Electrochemical sensor having nonporous working electrode

• US 7,736,479 B2
• Filed: 05/09/2005
• Issued: 06/15/2010
• Est. Priority Date: 10/22/2001
• Status: Expired due to Fees

• Current Assignee: PerkinElmer LAS, Inc. (Perkinelmer Incorporated)
• Original Assignee: PerkinElmer LAS, Inc. (Perkinelmer Incorporated)
• Inventors: Dalmia, Avinash, Prohaska, Otto J.
• Primary Examiner(s): Olsen; Kaj K
• Application Number:
  US11/124,659
• Publication Number:
  US 20050194252A1
• Time in Patent Office: 1,863 Days
• Field of Search: 204421-429
• US Class Current: 204/424
• CPC Class Codes: G01N 27/4045 for gases other than oxygen
• CPC Class Codes: G01N 27/4074 for detection of gases other than oxygen

Abstract

The invention relates to an electrochemical gas sensor having a substrate, substrate surface for depositing electrodes thereon, counter and sensing electrodes for measuring current flow, an electrolyte for providing an electrical connection between the electrodes, and an electrode surface having minimal porosity, pore size, and thickness for deterring flooding.

Claims

1. An electrochemical gas sensor, comprising:

a substrate having a surface;

a first electrode deposited on said surface;

a second electrode spaced apart from said first electrode and deposited on said surface for detecting a gas, said second electrode having a porosity of less than 5%, a pore size less than 0.12 micrometers at said pore size'"'"'s greatest measurement, and a thickness less than 0.2 micrometers for controlling flooding;

an electrolytic material in electrical contact with said first electrode and said second electrode for carrying a flow of current; and

,

a reservoir containing an acidic solution.

2. The electrochemical gas sensor of claim 1, wherein said porosity is less than 2%.

3. The electrochemical sensor of claim 1, wherein said pore size is less than 0.05 micrometers at said pore size'"'"'s greatest measurement.

4. The electrochemical gas sensor of claim 1, wherein said porosity is less than 1%.

5. The electrochemical gas sensor of claim 1, wherein said pore size is less than 0.01 micrometers at said pore size'"'"'s greatest measurement.

6. The electrochemical gas sensor of claim 1, wherein said thickness is less than 0.1 micrometers for deterring flooding.

7. The electrochemical gas sensor of claim 1, wherein said second electrode has negligible porosity.

8. The electrochemical gas sensor of claim 1, wherein said second electrode is nonporous.

9. The electrochemical gas sensor of claim 1, wherein said first electrode is sputter coated.

10. The electrochemical gas sensor of claim 1, wherein said first electrode is vapor deposited.

11. The electrochemical gas sensor of claim 1, wherein said second electrode is sputter coated.

12. The electrochemical gas sensor of claim 1, wherein said second electrode is vapor deposited.

13. The electrochemical gas sensor of claim 1, further including an acidic solution for hydrating said electrolyte.

14. The electrochemical gas sensor of claim 1, wherein each pore of said second electrode is less than 0.12 micrometers at its greatest measurement.

15. The electrochemical gas sensor of claim 1, wherein said substrate has a pore less than 0.05 micrometers at its greatest measurement.

16. The electrochemical gas sensor of claim 1, wherein said substrate has a pore less than 0.01 micrometers at its greatest measurement.

17. The electrochemical gas sensor of claim 1, wherein said surface of said substrate has negligible porosity.

18. The electrochemical gas sensor of claim 1, wherein said surface of said substrate is generally flat.

19. The electrochemical gas sensor of claim 1, wherein said surface of said substrate has a porosity of less than 5%.

20. The electrochemical gas sensor of claim 1, wherein said surface of said substrate has a porosity of less than 2%.

21. The electrochemical gas sensor of claim 1, wherein said surface of said substrate has a porosity of less than 1%.

22. The electrochemical gas sensor of claim 1, wherein said electrolytic material includes:

an acidic solution for hydrating said electrolyte.

23. The electrochemical gas sensor of claim 22, wherein said acidic solution is 30% acidic.

24. The electrochemical gas sensor of claim 22, wherein said acidic solution is 50% acidic.

25. An electrochemical gas sensor, comprising:

a substrate having a surface;

a first electrode deposited on said surface;

a second electrode spaced apart from said first electrode and deposited on said surface for detecting a gas, said second electrode having a porosity of less than 5%, a pore size greater than 0 micrometer and less than 0.12 micrometer, and a thickness less than 1 micrometer for controlling flooding;

an electrolytic material in electrical contact with said first electrode and said second electrode for carrying a flow of current; and

a reservoir containing an acidic solution.

26. The electrochemical gas sensor of claim 25, wherein said pore size is greater than 0 micrometer and less than 0.05 micrometer at said pore size'"'"'s greatest measurement.

27. The electrochemical gas sensor of claim 25, wherein said pore size is greater than 0 micrometer and less than 0.01 micrometer at said pore size'"'"'s greatest measurement.