Electrochemical NOx sensor

• US 4,770,760 A
• Filed: 07/30/1987
• Issued: 09/13/1988
• Est. Priority Date: 08/04/1986
• Status: Expired due to Term

• Current Assignee: NGK Insulators Limited
• Original Assignee: NGK Insulators Limited
• Inventors: Noda, Makoto, Kurachi, Hiroshi, Kato, Nobuhide
• Primary Examiner(s): Tung, T.
• Application Number:
  US07/079,466
• Time in Patent Office: 411 Days
• Field of Search: 204/1 N, 204/1 T, 204/421-429, 422/98
• US Class Current: 204/425
• CPC Class Codes: G01N 27/4072 characterized by the diffusion barrier
• CPC Class Codes: G01N 27/4074 for detection of gases other than oxygen

Abstract

An NOx sensor for determining the concentration of NOx contained in a measurement gas, having first and second electrochemical detecting elements each of which includes an oxygen pumping cell and an oxygen sensing cell. Each of the pumping and sensing cells of the first and second detecting elements consists of a solid electrolyte and a pair of electrodes. At least one of the electrodes of the oxygen pumping and sensing cells of the second detecting elements which are exposed to the introduced measurement gas, is used as a catalytic electrode which is provided with a catalyst for reducing the nitrogen oxides contained in the measurement gas. The second detecting element detects an oxygen partial pressure of the measurement gas while the nitrogen oxides are reduced by the catalyst of the catalytic electrode. The NOx concentration is determined, based on a difference between two outputs of the first and second detecting elements which represent the oxygen partial pressures of respective portions of the measurement gas detected by the first and second detecting elements.

Claims

1. An NOx sensor for determining the concentration of nitrogen oxides contained in a measurement gas in an external measurement-gas space, comprising:

a first electrochemical oxygen partial pressure detecting element including (a) a first electrochemical oxygen pumping cell having an oxygen-ion conductive solid electrolyte body, and a pair of electrodes, (b) a first electrochemical oxygen sensing cell having an oxygen-ion conductive solid electrolyte body, and a pair of electrodes, (c) first diffusion-resistance means for introducing said measurement gas from said external measurement-gas space, with a first predetermined diffusion resistance, so that one of said pair of electrodes of said first oxygen pumping cell, and one of said pair of electrodes of said first oxygen sensing cell, are exposed to the introduced measurement gas, and (d) first reference-gas inlet means for exposing the other of said pair of electrodes of said first oxygen sensing cell to a reference gas;

a second electrochemical oxygen partial pressure detecting element including (i) a second electrochemical oxygen pumping cell having an oxygen-ion conductive solid electrolyte body, and a pair of electrodes, (ii) a second electrochemical oxygen sensing cell having an oxygen-ion conductive solid electrolyte body, and a pair of electrodes, (iii) second diffusion-resistance means for introducing said measurement gas from said external measurement-gas space, with a second predetermined diffusion resistance substantially equal to said first predetermined diffusion resistance, so that one of said pair of electrodes of said second oxygen pumping cell, and one of said pair of electrodes of said second oxygen sensing cell, are exposed to the introduced measurement gas, and (iv) second reference-gas inlet means for exposing the other of said pair of electrodes of said second oxygen sensing cell to a reference atmosphere substantially the same as said reference gas;

at least one catalytic electrode which consists of at least one of said one electrode of said second oxygen pumping cell and said one electrode of said second oxygen sensing cell, which are exposed to a portion of the measurement gas introduced through said second diffusion-resistance means, said at least one catalytic electrode being provided with a catalyst for reducing nitrogen oxides contained in the introduced measurement gas, so that said second electrochemical oxygen partial pressure detecting element detects an oxygen partial pressure of the portion of the measurement gas introduced through said second diffusion-resistance means, while said nitrogen oxides are reduced by said catalyst; and

means for determining the concentration of said nitrogen oxides based on a difference between two outputs of said first and second electrochemical oxygen partial pressure detecting elements, said two outputs representing the oxygen partial pressures of the respective portions of the measurement gas introduced through said first and second diffusion-resistance means.

2. An NOx sensor according to claim 1, wherein said catalyst consists of at least one material selected from the group consisting of rhodium, cobalt oxide, nickel oxide, palladium, cerium oxide and lanthanum oxide.

3. An NOx sensor according to claim 1, wherein said catalyst is applied to said at least one catalytic electrode such that said at least one catalytic electrode is impregnated with said catalyst.

4. An NOx sensor according to claim 1, wherein said catalyst is applied to said at least one catalytic electrode such that said at least one catalytic electrode is coated with a layer of said catalyst.

5. An NOx sensor according to claim 1, wherein said catalyst is applied to said at least one catalytic electrode such that said at least one catalytic electrode is coated with a ceramic overcoat, and a layer of said catalyst formed on said ceramic overcoat.

6. An NOx sensor according to claim 1, wherein said catalyst is applied to said at least one catalytic electrode such that said at least one catalytic electrode is coated with a ceramic overcoat which is impregnated with said catalyst.

7. An NOx sensor according to claim 1, wherein said first and second electrochemical oxygen partial pressure detecting elements consist of an integrally formed one-piece structure.

