IMPROVED NDIR GAS SENSOR

Abstract: A miniaturized NDIR gas sensor is manufactured using semiconductor micromachining techniques from a semiconductor material such as SI or GaAS. The NDIR gas sensor (28) includes an optical waveguide (30), a light source (32) at one end of the waveguide, at least one light detector (36) at the end of the waveguide opposite the light source, a diffusion type gas sample chamber (34) formed within the waveguide and interposed in the optical path between the light source and light detector so that the light source and light detector are thermally isolated from the gas sample by windows (38, 39), and a separate bandpass filter (52) interposed between the light source and each light detector. Because the NDIR sensor is fabricated out of a semiconductor material, the source driver (76) and signal processing electronics (78) may be added directly to the sensor using integrated circuit fabrication techniques. Particles and smoke and dust may be kept out of the sample chamber by application of a gas permeable membrane (56) over apertures (54) in the sample chamber walls.

Description: DESCRIPTION Improved NDIR Gas Sensor Background of the Invention 1. Field of the Invention The present invention generally relates to the field of gas sensing devices and, more particularly, to NDIR gas analyzers. 2. Description of the Prior Art Nondispersive infrared (NDIR) gas analyzers are used for detecting the presence and concentration of various gases . The NDIR technique has long been considered one of the best methods for gas measurement. In addition to being highly specific, the NDIR gas analyzers are also very sensitive, stable and easy to maintain. In contrast to NDIR gas sensors, which are by defini¬ tion noninteractive, interactive optical gas sensors are less reliable, are generally nonspecific, and in some cases can be poisoned into a nonfunctional state. Interactive gas sensors are generally nonspecific because the reagent being used to determine the concentra¬ tion of the desired gas may react with other gases that are present. This will naturally result in false read¬ ings. Further, if the equilibrium of the reaction between the nonspecific gas and the reagent is such that the gas and reagent remain reacted even after the partial pressure of the gas drops in the environment being monitored, the sensor will no longer function properly and is poisoned. The response time for NDIR gas sensors is also typi¬ cally shorter than that for interactive gas sensors. The reason being that the kinetics of the reaction between the sample gas and reagent controls how quickly the sensor detects a change in the concentration of the gas in the environment being monitored. Despite the fact that interactive gas sensors are unreliable and that the NDIR gas measurement technique is one of the best, NDIR gas analyzers have not enjoyed wide spread application because of their complexity and high cost of implementation. In the past, NDIR gas analyzers typically included an infrared source, a motor-driven mechanical chopper to modulate the source, a pump to push or pull gas through a sample chamber, a narrow bandpass interference filter, a sensitive infrared detector plus expensive infrared optics and windows to focus the infrared energy from the source onto the detector. In an attempt to reduce the cost and simplify the implementation of the NDIR technique, a low-cost NDIR gas sensor technique was developed. The low-cost NDIR techni¬ que employs a diffusion-type gas sample chamber of the type disclosed in U.S. Patent No. 5,163,332, issued November 17, 1992, to the present applicant, and hereby incorporated by reference. This diffusion-type gas sample chamber eliminates the need for: expensive optics, mechanical choppers, and a pump for pushing or pulling the gas into the sample chamber. As a result, a number of applications for the NDIR technique, which were previously considered impractical because of cost and complexity, have been opened. The diffusion-type gas sample chamber of U.S. Patent No. 5,163,332 uses an elongated hollow tube having an inwardly-facing specularly-reflective surface that permits the tube to function as a light-pipe for transmitting radiation from a source to a detector through the sample gas. A plurality of filtering apertures in the wall of the non-porus hollow tube permit the sample gas to enter and exit freely under ambient pressure. Particles of smoke and dust of a size greater than 0.1 micron are kept out of the chamber by use of a semi-permeable membrane that spans the apertures in the hollow tube, and condensa¬ tion of the sample gas is prevented by heating the sample chamber electrically to a temperature above the dew point of the gas. Although the low-cost NDIR gas sensor technique opened a wide variety of new applications, the gas sample chamber and the corresponding gas sensor of the low-cost NDIR technique are still too large for many potential gas sensor applications. As a result, applications in which low-cost NDIR gas sensors may be used remain limited. Furthermore, while the cost of gas sensors employing the gas sample chamber of U.S. Patent No. 5,163,332 is less than previous NDIR gas sensors requiring expensive optics, pumps, and