Sensor for detecting gas

Abstract

A sensor for detecting a gas is disclosed. The sensor includes a housing and an electrolyte contained in the housing. The electrolyte includes manganese dichloride (MnCl2) and lithium chloride (LiCl), potassium chloride (KCl), sodium chloride (NaCl), or a combination thereof. Further, the sensing electrode is housed within the housing and in contact with the electrolyte within the housing. The sensing electrode further includes a first layer configured to prevent electrolyte permeation through the first layer and to allow gas permeation through the first layer, and a second layer including carbon paper and MnCl2.

Description

Technical Field

[0001] Exemplary embodiments of the present disclosure relate generally to a sensor, and more particularly to a sensor for detecting gas. Background Art

[0002] Gas sensors are used in various industrial applications to detect gas concentration levels within an environment. Typically, gas sensors are designed to operate in environments with low gas concentration levels. However, operating in environments with persistently high gas concentrations presents challenges. Furthermore, continuous exposure of gas sensors to elevated gas levels often leads to sensor saturation and reduced sensitivity. Due to this reduced sensitivity, gas sensors become unable to detect even small changes in gas concentration levels. Furthermore, in environments with low recovery rates, gas sensors struggle to return to ambient conditions after exposure to high gas concentration levels.

[0003] Applicants have identified numerous deficiencies and problems and, through applied effort, ingenuity, and innovation, have addressed many of these identified problems by developing solutions included in the embodiments of the present disclosure, many examples of which are described in detail herein. Summary of the Invention

[0004] The following presents a simplified summary to provide a basic understanding of some aspects of the present disclosure. This summary is not an extensive overview and is neither intended to identify key or important elements nor to delineate the scope of these elements. Its purpose is to give some ideas of the described features in a simplified form as a prelude to the more detailed description that will be given later.

[0005] In an exemplary embodiment, a sensor is disclosed. The sensor includes a housing and an electrolyte contained in the housing. The electrolyte includes manganese dichloride (MnCl2) and lithium chloride (LiCl), potassium chloride (KCl), sodium chloride (NaCl), or a combination thereof. Furthermore, a sensing electrode is contained within the housing and contacts the electrolyte within the housing. Furthermore, the sensing electrode includes a first layer and a second layer, the first layer being configured to prevent the electrolyte from permeating through the first layer and allowing gas to permeate through the first layer, and the second layer including carbon paper and MnCl2.

[0006] In some embodiments, the housing includes a top cover. In some embodiments, the sensing electrode is housed within the housing such that the sensing electrode contacts the top cover of the housing. In some embodiments, the contact between the sensing electrode and the top cover of the housing helps minimize the contact area between the second layer of the sensing electrode and gas entering the housing.

[0007] In some embodiments, MnCl2 corresponds to a high concentration of a mixed solution of divalent manganese ions. In some embodiments, the mixed solution of divalent manganese ions is in the range of 0.04-0.15 g / mL.

[0008] In some embodiments, the sensor further comprises a reference electrode and a counter electrode. In addition, the reference electrode is sandwiched between the sensing electrode and the counter electrode.

[0009] In some embodiments, the reference electrode and the counter electrode comprise a mixture of platinum (Pt) / ruthenium (Ru) powder and a hydrophobic binder. In some embodiments, the sensing electrode, the reference electrode, and the counter electrode are separated by a plurality of separators. In some embodiments, the plurality of separators are configured to provide electrical insulation between the sensing electrode, the reference electrode, and the counter electrode. In some embodiments, a plurality of connector pins are electrically coupled to the sensing electrode, the reference electrode, and the counter electrode via one or more connecting wires. In some embodiments, the one or more connecting wires are made of platinum or gold and are configured to supply the potential generated by the sensing electrode, the reference electrode, and the counter electrode to the plurality of connector pins.

[0010] In some embodiments, the housing is machined to have at least one gas inlet. The at least one gas inlet is configured to receive gas within the housing. The at least one gas inlet defines a diameter of 0.5-15 mm.

[0011] In some embodiments, the electrolyte comprises MnCl2 and LiCl. Furthermore, the ratio between the volume of LiCl and the volume of MnCl2 within the electrolyte is at least 10:1 and at most 1:10. In some embodiments, the housing defines an inner cavity. Furthermore, the electrolyte fills the inner cavity such that the volume of air within the inner cavity is less than 10% of the volume of the inner cavity.

