WO2014048335A1 - 防爆型小型化可燃气体传感器 - Google Patents

防爆型小型化可燃气体传感器 Download PDF

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Publication number
WO2014048335A1
WO2014048335A1 PCT/CN2013/084260 CN2013084260W WO2014048335A1 WO 2014048335 A1 WO2014048335 A1 WO 2014048335A1 CN 2013084260 W CN2013084260 W CN 2013084260W WO 2014048335 A1 WO2014048335 A1 WO 2014048335A1
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WO
WIPO (PCT)
Prior art keywords
module
combustible gas
compensation
detection
explosion
Prior art date
Application number
PCT/CN2013/084260
Other languages
English (en)
French (fr)
Inventor
刘福霞
苏爱民
Original Assignee
华瑞科学仪器(上海)有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CN 201220510916 external-priority patent/CN202886313U/zh
Priority claimed from CN201210367286.8A external-priority patent/CN102879435B/zh
Application filed by 华瑞科学仪器(上海)有限公司 filed Critical 华瑞科学仪器(上海)有限公司
Priority to EP13841122.8A priority Critical patent/EP2884271A4/en
Priority to US14/432,092 priority patent/US9778217B2/en
Publication of WO2014048335A1 publication Critical patent/WO2014048335A1/zh

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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
    • G01N27/02—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance
    • G01N27/04—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating resistance
    • G01N27/14—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating resistance of an electrically-heated body in dependence upon change of temperature
    • G01N27/16—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating resistance of an electrically-heated body in dependence upon change of temperature caused by burning or catalytic oxidation of surrounding material to be tested, e.g. of gas
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
    • G01N27/02—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance
    • G01N27/04—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating resistance
    • G01N27/045—Circuits
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
    • G01N33/0004—Gaseous mixtures, e.g. polluted air
    • G01N33/0009—General constructional details of gas analysers, e.g. portable test equipment

Definitions

  • the present invention relates to a combustible gas detector having a strong explosion-proof capability and being small and portable.
  • BACKGROUND ART In order to prevent explosion of a combustible gas after reaching a certain concentration to ensure safe production, a flammable gas detecting and alarming device is often required in a factory or a place where a combustible gas is produced and used.
  • the main component of this flammable gas detection and alarm device is a combustible gas detector.
  • the existing combustible gas detectors are mainly composed of a gas sensitive original, a gas sensitive original fixing sleeve, a rain cover and a cable introducing device.
  • the flammable gas detector of this structure is not intrinsically safe, and is applied to the flammable gas environment to have a risk of detonating the surrounding environment, and often cannot meet the requirements of a more stringent explosion-proof grade. Therefore, an explosion-proof package is required.
  • Combustible Gas Detector The traditional flameproof package is a catalytic bead packaged in a stainless steel housing with a flame capture, extinguishing the sintered sheet, and the end is sealed with epoxy epoxy. According to the European and American standards for explosion-proof certification, if any explosion-proof housing is sealed by a sealant, the length of the sealant and the shell in the direction of the seal should not be less than 3 mm.
  • the general measurement methods of flammable gas sensors include: thermal conductivity detector, infrared detector, catalytic combustion detection, etc. These detection methods mostly adopt the calorimetric method, that is, the temperature of the sensitive component after combustion or flow absorption or infrared absorption. The heat is affected to detect the combustible gas. According to general common sense, any test involving calorimetry will be affected by changes in ambient temperature.
  • calorimetric sensors typically require a reference detector or reference element to counteract the effects of environmental factors such as temperature, humidity, pressure, and gas flow on the measurement of the sensing element.
  • the reference component needs to be infinitely consistent with the detection component in terms of temperature, humidity, pressure and airflow, so that the maximum compensation effect can be achieved.
  • current combustible gas sensors especially catalytic combustion or thermal conductivity sensors, are often not advanced due to product design and production processes, resulting in compensating effects of the reference components and their unsatisfactory results, that is, most manufacturers now produce
  • the combustible gas sensor has been compensated by the reference element, it still has significant effects such as temperature, humidity, pressure and air flow.
