Solid state gas sensor and filter assembly

• US 5,841,021 A
• Filed: 09/05/1995
• Issued: 11/24/1998
• Est. Priority Date: 09/05/1995
• Status: Expired due to Fees

• Current Assignee: Minitech Sensors, LLC
• Original Assignee: Emory S De Castro, Genders J. David, Norman L. Weinberg
• Inventors: Genders, J. David, Weinberg, Norman L., De Castro, Emory S.
• Primary Examiner(s): Williams, Hezron E.
• Assistant Examiner(s): WIGGINS, JOHN DAVID
• Application Number:
  US08/523,687
• Time in Patent Office: 1,176 Days
• Field of Search: 73/23.2, 73/31.06, 73/23.4, 73/25.04, 73/25.29, 340/634, 324/71.5, 324/439, 422/98, 422/90, 422/94, 422/83, 204/412, 204/421, 204/424, 204/425, 204/426, 204/431, 204/427, 338/34, 338/224
• US Class Current: 73/23.2
• CPC Class Codes: G01N 27/4162 investigating the composition of gases, by the influence exerted on ionic conductivity in a liquid conductometry in general G01N27/06; amperometric gas sensors G01N27/404

Abstract

An electrochemical gas sensor is provided, the use of which permits quantitative measurement of volatile gas contaminants in an atmosphere being monitored, generally at ambient temperatures below 100° C. The sensor is constructed of a sensor electrode and a reference electrode on a separator in such a manner as to be exposed to the atmosphere which is sensed for gaseous contaminants. In an alternative embodiment, the sensors can be covered with a selective filter which will selectively allow only small molecule toxic gases to pass for sensing by the sensor electrode while excluding larger interfering gas molecules. In another alternative embodiment, a multiple layer electrochemical gas sensor detects the presence of volatile gas contaminants in a sample gas as well as humidity, temperature, and/or pressure of the gas sample.

Claims

1. A potentiometric gas sensor for detecting the presence of a gas contaminant in a gas sample being monitored, said gas sensor comprising:

a first electrically conductive element which interacts with said gas contaminant when said first electrically conductive element is exposed to said gas sample;

a second electrically conductive element which does not interact with said gas contaminant when said second electrically conductive element is exposed to said gas sample; and

an ion-conducting substrate having said first and second electrically conductive elements mounted thereon for ionic conduction between said first and second electrically conductive elements in support of the electronic conduction therebetween; and

measuring circuitry connected to said first and second electrically conductive elements for comparing an electrical signal corresponding to the difference between first and second electrical signals generated by said first and second electrically conductive elements with a reference electrical signal.

2. The potentiometric gas sensor of claim 1 further including a filter layer through which said gas being sampled flows prior to being exposed to said first and second electrically conductive elements, said filter layer being a material selected from the group comprising microporous, nanoporous, and non-porous membranes, and chemically reactive materials.

3. The potentiometric gas sensor of claim 1 wherein said first electrically conductive element is a sensing electrode.

4. The potentiometric gas sensor of claim 3 wherein said second electrically conductive element is a reference electrode.

5. The potentiometric gas sensor of claim 4 wherein said sensing electrode has a different output response to said gas contaminant in said gas sample than said reference electrode.

6. The potentiometric gas sensor of claim 5 wherein said sensing electrode is constructed with a metal deposited onto a layer of material selected from the group comprising an ion-exchange membrane, an ion-conducting polymer, an organic polymer, an ion-conductive electrolyte, carbon, and a layer of fiber assemblies.

7. The potentiometric gas sensor of claim 6 wherein said ion-conducting polymer is selected from the group consisting of doped polyvinylchloride, polyphenyleneoxide, polyphenyleneglycol, polythiophenes, polypyrrols, polydibenzocrown ethers, polyphenylenes, substituted polyacetylenes, doped ceramic material and combinations thereof.

8. The potentiometric gas sensor of claim 6 wherein said organic polymer is selected from the group consisting of free acid functionality, totally neutralized acid functionalities, partially neutralized acid functionalities, amine functionalities, totally neutralized amine functionalities or partially neutralized amine functionalities, carboxylic acid, quaternary ammonium functionalities, and ionically doped polymers.

9. The potentiometric gas sensor of claim 1 wherein said first and second electrically conductive elements are spaced from each other and disposed in side by side relation to each other on said ion-conducting substrate.

10. The potentiometric gas sensor of claim 1 wherein said first and second electrically conductive elements are spaced from each other and disposed on opposite sides of said ion-conducting substrate.

11. The potentiometric gas sensor of claim 5 wherein said sensing electrode is constructed of a material selected from a group consisting essentially of platinum, palladium, rhenium, ruthenium, gold, silver, and mixtures or alloys thereof;

carbon blacks and carbon fibers;

pure metal or metal coated structures, metal such as carbon, metal fibers, or metallic particulate deposited onto support structures;

polypyrrole;

tungsten, titanium and oxides thereof;

organometallic compounds containing elements from the group consisting of cobalt, iron, and nickel; and

transition metal complexes containing elements from the Periodic Table of Elements Groups IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB.

12. The potentiometric gas sensor of claim 5 wherein said sensing electrode is an electrode layer constructed of an electrolyte selected from the group comprising an ionic polymer and a solid state electrolyte.

