GAS DETECTING APPARATUS

Abstract: A gas detecting apparatus comprising a gas sensor, a load limiting resistor connected in series to the gas sensor, an electric source for applying a predetermined voltage to the gas sensor and the load limiting resistor, and means to detect resistance variations of the gas sensor, wherein the gas sen­ sor comprises a semiconductor of metal oxide placed at least at both ends thereof in close contact with a metallic heating member, the semiconductor being heated by the metallic heating member, whereby variations in combined resistance of the semiconductor and the metallic heating member which occur as the semiconductor adsorbs a gas are detected by said means.

Description: Gas Detecting Apparatus This invention relates to a gas detecting apparatus comprising a gas sensor which includes a semiconductor placed in contact with a heating wire. Varied gas sensors have been proposed for detecting gases. There are two types that have been in wide use, and they are the catalytic oxidation type and the semiconductor type. The former comprises a platinum coil and a sintered piece of powdery particles formed thereon to act as catalyst. When its catalytically active surface (which is maintained at about 300 C) comes into contact with air containing a combustible gas, the gas and oxygen react with each other even at a concentration below a lower explosion limit. A heat resulting from the reaction raises the temperature of the platinum coil and increases its resistance. The resistance variation is measured by a bridge circuit or other means, whereupon a gas detection signal is given. With this catalytic oxidation type gas sensor, there is a linear relationship between an output signal and a gas concentration, but this gas sensor is inferior to the semiconductor type gas sensor in longterm stability of gas sensitivity. On the other hand, the semiconductor type gas sensor comprises a sintered piece of metal oxide such as tin oxide, zinc oxide or the like formed between a pair of electrodes. One of the electrodes extends in coil and is connected to the other electrode to be used also as a heating electrode usually. The sensor is maintained at a temperature of 300-4000C by this heater electrode. Presence of a gas is detected by utilizing a decrease in the resistance between the two electrodes which takes place as the electric conductivity of the semiconductor increases with gas adsorption. The semiconductor type gas sensor is superior to the catalytic oxidation type sensor in durability and long-term stability and also in resistibility to poisoning. On the other hand, however, the semiconductor type gas sensor consumes greater power and requires a large capacity electric source comprising a transformer, and hence is costly. Further, since its output signal depends largely on voltage, a constant voltage circuit is required in order to achieve satisfactory performance, which adds to high cost. A further disadvantage of the semiconductor type gas sensor is that it has a large thermal capacity and takes a long time before its output signal stabilizes, which results in a long adjustment time required. Thus, the qualities tend to be unstable and also productivity is not satisfactory. Still further, the semiconductor type gas sensor requires a temperature compensating circuit since it depends on temperature and humidity to a great degree. This invention has been made having regard to the above state of the art. Therefore, the invention intends to provide a gas detecting apparatus comprising a gas sensor including a semiconductor placed in contact with a heating wire, which apparatus is capable of gas detection without consuming great power and with good gas sensitivity lasting over a long period of time. More particularly, the object of this invention is to provide a gas detecting apparatus wherein a gas sensor comprises a semiconductor of metal oxide placed in close contact with a metallic heating member, and load limiting resistor is connected in series to the gas sensor, the gas sensor being heated by the metallic heating member, and means is provided to detect variations in combined resistance of the metallic heating member and the semiconductor which occur as the semiconductor adsorbs a gas. In the gas detecting apparatus according to this invention, materials of the metallic heating member and/or the semiconductor are optimized thereby to minimize temperature dependence of the combined resistance whether there occurs gas adsorption or not, and to maximize gas concentration dependence of the combined resistance, namely gas sensitivity, when gas adsorption occurs. It is immaterial whether or not the metallic heating member is formed on a base plate, but the metallic heating member is in a spiral or zigzag form to heat the semiconductor effectively. Further, the load limiting resistor should