LOW COST APPARATUS FOR DETECTION OF NITROGEN-CONTAINING GAS COMPOUNDS

This invention relates to the field of detection of nitrogen-containing trace-gases, and in particular to a detector unit that uses a converter that converts nitrogen-containing compounds into nitrogen dioxide, and a low cost and compact nitrogen dioxide (NO₂) detector comprising a blue semiconductor laser and quartz-enhanced photo-acoustic sensor.

U.S. Pat. No. 6,612,306 “RESPIRATORY NITRIC OXIDE METER”, issued 2 Sep. 2003 to James R. Mault, and incorporated by reference herein, teaches a respiratory gas meter for detecting gas components of respiratory gas flowing along a flow path. As detailed in this reference, endogenous production of nitric oxide (NO) is increased in patients with asthma and other inflammatory lung diseases, as well as in patients with reactive airways disease. Mault cites U.S. Pat. No. 5,922,610 “SYSTEM TO BE USED FOR THE DETERMINATION OF NO LEVELS IN EXHALED AIR AND DIAGNOSTIC METHODS FOR DISORDERS RELATED TO ABNORMAL NO LEVELS”, issued 13 Jul. 1999 to Alving et al., incorporated by reference herein, for teaching the use of nitric oxide measurements in the diagnosis of inflammatory conditions of the airways, such as allergic asthma and rhinitis, in respiratory tract infections in humans and Kartagener's syndrome, as well as gastric disturbances. Other uses of nitric oxide detection for medical diagnoses are also cited by Mault.

In addition to detecting nitric oxide for medical diagnoses, detectors for measuring the concentrations of various nitrogen oxides, generally referred to as NOx are used to detect environmental concentrations, including vehicle emissions, and for industrial process control. Nitric oxide detectors may also be used to detect explosive material, which is an area of increased security concerns.

U.S. Pat. No. 6,612,306 (Mault) discloses a variety of techniques for detecting nitric oxide, including the detection of fluorescence from the gas induced by radiation, the detection of resonance changes on a micromechanical structure, and the detection of chemiluminescence when ozone is introduced in the airflow.

U.S. Pat. No. 6,160,255 “LASER-BASED PHOTOACOUSTIC SENSOR AND METHOD FOR TRACE DETECTION AND DIFFERENTIATION OF ATMOSPHERIC NO AND NO₂”, issued 12 Dec. 2002 to Rosario C. Sausa and incorporated by reference herein, teaches a dual-laser photoacoustic sensor that excites the air with pulsed, tunable lasers around 227 nm and 454 nm, and then detects the acoustic effects produced by the heat released from the excited nitric oxide and nitrogen dioxide. The excitation is caused by the nitric oxide absorbing the UV radiation around 227 nm, and the nitrogen dioxide absorbing the visible radiation around 454 nm.

Besides absorptions in UV, nitric oxide has absorption features in the mid-infrared spectrum. However, the cost of components in the UV and mid-infrared range are orders of magnitude more expensive than their visible-range counterparts, and thus the cost of components for photoacoustic sensing of nitric oxide does not currently provide for a low-cost nitric oxide detector. In U.S. Pat. No. 6,160,255 (Sausa), a doubling crystal and wavelength compensator are selectively enabled via an arrangement of mirrors to derive the 227 nm laser from the 454 nm laser. In converting the 454 nm radiation into 227 nm radiation less than 1% of the power remains, which results in a significant reduction in detection sensitivity in the UV. On the other hand, because components in the visible range continue to be developed for high-volume applications, such as optical storage devices (CDs, DVDs) and lighting devices, the cost of these visible-range components continues to decrease.

If a low-cost nitric oxide detector were available, each physician's office could be equipped with a diagnostic tool that will facilitate the detection and diagnosis of pulmonary and other physiological conditions, and asthmatic patients could be provided with a monitoring device for home use. A low cost NOx sensor could also be used for permanent/continuous exhaust-gas monitoring in cars and environmental-air quality monitoring. Similarly, low-cost nitric oxide detectors could be provided to security personnel at office buildings, train terminals, airports, and other potential terrorist targets.

It is an object of this invention to provide a low-cost, compact and highly sensitive detector for detection of nitrogen-containing gases. It is a further object of this invention to provide a detector that uses photoacoustic techniques.

