A novel high-precision oxygen sensor based on electrochemical principles

Abstract

This invention discloses a novel high-precision oxygen sensor based on electrochemical principles, belonging to the field of gas detection technology. The novel high-precision oxygen sensor disclosed in this invention includes a standardized encapsulation shell, a sensor reaction section, a sensor encapsulation port, a standardized sealing device, a standardized sample gas port, and two output electrodes. The sensor reaction section, composed of a cathode, an anode, and an electrolyte, is located inside the shell. The sensor encapsulation port covers the top of the reaction section and, together with the standardized sealing device, forms a controlled sealed cavity. The standardized sample gas port penetrates the sealing device and is sealed to the encapsulation port, serving as the sole channel for the sample gas. Electrodes ① and ②, respectively connected to the cathode and anode, extend out of the shell and are used to output an electrochemical signal proportional to the oxygen partial pressure. This invention achieves cross-platform adaptability through standardized dimensional design by unifying the dimensions of the shell, gas port, electrode groove, and sealing components.

Description

Technical Field

[0001] This invention relates to the field of gas detection technology, and in particular to a novel high-precision oxygen sensor based on electrochemical principles. Background Technology

[0002] Electrochemical high-precision oxygen sensors typically consist of a sensor reaction section composed of a cathode, an anode, and an electrolyte, combined with components such as a sample gas port, a sealing port, a sealing device, and a packaging shell to form a controlled reaction chamber.

[0003] In current applications, similar sensors often lack standardized specifications due to the customized housing size and connection methods of enterprises: the sample gas interface, seals, and electrode grooves vary, and multiple sets of accessories need to be prepared for production line switching or on-site calibration; the cumulative dimensional tolerances of the sealing parts can also easily lead to micro-leakage, causing electrolyte dehydration or external gas infiltration, affecting long-term accuracy and stability; with exposed electrode solder joints, there is a risk of mechanical damage to the sensor during transportation and installation.

[0004] To mitigate the aforementioned impacts, existing solutions have attempted to add independent sealing gaskets inside the housing, adopt detachable threaded air ports, or use an integral metal housing, and to add sleeves to the electrode section for stable connection; however, these improvements rely on their respective non-standard structures, have significant differences in assembly processes, and still limit cross-model interchangeability and rapid calibration, while the overall weight, cost, or ease of later maintenance have not been fundamentally improved. Summary of the Invention

[0005] In view of the aforementioned existing problems, the present invention is proposed.

[0006] This invention provides a novel high-precision oxygen sensor based on electrochemical principles, which solves the problem of severe long-term accuracy drift caused by inconsistent oxygen sensor interfaces and sealing failures.

[0007] To solve the above-mentioned technical problems, the present invention provides the following technical solution:

[0008] This invention provides a novel high-precision oxygen sensor based on electrochemical principles, comprising:

[0009] Standardized packaging shells are used to form receiving cavities;

[0010] The sensor reaction section is disposed within the accommodating cavity, and the sensor reaction section is composed of a cathode, an anode, and an electrolyte.

[0011] A sensor encapsulation port integrally formed with the top of the sensor reaction part;

[0012] A standardized sealing device is installed at the top of the sensor, which simultaneously seals with the standardized encapsulation shell and the sensor reaction part.

[0013] A standardized sample gas port that penetrates the standardized sealing device and is sealed to the sensor encapsulation port;

[0014] Electrode ①, located at the positive electrode of the sensor's reaction section and connected by electric welding;

[0015] Electrode ②, which is set in a standardized electrode groove and connected to the negative electrode of the sensor reaction part by electric welding;

[0016] A standardized electrode groove formed on the sidewall of the standardized package housing and used to accommodate the electrode ②;

[0017] Among them, electrode ① and electrode ② respectively output electrochemical signals that are proportional to the concentration of oxygen being measured.

[0018] As a preferred embodiment of the novel high-precision oxygen sensor based on electrochemical principles described in this invention, the electrodes ① and ② are both made of copper-plated nickel Ni-Cu material, with dimensions of 6mm × 25mm × 0.3mm.

[0019] As a preferred embodiment of the novel high-precision oxygen sensor based on electrochemical principles described in this invention, the area ratio of the anode to the cathode in the sensor reaction section is 1:1.

[0020] As a preferred embodiment of the novel high-precision oxygen sensor based on electrochemical principles described in this invention, the standardized sample gas port is made of aluminum alloy with an outer diameter of 6 mm and an inner diameter of 4 mm.

[0021] As a preferred embodiment of the novel high-precision oxygen sensor based on electrochemical principles described in this invention, the sensor encapsulation port is made of PFA material with a diameter of 5 mm and a thickness of 3.5 mm.

[0022] As a preferred embodiment of the novel high-precision oxygen sensor based on electrochemical principles described in this invention, the standardized packaging shell is injection molded from special plastic, with an external dimension of 25mm in diameter and 46mm in height.