13. The potentiometric gas sensor of claim 5 wherein said sensing electrode is constructed of a material from the group consisting of an ion-conducting polymer, an ion-conducting organic polymer, an ion-conductive solid state electrolyte, and a layer of fiber assemblies.

14. The potentiometric gas sensor of claim 13 wherein said layer of fiber assemblies consist of the catalytic element itself or the catalytic element affixed to a fiber assembly consisting of carbon fibers, carbon black, carbon particulates, metallic fibers, metallic particulates and mixtures thereof coated with a material from the group consisting essentially of platinum, platinum black, palladium, iridium, ruthenium, tungsten, gold, cobalt selenite, platinum/palladium alloy, palladium/rhodium alloy, gold/ruthenium alloy, and compounds containing elements from the group consisting of cobalt, iron, nickel, and transition metal complexes containing elements from the Periodic Table of elements, groups IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB.

15. The potentiometric gas sensor of claim 14 wherein said gas sensing electrode consists of:

noble metal catalysts from the group consisting of platinum, palladium, rhenium, ruthenium, gold, silver, and mixtures or alloys thereof;

carbon blacks and carbon fibers;

carbon, metal fibers, or metallic particulate deposited onto support structures;

polypyrrole;

tungsten, titanium and oxides thereof;

organometallic compounds containing elements from the group consisting of cobalt, iron, and nickel; and

transition metal complexes containing elements from the Periodic Table of Elements Groups IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB.

16. The potentiometric gas sensor of claim 5 wherein said reference electrode is selected from a group consisting of silver/silver ion, silver/silver chloride, mercury/mercury chloride, silver/silver halide, mercury/mercury halide, stable metal oxides, stable carbon oxides, and stable redox couples consisting of organic, organometallic, transition metal complexes, and a pH electrode.

17. The potentiometric gas sensor of claim 1 wherein said ion-conducting substrate is selected from the group consisting of an ion-exchange membrane, an ion-conducting polymer, an ion-conducting organic polymer, and a doped ceramic material.

18. The potentiometric gas sensor of claim 17 wherein said ion-exchange membrane is selected from the group of Nafion®

, Neosepta®

, and Raipore®

.

19. The potentiometric gas sensor of claim 18 wherein said ion-conducting polymer is selected from the group consisting of doped polyvinylchloride, polyphenyleneoxide, polyphenyleneglycol, polythiophenes, polypyrrols, polydibenzocrown ethers, polyphenylenes, substituted polyacetylenes, and combinations thereof.

20. The potentiometric gas sensor of claim 19 wherein said ion conductive organic polymer is selected from the group consisting of acid functionality, totally neutralized acid functionalities, partially neutralized acid functionalities, free acid functionality, amine functionalities, totally neutralized amine functionalities, HSO₄^-, HPO²₄^-, carboxylic acid, quaternary ammonium functionalities, and ionically doped polymers.

21. The potentiometric gas sensor of claim 1 wherein said first and second electrically conductive elements are bonded to said ion-conducting substrate.

22. The potentiometric gas sensor of claim 2 wherein said filter layer is mounted to said ion-conducting substrate to enclose said first electrically conductive element between said ion-conducting substrate and said filter layer.

25. The potentiometric gas sensor of claim 22 wherein said filter layer is a porous polymer membrane comprising a molecular sieve dispersed throughout an inert polymeric support.

29. The potentiometric gas sensor of claim 2 wherein said layer of nonporous membrane is selected from the group comprising celulose triacetate, polyesters, vinyl polymers, latex polymer, polysulfone, polyethylene, cellulose, polystyrene, polymethacrylates, polynitriles, polydienes, polyoxides, polyesters, polysiloxanes, polyamides, Nafion®

, Teflon®

, Kynar®

, polypropylene, and tetra polymers, and trifluoro polymers.

30. The potentiometric gas sensor of claim 2 wherein said chemically reactive materials are chemically impregnated substances selected from the group consisting of alumina, carbon, permanganate, silver, copper, high valent chromium, and combinations thereof.

31. The potentiometric gas sensor of claim 1 further including a sensor housing having openings therethrough encasing said first and second electrically conductive elements mounted to said ion-conducting substrate, an alarm device, and interconnecting circuitry.

32. The potentiometric gas sensor of claim 31 wherein said interconnecting circuitry is on a circuit board and said alarm device is a light and a horn.

33. The gas sensor of claim 31 wherein said interconnecting circuitry is connected to a computer.

34. The gas sensor of claim 32 further including said filter mounted within said casing between said openings and said first and second electrically conductive elements.

35. The potentiometric gas sensor of claim 2 wherein said filter material is selected from the group consisting of microporous, nanoporous, permselective, and chemically reactive material.

36. The potentiometric gas sensor of claim 35 wherein said permselective material is a polymer membrane selected from the group consisting of cationic membranes, anionic membranes, and bipolar membranes.

38. The potentiometric gas sensor of claim 35 wherein said permselective material is a polymer membrane selected from the group consisting of cationic membranes, anionic membranes, and bipolar membranes.