These objects, and others, are achieved by a system that uses a semiconductor laser or light emitting diode emitting in the blue-violet-green wavelength range and a narrow bandwidth photo-acoustic sensor with a resonant pickup unit. Nitrogen dioxide is directly detected by its absorption in the blue-violet wavelength range while other nitrogen-containing compounds are chemically converted into nitrogen dioxide before photosensitive sensing of the amount of nitrogen dioxide produced. A surface chemical oxidation unit is preferably used to convert nitric oxide to nitrogen dioxide, using, for example potassium permanganate (KMnO₄) filter, or a platinum (Pt) catalyst unit.

The invention is explained in further detail, and by way of example, with reference to the accompanying drawings wherein:

FIG. 1 is a schematic view of an example photo-acoustic nitrogen-dioxide detector in accordance with this invention.

FIG. 2A illustrates an example block diagram of a detection unit in accordance with this invention suitable for detection of a nitrogen-containing compound in a gas mixture.

FIG. 2B illustrates an example block diagram of a nitric oxide detection unit in accordance with this invention incorporating a surface chemical conversion unit.

FIG. 2C illustrates an example block diagram of a NOx detection unit in accordance with this invention incorporating an ozone based conversion unit.

FIG. 2D illustrates an example block diagram of a NOx detection unit in accordance with this invention incorporating a catalytic conversion unit.

FIG. 2E illustrates an example block diagram of a nitrogen compound detection unit in accordance with this invention incorporating a scrubber unit and a conversion unit.

FIG. 3A illustrates an example block diagram of a photo-acoustic sensor for use in a nitric oxide breath tester incorporating a scrubber and conversion unit in accordance with this invention.

FIG. 3B illustrates an example block diagram of a photo-acoustic sensor for use in a nitric oxide breath tester incorporating a conversion unit and applying a differential measurement procedure in accordance with this invention.

FIG. 3C illustrates an example block diagram of a photo-acoustic sensor for use in a breath tester enabling the measurement of nitric oxide and one or more other gases in the exhaled breath in accordance with this invention.

FIG. 4 illustrates a photo-acoustic sensor unit according to this invention suitable for the measurement of several gases.

Throughout the drawings, the same reference numeral refers to the same element, or an element that performs substantially the same function. The drawings are included for illustrative purposes and are not intended to limit the scope of the invention.

FIG. 1 shows schematically an example photoacoustic nitrogen dioxide sensor 10 in accordance with this invention. The acoustic sensor 10 comprises a piezoelectric sensing unit 111 in the form of a resonant tuning-fork 160 and cylindrical acoustic resonators 182a, 182b. The resonators 182 have open ends to allow gas in the cell 120 to enter the tubes. If necessary, part of the gas cell volume can be filled with solid material to guide the gas flow more efficiently through the resonators. Preferably, the tuning fork has a high quality factor and narrow bandwidth to obtain a high detection sensitivity for nitrogen dioxide and to reduce the sensitivity to acoustic background noise. The acoustic signal enhancing tubes 182a, 182b are positioned as close as possible to the tuning fork 160 so that the spacings 183a, 183b are small and a substantially continuous cavity resonator is formed.

European Patent application 05300164, Applicant's reference number FR050029, “PHOTOACOUSTIC SPECTROSCOPY DETECTOR AND SYSTEM”, filed 4 Mar. 2005 for Hans van Kesteren, discloses a technique for detecting acoustic signals generated in a photoacoustic spectroscopy system through absorption of light that includes a sensing unit that exhibits structural resonance at or near a frequency of the acoustic signals. The sensing unit forms at least part of a cavity resonator that is arranged to enable a formation of standing pressure waves inside the cavity resonator at a cavity resonance frequency substantially coinciding with a structural resonance frequency of the sensing unit. PCT patent application PCT/US03/18299, published as WO 03/104767, “QUARTZ-ENHANCED PHOTOACOUSTIC SPECTROSCOPY”, filed 10 Jun. 2003 for Anatoliy A. Kosterev, discloses the fundamental techniques for resonance-enhanced detection of photoacoustic signals.

