Patent Description:
In monitoring for the presence of various gases, other gases such as carbon monoxide (CO), or hydrogen sulfide (H<NUM>S) can be present that can also react within the sensor. For example, the working electrode can comprise a catalyst that can catalyze the reaction of both a target gas and an interferent gas. As a result, the presence of the interferent gas may create a cross-sensitivity in the sensor, resulting in the false impression that greater levels of the target gas are present in the ambient gases than are actually present. Due to the danger presented by the presence of various target gases, the threshold level for triggering an alarm can be relatively low, and the cross-sensitivity due to the presence of the interferent may be high enough to create a false alarm for the target gas sensor.

<CIT> discloses an electrochemical gas detector and method of using the same.

<CIT> discloses an electrochemical cell having a polargraphic device with ion selective electrode as working electrode and method of use.

<CIT> discloses an electrochemical measuring cell for the detection of HCN.

<CIT> discloses a filter for a gas sensor.

<CIT> discloses an electrochemical sensor with a non-aqueous electrolyte system.

<CIT> discloses a filter for an electrochemical measuring cell.

<CIT> discloses a hydrogen cyanide electrochemical sensor.

The present invention is defined by the appended independent claims <NUM> and <NUM>.

For a more complete understanding of the present invention, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques. The invention should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.

Hydrogen Cyanide (HCN) is used in many industrial applications. It is extremely toxic, and even relatively small amounts are lethal to humans. (Example regulations include OSHA PEL at <NUM> ppm HCN, and ACGIH TLV at <NUM> ppm HCN. ) In this context, there is an increasing demand for HCN gas sensors for safety monitoring. In many cases, there are many other toxic gases in addition to HCN gas, such as hydrogen sulfide (H<NUM>S). Currently, there are two types of HCN sensors that are commonly used. One uses gold (Au) as a working electrode, the other uses silver (Ag) as a working electrode. For sensors using Au, H<NUM>S gas often gives a large positive signal more so than HCN on the instrument, <NUM> ppm H<NUM>S results in an about <NUM> ppm HCN reading, which can trigger a false alarm. For Ag HCN gas sensors, H<NUM>S gas consumes silver to form silver sulfide, thereby reducing the sensor sensitivity and life significantly. H<NUM>S gas not only can cause false alarms, but may also quickly destroy the sensor. Under the conditions where H<NUM>S and HCN gases are present (or leaking), such as in a fire scenario, a large positive signal caused by the H<NUM>S may trigger an HCN detection alarm, and the false alarm may cause panic and inconvenience to users. So far, there is no sensor available that can reduce the cross-sensitivity or poison of H<NUM>S on HCN detectors without affecting the sensor sensitivity and performance.

In some electrochemical sensors, chemical filters may be used to remove or reduce the presence of certain gases in the sensor. However, typical chemical filters may not successfully reduce the cross-sensitivity of H<NUM>S for an HCN detector. For example, a soda lime filter, an activated carbon filter, and/or a rubber charcoal filter may be used to prevent sensor cross-sensitivity to H<NUM>S. However, the use of carbon filters may be restricted to only a few types of gas sensors, because activated carbon can absorb a wide range of gases including HCN. Therefore, the use of filters containing soda lime or activated carbon to prevent the cross-sensitivity of H<NUM>S on HCN gas sensors may not be successful, because soda lime or activated carbon can also react with and/or absorb HCN. Another type of filter may include activated alumina impregnated with potassium permanganate operable to absorb H<NUM>S gas, but it also may also absorb HCN gas. Some sensors may use filters containing Ag<NUM>SO<NUM> to reduce the cross-sensitivity to H<NUM>S on sulfur dioxide detectors. However, the Ag<NUM>SO<NUM> filter is prepared by impregnating the substrate by salt solutions, wherein the substrate comprises glass fibers. As is well known in the art, glass fibers typically comprise materials such as SiO<NUM>, Al<NUM>O<NUM>, TiO<NUM>, and ZrO<NUM>, which will absorb HCN gas. Therefore, an Ag<NUM>SO<NUM> filter would not work in an HCN gas sensor.

Embodiments described herein include an electrochemical sensor for detection of HCN, where the sensor may comprise a filter operable to remove H<NUM>S gas and not affect sensor sensitivity and performance. The electrochemical sensor may comprise one or more electrodes, such as working, counter and reference electrodes, as well as an electrolyte. The electrochemical sensor may also comprise a filter including silver sulfate layered onto a polytetrafluoroethylene (PTFE) support material, where PTFE has good hydrophobic performance, and has no absorption to HCN gas.

