JP2008203265A - Combined oxygen and nox sensor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an amperometric oxygen sensor which can be manufactured at a comparatively low cost and which improves the oxigen sensitivity, and to provide a combined sensor for oxygen and nitrogen oxides which fulfills the sensor technique capable of bringing about independent indications of nitrogen oxides in a gas. <P>SOLUTION: Generally, the combined sensor employs a sensor body (220) which includes two different types of electrodes, namely oxygen adsorptive porous electrode layers (16a, 16c) and dissociative oxygen-porous electrode layers (16b, 16d). In accordance with one embodiment of the present invention, the sensor includes a sensor body, an oxygen content electrical signal output end, and a nitrogen content electrical signal output end. The sensor body is disposed in the gas and comprises includes a plurality of adsorptive oxygen-porous electrode layers and a plurality of dissociative oxygen-porous electrode layers. The oxygen dissociative porous electrode layers comprise a material selected so as to dissociate the nitrogen oxides into nitrogen and oxygen. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

This application claims priority to US Provisional Application No. 60 / 254,081, filed Dec. 7, 2000. This application claims a priority of US Provisional Application No. 60 / 155,817 filed on September 23, 1999 and is a continuation of US Patent Application No. 09 / 662,773 filed September 15, 2000. It is also an application.

  The present invention relates to an apparatus for detecting a partial pressure of oxygen in a gas, and more particularly to an active multilayer sensor using an oxygen ion conductive material. The present invention also relates to a composite sensor for measuring oxygen content and nitrogen oxide content in a gas. Nitrogen oxide is used herein to denote nitric oxide, nitrogen dioxide, dinitrogen trioxide, and the like.

  It is widely recognized that one of the most important diagnostic methods for monitoring the efficiency of any combustion process is measuring the partial pressure of oxygen in the exhaust gas. Thus, oxygen sensors have long been used to measure the oxygen content of exhaust gases from various combustion processes such as automotive internal combustion engines or power generation facilities that burn coal, natural gas, and oil.

The most widely known and used oxygen sensor is based on partially stabilized zirconia (PSZ) as an ionic conductor. This type of sensor works by monitoring the electromotive force (EMF) across an ionic conductor that is exposed to different oxygen partial pressures. Oxygen tends to move from a gas containing high concentration oxygen to a lower concentration gas. When two gases are dissociated from each other by an electroded oxygen ion conductor, oxygen molecules are dissociated on one surface of the conductor and absorb electrons to form oxygen ions. These ions then diffuse through the ion-containing conductor and leave the entrance surface with electron vacancies (O ² + 4e = 2O ⁻² ). At the exit of the conductor, i.e. on the low oxygen concentration side, oxygen ions leaving the conductor give up electrons and form molecular oxygen, thus leaving excess electrons on the exit surface. Thereby, EMF is generated between the two surfaces of the ionic conductor.

  The problem with the use of partially stabilized zirconia sensors is that they must be operated in a temperature range of about 800 ° C. to reduce the internal resistance to a point where current measurement is possible. Furthermore, the raw material cost of stabilized zirconia is relatively high, and the melting point of zirconia is very high (2700 ° C.), which makes sensor formation expensive.

  US Pat. No. 4,462,891 in the name of Lawless describes a passive oxygen sensor using a ceramic ionic conductive material based on nickel niobate and bismuth oxide. This oxygen sensor is a porous metal conductor arranged to form a body having a plurality of layers of ceramic materials and alternately arranged ceramic layers and metal layers, the first alternating arrangement of metal layers being on one side of the body And a second alternating portion of the metal layer includes a conductor exposed along the opposite side of the body. The first and second interleaved portions of the metal layer are exposed to different gases, and one gas serves as a reference gas for generating a voltage output signal applied to electrodes connected to the interleaved metal layer. The voltage output signal indicates the relative oxygen partial pressure of the individual gases. Thus, the passive oxygen sensor does not expose the first and second metal layers in the body to the sample gas and the individual reference gas having a known oxygen partial pressure, i.e., does not expose both sides of the sensor body to the individual gas. As long as the oxygen partial pressure indication cannot be provided.

  Recently, amperometric sensors have been introduced that also use partially stabilized oxygen zirconium but do not require a reference gas for operation. As shown in FIG. 1, this type of sensor 80 includes a cavity 100 that communicates with an unknown gas through a diffusion hole 120. The base of the cavity 100 is a PSZ electrolyte 140 connected to a power source 170 via electrodes 160, 160 '. By applying a voltage, oxygen is pumped from the cavity to the atmospheric gas through diffusion as indicated by the arrow. When the cavity is sealed at the top of the base or when the top of the cavity has a small diffusion hole 120, when the voltage is increased, a larger amount of oxygen than the amount of penetration through the diffusion hole cannot be pumped out of the cavity. To reach. The current drawn at this point is called the amperometric current. As the oxygen partial pressure in the atmospheric gas increases, the current titration current increases. Thus, the measured value of the amperometric current results in an oxygen partial pressure. However, here too, this sensor has some of the same disadvantages of high material and manufacturing costs. An extremely small diffusion hole of about 5 μm is required, and precision processing is required because its size affects the operation of the sensor. In addition, the fabrication of the sensor of FIG. 1 requires 5 silk screen treatments and 4 firing steps. Finally, these sensors lose sensitivity above about 80% oxygen and the diffusion holes are prone to clogging.

Accordingly, there is a need in the art for a amperometric oxygen sensor that can be manufactured at a relatively low cost and provides improved oxygen sensitivity. There is also a need in the art for sensor technology that can provide an independent indication of nitrogen oxides in a gas.
US Pat. No. 4,462,891

  Accordingly, one object of the present invention is to provide an improved oxygen / nitrogen oxide detection device that satisfies the above-mentioned needs.

  The present invention meets the above needs by providing a composite oxygen / nitrogen oxide sensor. In general, a composite sensor uses a sensor body including two different types of electrodes, that is, an oxygen-adsorbing porous electrode layer and an oxygen-dissociating porous electrode layer.