desirably comprise a material having only negligible resistance variations due to Joule's heat. The described construction achieves the object of this invention. Details of the apparatus according to this invention will be apparent from the following description to be made with reference to the drawings. In tli drawings Fig. 1 is a circuit diagram showing a gas detecting apparatus according to a first embodiment of this invention; Figs. 2 and 3 are perspective views partly in section each showing an example of gas sensor used with the embodiment of Fig. 1; Fig. 4 is a sectional view of a further example of gas sensor; Fig. 5 is a graph showing general relationship between temperature and electric resistance of a metallic heating member and a semiconductor used in the gas sensor; ; Fig. 6 is a graph showing variations with temperatures in combined resistance of the metallic heating member and the semiconductor in the examples of Figs. 2 to 4; Fig. 7 is a graph showing relationship between voltage applied by an electric source to the sensor and output voltage of the sensor with respect to varied gases; Figs. 8 and 9 are graphs showing relationship between materials used for the metallic heating member and properties thereof in relation to electric resistance in a gas sensor according to a further embodiment; Fig. 10 is a section taken on line X-X of Fig. 11 showing a gas sensor according to a still further embodiment; Fig. 11 is a section taken on line XI-XI of Fig. 10; Fig. 12 is a circuit diagram showing an apparatus according to a further embodiment; and Figs. 13 and 14 are graphs showing output signals of the apparatus of Fig. 12. FIRST EMBODIMENT As shown in Fig. 1, a gas detecting apparatus according to this embodiment comprises a gas sensor 10, a load limiting resistor 12 connected in series to the gas sensor 10 and having a predetermined resistance R', an electric source 14 for applying a predetermined voltage V to the sensor 10 and the resistor 12, and detecting means 16 to detect variations in a combined resistance R of the gas sensor 10. The gas sensor 10 includes a metallic heating member 18 and a semiconductor 20 of metal oxide connected in parallel with each other, the semiconductor 20 being heated by the metallic heating member 18. The detecting means 16 comprises a voltmeter 22 and the load limiting resistor 12. Thus the resistor 12 is provided to perform two functions, one of which is to optimize an electric current i passing through the sensor 10, and the other, the more important of the two, is to act as resistance for detecting iR, namely variations of the combined resistance R, by utilizing a relationship V (const.) = i (R+R') and variations of partial voltage iR'. Examples of specific construction of the gas sensor 10 are shown in Figs. 2 to 4, any one of which may be employed. In the example of Fig. 2, the metallic heating member 18 comprises a platinum film formed by the vapor deposition method on an outer periphery of a heat resisting and electricity insulating tubular or columnar support member 24 and trimmed to be in a helical form and have a predetermined resistance. The metallic heating member 18 is peripherally contacted and covered by the semiconductor 20 having sensitivity to gases and comprising a metal oxide such as tin oxide. Numbers 26 and 28 denote lead wires connected to ends of the metallic heating member 18 and the semiconductor 20. In the example of Fig. 3, there is no support member but a coiled metallic heating member 18 is covered by a gas sensitive semiconductor 20 in spheroid form. In the example of Fig. 4 the metallic heating member 18 and the semiconductor 20 are in contact with each other at both ends thereof, with an intermediate portion electrically insulated by an insulator 30. Components in Figs. 2 to 4 are formed of the same materials, respectively. This embodiment including the examples of Figs. 2-4 has a feature far more important than the described specific constructions, and this important feature resides in that the metallic heating member has an appropriate positive temperature coefficient of electric resistance and the semiconductor of metal oxide has an appropriate " negative temperature coefficient of electric resistance", materials being selected for the metallic heating member and the semiconductor such that the two temperature coefficients offset each other. (For convenience sake, the term negative temperature coefficient of resistance" is used although the resistance of the semiconductor does not change in proportion to temperature.) This feature is hereinafter described referring to Figs. 5 to 7. A resistance RA of the metallic heating member 18, a resistance RB of the semiconductor 20 connected in parallel to the member 18, and combined resistance R thereof are derived, by a simple simulation utilizing acceptable models, from the following equations: