Abstract:
A gas sensor utilizes nano-sized CeO 2  and doped CeO 2  particles for detecting NO, NO2 and also for studying the cross sensitivity of oxygen, un-burnt hydrocarbons, CO and CO 2 . Nano-crystalline powders of CeO 2  and doped CeO 2  are employed to configure thin films on Platinum comb type electrodes preformed on alumina substrates. Various catalytic oxides are employed to convert the NO to NO 2  to get equal response to NOx gas. Gas sensing properties are measured using a dynamic chamber with a constant flow of air and NOX gas in required percentage in nitrogen gas.

Description:
TECHNICAL FIELD 
       [0001]    Embodiments are generally related to gas sensors. Embodiments are also related to the field of NO x  sensors using nano-crystalline CeO 2 . Embodiments are additionally related to CeO 2  (MOS) NO x  sensors for high temperature applications. 
       BACKGROUND OF THE INVENTION 
       [0002]    The role of gases and the measurement of their concentration have always received wide spread applications in many fields of science and technology. This has resulted in an increasing demand for small scale solid-state sensors. NO x  sensors for automotive exhaust gas environments are of great interest because of high expectations of nanostructured materials and ever increasing demands on emission control legislations. The sensitivity of a gas sensor is defined as the ratio of the resistance of the sensor element in air to the resistance of the sensor element in the test gas atmosphere (S=R air /R gas ). 
         [0003]    Many processes and devices have been used for sensing exhaust gases from automobile engines. NO x  is one of the unwanted exhaust gases which pollute the environment. NO x  is a term used to describe the total oxides of nitrogen, which are commonly estimated from the measured NO, based on the assumption that the total NO x  is (combination of NO and NO2 with varying concentrations depend upon the engine conditions ranging from 40% to 5% for NO2 and 60% to 95% of NO). This assumption is generally acceptable when combustion exhaust gases are measured at the outlet of a combustion system and the oxygen concentration is low. If the measurement is made at the exhaust outlet or in the atmosphere, the NO 2  is likely much higher than total 5% of the total NO x . 
         [0004]    Measurement of NO and NO 2  is recommended for accurate total NO x  formation. NO x  is important to measure because of reactions involving volatile organic compounds (VOCs) with nitrogen oxides (NO x ) in the presence of sunlight form ozone in the atmosphere. Ground-level ozone and NOx for example, causes throat irritation, congestion, chest pains, nausea and labored breathing. Ozone can also aggravate respiratory conditions, such as chronic lung and heart diseases, allergies and asthma. Additionally, Ozone ages the lungs and may contribute to various types of lung diseases. 
         [0005]    NO x  is found in emissions from aircraft, automobiles and industrial factories and contributes to the production of acid rain, smog, and the depletion of the ozone layer. With the increase in the number of vehicles traveling the earth, the amount of NO x  produced is also increasing, thereby causing a dangerous situation for the environment. Therefore, a reliable NO x  sensor to monitor and control emissions while exposed to the harsh conditions is needed. 
         [0006]    The development of gas sensor devices with optimized selectivity and sensitivity has been gaining prominence in recent years. The use of semiconductor fabrication line is the preferred manufacturing process because of the potential to reduce cost. However fundamental materials and processing issues which are critical for high performance gas sensors need to be addressed. Among the new technologies a nano-crystalline material offers immense promise for improved sensitivity. 
         [0007]    Nano-crystalline materials are currently receiving a great deal of attention due to their unique physical properties, which derive from their nanometer scaled sizes. In nano-sized materials, for example, the surface to bulk ratio is much greater than coarse materials, so that the surface properties become paramount, which makes them particularly appealing in applications, such as gas sensors, where nano-sized properties can be exploited. Grain size reduction, for example, is one of the main factors for enhancing the gas sensing properties of semiconducting oxides. It is believed that improved sensing technologies can therefore be configured and developed by taking advantage of recent advances in nano-sized materials. 
       BRIEF SUMMARY 
       [0008]    The following summary is provided to facilitate an understanding of some of the innovative features unique to the embodiments disclosed and is not intended to be a full description. A full appreciation of the various aspects of the embodiments can be gained by taking the entire specification, claims, drawings, and abstract as a whole. 
