MICROELECTRODES FOR ELECTROCHEMICAL GAS DETECTORS

Abstract

An electrochemical gas sensor having an electrode with a catalyst distributed on a porous surface is described. The porous surface can be a polytetrafluoroethylene tape. Alternate embodiments include layered or stacked electrodes.

Description

FIELD

This application pertains to electrochemical gas detectors, which incorporate microelectrodes. More particularly, this application pertains to electrochemical gas detectors, which include an electrode comprised of a catalyst deposited onto a porous surface.

BACKGROUND

Electrochemical gas sensors using microelectrodes have a number of benefits, such as the ability to use fast scanning voltammetric measurements, utilizing features such as convergent diffusion and potentially being simpler to construct than conventional gas diffusion electrodes. However they also suffer from disadvantages. In particular it is more difficult to achieve a reliable 3-phase region, i.e., a region where gas does not have to diffuse a long distance through the electrolyte before reaching the sensing electrode(s).

The analyte gas can dissolve in the electrolyte and give rise to a background current which remains after the target gas is removed, resulting is slow response times and background current errors.

This issue is normally overcome in conventional gas sensors by ensuring that all of the target gas is consumed by the sensing electrode (e.g., via capillary limitation of flux to a gas diffusion electrode). However the design of gas diffusion electrodes is complex, especially when using non-aqueous electrolytes such as ionic liquids, and the resulting large surface area and hence double layer capacitance means that dynamic electrochemical techniques such as scanning voltammetry are not feasible.

An example of the current state of the art in microband electrodes are those manufactured by Nanoflex® (http://www.nanoflex.com/Products/Product/Platinum_Substrate) which comprise band electrodes within wells of micrometer dimensions. Previously people have also used line electrode devices deposited on ionic conducting substrates (Kirsi Wallgren, PhD thesis 2005, University of Nottingham and references therein). Microband electrodes can be made via sandwich structures using, for example, micromachined silicon layers or line electrodes on the surface of a substrate. These approaches do not address the issue of ensuring easy gas access to the sensing electrode, since it is immersed within the electrolyte (which may be either a solid or liquid).

In accordance herewith, methods and structures are provided for utilizing microelectrodes and particularly microband electrodes in such a way as to ensure rapid gas access to the sensing electrode(s) and/or to compensate or correct the sensor behavior for variations in the degree to which the sensing electrode is wetted. The attached figures illustrate various aspects of embodiments hereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates an approach for locating the shape and location of the electrolyte meniscus by EIS.

FIG. 1B illustrates a well with layered microband electrodes and counter/reference electrode(s).

FIG. 1C illustrates an oxygen pump sensor concept.

FIG. 1D illustrates a sensing electrode located at the interface between the diffusion barrier and electrolyte.

FIG. 2A illustrates a configuration where a solid electrolyte and electrodes such as gas diffusion electrodes are used ‘end on’ to create a microband type of system.

FIG. 2B illustrates a configuration where electrodes and electrolyte protrude from the sensor.

FIG. 2C illustrates a configuration where a solid electrolyte, a filter, and electrodes such as gas diffusion electrodes are used ‘end on’ to create a microband type of system.

FIG. 2D illustrates a stacked configuration where several solid electrolytes and electrodes, such as gas diffusion electrodes, are used ‘end on’ to create a microband type of system.

FIG. 3A illustrates a simulated detector's structure.

FIG. 3B illustrates expected results of the detector of FIG. 3A.

