter and sensing electrodes, with said reference electrode formed of a non-porous, conductive material coated with a layer of a catalytic material, and with said counter electrode being a porous, hydrophilic, conductive structure containing a catalytic material, with said catalytic material of said sensing, counter and reference electrodes oxidizing or reducing a particular gas or particular gases coming in contact therewith, said sensing electrode closing off said sensor cavity at said front surface and sealing said counter electrode, reference electrode and electrolyte mat therein, said cell including a wick which extends between said electrolyte mat and the electrolyte in said electrolyte cavity and passes through said counter electrode and dividing wall, and including means for making electrical contact with said counter, reference and sensing electrodes, wherein said counter and reference electrodes are submerged within said sensor cavity by said sensing electrode and any gas contacting said counter and reference electrodes passes through said sensing electrode and is dissolved in said electrolyte, with said sensing electrode having a conductive outer surface, said cell including a conductive ring in contact with the outer surface of said sensing electrode and electrically connected to a sensing electrode terminal at a front portion of said cell, and including a planar sensor contact in contact with said conductive ring and extending to said sensing electrode terminal, said sensor contact having an enlarged portion spaced from and covering said sensing electrode, with said enlarged portion having a plurality of holes therethrough to permit gas flow to said sensing electrode.
Specification