# Patent

## Title
Hybrid gas analyzer with thermally insulated flow cell

## Abstract

Gas analyzer systems and methods for measuring concentrations of gases and in particular dry mole fraction of components of a gas. The systems and methods allow for rapid measurement of the gas density and/or dry mole fraction of gases for a number of environmental monitoring applications, including high speed flux measurements. A novel coupling design allows for tool-free removal of a cell enclosing a flow path to enable infield cleaning of optical components and to enable re-configuration between open- and closed-path analyzer configurations. In closed path configurations, the sample flow path is thermally isolated from the remainder of the gas analyzer to provide more accurate temperature measurements. Composite plastic/metal sample cells are presented with achieve this thermal isolation without compromising analyzer performance.

## Background
CROSS-REFERENCES TO RELATED APPLICATIONS
The present application is a continuation-in-part of U.S. patent application Ser. No. 12/508,003, filed Jul. 23, 2009, which is a continuation-in-part of U.S. patent application Ser. No. 12/266,379, filed Nov. 6, 2008, both of which are hereby incorporated by reference in their entirety for all purposes.


BACKGROUND
The present invention relates generally to gas analysis, and more particularly to systems and methods for measuring gas concentrations.
Increasing carbon dioxide concentration in the atmosphere and the resulting greenhouse effect and climate change have become important topics of scientific research. In order to understand the global carbon balance, it is necessary to determine the exchange rates of carbon dioxide and energy between the atmosphere and terrestrial and oceanic ecosystems. The “eddy covariance” technique has been widely used to determine these exchange rates. The air within a few hundred meters above the earth's surface is mostly turbulent, so that turbulent structures (vortices of variable sizes) called “eddies” are responsible for the vertical transport of most gases, including carbon dioxide and water vapor, as well as heat and momentum. The transport rates can be calculated from simultaneous, high-frequency measurements of the vertical component of wind speed, the concentrations of carbon dioxide and water vapor, and the air temperature.
A gas analyzer can be used to measure concentrations of carbon dioxide and water vapor. In certain gas analyzers, a sample gas containing unknown concentrations of carbon dioxide and water vapor is placed in a sample cell, and a reference gas with zero or known concentrations of carbon dioxide and water vapor is placed in a reference cell. The analyzer measures the unknown gas concentrations in the sample cell from calibrated signals that are proportional to the difference between light transmitted through the sample cell and light transmitted through the reference cell at selected wavelengths. This is most often configured as a closed-path analyzer.
In eddy covariance applications, ambient air potentially full of dust and pollen must be moved through the analyzer at high flow rates to achieve necessary frequency response. Even when the air is filtered, contamination of the sample cells is expected during long deployments, requiring the analyzer to be periodically cleaned. This is an expensive and time-consuming process, especially when the analyzer is used in a remote location such as the Amazon basin, the north slope of Alaska, or the deserts of Africa.
There are benefits in using an open-path gas analyzer in certain environments or applications, while a closed-path analyzer has advantages in other environments or applications. However, purchase of both a closed-path analyzer and an open-path analyzer may be quite expensive.
Additionally, cells defining flow paths used in gas analysis measurements may include, intentionally or unintentionally, mechanisms and components that act as heat sources or sinks to/from the sample gas. For example, heat transfer to and from the sample cell may occur through either radiative or convective heat transfer, either between internal electronic components and chamber cell walls or between the chamber cell walls and the internal environment of the flow path, or both. Inevitably, parasitic heat transfer occurs between the internal components and the chamber walls and the internal cell environment, thereby compromising the accuracy of gas temperature measurements within the cell. It is also therefore desirable to provide solutions that allow for more efficient insulation resulting in more accurate sample gas temperature measurement.
There is a need, therefore, for improved and adaptable gas analyzers. In particular, there is a need for gas analyzers that are easy to clean, provide robust measurement capabilities, and that can be used for different assays in different environments.
BRIEF SUMMARY
Systems and methods are provided for measuring concentrations of gases, and in particular, dry mole fractions of components of a gas. The systems and methods according to various embodiments allow for rapid measurement of the gas component density and/or dry mole fraction of gas components for a number of environmental monitoring applications, including high speed flux measurements. Gas analyzers according to various embodiments are adaptable to be used as open-path or closed-path analyzers.
According to various embodiments, systems and methods are provided that enable rapid measurements of gas concentrations simultaneously with rapid measurements of sampled gas temperature and pressure. In addition, closed-path devices according to various embodiments can advantageously use substantially shorter intake tubes compared to previously existing devices, and substantially lower power consumption. Embodiments also provide solutions to thermally insulate the sample cell environment from heat sources or sinks associated with the gas analysis system itself.
Various embodiments also provide unique mechanical-optical design solutions for gas analyzers that include novel elements in a tool-free removable gas cell that allow one to optionally configure the gas analyzer as either open-path or closed-path. Various embodiments also allow for measuring the dry mole fraction of a gas component in a removable gas cell in a closed-path configuration using high frequency temperature and pressure measurement in the gas stream.
Embodiments herein provide gas cell systems and methods of constructing gas cells which provide advantages over traditional gas cell systems, such as, for example, by using materials with significantly reduced (e.g., 1,000 times lower) thermal conductivity than traditional gas cell materials, utilizing manufacturing methods which allow the creation of intricate, internal, leak-free paths for gas flow without introducing any significant additional manufacturing expense, and/or reducing the weight of the gas cell by using materials which are significantly lighter (e.g., about 50% less dense) than traditional gas cell materials.
According to one aspect of the present invention, a gas analyzer is provided that typically includes a detector section including a detector, a source section including a light source, and a removable gas cell disposed between the source and detector sections. The removable gas cell typically includes a housing structure defining a gas flow channel, e.g., an enclosed gas flow channel, wherein, when attached, emitted light from the light source passes through the gas flow channel to the detector section along a light path. The gas cell also typically includes a gas inlet port, a gas outlet port, wherein the inlet and outlet ports are located on the housing structure, and a first temperature sensor adapted to measure a temperature of gas flowing in the flow channel, and a pressure sensor located at an interior point of the housing structure in the gas flow channel, the pressure sensor adapted to measure a pressure of the gas at an interior point in the flow cell. In certain aspects, the removable gas cell further includes a second temperature sensor located proximal to the outlet port, wherein the first temperature sensor is located proximal to the input port.
