METHOD FOR PREPARING A CARBON DIOXIDE SENSOR, SAID SENSOR AND ITS USES

Abstract

The present invention relates to a method for preparing a CO2 sensor comprising the following steps: (a) providing a support (1) made of an insulating material comprising a pH-sensitive electrode (2) and a reference electrode (3); (b) providing a double-sided adhesive (4) having an acrylic-based adhesive layer (41), an opposing silicone-based adhesive layer (42), and a through-hole (5) in its thickness; (c) applying the double-sided adhesive (4) to the support (1); (d) applying a carbon dioxide-permeable silicone membrane (6) to the double-sided adhesive (4), thereby obtaining a measuring chamber (7); and (e) filling the measuring chamber (7) with an electrolyte (9). The present invention also relates to a CO2 sensor thus prepared, a multi-sensor device comprising it, and their uses for measuring dissolved or gaseous CO2. Abstract figure: Fig. 1

Description

Title of the invention: METHOD FOR PREPARING A CARBON DIOXIDE SENSOR, SAID SENSOR AND ITS USES technical field

[0001] The present invention belongs to the field of electrochemical sensors useful for determining chemical parameters, in particular to the field of dissolved or volatile carbon dioxide sensors.

[0002] The present invention proposes a method for preparing a carbon dioxide sensor and in particular a miniaturized carbon dioxide sensor.

[0003] The present invention also relates to such a carbon dioxide sensor and its various uses. PREVIOUS STATE OF THE ART

[0004] The detection and / or monitoring of carbon dioxide is essential for many applications such as, for example, monitoring environmental conditions, assessing air pollution levels, understanding physiological processes, or regulating biopharmaceutical production processes, etc. Numerous technological approaches have been developed to detect and measure carbon dioxide, each with its own advantages and limitations.

[0005] Conventional methods for determining carbon dioxide concentration include infrared spectrometry and electrochemical sensors based on liquid or solid electrolytes. Infrared detection is a widely used technique that relies on the absorption of infrared light by carbon dioxide molecules. This method provides accurate and sensitive measurements but may require complex instrumentation and calibration. In contrast, electrochemical sensors offer a simpler and more cost-effective approach to carbon dioxide detection.

[0006] In addition, high-temperature solid-electrolyte sensors have also been widely used to measure dissolved carbon dioxide. These sensors have been used in a wide variety of industries, including environmental monitoring, biotechnology, biology, medicine, and the food industry. Beyond traditional electrochemical sensors, other methods such as non-dispersive infrared spectroscopy, photoacoustic effects, and thermal conductivity are also being explored to detect dissolved carbon dioxide.

[0007] Electrochemical sensors with liquid electrolytes are based on the principle of Se- Severinghaus, which involves indirectly measuring the partial pressure of carbon dioxide by monitoring the pH values ​​of an internal electrolyte. It should be noted, however, that while Severinghaus-type electrochemical sensors are inexpensive and relatively simple to use, they rely on an indirect measurement of the partial pressure of carbon dioxide and can be influenced by other dissolved gases with similar behavior. Nevertheless, due to their ease of integration and low cost, these sensors offer a practical solution for continuously monitoring carbon dioxide concentrations in various applications.

[0008] The so-called Severinghaus principle [1], i.e., the operating principle of an electrochemical carbon dioxide sensor, is based on a pH sensor immersed in a chamber containing a liquid electrolyte covered by a membrane permeable and selective to CO2. After passing through the CO2-permeable membrane, the gas is dissolved in the aqueous electrolyte. The concentration in the electrolyte is then correlated with that in the medium of interest.

[0009] Indeed, the dissolution of CO2 in the electrolytic solution leads to the formation of bicarbonate ions (HCO3) and consequently a change in pH via the equilibrium cascade as described by the following equations:

[0010] CO2 (dissolved) + H2O

[0011] co2 + h2o ^h2co3

[0012] H2C(k + HCO\ JK,

[0013] HC0\ <^H+ + CO2: 3 Y

[0014] where Kh is Henry's constant, and Ki and K2 are the first and second dissociation constants of carbonic acid (H2CO3). Taking into account the dissociation of water and the charge balance, the relationship between H+ ions and the partial pressure of CO2 is deduced as follows:

[0015] [zr]3+ Kw) [tC]-ZK^K^CO^Q

[0016] where [NaHCO3] is the concentration of sodium bicarbonate in the internal electrolyte and Kw is the water dissociation constant.

[0017] The variation of pH as a function of CO2 concentration can thus be described by:

[0018] „ _ „ , / [nœ3] \ pH - pKu + log I

[0019] with pKa, the dissociation constant of H2CO3 in water, the value of which is known. [HCO3] is the concentration of bicarbonate fixed in the electrolyte. The dissolution constant of CO2 in the medium is expressed by a, which is the inverse of Henry's constant for CO2.

[0020] This change in pH can be evaluated in real time by a potential measurement between the pH-sensitive electrode and a reference electrode also immersed in the electrolyte. It should be noted, however, that the CO2 measurement is obtained indirectly via a pH sensor.

[0021] Conventional Severinghaus-type sensors have certain limitations that must be taken into account. One of the main characteristics of these sensors is the use of an internal glass electrode. However, this manufacturing complexity results in high costs and relatively laborious production. Furthermore, due to their fragile nature, glass electrodes are prone to breakage, which can necessitate frequent replacements, impact measurement reliability, and lead to contamination of the medium under study. The regular maintenance required to maintain optimal performance of these sensors can also be a constraint, particularly in demanding environments.