RA = RAO ( 1 + ATc ) .... (i) ¯ B Tk RB RBO .e .... (ii) RA R R = .... (iii) RA + RB Wherein RAov A, RBO and B are numerical values characteristic of types of materials, respectively, Tc is temperature by centigrade (OC) and Tk is absolute teperature (or). The equation (i) is represented by a straight line ( 1) and the equation (ii) by .a curve (m) in Fig. 5, the positional relationship between the line ( l) and the curve (m) being schematically shown. The equation (iii) is represented by a curve in Fig. 6. In a range indicated by reference T' in Figs. 5 and 6, the line ( 1) and the curve (m) have about the same degree of inclination but incline in opposite directions, while the combined resistance R is substantially constant as seen in Fig. 6. The sensor, if used in this range, gives a highly reliable gas detection signal. In this embodiment materials are selected for the metallic heating member 18 and/or the semiconductor 20 so as to extend the range T' to a maximum. In particular, antimony pentoxide (Sb205) is added in an optimal proportion to the tin oxide (SnO2) forming the semiconductor 20. Fig. 7 clearly shows an effect produced thereby. This figure shows output voltage variations of the gas sensor 10 when detecting varied gases, which are measured while varying the voltage applied by the electric source to the gas sensor 10 to vary the sensor temperature. Curves a to e represent data resulting form detection of hydrogen gas, a gas mixture of carbon monoxide and hydrogen in a 2:1 ratio, ethanol, carbon monoxide and methane, all contained in air in a concentration of 100 ppm, respectively. Curve f represents data resulting from the case of clean air. As seen, the sensor output signal is stable when the output voltage of the electric source is in a range of about 2.6V to about 3.or. SECOND EMBODIMENT In the first embodiment described above, the temperature coefficient of electric resistance of the semiconductor is regulated whereas in the second embodiment the temperature coefficient of electric resistance of the metallic heating member of the sensor is regulated. The two embodiments are the same in the other respects. The foregoing equation (i) is modified into the following equation (i'): R' A Rc ( 1 + a A T ) .... (i' ) wherein Rc is a resistance n at a certain given temperature (OC) and R'A is a resistance fl when the given temperature is raised by A T (or). However, where the given teperature is OOC, the equation (i') is in agreement with the equation (i), and the coefficient a is equal to the coefficient A which is the temperature coefficient of electric resistance. Where the metallic heating member of the gas sensor comprises pure platinum, the absolute value of the coefficient a in the temperature range in which the gas sensor is used is greater than the absolute value of apparent coefficient of the semiconductor, as seen in Fig. 5. The coefficient a in the case of pure platinum is about 3.9 x 10 3/or. The present inventors prepared varied alloys by adding to platinum some noble metals such as rhodium and iridium and base metals such as nickel, and obtained results as shown in Table 1 below. TABLE 1 EMI9.1 <tb> <SEP> < <SEP> ¯ <SEP> S% <SEP> 10% <SEP> 20% <SEP> 30% <SEP> 40% <tb> I <SEP> Pt-Rhx <SEP> 2.6 <SEP> 1.7 <SEP> 1.4 <SEP> 1.3 <SEP> 1.3 <tb> 2 <SEP> Pt-Irx <SEP> 1.5 <SEP> 1.3 <SEP> 0.8 <SEP> - <SEP> 0.7 <tb> 3 <SEP> - <SEP> - <SEP> Pt-Nix <SEP> 2.4 <SEP> 1.4 <SEP> 0.8 <SEP> - <SEP> <tb> 4 <SEP> Ft-Pdx <SEP> 1.6 <SEP> 1.3 <SEP> 1.1 <SEP> 1.0 <SEP> 0.9 <tb> 5 <SEP> Pt-Agx <SEP> 0.8 <SEP> 0.4 <SEP> ¯ <SEP> - <SEP> <tb> 6 <SEP> Pd-Aux <SEP> 7 <SEP> 2.2 <SEP> 1.8 <SEP> 1.4 <SEP> <tb> 7 <SEP> 7 <SEP> Pd-Agx <SEP> - <SEP> 1.3 <SEP> 0.7 <SEP> 0.3 <SEP> <tb> 8 <SEP> Pd-1r18 <SEP> - <SEP> - <SEP> 0.61 <SEP> - <SEP> As seen in the above table, when any one of rhodium, iridium, nickel, palladium and silver is added to platinum, the value of a reduces in inverse proportion to the amount added. An alloy comprising palladium as the main component also provides a smaller a value than pure platinum. Fig. 8 is a graph showing a relationship between the a values and amounts (%) of rhodium added, as an example, to platinum. As seen in the graph, satisfactory a values, 0.55 0.50 times or less (i.e. about 1/2 or less) the case of pure platinum, are obtainable when rhodium is added in a range of 5-70 percent. However, an addition of rhodium in excess of 30 percent renders the alloy less workable, and therefore an optimal amount to be added is in a range of 5-30 percent. Further, an alloy comprising platinum as a main component is better than an alloy having palladium as the main component from the point of view of workability and resistibility to corrosion. Such alloys are preferable to pure platinum for other reasons too. As seen in Fig. 9, these alloys comprising components in the above ratio have, at 