According to another aspect of the present invention, a gas analyzer is provided that typically includes a detector section including a detector, a source section including a light source, and a removable gas cell disposed between the source and detector sections. The removable gas cell typically includes a housing structure defining a gas flow channel, e.g., an enclosed gas flow channel, wherein, when attached, emitted light from the light source passes through the gas flow channel to the detector section along a light path. The gas cell also typically includes a gas inlet port, a gas outlet port, wherein the inlet and outlet ports are located on the housing structure, and a first temperature sensor located proximal to the inlet port, and a second temperature sensor located proximal to the outlet port. In certain aspects, the gas analyzer includes a pressure sensor located at an interior point of the housing structure in the gas flow channel, the pressure sensor adapted to measure a pressure of the gas at an interior point in the flow cell.
In certain aspects, the gas analyzers include an intelligence module coupled with the temperature sensor(s), with the pressure sensor and with the detector. The intelligence module is typically adapted to determine a dry mole fraction of components of a gas within the flow channel based on a detector signal and substantially simultaneous measurements of the pressure of the gas by the pressure sensor and the temperature of the gas by the temperature sensor(s). In certain aspects, the intelligence module corrects for a delay due to spatial separation in the temperature signals received from the first and second temperature sensors, wherein the delay is typically a function of a flow rate of the gas in the flow channel. In certain aspects, the gas analyzer includes a first optical window proximal to the detector section and a second optical window proximal to the source section, wherein the first and second optical windows provide an airtight seal for components within the source and detector sections.
According to yet another aspect of the present invention, a method is provided for measuring dry mole fraction of components of a gas in a gas analyzer flow cell. The method typically includes flowing a gas through the flow cell, measuring an absorbance of particular light wavelengths of the components of the gas in the flow cell, substantially simultaneously measuring a temperature, T1, of the gas at an input port of the flow cell, substantially simultaneously measuring a temperature, T2, of the gas at an output of the flow cell, and substantially simultaneously measuring a pressure, P, of the gas at an interior point of the flow cell. The method also typically includes determining a dry mole fraction of the components of the gas based on the measured absorbance, P, T1 and T2. In certain aspects, the components of the gas include CO2 and H2O, and wherein the gas is air.
According to yet a further aspect, a gas analysis system that measures dry mole fraction of components of a gas is provided. The system typically includes a flow cell within which a gas is flowed from an inlet port to an outlet port, a light source configured to transmit light through the flow cell, and a detector subsystem configured to output an absorbance signal representing an absorbance of particular light wavelengths by the components of the gas in the flow cell. The system also typically includes a first temperature sensor positioned proximal to the input port of the flow cell, a second temperature sensor positioned proximal to the output port of the flow cell, and a pressure sensor adapted to measure pressure at an interior point of the flow cell. The system further typically includes an intelligence module coupled with the first and second temperature sensors, the pressure sensor, the source subsystem, and with the detector subsystem. The intelligence module is typically adapted to determine a dry mole fraction of the components based on the absorbance signal and the substantially simultaneous measurements of the pressure of the gas and of the temperature of the gas by the first and second temperature sensors. In certain aspects, the measurements of the pressure and of the temperature of the gas by the first and second temperature sensors occur within about 0.2 seconds or less of each other. In certain aspects, the measurements of the pressure and of the temperature of the gas by the pressure sensor, and the first and second temperature sensors are taken at a rate of about 1.0 Hz or faster.
According to another aspect, a removable gas cell adapted to be disposed between light source and detector sections of a gas analyzer system is provided. The removable gas cell typically includes a housing structure defining a gas flow channel, a first opening at one end of the gas flow channel, a second opening at the other end of the gas flow channel, wherein the first and second openings define a light path along which light from a light source passes through the cell to the detector section. The gas cell also typically includes a gas inlet port, a gas outlet port, wherein the inlet and outlet ports are located on the housing structure (e.g., typically off the optical axis), a first temperature sensor located proximal to the inlet port, and a second temperature sensor located proximal to the outlet port. In certain aspects, the gas cell includes a pressure sensor located at an interior point of the housing structure in the gas flow channel, the pressure sensor adapted to measure a pressure of a gas at an interior point in the flow cell. In certain aspects, at least one of the first and second temperature sensors includes a thermocouple or thermistor positioned at a central point of a flow path defined by the respective port.
According to still another aspect, a removable gas cell adapted to be disposed between light source and detector sections of a gas analyzer system is provided. The removable gas cell typically includes a housing structure defining a gas flow channel, a first opening at one end of the gas flow channel, a second opening at the other end of the gas flow channel, wherein the first and second openings define a light path along which light from a light source passes through the cell to the detector section. The gas cell also typically includes a gas inlet port, a gas outlet port, wherein the inlet and outlet ports are located on the housing structure, a first temperature sensor adapted to measure a temperature of a gas flowing in the flow channel, and a pressure sensor adapted to measure a pressure of the gas at an interior point in the flow cell.
In certain aspects, the removable gas cells include, or can be coupled with, a gas intake tube that couples the atmosphere with the input port. The intake tube can advantageously have a length of less than 2.0 meters and more advantageously less than about 1.0 meters. The intake tube can be short because the analyzer is weather-tight and can be positioned very close to the desired measurement point.