  • An object of the present invention is to provide an explosion-proof type miniaturized combustible gas sensor, which solves the problems of limited size, difficulty in miniaturization, and poor compensation of a combustible gas detector in the prior art.
  • the present invention provides an explosion-proof type miniaturized combustible gas sensor, comprising: a metal casing having an accommodation space therein; and having a space on one side of the metal casing a spatially connected gas-exchanged wire mesh for transporting the detected gas into the metal casing via the wire mesh; and a side opposite to the wire mesh and the other side opposite thereto a vertical vertical plane as a transmission surface of the combustible gas; an insulation module embedded in the accommodation space of the metal casing; a detection module sensitive to the combustible gas; insensitive to the combustible gas, and matched with the detection module
  • the compensation module has a higher flammable gas detection sensitivity than the compensation module; and the thermal insulation module, the detection module and the compensation module are disposed in the accommodating space of the metal casing a sealant, the bond length of the sealant located in the accommodating space of the metal casing as an effective bonding surface, the effective bonding surface and the The transmission surface of the com
  • the detecting module includes: a detecting component assembled in the heat insulating module, and a connecting body respectively connected to both ends of the detecting component and extending from a side of the metal casing via the sealing adhesive Pairing the detection pin;
  • the compensation module includes: a compensation component assembled in the heat insulation module and respectively connected to both ends of the compensation component and extending from the side of the metal casing via the sealant A pair of compensation pins.
  • the detecting module and the compensation module are fixed in the sensor by a fixing bracket, or the detecting module and the compensation module are coupled, nested or fastened to each other and fixed to each other. Inside the sensor.
  • the detecting module includes: a detecting component assembled in the heat insulating module, and a connecting body respectively connected to both ends of the detecting component and extending from a side of the metal casing via the sealing adhesive Pairing the detection pin;
  • the compensation module includes: a compensation component assembled in the heat insulation module and respectively connected to both ends of the compensation component and extending from the side of the metal casing via the sealant A pair of compensation pins.
  • the compensating element in the compensation module has a relatively low combustible gas detection sensitivity or even no combustible gas detection sensitivity compared to the detecting element in the detecting module.
  • the compensating module is matched with the detecting module, and the resistance of the compensation module is matched with the resistance of the detecting module; in a range of -40 ° C to +7 CTC, the detecting module and the detecting module
  • the ratio of the resistance of the compensation module ranges from 975 to 1 ⁇ 013.
  • the detecting module further includes a detection lead frame for supporting the pair of detecting pins, and the compensation module A compensation lead frame for supporting the pair of compensation pins is also included.
  • the thermal insulation material is composed of a thermal resistance material, and the thermal resistance material has a thermal conductivity of ⁇ 0.61.10.
  • the thermal resistance material is a gaseous state, a liquid state, or a solid state.
  • the inner wall of the metal casing is provided with a slot groove that is in contact with the sealant.
  • the coefficient of linear expansion of the sealant is 10- 6 in. / In. / ° C ⁇ 10- 5 in. / In. / ° C.
  • one surface of the metal casing is open, and the detecting module, the compensation module, and the heat insulating module are placed in the accommodating space in the metal casing via the opening, and the opening is opened by the sealing glue. The mouth is closed.
  • the explosion-proof miniaturized combustible gas sensor provided by the invention comprises a metal shell, a wire mesh provided on the metal shell, a heat insulating module embedded in the metal shell, and a detecting module assembled in the heat insulating module And the compensation module, as well as the sealant, such a structure has the following advantages:
  • the transfer surface of the flammable gas is perpendicular to the effective bonding surface of the sealant.
  • the bond length required for explosion-proof certification (for example, at least 3 mm) does not occupy the height of the sensor, thus reducing the overall height of the sensor.
  • the detection pins and compensation pins of the respective configurations are extended from the side of the metal casing, which greatly reduces the overall product compared to the prior art extending from the front or the bottom surface. Thickness, miniaturization of the product; further, an insulation module is placed around the detection module and the compensation module, so as to avoid a large gap between the two modules and the metal casing, thereby preventing heat loss In this way, the overall size of the sensor can be further reduced.
