Robust chemiresistor sensor

• US 7,112,304 B2
• Filed: 04/11/2003
• Issued: 09/26/2006
• Est. Priority Date: 04/11/2003
• Status: Active Grant

• Current Assignee: Therm-O-Disc Incorporated (Emerson Electric Company)
• Original Assignee: Therm-O-Disc Incorporated (Emerson Electric Company)
• Inventors: Khadkikar, Prasad S., Sterken, Robert, Volz, Charles L., Blok, Edward J., Donnelly, Donald E., Starling, Jared
• Primary Examiner(s): Warden, Jill
• Assistant Examiner(s): SINES, BRIAN J
• Application Number:
  US10/412,602
• Publication Number:
  US 20040200722A1
• Time in Patent Office: 1,264 Days
• Field of Search: 422/50, 422/56, 422/57, 422/58, 422/68.1, 422/69, 422/82.01, 422/82.02, 422/82.03, 422/82.04, 422/83, 422/88, 422/97, 422/98, 73/10.1, 73/10.2, 73/232, 73/530.1, 438/14, 438/17, 438/48, 438/49, 29/250.1, 295/92, 295/921
• US Class Current: 422/83
• CPC Class Codes: G01N 27/125 Composition of the body, e.g. the composition of its sensitive layer
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

A chemiresistor sensor probe for detecting target analytes. The probe includes a body having a first control surface and a second control surface recessed within the first. A sensor film comprises numerous conductive particles disposed upon the second surface. The film swells upon absorbing one or more analytes for which it has an affinity, thus causing the conductive particles to become more dispersed and increasing the resistance between the particles. The thickness of the film is equal to the distance between the first surface and the second surface, thus permitting the thickness to be controlled by varying the distance between the control surfaces. The robustness of the sensor probe is enhanced by placing a porous or mesh electrode along with, or in place of, a chemical binding agent between the film and the terminals. The robustness is also improved by placing a diode in series with the sensor circuit.

Claims

1. A chemiresistor sensor probe for detecting the presence of one or more target analytes in the atmosphere of an ambient environment, the probe comprising:

a body comprising a sensing portion and a terminal portion;

a sensor film located on said sensing portion; and

first and second terminals disposed within said body, each of said first and second terminals extending from said sensing portion to the terminal portion and protruding from said body; and

conductive interlocking portions, one each disposed between each of said first and second terminals and said sensor film, each said interlocking portion in direct contact with said sensor film and a respective one of said first and second terminals.

2. The chemiresistor sensor probe of claim 1, further comprising a cap attached to said body and covering said sensor film, said cap comprising at least one aperture that permits the atmosphere of the ambient environment to pass through the cap.

3. The chemiresistor sensor probe of claim 1, wherein at least one of said conductive interlocking portions comprise a conductive plate.

4. The chemiresistor sensor probe of claim 3, wherein said conductive plate comprises a mesh surface.

5. The chemiresistor sensor probe of claim 1, further comprising a chemical bond between at least one of said first and second terminals and said sensor film.

6. The chemiresistor sensor probe of claim 1, further comprising at least one aperture within each of said first and second terminals for receipt of a positioning rod for positioning said terminals within said body during manufacturing.

7. The chemiresistor sensor probe of claim 1, wherein said probe body comprises of a molded polymer.

8. The chemiresistor sensor probe of claim 1, wherein said sensor film comprises a crosslinked, polymeric matrix.

9. The chemiresistor sensor probe of claim 1, further comprising a sensor circuit having a diode to prevent bypass leakage from negatively affecting the performance of said sensor probe.

10. The chemiresistor sensor probe of claim 1, further comprising:

a plurality of conductive materials disposed within said sensor film, said conductive materials becoming more dispersed within said film as said film swells upon absorbing said analytes, thus increasing a resistance of said film.

11. The chemiresistor sensor probe of claim 1, wherein said sensor film is first applied to a second control surface of said sensing portion that is recessed beneath a first control surface in excess with a portion of said film extending beyond said first control surface being subsequently removed such that said film has a thickness equal to a distance that said second control surface is recessed beneath said first control surface.

12. The chemiresistor sensor probe of claim 1, further comprising:

a sensor circuit coupled with said sensor probe, said sensor circuit to prevent bypass leakage from negatively affecting performance of said sensor probe.

13. The chemiresistor sensor probe of claim 1, further comprising a control unit in communication with each of said first terminal and said second terminal to monitor electrical properties of said sensor film, said control unit is operable to generate a first signal representing the presence or absence of the analytes.

14. The chemiresistor sensor probe of claim 13, further comprising a user interface in communication with said control unit, said user interface operable to receive said first signal and generate a second signal representing the presence or absence of the analytes.

15. A chemiresistor sensor probe for detecting the presence of one or more target analytes in the atmosphere of an ambient environment, the probe comprising:

a molded body comprising a sensing region and a bottom surface opposite of said sensing region;

a sensor film comprising a cross-linked polymeric matrix located in said sensing region;

first and second terminals disposed within said body, each of said first and second terminals extending from said sensing region through said bottom surface so as to protrude from said body, each of said first and second terminals comprising an interlocking member disposed between and in direct contact with said sensor film and a respective one of said first and second terminals; and

a molded cap attached to said body and covering said sensor film, said cap comprising at least one aperture which permits the atmosphere of the ambient environment to pass through the cap.