choppers, a further reduction in the cost of NDIR gas sensors would further increase the number of applications in which such sensors are used and the frequency of their use. Therefore, while a need exists for a compact, inexpen¬ sive NDIR gas sensor, this need has gone unfilled. Accordingly, a goal of the present invention is to further advance the NDIR technique by providing a miniaturized, reliable, and low cost NDIR gas sensor. Summary of the Invention The present invention is directed to an NDIR gas sensor for detecting the concentration of a predetermined gas. To this end, an optical waveguide is provided having a light source at one end and a light detector at the other end. A bandpass filter is interposed in the optical path between the light source and detector, so that the detector primarily receives radiation of a wavelength that is strongly absorbed by the gas whose concentration is to be determined. The waveguide is formed from two or more substrates of a semiconductor material, at least one of which has been micromachined. In addition, the light source and detector are directly manufactured on at least one of the semiconductor substrates used to form the optical waveguide. A pair of windows are also optically disposed between the light source and detector so as to define therebetween a sample chamber within the optical waveguide. The windows thermally isolate the light source and light detector from the sample gas, thus preventing the sample gas from cooling these elements. The gas whose concentration is to be determined diffuses into and out of the sample chamber in the optical waveguide through apertures or slots in the semiconductor substrates. Because the walls of the optical waveguide are reflec¬ tive, radiation is transmitted from the light source to the light detector through the sample gas without the need for expensive optics. Furthermore, because gas sensors according to the present invention employ a diffusion-type gas sample chamber, no pump is required to push or pull the sample gas into the sample chamber. In a preferred embodiment, a gas permeable dielectric layer is deposited over the apertures to act as a filter and prevent dust or smoke particles from entering the optical waveguide sample chamber. Preferably, the gas permeable layer prevents particles larger than about 0.1 μm from entering. In another preferred embodiment, at least a portion of the optical waveguide is metallized thereby improving its internal reflectivity and the overall efficiency of the NDIR gas sensor according to the present invention. In yet another preferred aspect of the present inven¬ tion, an NDIR gas sensor is provided that prevents conden¬ sation of gases or vapors on the walls of the sample chamber. To accomplish this object, means are provided for heating the gas sample chamber so that its temperature remains above the dew point of any gas or vapor that might have a tendency to condense on an inner surface of the sample chamber. Other integrated circuit semiconductor devices can also be added wherever needed to further enhance the performance of the NDIR gas sensor according to the present invention. For example, temperature sensors, pressure transducers, and humidity sensors may be added. In addition, a micro-flow sensor may be added to detect the flow rate of the sample gas through the sample cham¬ ber. In a particularly preferred embodiment of the present invention, an NDIR gas sensor is provided which can be used to simultaneously determine the concentration of a plurality of gases in the gas sample. The NDIR gas sensor according to this embodiment is comprised of a plurality of detectors and a plurality of bandpass filters. Each bandpass filter is interposed in the optical path between the light source and one of the plurality of detectors. The number of gases whose concentration is desired to be determined dictates the specific number of detectors and bandpass filters that are required. Each bandpass filter, therefore, is designed so that the detector it is associ¬ ated with primarily receives radiation of a wavelength that is strongly absorbed by the gas whose concentration that detector is to determine. Alternatively, in this embodiment, at least one of the detectors may be used as a reference detector. In this situation, the bandpass filter interposed in the optical path between the light source and the reference detector must be designed to pass a neutral wavelength. In other words, the bandpass filter must pass a wavelength of light that is not absorbed by the gas sample. Accordingly, it is a primary object of the present invention to provide a miniaturized NDIR gas sensor which is micromachined from a semiconductor material. Further objects and advantages of the invention will be better understood from the following description considered in connection with accompanying drawings in which the preferred embodiments of the invention are illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. Brief Description of the Drawings Fig. 1 is an oblique view of an NDIR gas sensor according to the present invention; Fig. 2 is a an oblique view showing a partial cutaway of an NDIR gas sensor according to the present invention; Fig. 3 is a