  • a detection module sensitive to a combustible gas and a compensation module insensitive to a combustible gas are provided, the detection module having a higher sensitivity of combustible gas detection than the compensation module, so-called combustible gas
  • the detection sensitivity refers to: a change rate of a physical quantity or a chemical quantity used to indicate a change of a combustible gas with a change in the concentration of the combustible gas.
  • the detection module and the compensation module are made into two independent modules, and the two modules are matched and matched during production preparation, and the matching is matched (for example, resistance pairing, so that the resistance values of the two are equal or very different. Small)
  • the encapsulation is then performed to avoid the problem of poor compensation, so that the compensation module can compensate for the influence of ambient temperature, humidity, pressure, airflow, etc. on the signal of the detection module.
  • Fig. 1 is a perspective view of an explosion-proof type miniaturized combustible gas sensor provided by the present invention.
  • Fig. 2 is an exploded perspective view showing the explosion-proof type compacted combustible gas sensor provided by the present invention.
  • the explosion-proof miniaturized combustible gas sensor 1 of the present invention comprises: a metal casing 11, a wire mesh 13, an insulation module 15, a detection module 17, a compensation module 19, and a sealant.
  • the metal housing 11 has an accommodation space therein.
  • the metal casing 11 is substantially in the shape of a hexahedron box, preferably made of a stainless steel material, having high strength and good heat dissipation performance.
  • One surface (for example, the bottom surface) of the metal casing 11 is open, so that the mounting of the detecting module 17, the compensation module 19, the heat insulating module 15, and the like into the metal casing 11 via the opening can be provided. In the space, the opening is then closed by the sealant.
  • a side surface of the metal casing 11 which is perpendicular to the open surface (referred to as a front surface in the following description) is provided with an opening, and a wire mesh 13 is sintered at the corresponding opening.
  • a vertical plane perpendicular to the side on which the wire mesh 13 is located and the other side opposite thereto is used as a transmission surface of the combustible gas (i.e., T shown in Fig. 1).
  • T the transmission surface of the combustible gas
  • the wire mesh 13 is in contact with the accommodating space of the metal casing 11, and not only has the effect of maintaining gas permeable for the gas to be detected to be transported through the wire mesh 13 into the metal casing 11 for gas exchange, and further, It has a protective effect to prevent the flame of the combustible gas from being transmitted to detonate the surrounding environment.
  • the wire mesh 13 is a stainless steel wire mesh, and the holes thereof may be set according to the requirements of the production process or the characteristics of the combustible gas.
  • the heat insulating module 15 is embedded in the accommodating space of the metal casing 11 for heat insulation.
  • the thermal insulation module 15 may be made of a heat-resistance material (for example, plastic), and the thermal resistance of the thermal resistance material is ⁇ 0.60 / (!11.10, the thermal resistance material is gaseous, liquid or
  • the solid state when the heat resistant material is solid, may be in the shape of a rod, a block, a sheet, or even a powder.
  • the present invention also A clip 14 for fixing the heat insulating module 15 is provided.
  • the clip 14 may be substantially ⁇ -shaped, and the heat insulating module 15 Hold it.
  • a sealant joint (for example, epoxy epoxy casting) is also used between the heat insulating module 15 and the metal casing 11 to seal any gap.
  • a flange, a peg or an extension for reinforcing the degree of bonding between the heat insulating module 15 and the metal casing 11 may be disposed on the outer wall of the heat insulating module 15; on the other hand, the metal casing 11
  • the inner wall is specially provided with a mouth groove (not shown in the drawing) which is in contact with the sealant, so that the sealant can be embedded in the groove when sealing, preventing the sealant from slipping out , enhance the degree of sealing of the seal.
  • the present invention is particularly stress on the material selection, the selected linear expansion coefficient is substantially epoxy printed oxy 10- 6 in. / In. / ° C ⁇ 10- 5 in. / In. / ° C, and the insulating module 15
  • Their material thermal expansion coefficients are close enough and close to the linear expansion coefficient of the metal casing 11, so that even the maximum and low temperatures of up to one month as specified by the explosion-proof certification standards (high temperature not less than 95 ° C and low temperature -40 °) C) Circulation, the bond strength between the sealant and the stainless steel shell can still be maintained, no cracks will occur, and the explosive test will not crack the shell of the metal shell 11 enough to resist the next up to 4 MPa. Static hydraulic pressure test.