         [0009]    It is, therefore, one aspect of the present invention to provide for an improved NO x  sensor to monitor and control emissions when exposed to harsh conditions. 
         [0010]    It is another aspect of the present invention to provide for a gas sensor that utilizes nano-sized CeO 2  particles to detect NO x  and study the cross sensitivity for oxygen, unburnt hydrocarbons, CO and CO 2 . 
         [0011]    The aforementioned aspects and other objectives and advantages can now be achieved as described herein. CeO 2  nano-crystalline powders are synthesized by employing sol-gel, co-precipitation as well as chemical vapor synthesis (CVS). Such powders are used for configuring thin films of CeO 2  on platinum inter digital comb type electrodes performed on alumina substrates to form a sensor thereof. On the other side of the sensor, a platinum heater is provided to maintain the sensor at high temperatures. The nano powders obtained by the above said methods are dispersed on these substrates by dip coating, or screen printing by adding the appropriate binders for making thin and thick films. Dispersing the nano-crystalline powders in organic solvents and by employing electrophoresis techniques, thin films also can be fabricated. 
         [0012]    Sintering is carried out to enhance the adherence of these films to the substrate. Thick films are also prepared by using screen printing techniques of CeO 2  in association with an appropriate binder and sintered at higher temperatures. Such films can be impregnated with 2% platinum particles. The gas sensing properties of NOx can be carried out using a test apparatus, which can indicated that the sensitivity for 2500 pm of NO and NO 2  is approximately 250% and the response and recovery time are less than four seconds for the same concentration. The uniqueness of the disclosed technique and device stems from the control of the particle size and shape. Especially with chemical vapor synthesis, the particle size can be controlled up to 8 to 10 nm. Higher particle sizes are also easily achieved. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    The accompanying figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views and which are incorporated in and form a part of the specification, further illustrate the embodiments and, together with the detailed description, serve to explain the embodiments disclosed herein. 
           [0014]      FIG. 1  illustrates a gas sensor testing apparatus, which can be implemented in accordance with a preferred embodiment; 
           [0015]      FIG. 2  illustrates side view of the CeO 2  NOx gas sensor which can be implemented in accordance with an alternative embodiment; and 
           [0016]      FIG. 3  illustrates a perspective view of the back side of the sensor on which a platinum heater is provided on the substrate in accordance with the present embodiment. 
           [0017]      FIG. 4  illustrates a flowchart of operations depicting logical operational steps for the preparation of nano-crystalline CeO 2  and doped CeO2 coating, in accordance with a preferred embodiment; 
           [0018]      FIG. 5  illustrates a flowchart of operations depicting logical operational steps for the detection of NO x  gases using CeO 2 NO x  gas sensor, in accordance with a preferred embodiment; and 
           [0019]      FIG. 6  illustrates a side view of a sensor, which can be implemented in accordance with an alternative embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope thereof. 
         [0021]    Referring to  FIG. 1 , a gas sensor testing apparatus  100  is illustrated, which can be implemented in accordance with a preferred embodiment. The gas sensor testing apparatus  100  generally includes two gas cylinder tanks  110  and  120 . The gases NO x  filled in cylinder  120  and dry air filled in  110  respectively flow from gas cylinder tanks  120  and  110 , and are allowed to pass through a mass flow controller  130  to adjust the flow rate. Apparatus  100  further includes a two way gas valve  140 . By adjusting the two way gas valve  140 , NOx and dry air can be selectively passed on to a sensor  160  that detects the gas content. 
         [0022]    Current voltage properties can be measured using a high voltage source  170  (e.g., a power supply). A stand  150  can also be provided upon which the two-way gas valve  140  and gas sensor  160  are connected. The conductance of the sensor  160  can be measured with a digital multimeter  180  that is connected electrically to the high voltage source  170  and also to a computer  190 . The change in resistance can be simultaneously monitored by the digital multimeter  180 . The apparatus  100  also includes the control computer  190 , which is generally operable to control and manage the overall operation of the testing apparatus  100 . 