[0012] In an exemplary embodiment, a method is disclosed. The method includes housing an electrolyte within a housing. The electrolyte includes manganese dichloride (MnCl2) and lithium chloride (LiCl), potassium chloride (KCl), sodium chloride (NaCl), or a combination thereof. Thereafter, the method includes housing a sensing electrode within the housing and contacting the electrolyte within the housing. The sensing electrode includes a first layer and a second layer, the first layer being configured to prevent the electrolyte from permeating through the first layer and to allow gas to permeate through the first layer, and the second layer including carbon paper and MnCl2.

[0013] The above summary is provided only to outline some exemplary embodiments to provide a basic understanding of some aspects of the present disclosure. Therefore, it will be understood that the above embodiments are merely examples and should not be construed as narrowing the scope or spirit of the present invention in any way. It will be understood that the scope of the present disclosure encompasses many potential embodiments in addition to the embodiments summarized here, some of which are further explained in the following detailed description and its accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Having thus generally described certain exemplary embodiments of the present disclosure, reference will hereinafter be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0015] Figure 1 A schematic diagram of a sensor for detecting gas according to an exemplary embodiment of the present disclosure is shown;

[0016] Figure 2 shows a cross-sectional view of a top cover associated with a sensor according to an exemplary embodiment of the present disclosure;

[0017] Figure 3A shows a graphical representation of a first testing process of a sensor when exposed to a gas according to an exemplary embodiment of the present disclosure;

[0018] Figure 3B a graphical representation showing a second testing process of a sensor when exposed to a gas according to an exemplary embodiment of the present disclosure; and

[0019] Figure 4 A table with results of a first test process and a second test process according to an exemplary embodiment of the present disclosure is shown. DETAILED DESCRIPTION

[0020] The exemplary embodiments described herein provide details for illustrative purposes, and many variations are possible in structure and design. However, it should be understood that the embodiments are not limited to the specific disclosed embodiments shown or described. It should be understood that various omissions and substitutions of equivalents are contemplated where circumstances may suggest or provide expedients, but they are all intended to cover applications or implementations without departing from the spirit or scope of the claims.

[0021] Furthermore, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered as limiting. The terms "a," "an," and "the" herein do not indicate a limitation of quantity, but rather indicate the presence of at least one of the referenced object. It will also be understood that the terms "comprises" and / or "includes," when used in this specification, refer to the presence of the recited features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. In the accompanying drawings, like reference numerals denote like components.

[0022] Embodiments of the present disclosure will be described more fully below with reference to the accompanying drawings, in which like reference numerals represent like elements throughout the several views, and in which exemplary embodiments are shown. However, embodiments of the present disclosure may be embodied in alternative forms and should not be construed as limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples and are merely examples of other possible examples.

[0023] The present disclosure provides various embodiments of a sensor for detecting gas. The embodiment can be configured to include an electrolyte within a housing and configured to have: manganese dichloride (MnCl2); and lithium chloride (LiCl), potassium chloride (KCl), sodium chloride (NaCl) or a combination thereof. The embodiment can be configured to have a sensing electrode that can be placed within the housing and in contact with the electrolyte. The embodiment can also include a first layer and a second layer of sensing electrodes. The embodiment can be configured to prevent the electrolyte from penetrating through the first layer and allow gas to penetrate through the first layer. The embodiment can include carbon paper and MnCl2 within the second layer.

[0024] Figure 1 A schematic diagram of a sensor 100 for detecting gas according to an exemplary embodiment of the present disclosure is shown. The sensor 100 may include a housing 102 having at least one gas inlet 104, an electrolyte 106 housed within the housing 102, and a sensing electrode 108. The sensing electrode may include a first layer 110 and a second layer 112. The sensing electrode may include a reference electrode 114 and a counter electrode 116.

[0025] In some embodiments, the housing 102 can be configured to accommodate an electrolyte 106 and a sensing electrode 108. The housing 102 can be configured to accommodate a reference electrode 114 and a counter electrode 116. In addition, in at least one embodiment, the housing 102 can be installed with a medium source (not shown). In addition, the medium source can be configured to accommodate a gas that can be detected by the sensor 100. In some embodiments, the medium source can include but is not limited to at least one of a pipeline, a container, one or more gas reservoirs, etc. In another embodiment, the housing 102 can be installed in a confined space. In addition, the confined space can be exposed to the gas. In addition, the confined space can include but is not limited to at least one of a building, a warehouse, a conference room, a laboratory, etc.