<FIG> illustrates a cross-section drawing of an electrochemical sensor <NUM>. The electrochemical sensor <NUM> generally comprises a housing <NUM> defining a cavity or reservoir <NUM> designed to hold an electrolyte solution. A working electrode <NUM> can be placed between an opening <NUM> and the reservoir <NUM>. A counter electrode <NUM> and a reference electrode <NUM> can be positioned within the reservoir <NUM>. When the gas reacts within the reservoir <NUM>, an electrical current and/or potential can be developed between the electrodes to provide an indication of the concentration of the gas. A reference electrode <NUM> may also be positioned within the reservoir <NUM> to provide a reference for the detected current and potential between the working electrode <NUM> and the counter electrode <NUM>.

The housing <NUM> defines the interior reservoir <NUM>, and one or more openings <NUM>, <NUM> can be disposed in the housing to allow a gas to be detected to enter the housing <NUM>. The housing <NUM> can generally be formed from any material that is substantially inert to the electrolyte and gas being measured. In an embodiment, the housing <NUM> can be formed from a polymeric material, a metal, or a ceramic. For example, the housing can be formed from a material including, but not limited to, acrylonitrile butadiene styrene (ABS), polyphenylene oxide (PPO), polyvinyl chloride (PVC), polyvinylidene difluoride (PVDF), polystyrene (PS), polypropylene (PP), polyethylene (PE) (e.g., high density polyethylene (HDPE)), polyphenylene ether (PPE), or any combination or blend thereof. In some embodiments, the housing <NUM> may be formed form a polymer that is resistant to sulfuric acid.

One or more openings <NUM>, <NUM> can be formed through the housing <NUM> to allow the ambient gas to enter the housing <NUM> and/or allow any gases generated within the housing <NUM> to escape. In an embodiment, the electrochemical sensor <NUM> may comprise at least one inlet opening <NUM> to allow the ambient gas to enter the housing <NUM>. The opening <NUM> can be disposed in a cap <NUM> when a cap is present and/or in a wall of the housing <NUM>. In some embodiments, the opening <NUM> can comprise a diffusion barrier to restrict the flow of gas (e.g., HCN, etc.) to the working electrode <NUM>. The diffusion barrier can be created by forming the opening <NUM> as a capillary and/or a film or membrane can be used to control the mass flow rate through the one or more openings <NUM>, <NUM>.

In an embodiment, the opening <NUM> may serve as a capillary opening to provide a rate limited exchange of the gases between the interior and exterior of the housing <NUM>. In an embodiment, the opening <NUM> may have a diameter between about <NUM> and about <NUM>, where the opening <NUM> can be formed using a convention drill for larger openings and a laser drill for smaller openings. The opening <NUM> may have a length between about <NUM> and about <NUM>, depending on the thickness of the cap or housing <NUM>. In some embodiments, two or more openings may be present for the inlet gases. When a membrane is used to control the gas flow into and/or out of the housing <NUM>, the opening diameter may be larger than the sizes listed above as the film can contribute to and/or may be responsible for controlling the flow rate of the gases into and out of the housing <NUM>.

The reservoir <NUM> comprises the counter electrode <NUM>, the reference electrode <NUM>, and the working electrode <NUM>. In some embodiments, the electrolyte can be contained within the reservoir <NUM>, and the counter electrode <NUM>, the reference electrode <NUM>, and the working electrode <NUM> can be in electrical contact through the electrolyte. In some embodiments, one or more porous separators <NUM> or other porous structures can be used to retain the electrolyte in contact with the electrodes. The separators <NUM> can comprise a porous member that acts as a wick for the retention and transport of the electrolyte between the reservoir and the electrodes while being electrically insulating to prevent shorting due to direct contact between any two electrodes. One or more of the porous separators <NUM> can extend into the reservoir <NUM> to provide the electrolyte a path to the electrodes. In an embodiment, a separator <NUM> can be disposed between the counter electrode <NUM> and the reference electrode <NUM>, and a separator <NUM> can be disposed between the reference electrode <NUM> and the working electrode <NUM>.

One or more of the separators <NUM> can comprise a nonwoven porous material (e.g., a porous felt member), a woven porous material, a porous polymer (e.g., an open cell foam, a solid porous plastic, etc.), or the like, and is generally chemically inert with respect to the electrolyte and the materials forming the electrodes. In an embodiment, the separators <NUM> can be formed from various materials that are substantially chemically inert to the electrolyte including, but not limited to, glass (e.g., a glass mat), polymer (plastic discs), ceramics, or the like.

