Thin film mixed potential sensors

Abstract

A mixed potential sensor for oxidizable or reducible gases and a method of making. A substrate is provided and two electrodes are formed on a first surface of the substrate, each electrode being formed of a different catalytic material selected to produce a differential voltage between the electrodes from electrochemical reactions of the gases catalyzed by the electrode materials. An electrolytic layer of an electrolyte is formed over the electrodes to cover a first portion of the electrodes from direct exposure to the gases with a second portion of the electrodes uncovered for direct exposure to the gases.

Description

STATEMENT REGARDING FEDERAL RIGHTS [0001] This invention was made with government support under Contract No. W-7405-ENG-36 awarded by the U.S. Department of Energy. The government has certain rights in the invention.FIELD OF THE INVENTION [0002] The present invention relates generally to gas sensors, and, more particularly, to mixed-potential sensors for the detection of various oxidizable and reducible gases. BACKGROUND OF THE INVENTION [0003] Mixed potential sensors are used for the detection of various oxidizable and reducible gases. Oxidizable gases include hydrogen, hydrocarbons, carbon monoxide, nitric oxide, ethanol, and the like, while reducible gases include oxygen, nitrogen dioxide, and the like. Typical sensors utilize an ionic conducting electrolyte, such as yttria stabilized-zirconia (YSZ), and thin film metal and / or metal oxide electrodes, such as platinum (Pt) and perovskite-type oxides. Multiple reduction / oxidation reactions occurring between the gas phase and the el...

AI Technical Summary

Benefits of technology

The present invention is a sensor that can detect the presence of oxidizable or reducible gases by measuring the difference in voltage between two electrodes. The sensor has a substrate with two electrodes, each made of a different material that catalyzes the reaction of a gas. An electrolyte layer is formed over the electrodes, covering one part of them and leaving the other part exposed to the gas. The technical effect of this invention is a more accurate and reliable detection of gases that can be harmful or useful in various industrial processes.

Problems solved by technology

A highly porous electrode results in better gas access and greater 3-phase interface, whereas a denser electrode leads to poorer gas access and less 3-phase interface.

One drawback of this type of arrangement is that the gas has to meander through the pores of a catalytically active material (the electrode) before reaching the 3-phase interface where the reduction and oxidation reactions occur.

Hence, the hydrocarbons (or other reducing gases) are heterogeneously oxidized at the metal (or metal oxide) electrode before they reach the 3-phase interface with the electrolyte, with a concomitant loss in sensor sensitivity and increase in response time.

While this works well for an O2 sensor and improves performance, this will not provide a mixed potential sensor.

Further, Mueller et al. provide gas access only through a porous substrate onto an electrode embedded in an electrolyte where the 3-phase interface region is not well defined.

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