46. The gas sensor of claim 1 further including a smoke detector with an alarm device assembled with said ion-conducting substrate having said first and second electrically conductive elements mounted thereon and said voltage measuring circuit connected to said alarm device to activate said alarm device when a contaminant gas is sensed.

74. The multiple layer potentiometric sensor of claim 46 wherein said chemically reactive materials are chemically impregnated substances selected from the group consisting of alumina, carbon, permanganate, silver, copper, high valent chromium, and combinations thereof.

23. A potentiometric gas sensor for detecting the presence of a gas contaminant in a gas sample being monitored, said gas sensor comprising:

a first electrically conductive element which interacts with said gas contaminant present in said gas sample;

a second electrically conductive element which does not interact with said gas contaminant present in said gas sample;

an ionically conductive substrate having said first and second electrically conductive elements mounted thereon;

measuring circuitry connected to said first and second electrically conductive elements; and

a filter layer through which said gas being sampled flows prior to being exposed to said first and second electrically conductive elements, said filter layer being a material selected from the group comprising microporous, nanoporous, and non-porous membranes, and chemically reactive materials and wherein said filter layer is constructed of a polymer membrane selected from the group consisting of cationic membranes, anionic membranes, and bipolar membranes.

24. The potentiometric gas sensor of claim 23 wherein said filter layer is a cationic membrane comprised of sulfonic acid groups.

26. A potentiometric gas sensor for detecting the presence of a gas contaminant in a gas sample being monitored, said gas sensor comprising:

a first electrically conductive element which interacts with said gas contaminant present in said gas sample;

a second electrically conductive element which does not interact with said gas contaminant present in said gas sample;

an ionically conductive substrate having said first and second electrically conductive elements mounted thereon;

measuring circuitry connected to said first and second electrically conductive elements; and

a filter layer through which said gas being sampled flows prior to being exposed to said first and second electrically conductive elements, said filter layer being a material selected from the group comprising microporous, nanoporous, and non-porous membranes, and chemically reactive materials and said filter layer is mounted to said ionically conductive substrate to enclose said first electrically conductive element between said ionically conductive substrate and said filter layer and wherein said filter layer is a porous polymer membrane comprising a molecular sieve dispersed throughout an inert polymeric support and wherein said polymer membrane is a nonporous, inert polymeric support having zeolite powder dispersed throughout.

27. The potentiometric gas sensor of claim 26 wherein said zeolite powder is selected from the group consisting of zeolite W, chabazite, erionite, potassium erionite, calcium zeolite A, sodium zeolite A, potassium zeolite A, and lithium zeolite A.

28. A potentiometric gas sensor for detecting the presence of a gas contaminant in a gas sample being monitored, said gas sensor comprising:

a first electrically conductive element which interacts with said gas contaminant present in said gas sample;

a second electrically conductive element which does not interact with said gas contaminant present in said gas sample;

an ionically conductive substrate having said first and second electrically conductive elements mounted thereon;

measuring circuitry connected to said first and second electrically conductive elements; and

a filter layer through which said gas being sampled flows prior to being exposed to said first and second electrically conductive elements, said filter layer being a material selected from the group comprising microporous, nanoporous, and non-porous membranes, and chemically reactive materials, and wherein said layer of nanoporous membrane is selected from the group consisting of nanoporous alumina, polysulfone, and regenerated cellulose on a polymeric support.

37. A potentiometric gas sensor for detecting the presence of a gas contaminant in a gas sample being monitored, said gas sensor comprising:

a first electrically conductive element which interacts with said gas contaminant present in said gas sample;

a second electrically conductive element which does not interact with said gas contaminant present in said gas sample;

an ionically conductive substrate having said first and second electrically conductive elements mounted thereon;

measuring circuitry connected to said first and second electrically conductive elements; and

a filter layer through which said gas being sampled flows prior to being exposed to said first and second electrically conductive elements, said filter layer being a material selected from the group comprising microporous, nanoporous, and non-porous membranes, and chemically reactive materials and said filter material is selected from the group consisting of microporous, nanoporous, permselective, and chemically reactive material wherein said nanoporous material is a membrane selected from the group consisting of nanoporous alumina, polysulfone, and regenerated cellulose on a polymeric support.

39. A potentiometric method for sensing the presence of a gas contaminant in a gas sample being monitored comprising the steps of:

exposing an ion-conducting substrate having first and second electrically conductive elements mounted thereon with said gas sample for ionic conduction between said first and second electrically conductive elements;

measuring a first voltage signal corresponding to the difference between said first and second electrically conductive electrodes, respectively;

comparing said first voltage signal with a threshhold voltage signal; and

outputting a trigger signal indicating the presence of said contaminant gas whenever said first voltage signal is less than said threshhold voltage.

40. The method of claim 39 including the step of removing interference gases from said gas sample prior to exposing said exposing an ion-conducting substrate having first and second electrically conductive electrodes mounted thereon with said gas sample.

41. The method of claim 39 wherein the interterence gases are removed via a gas-selective barrier.

42. The method of claim 39 including the step of displaying the level of said contaminant gas on a meter activated with said trigger signal.

43. The method of claim 39 including the step of actuating an alarm with said trigger signal.

44. The method of claim 39 wherein said contaminant gas is selected from the group comprising carbon monoxide, hydrazine, H₂ S, hydrocarbons, and alcohols.