[0022] Another major limitation of these conventional sensors is related to their size. Due to their design, these sensors can be relatively bulky, which can limit their applicability in situations where space is limited, when discrete measurements are required, or in the context of a multi-sensor device. Furthermore, the presence of a glass electrode and associated components adds to the overall size of the device, which can be a constraint in contexts where miniaturization is essential.

[0023] Miniaturized Severinghaus-type electrochemical sensors aim to overcome some of the limitations inherent in conventional sensors. However, even in this category, several challenges remain. For example, with regard to the first "layer," that of pH measurement, any deficiency in this component can compromise the overall accuracy of the sensor, thus highlighting the importance of careful selection and optimization of this component. The nature of the internal electrolyte is also a crucial point to consider in terms of price, stability over time, and long-term storage. Finally, the permeable membrane that isolates the sensor from the medium being studied plays a crucial role in the overall performance of the sensor since it is in direct contact with the medium being measured, making the choice of an appropriate material crucial depending on the specific application.

[0024] Optimizing miniaturized Severinghaus-type sensors requires a balanced and meticulous approach in the selection and combination of these different layers. Performance, ease of industrial integration, and cost are closely linked to the synergy between these elements.

[0025] The inventors therefore set themselves the goal of proposing a rapid, easy-to-implement process enabling the preparation of a miniaturized, efficient and reliable sensor for the detection and measurement of carbon dioxide, in particular dissolved carbon dioxide. Description of the invention

[0026] The solution proposed by the inventors is a simple, fast and easily industrializable manufacturing process for obtaining a Severinghaus type carbon dioxide sensor with a specific architecture.

[0027] The process of preparing a carbon dioxide sensor according to the invention therefore involves an optimal choice and the execution of different steps in order to obtain the different constituent parts of the sensor which are (i) the pH sensitive layer, (ii) the structural material of the internal cavity, (iii) the internal electrolyte and (iv) the permeable membrane.

[0028] The specific architecture thus obtained has demonstrated the ability to develop a miniaturized Severinghaus-type sensor exhibiting, as illustrated in the experimental section below, all or part of the following properties: - maintaining excellent performance, particularly in terms of response time, even with low concentrations of dissolved CO2; - fully integrable into a multi-sensor system; - enabling simple and inexpensive manufacturing thanks to its compatibility with collective manufacturing processes such as screen printing, allowing for reproducible sensors at low cost; - offering strong versatility in terms of support, geometry, and configuration; - which, when the internal electrolyte is in the form of a hydrogel, can be stored in the open air and is therefore ready for use, thus significantly facilitating handling; and - requiring no maintenance.

[0029] Thus, the present invention relates to a method for preparing a carbon dioxide sensor, the steps of which are schematically shown in [Fig. 1]. This method comprises the following steps: a) provide a support 1 in an insulating material having a first face 11 and a second face 12 opposite to the first face, the first face having at least one area comprising a pH sensitive electrode 2 and a reference electrode 3; b) provide a double-sided adhesive 4 having a first adhesive layer 41 based on acrylic, a second adhesive layer 42 based on silicone opposite the first adhesive layer and, in its thickness, a through recess 5 having a first open end 51 and a second open end 52 opposite the first open end; c) Apply the first adhesive layer 41 of the double-sided adhesive 4 to the first face 11 of the support 1 so that the first open end 51 of the recess 5 of the double-sided adhesive 4 comes opposite the area of ​​the first face 11 of the support 1; d) apply, on the second adhesive layer 42 of the double-sided adhesive 4 and on the second open end 52 of the recess 5 of the double-sided adhesive 4, a carbon dioxide permeable membrane 6 based on silicone, thereby obtaining a measuring chamber 7, then e) fill the measuring chamber 7 thus obtained with an electrolyte 9 comprising bicarbonate ions (HCO3 ) by which means the pH sensitive electrode 2 and the reference electrode 3 are in contact with the electrolyte.

[0030] The support (or substrate) of the CO2 sensor prepared by the process according to the present invention can be any substrate made of an insulating material and in particular any substrate made of an insulating material typically used in Severinghaus-type CO2 sensors. It can also be substantially flat or, conversely, concave or convex and of any shape such as square, rectangular, round or oval.

[0031] Advantageously, the electrically non-conductive insulating material of the support used in the process according to the invention is chosen from the group consisting of non-conducting oxides, non-conducting polymers, amorphous insulating materials, crystalline insulating materials and any combination thereof.

[0032] In particular, the insulating material of the support used in the process according to the invention is chosen from the group consisting of silicon dioxide (SiO2), aluminium oxide (Al2O3), magnesium oxide (MgO), a glass generally containing silicates, silica glass, a ceramic, diamond, polyphenylene sulfide, polyethyleneimine, polytetrafluoroethylene, polyimide, polyethylene, polypropylene, polystyrene, polycarbonate, polymethyl methacrylate, polysulfone, polyetherimide, polyether ether ketone, parylene N™, Nuflon™, silicone, epoxy resin and any combination thereof.

[0033] The support used in the invention can be flexible or rigid. In a particular embodiment, this support is a substrate typically used for printed circuit boards (or "PCBs"). Such a substrate generally consists of insulating layers of epoxy resin reinforced by a mesh of glass or paper fibers.

[0034] The support used in the process according to the invention may have a single zone comprising a pH-sensitive electrode and a reference electrode. Alternatively, the support used in the process according to the invention may have several zones, identical or different, and in particular of identical or different sizes and shapes, each zone comprising a pH-sensitive electrode and a reference electrode.