  According to one embodiment of the present invention, a composite sensor for measuring oxygen content and nitrogen oxide content in a gas is provided. The sensor includes a sensor body, an oxygen content electrical signal output end, and a nitrogen oxide electrical signal output end. The sensor body is disposed in a gas and includes (i) a plurality of oxygen-adsorbing porous electrode layers and (ii) a plurality of oxygens selected to catalyze nitrogen oxides and dissociate into nitrogen and oxygen. A dissociated porous electrode layer; and (iii) a plurality of oxygen ion conductive ceramic layers interposed between each of the oxygen adsorbing porous electrode layer and each of the oxygen dissociating porous electrode layers. The oxygen content electrical signal output end is coupled to a plurality of oxygen-adsorbing porous electrode layers. Similarly, the nitrogen oxide electrical signal output end is coupled to a plurality of oxygen dissociated porous electrode layers. The nitrogen oxide electrical signal output end is electrically insulated from the oxygen content electrical signal output end.

  According to another embodiment of the present invention, a composite sensor for measuring the oxygen content and nitrogen oxide content in a gas is provided, wherein the oxygen dissociated porous electrode layer catalyzes nitrogen oxide and nitrogen. Has enough rhodium to dissociate into oxygen.

  According to yet another embodiment of the present invention, a composite sensor for measuring oxygen content and nitrogen oxide content in a gas is provided. The sensor includes a partial enclosure that defines a gas passage, a sensor body, and a diffusion barrier. The diffusion barrier defines a diffusion restriction portion of the gas passage, and the sensor body is disposed in the diffusion restriction portion of the gas passage.

  According to still another embodiment of the present invention, the sensor body includes a plurality of oxygen-adsorbing porous electrode layers, a plurality of oxygen-dissociating porous electrode layers, and a plurality of oxygen-ion conductive ceramic layers. The oxygen dissociated porous electrode layer comprises a material selected to dissociate nitrogen oxides into nitrogen and oxygen by catalysis. A plurality of oxygen ion conductive ceramic layers are interposed between each oxygen adsorbing porous electrode layer and each oxygen dissociating porous electrode layer.

  The following detailed description of preferred embodiments of the present invention can be best understood when read with reference to the following drawings, where like structure is indicated with like reference numerals and in which: The present invention will be described first with reference to an amperometric oxygen sensor and then with a combined oxygen and nitrogen oxide sensor using an additional structure similar to the oxygen sensor and basic oxygen sensor structure.

Current Titration Oxygen Sensor A schematic diagram representing an amperometric oxygen sensor constructed in accordance with the present invention is shown in FIG. As shown in the figure, the oxygen sensor 10 includes a sensor body 12 having alternating layers of an oxygen ion conductive material 14 and oxygen-adsorbing porous conductive materials 16a, 16b, 16c, and 16d. The first set of oxygen-adsorbing porous conductive layers 16 a and 16 b have end portions that are exposed along the first end portion 18 of the sensor body 12. For purposes of describing and defining the present invention, oxygen ion conductors include any material that can acquire electrical conductivity due to the displacement of oxygen ions within its crystal lattice.

  The conductive oxygen-adsorbing porous terminal 22 is fired at the end portions of the conductive layers 16a and 16b to form a plurality of cathode layers, whereby electrical connection is made to the conductive layers 16a and 16b. The second set of oxygen-adsorbing porous conductive layers 16 c and 16 d have end portions that are exposed along the second end portion 20 of the sensor body 12. The conductive layers 16c and 16d are electrically connected to each other by the conductive oxygen-adsorbing porous terminal 24 to form a plurality of anode electrodes. Silver or oxygen-adsorbing porous platinum is a material suitable for use as the conductive oxygen-adsorbing porous terminals 22 and 24. Terminals 22 and 24 are used to electrically connect the ceramic layers in parallel to reduce the electrical resistance of the sensor and allow increased current titration current.

  Each conductive layer 16a-16d includes two main surfaces. For example, the conductive layer 16 a includes the main surfaces 2 and 4. Each oxygen ion conducting wire layer 14 is disposed between the main surfaces of the opposing conductive layers. Furthermore, both main surfaces of each conductive layer are not exposed, that is, are sealed by the sensor body 12. Constructing the sensor body 12 using any number of oxygen adsorbing porous conductive layers and ionic conductive layers is contemplated by the present invention. The number of layers shown in FIG. 2 is provided for illustrative purposes only.

  A power source 26 is electrically connected to the terminals 22 and 24. Thus, the first electrode 26a of the power source 26 is electrically connected to the cathode layer made of the conductive layers 16a and 16b, and the second electrode 26b of the power source 26 is electrically connected to the anode layer made of the conductive layers 16c and 16d. Connected to. An amperometric ammeter 28 is connected between the power supply 26 and the terminal 24. A voltmeter 30 is connected to both ends of the power supply 26.

  The oxygen-adsorbing porous electrical conductive material forming the conductive layers 16a to 16d is composed of oxygen-adsorbing porous platinum, but is porous to oxygen and acts as an ion by catalyzing oxygen molecules in the cathode layer. An appropriate conductive material that catalyzes ions in the anode layer to form oxygen molecules can be used.

  The platinum electrode can be made porous with respect to oxygen by a known method. For example, the use of coarse platinum particles in electroded ink creates a porous electrode. Other additives to the electrode ink, such as zirconia particles, further increase the porosity. A platinum electrode in which pores occupy 5 to 30% of its volume is one preferred example. As another example, a zirconia powder having a particle size of 400 that forms an appropriate silk screening slurry for a weight ratio of 85 coarse platinum powder available as Demetron Ltd. product number 6432 \ 0101 platinum powder from Hanau, Germany. Can be combined at a weight ratio of 15.

  In one embodiment of the present invention, the width of the sensor body 12, i.e., the dimension of the sensor body from the first end 18 to the second end 20, is about 0.20 inches (0.5 cm) and is conductive. The short ends of layers 16a, 16b, 16c, and 16d terminate approximately 0.030 inches (0.075 cm) from the individual side edges and 0.14 inches (0.36 cm) of the conductive layer overlap. Is leaving. The length of the sensor body 12 is about 0.18 inch (0.46 cm). The thickness of the sensor body 12 is defined by the number and thickness of the oxygen ion conductive layers 14, the conductive layers 16a, 16b, 16c, and 16d and all the layers used in the heating circuit (described later). In one embodiment of the present invention, eleven oxygen ion conductive layers 14 are disposed between alternately arranged layers of twelve conductive layers 16a, 16b, 16e, and 16d. The oxygen ion conductive layer 14 can be made of yttria-stabilized zirconia having a thickness of 0.0030 inches (0.076 mm). The conductive layer is made of porous platinum having a thickness of 0.0001 inch (0.0025 mm). The resulting oxygen sensor is relatively compact in size and can be manufactured relatively inexpensively.