  • the present invention provides a detection module 17 that is sensitive to combustible gases and a compensation module 19 that is insensitive to combustible gases.
  • the detecting module 17 and the compensating module 19 can be fixed in the metal housing 11 by a fixing bracket, but not limited thereto.
  • the detecting module 17 and the compensating module 19 can also be coupled to each other. , nested or fastened to be fixed to each other and fixed in the metal casing 11.
  • the detecting module 17 detects the flammable gas, and includes: a detecting element 171 assembled in the heat insulating module 15, a pair of detecting leads respectively connected to both ends of the detecting element 171 and extending from the side of the metal casing 11 via the sealant A foot 173, and a sense lead frame 175 for supporting the pair of sense pins 173.
  • the compensating module 19 is configured to compensate for the influence of the ambient temperature, the humidity, the pressure, the airflow, and the like on the signal of the detecting module 17, and includes: a compensating component 191 assembled in the heat insulating module 15 and respectively connected to the two ends of the compensating component 191 and from the metal shell A pair of compensation pins 193 extending from the side of the body 11 via the sealant, and a compensation lead frame 195 for supporting the pair of compensation pins 193. Since the detecting pin 173 and the compensating pin 193, which are respectively configured by the detecting module 17 and the compensating module 19, extend from the side of the metal casing 11, the product is greatly reduced compared to the prior art extending from the front or the bottom surface. The overall thickness enables the miniaturization of the product.
  • the detection module 17 and the compensation module 19 have substantially the same structure, and their main difference is that the detection element 171 in the detection module 17 has a higher combustible gas detection sensitivity than the compensation element 191 in the compensation module 19, that is, the detection module.
  • the detecting element 171 in 17 has a relatively high combustible gas detection sensitivity
  • the compensating element 191 in the compensating module 19 has a relatively low combustible gas detection sensitivity or even no combustible gas detection sensitivity.
  • the flammable gas detection sensitivity refers to: a change rate of a physical quantity or a chemical quantity used to indicate a change of a combustible gas with a change in the concentration of the combustible gas.
  • the detecting component 171 includes: a precious metal load member and a package on the precious metal load member
  • the precious metal load member is a Pt wire coil
  • the ceramic material member is further loaded with a simple substance or compound sensitive to the combustible gas.
  • the compensating element 191 comprises: a precious metal load member and a ceramic material member wrapped on the precious metal load member.
  • the precious metal load member is a Pt wire coil.
  • the explosion-proof miniaturized combustible gas sensor of the present invention fully considers this in design:
  • the detection module 17 and the compensation module 19 are designed as two independent hardware modules, and the two modules are pre-matched and matched during production preparation. After the operation is completed, the module is moved to the heat insulating module 15 for packaging, thereby avoiding the problem of poor compensation, so that the compensation module 19 can compensate for the influence of ambient temperature, humidity, pressure, airflow and the like on the signal of the detecting module 17.
  • the matching of the resistance of the compensation module 19 with the detection module 17 means that the resistance of the compensation module 19 matches the resistance of the detection module 17 (for example, resistance pairing, so that the resistance values of the two are equal or the difference is small. ).
  • the ratio of the ratio of the resistance of the detection module 17 to the compensation module 19 is from 983 to 1. 020.
  • the present invention also provides a fixed frame 16 for fixing the detection module 17 and the compensation module 19.
  • the fixing frame 16 serves as a connecting device between the heat insulating module 15 and the detecting module 17 and the compensation module 19.
  • one end of the fixing frame 16 is used for housing the heat insulating module 15, and the other end of the fixing frame 16 is used for receiving
  • the detection element 171 of the detection module 17 and the compensation element 191 of the compensation module 19 are placed.
  • the detecting module and the compensation module are fixed in the sensor by a fixing bracket, or the detecting module and the compensation module are coupled, nested or fastened to each other and fixed to each other. Inside the sensor.
