# US 11,994,490 B2 · Electrochemical gas sensor assembly

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- Number: US 11,994,490 B2
- Document ID: US11994490B2
- Status: Granted
- Kind: B2
- Application number: 18/165,712
- Filed: 2023-02-07
- Published: 2023-06-22
- Granted: 2024-05-28
- Earliest claimed: 2018-12-29
- Assignees: Honeywell International Inc.
- Applicants: Honeywell International Inc.
- Inventors: Johnny Jian; Neils Hansen; Keith Francis Edwin Pratt; Paul Westmarland; Fuxia Liu
- Web page: https://patentgrep.com/patent/US11994490B2

## CPC

- 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 27/40: Semi-permeable membranes or partitions
- G01N 27/413: Concentration cells using liquid electrolytes {measuring currents or voltages in voltaic cells}
- G01N 33/0009: {General constructional details of gas analysers, e.g. portable test equipment (devices for withdrawing samples in the gaseous state G01N1/22)}
- G01N 27/4078: {Means for sealing the sensor element in a housing}
- 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)

## Abstract

Various example embodiments described herein relate to an electrochemical gas sensor. The electrochemical gas sensor can include a sensor cap having one or more solid features disposed on a surface of the sensor cap. The electrochemical gas sensor can include a counter electrode configured to generate a gas during use of the electrochemical gas sensor. The electrochemical gas sensor can include a vent assembly adapted to release at least a portion of the gas generated at the counter electrode out from the electrochemical gas sensor. The vent assembly can include a vent conduit and a vent membrane that defines a passage for the gas to flow from an extended portion of the counter electrode, to the vent conduit, via the vent membrane, so as to be vented from the electrochemical gas sensor.

## Claims

### Claim 1

An electrochemical gas sensor comprising:
a sensor cap comprising a plurality of solid features defined on a surface of the sensor cap;
a counter electrode configured to generate a gas; and
a vent assembly adapted to release at least a portion of the gas generated at the counter electrode out of the electrochemical gas sensor, wherein the vent assembly comprises a vent conduit and a vent membrane, wherein the plurality of solid features on the sensor cap define a cavity between an internal surface of the plurality of solid features and the vent membrane.

### Claim 2 (depends on 1)

The electrochemical gas sensor of claim 1, wherein the cavity is operable to accumulate at least a portion of the gas released out through the vent membrane before the at least the portion of the gas vents out through the vent conduit.

### Claim 3 (depends on 1)

The electrochemical gas sensor of claim 1, wherein the vent conduit is defined by an aperture from an outside surface of the sensor cap, through the sensor cap, and to a portion of an inner surface of the sensor cap corresponding to a portion of the vent membrane, and wherein the sensor cap is positioned at a top end of the electrochemical gas sensor.

### Claim 4 (depends on 1)

The electrochemical gas sensor of claim 1, wherein the vent membrane is positioned over the counter electrode so that a portion of the vent membrane overlaps with an extended portion of the counter electrode, thereby defining a passage for oxygen generated at the counter electrode to flow through the extended portion into the vent membrane, and further vent out through the sensor cap of the electrochemical gas sensor, via the vent conduit, and wherein the extended portion of the counter electrode extends out from one end through a periphery of a substrate of the counter electrode.

### Claim 5 (depends on 4)

The electrochemical gas sensor of claim 4, wherein the extended portion of the counter electrode comprises a first synthetic polymer having a first porosity.

### Claim 6 (depends on 5)

The electrochemical gas sensor of claim 5, wherein the vent membrane comprises a second synthetic polymer having a second porosity lower than the first porosity and a water ingress pressure within a defined range.