[0026] In some embodiments, housing 102 can be made of a material that can be selected from a group of materials, such as, but not limited to, polycarbonate, stainless steel. In addition, the material used to construct housing 102 can be selected to provide robust protection for electrolyte 106, sensing electrode 108, and other components of sensor 100. In addition, housing 102 can be configured to prevent any degradation of sensor 100 due to one or more environmental factors. Environmental factors can include at least one of dust, moisture, and high concentration fluids. In addition, housing 102 can be configured to ensure the long-term accuracy of sensor 100.

[0027] In some embodiments, the housing 102 may include at least one gas inlet 104. In addition, the at least one gas inlet 104 may be configured to receive gas within the housing 102. In some embodiments, the at least one gas inlet may define a diameter of 0.5-15 mm. In some embodiments, the housing 102 may define an inner cavity. In addition, the electrolyte 106, the sensing electrode 108, the reference electrode 114, and the counter electrode 116 may be configured to fill the inner cavity. In some embodiments, filling the inner cavity with the electrolyte 106 may ensure that the volume of air in the inner cavity is less than 5% of the volume of the inner cavity, for example, less than 3% of the volume of the inner cavity, for example, less than 1% of the volume of the inner cavity. In other words, the electrolyte 106 may at least substantially fill (e.g., completely fill) an area within the housing 102 that is not occupied by components of the sensor 100.

[0028] In some embodiments, the electrolyte 106 may be housed within the housing 102. In addition, the electrolyte 106 is configured to play an important role in the accurate and precise detection of the gas. In some embodiments, the electrolyte 106 may be made of a specialized material. In addition, the specialized material may include at least one of one or more solid electrolytes or one or more ionic liquids. In some embodiments, the electrolyte 106 may be configured to act as a medium for ion transport within the sensor 100. In addition, the transport of ions within the sensor 100 may provide insight into the electrochemical reactions within the sensor 100. In some embodiments, the electrochemical reaction may occur due to the interaction of the gas with the electrolyte 106. In some embodiments, the housing 102 may be designed to provide a controlled environment that ensures efficient ion exchange between the electrolyte 106 and one or more molecules of the gas.

[0029] In some embodiments, the electrolyte 106 may include manganese dichloride (MnCl2) and lithium chloride (LiCl), potassium chloride (KCl), sodium chloride (NaCl) or a combination thereof. In some embodiments, the electrolyte 106 includes MnCl2 and KCl. In some embodiments, the electrolyte 106 includes MnCl2 and NaCl. In some embodiments, the electrolyte 106 includes LiCl and MnCl2, and the ratio between the volume of LiCl and the volume of MnCl2 in the electrolyte 106 can be at least 10:1 and at most 1:10, for example, at least 1:5 and at most 1:9, for example, at least 1:7 and at most 1:9. MnCl2 corresponds to a high concentration of a mixed solution of divalent manganese ions. In one example, the amount of the mixed solution of divalent manganese ions can be limited to a range of 0.04-0.15 g / mL.

[0030] In some embodiments, MnCl2 may include one or more chemical properties. In addition, the one or more chemical properties of MnCl2 ensure the stability, high conductivity and compatibility of the sensor 100 when exposed to high concentrations of gas. In addition, MnCl2 may have a stable property, which ensures the long life of the electrolyte 106 and prevents the degradation of the electrolyte 106 over time. In some embodiments, lithium chloride (LiCl), potassium chloride (KCl) or sodium chloride (NaCl) can ensure efficient ion transport from gas molecules to the electrolyte 106. In addition, in one example, KCl or NaCl or a combination thereof can be used instead of LiCl. In some embodiments, lithium chloride (LiCl), potassium chloride (KCl) and sodium chloride (NaCl) may have one or more chemical properties. In addition, the chemical properties can ensure the versatility of the electrolyte 106 to detect gases with a variety of concentration levels.

