Thermionic emitter and method of manufacture thereof

Abstract: A thermionic emitter for providing positive ions incorporates a mixture of beta-alumina and inert material, such as charcoal, positioned on a filament for heating the mixture. Alternately, the emitter may incorporate beta-alumina with inert material, such as nickle, deposited in selected areas. As a result, the thermionic emitter overcomes the problem of generating positive ions with low power consumption.

Description: This invention relates to thermionic emitters, and more particularly, to positive ion emitters with low power consumption for use in instruments such as ion mobility spectrometers. The invention also relates to methods for the manufacture thereof. U.S.A. patent 2,742,585 which issued on April 17, 1956 to P.D. Zemany describes an electrical vapor detector. A thin refractory coating a few mills (1mill=0,0254mm) thick of specific metal oxides act both as insulators and alkali ion emitters at temperatures ranging from about 700°C to 1200-1300°C or higher. The refractory coating may be oxides of aluminum (alumina), titanium (titania), beryllium (beryllia), thorium (thoria), magnesium (magnesia), calcium, molybdenum, iron, manganese, silicon, cobalt, nickel and the rare earths (the rare earths having atomic numbers 57 to 71, inclusive). In operation, at a temperature above 700°C the initial ion current from the refractory coating subsides; the device is then prepared to detect vapors of halogens and their compounds in a vacuum system of lmm Hg. The admission of the vapors of halogens and their compounds to the surface of the refractory coating causes an increase in the positive ion current collected upon the negatively charged collector. The electrical vapor detector detects halogens and their compounds due to an increase in evaporation of alkali ions from the surface of the coating. In U.S.A. patent 2,806,991 which issued on September 17, 1957 to W.P. White, an electrical detector is described for the detection of certain substances or impurities in gases. The detector comprises a double helical wire heater winding wound on a cylindral ceramic core which has been impregnated with a solution of sodium hydroxide. An electrode inserted into tight fitting holes in the ceramic core which acts as the cold electrode. The ceramic core must be impregnated with a highly conductive salt such as NaOH, NaF, or LiCl. The vapor dectector is particularly adapted to detect the presence of hydrogen, inflammable gases, reducing gases, or vapors containing hydrogen. In U.S.A. patent 3,972,480 which issued on August 3, 1976 to R.W. Powers, a method of preparing a suspension of additive-free beta-alumina particles is described. In U.S.A. patent 4,166,009 which issued on August 28, 1979 to D.J. Fray, a method for the determination of impurities of specific elements in solid or molten metal or alloys is described by monitoring the e.m.f. generated between the substance and a reference material. The reference material may be a solid electrolyte comprising beta-alumina containing an element or a solid compound of the element to be detected. A beta-alumina pellet for the probe is formed in situ in one end of an alpha-alumina tube by a hot pressing technique. Sodium aluminate (NaAl 2 O 3 ) and alpha-Al 2 O 3 powder are well mixed and heated together in air at 1,400°C after which the mixture is ground to a powder. A carbon rod with a diameter of the internal diameter of the tube is used to cold press the powder at 25Kg/cm 2 and the load is maintained while the powder is heated to a temperature of 1,150°C. The load and temperature are subsequently increased. Most of the carbon rod is then drilled out of the alpha-Al 2 O 3 tube, and the remainder is burned out using a small oxygen lance; the high temperatures reached during this burning operation help to harden the pellet. in U.S.A. patent 4,499,054 which issued February 12,1985 to M. Katsura et al, a halogenated hydrocarbon gas detecting element is described comprising a cation source consisting essentially of beta-alumina, a heater and an ion collector electrode. In the presence of a halogenated gas, the emission of Na + ions is increased due to surface interactions. The Na + ions are then attracted to the collector electrode by a voltage. In Katsura et al, an increase in the emission of Na + ions is observed at times halogenated hydrocarbons are present near the surface of the beta-alumina. Finally USA Patent 4,783,595 describes a solid state source comprising an ion emission pellet capable of emitting positive ions upon being heated to an ion-emission temperature. The pellet consists of an alkali or alkali-earth electrolyte that is solid at the ion-emission temperature and has a metal coating from which ions can be emitted. None of the prior art references, however solve the problem of generating positive ions with low power consumption. Summary of the Invention