Several ceramic oxygen ion conducting materials can be used in accordance with the present invention. In fact, the advantages of the present invention due to the simple construction and reduced electrical resistance due to the sensor geometry are applicable to any of the various ceramic materials used. Preferably, the oxygen ion conductor of the present invention is a ceramic electrolyte, and more specifically yttria stabilized zirconia (ZrO ₂ stabilized with Y ₂ O ₃ ), which is stabilized bismuth oxide, stabilized ceria, etc. Can also be configured. The zirconia ceramic can also be stabilized with a material other than Y ₂ O ₃ .

ZrO ₂ : Y ₂ O ₃ fine particle size powder is sintered at a high density at 1150 to 1300 ° C., and a multilayer sensor body can be manufactured from this oxygen ion conductor. Because of the convenient sintering temperature of the ceramic material of the present invention, the ceramic can be “taped” into a monolithic body. As is known in the ceramic art, tape forming is a process for making a multilayered body (eg, a ceramic capacitor) in which suitable metal electrodes are interposed between ceramic layers. As the tape forming technique, those described in US Pat. No. 4,462,891 incorporated herein by reference can be used. The ceramic layer has a very thin wall thickness of about 25 to 100 μm. Furthermore, this tape forming process requires only one silk screen treatment and one firing step.

A higher porosity level in the conductive layer would be more suitable for detecting very low levels of oxygen in a gas with a partial oxygen pressure as low as 1 ppm, for example. Conversely, lower porosity levels in the conductive layer are more suitable for a wide range of oxygen partial pressure detection applications up to 10 ⁶ ppm. According to one embodiment of the present invention, the amperometric oxygen sensor 10 includes the entire sensor body 12, that is, the oxygen ion conductive layer 14, the conductive layers 16 a, 16 b, 16 c, 16 d, and any layers used for the heating circuit 12. The conductive layers 16a, 16b, 16c, and 16d are produced by sintering at a sintering temperature selected to provide a predetermined oxygen-adsorbing porosity. Sintering at a relatively high temperature for a relatively large amount of time reduces the porosity in the electrode layer because the density of the sensor body increases. Conversely, sintering at a relatively low temperature for a relatively small amount of time does not lead to an equal and significant reduction in the porosity in the electrode layer, which can be achieved at higher temperatures and longer periods of time. This is because the density of the sensor body does not increase as much as it does for sintering.

  Therefore, the current titration type oxygen sensor according to the present invention supplies the non-sintered sensor body, selects the target porosity of the oxygen-adsorbing porous electrode layer, and selects the corresponding sintering temperature for the sensor body. Can be generated. The sintering temperature is selected to correspond to the target porosity and can be determined through experimentation. The sensor body is sintered at a selected sintering temperature, resulting in a sintered sensor body including an oxygen-adsorbing porous electrode layer having a target porosity. For example, if the conductive layer is sintered at a temperature of about 1200 ° C. for a period of about 2 hours, the sintered sensor body has an oxygen content ranging from values normally found in air to values as low as 1 ppm or less. It becomes suitable for oxygen detection in the gas which has. When the sensor body is sintered at a higher temperature, eg, 1275 ° C., over the same period, a less porous layer is formed and the sintered sensor body has a higher oxygen concentration, eg, up to 100% oxygen. It becomes more suitable for oxygen detection of a gas having a high oxygen concentration.

  As a result of the sintering of the platinum particles in the electrode at the sensor operating temperature, there will be some resistance increase in the oxygen-adsorbing porous electrode layer over time. The long-term stability of the sensor according to the invention can be improved in some cases by stabilizing the oxygen-adsorbing porous electrode layer against sintering. It should be understood by practitioners of the present invention that various methods of stabilizing the platinum electrode against sintering are available.

  In operation, the oxygen sensor 10 is immersed in a gas whose oxygen partial pressure is to be measured. When oxygen does not yet exist in the porous conductive layers 16a to 16d, oxygen from the gas passes through the porous terminals 22 and 24 and enters the porous electrodes 16a to 16d through diffusion. A voltage from the power source 26 is applied across the terminals 22 and 24. Oxygen is pumped through the layer of oxygen ion conductive material 14 due to the voltage difference produced here between conductive layers 16a, 16b, also referred to herein as cathode layers, and between conductive layers 16c, 16d, also referred to herein as anode layers. . Since the porous electrode layers 16a to 16d catalyze oxygen molecules at the cathode electrodes 16a and 16b to become ions, and the anode electrodes 16c and 16d catalyze ions to become oxygen molecules, so that oxygen is the cathode layer 16a. 16b, is pumped through the layer of the ion conductive material 14, and is discharged through the anode layers 16c and 16d. The resulting current is measured by amperometric meter 28 and indicates the oxygen partial pressure of the gas.

  Sensors based on stabilized zirconia tend to have operating temperatures in excess of 700 ° C. The applied voltage is monitored by the voltage meter 30. It has been found that application of a DC voltage of 0.2 volts or more often leads to sensor instability, and an applied voltage of 0.05 volts results in an unstable current signal at large oxygen partial pressures. An applied voltage of 0.1 volts is a suitable bias voltage. The power source may be a DC power source or an AC power source operating at about 3 Hz. The preferred frequency is less than 50 Hz, and as the frequency increases, the responsiveness of the sensor to oxygen decreases. Since the oxygen sensor of the present invention operates at a high temperature, it is preferable to provide a heater and a thermometer with respect to the sensor body.

  A resistance heating electrode 35 is provided in the manner shown in FIGS. As shown in FIGS. 2 to 5, a cover plate heating electrode 35 in the form of a platinum track is embedded in the ion conductive material 14 of the sensor body 12, more specifically in the top and bottom cover plates 32. 3 to 5, the sensor body 12 includes a top heating track 2 and a bottom heating track 4. The back surface 5 of the sensor body 12 is provided with conductive terminals arranged to conductively connect the top heating track 2 to the bottom heating track 4. In addition, the front surface 7 of the sensor body 12 is provided with a pair of conductive terminals 6 that are conductively coupled to individual ones of the top heating track 2 and the bottom heating track 4. Thus, a complete circuit is formed by coupling the heating power source (incorporated within the heating circuit controller 50) and the terminal 8 into a separate one of the conductive terminals 6.