[0035] The preparation of the substrate used in the process according to the invention, with at least one area comprising a pH-sensitive electrode and a reference electrode, is a conventional method in the preparation of Se-veringhaus type CO2 sensors. Examples of techniques commonly used for this preparation include collective manufacturing by screen printing, by silicon process, or by inkjet printing techniques.

[0036] The pH-sensitive electrode presented in the support implemented in the process according to the invention has (i) at least one electrically conductive layer disposed on the support in an insulating material, i.e. the lower face of the conductive layer is in direct contact with the first face of the support as previously defined, and (ii) at least one pH-sensitive layer comprising pH-sensitive elements, directly or indirectly, disposed on this electrically conductive layer.

[0037] The conductive layer of the pH-sensitive electrode in the support used in the method according to the invention allows this electrode to be electrically connected to the electronic measuring unit. It can be made of any electrically conductive material, and in particular any electrically conductive material typically used in Severinghaus-type CO2 sensors.

[0038] Advantageously, the conductive layer is made of an electrically conductive material chosen from the group consisting of metals such as noble metals, carbons and electrically conductive polymers or copolymers.

[0039] More particularly, the conductive layer of the pH-sensitive electrode presented in the support used in the process according to the invention is made of a metal chosen from the group consisting of gold, copper, stainless steel, silver, nickel, aluminum, titanium, platinum, palladium, ruthenium, iridium, molybdenum or one of their alloys.

[0040] When the pH-sensitive layer is indirectly disposed on the electrically conductive layer, a layer comprising an electrochemical transducer is disposed between these two layers. Alternatively, when the pH-sensitive layer is directly disposed on the electrically conductive layer, the pH-sensitive layer comprises not only pH-sensitive elements but also an electrochemical transducer.

[0041] The electrochemical transducer in the pH-sensitive electrode presented in the support implemented in the process according to the invention is the element of this electrode whose function is to transcribe the chemical recognition of the pH-sensitive layer into an electrical signal, i.e. a measurable, sensitive and easily exploitable physical signal.

[0042] Any electrochemical transducer conventionally used in Severinghaus-type CO2 sensors can be used within the scope of the present invention. Typically, the electrochemical transducer is selected from carbon-based nanomaterials such as, for example, single-walled or multi-walled carbon nanotubes, carbon nanowires, and graphene; carbon inks such as, for example, C10903P14 graphite-based ink (Gwent Electronic Materials Ltd, Montypool, UK) or BQ242 carbon-based ink (DuPont, Bristol, UK); and semiconductor polymers such as, for example, poly(3,4-ethylenedioxythiophene) coupled to sodium poly(styrene sulfonate) (PEDOT:PSS) or poly(3-octylthiophene-2,5-diyl).

[0043] A person skilled in the art is aware of various pH-sensitive elements that can be used for the pH-sensitive electrode implemented in the invention. Advantageously, the pH-sensitive elements of the pH-sensitive electrode in the support implemented in the process according to the invention are made of a material selected from among the transition metal oxides.

[0044] In particular, the pH-sensitive elements of the pH-sensitive electrode in the support used in the process according to the invention are in nanometric form and in particular in the form of powder, grains, flakes, particles or a mixture thereof and are made of a material selected from the group consisting of titanium oxide (TiO2), ruthenium oxide (RuO2), palladium oxide (PdO2), platinum oxide (PtO2), iridium oxide (IrO2), tungsten oxide (WO2) and mixtures thereof.

[0045] More particularly, the pH-sensitive elements of the pH-sensitive electrode presented in the support implemented in the process according to the invention are made of iridium oxide (IrO2).

[0046] The CO2 sensor support prepared by the process according to the invention further comprises a reference electrode. Any reference electrode or pseudo-reference electrode conventionally used in Severinghaus-type CO2 sensors is usable within the scope of the present invention. Advantageously, the reference electrode in the support implemented in the process according to the invention is a silver chloride (AgCl / Ag) pseudo-reference electrode.

[0047] In the preparation process according to the invention, a double-sided adhesive is used. The three essential elements of this double-sided adhesive are a first acrylic-based adhesive layer, a second silicone-based adhesive layer, and a through-hole. The double-sided adhesive used in the process according to the invention has adhesive layers of different chemical compositions: it is therefore an asymmetrical double-sided adhesive.

[0048] The first acrylic-based adhesive layer of this double-sided adhesive is This adhesive is intended to be applied to the first surface of the substrate as previously described, ensuring strong adhesion and effective sealing. Similarly, the second silicone-based adhesive layer has excellent affinity with silicones, particularly the silicone of the CO2-permeable membrane intended to be applied over this second adhesive layer.

[0049] Finally, the through-hole in the double-sided adhesive used is intended to form the walls of the measuring chamber or cavity of the CO2 sensor, in which the pH-sensitive electrode, the reference electrode, and the electrolyte are located. Typically, the shape of the first open end of this hole is substantially identical to the shape of the area of ​​the first face of the support made of an insulating material as previously defined. Advantageously, this hole has a substantially parallelepiped shape. Machining such a hole is a routine task for a person skilled in the art, either manually using a punch or cutter, or by collective manufacturing using mechanical or laser cutting.

[0050] Typically, the double-sided adhesive used in the present invention comprises, between the first acrylic-based adhesive layer and the second silicone-based adhesive layer, a polymeric substrate, in particular a polyester substrate. Advantageously, the double-sided adhesive used in the invention has a thickness of between 50 µm and 585 µm, and in particular a thickness of approximately 85 µm (i.e., 85 µm ± 10 µm).