Accordingly, it is an object of the present invention to alleviate the deficiencies and disadvantages of the prior art by providing a thermionic emitter for an ion mobility spectrometer (or other instrument) which is capable of generating positive ions with low power consumption. A thermionic emitter according to the present invention is defined in claim 1. This thermionic emitter has a coating with a plurality of surface sites for emission of positive ions for use in an ion mobility spectrometer. The emitter includes a filament which has a coating formed by a mixture of a powder of beta-alumina and an inert material and an inorganic binder. The coating forms surface sites which provide a high work function for the emission of positive ions with relatively low power consumption. The filament is positioned to heat the mixture to a predetermined temperature. A method for making a thermionic according to the present invention is defined in claim 9. This method includes the step of applying on a filament a mixture of a powder of beta-alumina, an inert material and an inorganic binder and of heating it. The inert material thus provides a plurality of surface sites disposed over the surface. Embodiments of the invention are set out in the dependent claims. These and other objects of the present invention will become apparent from a reading of the following specification, taken in conjunction with the enclosed drawing. Brief Description of the Drawing Figure 1 is one embodiment of the invention. Description of the Preferred Embodiments Referring to Figure 1, a thermionic emitter 10 is shown for emitting ions into a gaseous environment 12. Thermionic emitter 10 may include a coating 14 on a filament wire 16. The filament wire 16 may be resistive, as for example, a wire made of nickel and chromium to provide heat and a predetermined temperature to coating 14, whenever a current is passed through filament wire 16. End 15 of filament wire 16 is connected by lead 17 to the negative terminal of a battery 18. The positive terminal of battery 18 is connected by lead 19 to one side of a switch 20, which may be a single-pole single-throw switch. The other side of switch 20 is connected by lead 21 to end 22 of filament 16. When switch 20 is closed, battery 18 supplies current over leads 19 and 17, respectively, to filament 16 to thereby heat coating 14 to a predetermined temperature. Coating 14 may be a mixture of beta-alumina 24 and an inert material 26, as for example: glass chips, charcoal, diatomacious earth, ceramic powder, silica powder, and alumina powder. Beta-alumina 24 may be expressed by the chemical formula Na 2 O · 5Al 2 O 3 . Beta-alumina 24 supplies alkali ions (as for example, sodium) in coating 14 and at its surface 28. Beta-alumina 24 may be purchased from Ceramatech, Inc. located at 2425 South 900 West, Salt Lake City, Utah 84119. Coating 14 may be prepared by grinding beta-alumina 24 into a fine powder (as for example, 80-100 mesh) and mixing the beta-alumina powder with sodium silicate, water and an inert material (which also has been ground to a powder). The proportions (excluding the inert material) may be 40.98% beta-alumina and 1.93% sodium silicate and the remainder is water. In place of sodium silicate, other inorganic binders may be used. The mixture forms a paste which may be applied to filament 16 to an approximate thickness of 1mm and cured by gradually heating the filament from 100°C for 2 hours to 200°C for two hours, to 300°C over night. Sources prepared in this matter provided sodium ions by ion emission when sufficient power (0.6 to 20 watts) is applied to filament 16 to heat coating 14 to 600-1000°K. In operation, coating 14 provides Na ion emission sodium atoms by giving up electrons to the filament 16. The sodium ions migrate through the lattice structure of the beta-alumina 24 to surface 28. Thermal emission of the sodium ions into the gaseous environment 12 occurs from surface 28 of coating 14. The Saha-Langmuir equation provides the energetics for thermionic emission and involves a free energy change expressed in the following: - (Φ + e(eE) ½ - I(A) - D(AX)) where Φ is the average work function (i.e. the energy needed to remove an electron) from the emitting surface 28, E is the electric field which exists at surface 28, I(A) is the ionization potential for the alkali atom A, and D(AX) is the dissociation energy required to cleave bonds between the alkali atom and surface 28. Since emission from surface 28 is enhanced when the free energy is large and negative (i.e. exothermic), a higher work function for emitting surface 28 is desired. Inert material 26 (which is chemically inert) provides sites on surface 28 with a higher work function adjacent the beta-alumina surface with the result that the surface of inert material 26 will more freely emit positive ions than the surface of beta-alumina 24. Alkali metal ions on the surface