[0031] In some embodiments, the sensor 100 may further include a sensing electrode 108. In some embodiments, the sensing electrode 108 may be positioned within the housing 102 such that the sensing electrode 108 may contact the electrolyte 106 within the housing 102. Furthermore, the sensing electrode 108 may be configured to detect a gas, and in at least one example, the sensing electrode 108 may be configured to detect a concentration level of a gas. In some embodiments, the sensing electrode 108 may include a first layer 110 and a second layer 112. In some embodiments, the first layer 110 may be configured to prevent the electrolyte 106 from permeating through the first layer 110. Furthermore, the first layer 110 may be configured to allow gas to permeate through the first layer 110.

[0032] In some embodiments, the second layer 112 may include carbon paper and MnCl2. In some embodiments, the first layer 110 and the second layer 112, together with the MnCl2, may be configured to provide a sensing platform for the sensor 100. In at least one example, the first layer 110 may correspond to a first material, which may include, but is not limited to, a graphite layer. In at least another example, the second layer 112 may correspond to a second material, which may include, but is not limited to, carbon paper. Furthermore, the graphite layer may be configured to block the electrolyte 106 from penetrating through the carbon paper while allowing gas to reach the carbon paper.

[0033] In some embodiments, the electrolyte 106 may undergo an oxidation reaction during the interaction of the gas molecules with the MnCl2. In some embodiments, a plurality of MnCl2 molecules may be consumed during the oxidation reaction. 2+ (Manganese) ions. In some embodiments, the second layer 112 can be treated with MnCl2 by a process that can include at least one of a brushing process, a spraying process, an immersion process, etc. In some embodiments, the sensing electrode 108 can be configured to generate an electrical signal corresponding to the gas received inside the housing 102. In addition, the electrical signal can include an electrical potential (V) that can be proportional to the concentration level of the gas. In at least one example, the sensor 100 can be exposed to ammonia gas. In addition, the sensing electrode 108 can be configured to generate an electrical signal corresponding to ammonia gas having a concentration level of 0-1000 ppm.

[0034] In some embodiments, the sensor 100 may further include a reference electrode 114 and a counter electrode 116. In some embodiments, the reference electrode 114 may be positioned between the sensing electrode 108 and the counter electrode 116. For example, the reference electrode 114 may be sandwiched between the sensing electrode 108 and the counter electrode 116. In some embodiments, the reference electrode 114 may be configured to provide a constant potential. Furthermore, the constant potential provided by the reference electrode 114 may be referenced by the sensing electrode 108 when providing an electrical signal. In some embodiments, the constant potential provided by the reference electrode 114 may enable accurate measurement of a gas or gas concentration level.

[0035] In some embodiments, the counter electrode 116 can be configured to complete the electromechanical circuit of the sensor 100. In addition, the counter electrode 116 can be configured to ensure the necessary current balance of the sensor 100 while the sensing electrode 108 detects the gas or the concentration level of the gas. During the detection of the gas or the concentration level of the gas, the sensing electrode 108 can undergo one or more reduction or oxidation reactions in response to the gas, which can cause the accumulation of charge and an unstable electrical environment inside the electromechanical circuit of the sensor 100. In addition, the counter electrode 116 can be configured to eliminate the accumulation of charge and maintain a stable electrical environment inside the electromechanical circuit of the sensor 100 to facilitate accurate measurement of the gas or the concentration level of the gas. In some embodiments, the reference electrode 114 and the counter electrode 116 can include a mixture of platinum (Pt) / ruthenium (Ru) powder and a hydrophobic binder. In addition, the mixture can ensure the durability of the sensor 100 when exposed to an environment with a certain concentration level of gas.

[0036] In some embodiments, the sensor 100 may further include a plurality of separators 118. The sensing electrode 108, the reference electrode 114, and the counter electrode 116 may be separated by the plurality of separators 118. In some embodiments, the plurality of separators 118 may be configured to provide electrical insulation between the sensing electrode 108, the reference electrode 114, and the counter electrode 116. In some embodiments, the plurality of separators 118 may be configured to prevent any direct contact between the sensing electrode 108, the reference electrode 114, and the counter electrode 116. In some embodiments, the plurality of separators 118 may be composed of a material having electrically insulating properties. In addition, the material may include, but is not limited to, a polymer electrolyte or a ceramic.