### Claim 7

A gas sensor cap for an electrochemical gas sensor comprising:
a housing, wherein a portion of the housing comprises an aperture through at least one surface of the housing, the aperture dimensioned and configured to prevent water ingress to the electrochemical gas sensor and allow gas egress from the electrochemical gas sensor; and
a plurality of solid features disposed on the at least one surface of the portion of the housing wherein a vent membrane is adapted to be heat sealed at a portion of the gas sensor cap, and wherein the plurality of solid features defines a cavity between an internal surface of a plurality of pillar shaped moldings and a portion of the vent membrane.

### Claim 8 (depends on 7)

The gas sensor cap of claim 7, wherein the gas sensor cap is adapted to be engaged at a top end of the electrochemical gas sensor, and wherein the aperture is in fluidic communication with a portion of the electrochemical gas sensor comprising a counter electrode.

### Claim 9 (depends on 8)

The gas sensor cap of claim 8, wherein upon engagement with the electrochemical gas sensor, the gas sensor cap is adapted to vent out the gas generated inside the electrochemical gas sensor through a top end of the gas sensor cap.

### Claim 10 (depends on 7)

The gas sensor cap of claim 7, wherein the vent membrane comprises a synthetic polymer having a porosity within a first defined range and a water ingress pressure within a second defined range.

### Claim 11 (depends on 7)

The gas sensor cap of claim 7, wherein the cavity is operable to accumulate at least a portion of the gas generated at a counter electrode of the electrochemical gas sensor and released out through the vent membrane before the gas vents out through a vent conduit, and wherein the vent membrane of the gas sensor cap is in fluidic communication with the counter electrode of the electrochemical gas sensor.

### Claim 12

An electrochemical oxygen sensor comprising:
a sensor cap comprising a plurality of pillar shaped moldings on a top surface of the sensor cap;
a counter electrode operable to generate oxygen;
a venting system comprising:
a vent membrane dimensioned and configured to have a porosity,
a vent conduit defined by an aperture in the sensor cap that is dimensioned and configured such that gas can vent from the electrochemical oxygen sensor and water is prevented from entering the electrochemical oxygen sensor at least partially through capillary forces, and
an extended portion of the counter electrode, wherein the extended portion of the counter electrode extends out from one end through a periphery of a substrate of the counter electrode.

### Claim 13 (depends on 12)

The electrochemical oxygen sensor of claim 12, wherein the venting system is operable to provide a passage to the oxygen generated at the counter electrode via the extended portion of the counter electrode to the vent membrane and further via the vent conduit through the top surface of the sensor cap.

### Claim 14 (depends on 12)

The electrochemical oxygen sensor of claim 12, wherein the sensor cap is positioned at a top end of the electrochemical oxygen sensor, and wherein the vent conduit comprises a channel defined from an open end at the top surface of the sensor cap, through the sensor cap, to one another end at a bottom surface of the sensor cap and further to a portion of the vent membrane.

### Claim 15 (depends on 14)

The electrochemical oxygen sensor of claim 14, wherein the extended portion of the counter electrode comprises a first synthetic polymer having a first porosity within a defined first range.

### Claim 16 (depends on 15)

The electrochemical oxygen sensor of claim 15, wherein the vent membrane comprises a second synthetic polymer having a second porosity within a defined second range and a water ingress pressure within a defined range.

### Claim 17 (depends on 12)

The electrochemical oxygen sensor of claim 12, wherein the vent membrane is positioned over the counter electrode so that a portion of the vent membrane overlaps with the extended portion of the counter electrode, thereby defining a passage for the oxygen generated at the counter electrode to flow through the extended portion into the vent membrane and vent out through a top end of the electrochemical oxygen sensor via an opening of the vent conduit.

### Claim 18 (depends on 12)

The electrochemical oxygen sensor of claim 12, wherein the plurality of pillar shaped moldings on the sensor cap defines a cavity between an internal surface of the plurality of pillar shaped moldings and the vent membrane.

### Claim 19 (depends on 18)

The electrochemical oxygen sensor of claim 18, wherein the cavity is operable to accumulate the oxygen released out through the vent membrane before the oxygen vents out through the vent conduit.