  The measured resistance in the buried platinum heater track 35 generally varies between about 2.3 and 6.5 Ω between 25 ° C. and 800 ° C., respectively. The measured heating power required to maintain the sensor body 12 is in the range of up to about 2 watts at a preferred sensor operating temperature of 800 ° C. The heating voltage is applied to both ends of the heating circuit by connecting a heating power source to both ends of the heating electrode 35. The resistance of the heating circuit generates heat when a voltage is applied. The resistance of the heating electrode 35 varies as a function of temperature. This temperature / resistance relationship provides a temperature measuring means for the sensor body 12. Preferably, the heating electrode 35 is coupled to a heating circuit controller 50 that is programmed to control the resistance of the heating electrode 35 by applying a constant current to the heating electrode 35 and controlling the voltage applied thereto.

  As shown in FIGS. 2-5, the top and bottom dielectric cover plates 32 are preferably on the top and bottom sides of the top and bottom electrode layers of the sensor body 12 for electrical insulation and structural integrity. It is composed of an additional 0.02 inch (0.05 cm) thick dielectric material. The sensor body 12 has two connections for the heating circuit, a cathode connection and an anode connection, is enclosed in a heat insulating material, and is incorporated into a 4-pin package encapsulated by a Teflon (tetrafluorofluoroethylene) particle filter. be able to.

  Conductive gold or platinum lead wires can be coupled to various sensor electrodes by attaching the lead wires to the exposed electrode portions on the sensor body 12 using gold or platinum paste. Alternatively, the sensor package can be simplified by embedding conductive lead wires in the sensor body 12. Specifically, a small hole (˜0.6 mm) can be drilled in the sensor body 12 before sintering, and a platinum or gold wire can be inserted into the hole together with an appropriate conductive paste.

  In a preferred heating control method, a constant current is applied to the heating electrode 35 as a rectangular wave pulse, and the pulse width of the current pulse is controlled (pulse width modulation) using a voltage signal. Under feedback control, the pulse width is modulated to keep the voltage constant, thereby maintaining the resistance of the heating electrode 35 at the desired value. In other words, the pulse width modulation of the current controls the heating power applied to the heating electrode 35 to keep the sensor temperature constant. This voltage can be easily read with an accuracy of ± 0.0015% using a 16-bit A / D converter. In the conventional current control method, a constant current is maintained within a range of about 0.01%. Therefore, the temperature of the integrated sensor body can be controlled within an allowable range.

  A suitable microprocessor-based heating circuit controller 50 comprises a temperature control unit and a sensor output unit. The latter cross section supplies a constant voltage to the heating electrode 35 and reads the current titration current in the heating electrode 35. The current signal is converted to an oxygen partial pressure reading and can be converted to an output suitable for controlling the combustion process.

  The sensor 10 is calibrated and used by first identifying the resistance of the heating electrode 35 within the desired operating temperature range. This resistance value, for example 9-10Ω at 600 ° C., is known and is generally well defined within a given temperature range. Corresponding current and voltage parameters, such as 0.47 amps, 4.1 volts, are programmed into the heating circuit controller 50 and the controller 50 is programmed to maintain these values. The actual operating temperature of any individual sensor is kept constant within the sensor operating range.

As an illustrative example where 1 mil = 0.001 inch = 0.0254 mm, a suitable sensor body is 166 mil x 124 mil x 53 mil (4.22 mm x 3.15 mm x 1.35 mm) and weighs 144 mg is there. In one embodiment of the invention using cover plate heating electrode 35, the total electrode overlap area per layer is preferably about 12.7 mm ² and the total area to wall thickness ratio of oxygen sensor body 12 is about 199 cm. The exposed end of each electrode is 50 mils (1.27 mm) wide and each electrode extends 153 mils (3.89 mm) into the body. The resistive heating electrode is preferably a porous platinum track having a length of about 166 mm mil (4.22 mm) and a width of 22 mil (0.559 mm), which provides a heating current of 223 mA for a controlled temperature of about 600 ° C. Become common.

  6A and 6B, a packaging method according to an embodiment of the present invention will be described. In the illustrated embodiment, the sensor body 12 is confined within a rustless steel tube 60. The wall thickness of the tube 60 is preferably selected so that the package mounting screw can be machined into the bulkhead or exhaust tube. The sensor body 12 is stabilized and insulated in the tube 60 by a suitable gas permeable heat insulating part 62 (eg Nextel 312 heat insulating material). The rear end 64 of the tube 60 is sealed with a ceramic 66. The electrical connection 68 to the sensor body 12 is potted in the ceramic 66 and distributed via the insulating part 62. Preferably, the electrical connection consists of 20 instrument copper leads coupled to 4 sensor leads. A non-rust steel screen 69 is provided at the front end 65 of the tube 60 to allow gas to reach the sensor body 12.

  For the purpose of illustrating the invention, certain representative embodiments and details have been shown, but various variations in the methods and apparatus disclosed herein depart from the scope of the invention as defined in the appended claims. It will be apparent to those skilled in the art that this is possible without. For example, the sensor 10 of the present invention is very suitable for measuring excess oxygen partial pressure because the oxygen adsorbing porous terminals 22 and 24 present a catalytic region for carbon monoxide and other combustibles. It should be noted that the present invention can be configured to measure actual oxygen partial pressure rather than excess oxygen partial pressure. Specifically, the cathode electrodes 16a, 16b exposed on the first end 18 of the sensor body 12 are very thin and present a very small catalytic area for combustion of carbon monoxide and other combustibles. Therefore, by omitting the oxygen-adsorbing porous terminals 22 and 24, the sensor 10 of the present invention can be configured to measure actual oxygen partial pressure, not excess oxygen partial pressure.

  Furthermore, it is contemplated that a pair of sensors can be packaged to provide both actual and excess oxygen measurements by simply placing the oxygen-adsorbing porous terminals 22 and 24 only on one sensor body. It is. Finally, an alternative approach to measuring actual oxygen and excess oxygen using two sensors is to make one sensor below the ignition temperature of carbon monoxide (600-650 ° C), also in a single package, Note that the sensor will be kept above this temperature.