The electrolyte can be any conventional aqueous acidic electrolyte such as sulfuric acid, phosphoric acid, or a neutral ionic solution such as a salt solution (e.g., a lithium salt such as lithium chloride, etc.), or any combination thereof. For example, the electrolyte can comprise sulfuric acid having a molar concentration between about <NUM> to about <NUM>. Since sulfuric acid is hygroscopic, the concentration can vary from about <NUM> wt % to about <NUM> wt % (<NUM> to <NUM> molar) over a relative humidity (RH) range of the environment of about <NUM>% to about <NUM>%. In an embodiment, the electrolyte can comprise phosphoric acid having a concentration in an aqueous solution between about <NUM>% to about <NUM>% H<NUM>PO<NUM> by weight. As another example, the electrolyte can include a lithium chloride salt having about <NUM>% to about <NUM>% LiCl by weight, with the balance being an aqueous solution.

In an embodiment of the sensor <NUM>, the electrolyte may comprise approximately <NUM> of sulfur acid and with additive of silver sulfate. In another embodiment of the sensor <NUM>, the electrolyte may comprise propylene carbonate with an addition of lithium perchlorate, with the concentration of lithium perchlorate of approximately <NUM>.

The working electrode <NUM> may be disposed within the housing <NUM>. The gas entering the electrochemical sensor <NUM> can contact one side of the working electrode <NUM> and pass through the working electrode <NUM> to reach the interface between the working electrode <NUM> and the electrolyte. The gas can then react to generate the current indicative of the gas concentration. As disclosed herein, the working electrode <NUM> can comprise a plurality of layers. The base or substrate layer can comprise a hydrophobic material or a hydrophobically treated material. A catalytic material can be formed as an electrode on one side of the working electrode <NUM> and placed in contact with the electrolyte. In an embodiment, the catalytic material in the working electrode may comprise gold to provide for the detection of acrylonitrile.

In an embodiment, the working electrode <NUM> can comprise a porous substrate or membrane as the base layer. The substrate can be porous to the gas of interest, which can comprise acrylonitrile. In an embodiment, the substrate can comprise a carbon paper formed of carbon or graphite fibers. In some embodiments, the substrate can be made to be electrically conductive through the addition of a conductive material such as carbon. The use of carbon may provide a sufficient degree of electrical conductivity to allow the current generated by the reaction of the gas with the electrolyte at the surface of the working electrode <NUM> to be detected by a lead coupled to the working electrode <NUM>. Other electrically conductive substrates may also be used such as carbon felts, porous carbon boards, and/or electrically conductive polymers such as polyacetylene, each of which may be made hydrophobic as described below. Alternatively, an electrically conductive lead can be coupled to the catalytic layer to electrically couple the catalytic material to the external circuitry, as described in more detail herein. In an embodiment, the substrate can be between about <NUM> mils to about <NUM> mils thick in some embodiments.

The porous substrate can be hydrophobic to prevent the electrolyte from passing through the working electrode <NUM>. The substrate can be formed from a hydrophobic material, or the substrate can be treated with a hydrophobic material. In an embodiment, the substrate can be made hydrophobic through the impregnation of the substrate with a hydrophobic material such as a fluorinated polymer (e.g., PTFE, etc.). In some embodiments, the substrate or membrane can comprise GEFC-IES (e.g., the copolymer of perfluorosulfonic acid and PTFE, which is commercially available from Golden Energy Fuel Cell Co. ), Nafion® (a copolymer of polytetrafluoroethylene and perfluoro-<NUM>,<NUM>-dioxa-<NUM>-methyl-<NUM>-octene-sulfonic acid, which is commercially available from Dupont), or pure or nearly pure polytetrafluoroethylene (PTFE). The impregnation process can include disposing a hydrophobic material containing solution or slurry on the substrate using a dipping, coating, or rolling process. Alternatively, a dry composition such as a powder can be applied to the substrate. In some embodiments, an optional sintering process can be used to infuse the hydrophobic material into the substrate to create the hydrophobic base layer for the working electrode <NUM>, where both sides of the hydrophobic base layer are hydrophobic. The sintering process can cause the hydrophobic polymer to bond or fuse with the carbon of the substrate to securely bond the hydrophobic material to the substrate.