[0037] like Figure 1 As shown, the sensor 100 may further include a plurality of connector pins 120, which may be electrically coupled to the sensing electrode 108, the reference electrode 114, and the counter electrode 116 via one or more connecting wires 122. In some embodiments, the one or more connecting wires 122 may be configured to supply the potential generated by the sensing electrode 108, the reference electrode 114, and the counter electrode 116 to the plurality of connector pins 120. In some embodiments, the one or more connecting wires 122 may be comprised of a material that may correspond to platinum or gold. In some embodiments, the material of the one or more connecting wires 122 may be selected to ensure stability and avoid corrosion from the electrolyte.

[0038] In some embodiments, the plurality of connector pins 120 can be configured to ensure integration of the sensor 100 with one or more devices. In addition, the one or more external systems can include, but are not limited to, a sensing device, a processor, etc. In addition, the one or more external systems can be configured to receive an electrical potential that can correspond to a concentration level of a gas.

[0039] Figure 2 1 shows a cross-sectional view of the top cover 202 of the sensor 100 according to an exemplary embodiment of the present disclosure. Figure 1 To describe Figure 2 .

[0040] In some embodiments, housing 102 may further include a top cover 202. Furthermore, top cover 202 may be configured to allow gas to enter the interior of sensor 100. Furthermore, top cover 202 may be configured to enclose electrolyte 106, sensing electrode 108, reference electrode 114, and counter electrode 116. In some embodiments, top cover 202 may be constructed of a material that is resistant to the gas and prevents electrolyte 106, sensing electrode 108, reference electrode 114, and counter electrode 116 from being contaminated by one or more environmental factors.

[0041] In some embodiments, the sensor 100 includes a membrane 204. The top cover 202 can be placed together with the membrane 204. In some embodiments, the membrane 204 can be placed on the top cover 202 so that there is no cavity or gap between the top cover 202 and the membrane 204. In addition, the membrane 204 can correspond to an electrode polytetrafluoroethylene (PTFE) membrane 204. In some embodiments, the membrane 204 can be configured to provide selective permeability to the top cover 202. In addition, the membrane 204 can be configured to allow specific gases to pass through while blocking other gases present near the sensor 100. In some embodiments, the membrane 204 can be configured to improve the life of the sensor 100. In addition, the membrane 204 and the top cover 202 can be configured to eliminate any cavity between the sensing electrode 108 and the top cover 202. In some embodiments, the top cover 202 can be configured to reduce the contact area between the second layer 112 of the sensing electrode 108 and the gas. In addition, due to the reduced contact area, the gas can be configured to permeate through the first layer 110, which can enhance the performance of the sensor 100 when the sensor 100 is exposed to a gas with a high concentration level.

[0042] Figure 3A A graphical representation 300 is shown of a first testing process of the sensor 100 when exposed to a gas, according to an exemplary embodiment of the present disclosure. Figure 3B A graphical representation 306 of a second test process of the sensor 100 when exposed to a gas is shown according to an exemplary embodiment of the present disclosure. Figure 1-2 To describe Figure 3A and 3B .

[0043] In some embodiments, graphical representation 300 shows a comparison of the output shown by sensor 100 in high concentrations of ammonia gas during a time period of 0-10,000 minutes with the output shown by multiple other gas detection sensors (not shown) in gases of different concentrations during a time period of 10,000 minutes. In some embodiments, graphical representation 300 can be configured to provide insight into the response of sensor 100 during the first testing process.

[0044] In some embodiments, the sensor 100 may be connected to a Figure 3A The responses are shown in the multiple trends 302. In addition, multiple other gas detection sensors can also be used as Figure 3A 3. The plurality of trends 304 shown illustrate the responses of the sensor 100. Additionally, the plurality of trends 302 corresponds to the response of the sensor 100 when exposed to the gas. Additionally, the plurality of trends 304 can be configured to provide insight into the responses of a plurality of other gas sensors when exposed to a gas at a predetermined threshold concentration level (i.e., 1000 ppm) and for a predetermined threshold period of time (i.e., 7 days).

[0045] In some embodiments, since the sensor 100 achieves a response when exposed to a gas having a higher concentration during the time period, such as Figure 3A As shown, sensor 100 is exposed to a gas having a high concentration level (greater than 1000 ppm). Furthermore, during the continuous exposure, sensor 100 shows a continuous response with a slower decline. In some embodiments, multiple trends 302 indicate that sensor 100 is able to handle higher gas concentrations for a longer period of time exceeding 10,000 minutes.