longitudinal cross sectional view along the line 3-3 in Fig. 1; Fig. 4 is simplified optical diagram showing the path of a ray of radiation through the gas sample chamber; Fig. 5 illustrates a black body light source for use in an NDIR gas sensor according to the present invention; Fig. 6 is a schematic diagram of a system using a gas sensor according to the present invention; Fig. 7 is a plan view of a bottom substrate for fabricating a gas sensor according to a second embodiment; Fig. 8 is a plan view of a bottom substrate for fabricating a gas sensor according to a third embodiment; and Fig. 9 is a plan view of a bottom substrate for fabricating a gas sensor according to a forth embodiment. Detailed Description of the Invention A first embodiment of the present invention is de¬ scribed in connection with Figs. 1-3. As shown in Figs. 1-3, the NDIR gas sensor 28 according to the present embodiment includes an optical waveguide 30. Optical waveguide 30 is comprised of a source chamber 32, sample chamber 34 and detector chamber 36. Source chamber 32 and detector chamber 36 are isolated from the sample chamber 34 by windows 38 and 39, which are interposed in the optical path between the source and detector. Top substrate 42 and bottom substrate 44 are micromachined from a semiconductor material using well known techniques so that when top substrate 42 is attached to bottom substrate 44 optical waveguide 30 is formed. Preferably substrates 42 and 44 are attached using a standard die-attaching process. Any semiconductor material may be used for substrates 42 and 44, including Si and GaAs . Si is the preferred semiconductor material . Other semiconductor materials that may be used for the substrates of the present invention include binary, ternary, and quaternary II-VI and III-V semiconductor materials. In addition, substrates consisting of epitaxially grown germanium on silicon may be used. Top substrate 42 and bottom substrate 44 may be made out of different semiconductor materials. Windows 38 and 39, which have been micromachined in bottom substrate 44, divide optical waveguide 30 into source chamber 32, sample chamber 34, and detector chamber 36. Windows 38 and 39 thermally isolate the source and the detector from the gas sample being analyzed so that the gas sample does not cool the detector or source, which would result in an erroneous reading, or at a minimum, reduced sensitivity. The thickness of the windows is selected so as to achieve thermal isolation while at the same time permitting the windows to be optically transpar¬ ent as to at least desired wavelengths. That is, the thickness of the windows is selected to transmit at least a portion of the light having a desired wavelength, the desired wavelength being dictated by the gas whose concen- tration is to be measured. As a result, windows 38 and 39 will typically have a thickness in the range of approxi¬ mately 0.1 mm to 1 mm. Source chamber 32 contains a radiation source 40. In the present embodiment, source 40 is a black body; thus, source 40 produces radiation of all wavelengths. Radia¬ tion from source chamber 32 passes through window 38 into sample chamber 34. Sample chamber 34 contains the gas sample to be analyzed for the concentration of a particu¬ lar gaseous component . Radiation entering sample chamber 34 passes through the gas sample, and thereafter, the radiation enters detector chamber 36 through window 39 and falls on detector 50 after passing through bandpass filter 52. Fig. 4 is a simplified optical diagram showing the optical path taken by a ray 46 emitted by the source 40. As illustrated, ray 46 is reflected multiple times as it progresses down the length of optical waveguide 30 and eventually falls on the detector 50. Referring back to Figs. 1-3, bandpass filter 52 is preferably a narrow bandpass interference filter. The purpose of bandpass filter 52 is to remove extraneous wavelengths of radiation from the light produced by black body source 40 so that the detector 50 primarily receives radiation of a wavelength that is strongly absorbed by the gas whose concentration is to be determined. In the present embodiment, bandpass filter 52 is a thin film interference filter deposited on top of detector 50 and is, therefore, interposed in the optical path between source 40 and detector 50. The method of produc¬ ing such filters is well known in the art. The theory and physics of interference bandpass filters is described in detail in The Infrared Handbook §§ 7.7-7.14 (W. Wolfe &. G. Zissis Rev. ed. 3rd printing 1989) , hereby incorporated by reference. The specific characteristics of the bandpass filter simply depends on the wavelength of the radiation absorbed by the gas being analyzed. For example, a bandpass filter that has a center wavelength (CWL) of about 4.26 μm and a full width at half maximum (FWHM) of about 0.1 μm is appropriate for C0 2 . As noted above, radiation source 40 in the present embodiment is a black body. Fig. 5 illustrates one possible configuration of a black body light source. Black body source 40 is comprised of a thin film resistive heating element 66 deposited on cantilever 68. Thin film resistor 66 may be made out of platinum or other suitable metal. Cantilever 68 is