  • the sealant (not shown in the drawings) is used to encapsulate the above-described heat insulating module 15, the detecting module 17, and the compensation module 19 in the accommodating space of the metal casing 11.
  • the bonding length of the sealant penetrating into the accommodating space of the metal casing 11 (corresponding to W shown in FIG. 1) as an effective bonding surface, the effective bonding surface and the The transmission surface of the combustible gas is perpendicular.
  • the effective bonding surface of the sealant does not affect the transmission surface of the combustible gas, and the bonding length required for the explosion-proof certification (for example, at least 3 mm) does not occupy the height of the sensor (ie, the transmission surface distance of the gas body)
  • the overall height of the sensor is reduced, so that the metal casing 11 can be made in a flat box shape, which can be as small as 14 mm * 14 mm * 5 mm (i.e., L*W* in Fig. 1) T), where 5 mm is the metal casing 11
  • the thickness corresponding to the transmission surface of the flammable gas is relatively small compared to the conventional sensor, which is generally not less than 8 mm.
  • the practical application example of the sensor disclosed in the patent is a catalytic combustion combustible gas detector, and the working principle is: the detecting component 171 in the detecting module 17 has catalytic combustion activity on methane; the compensation module 19 The compensating element 191 has no catalytic combustion activity for methane or has relatively low catalytic combustion activity. Therefore, when a combustible gas is present, the resistance of the detecting element 171 rises, and the resistance of the compensating element 191 decreases, does not change, or a relatively low amplitude rises.
  • the detecting element 171 and the working element can capture the relative change of the resistance of the two components, and the information is correlated with the concentration of the methane gas and passed through a predetermined calibration process to obtain the concentration value of the methane gas.
  • the detection module and compensation module of the insulation module, as well as the sealant have the following advantages:
  • the transfer surface of the flammable gas is perpendicular to the effective bonding surface of the sealant.