Preferably, the sensor 10 incorporates the principles of application FR050029 by choosing the radius of the cylindrical cavity 161 between the prongs of the tuning-fork 160 to be the same as the radii of the tube-shaped signal enhancing means 182a, 182b. The acoustic resonator has a resonance frequency close to or coinciding with the resonance frequency of the tuning fork so both the structural resonance of the tuning fork and the cavity resonance help in obtaining a high photo-acoustic detection sensitivity.

The tuning-fork 160 is provided with electrodes on the various tuning-fork surfaces, using techniques commonly known to those skilled in the field of quartz tuning fork resonators, so as to provide an electric signal that corresponds to the symmetric vibration of the prongs moving in opposite directions. Wires 112 are attached to the tuning fork electrodes to provide the signal from the tuning-fork sensing element to detection electronics (not illustrated).

The tuning-fork pickup element and acoustic resonator are incorporated in a gas cell 120 with gas inlet 121 and gas outlet 122. The gas mixture flows through the gas cell 120 and sensing unit 111. Windows 130 are incorporated in the gas cell 120 to enable a laser beam 131 to pass through the acoustic resonator and between the tuning fork prongs. The laser light with a wavelength in the 370-480 nm wavelength range is provided by a small semiconductor laser in a laser module 132. The divergent light form the laser module 132 is collimated by a lens or lens system 133. To obtain a compact sensor, a GRIN (Gradient Index) lens can be used for this purpose.

During operation, the current fed to the laser by wires 113 is modulated to obtain a modulated laser beam at a frequency corresponding to the resonance frequency of the sensing unit, such as an integer multiple (1×, 2×, etc.) or sub-multiple (½×, ⅓×, etc.) of the resonance frequency. In the referenced patent application, WO 03/104767, an embodiment is described wherein the wavelength of an infrared laser is modulated at half the resonant frequency of the sensing unit, so as to avoid a direct excitation of the tuning fork by the laser beam. In a preferred embodiment of this invention, however, because low-cost blue semiconductor lasers are more easily power modulated than wavelength modulated and the absorption wavelength range of nitrogen dioxide is broader than the wavelength range available from a blue semiconductor laser, a power modulation of the laser beam, at a frequency equal to the resonant frequency is preferred. In such an embodiment, the beamwidth of the laser inside the tuning fork and acoustic resonator is sufficiently controlled, or other methods employed, to avoid direct excitation of the tuning fork. The shorter wavelength of blue radiation compared to infrared radiation as well as the availability of high-quality optical components in the visible wavelength range make it easier to obtain these small beamwidths in the blue wavelength range than in the infrared wavelength range. Laser modulation at other multiples or sub-multiples of the resonant frequency may also be used, albeit with a possible loss of efficiency.

During absorption by the nitrogen dioxide, heat is dissipated in the gas mixture and pressure waves are generated that are amplified by the acoustic resonator and picked up by the tuning fork. Amplification and phase-sensitive detection of the tuning fork response communicated by the wires 112, using techniques common in the art of photoacoustic detection, provides a result that corresponds to the nitrogen dioxide concentration.

Nitrogen dioxide has a broad absorption band in the visible-light spectrum. As such, because of the greater production quantities of semiconductor lasers and optical components that operate in the visible spectrum, the cost of providing the visible-light sensor 10 can be expected to be substantially less than the cost of an ultraviolet-light or infrared sensors as taught in for instance U.S. Pat. No. 6,160,255 (Sausa, above). Quartz tuning fork sensor elements can also be produced at low cost because this technology is similar to the technology for making tuning-fork frequency reference crystals. Semiconductor lasers and quartz tuning forks have millimeter size dimensions and low power consumption, which enables the integration of all components into a very compact and low power device, suitable for portable applications.

FIG. 2A shows a detector unit 200 for the detection of one or more nitrogen-containing compounds in a gas mixture. The detector includes a converter 210 that is configured to convert one or more nitrogen-containing compound(s) in the incoming gas mixture 201 to nitrogen dioxide (NO₂) molecules. The converted gas stream 219 is provided to a photoacoustic sensor 10 via inlet port 121 and discharged via the output port 122. The photoacoustic sensor 10 is configured to detect the presence of nitrogen dioxide molecules in the converted air 219.