produced using well known microm- achining techniques. Such techniques are discussed in K. Petersen, Silicon as a Mechanical Material, Proceedings of the IEEE, Vol. 70, No. 5, May 1982, pp. 420-457, hereby incorporated by reference. Heating element 66 is placed on cantilever 68 to thermally isolate it from substrate 44. Thermal isolation of heating element 66 is important so that the response time of black body source 40 is kept small and so that the entire substrate is not heated. In addition, cantilever 68 prevents heat produced by heating element 66 from draining to substrate 44 too quickly. Detector 50 may be any device that creates varying electrical responses to corresponding variations in the strength of radiation reaching it from the source. Any of the following detectors may be used when measuring infra- red radiation: thermopile, thermocouple, Platinum Silicide Schottky photodiode, and bolometer. A Thermopile is an especially preferred detector for the detection of infra¬ red radiation. The more recent micromachined electron-tunneling infrared detector disclosed in U.S. Patent No. 5,265,470, issued November 30, 1993, hereby incorporated by refer¬ ence, can also be used in the present embodiment to detect infrared radiation. Sample chamber 34 is a diffusion-type gas sample chamber. Thus, the gas sample contained within sample chamber 34 is present by diffusion only, no pumps are required to push or pull the gas sample into sample chamber 34. To permit gas to diffuse into and out of sample chamber 34, sample chamber 34 contains at least one filtering aperture, of which filtering aperture 54 is typical . The filtering apertures can have a wide variety of shapes and sizes. However, it is preferable to prevent particles of dust and smoke from entering sample chamber 34. To that end, filtering apertures 54 are covered in the present embodiment with a gas permeable layer 56, which serves as a filter. Gas permeable layer 56 prefera- bly keeps out particles of a size greater than about 0.1 μm. Gas permeable layer 56 may be a dielectric layer that can be deposited by evaporation or sputtering. Silicon oxide, silicon nitride, TEFLON ® , and KAPTON ® are dielec¬ trics suitable for this purpose, preferably the dielectric layer is silicon oxide or silicon nitride. To achieve high rates of diffusion for particles of size less than 0.1 μm, gas permeable layer 56 should be kept quite thin, typically several thousand angstroms. Thus, it is better to have a large number of smaller apertures than a few larger ones. In the present embodiment, both the top and bottom substrates contain apertures 54 permitting gas to diffuse into and out of the sample chamber. By having apertures 54 in both the top substrate 42 and bottom substrate 44, the gas sample flows more easily into and out of sample chamber 34, especially if the sensor 28 is placed in a flowing gas stream. Of course, however, the apertures may be contained in only the top substrate 42 or bottom substrate 44. Throat 57 in the top substrate 42 and throat 59 in the bottom substrate 44 merely permit substrates 42 and 44 to have thicker cross sections while at the same time reduc- ing the amount of semiconductor material that must be etched through to form apertures 54 in walls 60 and 62 of optical waveguide 30. This enhances the overall struc¬ tural integrity of sensor 28 without increasing the difficulty of etching apertures 54 in the substrates. Throats 57 and 59, however, are not required. Thinner blocks of semiconductor material can be used to produce substrates 42 and 44 without increasing the difficulty of etching holes in walls 60 and 62 of the waveguide to form apertures 54. For ease of manufacture, it is preferred that the sample chamber 34 have a square or rectangular cross section. But, other shapes can also be used. For exam- pie, sample chamber 34 in waveguide 30 can have a circular or triangular shape. Source chamber 32 and detector chamber 36 are similarly not limited to the preferred embodiment shapes. If silicon is used as the semiconductor material for substrates 42 and 44, only about half of the light will be reflected from the walls of the optical waveguide because silicon is only about 50% reflective. The efficiency of an NDIR detector according to the present embodiment may be improved, therefore, by metallizing at least a portion of the inwardly facing walls of optical waveguide 30. Of course windows 38 and 39 should not be metallized in such a manner as to prevent detector 50 from receiving the wavelength of light that is strongly absorbed by the gas whose concentration is being measured. This would natu¬ rally defeat the purpose of the waveguide. Thus, in the present embodiment, only the side walls 58, upper wall 60 and lower wall 62 of the sample chamber are metallized. .And in the source and detector chambers, only side walls 64 and upper walls 66 are metallized. A variety of different metallizations can be used to increase the reflectivity of the inwardly facing walls of optical waveguide 30, including Al, Au, Cr, Ni, and Pt . Each of these metals are easily deposited on the surface of the inwardly facing walls of waveguide 30 using vapor deposition techniques well known in the art . To ensure