DETAILED DESCRIPTION

The use of non-gas diffusion electrodes in electrochemical gas sensors can alleviate some problematic issues that persist in traditional systems, such as humidity transients, low sensitivity, and slow response times. The novel electrochemical gas sensor described herein includes a sensing electrode fabricated by depositing a catalyst onto a porous support material. The catalyst can be platinum or another noble metal or other catalysts or mixtures thereof known in the art. The porous material can be polytetrafluoroethylene (PTFE) or other porous materials known in the art. This catalyst can be deposited randomly or uniformly. On deposition technique is vacuum sputtering, which when utilized, yields a thin, fully wetted electrode having pores through which a gas can travel. The electrode gives negligible humidity transients when used with an electrolyte such as sulfuric acid, phosphoric acid, ethylmethylimidazolium hydrogen sulfate (EMIM HS) or other known electrolytes or mixtures thereof. The electrode also gives fast response times to hydrogen sulfide gas when used with the above electrolytes.

The electrolyte can be present as a free liquid, absorbed in a wick or separator material, or absorbed in a solid support. The solid support that the electrolyte is absorbed on can be polybenzimidazole film.

FIGS. 1A-1D illustrate aspects of one method of improving on a single, line or band or other type of electrode. One or more sensing electrodes are coated with a meniscus of electrolyte. The upper most electrode rapidly responds to changes in the gas phase due to the thinly wetted electrolyte layer. ‘Auxiliary’ electrodes deeper into the electrolyte will not respond so quickly and can be used to measure dissolved gas in the bulk of, or spatially varying within, the electrolyte and can then be used to correct the main sensing electrode signal for the effect of these background currents.

This approach requires the shape and location of the electrolyte meniscus to be well defined, which in practice does not always occur—for example changes in temperature and or hydration level of the electrolyte can cause the electrolyte layer to move. By performing measurements such as electrochemical impedance spectroscopy (EIS) on the different electrodes within the structure in FIG. 1A, the position of the electrolyte layer can be determined, and the resulting calculated geometry used in combination with current measurements to compensate for background currents. In extreme cases, the meniscus may even move to the extent that the uppermost electrode is no longer in contact with it, in which case the next electrode down will be used as the sensing electrode.

FIG. 1B illustrates one practical implementation of this approach comprising a well with layered microband electrodes and counter/reference electrode(s). FIG. 1C shows an oxygen pump sensor concept based on a similar approach. An optional solid PTFE oxygen diffusion barrier can be used as a diffusion limiter and/or retainer for liquid electrolyte. The sensing electrode may beneficially be located at the interface between the diffusion barrier and electrolyte as shown in FIG. 1D. The counter electrode may be a conventional gas diffusion electrode or similar for oxygen generation, a further electrode or electrodes may be included to measure and compensate for background currents.

FIG. 2A illustrates a configuration where a solid electrolyte and electrodes such as gas diffusion electrodes are used ‘end on’ to create a microband type of system. In this case the stack could be implemented with a commercial membrane electrode assembly (MEA) or similar structure. FIG. 2B illustrates that the electrodes and electrolyte could protrude from the sensor and not be flush as in FIG. 2A. Variations on this approach include filters, FIG. 2C, and stacked systems to increase electrode areas as in FIG. 2D.

Structures as described above and illustrated by the attached can be fabricated using, for example, screen printing, MEMS fabrication, multilayer printed circuit boards (e.g., with platinum plated copper), or techniques such as those used for making film and foil capacitors or multilayer batteries.

FIG. 3A illustrates a simulated detector's structure in accordance herewith. FIG. 3B illustrates expected simulated results of the detector of FIG. 3A, namely, the results of a finite element model where the signal from an auxiliary electrode is used to compensate the main electrode signal for the slow secondary response due to dissolved gas.

From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims.

Further, logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. Other steps may be provided, or steps may be eliminated, from the described flows, and other components may be add to, or removed from the described embodiments.

Claims

1. An electrochemical gas detector comprising: a well with multiple layered microband electrodes, which are used to compensate for dissolved gases in the electrolyte, and at least one of a counter, or a reference electrode.

2. An electrochemical gas detector which includes a stack comprising a plurality of elements, each having a solid electrolyte and electrodes such as gas diffusion electrodes, where the gas access is to exposed ends of the electrode stack.

