Gas sensor with dual electrolytes

• US 6,080,294 A
• Filed: 07/15/1998
• Issued: 06/27/2000
• Est. Priority Date: 07/15/1998
• Status: Expired due to Fees

• Current Assignee: Dura Operating Corporation (Dura Automotive Systems)
• Original Assignee: Atwood Industries, Inc. (Stanley Black & Decker, Inc.)
• Inventors: Consadori, Franco, Shen, Yousheng
• Primary Examiner(s): Tung, T.
• Application Number:
  US09/116,121
• Time in Patent Office: 713 Days
• Field of Search: 204/421-429, 204/415, 204/431, 204/432
• US Class Current: 204/415
• CPC Class Codes: G01N 27/404 Cells with anode, cathode and cell electrolyte on the same side of a permeable membrane which separates them from the sample fluid , e.g. Clark-type oxygen sensors

Abstract

A highly accurate, long life, low cost gas sensor is disclosed, particularly useful for measuring oxygen in an environment. The gas sensor has a first, sensing electrode and a second, counting electrode. Dual electrolytes are electrically serially connected between the first and second electrodes. One of the electrolytes is an ion conducting solid electrolyte, the second is a liquid electrolyte. In response to an electric current an electrical characteristic is produced, and the electrical characteristic changes in response to changes in the concentration of a gas such as oxygen introduced at the first, sensing electrode. The solid electrolyte can be a perfluorinated polymer which advantageously controls the rate of the electrochemical reaction to give the sensor a long life without need for continuous recalibration. A dense liquid impermeable membrane may be positioned over the first electrode so that only gas reaches the first electrode and all gas that reaches the first electrode passes through the membrane. Advantageously, the solid electrolyte isolates the liquid electrolyte from the first, sensing electrode. The liquid electrolyte may comprise an acidic solution, a basic solution or a salt solution.

Claims

1. A gas sensor for measurement of a gas in an environment comprising, in combination:

a first electrode;

a membrane permeable to the gas and impermeable to water vapor, positioned between the environment and the first electrode;

a second electrode;

a solid electrolyte positioned between the first electrode and the second electrode;

a liquid electrolyte isolated from the gas to be measured, positioned between the first electrode and the second electrode, electrically serially connected to the solid electrolyte, and cooperating with the solid electrolyte in response to an electric current to produce a voltage between the first electrode and the second electrode, wherein the voltage changes in response to changes in the concentration of the gas wherein the second electrode is in direct contact with the liquid electrolyte; and

means for electrical measurement of the voltage electrically connected to the first electrode and the second electrode.

2. The gas sensor of claim 1 wherein the solid electrolyte is a cationic conductive membrane, substantially composed of a solid, perfluorinated polymer.

3. The gas sensor of claim 1 wherein the first electrode is a metal coating applied to a surface of the solid electrolyte.

4. The gas sensor of claim 1 wherein the first electrode comprises a metal selected from the group of gold, platinum and palladium.

5. The gas sensor of claim 1 wherein the means for electrical measurement comprises a voltage meter which measures potential difference between the first electrode and the second electrode.

6. The gas sensor of claim 1 wherein the liquid electrolyte comprises an aqueous solution of an organic acid.

7. The gas sensor of claim 6 wherein the organic acid is acetic acid, the liquid electrolyte further comprises an aqueous solution of sodium acetate and lead acetate, and the solid electrolyte conducts hydrogen ions to the first electrode.

8. The gas sensor of claim 1 wherein the liquid electrolyte comprises an aqueous solution of a salt.

9. The gas sensor of claim 8 wherein the salt is sodium chloride and the solid electrolyte conducts hydroxyl ions to the first electrode.

10. The gas sensor of claim 1 wherein the liquid electrolyte comprises an aqueous solution of a base.

11. The gas sensor of claim 10 wherein the base is potassium hydroxide and the solid electrolyte conducts hydroxyl ions to the first electrode.

12. The gas sensor of claim 1 further comprising a gas permeable, liquid impermeable solid polymer membrane positioned between the solid electrolyte and the environment so that only gas from the environment penetrates the membrane to reach the solid electrolyte.