[0046] In addition, in comparison, a number of other gas sensors were exposed to gases with higher concentrations during this period, such as Figure 3A As shown, several other gas sensors were exposed to a gas having a high concentration level (greater than 1000 ppm). Furthermore, during the continuous exposure, the output level dropped from 3000-4000 nA to zero before 1000 minutes. In some embodiments, several trends 304 indicate that several other gas sensors were unable to handle the higher gas concentration for a longer period of time exceeding 1000 minutes.

[0047] like Figure 3BAs shown, graphical representation 306 can be configured to provide insight into the response of sensor 100 during the second test process. Furthermore, graphical representation 306 can include a plurality of trends 308 associated with the response of sensor 100 when exposed to the gas. Furthermore, graphical representation 306 can include a plurality of trends 310 that can be configured to provide insight into the response of other gas sensors when exposed to a gas having a predetermined threshold concentration level (i.e., 1000 ppm) and for a predetermined threshold period of time (i.e., 7 days). Furthermore, as depicted from graphical representations 300 and 306, sensor 100 can remain functional in high gas concentration levels.

[0048] Figure 4 A table 400 is shown with results associated with first and second testing procedures according to an exemplary embodiment of the present disclosure. Figure 1-3B To describe Figure 4 .

[0049] In some embodiments, table 400 can be configured to provide results of a first test procedure for sensor 100 and a second test procedure for sensor 100. In some embodiments, table 400 can include multiple rows having results 402 associated with before the test procedure, results 404 associated with after the test procedure, and results 406 associated with the recovery of sensor 100. In some embodiments, table 400 can also include multiple columns having results associated with multiple other sensors (i.e., sensor-1 408, sensor-2 410, sensor-3 412, sensor-4 414, and sensor-5 416) and results associated with sensor 100. In some embodiments, the recovery 406 of sensor 100 can be calculated by a mathematical equation (i.e., recovery = sensitivity after the test procedure / sensitivity before the test procedure × 100%).

[0050] In some embodiments, table 400 may include data corresponding to the sensitivities of multiple other sensors and sensor 100 during the first and second test procedures. Furthermore, before the first and second test procedures, sensor-1 408 may have sensitivities of 150 nA / ppm and 152 nA / ppm. After the first and second test procedures, sensor-1 408 may have sensitivities of 16 nA / ppm and 8 nA / ppm. Furthermore, table 400 may also include recovery rates for sensor-2 410 during the first and second test procedures, which were 10.9% and 5.3%, respectively.

[0051] In some embodiments, before the first and second test processes, sensor 2410 may have sensitivities of 46 nA / ppm and 47 nA / ppm. After the first and second test processes, sensor 2410 may have sensitivities of 23 nA / ppm and 21 nA / ppm. Table 400 may also include recovery rates of sensor 2410 during the first and second test processes, which are 49% and 46%, respectively.

[0052] In some embodiments, before the first test process and the second test process, sensor 3412 may have sensitivities of 93 nA / ppm and 99 nA / ppm. After the first test process and the second test process, sensor 3412 may have sensitivities of 30 nA / ppm and 20 nA / ppm. Furthermore, table 400 may also include recovery rates of sensor 3412 during the first test process and the second test process, which are 32% and 20%, respectively.

[0053] In some embodiments, before the first test process and the second test process, sensor-4414 may have sensitivities of 101 nA / ppm and 105 nA / ppm. After the first test process and the second test process, sensor-4414 may have sensitivities of 15 nA / ppm and 10 nA / ppm. Furthermore, table 400 may also include recovery rates of sensor-4414 during the first test process and the second test process, which are 15% and 10%, respectively.

[0054] In some embodiments, sensor 5416 may have sensitivities of 6 nA / ppm and 6 nA / ppm before the first test process and the second test process. Sensor 5416 may have sensitivities of 4 nA / ppm and 4 nA / ppm after the first test process and the second test process. Furthermore, table 400 may also include recovery rates of sensor 5416 during the first test process and the second test process, which are 76% and 75%, respectively.

[0055] In some embodiments, sensor 100 may have sensitivities of 32 nA / ppm and 30 nA / ppm before the first and second test processes. After the first and second test processes, sensor 100 may have sensitivities of 30 nA / ppm and 30 nA / ppm. Furthermore, table 400 may also include recovery rates of sensor 100 during the first and second test processes, which are 95% and 97%, respectively. In summary, sensor 100 may achieve a higher recovery rate when compared to many other sensors.

