Oxygen sensors

• US 8,252,158 B2
• Filed: 10/23/2007
• Issued: 08/28/2012
• Est. Priority Date: 11/01/2006
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Chapples, John, McLeod, Ian, Williamson, Martin, Tillotson, John Anthony
• Primary Examiner(s): Olsen, Kaj K
• Assistant Examiner(s): LEONG, SUSAN DANG
• Application Number:
  US11/877,331
• Publication Number:
  US 20080202929A1
• Time in Patent Office: 1,771 Days
• Field of Search: 204/400, 204/415, 204408-409, 204418-419, 204/424, 204/432, 205/775, 205/782.5, 205/783, 205784-7855
• US Class Current: 204/408
• 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

An electrochemical oxygen sensor includes a micro-porous plastic membrane supported on a sealing disk and located between a gas inflow port and the sensor'"'"'s electrolyte. The membrane and disk minimize thermal shock effects due to using the sensor at a first location, at a first temperature, and then moving it to a second location at a different temperature.

Claims

1. An electrochemical gas sensor comprising:

a body having first and second chambers located inside the body separated by an opening that is also located inside the body;

a working electrode disposed within one of the chambers; and

a sealing member disposed over the opening between the first and second chambers, the sealing member, in turn, having at least one opening therethrough and an overlying micro-porous membrane carried therein to minimize temperature based shocks, said micro-porous membrane allowing electrolyte ions to pass through the micro-porous membrane and preventing the bulk transport of gas and exchange of air between the first and second chambers, said micro-porous membrane holding liquid in the pores of the micro-porous membrane by surface tension and capillary action and wherein pressure must be applied across the micro-porous membrane between the first and second chambers to overcome the surface tension and the capillary action before gas is able to cross the sealing member between the first and second chambers, the micro-porous membrane having a bubble point pressure of at least 0.13 bar.

2. An electrochemical gas sensor as in claim 1 wherein the working electrode further comprises at least one of a sensing electrode and a counter electrode.

3. An electrochemical gas sensor as in claim 1 where the micro-porous membrane is positioned in the sensor between a counter electrode and a gas inflow port.

4. An electrochemical gas sensor as in claim 3 which includes a compressible gasket which carries the micro-porous membrane.

5. An electrochemical gas sensor as in claim 1 which includes a compressible foam adhesive gasket which carries the membrane.

6. An electrochemical gas sensor comprising a hollow housing having first and second chambers, at least one of which carries at least one electrode and which includes an inwardly extending, annular support surface located inside the hollow housing between the first and second chambers for a sealing member, a gasket and a micro-porous membrane, the micro-porous membrane allowing electrolyte ions to pass through the micro-porous membrane between the first and second chambers and preventing the bulk transport of gas and exchange of air between the first and second chambers, said micro-porous membrane holding liquid in the pores of the micro-porous membrane by surface tension and capillary action and wherein pressure must be applied across the micro-porous membrane to overcome the surface tension and the capillary action before gas is able to cross the micro-porous membrane, the micro-porous membrane having a bubble point pressure of at least 0.13 bar.

7. An electrochemical gas sensor as in claim 6 where the gasket carries the micro-porous membrane.

8. An electrochemical sensor as in claim 7 with the sealing member comprising a generally planar structure fixedly attached to the hollow housing.

9. An electrochemical gas sensor as in claim 6 where the housing carries the sealing member, the gasket and the membrane in a multi-layer, stacked configuration.

10. An electrochemical gas sensor as in claim 9 where the housing is closed with a cover with a gas inflow port, the cover being adjacent to the micro-porous membrane, the sealing member being adjacent to an internal region in the housing and to an electrode.

11. A portable oxygen sensor which comprises a hollow housing having first and second chambers;

the housing carrying at least sensing and counter electrodes;

a body of electrolyte in contact with one of the electrodes;

the housing defining a gas inflow port; and

a micro-porous planar membrane located within an interior of the hollow housing closing the interior of the housing between the first and second chambers and between the inflow port and a counter electrode to regulate an inflow of ambient gas, said micro-porous membrane allowing electrolyte ions to pass through the micro-porous membrane and preventing the exchange of air between the first and second chambers, the micro-porous membrane holding liquid in the pores of the micro-porous membrane by surface tension and capillary action and wherein pressure must be applied across the micro-porous membrane to overcome the surface tension and the capillary action before gas is able to cross the micro-porous membrane, the micro-porous membrane has a bubble point pressure of at least 0.13 bar.

12. An oxygen sensor as in claim 11 which includes a compressible gasket which carries the micro-porous membrane.

13. An oxygen sensor as in claim 12 wherein the housing carries an internal support member for the gasket, the support member contributing to a gas tight seal between the inflow port and an internal region of the housing.

14. An oxygen sensor as in claim 13 where the electrolyte is adjacent to the support member and in the internal region of the housing.

15. An oxygen sensor as in claim 14 where the support member includes an annular plastic element to which the gasket can be attached where the annular element can be sealed to a portion of the housing adjacent to the internal region.

16. An oxygen sensor as in claim 13 where the support member is one of perforated, or, permeable to a selected electrolyte carried in the housing.

17. An oxygen sensor as in claim 16 where the support member comprises one of an annular disk, or a disk exhibiting a plurality of spaced apart openings therethrough.