Composite Oxygen / Nitrogen Oxide Sensor A composite sensor 200 that measures the oxygen content and nitrogen oxide content in a gas will be described with reference to FIGS. 7 and 8A to 8C. The sensor 200 includes a partial enclosure 210, a sensor body 220 disposed in the partial enclosure 210, a diffusion barrier 230, and an oxygen sensor 240. As described in more detail below, the sensor body 220 is configured to provide an indication of the nitrogen oxide content of the gas, and the oxygen sensor 240 is configured to provide an indication of the oxygen content of the gas. The sensor 200 includes a number of components that are identical or similar in configuration to those detailed above with reference to FIG. 2 and 7, like reference numerals are used corresponding to like elements, and reference is made to the explanation of FIG. 2 for explanation of these elements.

  The partial enclosure 210 defines a gas passage 212, referred to herein as “partial”, although it encloses the definition space, the gas passage 212, the inlet portion 214, and the outlet portion 216. This is because it is also defined. The partial enclosure 210 generally comprises an oxygen ion conductor ceramic tube. Note that although the enclosure is shown with a rectangular cross-section, an enclosure with a circular cross-section is probably more effective and easier to manufacture.

  The diffusion barrier 230 extends across the gas passage 212 and defines a diffusion restriction portion 218 of the gas passage 212 between the inlet portion 214 and the outlet portion 216. The enclosure 210, the diffusion barrier 230, and the sensor body 220 have a hermetically sealed region including a diffusion inlet in which the diffusion restriction portion 218 of the gas passage 212 is defined by the diffusion barrier 230 and a sensor outlet defined by the sensor body 220. It is configured to provide. An oxygen pumping section 250, described in detail below, is also provided in the hermetically sealed area.

  The diffusion barrier 230 is porous to oxygen and nitrogen oxides and may include, for example, a substantially uniform zirconia barrier. Generally, the diffusion barrier is configured to pass a certain amount of gas that varies as a function of the oxygen partial pressure of the gas in the inlet of the gas passage. It is contemplated that the diffusion barrier can define a variety of shapes including, for example, a perforated plate, a plate with a single constrained aperture, and the like.

  The sensor body 220 extends across the outlet portion 216 of the gas passage 212 and is disposed in the diffusion restriction portion 218 of the gas passage 212. The sensor body 220 is made of a material in which a selected one of the oxygen-adsorbing porous conductor layers catalyzes nitrogen oxides to dissociate nitrogen and oxygen. Are different. Thus, the dissociated oxygen is measured as an amperometric current, which can be related to the nitrogen oxide content. A conductive layer that does not catalyze nitrogen oxides to dissociate nitrogen and oxygen, ie, a non-dissociative electrode layer, is used to provide an indication of oxygen content, as will be described in detail below.

  Specifically, the sensor body 220 includes a plurality of oxygen-adsorbing porous electrode layers 16a and 16c and a plurality of oxygen-dissociating porous electrode layers 16b and 16d. As described above with reference to the oxygen sensor of FIG. 2, the oxygen-adsorbing porous electrode layers 16a and 16c catalyze oxygen molecules in the cathode layer into ions, and catalyze ions in the anode layer to oxygen molecules. As a result, the cause oxygen is catalyzed through the layer of the oxygen ion conductive material 14. That is, the generated current is measured by the amperometric measuring instrument 28 and indicates the oxygen partial pressure of the gas. Oxygen dissociating porous electrode layers 16b and 16d pump oxygen through this process, but oxygen is additionally dissociated from nitrogen oxides in the gas by dissociating nitrogen oxides into nitrogen and oxygen by catalysis in the cathode layer. Pump. As a result, the current generated in the oxygen dissociated porous electrode layers 16b, 16d provides an indication of the nitrogen oxides present in the gas.

  As is the case in the embodiment of FIG. 2, a plurality of oxygen ion conductive ceramic layers are interposed between an individual one of the oxygen-adsorbing porous electrode layers 16a and 16c and one of the oxygen-dissociating porous electrode layers 16b and 16e. Has been. It goes without saying to the practitioner of the present invention that the oxygen content electric signal output terminal is arranged in the form of an electric lead wire coupled to the plurality of oxygen-adsorbing porous electrode layers 16a and 16c. Similarly, the nitrogen oxide electric signal output end is arranged in the form of an electric lead wire coupled to the plurality of oxygen dissociating porous electrode layers 16b and 16d. Thus, the oxygen-adsorbing porous electrode layers 16a and 16b are coupled to the electric signal output end indicating the oxygen content of the gas in the diffusion limiting portion 218 of the gas passage 212, and the oxygen-dissociating porous electrode layers 16b and 16d are gasses. It is coupled to an electrical signal output that indicates the nitrogen oxide content of the gas in the diffusion limiter 218 of the passage 212.

  The nitrogen oxide content electrical signal output is electrically isolated from the oxygen content electrical signal output to ensure proper device performance. In order to further improve the device performance, the power supply 30 and the electrode layers 16a, 16b, 16c and 16d define only adjacent pairs of electrode layers of different types in which the oxygen-adsorbing porous electrode layer 16a and the oxygen-dissociating porous electrode layer 16b are different. However, it is configured to have a matching polarity. The electrode layers 16a and 16b are also at an electrically equivalent potential (for example, DC 0.1 volts). Thus, oxygen pumping between the oxygen-adsorbing porous electrode layer 16a and the oxygen-dissociating porous electrode layer 16b is suppressed. In contrast, the sensor configuration shown in FIG. 2 includes alternating polarity electrode layers.

  At elevated temperature, for example, about 600 ° C., rhodium separates nitrogen oxide nitrogen by catalyzing oxygen and nitrogen. Therefore, the oxygen dissociated porous electrode layers 16b and 16d can be made of rhodium. As described above, the non-dissociable electrode layers 16a and 16c include oxygen-adsorbing porous platinum, and may additionally include a sufficient amount of gold to prevent catalytic dissociation of nitrogen oxides. As described above with reference to the oxygen sensor of FIG. 2, the heater of the heating electrode is preferably configured to raise the operating temperature of the composite sensor well above room temperature, typically to around 800 ° C. operating temperature. This sensor is not temperature dependent in this range. The heater can be provided in the form of a heating electrode formed in the atmosphere of the enclosure 210, for example.