that the full benefit of the metallization is achieved, the metallization must be thicker than the skin depth for the particular metal selected at the wavelength being used to measure the concentration of the desired gas. If the metallization is not sufficiently thick, the electric field will penetrate the metallization and interact with the Si substrate; thus reducing the amount of light reflected. In the present embodiment, Applicant has described the use of a top substrate 42 and a bottom substrate 44 to form gas sensor 28. However, to the extent that gas sensor 28 is micromachined from a single substrate, the resulting gas sensor would still fall within the scope of the present invention. The NDIR gas sensor 28 can be used in a system such as the one illustrated schematically in Fig. 6. The broken line 28 represents the NDIR gas sensor 28 shown in more detail in Figs. 1-3. In operation, source 40 is energized through an electric current delivered by source driver 76 through a circuit including leads 70. As is well known in the art, source driver 76 delivers power to source 40 in pulses at a set frequency to modulate the source so that synchronous detection can be achieved. Typically, source driver 76 delivers pulses of energy at a frequency of 1 Hz, 2 Hz, or 3 Hz. After the radiation from source 40 reaches detector 50, detector 50 produces an electrical signal that repre¬ sents the intensity of the radiation falling on it. This signal is inversely proportional to the amount of gas being detected. For example, if C0 2 is being detected, the more C0 2 there is in sample chamber 34 the weaker the infrared spectrum will be striking detector 50. The electrical signal produced by detector 50 is applied to an electronic circuit 78 that converts it to a signal which represents the concentration of the gas in question. The signal output 80 of the signal processing electronics 78 may be applied to a meter, an alarm, process control means or the like as is well known in the art. The source driver 76 and signal processing electronics 78 are in electronic communication through line 82 so that the entire system is coordinated and synchronous detection can be achieved. The signal processing is generally straight forward and is taught in a number of places, including, for example, U.S. Patent No. 4,578,762, hereby incorporated by reference, and U.S. Patent No. 4,694,173, hereby incorporated by reference. In practice, a device embodying the present invention may be calibrated by placing it within a bell jar and purging the bell jar with nitrogen. When the bell jar has been thoroughly purged with nitrogen, the zero condition for the sensor is established. Thereafter, a gas whose concentration will be measured by the sensor is fed into the bell jar in a gas stream of known concentration. For example, if C0 2 is the desired gas then the bell jar would be purged with a gas having a C0 2 concentration of 5% until the concentration of the gas within the bell jar stabiliz¬ es. The signal processing electronics 78 are then manipu¬ lated until a reading of 5% is obtained from the sensor 28. This process is repeated using gases having different concentrations of C0 2 until the NDIR gas sensor 28 is calibrated over the desired range of concentrations. In the present embodiment, source 40 and detector 50 are both fabricated on the same substrate. However, as would be apparent to a person of ordinary skill in the art, source 40 and detector 50 could be fabricated on different substrates. But, by fabricating both source 40 and detector 50 on the same substrate 44, the fabrication of the NDIR gas sensor 28 is simplified. A plan view of a bottom substrate 44 according to a second embodiment of the present invention is illustrated in Fig. 7. As shown in Fig. 7, if source 40 and detector 50 are both fabricated on substrate 44, the source driver 76 and signal processing electronics 78 may also be fabricated on substrate 44 near the source and detector using standard IC fabrication techniques. Substrate 44 is identical to substrate 44 of the first embodiment, which is illustrated in Figs. 1-3, in all other respects. Top substrate 42 is not shown, however, it is identi¬ cal to the top substrate 42 shown in Figs. 1-3. By virtue of free diffusion of gas through layer 56 that covers the filtering apertures 54, the gas sample chamber 34 is always filled with gas. As a result, there is a possibility that if the ambient temperature falls sufficiently, water vapor or one of the other gases in the sample chamber will condense to a liquid state and be deposited in the form of small droplets on the interior walls of gas sample chamber 34. This would interfere with the internal reflectivity that is needed for operation of waveguide 30, and would lead to erroneous results. To prevent this from happening, and thus increase the efficiency and repeatability of the transmission of radiation, a particularly preferred bottom substrate 44 as shown in Fig. 8 may be used to fabricate an NDIR gas sensor 28 according to a third embodiment. As in the previous embodiment, top substrate 42 is not shown. Again, however, it is identical to the top substrate 42 illustrated in Figs. 1-3 so that when it is attached to substrate 