[0023] As a preferred embodiment of the novel high-precision oxygen sensor based on electrochemical principles described in this invention, the standardized sealing device is made of aluminum alloy with a diameter of 22 mm and a thickness of 3.5 mm.

[0024] As a preferred embodiment of the novel high-precision oxygen sensor based on electrochemical principles described in this invention, the standardized electrode groove is integrally molded from special plastic and has dimensions of 10mm×5mm×40mm.

[0025] As a preferred embodiment of the novel high-precision oxygen sensor based on electrochemical principles described in this invention, the standardized sealing device, the standardized sample gas port, and the sensor packaging port form a detachable sealing structure to facilitate the rapid replacement of the calibration sample gas.

[0026] The beneficial effects of this invention are:

[0027] This invention features standardized specifications: the outer shell, sample gas inlet, and electrode slot all adopt standard size design, which facilitates quick replacement of different testing equipment and large-scale production.

[0028] This invention provides reliable sealing: the sensor encapsulation port and the standardized sealing device form a double-sealed interface, which can effectively reduce electrolyte water loss and the probability of external gas infiltration, thereby improving long-term stability.

[0029] This invention features efficient assembly: the reaction part and the packaging are integrated into one design, the electrode resistance welding process is simple, and assembly can be completed directly on an automated production line.

[0030] This invention is easy to maintain: the sample gas port is a detachable structure, and different concentration sample gas connectors can be quickly replaced during calibration or maintenance without disassembling the main body.

[0031] The invention features an impact-resistant structure: the outer shell is made of special plastic or glass fiber reinforced material, and a flexible sheath is added inside the electrode groove, which can maintain the integrity of the solder joints and electrolyte in drop and vibration scenarios, thereby ensuring measurement consistency. Attached Figure Description

[0032] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0033] Figure 1 This is a schematic diagram of the structure of the novel high-precision oxygen sensor based on electrochemical principles in Example 1.

[0034] Legend:

[0035] 1. Electrode ①; 2. Electrode ②; 3. Standardized sample gas port; 4. Sensor packaging port; 5. Sensor reaction part; 6. Standardized packaging shell; 7. Standardized sealing device; 8. Standardized electrode groove. Detailed Implementation

[0036] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0037] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0038] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0039] Example 1, referring to Figure 1 This is the first embodiment of the present invention, which provides a novel high-precision oxygen sensor based on electrochemical principles, comprising:

[0040] The sensor reaction section 5, located at the center of the sensor, consists of a cathode, an anode, and an electrolyte, with an anode-cathode area ratio of 1:1.

[0041] The sensor encapsulation port 4, covering the top of the sensor reaction part 5, is integrally molded with PFA material, with a diameter of 5mm and a thickness of 3.5mm, and is used to isolate the sample gas from the electrolyte.

[0042] The standardized sealing device 7, an aluminum alloy disc with a diameter of 22mm and a thickness of 3.5mm, is fitted onto the outside of the sensor encapsulation port 4 and is interference-fitted with the standardized encapsulation shell 6 to form the first sealing interface;

[0043] The standardized sample gas port 3 is located at the top, and is made of thin-walled aluminum alloy tube with an outer diameter of 6mm and an inner diameter of 4mm. Its lower end is inserted into the central through hole of the sensor encapsulation port 4 and a second sealing interface is achieved through an O-ring, so that the sample gas enters the sensor reaction part 5 only through this channel.

[0044] Standardized encapsulation shell 6, special plastic injection molded part, with external dimensions of φ25mm×46mm; the bottom is a hemispherical sealed bottom, and a long strip of standardized electrode groove 8 is opened on the side wall along the height direction;

[0045] Electrode ①1, made of copper-plated nickel strip 6mm×25mm×0.3mm, is welded to the positive electrode of the sensor reaction part 5;

[0046] Electrode ②2, with the same specifications as electrode ①1, is embedded in the standardized electrode groove 8 and welded to the negative electrode (inner wall of the outer shell) of the sensor reaction part 5.

[0047] Assembly steps include:

[0048] 1. Electrode assembly: Weld electrode ①1 to the cathode with resistance, and lead out in the same direction as the sample gas port; insert electrode ②2 into the standardized electrode slot 8 along the axial direction and weld it to the anode or the negative electrode of the outer shell.

[0049] 2. Electrolyte injection and encapsulation: The prepared electrolyte is injected into the sensor reaction part 5, and then the sensor encapsulation port 4 is fixed by thermo-pressing integral molding.

[0050] 3. Installation of sealing components: Fit the standardized sealing device 7 onto the outer periphery of the sensor encapsulation port 4; after aligning it with the upper port of the housing 6, press it in to form a first seal with the side wall of the housing 6.

[0051] 4. Sample gas port installation: Insert the standardized sample gas port 3 into the center through hole of the sealing port 4, and obtain a second seal through O-rings or adhesives to ensure that the sample gas enters the reaction chamber only along the predetermined path.

[0052] 5. Finished product inspection: Perform airtightness test (hold pressure of −50kPa for 60s without leakage), initial open circuit voltage and sensitivity test on the assembled sensor, and package it after passing the test.