of beta-alumina 24 lowers the work function of the surface of beta-alumina. With inert material 26 dispersed on surface 28, the temperature of filament 16 and surface 28 may be lowered with surface 28 emitting adequate or a saturated stream of alkali ions. It is noted that in the older thermionic sources, alkali ion emission was dependent on the rate of diffusion of the ions through the solid material to the surface. By using beta-alumina 24 for alkali ion emission, sodium ions may move through vacancies in the latice structure to the surface 28 and therefore provide an endless supply of sodium ions. Inert material 26 provides a plurality of surface sites 30 for emission which are dispersed over surface 28. One example of an inert material (which has been tried experimentally) is charcoal which has been ground up and mixed with the original mixture of beta-alumina, sodium silicate and water. The range of charcoal may vary from 0-100% in coating 14. By using 10% charcoal in coating 14, it was found that coating 14 required less power for ion emission and that coating 14 was a source of primarily potassium cations. The reduced power is believed to be due not only to the higher work function of carbon surface sites 30 but also to the lower ionization potential of potassium. The potassium cation is believed to arise from impurities in the charcoal and results in more ions of potassium than sodium being emitted simultaneously. Thermionic emitter 10 may be used in an ion mobility spectrometer to provide alkali ions as reactant ion in the reaction region to react with the sample ions to be detected. One example of an ion mobility spectrometer is described in U.S.A. patent 4,712,008 which issued on December 8, 1987 to K.N. Vora et al and assigned to the Environmental Analytical Systems, Inc. which name has been changed to Environmental Technologies Group, Inc.. The thermionic emitter 10 may be placed in a reaction region 74 shown in Fig. 2 of U.S.A. patent 4,712,008 with the radioactive ion source, foil 83, removed. Accordingly, it will be appreciated by those skilled in the art that a thermionic emitter has been described for providing a continuous flow of positive ions, including a mixture of beta alumina and inert material (for example, charcoal) each having portions thereof exposed on the surface of the mixture. The exposed inert material portions form surface sites having a high work function for the emission of positive ions, and the mixture is heated to a predetermined temperature. The heater, for example, may comprise a resistive filament wire and a source of electrical power.

Claims: A thermionic emitter (10) with a coating having a plurality of surface sites (30) for emission of positive ions for use in an ion mobility spectrometer, characterized by a filament (16) having a coating (14) formed by a mixture of a powder of beta alumina (24) and an inert material (26) in an inorganic binder, the coating (14) having portions of the beta alumina (24) and the inert material (26) exposed on the surface thereof, thereby forming the sites (30) which provide a high work function for the emission of positive ions with relatively low power consumption. The thermionic emitter of claim 1, further characterized in that the inert material is charcoal. The thermionic emitter of claim 1, further characterized in that the inert material is diatomaceous earth. The thermionic emitter of claim 1, further characterized in that the inert material is glass powder chips. The thermionic emitter of claim 1, further characterized in that the inert material is silica. The thermionic emitter of claim 1, further characterized in that the inert material is nickel. The thermionic emitter of claim 1, further characterized in that the inert material is a metal. The thermionic emitter of claim 1, further characterized in that the inorganic binder is sodium silicate. A method for making a thermionic emitter (10), comprising a filament (16) having a coating (14) with a plurality of surface sites (30) for emission of positive ions, characterized in that the coating (14) is formed on the filament (16) by applying a mixture of a powder of beta-alumina, an inert material (26) and an inorganic binder on the filament and by heating it, the coating (14) having portions of the beta alumina (24) and the inert material (26) exposed on the surface thereof, thereby forming the sites (30) which provide a high work function for the emission of positive ions with relatively low power consumption. Method according to claim 9, characterized in that the mixture is heated to approximately 300°C to form a solid body.

Inventors: CAMPBELL DONALD NOBLE, CARRICO JOHN PAUL JR, SPANGLER GLENN EDWARD, CAMPBELL, DONALD NOBLE, CARRICO, JOHN PAUL, JR., SPANGLER, GLENN EDWARD
Applicants: ENVIRONMENTAL TECH GROUP, ENVIRONMENTAL TECHNOLOGIES GROUP, INC.
Application year: 1990
Main classification: H01J27
IPC codes: H01J27