[0051] Any asymmetrical double-sided adhesive, particularly a commercial one, that exhibits the above characteristics can be used in the preparation process according to the invention. As a specific example, the double-sided adhesive reference 5302A, marketed by NITTO DENKO, may be cited.

[0052] Once the double-sided adhesive is placed on the first side of the substrate, a silicone-based CO2-permeable membrane is placed on the second silicone-based adhesive layer of the double-sided adhesive and on the second open end of the recess in the double-sided adhesive. Typically, this CO2-permeable membrane is a cross-linked silicone film.

[0053] Advantageously, the CO2 permeable membrane implemented in the process according to the invention has a thickness between 20 pm and 400 pm and in particular a thickness of the order of 50 pm (i.e. 50 pm ± 10 pm).

[0054] Any CO2-permeable membrane exhibiting the above characteristics is usable in the preparation process according to the invention. However, permeable membranes made from a two-part commercial formulation (MED-6010, Nusil) coated by spin-coating onto a silicon wafer to obtain the thinnest possible membrane and then followed Initial trials of a transfer onto double-sided adhesive revealed reproducibility issues, primarily due to difficulties in transferring the silicones, resulting in roughness and / or cracks on the membrane after transfer. To address this problem and simplify future industrialization of the process, an optimal method was determined using commercial silicone films. Integrating these silicones into the carbon dioxide sensor manufacturing process demonstrated excellent transfer reproducibility while also simplifying production.

[0055] Thus, the CO2 permeable membrane used in the process according to the invention is a commercial membrane and in particular a cross-linked silicone film of reference SILPURAN® Film 2030 marketed by the company Wacker Chemie AG.

[0056] The side walls of the measuring chamber or cavity of the CO2 sensor prepared by the method according to the present invention correspond to the lateral edges of the recess in the double-sided adhesive. The lower part of this measuring chamber corresponds to the support made of an insulating material in the area as previously defined, and the upper part of this measuring chamber corresponds to the CO2-permeable membrane covering the second open end of the recess in the double-sided adhesive.

[0057] The process according to the present invention makes it possible to obtain measuring chambers with a small volume, which allows for the production of highly efficient CO2 sensors (see experimental section below). The measuring chamber obtained during the preparation process according to the invention has a volume between 1 cm³ and 12 cm³, in particular between 1.1 cm³ and 9 cm³, and, in particular, on the order of 1.275 cm³ (i.e., 1.275 cm³ ± 0.05 cm³). By way of specific examples, the measuring chamber obtained during the preparation process according to the invention can have a volume on the order of 1.275 cm³, on the order of 5.025 cm³ (i.e., 5.025 cm³ ± 0.05 cm³), and on the order of 8.775 cm³ (i.e., 8.775 cm³ ± 0.05 cm³).

[0058] Step e) of the preparation process according to the invention consists of filling the measuring chamber with an electrolyte. This filling is carried out by means of at least two fluidic channels 81, 82 opening into the measuring chamber and adapted to bring an electrolyte or a precursor thereof into the measuring chamber and to extract the air contained in the measuring chamber. These fluidic channels are typically microfluidic channels, perforated at the level of the CO2-permeable membrane and / or machined at the level of the double-sided adhesive, in particular at the level of the polymeric substrate and, in particular, at the level of the polyester substrate comprising this double-sided adhesive. In a particular embodiment, the permeable membrane is perforated, in particular, using a needle associated with a syringe for the injection of the electrolyte or its precursor. The silicone of the permeable membrane, and in particular of the commercial permeable membrane as previously defined, is "self-healing". However, to ensure that the measuring chamber or internal cavity is airtight, a second adhesive or a second permeable membrane can be added on top of the assembly.

[0059] In a first embodiment, the electrolyte used in the preparation process according to the present invention is a liquid electrolyte. The fluidic channel(s) as defined above allow such a liquid electrolyte to be brought into the measuring chamber.

[0060] In a second embodiment, the electrolyte used in the preparation process according to the present invention is an electrolyte in the form of a hydrogel. An internal electrolyte in the form of a hydrogel makes it possible to limit or even eliminate evaporation during the storage and use phases of the CO2 sensor, as well as to simplify manufacturing.

[0061] In this second embodiment, to avoid any clogging of the fluidic channel(s) as previously defined, a solution comprising the precursor compounds of this hydrogel will be brought, via this or these fluidic channel(s), into the measuring chamber.

[0062] Typically, a hydrogel refers to a material formed of at least two constituents: a solution, also called a gelled solution, which is a liquid "trapped" by a second compound which forms a three-dimensional network throughout the solution, the solution of a hydrogel being water or an aqueous solution i.e. a solution whose solvent is water.

[0063] In the present invention, all precursor compounds generally used to prepare a hydrogel can be used. Advantageously, these precursor compounds are chosen from the group consisting of chitosan, xanthan gum, carrageenan, dextran, agar, alginate, gelatin, collagen, fibrin, polyethylene glycol, hyaluronic acid, their (meth)acrylated derivatives and mixtures thereof.

[0064] In a particular embodiment, the electrolyte in the form of a hydrogel implemented in the invention is a hydrogel obtained from precursors selected from the group consisting of agar, gelatin, chitosan, and methacrylated dextran. In this particular embodiment, the solution comprising the precursor compounds of such a hydrogel typically comprises 1% by mass of agar, 25% by mass of gelatin, 10% by mass of chitosan, or 5% by mass of methacrylated dextran.