According to yet a further aspect, a gas analyzer is provided that is adapted to operate in an open-path configuration or a closed-path configuration. The gas analyzer typically includes a detector section including a detector, a source section including a light source, and a support structure coupling the detector section with the source section and forming or defining an open air optical path measuring region between the detector and the light source. The gas analyzer also typically includes a gas cell adapted to be removably disposed between the source and detector sections, the gas cell including a housing structure defining a closed-path gas flow channel, wherein light from the light source passes through the gas flow channel to the detector section when the gas cell is disposed between the source and detector section. In a first configuration with the gas cell removed, the gas cell is operable as an open-path gas analyzer to analyze gases in the open air optical path measuring region, and in a second configuration with the gas cell disposed between the source and detector sections, the gas cell is operable as a closed-path gas analyzer to analyze gases in the gas flow channel. In certain aspects, the gas cell includes a gas inlet port, a gas outlet port, wherein the inlet and outlet ports are located on the housing structure, and a first temperature sensor adapted to measure a temperature of gas flowing in the flow channel. In certain aspects, the gas cell also includes a pressure sensor located at an interior point of the housing structure in the gas flow channel, the pressure sensor adapted to measure a pressure of the gas at an interior point in the flow cell. In certain aspects, the gas cell also includes a first temperature sensor located proximal to the inlet port, and a second temperature sensor located proximal to the outlet port. In certain aspects, one or more temperature sensors and one or more pressure sensors are coupled with the gas analyzer for use during open-path gas analysis assays.
According to yet a further aspect, a gas analyzer is provided that is adapted to operate in an open-path configuration or a closed-path configuration. The gas analyzer typically includes a detector section including a detector, a source section including a light source, and a support structure coupling the detector section with the source section and forming an open air optical path measuring region that begins at the source section and ends at the detector section. The gas analyzer also typically includes a gas cell adapted to be removably coupled with the support structure, the gas cell including a housing structure defining a closed-path gas flow channel, wherein light from the light source passes through the gas flow channel to the detector section when the gas cell is coupled with the support structure. In a first configuration, with the gas cell removed, the gas cell is operable as an open-path gas analyzer to analyze gases in the open air optical path measuring region. In a second configuration, with the gas cell coupled with the support structure, the gas cell is operable as a closed-path gas analyzer to analyze gases in the gas flow channel. In certain aspects, the support structure holds the detector section and source sections opposite each other along an axis such as to form the open air optical path measuring region between the detector and the light source. In certain aspects, the open air optical path measuring region includes at least one mirror that reflects light from the light source. In certain aspects, the gas analyzer further includes a removable shroud adapted to couple the gas cell with the support structure and facilitate removal of the gas cell.
According to still a further aspect, a gas analyzer adapted to operate in an open-path configuration or a closed-path configuration is provided. The gas analyzer typically includes a detector section, a source section including a light source and a support structure coupling the detector section with the source section and forming an open air optical path measuring region between the detector and the light source. The gas analyzer also typically includes a gas cell adapted to be disposed between the source and detector sections, the gas cell including a housing structure having internal surface(s) defining a closed-path gas flow channel, wherein the internal surface(s) are metal plated. In a first configuration, with the support structure separated from the gas cell, the gas analyzer is operable as an open-path gas analyzer to analyze gases in the open air optical path measuring region. In a second configuration, with the gas cell disposed between the source and detector sections, light from the light source passes through the gas flow channel to the detector section and the gas analyzer is operable as a closed-path gas analyzer to analyze gases in the gas flow channel. In certain aspects, the metal includes nickel. In certain aspects, the metal plated internal surface(s) are formed using electroless nickel plating on the internal surface(s). In certain aspects, the flow cell substrate is constructed of a plastic material and/or aluminum and/or a fiberglass reinforced (epoxy/glass) laminated composite. In certain aspects, the metal includes tin or gold. In certain aspects, the plastic material is selected from the group consisting of Polyetherimide (PEI), Polyethylene Terephthalate (PET), Polytetrafluoroethylene (PTFE), nylon, glass-filled nylon and Acrylonitrile Butadiene Styrene (ABS).
According to yet another aspect, a gas cell adapted to be disposed between light source and detector sections of a gas analyzer system is provided. The gas cell typically includes a housing structure having internal surface(s) defining a gas flow channel, wherein the internal surface(s) are metal plated, a first opening at one end of the gas flow channel, and a second opening at the other end of the gas flow channel, wherein the first and second openings define a light path along which light from a light source passes through the cell to the detector section. The gas cell also typically includes a gas inlet port, and a gas outlet port, wherein the inlet and outlet ports are located on the housing structure. The gas cell also typically includes a first temperature sensor adapted to measure a temperature of a gas flowing in the flow channel, and a pressure sensor adapted to measure a pressure of the gas at an interior point in the flow cell. In certain aspects, the metal includes nickel. In certain aspects, the metal plated internal surface(s) are formed using electroless nickel plating on the internal surface(s). In certain aspects, the internal surface(s) of the flow cell includes a plastic material and/or aluminum and/or a fiberglass reinforced laminated composite. In certain aspects, the metal includes tin or gold. In certain aspects, an internal surface(s) includes an epoxy/glass composite. In certain aspects, one or both of the gas inlet port and the gas outlet port have internal walls defining channels, wherein the internal walls are metal plated. In certain aspects, the metal includes nickel. In certain aspects, the plastic material is selected from the group consisting of Polyetherimide (PEI), Polyethylene Terephthalate (PET), Polytetrafluoroethylene (PTFE), nylon, glass-filled nylon and Acrylonitrile Butadiene Styrene (ABS).
In certain aspects, the gas cell is securely attached between the source and detector sections of the gas analyzer, wherein the gas cell is intended to be a fixed part of the gas analyzer (e.g., can only be removed with extensive effort by a user). Examples of such gas cells can be found in U.S. patent application Ser. No. 12/266,379, filed Nov. 6, 2008, and U.S. Pat. No. 6,369,387, entitled “Gas Analyzer,” which are both incorporated by reference in their entirety. In other aspects, the gas cell is removably disposed between the source and detector sections of the gas analyzer, e.g., to facilitate easy separation of the source and detector sections from the gas cell or vice-versa, either by tool free removal, or with minimal effort by a user in manipulating connection components.
Reference to the remaining portions of the specification, including the drawings and claims, will realize other features and advantages of the present invention. Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below with respect to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.