45. The method of claim 44 wherein said contaminant gas is carbon monoxide.

47. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a filter layer;

a first ion-conducting substrate for providing ionic conduction in support of the electronic conduction disposed adjacent said filter layer and having at least one gas sensing electrode mounted to an upper surface of said first ion-conducting substrate, said gas sensing electrode being disposed between said first ion-conducting substrate and said filter layer;

a second ion-conducting ionically conductive substrate for providing ionic conduction in support of the electronic conduction disposed below said first ion-conducting substrate;

at least one reference electrode disposed between a lower surface of said first ion-conducting substrate and an upper surface of said second ion-conducting substrate; and

at least one environmental variable sensing electrode mounted to a lower surface of said second ion-conducting substrate.

48. The multiple layer potentiometric sensor device of claim 47 further including a porous, inert protective layer below said lower surface of said second ion-conducting substrate to cover said environmental variable sensing electrode.

49. The multiple layer potentiometric sensor device of claim 48 wherein said filter layer is a material selected from the group consisting of microporous, nanoporous, permselective, and chemically reactive material.

50. The multiple layer potentiometric sensor device of claim 48 wherein said first and second ion-conducting substrates are selected from the group consisting of an ion-exchange membrane, an ion-conducting polymer, ion-conducting organic polymer, and doped ceramic material.

51. The multiple layer potentiometric sensor device of claim 48 wherein said gas sensing electrode has an output response to a first gas contaminant in said gas sample which is different from the output response of said reference electrode to said first gas contaminant.

52. The multiple layer potentiometric sensor device of claim 51 wherein said gas sensing electrode is constructed with a metal deposited onto a layer of material selected from the group consisting of an ion-exchange membrane, an ion-conducting polymer, an ion-conducting organic polymer, an ion-conductive electrolyte, carbon, and a layer of fiber assemblies.

53. The multiple layer potentiometric sensor device of claim 51 wherein said gas sensing electrode consists of:

noble metal catalysts from the group consisting of platinum, palladium, rhenium, ruthenium, gold, silver, and mixtures or alloys thereof;

carbon blacks and carbon fibers;

carbon, metal fibers, or metallic particulate deposited onto support structures;

polypyrrole;

tungsten, titanium and oxides thereof;

organometallic compounds containing elements from the group consisting of cobalt, iron, and nickel; and

transition metal complexes containing elements from the Periodic Table of Elements Groups IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB.

54. The multiple layer potentiometric sensor device of claim 51 wherein said gas sensing electrode is an electrode layer constructed of an electrolyte selected from the group comprising an ionic polymer and a solid state electrolyte.

55. The multiple layer potentiometric sensor device of claim 51 wherein said gas sensing electrode is a material selected from the group consisting of a deposit of metal and ion-conductive electrolyte on a layer of carbon, an electronically conductive polymer, and a layer of fiber assemblies.

56. The multiple layer potentiometric sensor device of claim 51 wherein said reference electrode is selected from a group consisting of silver/silver ion, silver/silver chloride, mercury/mercury chloride, silver/silver halide, mercury/mercury halide, stable metal oxides, stable carbon oxides, and stable redox couples consisting of organic, organometallic, transition metal complexes, and a pH electrode.

64. The multiple layer potentiometric sensor device of claim 47 further including a second gas sensing electrode which has an output response to a second gas contaminant in said gas sample which is different from the output response of said first gas sensing electrode and said reference electrode to said second gas contaminant.

65. The multiple layer potentiometric sensor device of claim 47 wherein said first gas sensing electrode is a carbon monoxide sensing electrode.

66. The multiple layer potentiometric sensor of claim 49 wherein said filter layer is constructed of a polymer membrane selected from the group consisting of cationic membranes, anionic membranes, and bipolar membranes.

67. The multiple layer potentiometric sensor at claim 66 wherein said filter layer is a cationic membrane comprised of sulfonic acid groups.

69. The multiple layer potentiometric sensor of claim 66 wherein said polymer membrane is a nonporous, inert polymeric support having zeolite powder dispersed throughout.

70. The multiple layer potentiometric sensor of claim 69 wherein said zeolite powder is selected from the group consisting of zeolite W, chabazite, erionite, potassium erionite, calcium zeolite A, sodium zeolite A, potassium zeolite A, and lithium zeolite A.

71. The multiple layer potentiometric sensor of claim 69 wherein said nonporous, inert polymeric support is a layer of material selected from the group consisting of celulose triacetate, polyesters, vinyl polymers, latex polymer polysulfone, polyethylene, cellulose, polystyrene, polymethacrylates, polynitriles, polydienes, polyoxides, polyesters, polysiloxanes, polyamides, Nafion™

, Teflon™

, Kynar™

, polypropylene, polyethylene, tetra polymers and trifluoro polymers.

73. The multiple layer potentiometric sensor of claim 49 wherein said layer of nonporous membrane is celulose triacetate, polyesters, vinyl polymers, latex polymer polysulfane, polyethylene, cellulose, polystyrene, polymethacrylates, polynitriles, polydienes, polyoxides, polyesters, polysiloxanes, polyamides, Nafion™

, Teflon™

, Kynar™

, polypropylene, polyethylene, tetra fluoro polymer and trifluoro polymer.

57. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a filter layer;

a first ionically conductive substrate disposed adjacent said filter layer and having at least one gas sensing electrode mounted to an upper surface of said ionically conductive substrate, said gas sensing electrode being disposed between said first ionically conductive substrate and said filter layer;

a second ionically conductive substrate disposed below said first ionically conductive substrate;

at least one reference electrode disposed between a lower surface of said first ionically conductive substrate and an upper surface of said second ionically conductive substrate; and

at least one environmental variable sensing electrode mounted to a lower surface of said second ionically conductive substrate; and

a porous, inert protective layer below said lower surface of said second ionically conductive substrate to cover said environmental variable sensing electrode, wherein said porous, inert protective layer is constructed of porous polypropylene or porous polyethylene.

58. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a filter layer;

a first ionically conductive substrate disposed adjacent said filter layer and having at least one gas sensing electrode mounted to an upper surface of said ionically conductive substrate, said gas sensing electrode being disposed between said first ionically conductive substrate and said filter layer;

a second ionically conductive substrate disposed below said first ionically conductive substrate;

at least one reference electrode disposed between a lower surface of said first ionically conductive substrate and an upper surface of said second ionically conductive substrate, wherein said at least one environmental variable sensing electrode is a temperature/% RH compensator electrode.

59. The multiple layer potentiometric sensor device of claim 58 wherein said temperature/% RH compensator electrode is a gas diffusion electrode.

60. The multiple layer potentiometric sensor device of claim 58 wherein said at least one environmental variable sensing electrode outputs a voltage signal proportional to changes in both temperature and % RH that is substantially equal to the voltage signal output of said gas sensing electrode in response to variations in both temperature and % RH.

61. The multiple layer potentiometric sensor device of claim 60 wherein said at least one environmental variable sensing electrode does not output a response signal in response to the presence of said gas contaminant for which gas sensing electrode outputs a response signal.

62. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a filter layer;

a first ionically conductive substrate disposed adjacent said filter layer and having at least one gas sensing electrode mounted to an upper surface of said ionically conductive substrate, said gas sensing electrode being disposed between said first ionically conductive substrate and said filter layer;

a second ionically conductive substrate disposed below said first ionically conductive substrate;

at least one reference electrode disposed between a lower surface of said first ionically conductive substrate and an upper surface of said second ionically conductive substrate; and

a second environmental variable sensing electrode which outputs signals proportional to the pressure of said gas sample.

63. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a filter layer;

a first ionically conductive substrate disposed adjacent said filter layer and having at least one gas sensing electrode mounted to an upper surface of said ionically conductive substrate, said gas sensing electrode being disposed between said first ionically conductive substrate and said filter layer;

a second ionically conductive substrate disposed below said first ionically conductive substrate;

at least one reference electrode disposed between a lower surface of said first ionically conductive substrate and an upper surface of said second ionically conductive substrate; and

a third environmental variable sensing electrode which outputs signals proportional to the temperature of said gas sample.

68. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a filter layer;

a first ionically conductive substrate disposed adjacent said filter layer and having at least one gas sensing electrode mounted to an upper surface of said ionically conductive substrate, said gas sensing electrode being disposed between said first ionically conductive substrate and said filter layer;

a second ionically conductive substrate disposed below said first ionically conductive substrate;

at least one reference electrode disposed between a lower surface of said first ionically conductive substrate and an upper surface of said second ionically conductive substrate; and

a porous, inert protective layer below said lower surface of said second ionically conductive substrate to cover said environmental variable sensing electrode; and

said filter layer is a material selected from the group consisting of microporous, nanoporous, permselective, and chemically reactive material and wherein said filter layer is constructed of a polymer membrane selected from the group consisting of cationic membranes, anionic membranes, and bipolar membranes; and

wherein said filter layer is a porous polymer membrane comprising a molecular sieve dispersed throughout an inert polymeric support.

72. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a filter layer;

a first ionically conductive substrate disposed adjacent said filter layer and having at least one gas sensing electrode mounted to an upper surface of said ionically conductive substrate, said gas sensing electrode being disposed between said first ionically conductive substrate and said filter layer;

a second ionically conductive substrate disposed below said first ionically conductive substrate;

at least one reference electrode disposed between a lower surface of said first ionically conductive substrate and an upper surface of said second ionically conductive substrate; and

a porous, inert protective layer below said lower surface of said second ionically conductive substrate to cover said environmental variable sensing electrode; and

said filter layer is a material selected from the group consisting of microporous, nanoporous, permselective, and chemically reactive material and said layer of nanoporous material is a membrane selected from the group consisting of nanoporous alumina, polysulfone, and regenerated cellulose on a polymeric support.

75. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a casing with top and bottom sections and openings through said top section;

a filter layer disposed in the interior of said casing and dividing said interior into first and second chambers wherein said first chamber includes said top section of said casing and said second chamber includes said bottom section of said casing;

an ionically conductive substrate disposed in said second chamber and having at least one gas sensing electrode mounted to an upper surface thereof;

a reference electrode mounted to a lower surface of said ionically conductive substrate whereby said ionically conductive substrate provides ionic conduction between said at least one gas sensing electrode and said reference electrode; and

at least one environmental variable sensing electrode mounted to said upper surface of said ionically conductive substrate.