3. An electrochemical gas sensor comprising an electrode including a catalyst deposited on a porous material wherein the catalyst is deposited by vacuum sputtering the catalyst onto the porous material.

4. (canceled)

5. The electrochemical gas sensor of claim 3 wherein the catalyst comprises platinum or another noble metal.

6. The electrochemical gas sensor of claim 3 wherein the porous material comprises polytetrafluoroethylene.

7. The electrochemical gas sensor of claim 3 further comprising an electrolyte.

8. The electrochemical gas sensor of claim 7 wherein the electrolyte comprises sulfuric acid, phosphoric acid, or ethylmethylimidazolium hydrogen sulfate.

9. The electrochemical gas sensor of claim 7 wherein the electrolyte comprises one of a free liquid, is absorbed in a wick or separator material, of is absorbed in a solid support.

10. The electrochemical gas sensor of claim 9 wherein the electrolyte is absorbed in polybenzimidazole film.

11. The electrochemical gas sensor of claim 9 wherein the electrolyte is absorbed in a wick.

12. The electrochemical gas sensor of claim 9 wherein the electrolyte comprises a free liquid.

13. The electrochemical gas sensor of claim 7 wherein the electrolyte comprises sulfuric acid.

14. The electrochemical gas sensor of claim 7 wherein the electrolyte comprises phosphoric acid.

15. The electrochemical gas sensor of claim 7 wherein the electrolyte comprises ethylmethylimidazolium hydrogen sulfate.

16. The electrochemical gas sensor of claim 4 wherein the catalyst comprises platinum and the porous material comprises polytetrafluoroethylene tape.

17. The electrochemical gas sensor of claim 8 wherein the catalyst comprises platinum, the porous material comprises polytetrafluoroethylene tape, and the electrolyte comprises phosphoric acid.

18. The electrochemical gas sensor of claim 8 wherein the catalyst comprises platinum, the porous material comprises polytetrafluoroethylene tape, and the electrolyte comprises sulfuric acid.

19. The electrochemical gas sensor of claim 8 wherein the catalyst comprises platinum, the porous material comprises polytetrafluoroethylene tape, and the electrolyte comprises ethylmethylimidazolium hydrogen sulfate.

20. The electrochemical gas sensor of claim 9 wherein the catalyst comprises platinum, the porous material comprises polytetrafluoroethylene tape, the electrolyte comprises ethylmethylimidazolium hydrogen sulfate, and the electrolyte is absorbed in a solid support.

21. The electrochemical gas sensor of claim 7 where the electrolyte comprises one of an aqueous, ionic liquid or polymeric electrolyte.

22. The electrochemical gas sensor of claim 1 which includes at least one sensing electrode and wherein that electrode is coated with a meniscus of electrolyte.

23. The electrochemical gas sensor of claim 22 which includes at least a second sensing electrode displaced toward the electrolyte from the at least one sensing electrode wherein the second sensing electrode responds to measured dissolved gas in the bulk of, or spatially varying within the electrolyte, to correct the signal of the at least one sensing electrode for the effect of background currents.

24. The electrochemical gas sensor of claim 1 which includes an oxygen diffusion barrier or retainer for an electrolyte in the well wherein a sensing electrode is located at an interface between the diffusion barrier and the electrolyte.

25. The electrochemical gas sensor of claim 2 which includes at least first, second gas diffusion electrodes with a solid electrolyte therebetween and with an end region that includes an end portion of each electrode and an end part of the solid electrolyte all of which are gas accessible.

26. The electrochemical gas sensor of claim 25 wherein the electrodes and the solid electrolyte are carried by a support.

27. The electrochemical gas sensor of claim 26 where relative to an end of the body, the end region is located at one of, flush with the end of the body, extending from the end of the body, or recessed relative to the end of the body.

28. The electrochemical gas sensor of claim 27 which includes a plurality of first, second electrode combinations with each separated by electrolyte wherein members of the plurality are carried by a common housing.