The converter 210 can use any of a variety of techniques that are well known in the art to convert nitrogen-containing compounds to nitrogen dioxide. Examples of nitrogen-containing compounds are nitric oxide (NO), ammonia (NH₃), and amines. Nitric oxide can be converted into nitrogen dioxide by an oxidation step while ammonia can be converted by, for example, the Oswald process. In the Oswald process, NH₃is converted into NO₂by a Pt catalytic reaction and subsequent reaction with oxygen.

A number of example configurations for the detector 200 are provided in FIGS. 2B-2E, although one of ordinary skill in the art will recognize that the invention is not limited to these examples.

FIG. 2B shows an example NO detection unit. The incoming gas mixture 201 is led via a three way valve 220 to a NO to NO₂conversion unit 210. Preferably, a surface-oxidation device is used, to provide a low cost and compact design. An example of a surface-chemical oxidation device is provided by B. Fruhberger et al. in “Detection and quantification of nitric oxide in human breath using a semiconducting oxide based chemiresistive microsensor,” Sensors and Actuators B: Chemical, 76(1-3):226-34, 2001, wherein an alumina supported permanganate (KMnO₄) filter provides a surface-chemical oxidation of nitric oxide into nitric dioxide. The sum of the NO₂present in the incoming gas stream and the NO₂generated in the conversion unit is measured in the photo-acoustic sensor 10. To compensate for the presence of NO₂in the incoming gas stream, a reference measurement can be performed without the converter by leading the incoming gas mixture 201 via the three way valve 220 through the bypass 230 to the sensor 10.

FIG. 2C illustrates a configuration to measure the total NOx concentration i.e. the sum of NO and NO₂in a gas stream 201. An ozone based converter 250 converts the nitric oxide present in the gas stream 201 into NO₂which can be detected together with the NO₂already present in the gas stream. The converter consists of an ozone generator 251 and a mixing chamber 252 in which the ozone reacts with the nitric oxide present in the gas mixture. Ozone can be generated from ambient air by a variety of techniques known to the art.

Alternatively, as illustrated in FIG. 2D, a platinum (Pt) catalytic converter can be used to cause the oxidation of nitric oxide to nitrogen dioxide. This alternative requires that the catalyst be heated to 300° C., but avoids the need to regularly replace the permanganate filter of FIG. 2B. The incoming gas stream 201 from, for instance, the exhaust of a car is led via the catalytic converter 260 to the photo-acoustic sensor 10. If it is necessary to discriminate between NO and NO₂in the incoming gas mixture, a reference measurement for obtaining the NO₂concentration can be done by reducing the catalyst temperature below the conversion temperature. Another faster approach is to apply a three way valve 220 and a bypass 230, as illustrated.

FIG. 2E illustrates a block diagram of an example configuration incorporating a scrubber 215 and a converter 210. This configuration can be applied for monitoring the generation of nitrogen-containing gas compounds in an enclosed environment 225. The scrubber removes one or several nitrogen-containing compounds from the incoming gas mixture 202. The scrubber should remove at least nitrogen dioxide, compounds that produce nitrogen dioxide from the incoming gas mixture when led through the converter, and the components that are generated in the compartment 225. The advantage of combining a scrubber and a converter is that a good specificity for the detection of specific nitrogen-containing compounds can be obtained with relatively simple scrubber and converter compositions.

FIG. 3A shows a block diagram of a breath tester suitable for the detection of nitric oxide and based on a scrubber 312, a converter unit 310, and a miniature photo-acoustic sensor 10. During inhalation through the mouthpiece 301, ambient air is led through the inlet 302, scrubber 312, and one-way valve 330. The scrubber removes the NO and NO₂from the inhaled air. During exhalation, through the mouthpiece 301, the air is guided via one-way valve 350 and flow restrictor 360 to the converter unit 310. Flow restrictor 340 causes a part of the flow to enter the photo-acoustic sensor 10, and another part to enter the bypass 390, and the exhaled air leaves the breath tester via exit port 309.