BRIEF DESCRIPTION OF THE DRAWINGS
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
FIG. 1 illustrates a gas analyzer including a removable sample flow cell according to one embodiment.
FIG. 2 illustrates a thermocouple design used in the sample cell inlet and outlet according to one embodiment
FIG. 3 is a diagram of a pressure measurement scheme according to one embodiment.
FIG. 4 illustrates thermal conductivity within a flow cell for an un-insulated (top) flow cell and an insulated (bottom) flow cell.
FIG. 5 illustrates one embodiment including a sample cell with a cell insert removed.
FIG. 6 illustrates a temperature and pressure measurement scheme for a gas flow cell according to one embodiment.
FIG. 7 illustrates a gas analyzer adapted to operate in an open-path configuration or a closed-path configuration according to one embodiment; FIG. 7a shows the analyzer configured for open-path analysis; FIG. 7b shows the analyzer configured for closed-path analysis; FIG. 7c shows the sample cell and analyzer separately.



DETAILED DESCRIPTION
The present invention provides systems and methods for measuring concentrations of gases such as carbon dioxide and water vapor. The systems and methods are particularly useful in turbulent air structures. For example, in certain embodiments, the systems and methods advantageously sample and measure gas concentration, temperature and pressure at high speed and at high bandwidth, and allow for calculation of dry mole fraction of gas species.
Operational Overview
The gas analyzers according to various embodiments generally include a light source, a sample cell, and a detector. The sample cell is removable in certain aspects to facilitate in-field cleaning and repair. Due to the hybrid nature of these analyzers, removal of the sample cell allows for configuration of the analyzer as an open-path analyzer, or as a closed-path analyzer. The gas analyzers disclosed herein can be used to measure a concentration of one or more gases that have a high absorbance at different wavelength bands. For example, in one application, a gas analyzer can be used to measure the concentration of carbon dioxide (CO2) and water vapor (H2O) in a sample gas, typically air. Generally, the gas analyzer uses non-dispersive infrared (NDIR) absorption to measure concentration of a gas in a sample cell based on the difference between absorption of infrared radiation passing through the sample cell and a reference cell, or against a calibrated reference signal, Advantageously, the gas analyzers do not require long intake tubes and are thus capable of taking high speed measurements which enable, inter alia, calculation of dry mole fraction of gas components.
In operation, a light source transmits light having a spectrum of wavelengths through sample and reference cells. Gases present in the sample cell absorb light at different wavelength bands. For example, CO2 has a high absorbance at 4.255 μm, and water vapor has a high absorbance at 2.595 μm. Light exiting the sample cell is detected by the detector, which is sensitive to wavelength bands absorbed by the gases (e.g., CO2 and H2O), or two detectors can be used, each sensitive to the wavelength band absorbed by one of the gases. The concentration of the gases in the sample cell can be determined by calculating the difference between absorption in the sample cell and the reference cell or a reference signal. For example, when a reference cell contains a non-absorber gas, the signal detected in the sample cell is compared to the signal detected in the reference cell to provide an absolute measurement of gas concentration in the sample cell. Gases such as methane or other gases can be similarly measured and detected.
It should be appreciated that a reference cell is not needed and that other referencing techniques may be used for such things as reducing the drift in the measurement. For example, an optical filter disk can be used to measure light intensity at a wavelength close to the wavelength of interest, but which is not absorbed by the gas component of interest. Also, a feedback mechanism to keep the light source (e.g., laser) locked at a specific frequency and intensity may be used One example would be a source of pure CH4 that can be used, not to measure absorbance, but rather to keep the light source locked on the desired wavelength through a feedback mechanism. It should also be appreciated that types of spectroscopy measurement other than absorption spectroscopy may be used, for example, tunable diode laser spectroscopy (TDLS), wavelength modulation spectroscopy (WMS) and others as are well known.
U.S. Pat. Nos. 6,317,212 and 6,369,387, which are each hereby incorporated by reference in its entirety, disclose various features of open and closed path gas analyzers, including optical filter configurations and measurement techniques.
Contamination of the gas analyzer can result in inaccurate concentration measurements. Contamination can occur in the sample cell and on the optical windows of the sections of the gas analyzer that house the light source and detectors. Additionally, inaccurate mole fraction measurements can result due to fluctuations in gas temperature. The following embodiments offer solutions to these problems and others. It should be noted that any of these embodiments can be used alone or in combination with one another.
Removable Flow Cell
According to various embodiments, a gas analyzer includes a packaging scheme that enables simple, tool-free removal of the sample flow cell to facilitate in-field cleaning of optical components such as source and detector optical windows and the gas sample path. Such a packaging scheme also advantageously allows for maintaining a desiccant and scrub path (see e.g., U.S. Pat. No. 6,317,212, previously incorporated by reference) and advantageously allows for repeatable distance between the source and detector.
FIG. 1 illustrates a gas analyzer 10 including a removable sample flow cell 20 according to one embodiment. Sample cell 20 includes a housing structure having a gas inlet port 25 and a gas outlet port 30. A cylindrical portion 40 defines a gas flow path which has two openings at either end. The cylindrical portion may be part of the housing structure of cell 20 or it may itself be separable from the housing structure. In operation, gas enters input port 25, flows through the flow path defined by cylindrical portion 40 and exits outlet port 30. In one embodiment, a pressure sensor 35 (external portion shown) is positioned to measure the pressure at an internal point within the flow path.
Removable sample cell 20 is configured to couple with structure 22 of gas analyzer 10. Structure 22 includes a source portion 60 that houses a light or radiation source and associated electrical and optical components. Structure 22 also includes a detector portion 50 that houses one or more detectors and associated optical and electrical components. A first optical window 70 is provided in one embodiment proximal to source portion 60 as shown in FIG. 1. A second optical window (not shown) is provided in one embodiment proximal to detector portion 50. In typical operation, light (typically IR light) emanating from source portion 60 travels to detector portion 50 along an optical path defined by the first and second optical windows. In one embodiment, an O-ring is provided proximal the first and second optical windows to provide a more robust seal between the sample cell 20 and the source portion 70 and detector portion 50 when in a coupled state.
When in a coupled state, the gas flow path defined by cylindrical portion 40 substantially aligns with the optical path defined by the first and second optical windows. It should be appreciated that the optical path and the flow path do not need to align, and that only a portion of the gas flow path need be contiguous with the optical path. It should also be appreciated that although cylindrical portion 40 includes an open-ended flow path when decoupled from housing 22, optical windows could be coupled to or located on sample cell 20 at either end of the flow path in place of or in addition to the first and second optical windows of structure 22. In the coupled state, the gas analyzer is operable to analyze gases as a closed-path analyzer, i.e., the gas analyzer analyzes gas(es) introduced into the gas flow path of the sample cell 20.