[0065] In a further particular embodiment, the electrolyte in the form of a hydrogel used in the invention is an agar hydrogel. In this In a more particular embodiment, the solution comprising the precursor compounds of such a hydrogel includes 1% by mass of agar.

[0066] Whether the electrolyte used in the present invention is in liquid form or in the form of a hydrogel, it comprises bicarbonate ions in an amount between 1 mM and 20 mM, in particular between 3 mM and 10 mM, and especially in the range of 5 mM (i.e., 5 mM ± 1 mM). This bicarbonate ion concentration refers to the concentration in the liquid electrolyte or in the solution comprising the precursor compounds of the hydrogel forming the electrolyte. The bicarbonate ions are typically present in the form of sodium bicarbonate (NaHCO3).

[0067] Advantageously, in the process according to the invention, the liquid electrolyte and the solution comprising the precursor compounds of the hydrogel forming the electrolyte further comprise a salt in which the anion is a chloride (Cl). Advantageously, the cation of this salt is an alkali metal cation such as Li+, Na+, K+; an alkaline earth metal cation such as Mg2+, Ca2+; or a transition metal cation such as Cu2+, Zn2+, and Al3+. In a particular embodiment, the salt used in the liquid electrolyte and the solution comprising the precursor compounds of the hydrogel forming the electrolyte is KCl. More specifically, this salt is present in the liquid electrolyte and the solution comprising the precursor compounds of the hydrogel forming the electrolyte in an amount between 25 mM and 250 mM, in particular between 50 mM and 150 mM and, in particular, in the order of 100 mM (i.e. 100 mM ± 10 mM).

[0068] Finally, the solution comprising the precursor compounds of the hydrogel forming the electrolyte, implemented in the preparation process according to the invention, may include at least one element necessary for the formation of a hydrogel from these precursor compounds. Such an element may be, for example, a crosslinking agent such as polyethylene glycol diglycidyl ether (or PEGDE) or a photoinitiator such as lithium phenyl-2,4,6-trimethylbenzoylphosphinate (or LAP).

[0069] It should be noted that it is possible, before step e) of the process of the invention, i.e., before filling the sensor's measuring chamber with the electrolyte, to subject the assembly obtained at the end of step d), the assembly comprising the support made of an insulating material, the pH-sensitive electrode, the reference electrode, the double-sided adhesive, and the CO2-permeable membrane as previously defined, i.e., the sensors without internal electrolyte, to a sterilization step, in particular by autoclave or gamma irradiation. Indeed, no deterioration of the sensor structure following such sterilization has been observed.

[0070] The present invention also relates to a CO2 sensor obtained by the preparation process as defined above. This sensor comprises: - a support 1 made of an insulating material having a first face 11 and a second face 12 opposite to the first face, the first face having at least one area comprising a pH sensitive electrode 2 and a reference electrode 3; - a double-sided adhesive 4 having a first adhesive layer 41 based on acrylic, a second adhesive layer 42 based on silicone opposite the first adhesive layer and, in its thickness, a through recess 5 having a first open end 51 and a second open end 52 opposite the first open end; the first adhesive layer 41 of the double-sided adhesive 4 being in contact with (i.e. applied to) the first face 11 of the support 1 so that the first open end 51 of the recess 5 of the double-sided adhesive 4 is opposite the area of ​​the first face 11 of the support 1; - a carbon dioxide permeable silicone-based membrane 6 in contact with (i.e. applied to) the second adhesive layer 42 of the double-sided adhesive 4 and in contact with (i.e. applied to) the second open end 52 of the recess 5 of the double-sided adhesive 4; - a measuring chamber 7 whose side walls correspond to the side edges of the recess 5 of the double-sided adhesive 4, whose lower part corresponds to the support 1 in an insulating material at the level of the area as previously defined and whose upper part corresponds to the CO2 permeable membrane 6 covering the second open end 52 of the recess 5 of the double-sided adhesive 4; said measuring chamber being filled with an electrolyte 9 comprising bicarbonate ions (HCO3).

[0071] The various elements comprising the sensor according to the present invention are as previously defined in the context of the preparation process according to the present invention.

[0072] The present invention also relates to a multi-sensor device comprising at least one CO2 sensor as previously defined. In such a multi-sensor device, the CO2 sensor can be associated, for example, with one or more sensors selected from the group consisting of temperature sensors, relative humidity sensors, and electrochemical sensors such as, for example, metabolic sensors, pH sensors, and ionic sensors.

[0073] The present invention finally relates to the use of a CO2 sensor as previously defined or a multi-sensor device as previously defined to measure (i) CO2 dissolved in a liquid medium in contact with said sensor or said multi-sensor device such as, for example, water or a biological fluid or (ii) gaseous CO2 present in a gaseous fluid in contact with said sensor or said multi-sensor device.

[0074] Examples of applications of such use include:

[0075] - in the chemical and especially pharmaceutical industry: For example, CO2 Dissolved pH is a critical parameter in biopharmaceutical production processes according to PAT guidelines. By influencing other parameters such as extracellular and intracellular pH, it has an effect on various metabolic pathways involved in growth or in the formation and quality of products;

[0076] - in physiological analysis and medical diagnosis: For example, sensors worn on the person for monitoring the arterial carbon dioxide pressure (PaCO2) of patients with respiratory failure;

[0077] - in the food industry: For example, for brewing or manufacturing In a brewery, dissolved CO2 is measured to monitor quality attributes, particularly to ensure an identical taste sensation;

[0078] - in the industrial field: For example, the measurement of dissolved CO2 is a a very important parameter for the optimization of industrial processes;

[0079] - in environmental analysis and in particular for water quality: By For example, the measurement of dissolved CO2 is a very important parameter for assessing the water quality of fish farm ponds and for monitoring marine and freshwater.