44, NDIR gas sensor 28 is formed. As shown in Fig. 8, a thin film resistive type heater 86 is added to the top of each boss 88. Bosses 88 have been micromachined into substrate 44 and form the side- walls of optical waveguide 30. Thin film resistance temperature detectors (RTD's) 90 measure the temperature of sidewalls 58 of the sample chamber 34. The heaters 86 and the thin film RTD's 90 are connected to a temperature control circuit 92, which functions as a closed loop controller that operates in a well-known way to maintain the sample chamber at a set temperature. As with the source driver 76 and signal processing electronics 78, the temperature control circuit 92 may be fabricated on substrate 44 using standard IC fabrication techniques. Because the gas sensor of the present invention is fabricated from a semiconductor material such as silicon, other semiconductor integrated circuit devices may also be added wherever needed to further enhance the performance of the NDIR gas sensor 28 according to the present inven- tion. For example, temperature sensors, pressure trans¬ ducers, and humidity sensors may be added to accomplish any of the signal compensation schemes known in the art. In addition, a micro-flow sensor may be added to detect the flow rate of the sample gas through the sample cham¬ ber. A fourth embodiment of the present invention is described in connection with Fig. 9. This embodiment is preferred when the ability to detect multiple gases is desired or when a reference detector is desired. According to this embodiment, a bottom substrate 44 is provided. Bottom substrate 44 can have the basic features of any of the previous embodiments. However, instead of a single detector 50 and bandpass filter 52 being fabri¬ cated on substrate 44, a plurality of detectors 50 and bandpass filters 52 are fabricated on substrate 44 so that when top substrate 42, which has been omitted from Fig. 9, is attached they are all within the detector chamber 36. Each bandpass filter 52 is interposed in the optical path between the light source 40 and one of the plurality of detectors 50. The number of gases whose concentration is desired to be determined dictates the specific number of detectors 50 and bandpass filters 52 that are required. Each bandpass filter 52 is designed so that the detector 50 it is associated with primarily receives radiation of a wavelength that is strongly absorbed by the gas whose concentration that specific detector 50 is to determine. Thus, the illustrated substrate 44 can be used to form an NDIR gas sensor that can simultaneously deter¬ mine the concentration of a plurality of gases. Of course, the source driver 76 and signal processing electronics 78 may be added to substrate 44 in this embodiment. Similarly, if desired, the heaters 86, RTD's 90 and temperature control circuit 92 shown in Fig. 8 may also be added to substrate 44. Alternatively, if desired, in this embodiment one of the detectors 50 shown on substrate 44 in Fig. 9 may be used as a reference detector. The reference detector provides the signal processing electronics 78 with a baseline output signal against which to compare the output signal from the detector that is being used to measure the concentration of the desired gas. As a result, the intrinsic stability of the sensor over time may be im¬ proved because variations in the light intensity from source 40 are compensated for. If one of the detectors 50 is to be used as a refer¬ ence detector, the bandpass filter 52 associated with it must be designed so that the detector primarily receives radiation of a neutral wavelength. In other words, the bandpass filter 52 must primarily pass radiation that is not absorbed by the gas sample within sample chamber 34 and filter out other extraneous wavelengths of radiation. If there are more than two detectors within sample chamber 36, more than one of them may be used as a refer- ence detector. For example, if there are three detectors 50 within detector chamber 36, two of them could be used as reference detectors, the bandpass filter 52 for each passing a different neutral wavelength. The third detec¬ tor in this situation would be used to determine the concentration of a desired gas. Therefore, as would be apparent to one of ordinary skill in the art, the NDIR gas sensor 28 according to the present embodiment is very flexible. It may be used to measure the concentration of a plurality of different gases, or it may be used to measure the concentration of one or more gases while simultaneously using at least one reference detector to maintain the intrinsic stability of the sensor over time. While the present invention has been made clear in the illustrative embodiments, it will be immediately obvious to those skilled in the art that many modifications of structure, arrangement, proportions, the elements, materi¬ als, and components used in the practice of the invention, and otherwise, which are particularly adapted to specific environments and operative requirements, can be made without departing from the principles disclosed. Thus, it is to be clearly understood that this description is made only by way of example and not as a limitation to the scope of the invention as claimed below.