4000C, a specific resistance PC 400 C of about R0 x 10 fl cm which is about 1.3 times the value, about 23 x 10 n cm, of platinum. Therefore RA and RB slightly approach each other in the equation (iii), which increases the ratio of change in the combined resistance R with respect t6 the change in the resistance RB of the semiconductor due to gas adsorption. In other words, it increases the gas sensitivity of this sensor. It is an extremely advantageous fact in view of difficulties in lowering RB relative to RA by modifying the material of said semiconductor. THIRD EMBODIMENT From the point of view of an overall construction, the third embodiment shown in Figs. 10 and 11 is based on the same principle as are the first and second embodiments. As regards the gas sensor which is a main component of the overall construction, it should be noted that the material for the semiconductor of metal oxide such as tin oxide and/or the material for the metallic heating member which constitute the gas sensor are also prepared according to the same principle as in the cases of the first and second embodiments. Furthermore, this third embodiment has the basic and important features of the apparatus according to this invention that the gas sensor includes the metallic heating member and the semiconductor to be heated thereby are formed close to each other and that two lead wires are sufficient for connecting the metallic heating member and the semiconductor to an electric source to detect combined resistance of the two elements. The third embodiment, however, is different from the first embodiment in specific construction of the gas sensor. More particularly, the gas sensor 10 according to the third embodiment has a metallic heating member 18 comprising a film of platinum or of platinum alloy formed in a zigzag pattern on a heat resisting and electric insulating base plate 24'. The zigzag pattern herein, preferably, is a continuation of U-shape portions and inverted U-shape portions arranged alternately as shown in Fig. 10, but this embodiment is by no means restricted to such a pattern. It will be apparent that the pattern may, for example, be formed by interconnecting legs of V-shape portions. The metallic heating member comprises a plurality-of courses 32 as shown in Fig. 10. The semiconductor 20 comprising tin oxide, zinc oxide or the like and placed in close contact with the metallic heating member so as to cover an entire length thereof also lies between an adjacent pair of courses 32 as seen in Fig. 11. Needless to say, according to the construction of Figs. 10 and 11, the metallic heating member 18 is in contact with the semiconductor 20 over very large areas so that the former heats the latter and the base plate 24' effectively, thereby maintaining the whole sensor at a predetermined temperature easily and accurately. However, this embodiment has a more important function and advantage than the foregoing, as follows: When in use, an electric current flows from one point in one of the courses 32 of the metallic heating member to another point in an adjacent one of the courses 32 across a semiconductor portion lying between the two points. In other words, this gas sensor realizes a multiplicity of electric shunts therein, and this feature provides the gas sensor according to this embodiment with an extremely good gas sensitivity. FOURTH EMBODIMENT This embodiment is an improvement on the preceding gas detecting apparatus, which is particularly suited to detection of a high concentration gas. And in particular this embodiment relates to the nature of load limiting resistor. Referring to Fig. 1-2, if the load limiting resistor 12' is the type having resistance greatly variable by Joule's heat, such as what is called a temperature compensating element, the following inconvenience will arise: When the gas sensor 10 connected in series to the resistor 12' adsorbs a high concentration gas, the resistance decreases sharply. As a result the voltage acting on the resistor 12' increases and so does Joule's heat. The increased Joule's heat in turn increases the resistance of the resistor 12' further, and hence a vicious cycle. Thus, this apparatus provides an output signal, namely an output of a bridge circuit 34, varying between curve portions Ia and Ib in Fig. 13. In extreme cases the apparatus may provide an output signal as shown by a curve IVa of Fig. 14 or an output signal as shown by a curve IVb therein. The apparatus must provide very stable output signals as represented by curves II and III of Figs. 13 and 14, respectively. For this purpose, the load limiting resistor connected in series to the gas sensor has a resistance substantially equal to a resistance of the gas sensor at times of use in the ambient air, and is formed of a material waving only negligible resistance variations due to Joule's heat. 1 n j'irticular, the