Electrochemical micro sensor

• US 4,865,717 A
• Filed: 08/10/1988
• Issued: 09/12/1989
• Est. Priority Date: 05/26/1987
• Status: Expired due to Fees

• Current Assignee: TSI Incorporated
• Original Assignee: Transducer Research, Inc. (TSI Incorporated)
• Inventors: Setter, Joseph R., Maclay, G. Jordan
• Primary Examiner(s): Kaplan, G. L.
• Application Number:
  US07/230,684
• Time in Patent Office: 398 Days
• Field of Search: 204/415, 204/425, 204/426, 204/412
• US Class Current: 204/412
• CPC Class Codes: G01N 27/4045 for gases other than oxygen

Abstract

A micro-amperometric electrochemical sensor for detecting the presence of a pre-determined species in a fluid material is disclosed. The sensor includes a smooth substrate having a thin coating of solid electrolytic material deposited thereon. The working and counter electrodes are deposited on the surface of the solid electrolytic material and adhere thereto. Electrical leads connect the working and counter electrodes to a potential source and an apparatus for measuring the change in an electrical signal caused by the electrochemical oxidation or reduction of the species. Alternatively, the sensor may be fabricated in a sandwich structure and also may be cylindrical, spherical or other shapes.

Claims

1. A solid electrochemical sensor which operates at temperatures below 300°

C. for generating an electrical signal in response to contact with a pre-determined species present in a fluid material comprising;

a substrate having at least one surface,

a solid electrolytic medium having sufficient ionic conductivity at temperatures below 100°

C. to sustain an ionic current flow and having first and second surfaces, said first surface of said medium being in contact with and adhering to said at least one surface of said substrate,

a working electrode means in contact with and adhering to said second surface of said medium,

an electrical power source connected for biasing said working electrode means at a potential at which said species will be consumed at said working electrode means, and

a counter electrode means in contact with and adhering to said second surface of said medium and being connected to said power source for completing a circuit in which a current is capable of flowing through both of said electrode means as a result of the electrochemical reaction occurring at said first working electrode means.

2. An apparatus in accordance with claim 1 further comprising a reference electrode having at least one surface in contact with and adhering to said second surface of said medium.

3. An apparatus in accordance with claim 2 further comprising a coating over said reference electrode to prevent exposure of said reference electrode to said species.

4. An apparatus in accordance with claim 2 further comprising a selectively permeable membrane means separating all of said electrodes means from said fluid material.

5. An apparatus in accordance with claim 1 wherein said substrate comprises an insulating material.

6. An apparatus in accordance with claim 1 wherein said electrolytic medium comprises a layer of between about 0.1 and about 4.0 microns in thickness.

7. An apparatus in accordance with claim 6 wherein said working electrode means comprises thin strips of metal which form a grid pattern having a perimeter² to area ratio of between 2 and about 500.

8. An apparatus in accordance with claim 1 wherein said substrate comprises an oxide layer on said at least one surface of said substrate.

9. An apparatus in accordance with claim 1 wherein said substrate further comprises at least one adhesion promoter on said at least one surface of said substrate to promote adherence between said electrolytic medium and said substrate.

10. An apparatus in accordance with claim 1 further comprising a second layer of a solid electrolytic medium having a first surface in contact with and adhering to said working and counter electrode means.

11. A solid electrochemical sensor for generating an electrical signal in response to contact with a pre-determined species present in a fluid material comprising

a substrate comprising an insulating material and having at least one surface,

a first layer of solid electrolytic medium having first and second surfaces, said first surface of said first layer of said medium being in contact with and adhering to said at least one surface of said substrate,

a counter electrode means in contact with and adhering to said second surface of said first layer of electrolytic medium,

a second layer of a solid electrolytic medium having first and second surfaces, said first surface of said second layer of said medium being in contact with and adhering to said counter electrode means,

a working electrode means in contact with and adhering to said second surface of said second layer of electrolytic medium,

an electrical power source connected for biasing said working electrode means at a potential at which said species will be consumed at said working electrode means, and means for connecting said counter electrode means to said power source for completing a circuit in which a current is capable of flowing through both of said electrode means as a result of the electrochemical reaction occurring at said working electrode means.

12. An apparatus in accordance with claim 11 further comprising a reference electrode in contact with and adhering to said second surface of said first layer of electrolytic medium.

13. An apparatus in accordance with claim 12 wherein said reference electrode is also in contact with an adhering to said first surface of said second layer of electrolytic medium.

14. An apparatus in accordance with claim 12 wherein said reference electrode further comprises a coating to prevent exposure of said reference electrode to said species.

15. An apparatus in accordance with claim 11 further comprising a third layer of electrolytic medium in contact with and adhering to said working electrode means.

16. An apparatus in accordance with claim 11 further comprising a selectively permeable membrane means separating said working electrode means from said fluid material.

17. An apparatus in accordance with claim 11 wherein said substrate comprises an oxide layer on said at least one surface.

18. An apparatus in accordance with claim 11 wherein said substrate compriss at least one adhesion promoter on said at least one surface of said substrate to promote adherence of said electrolytic medium and said substrate.

19. An apparatus in accordance with claim 11 wherein said working electrode means comprises thin strips of metal which form a grid pattern having has a perimeter² to area ratio of between about 0.4 and about 500.

20. An apparatus in accordance with claim 11 wherein said first and second layers of electrolytic medium each have a thickness of between about 0.1 and about 4.0 microns.