Blister Pack Gas Sensor Calibration System
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Solution Overview
Problem
Existing gas sensor testing and calibration methods lack efficiency in providing reproducible gas mixtures for simultaneous testing and calibration of multiple gases like CO, CH4, and H2S, especially in portable and fixed sensors, where current methods are either cumbersome or require complex setups.
Innovation Solution
A system utilizing sealed blister packs or bubble foils made of low permeability materials, where each blister pack contains a specific gas mixture that can be easily and reproducibly released into a defined air volume, transported, and pumped to sensors for calibration, using a mechanism similar to a cap gun mechanism for puncturing and air pumping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gas is generated using complex gas generation systems, then gas sensor testing and calibration can be performed, but the system complexity and setup requirements increase
Solution Approach 1:
The patent employs disposable blister packs containing pre-mixed gas samples instead of complex reusable gas generation systems. Each blister pack is a single-use container that holds a defined amount of gas mixture, eliminating the need for sophisticated gas generation equipment while ensuring reliable and reproducible sensor testing and calibration.
Solution Approach 2:
The gas mixtures are prepared and sealed in blister packs before use. The calibration gases are pre-mixed in specific concentrations and stored in hermetically sealed containers, so that when testing is needed, the gas is already ready in the correct formulation, eliminating the need for complex real-time gas generation systems.
2Productivity
If multiple gases are mixed for simultaneous testing, then testing efficiency improves, but gas interaction reactions may occur
Solution Approach 1:
The patent creates localized gas environments by sealing different gas mixtures in separate blister packs. Each blister pack contains a specific gas or gas mixture tailored for particular sensor testing, allowing multiple gas types to be stored and transported separately without risk of interaction, while still enabling simultaneous testing of multiple sensor types.
Solution Approach 2:
The blister pack serves as an intermediary container that holds gas mixtures in isolation. The hermetically sealed packaging acts as a barrier that prevents different gases from interacting with each other during storage and transport, while still allowing controlled release to the sensor for testing.
3Measurement precision
If gas is released into a defined volume of air, then reproducible gas pulses are achieved, but the release mechanism becomes more complex
Solution Approach 1:
The blister pack is designed to be self-puncturing through simple mechanical action. When the blister pack is pressed against a sensor or placed in a testing chamber, the sealed container naturally ruptures to release the gas, eliminating the need for complex pump or valve mechanisms while ensuring consistent and reproducible gas pulse delivery.
Solution Approach 2:
The gas release mechanism utilizes pneumatic pressure built up within the sealed blister pack. As the gas is confined in the sealed container, pressure accumulates until the moment of release, at which point the gas expands rapidly into the surrounding environment, creating a controlled and reproducible pulse without requiring complex mechanical release systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and reproducible testing and calibration of gas sensors by providing precise gas mixtures, reducing the need for complex gas generation systems and ensuring reliable health checks for sensors in various environments.
Implementation Method 1
sealed blister packs or bubble foils made of low permeability materials
Implementation Method 2
released into a defined volume of air
Implementation Method 3
transported to a gas sensor for testing and/or calibration
Data Source
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AI summary
A system for testing and calibrating gas sensors with gas stored in a strip of packets. The strip may be fed into a chamber having a defined volume of air. A packet may be punctured with a mechanism to release one or more gases into the volume of air to result in an air-gas mixture. New air may be moved into the chamber to push the mixture out of the chamber to a sensor for testing and/or calibration. Then another packet may be punctured to release one or more gases into the volume of new air in the chamber for another air-gas mixture. This mixture may be moved out of the chamber, in the same manner as the previous mixture, to another sensor for testing and/or calibration. This procedure may be repeated with additional packets on the strip.