In one embodiment, to couple and uncouple sample cell 20 from the gas analyzer housing structure 22, one or more thumbscrews 65 (two shown) are provided to increase or decrease the distance of detector section 50 relative to column 23. When in a coupled state, a user need only activate the thumbscrews, separate detector section 50 a sufficient distance from column 23 and remove sample cell 20. Similarly, to couple sample cell 20 with the gas analyzer, the user would extend the detector section 50 a sufficient distance, insert cell 20 adjacent to column 23 and activate the thumbscrews to re-engage the detector section 50 with column 23 and simultaneously engage sample cell 20 between detector section 50 and source section 60. The optical windows and O-rings help ensure an airtight seal for the gas flow path in sample cell 20. Alternative coupling mechanisms could include a bayonet (such as used in cameras), clamps, clips or other fastening mechanisms.
Advantageously, the design shown in FIG. 1 enables easy removal of the sample cell 20 and associated components. The mechanical packaging scheme enables easy, tool-free removal of the sample cell to clean the source and detector optical windows, and sample flow path. This enables use of the gas analyzer (e.g., an IR gas analyzer or IRGA) without need to filter the air sample for dust (which lowers the power requirements for air flow). To maintain air-tight seals and allow the sample cell to be removed, the detector enclosure 50 is extended away from the rest of the assembly as shown in FIG. 1. Air-tight paths are provided from the detector enclosure 50, through circulation column portion 23, to the source enclosure 60 to run CO2 and H2O free air as well as necessary electrical components. It should be appreciated that the gas analyzer could be configured such that attachment mechanisms enable the source section 60 to extend away from column 23 in addition to or in lieu of detector section 50 extending away from column 23.
Open-Path and Closed-Path Analyzer
According to various embodiments, a gas analyzer includes a packaging scheme that enables simple, tool-free removal of the sample flow cell to facilitate in-field cleaning of optical components such as source and detector optical windows in a closed-path configuration, and also to configure the analyzer for open-path analysis. Such a packaging scheme also advantageously allows for maintaining a desiccant and scrub path (see e.g., U.S. Pat. No. 6,317,212, previously incorporated by reference) and advantageously allows for repeatable distance between the source and detector.
FIG. 7 illustrates a gas analyzer 110 including a removable sample flow cell 120 according to one embodiment. Sample cell 120 includes a housing structure having a gas inlet port 125 and a gas outlet port 130. A cylindrical portion 140 (See FIG. 7c top opening of cylindrical portion 140 shown) defines a gas flow path which has two openings at either end. The cylindrical portion may be part of the housing structure of cell 120 as shown in FIG. 7c or it may itself be separable from the housing structure. In operation, gas enters input port 125, flows through the flow path defined by cylindrical portion 140 and exits outlet port 130. In one embodiment, a pressure sensor 135 (external portion shown) is positioned to measure the pressure at an internal point within the flow path.
Removable sample cell 120 is configured to couple with the structure of gas analyzer 110. The structure of the analyzer includes a source portion 160 that houses a light or radiation source and associated electrical and optical components, and a detector portion 150 that houses one or more detectors and associated optical and electrical components. The structure further includes a set of three support columns 123 equally spaced around a center axis as shown in FIG. 7. It should be appreciated that fewer than, or more than, three support columns may be used and that the support columns need not have equidistant spacing around the axis. A first optical window 170 is provided in one embodiment proximal to source portion 160 as shown in FIG. 7. A second optical window 180 is provided in one embodiment proximal to detector portion 150. In one embodiment, an O-ring is provided proximal the first and second optical windows to provide a more robust seal between the sample cell 120 and the source portion 160 and detector portion 150 when in a coupled state.
When in a coupled state as shown in FIG. 7b, the gas flow path defined by cylindrical portion 140 substantially aligns with the optical path defined by the first and second optical windows. It should be appreciated that the optical path and the flow path do not need to align, and that only a portion of the gas flow path need be contiguous with the optical path. It should also be appreciated that although cylindrical portion 140 includes an open-ended flow path when decoupled from the housing structure of analyzer 110, optical windows could be coupled to or located on sample cell 120 at either end of the flow path in place of or in addition to the first and second optical windows of the housing structure. In the coupled state, the gas analyzer is operable to analyze gases as a closed path analyzer, i.e., the gas analyzer analyzes gas(es) introduced into the gas flow path of the sample cell 120.
When in an un-coupled state as shown in FIG. 7a, e.g., with the sample cell 120 removed, the gas analyzer is operable to analyze gases as an open-path analyzer, i.e., the gas analyzer analyzes gas(es) within the open air optical path measuring region.
In one embodiment, to couple and uncouple sample cell 120 from the gas analyzer housing structure, one or more thumbscrews (not shown in FIG. 7, but see FIG. 1 for example) are provided to increase or decrease the distance of detector section 150 relative to columns 123. When in a coupled state, a user need only activate the thumbscrews, separate detector section 150 a sufficient distance from support columns 123 and remove sample cell 120. Similarly, to couple sample cell 120 with the gas analyzer, the user would extend the detector section 150 a sufficient distance, insert cell 120 adjacent to columns 123 and activate the thumbscrews to re-engage the detector section 150 with columns 123 and simultaneously engage sample cell 120 between detector section 150 and source section 160. The optical windows and O-rings help ensure an airtight seal for the gas flow path in sample cell 120. Alternative coupling mechanisms could include a bayonet (such as used in cameras), clamps, clips or other fastening mechanisms. For example, telescoping tubing may be used or rotating/sliding wall portions may be used. Such mechanisms may also be automated, e.g., to allow a user to change between open and closed modes of use automatically. For example, control signals sent from a remote location may be used to control modes of operation. In one alternate embodiment, a shroud may be used to facilitate coupling and removal of the gas cell. A shroud may include compressible gaskets on either end, and/or a shroud may be placed around the entire analyzer or a portion of the analyzer.
Advantageously, the design shown in FIG. 7 enables easy removal of the sample cell 120 and associated components. The mechanical packaging scheme enables easy, tool-free removal of the sample cell to reconfigure between open and closed path configurations. Air-tight paths are provided from the detector enclosure 150, through circulation one or more of the support columns 123, to the source enclosure 160 to run CO2 and H2O free air as well as necessary electrical components. It should be appreciated that the gas analyzer could be configured such that attachment mechanisms enable the source section 160 to extend away from columns 123 in addition to or in lieu of detector section 150 extending away from columns 123.
In an alternate embodiment the detector and source sections may be located other than along an optical axis as shown in FIG. 1. For example, the source and detector sections may be coupled by the support structure on the same side, e.g., adjacent each other, or they may be coupled in other geometric configurations. One or more mirrors may be used to reflect light from the source to the detector within the measurement region defined by the geometric configuration used. In one alternate arrangement, as an example, the source and detector sections may be positioned adjacent each other, and a mirror may be positioned a certain distance from the source and detector and oriented so as to reflect light from the source to the detector; hence, the path measuring region of this configuration would include the source-to-mirror segment and the mirror-to-detector segment.