Claims: Claims 1. An improved NDIR gas sensor, comprising: a. a first semiconductor material substrate; b. a second semiconductor material substrate attached to the first substrate; c. an optical waveguide formed between the first and second substrates; d. a light source integrally formed on one of the substrates and positioned at one end of the optical waveguide; e. a light detector integrally formed on one of the substrates and positioned at the end of the optical waveguide opposite the light source; f. a bandpass filter interposed in the optical path between the light source and light detector; g. a pair of windows interposed in the optical path between the light source and light detector so as to define therebetween a sample chamber within the waveguide and thermally isolate the light source and light detector; and h. means for permitting diffusion of gas into and out of the sample chamber. 2. An NDIR gas sensor according to claim 1, wherein the light source and light detector are fabricated on the same substrate. 3. An NDIR gas sensor according to claim 1, wherein, the semiconductor material for the first and second substrates is selected from the group consisting of Si and GaAs. 4. An NDIR gas sensor according to claim 1, wherein: a. the light source is a black body; b. the light detector is an infrared detector; and c. the bandpass filter has a center wavelength (CWL) of about 4.26 μm and a FWHM of about 0.1 μm. 5. An NDIR gas sensor according to claim 1, wherein at least a portion of the walls of the optical waveguide are metallized to improve internal reflectivity of the waveguide. 6. An NDIR gas sensor according to claim 1, further comprising means for heating the walls of the optical waveguide to a temperature above the dew point of the gas in the sample chamber. 7. An NDIR gas sensor according to claim 1, further comprising means for sensing the humidity level in the optical waveguide sample chamber. 8. An NDIR gas sensor according to claim 1, further comprising means for detecting the pressure level within the optical waveguide sample chamber. 9. An NDIR gas sensor according to claim 1, wherein the light detector is an infrared detector selected from the group consisting of Platinum Silicide Schottky photodiode, bolometer, infrared tunnel sensor, thermocouple, and thermopile. 10. An NDIR gas sensor according to claim 1, further comprising: a. a source driver for energizing the source at a preset frequency; and b. signal processing electronics for converting the electrical output produced by the detector into a signal which represents the concentration of the gas being measured. 11. An NDIR gas sensor according to claim 10, further comprising a micro-flow sensor for detecting the gas flow rate within the optical waveguide sample chamber. 12. An NDIR gas sensor according to claim 1, wherein the means for permitting gas to diffuse into and out of the space within the sample chamber comprises at least one aperture in a wall of the sample chamber. 13. An NDIR gas sensor according to claim 1, wherein the means for permitting gas to diffuse into and out of the sample chamber comprises: a. a plurality of apertures in at least one wall of the sample chamber; and b. a gas permeable layer covering the plurality of apertures. 14. An NDIR gas sensor according to claim 13, wherein the gas permeable layer is made from a dielectric selected from the group consisting of TEFLON ® , KAPTON ® , silicon oxide, and silicon nitride. 15. An NDIR gas sensor according to claim 13, wherein the gas permeable layer prevents particles larger than 0.1 μm from entering the sample chamber within the optical waveguide. 16. An NDIR gas sensor according to claim 1, wherein the pair of windows are micromachined from one of the semiconductor material substrates. 17. An NDIR gas sensor according to claim 1, further comprising: a. a plurality of light detectors integrally formed on one of the substrates and positioned at the end of the optical waveguide opposite the light source; b. a plurality of bandpass filters, wherein each bandpass filter passes a different range of wavelengths and is interposed between the light source and one of the plurality of light detectors. 18. An NDIR gas sensor according to claim 17, wherein at least one of the plurality of detectors is used as a reference detector. 19. A micromachined NDIR gas sensor cell made out of a semiconductor material, comprising: a. an optical waveguide; b. a light source at one end of the waveguide; c. at least one light detector at the end of the waveguide opposite the light source; d. a diffusion-type gas sample chamber formed within the waveguide and interposed in the optical path between the light source and light detector so that the light source and light detector are thermally isolated from the gas sample; and e. at least one bandpass filter interposed between the light source and at least one light detector. 