Self-calibrating carbon monoxide detector and method

A carbon monoxide sensor assembly, comprising:

• a can forming a water reservoir therein;
• a bottom disk positioned within said can to separate said water reservoir from an upper sensor portion of said can, said bottom disk including at least one aperture therein;
• a hydrophobic layer positioned on said bottom disk covering said at least one aperture;
• an electrode assembly positioned on said hydrophobic layer;
• a first washer positioned on said electrode assembly, said first washer having an outer periphery that is closely accommodated by an inner surface of said can, said first washer further defining a hole therein having a diameter that is smaller than a diameter of said electrode assembly;
• a diffusion layer positioned on said first washer;
• a second washer positioned on said diffusion layer, said second washer having an outer periphery that is closely accommodated by said inner surface of said can, said second washer further defining a hole therein having a diameter that is smaller than a diameter of said diffusion layer;
• a gasket positioned on said second washer;
• and
• a top disk in sealing engagement with said gasket, said top disk defining an aperture therein;
• and
• wherein said can is crimped to seal said carbon monoxide sensor assembly, said diffusion layer being deformed therein to provide electrical contact between said top disk and a top of said electrode assembly, electrical contact between a bottom of said electrode assembly and said can being provided by said hydrophobic layer and said bottom disk.

A carbon monoxide gas generator assembly, comprising:

• a can forming a water reservoir therein;
• a bottom disk positioned within said can to separate said water reservoir from an upper generator portion of said can, said bottom disk including at least one aperture therein;
• a hydrophobic layer positioned on said bottom disk covering said at least one aperture;
• an electrode assembly positioned on said hydrophobic layer, said electrode assembly comprising an ion exchange membrane having electrodes deposited on an upper and on a lower surface thereof, said electrodes containing a mixture of carbon black and ion exchange polymer and no platinum;
• a diffusion layer;
• a gasket;
• and
• a top disk in sealing engagement with said gasket, said top disk defining an aperture therein;
• and
• wherein said can is crimped to seal said carbon monoxide gas generator assembly, said diffusion layer providing electrical contact between said top disk and a top of said electrode assembly, electrical contact between a bottom of said electrode assembly and said can being provided by said hydrophobic layer and said bottom disk.

A carbon monoxide gas generator assembly, comprising:

• a can forming a water reservoir therein;
• a bottom disk positioned within said can to separate said water reservoir from an upper generator portion of said can, said bottom disk including at least one aperture therein;
• a hydrophobic layer positioned on said bottom disk covering said at least one aperture containing no platinum;
• an electrode assembly positioned on said hydrophobic layer, said electrode assembly comprising an ion exchange membrane;
• a diffusion layer containing no platinum positioned to contact said electrode assembly;
• a gasket;
• and
• a top disk in sealing engagement with said gasket, said top disk defining an aperture therein;
• and
• wherein said can is crimped to seal said carbon monoxide gas generator assembly, said diffusion layer providing electrical contact between said top disk and a top of said electrode assembly, electrical contact between a bottom of said electrode assembly and said can being provided by said hydrophobic layer and said bottom disk.

A method of calibrating a carbon monoxide detector having a carbon monoxide sensor and a carbon monoxide gas generator in gaseous communication, comprising the steps of:

• controlling the carbon monoxide gas generator to generate a known quantity of carbon monoxide;
• monitoring a response of the carbon monoxide sensor to the known quantity of carbon monoxide;
• and
• correcting a calibration of the carbon monoxide sensor when the response is outside of a predetermined range.