Temperature and Pressure Measurements
Knowing the temperature of the sample gas is important for various measurements, such as for calculating the mole fraction from the number density. According to one embodiment, the temperature is measured at the inlet port 25 (or 125) and at the outlet port 30 (or 130) of the sample cell 20 (or 120) in a manner that does not block any of the optical signal (e.g., IRGA signal) in the flow path. The volume average temperature in the cell can be calculated from a relationship between the inlet and outlet temperatures along with the flow rate of the sample gas. In certain aspects, for example, a generic function is TIRGA=f(Tin, Tout, Tblock, U), where U is the mean velocity through the cell. In certain aspects, additional temperature sensors may be used, e.g., to measure the block temperature of cylinder 40, and/or to measure the gas temperature at different points in the flow path.
In one embodiment, the inlet and outlet temperatures are measured using a disposable thermocouple (e.g., type-E thermocouple). For example, in certain aspects, a thermocouple is strung taught across a printed circuit board with a hole through for the sample gas to flow. FIG. 2 illustrates a thermocouple design used in the sample cell inlet and outlet ports according to one embodiment. A printed circuit board 80 includes an aperture across which is strung a thermocouple bead 85. In certain aspects, the printed circuit board is included in structure 20 or mounted on structure 20 such that the aperture is contiguous with the gas flow path of the entry/exit port 25/30. An O-ring 90 provides an air tight gas path. This design allows the thermocouples to be easily replaced as well as measuring temperature in the center axis of the gas flow. In general, it is desirable to match the frequency response of the thermocouple to that of the volumetric frequency response, e.g., physical response of the flow cell. For example, a 0.002′′ thermocouple advantageously provides a frequency response to a 15 liter/minute (LPM) flow that is substantially the same as the signal attenuation due to the volume averaging within the RIGA. In one embodiment, the measurements are synchronized with each other to account for slight timing variations and frequency variations. For example, the measurements of gas concentration (e.g., CO2 and H2O), temperature and pressure are advantageously taken within about 0.2 seconds, and more advantageously within about 0.1 seconds of each other in certain embodiments. This enables a calculation of dry mole fraction as will be described more below. These signals may be aligned in real time to account for time variations/delays as will be discussed more below.
In certain embodiments, a single temperature sensor is used. For example, a single temperature sensor may be located proximal to the inlet port, proximal to the outlet port, or proximal to an internal portion of the flow cell. Temperature measurements can be taken and a volume temperature can be calculated using the single temperature sensor signal and known parameters, such as flow rate, flow cell volume, etc. However, it is appreciated that the use of two (or more) temperature sensors as described above will provide a more representative temperature for the gas in the flow cell.
The pressure in the flow cell is required to calculate the mole fraction from number density. FIG. 3 is a diagram of a pressure measurement scheme according to one embodiment. In one embodiment, the pressure sensor, e.g., sensor 35 or 135 includes a differential pressure sensor. In order to maintain the sensor head as compact as possible, in one embodiment, a coupled set of absolute/differential pressure transducers are used to obtain high frequency pressure data from the sample cell (since a pressure sensor that measures absolute sensor may be quite bulky). The pressure of the gas at the interior of the flow cell can be determined by adding the differential pressure and the mean pressure. In one embodiment, the pressure sensor is a high speed pressure sensor. Useful pressure sensors include a piezoresistive silicon differential pressure transducer (e.g., MPX2010DP, Freescale Semiconductor Inc. (Motorola)) and a piezoresistive silicon absolute pressure transducer (MPX4115A, Freescale Semiconductor Inc. (Motorola)). Other pressure sensors as would be apparent to one skilled in the art may be used.
According to one embodiment, the sample flow cell includes an insulating sleeve made out of a low thermal conductivity material and/or pockets of air or vacuum. Useful materials include low-CO2 absorption plastics (e.g., Teflon® DuPont, PTFE (polytetrafluoroethylene) which can be very useful because all plastics absorb some CO2 and water vapor, but Teflon is exceptionally low in absorption) and other suitable materials. A double-wall vacuum metal sleeve or other designs may be used. Such sleeves advantageously minimize the temperature change between the inlet and outlet ports (to maximize accuracy) by decoupling the air flow from the heat dissipation of the gas analyzer, e.g., heat dissipation due to electronics of the gas analyzer. In general, the bigger the temperature change, the more the characterization between the volume average temperature as a function of the two measured temperatures is relied on. Thus, the thermal insulation sleeve, when used, should insulate at least a portion of the flow cell from other components of the system. FIG. 4 illustrates an example of the thermal conductivity within a flow cell for an un-insulated (top) flow cell and an insulated (bottom) flow cell. The top image is a typical metal sample cell, while the lower image shows an insulated cell where the only heat flux comes from the windows on either end. As can be seen, the heat flux is greatly reduced and the error in temperature measurement is also greatly reduced. In both cases, the error is calculated by the actual temperature minus an un-weighted average of the inlet and outlet temperatures.
FIG. 5 illustrates one embodiment including a sample cell with a cell insert 95 (defining the gas flow path) removed. As can be seen, a position and sealing scheme for the thermocouple boards 80 proximal to both the inlet and outlet ports is also shown.
Mole Fraction Measurement
To determine and output mole fraction, calculations should be performed in real time. To implement this, digital electronics receive various signals and perform calculations in real-time. The high speed temperature and pressure signals are acquired from spatially separated sensors. Also, each sensor typically has its own characteristic frequency response (sometimes depending on the flow rate). According to one embodiment, the timing of the sensors is aligned (e.g., delays removed) and the frequency responses, where necessary, are accounted for to calculate the mole fraction in the center of the sample cell (e.g., without directly measuring temperature in that position). As shown in FIG. 6, according to one embodiment, the inlet temperature is measured at point ‘A’, the pressure is measured at point ‘B’, the outlet temperature is measured at point ‘C’, and the gas concentrations are a volume-averaged measurement contained within the dotted outline. In certain aspects, signal alignment occurs in real time as signals are received (e.g., by an intelligence module adapted to process such signals). It should be appreciated, however, that signal processing may be performed later. For example, the signals, or data representing the signals, may be stored and provided to an intelligence module for processing at a later time, after measurements have been taken.