76. The multiple layer potentiometric sensor device of claim 75 further including electrical contact members connected to said sensing electrode, said least one environmental variable sensing, and said reference electrode.

77. The multiple layer potentiometric sensor device of claim 75 wherein said ionically conductive substrate is selected from the group consisting of an ion-exchange membrane, an ion-conducting polymer, ion-conducting, organic polymer, and doped ceramic material.

78. The multiple layer potentiometric sensor device of claim 75 wherein said gas sensing electrode has an output response to a gas contaminant in said gas sample which is different from the output response of said reference electrode to said gas contaminant.

79. The multiple layer potentiometric sensor device of claim 78 wherein said gas sensing electrode is a carbon monoxide sensing electrode.

80. The multiple layer potentiometric sensor device of claim 75 wherein said gas sensing electrode is constructed with a metal deposited onto a layer of material selected from the group consisting of an ion-exchange membrane, an ion-conducting polymer, an ion-conducting organic polymer, an ion-conductive electrolyte, carbon, and a layer of fiber assemblies.

81. The multiple layer potentiometric sensor device of claim 75 wherein said gas sensing electrode is constructed of a material selected from a group consisting of:

noble metal catalysts from the group consisting of platinum, palladium, rhenium, ruthenium, gold, silver, and mixtures or alloys thereof;

carbon blacks and carbon fibers;

carbon, metal fibers, or metallic particulate deposited onto support structures;

polypyrrole;

tungsten, titanium and oxides thereof;

organometallic compounds containing elements from the group consisting of cobalt, iron, and nickel; and

transition metal complexes containing elements from the Periodic Table of Elements Groups IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB.

82. The multiple layer potentiometric sensor device of claim 75 wherein said gas sensing electrode is an electrode layer constructed of an electrolyte selected from the group consisting of an ionic polymer and a solid state electrolyte.

83. The multiple layer potentiometric sensor device of claim 75 wherein said gas sensing electrode is selected from the group consisting of a deposit of metal and ion-conductive electrolyte on a layer of carbon, an electronically conductive polymer, and a layer of fiber assemblies.

84. The multiple layer potentiometric sensor device of claim 75 wherein said reference electrode is selected from a group consisting of silver/silver ion, silver/silver chloride, mercury/mercury chloride, silver/silver halide, mercury/mercury halide, stable metal oxides, stable carbon oxides, and stable redox couples consisting of organic, organometallic, transition metal complexes, and a pH electrode.

90. The multiple layer potentiometric sensor device of claim 75 wherein said filter layer is a material selected from the group consisting of microporous, nanoporous, and permselective membranes, and chemically reactive material.

91. The multiple layer potentiometric sensor device of claim 90 wherein said membrane is selected from the group consisting of cationic membranes, anionic membranes, and bipolar membranes.

93. The multiple layer potentiometric sensor device of claim 91 wherein said filter layer is a porous polymer membrane comprising a molecular sieve dispersed throughout an inert polymeric support.

94. The multiple layer potentiometric sensor device of claim 91 wherein said polymer membrane is a nonporous, inert polymeric support having zeolite powder dispersed throughout.

95. The multiple layer potentiometric sensor device of claim 94 wherein said zeolite powder is selected from the group consisting of zeolite W, chabazite, erionite, potassium erionite, calcium zeolite A, sodium zeolite A, potassium zeolite A, and lithium zeolite A.

96. The multiple layer potentiometric sensor device of claim 94 wherein said nonporous, inert polymeric support is a layer of material selected from the group consisting of celulose triacetate, polyesters, vinyl polymers, latex polymer polysulfane, polyethylene, cellulose, polystyrene, polymethacrylates, polynitriles, polydienes, polyoxides, polyesters, polysiloxanes, polyamides, Nafion™

, Teflon™

, Kynar™

, polypropylene, polyethylene, tetra polymer and trifluoro polymer.

98. The multiple layer potentiometric sensor device of claim 90 wherein said layer of nonporous membrane is celulose triacetate, polyesters, vinyl polymers, latex polymer polysulfane, polyethylene, cellulose, polystyrene, polymethacrylates, polynitriles, polydienes, polyoxides, polyesters, polysiloxanes, polyamides, Nafion™

, Teflon™

, Kynar™

, polypropylene, polyethylene, tetra polymer and trifluoro polymer.

99. The multiple layer potentiometric sensor device of claim 90 wherein said chemically reactive materials are chemically impregnated substances selected from the group consisting of alumina, carbon, permanganate, silver, copper, high valent chromium, and combinations thereof.

100. The multiple layer potentiometric sensor device of claim 90 wherein said filter layer is a cup shaped support containing said chemically reactive material.

85. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a casing with top and bottom sections and openings through said top section;

a filter layer disposed in the interior of said casing and dividing said interior into first and second chambers wherein said first chamber includes said top section of said casing and said second chamber includes said bottom section of said casing;

an ionically conductive substrate disposed in said second chamber and having at least one gas sensing electrode mounted to an upper surface thereof;

a reference electrode mounted to a lower surface of said ionically conductive substrate; and

at least one environmental variable sensing electrode mounted to said upper surface of said ionically conductive substrate, said at least one environmental variable sensing electrode is a temperature/% RH compensator electrode.