  • the bond length required for explosion-proof certification (for example, at least 3 mm) does not occupy the height of the sensor, thus reducing the overall height of the sensor.
  • the detection pins and compensation pins of the respective configurations are extended from the side of the metal casing, which greatly reduces the overall product compared to the prior art extending from the front or the bottom surface. Thickness, miniaturization of the product; further, an insulation module is placed around the detection module and the compensation module, so as to avoid a large gap between the two modules and the metal casing, thereby preventing heat loss In this way, the overall size of the sensor can be further reduced.
  • a detection module sensitive to combustible gases and a compensation module insensitive to combustible gases are provided, the detection module having a higher sensitivity to combustible gas detection than the compensation module.
  • the detection module and the compensation module are made into two independent modules, and the two modules are matched and matched during production preparation, and matched.

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Abstract

一种防爆型小型化可燃气体传感器（1），包括：金属壳体（11），内有容置空间；金属丝网（13），将与所述金属丝网（13）所在的侧面及与其相对的另一侧面相垂直的垂直面作为可燃气体的传输面；嵌入于金属壳体（11）内的绝热模块（15）；对可燃气体敏感的检测模块（17）；对可燃性气体不敏感、且与检测模块（17）相匹配的补偿模块（19）；所述检测模块（17）要比所述补偿模块（19）具有更高的催化燃烧活性；密封胶，密封胶位于金属壳体（11）的容置空间内的粘结长度作为有效粘结面，有效粘结面与传输面相垂直。本申请具有尺寸小型化、防爆性能强及性能可靠的优点。

Description

防爆型小型化可燃气体传感器
技术领域 本发明涉及一种具有强防爆能力、 小巧便携的可燃气体探测器。 背景技术 为防止可燃性气体达一定浓度后发生爆炸， 以保证安全生产， 在生产和使用可燃性气体 的工厂或场所常常需要设置可燃性气体检测报警装置。 这种可燃性气体检测报警装置的主要 构成部分是可燃气体探测器。 现有的可燃气体探测器主要是由气敏原件、 气敏原件固定套， 防雨罩及电缆引入装置构成。 目前这种结构的可燃气体探测器因为其非本质安全， 应用于可燃气体环境有引爆周围环 境的风险， 往往不能满足更严格的防爆等级的要求， 因此， 需要进行隔爆封装。 可燃气体检 测器传统的隔爆封装方式为催化珠封装在不锈钢壳体内， 该壳体带有火焰扑捉、 扑灭烧结 片， 并且末端使用环氧树脂 epoxy浇注防漏。 按欧洲北美等防爆认证的标准， 要求任何防爆 壳体若采用密封胶方式进行密封， 则密封胶与壳体的粘结沿着粘封的方向上的长度不应低于 3mm。 并且， 胶封这种设计必须具备足够大的尺寸才能保证具有隔爆效果。 因此， 传统的设 计尺寸往往较高， 无法实现小巧便携的可燃气体探测器。 可燃气体传感器一般测量手段包括： 热导检测器， 红外检测器， 催化燃烧检测等， 这些 检测手段大都采用量热的方式， 即通过可燃气体燃烧， 流动或红外吸收后对敏感元件的温度 或说热量造成影响而检测可燃气体的。 而根据一般的常识， 凡是涉及量热的检测一定会受到 周围环境温度变化的影响。 因此， 量热的传感器一般需要一个参比检测器或叫做参比元件， 用于抵消温度， 湿度， 压力和气流等环境因素对检测元件测量造成的影响。 显然， 参比元件 需要与检测元件在温度， 湿度， 压力和气流等若干因素无限一致， 这样才能做到最大的补偿 效果。 遗憾的是， 目前的可燃气体传感器， 尤其是催化燃烧或热导传感器往往由于产品设计 及生产工艺不够先进， 导致参比元件的补偿效果及其不理想， 也就是说， 现在大部分厂家生 产的可燃气体传感器尽管已经经过参比元件的补偿， 但仍具有显著的温度， 湿度， 压力以及 气流等效应。 