[0080] Other features and advantages of the present invention will become apparent to the person skilled in the art upon reading the following examples given by way of illustration and not limitation, with reference to the attached figures. Brief description of the drawings

[0081] The [Fig. 1] already presented corresponds to the schematic representation of the process of preparing a CO2 sensor according to the invention.

[0082] Figure 2 shows an example of the responses of dissolved CO2 sensors according to the invention. Responses to different dissolved CO2 concentrations of 4 sensors according to the invention (INV-1) with a thickness of 5302A adhesive (Nitto) and a permeable membrane of Silpuran 2030 (Wacker).

[0083] Fig. 3A presents the characterization of the impact of the internal electrolyte volume on the response time of the dissolved CO2 sensors according to the invention.

[0084] Fig. 3B shows the indicated response times corresponding to T99% for different volumes of internal liquid electrolytes (5 mM NaHCO3 and 0.1 M KC1).

[0085] Figure 4 shows the responses of three dissolved CO2 sensors according to the invention (INV-1) during changes in PBS solutions (250 mM) having different dissolved CO2 concentrations. The dashed curve represents the average response of the dissolved sensors according to the invention (INV-1), and the transparent area represents the standard deviation. The solid curve represents the response of a commercial optical sensor (CE-1), and the transparent area represents the accuracy range. expected, ±10% of the reference value.

[0086] Figure 5 shows the interferences of conductivity, pH and oxygen dissolved on 4 CO2 sensors according to the invention (INV-1) compared to a commercial sensor (CE-1).

[0087] Figure 6 shows the response of 4 dissolved CO2 sensors according to the invention (INV-1) with an internal liquid electrolyte (5 mM NaHCO3, 100 mM KC1) in solid line and 4 dissolved CO2 sensors according to the invention (INV-2) with an AGAR-based electrolyte (1%) in dotted line.

[0088] DETAILED DESCRIPTION OF PARTICULAR EMBODIMENTS I. Preparation of CO2 sensors.

[0089] 1.1. CO2 sensors according to the invention.

[0090] The proof of concept of the manufacturing and integration process for the dissolved carbon dioxide sensors of the present invention was carried out with two examples, INV-1 and INV-2, whose substrate is made of epoxy resin reinforced with a glass or paper fiber mesh (PCB) and whose reference electrode is a pseudo-reference electrode made of Ag / AgCl. The other elements constituting these sensors are as defined in Table 1 below.

[0091] [Tables 1] pH-sensitive electrode, cavity-forming film, electrolyte, CO2-permeable membrane, INV-1 IrOx, Nitto 5302A adhesive, NaHCO3 (5 mM), KC1 (100 mM), DI water, Silpuran® 2030 50 pm, INV-2 IrOx, Nitto 5302A adhesive, agar (1%), NaHCO3 (5 mM), KC1 (100 mM), DI water, Silpuran® 2030 50 pm

[0092] Table 1. The pH-sensitive electrodes used in the sensors according to the invention are prepared as follows:

[0093] - Formulation and mixing step: using commercial ink BQ242 (DuPont, Bristol, United Kingdom) without modification and mixed with iridium oxide (IrO2) powder, the dry mass ratio of IrO2 to BQ242 being 6%

[0094] - Deposition on a conductive gold layer: screen printing process

[0095] - Drying: 2-3 hours at 80°C.

[0096] The generic preparation process for a CO2 sensor consists of, chronologically- logically, in: - fabrication of a pH sensor based by collective fabrication (by screen printing or by silicon process), on the substrate 1 in epoxy resin reinforced by a glass or paper fiber mesh (PCB) with conductive tracks in gold, of the pH sensitive electrode 2 based on a metal oxide and of the reference electrode 3 in Ag / AgCl; - machining and application of a double-sided adhesive 4 to the geometries of the internal cavity of the sensor to obtain the desired volume; - transfer by bonding of the CO2 permeable membrane 5; - injection of the internal electrolyte 9 or its precursor using micro fluidic channels 81, 82 drilled at the level of the CO2 permeable membrane 5 or machined at the level of the double-sided adhesive 4.

[0097] 1.2. Prior art CO2 sensor.

[0098] In order to highlight the functionality and performance of the sensors according to the invention, a counterexample was carried out and studied under the same conditions with a commercial optical sensor from the Presens brand (CE-1). II. Characterization and tests.

[0099] II. 1. Methods.

[0100] For both examples, the sensors are immersed in solutions, connected to potentiostats which allow measurement of the open circuit potential values ​​for different solutions (changes in solution with known NaHCO3 concentration or dosed additions of gas (CO2 or N2)).

[0101] II.2. Results.

[0102] Validation in principle carried out

[0103] Figure 2 illustrates a typical response during changes in solutions with different NaHCO3 concentrations from four dissolved CO2 sensors (INV-1) manufactured simultaneously on the same substrate according to the process as previously defined (raw, unprocessed data). Good inter-sensor reproducibility can be observed.