[0056] In an exemplary embodiment, a method for detecting gas is disclosed. The method includes the steps of housing an electrolyte 106 within a housing 102. Furthermore, the electrolyte 106 includes manganese dichloride (MnCl2) and lithium chloride (LiCl), potassium chloride (KCl), sodium chloride (NaCl), or a combination thereof. In some embodiments, the manganese dichloride (MnCl2) and lithium chloride (LiCl), potassium chloride (KCl), sodium chloride (NaCl), or a combination thereof can be configured to provide durability for the sensor 100 when the sensor 100 is exposed to a gas having a high concentration level. Furthermore, the electrolyte 106 can be exposed to the gas via at least one gas inlet 104 formed in the housing 102.

[0057] Furthermore, the method includes the step of housing a sensing electrode 108 within the housing and contacting the electrolyte 106 within the housing 102. Furthermore, the sensing electrode 108 includes a first layer 110 and a second layer 112. Furthermore, the first layer 110 can be configured to prevent the electrolyte 106 from permeating through the first layer 110. Furthermore, the first layer 110 can allow gas to permeate through the first layer 110 and reach the second layer 112. Furthermore, the second layer 112 can include carbon paper and MnCl2. Furthermore, the top cover 202 of the housing 102 can enable the sensing electrode 108 to be efficiently exposed to the gas by eliminating the space between the sensing electrode 108 and the at least one gas inlet 104, thereby ensuring that the sensor 100 recovers faster when exposed to a gas with a high concentration level.

[0058] The present disclosure can provide various embodiments of the sensor 100 to detect gas. First, the sensor 100 can be configured to efficiently and accurately detect gas with high concentration levels. The electrolyte 106 having manganese dichloride (MnCl2) and lithium chloride (LiCl), potassium chloride (KCl), sodium chloride (NaCl) or a combination thereof can ensure the sustainability and durability of the sensor 100. In addition, the embodiment can ensure that the sensor 100 recovers from high concentrations of gas. The sensor 100 can be configured to provide accurate output because the gas permeates through the first layer 110 and reaches the second layer 112. In addition, the top cover 202 can enhance the recovery of the sensor 100 by eliminating the distance between the at least one gas inlet 104 and the sensing electrode 108.

[0059] As will be appreciated by those skilled in the art, aspects of the present disclosure may be implemented as systems, methods, or computer program products. Thus, aspects of the various embodiments may take the form of complete hardware embodiments, complete software embodiments (including firmware, resident software, microcode, etc.), or embodiments combining software and hardware aspects, which may be collectively referred to herein as "circuits," "modules," "systems," or "subsystems." Additionally, aspects of the present disclosure may take the form of a computer program product embodied in one or more computer-readable media having computer-readable program code embodied thereon.

[0060] For the purpose of illustration and description, the above descriptions of specific embodiments have been given. They are not intended to be exhaustive, nor are they intended to limit the embodiments to the exact form disclosed, and it is clear that many modifications and variations are possible in light of the above teachings. The embodiments are selected and described in order to best explain their principles and practical applications, and thereby enable other persons skilled in the art to best utilize various embodiments with various modifications suitable for the specific purposes contemplated. It should be understood that when circumstances may suggest or provide expediency, various omissions and substitutions of equivalents may be expected, but they are intended to cover applications or implementations without departing from the spirit or scope of the claims. The appended claims are in no way intended to limit the scope of the embodiments to the specific embodiments described herein.

Claims

1. A sensor for detecting gas, the sensor comprising: case; an electrolyte contained in the housing, wherein the electrolyte comprises: Manganese dichloride (MnCl2); and Lithium chloride (LiCl), potassium chloride (KCl), sodium chloride (NaCl), or a combination thereof; and a sensing electrode housed in the housing and in contact with the electrolyte in the housing, wherein the sensing electrode comprises: a first layer configured to prevent the electrolyte from permeating through the first layer and to allow the gas to permeate through the first layer; and The second layer comprises carbon paper and MnCl2.

2. The sensor according to claim 1, wherein The housing further includes a top cover, and wherein the sensing electrode is received within the housing such that the sensing electrode is in contact with the top cover of the housing.