20. An NDIR gas sensor according to claim 19, wherein the optical waveguide is formed between two or more semiconductor material substrates of which at least one has been micromachined. 21. An NDIR gas sensor according to claim 19, wherein the light source and the at least one light detector are fabricated on the same substrate. 22. An NDIR gas sensor according to claim 21, wherein the light source is a black body and the at least one light detector is at least one detector selected from the group consisting of Platinum Silicide Schottky photodiode, bolometer, infrared tunnel sensor, thermocouple, and thermopile. 23. An NDIR gas sensor according to claim 19, wherein the gas sensor cell is produced from a semiconductor selected from the group consisting of Si and GaAs. 24. An NDIR gas sensor according to claim 19, wherein at least a portion of the walls of the optical waveguide are metallized to improve the internal reflectivity of the waveguide. 25. An NDIR gas sensor according to claim 19, further comprising a thin film temperature sensor for inputting a temperature signal to a temperature control circuit for controllably outputting a heating current to a thin film heat source. 26. An NDIR gas sensor according to claim 19, wherein gas diffuses into and out of the sample chamber through a plurality of apertures in at least one wall of the sample chamber that are covered by a gas permeable layer which prevents particles lager than 0.1 μm from entering the sample chamber within the optical waveguide. 27. An improved NDIR gas sensor, comprising: a. an optical waveguide formed between two or more semiconductor material substrates of which at least one has been micromachined, the semiconductor material being selected from the group consisting of Si and GaAs; b. a light source fabricated at one end of the waveguide on one of the substrates; c. at least one light detector fabricated at the end of the waveguide opposite the light source and on the same substrate as the light source; d. a diffusion-type gas sample chamber formed within the waveguide and interposed in the optical path between the light source and light detector so that the light source and light detector are thermally isolated; and e. at least one bandpass filter interposed between the light source and at least one light detector. 28. An NDIR gas sensor according to claim 27, wherein at least a portion of the walls of the optical waveguide are metallized with a metal selected from the group consisting of Al, Au, Cr, Ni, and Pt to improve the internal reflectivity of the waveguide. 29. An NDIR gas sensor according to claim 27, wherein gas diffuses into and out of the sample chamber through a plurality of apertures in at least one wall of the sample chamber that are covered by a gas permeable layer selected from the group consisting of TEFLON ® , KAPTON ® , silicon oxide, and silicon nitride and which prevents particles larger than 0.1 μm from entering the sample chamber within the optical waveguide. 30. An improved NDIR gas sensor, comprising: a. a first silicon substrate; b. a second silicon substrate attached to the first silicon substrate; c. an optical waveguide formed between the first and second silicon substrates; d. a black body light source integrally formed on the first silicon substrate and positioned at one end of the optical waveguide; e. an infrared light detector integrally formed on the first silicon substrate and positioned at the end of the optical waveguide opposite the light source; f. a bandpass filter interposed in the optical path between the light source and light detector; g. a pair of optically transparent silicon windows interposed in the optical path between the light source and light detector so as to define therebetween a sample chamber within the waveguide and thermally isolate the light source and light detector from the sample gas; h. a plurality of apertures in at least one wall of the sample chamber; i. a gas permeable layer covering the plurality of apertures to prevent particles larger than 0.1 μm from entering the sample chamber; j . a source driver for energizing the source at a preset frequency; and k. signal processing electronics for converting the electrical output produced by the detector into a signal which represents the concentration of the gas being measured.

Inventors: WONG JACOB Y, WONG, JACOB, Y.
Applicants: TELAIRE SYSTEMS INC, TELAIRE SYSTEMS, INC.
Application year: 1995
Main classification: G01N21
IPC codes: G01N21