In some embodiments, the sensor <NUM> may comprise a filter <NUM> deposited above the opening <NUM> of the sensor <NUM>, operable to filter a targeted gas. For example, the filter <NUM> may be operable to remove and/or absorb H<NUM>S gas. In some embodiments, the filter may comprise silver sulfate layered onto a substrate of PTFE powder.

The preparation method of the filter <NUM> may comprise grinding the silver sulfate and then, applying the silver sulfate to a PTFE emulsion, and stirring the mixture. In some embodiments, the mixture may comprise approximately <NUM> grams of silver sulfate and approximately <NUM> grams of the PTFE emulsion. Then, the mixture may be dried to form the filter <NUM>, for example at approximately <NUM>° C. for approximately <NUM> hours.

In fabricating the electrochemical HCN sensor <NUM>, a separator <NUM> may be first placed within housing <NUM>. The counter electrode <NUM> may then be placed into housing <NUM>. Another separator <NUM> may preferably then be placed within housing <NUM>, followed by reference electrode <NUM>. Yet another separator <NUM> may be subsequently placed within housing <NUM> followed by working electrode <NUM>. The working electrode <NUM> may be inserted face down whereas the counter electrode <NUM> may be oriented face up. After placement of the working electrode <NUM> within the housing <NUM>, the perimeter of the working electrode <NUM> may be heat sealed to a cap <NUM> which comprises the opening <NUM>. Then, the filter <NUM> may be placed against the cap <NUM>, which may be wrapped by a membrane. In some embodiments, a top cover <NUM> and dust cover <NUM> may be placed above the filter <NUM>. The top cover <NUM> may also comprise an opening <NUM>, which may be larger than opening <NUM>.

The interior of housing <NUM> may then be filled with an electrolyte via an opening <NUM> in the housing <NUM>. Upon filling of the interior of housing <NUM> with electrolyte, opening <NUM> may be sealed, optionally via heat sealing using a diffusion barrier through which gas is mobile but through which the electrolyte is substantially immobile. An example of a diffusion barrier suitable for use in the present invention is a Zintex® film. The separators <NUM> operate to prevent physical contact of the electrodes while allowing the liquid electrolyte to contact the electrodes, thereby providing ionic connection between working electrode <NUM> and counter electrode <NUM>. The separators <NUM> may comprise at least one material selected for the group consisting of fiberglass, fumed SiO<NUM>, Al<NUM>O<NUM>, TiO<NUM>, and ZrO<NUM>.

In some embodiments, a metal catalyst may be incorporated into one or more of the electrodes. The metal catalyst can be chosen from Au and Ag. And the corresponding electrolyte can be chosen from sulfuric acid with an additive of silver sulfate, and propylene carbonate with an addition of lithium perchlorate.

An exemplary Au electrode may comprise a substrate, and a carbon supported gold catalyst deposited on the substrate. In some embodiments, the carbon supported gold catalyst may comprise <NUM>-<NUM>% by weight of a hydrophilic material, <NUM>-<NUM>% by weight of gold, and <NUM> to <NUM>% by weight of a hydrophobic fluoropolymer blocking agent. In some embodiments, the carbon supported gold catalyst may include a hydrophilic aerogel with a weight percent of <NUM>-<NUM>%, a hydrophobic fluoropolymer adhesive with a weight percent of <NUM>-<NUM>%, gold with a weight percent of <NUM>-<NUM>%, and carbon particles with the weight percent of <NUM>-<NUM>%.

The carbon support may be solid, porous, absorbent carbon of any desired shape, form and size onto which the gold catalyst is deposited. Such electrodes may be prepared for example by impregnating the absorbent carbon with a solution of a gold salt decomposable to gold oxide, heating the impregnated carbon at an elevated temperature sufficient to effect said decomposition to the oxide followed by heating gold in the presence of hydrogen to reduce the gold oxide to the catalytically active free metal. The preferred electrodes may comprise carbon particles containing catalytic amounts of gold provided thereon by any suitable technique known in the art of catalyst preparation. A method of forming the catalyst may involve forming a solution of metallic gold or a salt thereof, impregnating carbon particles with the resulting solution, drying the impregnated carbon particles followed by heating at elevated temperatures, usually of at least <NUM>° F. , optionally <NUM>° F. in the presence of a reducing gas, such as hydrogen, so as to ensure conversion of the gold salt to its free metal state and provide an active catalyst. The carbon employed as the support can be any of the carbons conventionally employed as supports in the catalyst art.