According to one embodiment, the dry mole fraction is determined using a gas analyzer according to the various embodiments disclosed herein. Advantageously, gas analyzers as disclosed herein are capable of making dry mole fraction measurements at high bandwidth. For example, it is desirable to determine a dry mole fraction of CO2 or other gas component at a certain frequency response, e.g., 10 Hz. In order to provide this output, the following steps occur according to one embodiment. First, a flow rate is introduced through the IRGA that purges the volume, for example, at about a 10 Hz or greater purge rate. For example, a flow of ambient air into the inlet port, through the flow cell and out the outlet port is initiated at the desired flow rate. The temperature is then measured at points A and C with a frequency response similar to the volume-average (e.g., type ‘E’ thermocouples of 0.002′′ diameter provides a similar response to a flow rate of 15 liters-per-minute (LPM) through the IRGA). The pressure (e.g., differential pressure) is measured at point B with a similar frequency response to the other measurements. The temperature measurements are taken substantially simultaneously with each other and with the pressure measurement. The temperatures at A and C are corrected for spatial separation (e.g., TA(t+delay) and TC(t−delay) where the delay is a function of the flow rate and flow pith/IRGA geometry). Simultaneously with these measurements, the detector system is determining concentration of gas components (e.g., carbon dioxide and water vapor). In certain aspects, the bandwidth of all the signals (e.g., temperature, pressure, absorbance) is matched to the physical time constant of the flow through the flow cell volume (i.e., flow rate divided by volume). Appendix A illustrates exemplary calculations for determining the dry mole fraction. Once determined, the dry mole fraction may be returned, e.g., displayed or stored for later use.
It should be understood that, herein and elsewhere, when referring to a mole fraction (e.g., CO2 mole fraction) that includes water vapor, the term “mole fraction” is typically used; when referring to a mole fraction after water vapor is removed, the term “dry mole fraction” is typically used, and in certain instances the term “instantaneous mole fraction” or “instantaneous dry mole fraction,” may be used to refer to high speed measurements.
It should be appreciated that the gas analysis processes, including the mole fraction determination processes, may be implemented in computer code running on a processor of a computer system. The code includes instructions for controlling a processor to implement various aspects and steps of the gas analysis processes. The code is typically stored on a hard disk, RAM or portable medium such as a CD, DVD, etc. Similarly, the processes may be implemented in a gas analyzer including an intelligence module, typically having one or more processors executing instructions stored in a memory unit coupled to the processor(s). The intelligence module may be part of the gas analyzer, or part of a separate system directly or indirectly coupled with the gas analyzer. Code including such instructions may be downloaded to the gas analyzer memory unit over a network connection or direct connection to a code source or using a portable medium as is well known.
One skilled in the art should appreciate that the processes of the present invention can be coded using a variety of programming languages such as C, C++, C#, Fortran, VisualBasic, etc., as well as applications such as Mathematica® which provide pre-packaged routines, functions and procedures useful for data visualization and analysis. Another example of the latter is MATLAB®.
Insulated Sample Flow Cell
According to one embodiment, the sample flow cell may be constructed of polymers or plastics to provide a thermal bather between the sample gas and the analyzer. Depending on the sorptive properties of this sample cell and the gases under analysis, the cell walls may be coated with a metal film to provide the sorptive benefits of a metal layer compounded with the thermal barrier properties of plastics and polymers. In a particular embodiment, the plastic material is Polyetherimide (PEI), in particular Ultem (®Sabic Plastics), and the metal film is nickel deposited by electro less nickel plating. PEI/Ultem has a thermal conductivity approximately 1000 times less than that of aluminum. Other metals, such as tin, gold, etc, may be used.
In another particular embodiment, Selective Laser Sintering (SLS) or Fused Deposition Modeling (FDM) of plastic materials, such as nylon (SLS), glass-filled nylon (SLS) and Acrylonitrile Butadiene Styrene (or ABS) (FDM), may be used to produce sample flow cells and other system components. Alternative Direct Digital Manufacturing (DDM) techniques and materials may be used as they become available. In one embodiment, electro-less nickel plating of plastic materials is used, e.g., to avoid the sorption problems which might occur with bare plastics, SLS, FDM or epoxy-glass composite flow cells.
Both Selective Laser Sintering (SLS) and Fused Deposition Modeling (FDM) are technologies developed in the field of rapid-prototyping. These technologies are being expanded beyond prototypes to functional product components. When these technologies are employed in the manufacture of a product, they are classified as Direct Digital Manufacturing (DDM). Key advantages of DDM methods include:
1. nearly arbitrary geometry can be created without the limitations of traditional material removal machining processes (milling, turning, drilling, etc.),
2. complex geometry can be created directly from a CAD model without the time and tooling costs associated with molded parts, and
3. complex internal geometry can be created that is not possible with any other conventional manufacturing process (machining or molding).
Also, the flexibility of these DDM processes allows single parts with intricate internal passageways to be created. These internal passageways can be optimized, for example, so that the flow is optimized for both gas analysis and heat exchange.
Alternative methods for depositing metal films upon non-metallic (e.g., plastic) substrates include vacuum deposition. Vacuum deposition requires a line-of-sight between the source of metal atoms and the target. Thus, coating internal passageways with vacuum deposition would be difficult at best. Vacuum deposition processes are also more expensive than conventional plating processes, as they require a vacuum chamber.
As described above, certain of the advantages provided by the various embodiments include thermal isolation of the gas in the sample cell. SLS/FDM and other direct digital manufacturing technologies bring the added ability to create complex and intricate flow passageways; leveraging the extremely low thermal conductivity of Ultem (Polyetherimide-PEI), nylon, ABS, other plastic and composite materials (e.g. FR4) to produce flow cells that thermally insulate the sample flow path from the remainder of the instrument allowing a more representative temperature representation; the direct use of nickel plated plastics or composites in the production of flow cells; and a reduction in diffusion and sorption of gases due to the nickel plating.
In other embodiments, electroless nickel plating is used to coat metal parts, for example, traditionally, flow cells are constructed of light-weight aluminum. Bare aluminum naturally forms an oxide layer. This oxide layer is quite porous, and will retain and release water molecules through sorption. To combat water sorption in such aluminum cells, the aluminum components are plated with nickel via Electroless Nickel Plating in certain embodiments. The thin layer of nickel deposited on the surface of the aluminum substrate greatly reduces water sorption. Also, electroless plating provides nearly uniform thickness on complex parts, unlike electroplating, in which plating thickness can change depending on exposure to electrical fields during plating. Other plating options (e.g. tin) may be more cost-effective on the epoxy/glass composites. Plating with other metals, such as gold, may be performed
Sorption of water vapor is particularly sensitive to the surface finish of the sample cell walls. In certain embodiments, the roughness of the internal metal plated surfaces are carefully controlled to reduce effective surface area and thereby minimize sorption. For example, in one embodiment, surface finishes less than about 16 microinches Ra (average roughness) are used to minimize the impact of surface finish.
While the invention has been described by way of example and in terms of the specific embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.

