Gas sensor with a diagnostic device

• US 6,200,443 B1
• Filed: 09/29/1998
• Issued: 03/13/2001
• Est. Priority Date: 09/29/1998
• Status: Expired due to Term

• Current Assignee: Dometic Sweden AB (Dometic Group AB)
• Original Assignee: Atwood Industries, Inc. (Stanley Black & Decker, Inc.)
• Inventors: Consadori, Franco, Shen, Yousheng
• Primary Examiner(s): TUNG, TA HSUNG
• Application Number:
  US09/162,594
• Time in Patent Office: 896 Days
• Field of Search: 204/421-429, 204/401
• US Class Current: 204/401
• CPC Class Codes: G01N 27/4045 for gases other than oxygen
• CPC Class Codes: G01N 27/4175 Calibrating or checking the analyser
• CPC Class Codes: G01N 33/004 CO or CO2

Abstract

A highly accurate, long life, low cost gas sensor is disclosed, particularly useful for measuring carbon monoxide and other toxic gases in an environment. The gas sensor has a first, sensing electrode and a second, counting electrode. Positioned between the first and second electrodes is an ion conducting, solid electrolyte membrane. In response to the presence of a toxic gas introduced to the first electrode, an electric signal is produced between the first electrode and the second electrode. The electric signal changes in response to changes in the concentration of the toxic gas. Detection circuitry measures the electric signal to determine the concentration of the toxic gas. An electrically conductive, hydrophobic top membrane electrically connects the first electrode to the detection circuitry while preventing liquid water from contacting the first electrode. An electrically conductive, hydrophobic bottom membrane electrically connects the second electrode to the detection circuitry. The top and bottom membranes, though hydrophobic, are preferably also microporous so as to be gas permeable, including permeable to water vapor. Preferably the top and bottom membranes are ion insulating as well. Optionally the sensor is provided with a water reservoir to maintain constant relative humidity at the ion conducting electrolyte membrane. The sensor may also have a heating element. Internal and external self-diagnostic features to ensure that the sensor is functioning normally are disclosed, as well as self-calibration features, so as to ensure sensor accuracy.

Claims

1. A gas sensor comprising, in combination:

a first electrode and a second electrode;

an ion conducting, solid electrolyte membrane positioned between the first electrode and the second electrode, wherein ions migrate through the solid electrolyte membrane in response to the presence of a reactive gas at the first electrode; and

a diagnostic device for diagnosing whether the sensor is operating properly, comprising;

A) an applied voltage source coupled to the first electrode and the second electrode;

B) a programmed processor, coupled to at least one of the electrodes and to the applied voltage source for

i. applying a predetermined applied voltage across the electrodes during at least one charging portion of at least one test period

ii. monitoring a monitored voltage across the electrodes in a discharge portion which occurs after the at least one charging portion of the test period and;

iii. generating an output error signal if the monitored voltage corresponds to a faulty condition.

2. The gas sensor of claim 1 wherein the applied voltage is of sufficiently low magnitude and duration that no significant amount of ions migrate through the solid electrolyte membrane, and the monitored voltage is a voltage differential between the first electrode and the second electrode, and the programmed processor monitors the rate of decrease of the monitored voltage.

3. The gas sensor of claim 1 wherein the applied voltage is of sufficient magnitude and duration that in a gas sensor which is operating properly a reactive chemical is generated at one of the electrodes while the power source is applied, and after the power source is removed the volatile chemical is oxidized at the one of the electrodes, generating the electric signal.

4. The gas sensor of claim 1 wherein the programmed processor prevents actuation of the diagnostic device between the first electrode and the second electrode when the gas is present at the first electrode when the reactive gas is present at the first electrode.

5. The gas sensor of claim 1 wherein the programmed processor comprises an analog to digital converter for receiving the electric signal, coupled to at least one electrode for converting an analog voltage value to a corresponding digital voltage value.

6. The gas sensor of claim 1 wherein the programmed processor compares the monitored voltage with a predetermined value range for a sensor which is functioning properly and produces the output error signal.

7. The gas sensor of claim 6 further comprising an alarm electrically connected to the output error signal for indicating that the sensor is not functioning properly.

8. A gas sensor comprising, in combination:

a first electrode and a second electrode;

an ion conducting, solid electrolyte membrane positioned between the first electrode and the second electrode, wherein ions migrate across the solid electrolyte membrane in response to the presence of a first gas sensed at the first electrode; and

a diagnostic device for diagnosing whether the sensor is operating properly, comprising;

A) an external source of a second, reactive gas different from the fist gas which when introduced to the first electrode generates an electric signal between the first electrode and the second electrode;

B) a programmed processor, coupled to at least one of the electrodes and the external source of the second, reactive gas

i. sending a control signal to the external source at a predetermined interval to release the second, reactive gas to the first electrode, and

ii. monitoring a monitored voltage across the electrodes after the release of the second, reactive gas to the first electrode.

9. The gas sensor of claim 8 wherein the second, reactive gas is an alcohol.

10. The gas sensor of claim 8 wherein the second, reactive gas is hydrogen.

11. The gas sensor of claim 8 wherein the second, reactive gas is ozone.

12. The gas sensor of claim 8 wherein the external source has a release valve which opens and closes in response to a control signal from the programmed processor, permitting intermittent release of the second, reactive gas to the first electrode.

13. The gas sensor of claim 8 wherein the programmed processor comprises an analog to digital converter for receiving the electric signal, coupled to at least one electrode for converting an analog voltage value to a corresponding digital voltage value.

14. A gas sensor comprising, in combination:

a first electrode and a second electrode;

an ion conducting, solid electrolyte membrane positioned between the first electrode and the second electrode, wherein ions migrate across the solid electrolyte membrane in response to the presence of a first gas sensed at the first electrode; and

calibration means for calibrating the sensor, comprising

A) an external source of a reactive gas which when introduced to the first electrode generates an electric signal between the first electrode and the second electrode,

B) a programmed processor, coupled to at least one of the elects and external source of the reactive gas

i. sending a control signal to the external source at a predetermined interval to release a controlled amount of the reactive gas to the first electrode,

ii. monitoring a monitored voltage across the elect after the release of the reactive gas to the first electrode, and

iii. comparing the monitored voltage with a predetermined value range for a sensor which is functioning properly and produces an output which compensates for any difference between the electric signal and a known electric signal;

wherein the programmed processor prevents release of the reactive gas to the first electrode when a measurable amount of the first gas is present at the first electrode.