# US 10,119,932 B2 · Electrochemical gas sensor

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- Number: US 10,119,932 B2
- Document ID: US10119932B2
- Status: Granted
- Kind: B2
- Application number: 14/289,222
- Filed: 2014-05-28
- Published: 2015-12-03
- Granted: 2018-11-06
- Earliest claimed: 2014-05-28
- Assignees: Honeywell International Inc.
- Applicants: Honeywell International Inc.
- Inventors: Ling Liu; Yan Zhang; Qian Zheng
- Web page: https://patentgrep.com/patent/US10119932B2

## CPC

- G01N 27/403: Cells and electrode assemblies
- C23C 30/00: Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process (C23C26/00, C23C28/00 take precedence)
- G01N 27/404: Cells with anode, cathode and cell electrolyte on the same side of a permeable membrane which separates them from the sample fluid {, e.g. Clark-type oxygen sensors}
- G01N 27/4045: {for gases other than oxygen}
- H01M 4/8807: {Gas diffusion layers}
- H01M 4/8832: {Ink jet printing}
- H01M 4/8882: {Heat treatment, e.g. drying, baking}
- B05D 1/26: performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
- B05D 1/28: performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
- B05D 3/02: by baking {(B05D3/04 takes precedence)}
- B05D 5/12: to obtain a coating with specific electrical properties
- H01M 4/8668: {Binders}
- H01M 4/8828: {Coating with slurry or ink}
- H01M 4/90: Selection of catalytic material
- H05K 3/12: using {thick film techniques, e.g.} printing techniques to apply the conductive material {or similar techniques for applying conductive paste or ink patterns}
- H05K 3/125: {by ink-jet printing}
- H05K 3/227: {Drying of printed circuits}
- Y02E 60/50: Fuel cells
- G01N: INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES (measuring or testing apparatus or processes other than immunoassay, involving enzymes or microorganisms C12M, C12Q)
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A gas detector includes an electrochemical gas sensor. The sensor includes a plurality of electrodes. At least one of the electrodes is formed of a catalyst/binder slurry which is halftone printed onto a substrate. The composite printed element and substrate are sintered to form the electrode.

## Claims

### Claim 1

A method comprising:
heating a slurry prior to halftone printing the slurry;
providing the slurry comprising at least a catalyst and a binder;
halftone printing the slurry in a selected shape onto a porous substrate;
sintering the printed shape and associated substrate; and
incorporating the sintered shape and the associated substrate as an electrode into an electrochemical sensor;
wherein a composition of the slurry comprises 75% weight Platinum black, 10% weight graphite and 15% weight perfluorinated ion electrolyte solution;
wherein a response time for the electrochemical sensor comprising the composition is between 24 and 47 seconds for 20.9% oxygen in air.

### Claim 2

A method comprising:
heating a slurry prior to halftone printing the slurry;
providing the slurry comprising at least a catalyst and a binder;
halftone printing the slurry in a selected shape onto a porous substrate;
sintering the printed shape and associated substrate; and
incorporating the sintered shape and the associated substrate as an electrode into an electrochemical sensor;
wherein the slurry further comprises a diluent comprising glycol;
wherein a response time for the electrochemical sensor is between 231 and 254 seconds for nitrogen.

### Claim 3 (depends on 2)

A method as in claim 2, wherein the binder comprises a perfluorinated ion electrolyte solution.

### Claim 4 (depends on 2)

A method as in claim 2, wherein the catalyst comprises at least one of: platinum, platinum black, a mixture of graphite and platinum, a mixture of carbon and platinum black, a noble metal, or mixtures thereof.

### Claim 5 (depends on 4)

A method as in claim 4, wherein the binder comprises at least one of a perfluorinated ion electrolyte solution or a copolymer of tetrafluoroethylene and a sulfonic acid.