         [0023]    Referring to  FIG. 2  a side view of a CeO 2  NOx gas sensor element  200  is illustrated, which can be implemented in accordance with a preferred embodiment. In  FIGS. 2 and 3(   a )- 3 ( b ), identical or similar parts or elements are generally indicated by identical reference numerals. Note that the CeO 2 NOx gas sensor element  200  depicted in  FIG. 2  can be adapted for use with the sensor  160  depicted in  FIG. 1 . The gas sensor  160  functions based on the fact that the changes of the oxide film resistance result from the reactions of the gases on the surface of the film  220  The gas sensor  160  includes the CeO 2 NOx gas sensor element  200 , which is composed of a platinum heater  240  formed in association with an alumina ceramic substrate  230 . An interdigital comb of platinum electrodes  210  can be formed on one side of the alumina ceramic substrate  230 . One or more thin films  220  of CeO 2  can be fabricated on the platinum electrodes  210  by electrophoresis. On the other side of the sensor element  200 , the platinum heater  240  can be provided to maintain the sensor element  200  at high temperatures. 
         [0024]    Referring to  FIG. 3A , a front view of the CeO 2  NOx gas sensor element  200  is depicted, including a CeO 2  coating, in accordance with a preferred embodiment. The sensor platinum electrode  210  is generally provided in the context of an inter-digital comb structure, which maintains the resistance in an easily measurable range. The sensing mechanism of sensor element  200  is based on the electrofilic adsorption of NO x  gas on the semi conducting oxide material (i.e., CeO 2 ) of the films  220 . The change in conductivity of the sensor element  200  can be measured and calibrated with known concentrations. 
         [0025]    Referring to  FIG. 3B  a back view of CeO 2  NOx gas sensor element  200  including one or more platinum heaters is illustrated in accordance with a preferred embodiment. On the back side of the substrate  230 , the platinum heater  240  can be mounted in order to maintain the sensor element  200  at an appropriate operating temperature. A chemical reaction occurs when combustible gas reaches the sensing element  200 . This action increases the temperature of the element  200 , such that the heat is transmitted to the platinum heater  240 . 
         [0026]    A heating element is used to regulate the sensor temperature, since the finished sensors exhibit different gas response characteristics at different temperature ranges. This heating element can be a platinum or platinum alloy wire, a resistive metal oxide, or a thin layer of deposited platinum. The sensor element  200  can then be processed at a specific high temperature, which determines the specific characteristics of the finished sensor. In the presence of gas, the metal oxide causes the gas to dissociate into charged ions or complexes, which results in the transfer of electrons. The built-in platinum heater  240  thus heats the metal oxide material to an operational temperature range that is optimal for gas to be detected, and can optionally be regulated and controlled by a specific circuit. This specific circuit can be a chip (Application-Specific Integrated Circuit, ASIC) which can control sensor temperature through an independent measurement and heating mechanism of the micro heater present inside the chip. 
         [0027]    Referring to  FIG. 4  a flowchart of operations is illustrated depicting logical operational steps for the preparation of a nano-crystalline CeO 2  coating, in accordance with a preferred embodiment. As indicated at block  310 , CeO 2  nano crystalline powders can be synthesized by employing sol-gel, precipitation as well as chemical vapor synthesis. Inter digital comb type of Platinum electrodes are generally formed on one side of an alumina ceramic substrate, as indicated at block  320 , by using a screen printing technique. Thereafter, as indicated at block  330 , on the other side of the sensor, a Platinum heater can be provided to maintain the sensor at high temperatures. Nano-crystalline powders are generally dispersed in organic solvents and by employing electrophoresis or a dip coating technique as illustrated at block  340 , the thin films can be fabricated. 
         [0028]    Next, as indicated at block  350 , a sintering operation can be carried out to enhance the adherence of these films to the substrate. The difficulty of sintering of CeO 2  (as the sintering temperature of CeO 2  is beyond 1600 C) is solved by adding inorganic binders mixing (5%) with CeO 2 . Thick films can also be prepared using a screen printing technique of CeO 2  with an appropriate binder and sintered at high temperatures. The cross sensitivity of other gases (e.g., hydrocarbons, CO, CO 2  etc) can be checked thoroughly by adding a catalytic metal such as platinum  360  as depicted block  360 . The cross sensitivity can thus be reduced to specified limits. 