[0104] Effect of electrolyte volume

[0105] The response time of sensors to variations in dissolved CO2 is a crucial criterion. As a reminder, adding a membrane to the sensor slows the diffusion of chemical species in contact with the electrode, thus increasing the response time. This phenomenon is further accentuated when the volume of the electrolyte increases, since the distance traveled by the analyte after passing through the membrane also increases. In addition, there is no mechanical convection within the chamber.

[0106] The influence of the internal electrolyte volume was studied by varying the thickness internal chambers thanks to the manufacturing flexibility (machining and stacking) made possible by the choice of adhesives used in their production. Thus, three different internal chamber volumes for INV-1 type sensors were characterized, the three volumes tested being 1.275 cm3, 5.025 cm3 and 8.775 cm3.

[0107] A significant impact was observed; thus, as described above, the response time varies with the electrolyte volume: as the volume increases, so does the response time ([Fig. 3A]). The devices with the smallest volumes that could be fabricated showed excellent mean 99% signal response times of 1.34 min (± 0.55 SD) over a range of 0 to 5% CO2, a value that can be compared to that reported by Presens of: t90 < 3 min for a change of 2 to 5% (or 15 mmHg - 38 mmHg in pCO2) ([Fig. 3B]).

[0108] The internal electrolyte with the smallest volume enabled 99% response times to be achieved on the order of a minute. As of the date of the invention, such fast 99% signal response times had never been obtained with a similar Severinghaus-type configuration.

[0109] Performance characterization

[0110] Performance characterization was achieved by measuring the accuracy of the sensors using a commercial Presens sensor (CE-1) and calculating the relative bias. Considering the CE-1 response as a reference value, the accuracy of the sensors developed according to the invention can be characterized by measuring the absolute deviation of their responses from that of the commercial sensor.

[0111] Figure 4 illustrates the results obtained. The dashed curve represents the average of the responses of three sensors developed according to the architecture and manufacturing process of the present invention, and the transparent area at the calculated standard deviation. This curve is compared with the response of the commercial optical sensor (CE-1, solid line) and the required accuracy zone of ±10% of the reference value (transparent area). Two points can be observed: - the dissolved CO2 sensors according to the invention are accurate to at least ±10% (compared to the commercial optical sensor) because their responses overlap with the area of ​​the commercial optical sensor; - the accuracy of the sensors is satisfactory because the standard deviation (transparent area) is relatively low.

[0112] Interferences induced by pH, dissolved oxygen and temperature

[0113] The interferences induced by pH, dissolved oxygen and temperature were then characterized with different dissolved CO2 sensors of the INV-1 type.

[0114] After performing a calibration against the commercial Presens sensor (CE-1), the values ​​of the conductivity of the solution were modified by adding KC1, the pH by adding HCl and NaOH, and the dissolved oxygen by bubbling ultrapure O2.

[0115] Figure 5 illustrates the response to these parameter changes of four dissolved CO2 sensors (INV-1) in parallel with one commercial optical sensor (CE-1). The results showed that the dissolved CO2 sensors are not affected by variations in the conductivity of the medium from 7.6 mS / cm to 31.6 mS / cm, nor by variations in pH from 3.64 to 8.42 pH units, nor by variations in the concentration of dissolved oxygen from 0% (argon) to 100% (ultrapure O2).

[0116] Finally, these results highlight a significantly better resolution for the dissolved CO2 sensors according to the present invention compared to commercial sensors of the Presens brand on very low concentrations of dissolved CO2.

[0117] The results presented in this section show that the dissolved CO2 sensors of the present invention are capable of providing accurate and reliable measurements to within at least ±10% over a measurement range of 0 to 25% dissolved CO2. Furthermore, the response times obtained are very satisfactory under varying conditions of conductivity, dissolved oxygen, and pH.

[0118] Influence of hydrogel

[0119] A particular feature of some of the dissolved CO2 sensors of the present invention is the presence of an internal electrolyte in the form of a hydrogel in order to limit or even eliminate evaporation during the storage and use phases, as well as to simplify manufacturing.

[0120] In this regard, several electrolyte alternatives in the form of hydrogel have been evaluated: Agar (1% by mass), 5 mM NaHCO3, 100 mM KCl, - Gelatin (25% by mass), 5 mM NaHCO3, 100 mM KCl, - Chitosan (10% by mass), polyethylene glycol diglycidyl ether (or PEGDE) (40 mM), 5 mM NaHCO3, 100 mM KCl, - Methacrylated dextran (5% by mass), phenyl- Lithium 2,4,6-trimethylbenzoylphosphinate (or LAP) (0.5% by mass), 5 mM NaHCO3, 100 mM KC1.

[0121] The formulation containing an agar hydrogel (1 wt%) showed the best results in terms of 99% response time and ease of preparation. As detailed in [Fig. 6], such a formulation exhibits a response to dissolved CO2 (sensitivity and 99% response time) similar to that of liquid electrolytes.

[0122] Furthermore, a preliminary evaluation of ambient air storage of these sensors was carried out. The sensors were left in open air for 24 hours, then rehydrated with steam. By performing an identical calibration following this rehydration phase, the dissolved CO2 sensors made from a "solid" AGAR electrolyte retained similar sensitivity (Table 2 below).

[0123] [Tables2] Liquid electrolyte Electrolyte Agar 1% Electrolyte Agar 1% Dried then rehydrated 66.37 ± 0.68 (n=4) 70.63 ± 0.32 (n=4) 61.54 + 6.8 (n=4)

[0124] Table 2: Slope values ​​(mean ± SD) of linear regressions for these sensors with liquid electrolyte, AGAR (1 wt%) and AGAR (1 wt%) rehydrated after 24 h of evaporation in ambient air (Sensitivity [Log(%CO2) / mV]) Bibliographic reference

[0125] [1] Severinghaus, John W.; Bradley, A. Freeman (1958). "Electrodes for Blood pO2 and pCO2 Détermination". Journal of Applied Physiology. American Physiological Society, vol. 13, pages 515-520.