The electrochemically active surface of one or more of the electrodes may comprise silver (Ag). The electrode(s) may be fabricated via deposition of an ink comprising silver metal powder and a dispersed Teflon® powder upon a Zintex® membrane. The ink may be deposited via silk screening upon a Zintex® film as known in the art in connection with deposition of electrochemically active materials upon GoreTex® films. Zintex® films were found to provide a good support for the electrochemically active material. The ink may also be deposited using hand painting techniques as known in the art. Some electrodes may be fabricated via silk screening a silver metal ink upon a Zintex® membrane. In some embodiments, a film of electrochemically active material having a thickness in the range of approximately <NUM> mil to <NUM> mil (or <NUM> to <NUM>) may be deposited upon the electrodes of the present invention. In some embodiments, the silver powder used to form the electrodes may comprise nanopowder.

<FIG> illustrate the results of testing two HCN electrochemical sensors, wherein a first sensor is illustrated in <FIG> and a second sensor is illustrated in <FIG>. The first sensor, illustrated in <FIG>, may comprise an electrochemical HCN sensor including Au electrodes and an electrolyte of approximately <NUM> of sulfur acid and with an additive of silver sulfate. The second sensor, illustrated in <FIG>, may comprise an electrochemical hydrogen cyanide sensor including Ag electrodes and an electrolyte of propylene carbonate with an addition of lithium perchlorate.

In <FIG>, the sensors have been exposed to approximately <NUM> ppm HCN. As shown in both graphs, the current over time as the sensors are exposed to the HCN gas increases to a level where the current may indicate the presence of HCN, thereby activating a notification and/or alarm by the sensor. In other words, the filter materials incorporated into the sensors may not affect the ability of the sensors to sufficiently detect and indicate the presence of the HCN gas.

<FIG> illustrates the results of testing the same two HCN electrochemical sensors as described in <FIG>, where the sensors may be exposed to approximately <NUM> ppm H<NUM>S gas. As shown in both graphs, the H<NUM>S gas does not increase the current reading to a level that would cause a false alarm in the sensor. For example, the current readings caused by exposure to H<NUM>S gas may be less than approximately <NUM>% of the current readings caused by exposure to HCN gas. In other words, a ratio of <NUM>) a sensitivity of the sensor to HCN to <NUM>) a sensitivity of the sensor to H<NUM>S is greater than about <NUM>. Therefore, the filter material incorporated into the sensors may sufficiently remove (or block) the H<NUM>S from the sensor.

While various embodiments in accordance with the principles disclosed herein have been shown and described above, modifications thereof may be made by one skilled in the art. The embodiments described herein are representative only and are not intended to be limiting. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention(s). Furthermore, any advantages and features described above may relate to specific embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages or having any or all of the above features.

Use of broader terms such as "comprises," "includes," and "having" should be understood to provide support for narrower terms such as "consisting of," "consisting essentially of," and "comprised substantially of. " Use of the terms "optionally," "may," "might," "possibly," and the like with respect to any element of an embodiment means that the element is not required, or alternatively, the element is required, both alternatives being within the scope of the embodiment(s). Also, references to examples are merely provided for illustrative purposes, and are not intended to be exclusive.

Claim 1:
A method for detecting hydrogen cyanide, HCN, the method comprising:
receiving an ambient gas into a housing (<NUM>) of a sensor (<NUM>), wherein the ambient gas comprises HCN gas and hydrogen sulfide, H<NUM>S, gas, and wherein the sensor (<NUM>) comprises a porous working electrode (<NUM>) and a counter electrode (<NUM>);
filtering the H<NUM>S gas from the ambient gas through a filter (<NUM>), wherein the filter (<NUM>) is incorporated into the sensor (<NUM>) and the filter (<NUM>) comprises <NUM> grams of silver sulfate layered onto an <NUM> grams of polytetrafluoroethylene, PTFE, support material;
applying a voltage potential between the counter electrode (<NUM>) and the porous working electrode (<NUM>);
contacting the ambient gas with the porous working electrode (<NUM>);
allowing the ambient gas to diffuse through the porous working electrode (<NUM>) to contact an electrolyte within the housing (<NUM>);
generating a current between the porous working electrode (<NUM>) and the counter electrode (<NUM>) in response to a reaction between the ambient gas and the electrolyte at a surface area of the porous working electrode (<NUM>); and
determining a concentration of the HCN in the ambient gas based on the current.