         [0029]    Referring to  FIG. 5  a flowchart  400  of operations depicting logical operational steps for the detection of NO x  gases using a CeO 2  NO x  gas sensor is illustrated, in accordance with a preferred embodiment. As depicted at block  410 , the exhaust gas can be absorbed on semi conducting oxide material. Thereafter, as indicated at block  420 , catalytic metals can be applied to avoid cross-sensitivity and interference from other gases. Next, NO x  gas can be sensed on a semi-conducting oxide material (CeO 2 ) based on electrophilic adsorption, as depicted at block  430 . Thereafter, as depicted at block  440 , changes in the conductivity of the semi-conducting oxide material can be measured. A Cerium Oxide (CeO 2 ) NOx sensor can then be calibrated with known concentration, as depicted at block  450 . 
         [0030]    In such an application, the sensor may produce a sensitivity of 200% with respect to a change of resistance for 2500 ppm of NO and NO 2 . The particle size effect begins to occur below 50 nm with an order of magnitude increase in sensitivity for particles in 20 to 30 nm range. This particle size effect is due, in part, to an increase in the surface area since. In this range, a large fraction of the atoms (e.g., up to 50) are generally present at the surface or the interface region so that the structure and properties are different from that of the bulk material. However, the main effect is associated with the depth of the surface space charge region affected by gas adsorption in relation to the particle size. By employing a sol-gel process, for example, a 20 nm size of CeO 2  can be obtained. Such nano-powders are preferably mixed with adequate (5 to 10 wt %) amounts of ethylene glycol and the paste is then applied on to the platinum electrodes on an alumina substrate. The other method employed is by adding an appropriate amount (5 to 20% by wt) of binder ink making the printable ink for screen printing to be used for thick film sensor production. 
         [0031]    The sensor described herein is very simple to fabricate and possesses a fast response and recovery for the NO x  gas because of the presence of the nano-sized particles. Such benefits can be achieved due to the large surface area and reactive nature of the nano-crystalline powders. The cost of the sensor is relatively inexpensive, because large scale manufacturing processes such as screen printing can be employed. The electronics used to measure conductivity change are also much less complex and generally inexpensive. Cerium oxide in a thick film form, for example, can also be prepared using nanopowders and tested for NO x  sensing. The methodology and device disclosed herein therefore uses nano-sized CeO 2  particles to detect NO and NO 2  and employs nano-crystalline powders of CeO 2  to configure thin films on Platinum comb type electrodes preformed on alumina substrates. 
         [0032]      FIG. 6  illustrates a side view of a sensor  500 , which can be implemented in accordance with an alternative embodiment. Sensor  500  generally includes a thick platinum film heater  550  formed in association with a substrate  540 , which can be configured from alumina or ceramic. An inter-digital comb of electrodes  510  can be formed on one side of the alumina or ceramic substrate  540 . Electrodes  510  can be formed from platinum. A thick film  530  of sensing element Ce (1-x)  T x  O (2-y)  can be fabricated on the electrodes  510  by electrophoresis or screen printing, depending upon design considerations. A thick film  520  of catalyst material can be fabricated on the sensing element  530  (i.e., Ce (1-x)  T x  O (2-y) ). On the other side of the sensor element  500 , the platinum film heater  550  can be provided to maintain the sensor element  500  at high temperatures. The configuration of sensor  500  generally permits a catalyst material  520  or a combination of catalysts (e.g., WO 3 , MoO 3 , XWO 4 , X 3 WO 5 , X 3 W 2 O 9  (x=Ca, Ba, Sr), YMoO 4 , Y 2 MoO 5 , Y 3 Mo 3 O 9  (Y=Ca, Ba, Sr), to be used to convert the NO to NO 2  and sense the NOx gas of any combination of NO and NO 2  and to provide the same output. Sensor  500  thus constitutes an alternative version of a CeO 2  NO x  sensor. 
         [0033]    It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.