load limiting resistor comprises a film formed by vapor deposition of nichrome, tin oxide, indium oxide or the like. This gas detecting apparatus comprises the bridge circuit 34 connected to an electric source 14 and including the load limiting resistor 12', the gas sensor 10 and resistors 36 and 37 as shown in Fig. 12. Numbers 38 and 40 denote output terminals and P2 represents a bridge output. When the sensor 10 detects a gas, the bridge circuit loses a balance and provides a bridge output P2 corresponding to a gas concentration. For particulars of the performance, the apparatus has been tested in airs containing hydrogen in varied proportions, results of which are shown in Fig. 13, and variations with the passage of time in air containing 20 percent hydrogen are checked, results of which are shown in Fig. 14. From Fig. 13 it will be seen that the output signal of the above apparatus increases in proportion to an increasing gas concentration. From Fig. 14 it will be seen that the bridge output P2 (solid line XII) remains stable in the air containing 20 percent hydrogen aver a long period of time (o-60 minutes) and quickly returns to a normal value after the gas is removed (after lapse of 60 minutes). Thus, the apparatus is excellent in output signal reproducibility. When its gas concentration detecting precision is likely to deteriorate by catalytic oxidation of hydrogen or other gas on the surface of the sensor 10 due to heat generated by the load limiting resistor 12', an oxiciation preventing agent such as Plç, Ass Sb, P, Si, S, Cl, Se, Te or the like may be added to the material for forming the semiconductor of the sensor 10. While the bridge circuit 34 is used as gas detecting circuit in this embodiment as shown, the circuit shown in Fig. 1 can be used therefor. In other words, one of the output terminals should be disposed on a standard electric potential point in the circuit whereas the other terminal is to be disposed on a connecting point between the gas sensor and the load limiting resistor. Preferably, the standard electric potential point has an adjustable potential. As noted above, this apparatus is capable of gas detection with good stability and with good reproducibility even in a high concentration range. Further, since no compensation element is required, the apparatus has outstanding advantages of not only low material cost and simple production process but also compactness of the entire apparatus.

Claims: What is claimed is: 1. A gas detecting apparatus comprising a gas sensor, a load limiting resistor connected in series to the gas sensor, an electric source for applying a predetermined voltage to the gas sensor and the load limiting resistor, and detecting means to detect resistance variations of the gas sensor, characterized in that the gas sensor (10) comprises a semiconductor (20) of metal oxide placed at least at both ends thereof in close contact with a metallic heating member (18), the semiconductor (20) being heated by the metallic heating member (18), variations in combined resistance (R) of the semiconductor (20) and the metallic heating member (18) which occur as the semiconductor (20) adsorbs a gas being detected by said detecting means (16). 2. A gas detecting apparatus as claimed in claim 1 characterized in that the metallic heating member (18) has a positive temperature coefficient of electric resistance and the metal oxide semiconductor (20) has a negative temperature coefficient of electric resistance, materials being selected for the metallic heating member (18) and the semiconductor (20) such that the two temperature coefficients offset each other. 3. A gas detecting apparatus as claimed in claim 2 characterized in that the metallic heating member (18) comprises a metal having a smaller temperature coefficient of electric resistance than pure platinum. 4. A gas detecting apparatus as claimed in claim 3 characterized in that the metallic heating member (18) comprises a platinum alloy containing at least one of rhodium, iridium and nickel in a range of 5-30 percent, and has a temperature coefficient of electric resistance half or less than half of that of pure platinum and a specific resistance at least about 1.25 times that of pure platinum. 5. A gas detecting apparatus as claimed in any one of claimes 1 to 4 characterized in that the metallic heating member (18) is formed in a zigzag or like pattern on a base plate (24') having heat resisting and electrically insulating properties. 6. A gas detecting apparatus as claimed in any one of claimes 1 to 5 characterized in that the load limiting resistor (12) comprises a material having only negligible resistance variations due to Joule's heat.

Inventors: IGARASHI, ARIO, KAINO, HIROSHI, KITAGUCHI, HISAO, SAKAI, SAI
Applicants: NEW COSMOS ELECTRIC CO., LTD.
Application year: 1984
Main classification: G01N27
IPC codes: G01N27