3. The sensor according to claim 2, wherein The contact between the sensing electrode and the top cover of the housing helps minimize the contact area between the second layer of the sensing electrode and the gas entering the housing.

4. The sensor according to claim 1, wherein The MnCl2 corresponds to a high-concentration divalent manganese ion mixed solution, and wherein the divalent manganese ion mixed solution is in the range of 0.04-0.15 g / mL.

5. The sensor of claim 1 , further comprising a reference electrode and a counter electrode, wherein The reference electrode is sandwiched between the sensing electrode and the counter electrode.

6. The sensor according to claim 5, wherein The reference electrode and the counter electrode include a mixture of platinum (Pt) / ruthenium (Ru) powder and a hydrophobic binder.

7. The sensor according to claim 5, wherein The sensing electrode, the reference electrode, and the counter electrode are separated by a plurality of separators, and wherein the plurality of separators are configured to provide electrical insulation between the sensing electrode, the reference electrode, and the counter electrode.

8. The sensor of claim 5, further comprising a plurality of connector pins electrically coupled to the sensing electrode, the reference electrode, and the counter electrode via one or more connecting wires.

9. The sensor according to claim 8, wherein The one or more connecting wires are made of platinum or gold and are configured to supply the potentials generated by the sensing electrode, the reference electrode, and the counter electrode to the plurality of connector pins.

10. The sensor according to claim 1, wherein The housing includes at least one gas inlet, and the at least one gas inlet is configured to receive the gas within the housing, wherein the at least one gas inlet defines a diameter of 0.5-15 mm.

11. The sensor according to claim 1, wherein The electrolyte includes MnCl 2 and LiCl, and wherein a ratio between a volume of LiCl and a volume of MnCl 2 within the electrolyte is at least 10:1 and at most 1:

10.

12. The sensor according to claim 1, wherein The housing defines an interior cavity, and wherein the electrolyte fills the interior cavity such that a volume of air within the interior cavity is less than 10% of a volume of the interior cavity.

13. A method comprising: containing an electrolyte within the housing, wherein the electrolyte comprises manganese dichloride (MnCl2) and lithium chloride (LiCl), potassium chloride (KCl), sodium chloride (NaCl), or a combination thereof; and A sensing electrode is housed within the housing and in contact with the electrolyte within the housing, wherein the sensing electrode comprises a first layer and a second layer, the first layer being configured to prevent the electrolyte from permeating through the first layer and allowing the gas to permeate through the first layer, the second layer comprising carbon paper and MnCl2.

14. The method of claim 13, wherein: The housing includes a top cover, and wherein the method further comprises disposing the sensing electrode within the housing such that the sensing electrode contacts the top cover of the housing.

15. The method of claim 14, wherein: The contact between the sensing electrode and the top cover of the housing facilitates minimizing the contact area between the second layer of the sensing electrode and the gas entering the housing.

16. The method of claim 13, wherein: The MnCl2 corresponds to a high-concentration divalent manganese ion mixed solution, and wherein the concentration level is defined within the range of 0.04-0.15 g / mL.

17. The method of claim 13, further comprising: A reference electrode and a counter electrode are housed within the housing and in contact with the electrolyte within the housing, wherein the reference electrode is positioned between the sensing electrode and the counter electrode, wherein the reference electrode and the counter electrode comprise a mixture of platinum (Pt) / ruthenium (Ru) powder and a hydrophobic binder.

18. The method of claim 17, wherein: The sensing electrode, the reference electrode, and the counter electrode are separated by a plurality of separators, and wherein the plurality of separators are configured to provide electrical insulation between the sensing electrode, the reference electrode, and the counter electrode.

19. The method of claim 17, further comprising: A plurality of connector pins are housed within the housing such that each of the plurality of connector pins is electrically coupled to the sensing electrode, the reference electrode, and the counter electrode via one or more connecting wires, and wherein the one or more connecting wires are made of platinum or gold and are configured to supply an electric potential generated by the sensing electrode, the reference electrode, and the counter electrode to the plurality of connector pins.

20. The method of claim 13, wherein: The electrolyte includes MnCl 2 and LiCl, and wherein a ratio between a volume of LiCl and a volume of MnCl 2 within the electrolyte is at least 10:1 and at most 1:10.

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