Claims

Demands

1. A method for preparing a carbon dioxide sensor comprising the following steps: a) providing a support (1) of an insulating material having a first face (11) and a second face (12) opposite the first face, the first face having at least one area comprising a pH-sensitive electrode (2) and a reference electrode (3); b) providing a double-sided adhesive (4) having a first adhesive layer (41) based on acrylic, a second adhesive layer (42) based on silicone opposite the first adhesive layer and, in its thickness, a through recess (5) having a first open end (51) and a second open end (52) opposite the first open end;c) apply the first adhesive layer (41) of the double-sided adhesive (4) onto the first face (11) of the support (1) so that the first open end (51) of the recess (5) of the double-sided adhesive (4) is opposite the area of ​​the first face (11) of the support (1); d) apply, onto the second adhesive layer (42) of the double-sided adhesive (4) and onto the second open end (52) of the recess (5) of the double-sided adhesive (4), a carbon dioxide permeable silicone membrane (6) thereby forming a measuring chamber (7); then e) fill the measuring chamber (7) thus formed with an electrolyte (9) comprising bicarbonate ions (HCO3) thereby bringing the pH-sensitive electrode (2) and the reference electrode (3) into contact with the electrolyte.

2. A preparation method according to claim 1, characterized in that the pH-sensitive elements of said pH-sensitive electrode are made of a material among the transition metal oxides and, advantageously, are made of iridium oxide (IrO2).

3. A preparation method according to claim 1 or 2, characterized in that said reference electrode which is present in the support implemented in the process according to the invention is a silver chloride (AgCl / Ag) pseudo-reference electrode.

4. A preparation method according to any one of claims 1 to 3, characterized in that said double-sided adhesive has a thickness between 50 µm and 585 µm and in particular a thickness of the order of 85 pm (i.e. 85 pm ± 10 pm).

5. A preparation method according to any one of claims 1 to 4, characterized in that said CO2 permeable membrane has a thickness between 20 pm and 400 pm and in particular a thickness of the order of 50 pm (i.e. 50 pm ± 10 pm).

6. A preparation method according to any one of claims 1 to 5, characterized in that said measuring chamber has a volume between 1 cm3 and 12 cm3, in particular between 1.1 cm3 and 9 cm3 and, in particular, of the order of 1.275 cm3 (i.e. 1.275 cm3 ± 0.05 cm3).

7. A preparation method according to any one of claims 1 to 6, characterized in that the filling during said step e) is carried out by means of at least two fluidic channels (81, 82) opening into said measuring chamber and adapted to bring, into said measuring chamber, an electrolyte or a precursor thereof and to extract the air contained in said measuring chamber, said fluidic channels being pierced at the level of the CO2 permeable membrane and / or machined at the level of the double-sided adhesive.

8. A preparation method according to any one of claims 1 to 7, characterized in that said electrolyte is a liquid electrolyte.

9. A preparation method according to any one of claims 1 to 7, characterized in that said electrolyte is an electrolyte in the form of a hydrogel and, advantageously, an agar hydrogel.

10. A preparation method according to any one of claims 1 to 9, characterized in that said bicarbonate ions are present, in the liquid electrolyte or in the solution comprising the precursor compounds of the hydrogel forming the electrolyte, in an amount between 1 mM and 20 mM, in particular between 3 mM and 10 mM and, in particular, in the order of 5 mM (i.e. 5 mM ± 1 mM).

11. A CO2 sensor obtained by the preparation process according to any one of claims 1 to 10, comprising: - a support 1 made of an insulating material having a first face 11 and a second face 12 opposite the first face, the first face having at least one area comprising a pH-sensitive electrode 2 and a reference electrode 3; - a double-sided adhesive 4 having a first acrylic-based adhesive layer 41, a second silicone-based adhesive layer 42 opposite the first adhesive layer, and, in its thickness, a through-hole 5 having a first open end 51 and a second open end 52 opposite to the first open end; the first adhesive layer 41 of the double-sided adhesive 4 being in contact with the first face 11 of the support 1 so that the first open end 51 of the recess 5 of the double-sided adhesive 4 is opposite the area of ​​the first face 11 of the support 1; - a carbon dioxide permeable membrane 6 based on silicone in contact with the second adhesive layer 42 of the double-sided adhesive 4 and with the second open end 52 of the recess 5 of the double-sided adhesive 4; - a measuring chamber 7 whose side walls correspond to the side edges of the recess 5 of the double-sided adhesive 4, whose lower part corresponds to the support 1 in an insulating material at the level of the area as previously defined and whose upper part corresponds to the CO2 permeable membrane 6 covering the second open end 52 of the recess 5 of the double-sided adhesive 4; said measuring chamber being filled with an electrolyte 9 comprising bicarbonate ions (HCO3).

12. Multi-sensor device comprising at least one CO2 sensor according to claim 11.

13. Use of a CO2 sensor according to claim 11 or a multi-sensor device according to claim 12 to measure (i) CO2 dissolved in a liquid medium in contact with said sensor or multi-sensor device or (ii) gaseous CO2 present in a gaseous fluid in contact with said sensor or multi-sensor device.

Images