8. An NOx sensor according to claim 7, wherein said first and second diffusion-resistance means are defined by an integral portion of said integrally formed one-piece structure.

9. An NOx sensor according to claim 7, wherein said first and second reference-gas inlet means are defined by an integral portion of said integrally formed one-piece structure.

10. An NOx sensor according to claim 7, wherein at least one of said pair of electrodes of said first oxygen pumping cell is commonly used as at least one of said pair of electrodes of said first oxygen sensing cell.

11. An NOx sensor according to claim 7, wherein at least one of said pair of electrodes of said second oxygen pumping cell is commonly used as at least one of said pair of electrodes of said second oxygen sensing cell.

12. An NOx sensor according to claim 1, further comprising integrally formed heating means for heating said first and second oxygen pumping and sensing cells of said first and second electrochemical oxygen partial pressure detecting elements.

13. An NOx sensor for determining the concentration of nitrogen oxides contained in a measurement gas in an external measurement-gas space, comprising:

a first electrochemical oxygen partial pressure detecting element and a second electrochemical oxygen partial pressure detecting element, said first and second elements consisting of an integrally formed one piece structure;

said first electrochemical oxygen partial pressure detecting element including (a) a first electrochemical oxygen pumping cell having an oxygen-ion conductive solid electrolyte body, and a pair of electrodes, (b) a first electrochemical oxygen sensing cell having an oxygen-ion conductive solid electrolyte body, and a pair of electrodes, (c) first diffusion-resistance means for introducing said measurement gas from said external measurement-gas space, with a first predetermined diffusion resistance, so that one of said pair of electrodes of said first oxygen pumping cell, and one of said pair of electrodes of said first oxygen sensing cell, are exposed to the introduced measurement gas, and (d) first reference-gas inlet means for exposing the other of said pair of electrodes of sald first oxygen sensing cell to a reference gas;

said second electrochemical oxygen partial pressure detecting element including (1) a second electrochemical oxygen pumping cell having an oxygen-ion conductive solid electrolyte body, and a pair of electrodes, (ii) a second electrochemical oxygen sensing cell having an oxygen-ion conductive solid electrolyte body, and a pair of electrodes, (iii) second diffusion-resistance means for introducing said measurement gas from said external measurement-gas space, with a second predetermined diffusion resistance substantially equal to said first predetermined diffusion resistance, so that one of said pair of electrodes of said second oxygen pumping cell, and one of said pair of electrodes of said second oxygen sensing cell, are exposed to the introduced measurement gas, and (iv) second reference-gas inlet means for exposing the other of said pair of electrodes of said second oxygen sensing cell to a reference atmosphere substantially the same as said reference gas;

at least one catalytic electrode which consists of at least one of said one electrode of said second oxygen pumping cell and said one electrode of said second oxygen sensing cell, which are exposed to a portion of the measurement gas introduced through said second diffusion-resistance means, said at least one catalytic electrode being provided with a catalyst for reducing nitrogen oxides contained in the introduced measurement gas, so that said second electrochemical oxygen partial pressure detecting element detects an oxygen partial pressure of the portion of the measurement gas introduced through said second diffusion-resistance means, while said nitrogen oxides are reduced by said catalyst;

means for determining the concentration of said nitrogen oxides based on a difference between two outputs of said first and second electrochemical oxygen partial pressure detecting elements, said two outputs representing the oxygen partial pressures of the respective portions of the measurement gas introduced through said first and second diffusion-resistance means; and

heating means for heating said first and second oxygen pumping and sensing cells of said first and second electrochemical oxygen partial pressure detecting elements, said heating means being integrally formed with said one-piece structure.

14. An NOx sensor according to claim 13, wherein said catalyst consists of at least one material selected from the group consisting of rhodium, cobalt oxide, nickel oxide, palladium, cerium oxide and lanthanum oxide.

15. An NOx sensor according to claim 13, wherein said catalyst is applied to said at least one catalytic electrode such that said at least one catalytic electrode is impregnated with said catalyst.

16. An NOx sensor according to claim 13, wherein said catalyst is applied to said at least one catalytic electrode such that said at least one catalytic electrode is coated with a layer of said catalyst.

17. An NOx sensor according to claim 13, wherein said catalyst is applied to said at least one catalytic electrode such that said at least one catalytic electrode is coated with a ceramic overcoat, and a layer of said catalyst formed on said ceramic overcoat.

18. An NOx sensor according to claim 13, wherein said catalyst is applied to said at least one catalytic electrode such that said at least one catalytic electrode is coated with a ceramic overcoat which is impregnated with said catalyst.

19. An NOx sensor according to claim 13, wherein said first and second diffusion-resistance means are defined by an integral portion of said integrally formed one-piece structure.

20. An NOx sensor according to claim 13, wherein said first and second reference-gas inlet means are defined by an integral portion of said integrally formed one-piece structure.

21. An NOx sensor according to claim 13, wherein at least one of said pair of electrodes of said first oxygen pumping cell is commonly used as at least one of said pair of electrodes of said first oxygen sensing cell.

22. An NOx sensor according to claim 13, wherein at least one of said pair of electrodes of said second oxygen pumping cell is commonly used as at least one of said pair of electrodes of said second oxygen sensing cell.