The scrubber 312 preferably removes the NO and NO₂from the inhaled air, while the converter 310 is preferably based on a surface chemical conversion of nitric oxide into nitrogen dioxide. The scrubber 312 and converter 310 are part of a replaceable unit 315. Because the inhaled air is free of nitric oxide, all the nitric oxide present in the exhaled gas stream is generated in the body that provides the exhaled air. Therefore, the amount of nitrogen dioxide measured in the sensor 10 directly corresponds to the amount of nitric oxide generated in the body.

A pressure sensor 311 is also provided to monitor exhalation and inhalation. During exhalation, the flow is preferably restricted by 360 to a fixed flow rate that conforms to the generally accepted measuring conditions for nitric oxide measurements in exhaled air. Electronics for signal detection, pressure monitoring, laser power control, etc, are illustrated in block 317. The results of the breath test can be presented to the physician or patient via a user interface 316.

FIGS. 3B and 3C illustrate alternative embodiments of an exhaled breath tester. The blocks similar to those used in FIG. 3A are denoted by the same number.

The exhaled breath tester in FIG. 3B incorporates a replaceable NO to NO₂converter unit 315 but does not include a scrubber unit. In the embodiment of FIG. 3B, the inhaled air passes through inlet port 302, one-way valve 303, and converter 310. During this stage, the sum of the nitrogen dioxide produced in the converter and the nitrogen dioxide already present in the ambient air is detected by the photo-acoustic sensor 10. As in FIG. 3A, the flow through the detector can be restricted by flow restrictor 340, with the excess of the inhaled air going though bypass 390. After passing another one-way valve 330, the air enters the mouth through the mouthpiece 301; one-way valve 370 prevents the intake of air from the exit port 309.

The exhaled air in FIG. 3B follows a similar path as described for FIG. 3A. The nitric oxide produced in the body can be derived from the difference of NO₂concentration measured by the sensor unit 10 in the inhaled and exhaled gas mixture.

FIG. 3C shows a block diagram of an exhaled breath tester that measures nitric oxide in combination with one or several other gases in the exhaled breath. In particular, O₂, CO₂, and H₂O are present in high concentrations and can be measured relatively simply with various types of sensors. Measuring the exhalation profile of O₂, CO₂and/or H₂O and linking this profile to the exhalation profile of nitric oxide provides information that facilitates a better diagnosis of a specific airway disease. It also enables sampling of the NO concentration in the exhaled air stemming from a specific part of the airways or lungs. A measurement unit for measuring O₂, CO₂or H₂O is denoted by 321 in FIG. 3C. Oxygen and water have absorption features in the visible range. This makes it attractive to combine a nitrogen dioxide and for instance oxygen sensor into one photo-acoustic module, as illustrated by the dashed combination 320 of sensors 10 and 321.

FIG. 4 illustrates a block diagram of an example combined nitrogen dioxide and oxygen photo-acoustic module for use in the combination 320. Oxygen shows an absorption feature around a wavelength of 760 nm, where semiconductor lasers are available. In the photo-acoustic sensor module 320, a dichroic mirror 440 guides both the laser beam from the red laser unit 430 and the laser beam from the blue laser unit 420 into the photo-acoustic sensor 450, such as the sensor 10 in FIG. 1. The components present in the photo-acoustic sensor 10, such as the tuning fork, acoustic resonator, and windows, are not wavelength specific within the visible wavelength range, and therefore operation at two wavelengths is feasible. During operation, the two lasers can be powered alternatively for short periods of time during the exhalation time, to obtain both the oxygen and nitrogen dioxide exhalation profile.

In interpreting these claims, it should be understood that:

a) the word “comprising” does not exclude the presence of other elements or acts than those listed in a given claim;

b) the word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements;

c) any reference signs in the claims do not limit their scope;

d) several “means” may be represented by the same item or hardware or software implemented structure or function;

e) each of the disclosed elements may be comprised of hardware portions (e.g., including discrete and integrated electronic circuitry), software portions (e.g., computer programming), and any combination thereof;

f) hardware portions may be comprised of one or both of analog and digital portions;

g) any of the disclosed devices or portions thereof may be combined together or separated into further portions unless specifically stated otherwise;

h) no specific sequence of acts is intended to be required unless specifically indicated; and

i) the term “plurality of” an element includes two or more of the claimed element, and does not imply any particular range of number of elements; that is, a plurality of elements can be as few as two elements.