16. The chemiresistor sensor probe of claim 15, wherein at least one of said conductive interlocking members comprise a conductive plate.

17. The chemiresistor sensor probe of claim 16, wherein said conductive plate comprises a mesh surface.

18. The chemiresistor sensor probe of claim 15, further comprising a chemical bond between at least one of said first and second terminals and said sensor film.

19. The chemiresistor sensor probe of claim 15, wherein said sensor film is first applied to a second control surface of said sensing region that is recessed beneath a first control surface in excess with a portion of said film extending beyond said first control surface being subsequently removed such that said film has a thickness equal to a distance that said second control surface is recessed beneath said first control surface.

20. The chemiresistor sensor probe of claim 15, further comprising:

a sensor circuit coupled with said sensor probe, said sensor circuit to prevent bypass leakage from negatively affecting performance of said sensor probe.

21. The chemiresistor sensor probe of claim 15, further comprising a control unit in communication with each of said first terminal and said second terminal to monitor electrical properties of said sensor film, said control unit is operable to generate a first signal representing the presence or absence of the analytes.

22. The chemiresistor sensor probe of claim 21, further comprising a user interface in communication with said control unit, said user interface operable to receive said first signal and generate a second signal representing the presence or absence of the analytes.

23. A chemiresistor sensor probe for detecting the presence of one or more target analytes comprising:

a probe body;

a sensor film that absorbs the target analytes when the analytes are present mounted at an exterior surface of said probe body; and

a first and a second terminal each having an interlocking device in direct contact with said sensor film.

24. The chemiresistor sensor probe of claim 23, further comprising a cap attached to said body and covering said sensor film, said cap comprising at least one aperture that permits the atmosphere of the ambient environment to pass through the cap.

25. The chemiresistor sensor probe of claim 23, wherein said interlocking device comprises a conductive plate.

26. The chemiresistor sensor probe of claim 25, wherein said conductive plate comprises a mesh surface.

27. The chemiresistor sensor probe of claim 23, further comprising a chemical bond between at least one of said first and second terminals and said sensor film.

28. The chemiresistor sensor probe of claim 23, wherein said probe body comprises a molded polymer.

29. The chemiresistor sensor probe of claim 23, wherein said sensor film comprises a crosslinked, polymeric matrix.

30. The chemiresistor sensor probe of claim 23, wherein said sensor film is first applied to a second control surface of said probe body that is recessed beneath a first control surface in excess with a portion of said film extending beyond said first control surface being subsequently removed such that said film has a thickness equal to a distance that said second control surface is recessed beneath said first control surface.

31. The chemiresistor sensor probe of claim 23, further comprising a control unit in communication with each of said first terminal and said second terminal to monitor electrical properties of said sensor film, said control unit is operable to generate a first signal representing the presence or absence of the analytes.

32. The chemiresistor sensor probe of claim 31, further comprising a user interface in communication with said control unit, said user interface operable to receive said first signal and generate a second signal representing the presence or absence of the analytes.

33. A chemiresistor sensor system for detecting the presence of one or more analytes comprising:

a probe including a first electrode and a second electrode each having a conductive interlocking device in direct contact with a sensor film, said probe operable to generate a first output indicative of the absence or presence of the analytes in the environment;

a control unit in electrical communication with said first and second electrodes, said control unit operable to receive said first output from said probe and generate a signal corresponding to said first output; and

a user interface in communication with said control unit, said user interface operable to receive said signal from said control unit and generate a second output corresponding to the absence or presence of analytes in the environment.

34. A chemiresistor sensor probe for detecting the presence of one or more target analytes comprising:

a probe body;

a sensor film including a crosslinked polymeric matrix mounted at an exterior surface of said probe body; and

a first and a second terminal each having a conductive interlocking device in direct contact with said sensor film, said first and second terminals extending from said sensor film through said probe body and protruding from said probe body.

35. The chemiresistor sensor probe of claim 34, further comprising a control unit in communication with each of said first terminal and said second terminal to monitor electrical properties of said sensor film, said control unit is operable to generate a first signal representing the presence or absence of the analytes.

36. The chemiresistor sensor probe of claim 35, further comprising a user interface in communication with said control unit, said user interface operable to receive said first signal and generate a second signal representing the presence or absence of the analytes.

37. A chemiresistor sensor probe for detecting the presence of one or more analytes comprising:

a probe body;

a sensor film including a crosslinked polymeric matrix mounted at an exterior surface of said probe body; and

a first terminal having a first conductive mesh plate mounted directly to said first terminal and a second terminal having a second conductive mesh plate mounted directly to said second terminal, said first and said second mesh plates each in direct contact with said sensor film.

38. The chemiresistor sensor probe of claim 37, further comprising a control unit in communication with each of said first terminal and said second terminal to monitor electrical properties of said sensor film, said control unit is operable to generate a first signal representing the presence or absence of the analytes.

39. The chemiresistor sensor probe of claim 38, further comprising a user interface in communication with said control unit, said user interface operable to receive said first signal and generate a second signal representing the presence or absence of the analytes.