## Claims

1. A gas analyzer adapted to operate in an open-path configuration or a closed-path configuration, the gas analyzer comprising:
a) a detector section including a detector and a first optical window;
b) a source section including a light source and a second optical window, wherein the first and second optical windows provide an airtight seal for components within the source and detector sections;
c) a support structure coupling the detector section with the source section and forming an open air optical path measuring region between the detector and the light source; and
d) a gas cell adapted to be removably coupled with the support structure between the source and detector sections, the gas cell including a housing structure having internal surface(s) defining a closed-path gas flow channel, wherein the internal surface(s) are metal plated; and
wherein in a first configuration with the gas cell separated from the support structure, the gas analyzer is operable as an open-path gas analyzer to analyze gases in the open air optical path measuring region, and
wherein in a second configuration with the gas cell coupled with the support structure between the source and detector sections, light from the light source passes through the gas flow channel to the detector section and the gas analyzer is operable as a closed-path gas analyzer to analyze gases in the gas flow channel.

2. The gas analyzer of claim 1, wherein the metal plated internal surface(s) are formed using an electroless metal plating process on the internal surface(s).

3. The gas analyzer of claim 1, wherein the internal surface(s) of the gas cell comprises a plastic material.

4. The gas analyzer of claim 3, wherein the plastic material is selected from the group consisting of Polyetherimide (PEI), Polyethylene Terephthalate (PET), Polytetrafluoroethylene (PTFE), nylon, glass-filled nylon and Acrylonitrile Butadiene Styrene (ABS).

5. The gas analyzer of claim 1, wherein the internal surface(s) of the gas cell comprises aluminum.

6. The gas analyzer of claim 1, wherein the gas cell further includes:
a gas inlet port;
a gas outlet port, wherein the inlet and outlet ports are located on the housing structure;
a first temperature sensor adapted to measure a temperature of gas flowing in the flow channel; and
a pressure sensor located at an interior point of the housing structure in the gas flow channel, the pressure sensor adapted to measure a pressure of the gas at an interior point in the flow cell.

7. The gas analyzer of claim 6, further including a second temperature sensor located proximal to the outlet port, wherein the first temperature sensor is located proximal to the input port.

8. The gas analyzer of claim 7, further including an intelligence module coupled with the first and second temperature sensors, with the pressure sensor and with the detector, the intelligence module adapted to determine a dry mole fraction of components of a gas within the flow channel based on a detector signal and substantially simultaneous measurements of the pressure of the gas by the pressure sensor and the temperature of the gas by the first and second temperature sensors.

9. The gas analyzer of claim 8, wherein the components of the gas include CO2 and H2O, and wherein the gas is air.

10. The gas analyzer of claim 8, wherein the measurements of the pressure and of the temperature of the gas by the first and second temperature sensors occur within about 0.2 seconds or less of each other.

11. The gas analyzer of claim 8, wherein the intelligence module corrects for a delay due to spatial separation in the temperature signals received from the first and second temperature sensors, wherein the delay is a function of a flow rate of the gas in the flow channel.

12. The gas analyzer of claim 6, wherein the measurements of the pressure and of the temperature of the gas are taken at a rate of about 1.0 Hz or faster.

13. The gas analyzer of claim 1, wherein the source section includes a first optical window, wherein the detector section includes a second optical window, and wherein the first and second optical windows provide an airtight seal for components within the source and detector sections.

14. The gas analyzer of claim 1, wherein detector section and the source section each include an optical window or other element that allows light of a desired wavelength range to pass.

15. The gas analyzer of claim 1, wherein the support structure holds the detector section and source sections opposite each other along an axis such as to form the open air optical path measuring region between the detector and the light source.

16. The gas analyzer of claim 15 wherein the gas cell is adapted to be removably coupled between the source section and detector section.

17. The gas analyzer of claim 1, further including a removable shroud adapted to couple the gas cell with the support structure.

18. The gas analyzer of claim 1, wherein the open air optical path measuring region includes at least one mirror that reflects light from the light source.

19. The gas analyzer of claim 1, wherein the support structure includes a channel coupling the source section with the detector section, and wherein the channel a) enables purged gas to flow between the source and detector sections, and/or b) houses electrical connectors coupling the source section with the detector section.

20. The gas analyzer of claim 1, where the roughness of the internal metal plated surfaces is carefully controlled to reduce effective surface area and thereby minimize sorption.

21. A gas cell adapted to be removably coupled between a light source and a detector section of a gas analyzer, the gas cell including:
a gas cell housing structure having internal surface(s) defining a gas flow channel, wherein the internal surface(s) are metal plated;
a first opening at one end of the gas flow channel;
a second opening at the other end of the gas flow channel, wherein the first and second openings define a light path along which light from a light source passes through the cell to the detector section;
a gas inlet port;
a gas outlet port, wherein the inlet and outlet ports are located on the gas cell housing structure;
a first temperature sensor adapted to measure a temperature of a gas flowing in the flow channel; and
a pressure sensor adapted to measure a pressure of the gas at an interior point in the flow channel,
wherein in a first configuration with the gas cell housing structure separated from the light source and detector sections of the gas analyzer, the gas analyzer is operable as an open-path gas analyzer to analyze gases in the open air optical path measuring region, and
wherein in a second configuration with the gas cell housing structure coupled with the light source and detector sections of the gas analyzer between the light source and detector sections, light from the light source passes through the gas flow channel to the detector section and the gas analyzer is operable as a closed-path gas analyzer to analyze gases in the gas flow channel.

22. The gas cell of claim 21, wherein the metal plated internal surface(s) are formed using an electroless plating process on the internal surface(s).

23. The gas cell of claim 21, wherein the internal surface(s) of the gas cell comprises a plastic material.

24. The gas cell of claim 23, wherein the plastic material is selected from the group consisting of Polyehterimide (PEI), Polyethylene Terephthalate (PET), Polytetrafluoroethylene (PTFE), nylon, glass-filled nylon and Acrylonitrile Butadiene Styrene (ABS).

25. The gas cell of claim 21, wherein the internal surface(s) of the gas cell comprises aluminum.

26. The gas cell of claim 21, wherein one or both of the gas inlet port and the gas outlet port have internal walls defining channels, wherein the internal walls are metal plated.