86. The multiple layer potentiometric sensor device of claim 85 wherein said temperature/% RH compensator electrode is a gas diffusion electrode.

87. The multiple layer potentiometric sensor device of claim 85 wherein said at least one environmental variable sensing electrode outputs a voltage signal proportional to changes in both temperature and % RH that is substantially equal to the voltage signal output of said gas sensing electrode in response to variations in both temperature and % RH.

88. The multiple layer potentiometric sensor device of claim 87 wherein said at least one environmental variable sensing electrode does not output a response signal in response to the presence of said gas contaminant for which gas sensing electrode outputs a response signal.

89. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a casing with top and bottom sections and openings through said top section;

a filter layer disposed in the interior of said casing and dividing said interior into first and second chambers wherein said first chamber includes said top section of said casing and said second chamber includes said bottom section of said casing;

an ionically conductive substrate disposed in said second chamber and having at least one gas sensing electrode mounted to an upper surface thereof;

a reference electrode mounted to a lower surface of said ionically conductive substrate; and

at least one environmental variable sensing electrode mounted to said upper surface of said ionically conductive substrate,

said gas sensing electrode is selected from the group consisting of a deposit of metal and ion-conductive electrolyte on a layer of carbon, an electronically conductive polymer, and a layer of fiber assemblies;

said at least one environmental variable sensing electrode being constructed of the same material from which said gas sensing electrode is constructed; and

means for isolating said at least one environmental variable sensing electrode from said gas sample in said second chamber.

92. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a casing with top and bottom sections and openings through said top section;

a filter layer disposed in the interior of said casing and dividing said interior into first and second chambers wherein said first chamber includes said top section of said casing and said second chamber includes said bottom section of said casing;

an ionically conductive substrate disposed in said second chamber and having at least one gas sensing electrode mounted to an upper surface thereof;

a reference electrode mounted to a lower surface of said ionically conductive substrate; and

at least one environmental variable sensing electrode mounted to said upper surface of said ionically conductive substrate, said filter layer is a material selected from the group consisting of microporous, nanoporous and permselective membranes, and chemically reactive material, said membranes are selected from the group consisting of cationic membranes, anionic membranes, and bipolar membranes; and

wherein said filter layer is a cationic membrane comprised of sulfonic acid groups.

97. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a casing with top and bottom sections and openings through said top section;

a filter layer disposed in the interior of said casing and dividing said interior into first and second chambers wherein said first chamber includes said top section of said casing and said second chamber includes said bottom section of said casing;

an ionically conductive substrate disposed in said second chamber and having at least one gas sensing electrode mounted to an upper surface thereof;

a reference electrode mounted to a lower surface of said ionically conductive substrate; and

at least one environmental variable sensing electrode mounted to said upper surface of said ionically conductive substrate, said filter layer is a material selected from the group consisting of microporous, nanoporous, and permselective membranes, and chemically reactive material;

said layer of nanoporous membranes is a membrane selected from the group consisting of nanoporous alumina, polysulfone, and regenerated cellulose on a polymeric support.

101. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a casing with top and bottom sections and openings through said top section;

a filter layer disposed in the interior of said casing and dividing said interior into first and second chambers wherein said first chamber includes said top section of said casing and said second chamber includes said bottom section of said casing;

an ionically conductive substrate disposed in said second chamber and having at least one gas sensing electrode mounted to an upper surface thereof;

a reference electrode mounted to a lower surface of said ionically conductive substrate; and

at least one environmental variable sensing electrode mounted to said upper surface of said ionically conductive substrate, said filter layer is a material selected from the group consisting of microporous, nanoporous, and permselective membranes, and chemically reactive material; and

said filter layer is a cup shaped support containing said chemically reactive material and said cup shaped support has a meshed bottom surface and support sides extending outward from said cup support and attached to said casing to divide said casing into said first and second chambers.

102. A method for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising the steps of:

directing said gas sample across a filter layer disposed in the interior of a casing to remove any interference gas from said gas sample;

exposing an ionically conductive substrate having at least one gas sensing electrode and at least one environmental variable sensing electrode mounted to one surface thereof and a reference electrode mounted to a different surface thereof to said gas sample subsequent to the removal of said interference gas;

compensating for changes in at least one environmental variable by subtracting a function of first voltage signal output by said at least one gas sensing electrode from a second voltage signal output by said at least one environmental variable sensing electrode to generate a compensated voltage signal output;

generating a third voltage signal corresponding to the difference between said compensated voltage signal output;

comparing said third voltage signal with a reference signal; and

generating a trigger signal indicating the presence of said contaminant gas whenever said third voltage signal is less than said reference signal.

103. The method of claim 102 including the step of detecting the presence of one or more gas contaminants selected from the group consisting of carbon monoxide, hydrazine, H₂ S, hydrocarbons, and alcohols.

104. The method of claim 103 including the step of activating an alarm with said trigger signal whenever said one or more gas contaminants are detected.

105. The method of claim 103 wherein said contaminant gas is carbon monoxide.

106. The method of claim 104 including the step of generating a second voltage signal output by said at least one environmental variable sensing electrode corresponding to changes in temperature and % RH.

107. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a casing with top and bottom section and openings through said top section into an interior of said casing;

a chemical filter material dispersed throughout interior of said casing;

an ionically conductive substrate disposed in said interior and having at least one gas sensing electrode mounted to an upper surface thereof;

a reference electrode mounted to a lower surface of said ionically conductive substrate whereby said ionically conductive substrate provides ionic conduction in support of the electronic conduction between said at least one gas sensing electrode and said reference electrode; and

at least one environmental variable sensing electrode mounted to the upper surface of said ionically conductive substrate.

108. The multiple layer potentiometric sensor device of claim 107 further including electrical contact members connected to said gas sensing electrode, said least one environmental variable sensing, and said reference electrode.

109. The multiple layer potentiometric sensor device of claim 107 wherein said ionically conductive substrate is selected from the group consisting of an ion-exchange membrane, an ion-conducting polymer, ion-conducting, organic polymer, and doped ceramic material.

110. The multiple layer potentiometric sensor device of claim 107 wherein said gas sensing electrode has an output response to a gas contaminant in said gas sample which is different from the output response of said reference electrode to said gas contaminant.

111. The multiple layer potentiometric sensor device of claim 110 wherein said gas sensing electrode is a carbon monoxide sensing electrode.

112. The multiple layer potentiometric sensor device of claim 107 wherein said gas sensing electrode is constructed with a metal deposited onto a layer of material selected from the group consisting of an ion-exchange membrane, an ion-conducting polymer, an ion-conducting organic polymer, an ion-conductive electrolyte, carbon, and a layer of fiber assemblies.

113. The multiple layer potentiometric sensor device of claim 107 wherein said gas sensing electrode is constructed of a material selected from a group consisting essentially of platinum, ruthenium, tungsten, tungstenates, carbon black, carbon fibers, carbon particulates, electrically conductive polymers, metallic particulates, or mixtures thereof coated with a material from the group consisting essentially of platinum, platinum black palladium, iridium, gold, cobalt selenite, platinum/palladium alloy, platinum/ruthem alloy palladium/rhodium alloy, gold/ruthenium alloy, and organometallic compounds containing elements from the group consisting of cobalt, iron and nickel, and transition metal complexes containing elements from the Periodic Table of elements:

groups IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB.

114. The multiple layer potentiometric sensor device of claim 107 wherein said gas sensing electrode is an electrode layer constructed of an electrolyte selected from the group consisting of an ionic polymer and a solid state electrolyte.

115. The multiple layer potentiometric sensor device of claim 107 wherein said gas sensing electrode is constructed of a deposit of metal and ion-conductive electrolyte on a layer of carbon, an electronically conductive polymer, or a layer of fiber assemblies.

116. The multiple layer potentiometric sensor device of claim 107 wherein said reference electrode is selected from a group consisting essentially of silver/silver ion, silver/silver chloride, mercury/mercury chloride, silver/silver halide, mercury/mercury halide, stable metal oxides, stable carbon oxides, and stable redox couples consisting of organic, organometallic, transition metal complexes, and a pH electrode.

117. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a casing with top and bottom section and openings through said top section into an interior of said casing;

a chemical filter material dispersed throughout interior of said casing;

an ionically conductive substrate disposed in said interior and having at least one gas sensing electrode mounted to an upper surface thereof;

a reference electrode mounted to a lower surface of said ionically conductive substrate; and

at least one environmental variable sensing electrode mounted to the upper surface of said ionically conductive substrate, said at least one environmental variable sensing electrode is a temperature/% RH compensator electrode.

120. The multiple layer potentiometric sensor device of claim 117 wherein said at least one environmental variable sensing electrode does not output a response signal in response to the presence of said gas contaminant for which gas sensing electrode outputs a response signal.

121. The multiple layer potentiometric sensor device of claim 117 wherein:

said at least one environmental variable sensing electrode is constructed of the same material from which said gas sensing electrode is constructed; and

means for isolating said at least one environmental variable sensing electrode from said gas sample in said second chamber.

118. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a casing with top and bottom section and openings through said top section into an interior of said casing;

a chemical filter material dispersed throughout interior of said casing;

an ionically conductive substrate disposed in said interior and having at least one gas sensing electrode mounted to an upper surface thereof;

a reference electrode mounted to a lower surface of said ionically conductive substrate; and

at least one environmental variable sensing electrode mounted to the upper surface of said ionically conductive substrate, said temperature/% RH compensator electrode is a gas diffusion electrode.

119. A multiple layer potentiometric sensor device for detecting the presence of one or more gas contaminants in a gas sample being monitored, comprising:

a casing with top and bottom section and openings through said top section into an interior of said casing;

a chemical filter material dispersed throughout interior of said casing;

an ionically conductive substrate disposed in said interior and having at least one gas sensing electrode mounted to an upper surface thereof;

a reference electrode mounted to a lower surface of said ionically conductive substrate; and

at least one environmental variable sensing electrode mounted to the upper surface of said ionically conductive substrate, said at least one environmental variable sensing electrode outputs a voltage signal proportional to changes in both temperature and % RH that is substantially equal to the voltage signal output of said gas sensing electrode in response to variations in both temperature and % RH.