Tape-cast sensors and method of making
AssigneeThe Regents of the University of California
InventorsRangachary Mukundan, Eric Brosha, Fernando Garzon
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Abstract
A method of making electrochemical sensors in which an electrolyte material is cast into a tape. Prefabricated electrodes are then partially embedded between two wet layers of the electrolyte tape to form a green sensor, and the green sensor is then heated to sinter the electrolyte tape around the electrodes. The resulting sensors can be used in applications such as, but not limited to, combustion control, environmental monitoring, and explosive detection. A electrochemical sensor formed by the tape-casting method is also disclosed.
Claims20
A method of making a solid state electrochemical sensor, the sensor comprising a plurality of electrodes partially disposed within an electrolyte, the method comprising the steps of:
- a) providing the electrolyte;
- b) casting the electrolyte to form an electrolyte tape, wherein the electrolyte tape has a wet first surface;
- c) providing the plurality of electrodes;
- d) contacting a portion of each of the plurality of electrodes with a first portion of the wet first surface;
- e) contacting a second portion of the wet first surface with the portion of each of the plurality of electrodes and the first portion of the wet first surface, wherein each of the plurality of electrodes is partially embedded within the electrolyte;
- f) drying the electrolyte tape and the partially enclosed first and second electrodes to form a green sensor body;
- and
- g) sintering the green sensor body to form the solid state electrochemical sensor.
A method of making a green sensor body, the method comprising the steps of:
- a) providing the electrolyte;
- b) casting the electrolyte to form an electrolyte tape, wherein the electrolyte tape has a wet first surface in contact with a carrier and a second surface opposite the wet first surface, the second surface being exposed to air;
- c) partially drying the second surface for a predetermined time;
- d) reversing the electrolyte tape such that the wet first surface is exposed to air and the partially dried second surface contacts the carrier;
- e) providing at least a first electrode and a second electrode;
- f) contacting a portion of each of the first electrode and the second electrode with a first portion of the wet first surface;
- g) contacting a second portion of the wet first surface with the portion of each of the first electrode and the second electrode and the first portion of the wet first surface, wherein the first and second electrodes are partially embedded within the electrolyte;
- and
- h) drying the electrolyte tape and the partially enclosed first electrode and second electrode to form a green sensor body.
A method of making a solid state mixed potential sensor, the sensor comprising at least a first electrode and a second electrode partially disposed within an electrolyte, the method comprising the steps of:
- a) providing the electrolyte;
- b) casting the electrolyte into an electrolyte tape, wherein the electrolyte tape has a wet first surface in contact with a carrier and a second surface opposite the wet first surface, the second surface being exposed to air;
- c) partially drying the second surface for a predetermined time;
- d) reversing the electrolyte tape such that the wet first surface is exposed to air and the partially dried second surface contacts the carrier, wherein the first surface is wet;
- e) providing at least a first electrode and a second electrode;
- f) contacting a portion of the first electrode and the second electrode with a first portion of the wet first surface;
- g) contacting a second portion of the wet first surface with the portion of the first electrode and the second electrode and the first portion of the wet first surface, wherein the first and second electrodes are partially embedded within the electrolyte tape;
- h) drying the electrolyte tape and the partially enclosed first and second electrodes to form a green sensor body;
- and
- i) sintering the green sensor body to form the solid state mixed potential sensor.
An electrochemical sensor, the sensor comprising:
- a) a tape-cast electrolyte, the tape-cast electrolyte having a first portion and a second portion;
- and
- b) a plurality of electrodes, wherein a portion of each of the plurality of electrodes is embedded between the first portion and the second portion of the tape-cast electrolyte.
A solid state electrochemical sensor, the sensor comprising a plurality of electrodes partially disposed within a tape-cast electrolyte, wherein the sensor is formed by:
- a) casting the electrolyte into an electrolyte tape, wherein the electrolyte tape has a wet first surface;
- b) contacting a portion of each of the plurality of electrodes with a first portion of the wet first surface;
- c) contacting a second portion of the wet first surface with the portion of each of the plurality of electrodes and the first portion of the wet first surface, wherein plurality of electrodes are partially embedded within the electrolyte tape;
- d) drying the electrolyte tape and the partially embedded first and second electrodes to form a green sensor body;
- and 1Q
- e) sintering the green sensor body to form the solid state mixed potential sensor.
Dependencies are inferred from the claim text.