13. The gas sensor of claim 12 wherein the solid polymer membrane comprises a dense polytetrafluoroethlyene film.

14. The gas sensor of claim 1 wherein the second electrode comprises lead and is positioned in electrical contact with the liquid electrolyte.

15. The gas sensor of claim 1 further comprising:

a housing for receiving the liquid electrolyte and the solid electrolyte;

a top cover and a bottom spacer, wherein the top cover is positioned between the environment and the solid electrolyte, and the bottom spacer is positioned between the solid electrolyte and the liquid electrolyte.

16. The gas sensor of claim 15 wherein the bottom spacer is positioned on a ledge extending from the housing and supports the solid electrolyte, and the bottom spacer has a plurality of openings which permit the liquid electrolyte to contact the solid electrolyte.

17. The gas sensor of claim 1 wherein a reduction reaction occurs at the first electrode and an oxidation reaction occurs at the second electrode.

18. An oxygen sensor comprising, in combination:

a solid polymer membrane permeable to oxygen and impermeable to water vapor;

a solid polymer electrolyte having a top surface and a bottom surface and being capable of conducting ions between the top surface and the bottom surface;

a liquid electrolyte isolated from the gas to be measured, electrically connected to the solid polymer electrolyte;

a metal in direct contact with the liquid electrolyte, wherein in response to electrical current the metal is oxidized in an oxidation reaction; and

an electrically conductive metal film in electrical connection with the top surface of the solid polymer electrolyte and separated from the liquid electrolyte by the solid electrolyte;

wherein oxygen passes through the polymer membrane, and in response to an electric current ions are conducted through the solid polymer electrolyte to react with the oxygen in a reduction reaction near the top surface of the solid polymer electrolyte.

19. The oxygen sensor of claim 18 wherein the metal is selected from the group consisting of lead and cadmium.

20. The oxygen sensor of claim 18 further comprising a spacer having a plurality of openings allowing the liquid electrolyte to contact the solid electrolyte, wherein the metal is positioned adjacent the spacer.

21. The oxygen sensor of claim 18 wherein the solid polymer membrane comprises dense polytetrafluoroethylene, the solid electrolyte comprises a thin membrane of a perfluorosulfonate ionomer, and the electrically conductive metal film is gold.

22. A sensor for sensing oxygen in an environment comprising, in combination:

a first electrode;

a polymer membrane permeable to oxygen and impermeable to water vapor, positioned between the environment and the first electrode;

a second electrode, wherein in response to an electric current a voltage is produced between the first electrode and the second electrode which is proportional to the concentration of oxygen sensed at the first electrode;

a first electrolyte and a second electrolyte, wherein the first electrolyte is in direct contact with the second electrolyte such that the first electrolyte isolates the first electrode from the second electrolyte, and the second electrolyte is isolated from the oxygen to be sensed and the second electrode is in direct contact with the second electrolyte.

23. The sensor of claim 22 wherein in response to an electric current the oxygen reacts in a reduction reaction at the first electrode.

24. The sensor of claim 23 wherein the first electrolyte is a solid electrolyte capable of conducting ions, and the ions react with oxygen in the reduction reaction.

25. The sensor of claim 24 wherein the ions are hydrogen ions and the second electrolyte is a liquid electrolyte comprising an aqueous solution of an organic acid.

26. The sensor of claim 24 wherein the ions are hydroxyl ions and the second electrolyte is a liquid electrolyte comprising an aqueous solution of one of a base and a salt.

27. The sensor of claim 23 wherein the rate of the reduction reaction at the first electrode is proportional to the concentration of oxygen sensed at the first electrode.

28. The sensor of claim 22 wherein an oxidation reaction occurs near a boundary between the second electrode and the second electrolyte generating electrons.

29. The sensor of claim 28 wherein the second electrode is an anode comprising lead which in the oxidation reaction is oxidized to form lead oxide.

30. The oxygen sensor of claim 22 wherein the second electrolyte is a liquid electrolyte and further comprising a sponge positioned in the liquid electrolyte, in contact with the first electrolyte.