  Partial enclosure 210 also defines an oxygen pumping section 250 configured to maintain a convenient nitrogen oxide to oxygen ratio within diffusion restriction 218 of gas passageway 212. Depending on the operational constraints of the equipment used with the present invention, accurate measurement of nitrogen oxides can be problematic if the amount of oxygen in the diffusion limiter versus the amount of nitrogen oxides is too high. The oxygen pumping unit 250 includes an oxygen-adsorbing porous cathode electrode 252, an oxygen-adsorbing porous anode electrode 254, and an oxygen ion conductive ceramic material 256. The oxygen-adsorbing porous cathode electrode 252 is disposed so as to cover the inner surface of the partial enclosure 210 in the diffusion limiting portion 218 of the gas passage 212. The oxygen-adsorbing porous anode electrode 254 is disposed so as to cover the outer surface of the partial enclosure 210 outside the diffusion restricting portion 218 of the gas passage 212. The oxygen ion conductive ceramic material 256 is generally formed by the main body of the enclosure 210 and is inserted between the cathode electrode 252 and the anode electrode 254 as it is. The oxygen-adsorbing porous anode electrode 254 is made of platinum, and the oxygen-adsorbing porous cathode electrode 252 is also made of platinum having a sufficient amount of gold additive to prevent dissociation of nitrogen oxides.

  Preferably, the nitrogen oxide to oxygen ratio in the diffusion limiter 218 is less than nitrogen oxide 1 for about 5 oxygen, but may be higher when the instrument is used for current titration current measurement, Voltage control at the electrode is optimized to meet higher oxygen levels. If the amount of oxygen in the diffusion limiter is too high relative to the amount of nitrogen oxides, accurate measurement of the nitrogen oxide content becomes a problem. For example, there is a logarithmically linear relationship between the amperometric current and the oxygen partial pressure below 1000 ppm, but accurate measurement beyond this level is problematic. A feedback loop may be coupled between the sensor body 220 and the oxygen pumping unit 250. The feedback loop can be configured to control the oxygen pumping unit 250 according to the amount of oxygen detected by the sensor body 220. Specifically, the oxygen measurement value from the sensor body 220 is used to continuously adjust the oxygen pumping speed to the outside of the diffusion limiting unit 218, thereby providing an accurate measurement of the nitrogen oxide content. It is possible to prevent more oxygen from being pumped out of the tube than is assumed (eg, to maintain a ratio of oxygen released nitrogen oxides to background oxygen of approximately 1: 5). The feedback loop can also be configured to switch the pumping function on / off depending on the detected amount of oxygen. Thus, the oxygen pumping unit 250 can be operated to minimize the power consumption of the composite sensor 200.

  The oxygen sensor 240 is disposed in the inlet portion 214 of the gas passage 212 and supplies a signal indicating the oxygen partial pressure of the gas in the inlet portion 214. Thus, the composite sensor 200 is configured to provide independent indications of oxygen partial pressure and nitrogen oxide content.

  Here, referring to how to determine the nitrogen oxide content, the nitrogen oxide present in the gas in the diffusion limiting portion 218 is dissociated on the oxygen dissociating porous electrode layers 16b and 16d, and the released oxygen is nitrogen oxide. A current titration current is generated at the electric signal output terminal. The oxygen in the atmosphere gas also contributes to the nitrogen oxide content electrical signal output and increases the current titration current, which is due to the dissociative electrodes 16b and 16d from the oxygen in the gas and the nitrogen oxide present in the gas. This is because the dissociated oxygen is pumped. This “background” oxygen and increased current titration current can be used as a basis for the oxygen content electrical signal output from the electrodes 16a, 16c, which is due to the corresponding current titration current at the non-dissociative electrodes 16a, 16c. Because it provides an independent measure of oxygen.

  As described above, in order to accurately measure the nitrogen oxide content, the background oxygen in the diffusion limiter is at a level corresponding to the nitrogen oxide from which oxygen is released (for example, a ratio of oxygen to nitrogen oxide is about 5 to 1). It is also necessary to reduce to

  As described above, the sensor body 220 has two sets of separated porous electrodes, one of which catalyzes nitrogen oxide to dissociate nitrogen and oxygen. For convenience of illustration, FIG. 7 only illustrates a pair of electrode layers in each set. However, it is also contemplated that a large number of electrode layers can be disposed in each set. Preferably, the same number of electrode layers are disposed in each set. However, with the present invention, it is contemplated that more electrode layers can be disposed in one set than for the other, as long as the numerical difference is meaningful for the subsequent calculation of nitrogen oxide content. is there.

  The sensor 200 can be mounted directly in the exhaust gas or sample gas. There is no need for a reference gas supply. A particulate filter or other type of filter is provided to prevent damage to the sensor and extend sensor life.

  The sensor 200 is preferably manufactured in a manner similar to that described above with reference to the oxygen sensor of FIG. Although various manufacturing techniques are available, the multi-layer manufacturing process has the flexibility to produce platinum / gold electroded layers and rhodium individual electrode layers within the same sensor body. The sensor lead wire is preferably embedded in the sensor body by punching a small hole (about 0.5 mm) in the unprocessed sensor body 220. The sensor body 220 is sintered there, and the platinum wire is baked in the hole having the platinum paste. The hardness of the platinum wire has the advantage of providing mechanical support. A lead wire for the oxygen sensor 240 is similarly embedded.

  The actual composite sensor length would be about 1 inch (2.5 cm) and the major outer diameter would be 1/2 inch (1.25 cm) wide. The enclosure 210 can be composed of a zirconia pipe manufactured by casting. The tube is ground in a green state to provide a passage for the electrical lead and subsequently post-sintered. The platinum / gold and platinum electrodes 252 and 254 are then fired inside and outside the tube, respectively. Finally, ceramic glass for sealing together the zirconia portion is used, and the sensor body 220, the diffusion barrier 230, and the oxygen sensor 240 are sealed in the zirconia tube by one firing. The first two components are hermetically sealed. A platinum lead wire for the internal platinum / gold electrode passes through the tube wall and is similarly hermetically sealed. A slot in the zirconia tube at the large open end provides a passage for the two oxygen sensor leads and an opposing slot in the small closed end provides a passage for the four dual sensor leads. The sensor body or dual sensor 220 and its four leads are hermetically sealed in zirconia using commercially available glass.