[0053] When the oxygen-containing sample gas enters through the sample gas port 3, it diffuses through the pores of the encapsulation port 4 to the sensor reaction section 5. Oxygen undergoes a reduction reaction at the cathode, generating a current signal proportional to the oxygen partial pressure, which is output to the downstream circuit via electrodes ①1 and ②2. The standardized sealing device 7 and the encapsulation shell 6 form a double-sealed structure, limiting electrolyte water loss and environmental gas infiltration, ensuring long-term stability. The uniformly sized shell, sample gas port, and electrode interfaces facilitate quick replacement of different instrument models, reducing the complexity of parts and maintenance.

[0054] Example 2, a second embodiment of the present invention, provides a novel high-precision oxygen sensor with detachable calibration, comprising:

[0055] Based on Example 1, the standardized sample gas port 3 is designed with a threaded connection, and a PTFE gasket is added between the sealing device 7 and the encapsulation port 4. During calibration, the user can unscrew the sample gas port 3 to replace the sample gas generator connector with a different concentration, achieving rapid on-site calibration. The remaining structure and dimensions remain consistent. Those skilled in the art can select equivalent sealing materials without departing from the core design.

[0056] Example 3, the third embodiment of the present invention, provides a novel impact-resistant high-precision oxygen sensor, comprising:

[0057] To meet the drop test requirements of portable testing instruments, the standardized encapsulation shell 6 can be replaced with glass fiber reinforced PBT, and the inner wall of the shell can be locally thickened by 0.5mm. A flexible silicone rubber sheath is added to the inside of the electrode groove 8 to absorb impact stress and prevent the electrode ②2 from loosening from the solder joint. The remaining dimensions and assembly method are the same as in Example 1. Those skilled in the art can select equivalent reinforcement materials without departing from the core design.

[0058] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A novel high-precision oxygen sensor based on electrochemical principles, characterized in that, include: Standardized packaging shells are used to form receiving cavities; The sensor reaction section is disposed within the accommodating cavity, and the sensor reaction section is composed of a cathode, an anode, and an electrolyte. A sensor encapsulation port integrally formed with the top of the sensor reaction part; A standardized sealing device is installed at the top of the sensor. The standardized sealing device is sleeved on the outside of the sensor package opening and is interference-fitted with the opening end of the standardized package shell to form a first sealing interface between the standardized sealing device and the standardized package shell. A standardized sample gas port is passed through the standardized sealing device and sealed to the central through hole of the sensor package port. The lower end of the standardized sample gas port is inserted into the sensor package port, and a second sealing interface is formed between the standardized sample gas port and the sensor package port through a sealing member, so that the sample gas enters the sensor reaction part only through the channel connecting the standardized sample gas port and the sensor package port. Electrode ①, located at the positive electrode of the sensor's reaction section and connected by electric welding; Electrode ②, which is set in a standardized electrode groove and connected to the negative electrode of the sensor reaction part by electric welding; A standardized electrode groove formed on the sidewall of the standardized package housing and used to accommodate the electrode ②; The standardized sealing device, the standardized sample gas port, and the sensor encapsulation port constitute a detachable sealing structure. Electrode ① and electrode ② respectively output electrochemical signals that are proportional to the oxygen concentration being measured.

2. The novel high-precision oxygen sensor based on electrochemical principles as described in claim 1, characterized in that, Both electrodes ① and ② are made of copper-plated nickel Ni-Cu material, with dimensions of 6mm × 25mm × 0.3mm.

3. A novel high-precision oxygen sensor based on electrochemical principles as described in any one of claims 1 and 2, characterized in that, The area ratio of the anode to the cathode in the sensor's reaction section is 1:

1.

4. The novel high-precision oxygen sensor based on electrochemical principles as described in claim 1, characterized in that, The standardized sample gas inlet is made of aluminum alloy, with an outer diameter of 6 mm and an inner diameter of 4 mm.

5. A novel high-precision oxygen sensor based on electrochemical principles as described in claim 1, characterized in that, The sensor package opening is made of PFA material, with a diameter of 5mm and a thickness of 3.5mm.

6. A novel high-precision oxygen sensor based on electrochemical principles as described in claim 1, characterized in that, The standardized packaging shell is injection molded from special plastic, with an external dimension of 25mm in diameter and 46mm in height.

7. A novel high-precision oxygen sensor based on electrochemical principles as described in claim 1, characterized in that, The standardized sealing device is made of aluminum alloy, with a diameter of 22 mm and a thickness of 3.5 mm.

8. A novel high-precision oxygen sensor based on electrochemical principles as described in claim 1, characterized in that, The standardized electrode groove is integrally molded from special plastic and measures 10mm × 5mm × 40mm.

9. A novel high-precision oxygen sensor based on electrochemical principles as described in claim 1, characterized in that, The standardized sealing device, the standardized sample gas port, and the sensor encapsulation port form a detachable sealing structure.

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