  Usually, the operation of the composite sensor 200 is as follows. This apparatus is heated to and maintained at an operating temperature (for example, 800 ° C.), and the oxygen sensor 240 measures the oxygen partial pressure of the exhaust gas, that is, the sample gas. The gas diffuses through the diffusion barrier 230 into the enclosure internal diffusion restriction 218, that is, into the tube 210. The voltage across the cathode 252 and anode 254 pumps internal oxygen to a sufficiently low level. The sensor body 220 measures this low oxygen level using the non-dissociable layers 16a and 16c. The dissociative electrode layers 16b and 16d measure both the low oxygen level and the oxygen released by the dissociation of nitrogen oxides. These amperometric currents from both electrode assemblies are then used to determine the nitrogen oxide content.

  A zirconia diffusion barrier 230 limits the amount of exhaust gas that penetrates the interior of the tube, thereby ensuring that low levels of oxygen can enter and reach the interior through the pumping process (ie, without this plug, the interior is exhausted. Always overflowing). Nitrogen oxide diffuses through this plug as molecular nitrogen oxide.

  The heater (not shown in FIG. 2) has a temperature dependent resistance, thereby providing a means to measure and control the operating temperature. However, the operating temperature is always subject to replacement conditions. On the other hand, the higher the temperature, the more power is consumed by the heater to maintain this temperature. On the other hand, the temperature should be high enough to reduce the resistance of the zirconia tube to a low value and avoid large amounts of power consumption for pumping oxygen out of the tube.

  For purposes of describing and defining the present invention, the term “substantially” is used herein to indicate the degree of inherent uncertainty that can be attributed to quantitative comparisons, values, measurements, or other representations. Please be careful. The term “substantially” is also used herein to indicate the extent to which the quantitative expression changes from the assertion criteria without causing a change in the basic function of the main subject matter in question.

  Although the invention has been described in detail with reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention as defined in the appended claims. More specifically, although certain aspects of the invention have been identified herein as preferred or special advantages, it is contemplated that the invention is not necessarily limited to these preferred aspects of the invention. .

1 is a schematic diagram representing a prior art oxygen sensor. FIG. It is the schematic showing the oxygen sensor which becomes this invention. It is a figure which shows the alternative heating circuit structure which becomes this invention. It is a figure which shows the alternative heating circuit structure which becomes this invention. It is a figure which shows the alternative heating circuit structure which becomes this invention. It is a figure which shows the packaging system which becomes one Embodiment of this invention. It is a figure which shows the packaging system which becomes one Embodiment of this invention. It is a figure which shows the sensor main body used for the composite sensor which measures oxygen content and nitrogen oxide content in gas. It is a figure which shows the composite sensor which measures oxygen content and nitrogen oxide content in gas. It is a figure which shows the composite sensor which measures oxygen content and nitrogen oxide content in gas. It is a figure which shows the composite sensor which measures oxygen content and nitrogen oxide content in gas.

Claims (28)

A composite sensor for measuring oxygen content and nitrogen oxide content in gas,
An oxygen sensor disposed upstream in the gas flow direction;
A nitrogen oxide sensor body disposed downstream in the gas flow direction;
Consisting of
The oxygen sensor provides a signal indicating an oxygen partial pressure of the gas through the oxygen sensor;
The nitrogen oxide sensor body is
A plurality of conductive oxygen-adsorbing porous electrode layers;
A plurality of conductive oxygen dissociating porous electrode layers composed of a material selected to dissociate nitrogen and oxygen by catalyzing nitrogen oxides;
A plurality of oxygen ion conductive ceramic layers interposed between each of the plurality of conductive oxygen adsorbing porous electrode layers and each of the plurality of conductive oxygen dissociating porous electrode layers;
A power source connected between the plurality of conductive oxygen-adsorbing porous electrode layers and the plurality of conductive oxygen dissociating porous electrode layers;
Oxygen content electrical signal output end,
Nitrogen oxide content electrical signal output end,
Consisting of
The oxygen content electrical signal output end is coupled to the plurality of conductive oxygen adsorbing porous electrode layers, and the nitrogen oxide content electrical signal output end is connected to the plurality of conductive oxygen dissociating porous electrode layers. The oxygen content electrical signal output end and the nitrogen oxide content electrical signal output end are electrically separated,
The conductive oxygen-adsorbing porous electrode layer and the conductive oxygen-dissociating porous electrode layer adjacent to each other have the same polarity and the same potential, so that the adjacent conductive oxygen-adsorption Suppresses the movement of oxygen between the porous electrode layer and the conductive oxygen dissociating porous electrode layer,
The reading obtained from the nitrogen oxide content electrical signal output is adjusted such that background oxygen is measured using the reading obtained from the oxygen content electrical signal output;
The nitrogen oxide sensor body further comprises means for maintaining a preferred nitrogen oxide to oxygen ratio within the region of the nitrogen oxide sensor. The composite sensor includes a partial enclosure having an interior defining a gas passage;
A diffusion barrier defining a diffusion limiting portion of the partial enclosure;
Further including
The gas passage extends from the inlet portion of the partial enclosure through the diffusion limiting portion, and the inlet portion is connected to the oxygen sensor,
The composite for measuring oxygen content and nitrogen oxide content in gas according to claim 1, wherein the nitrogen oxide sensor main body is disposed in the diffusion limiting portion of the partial enclosure. Sensor.   The gas passage extends from the inlet portion to an outlet portion of the partial enclosure, and the nitrogen oxide sensor main body extends across the outlet portion of the gas passage. The combined sensor for measuring the oxygen content and nitrogen oxide content in the gas.   3. The oxygen content and nitrogen in the gas of claim 2, wherein the diffusion limiting portion of the partial enclosure defines an oxygen pumping portion configured to maintain a preferred nitrogen oxide to oxygen ratio. Composite sensor for measuring oxide content.   3. The combined sensor for measuring oxygen content and nitrogen oxide content in gas according to claim 2, wherein the preferable nitrogen oxide to oxygen ratio is about 1: 5 or more.   The composite sensor further includes a feedback loop coupled between the nitrogen oxide sensor body and the oxygen pumping portion, the feedback loop being a function of the amount of oxygen detected by the nitrogen oxide sensor body. The composite sensor for measuring an oxygen content and a nitrogen oxide content in a gas according to claim 4, wherein the pumping unit is configured to be controlled.   The oxygen content and the nitrogen oxide content in the gas according to claim 6, wherein the feedback loop is configured to reduce a pumping speed of the oxygen pumping unit as the detected oxygen amount decreases. Composite sensor to measure. At least a portion of the partial enclosure defines an oxygen pumping portion, and the oxygen pumping portion is disposed over the inner surface of the partial enclosure inside the diffusion restriction portion of the gas passage. Electrodes,
An oxygen-adsorbing porous anode electrode disposed over the outer surface of the partial enclosure outside the diffusion restriction part of the gas passage;
An oxygen ion conductive ceramic material interposed between the cathode electrode and the anode electrode;
The composite sensor for measuring an oxygen content and a nitrogen oxide content in a gas according to claim 2, comprising:   9. The oxygen content and nitrogen oxide content in gas according to claim 8, wherein the oxygen-adsorbing porous anode electrode contains platinum, and the oxygen-adsorbing porous cathode electrode contains platinum and gold. Composite sensor that measures   The gas according to claim 2, wherein the plurality of oxygen-adsorbing porous electrode layers in the nitrogen oxide sensor body include a material selected to suppress dissociation of nitrogen oxides into nitrogen and oxygen. Composite sensor that measures the oxygen content and nitrogen oxide content in the inside.   The composite sensor for measuring oxygen content and nitrogen oxide content in gas according to claim 10, wherein the plurality of oxygen-adsorbing porous electrode layers contain platinum and gold.   The plurality of oxygen-dissociating porous electrode layers in the nitrogen oxide sensor body include a material selected to dissociate nitrogen oxides into various forms of ions of nitrogen and oxygen. The composite sensor which measures the oxygen content and nitrogen oxide content in gas of Claim 2.   13. The oxygen content in gas according to claim 12, characterized in that the oxygen dissociating porous electrode layer material is selected to catalyze nitrogen oxides to dissociate nitrogen and oxygen. And sensor that measures nitrogen oxide content.   The composite sensor for measuring an oxygen content and a nitrogen oxide content in a gas according to claim 13, wherein the plurality of oxygen dissociative porous electrode layers contain rhodium.   The composite sensor further includes a power source, and the power source includes an adjacent pair of oxygen-adsorbing porous electrode layers and oxygen-dissociating porous electrode layers of the nitrogen oxide sensor body having matching polarities and substantially equivalent potentials. Each of the electrode layers is configured to suppress oxygen pumping between the oxygen-adsorbing porous electrode layer and the oxygen-dissociating porous electrode layer according to claim 2, A composite sensor that measures oxygen content and nitrogen oxide content in gas.   The gas according to claim 2, wherein the oxygen-adsorbing porous electrode layer of the nitrogen oxide sensor body is electrically separated from the oxygen-dissociating porous electrode layer of the nitrogen oxide sensor body. Composite sensor that measures the oxygen content and nitrogen oxide content in the inside.   The plurality of oxygen-adsorbing porous electrode layers of the nitrogen oxide sensor main body are connected to an electric signal output end independent of an electric signal output end combined with the oxygen dissociating porous electrode layer of the nitrogen oxide sensor main body. The combined sensor for measuring oxygen content and nitrogen oxide content in a gas according to claim 2, wherein the sensor is combined.   The oxygen-adsorbing porous electrode layer is coupled to an electrical signal output end indicating the oxygen content of the gas in the diffusion limiting portion of the gas passage, and the oxygen dissociating porous electrode layer is the diffusion of the gas passage The combined sensor for measuring the oxygen content and the nitrogen oxide content in the gas according to claim 17, wherein the combined sensor is connected to an electric signal output terminal indicating the nitrogen oxide content of the gas in the restricting portion.   The partial enclosure includes an oxygen ion conductive ceramic tube, the diffusion barrier extends over an inner diameter of the tube, the inner diameter is an inner diameter of the gas passage in the tube, and the diffusion barrier is 3. The composite sensor for measuring oxygen content and nitrogen oxide content in gas according to claim 2, wherein the inflow portion of the partial enclosure and the diffusion limiting portion of the partial enclosure are separated.   The diffusion restriction of the gas passage includes a substantially sealed sealing region including a diffusion inlet defined by the diffusion barrier and a sensor outlet defined by the nitrogen oxide sensor body. The composite sensor for measuring the oxygen content and the nitrogen oxide content in the gas according to claim 2.   The composite sensor for measuring oxygen content and nitrogen oxide content in gas according to claim 20, wherein the substantially sealed sealing region further includes an oxygen pumping unit.   The diffusion barrier defines a barrier between the diffusion restriction portion of the gas passage and the inlet portion of the gas passage, and the oxygen sensor body is disposed in the inlet portion of the gas passage. The composite sensor for measuring an oxygen content and a nitrogen oxide content in a gas according to claim 2, wherein the sensor is a gas sensor.   The composite sensor for measuring an oxygen content and a nitrogen oxide content in a gas according to claim 2, wherein the diffusion barrier includes a zirconia partition wall.   3. The composite sensor for measuring oxygen content and nitrogen oxide content in air according to claim 2, wherein the diffusion barrier extends across the gas passage.   25. The composite sensor for measuring oxygen content and nitrogen oxide content in gas according to claim 24, wherein the diffusion barrier comprises a substantially uniform partition wall.   3. The oxygen content in the gas according to claim 2, wherein the diffusion barrier is configured to pass a certain amount of gas that changes as a function of the oxygen partial pressure of the gas in the inlet of the gas passage. And sensor that measures nitrogen oxide content.   The composite sensor for measuring an oxygen content and a nitrogen oxide content in gas according to claim 2, further comprising a heater configured to raise the operating temperature of the composite sensor to about 800 ° C.   28. The oxygen content and nitrogen oxide content in gas according to claim 27, wherein the partial enclosure includes a zirconia tube, and the heater is formed around the zirconia enclosure. Compound sensor.

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