发明内容 本发明的目的在于提供一种防爆型小型化可燃气体传感器， 解决现有技术中可燃气体检 测器尺寸受限、 难以小型化及补偿不佳等问题。 为解决上述问题及其他问题， 本发明提供一种防爆型小型化可燃气体传感器， 包括： 金 属壳体， 内有容置空间； 在所述金属壳体的其中一个侧面上设有与所述容置空间相接的进行 气体交换的金属丝网， 以供被检测气体经由所述金属丝网传输至所述金属壳体内； 将与所述 金属丝网所在的侧面及与其相对的另一侧面相垂直的垂直面作为可燃气体的传输面； 嵌入于 所述金属壳体的容置空间内的绝热模块； 对可燃气体敏感的检测模块； 对可燃性气体不敏 感、 且与所述检测模块相匹配的补偿模块;所述检测模块要比所述补偿模块具有更高的可燃 气体检测敏感性； 用以将上述的绝热模块、 检测模块以及补偿模块配置于所述金属壳体的容 置空间内的密封胶， 将所述密封胶位于所述金属壳体的容置空间内的粘结长度作为有效粘结 面， 所述有效粘结面与所述可燃气体的传输面相垂直。 可选地， 所述检测模块包括： 组装于所述绝热模块内的检测元件以及与所述检测元件的 两端分别连接、 且从所述金属壳体的侧面经由所述密封胶延伸出的一对检测引脚； 所述补偿 模块包括： 组装于所述绝热模块内的补偿元件以及与所述补偿元件的两端分别连接、 且从所 述金属壳体的侧面经由所述密封胶延伸出的一对补偿引脚。 可选地， 所述检测模块和所述补偿模块通过固定支架固定于所述传感器内， 或者， 所述 检测模块与所述补偿模块之间互相耦合、 嵌套或者卡牢以相互固定并固定于传感器内。 可选地， 所述检测模块包括： 组装于所述绝热模块内的检测元件以及与所述检测元件的 两端分别连接、 且从所述金属壳体的侧面经由所述密封胶延伸出的一对检测引脚； 所述补偿 模块包括： 组装于所述绝热模块内的补偿元件以及与所述补偿元件的两端分别连接、 且从所 述金属壳体的侧面经由所述密封胶延伸出的一对补偿引脚。 可选地， 所述补偿模块中的补偿元件与所述检测模块中的检测元件相比具有相对较低的 可燃气体检测敏感性甚至没有可燃气体检测敏感性。 可选地， 所述补偿模块与所述检测模块相匹配包括所述补偿模块的电阻与所述检测模块 的电阻相匹配； 在 -40°C至 +7CTC的范围内， 所述检测模块与所述补偿模块的电阻之比范围为 0. 975至 1· 013。 可选地， 所述检测模块还包括用于支撑所述一对检测引脚的检测引脚框， 所述补偿模块 还包括用于支撑所述一对补偿引脚的补偿引脚框。 可选地， 所述绝热模块由热阻材料构成， 所述热阻材料的导热系数〈0. 6 011. 10， 所述 热阻材料为气态、 液态或固态。 可选地， 所述金属壳体的内壁设置有与所述密封胶相接触的止口槽。 可选地， 所述密封胶的线膨胀系数为 10— 6 in. /in. /°C~10— 5 in. /in. /°C。 可选地， 所述金属壳体的一个面为敞口， 所述检测模块， 补偿模块， 绝热模块经由所述 敞口放入金属壳体内的容置空间， 由所述密封胶将所述敞口封闭。
本发明提供的防爆型小型化可燃气体传感器， 包括金属壳体、 设在所述金属壳体上的金 属丝网、 嵌入于所述金属壳体内的绝热模块、 组装于所述绝热模块的检测模块和补偿模块、 以及密封胶， 这样的结构具有如下优点：
1、 可燃气体的传输面与密封胶的有效粘结面相垂直， 这样， 防爆认证要求的粘结长度 (例如， 至少 3 mm) 不占据传感器的高度， 这样就减小了传感器的整体高度。 另外， 对于 检测模块和补偿模块， 其各自配置的检测引脚和补偿引脚是从金属壳体的侧面延伸出， 相比 于从正面或底面延伸出的现有技术， 大大降低了产品的整体厚度， 实现了产品的小型化； 再 有， 在检测模块和补偿模块的周围垫有绝热模块， 这样可避免因这两个模块与金属壳体之间 留有较大的空隙， 从而防止热量损失， 如此， 可以进一步减小传感器的整体尺寸。
2、 在本发明中， 提供了对可燃气体敏感的检测模块和对可燃性气体不敏感的补偿模 块， 所述检测模块要比所述补偿模块具有更高的可燃气体检测敏感性， 所谓可燃气体检测敏 感性是指： 用随可燃气体浓度的变化， 用于指示可燃气体变化的物理量或化学量的变化率。 特别地， 是将检测模块和补偿模块做成独立的两个模块， 并在生产制备时将这两个模块进行 配对匹配操作， 匹配 （例如： 电阻配对， 使得两者的电阻值相等或相差很小） 之后再进行封 装， 从而避免了补偿不佳的问题， 使得所述补偿模块可以补偿环境温度、 湿度以及压力、 气 流等对所述检测模块的信号造成的影响。
3、 所选用的密封胶的线膨胀系数 10— 6 in. /in. /°C ~10— 5 in. /in. /°C与不锈钢的线膨胀 系数接近， 这样， 即使经过防爆认证标准规定的长达一个月的极限高低温度循环， 密封胶与 不锈钢壳体之间仍能保持足够的粘结强度， 足以抵抗接下来的高达 4 MPa的静态水压压力测 试。 附图说明 图 1为本发明提供的防爆型小型化可燃气体传感器的立体图。 图 2为本发明提供的防爆型小型化可燃气体传感器的结构分解图。
Figure imgf000006_0001
具体实施方式 本发明的发明人发现： 现有的可燃气体传感器存在尺寸受限、 难以小型化及补偿不佳等 问题。 因此， 本发明的发明人对现有技术进行了改进， 提出了一种新型的防爆型小型化可燃 气体传感器， 将气体传输面与密封胶的有效粘结面垂直， 同时将各个引脚从金属壳体的侧面 延伸出， 从而降低了产品的整体厚度以实现小型化， 并通过将检测模块和补偿模块做成独立 的且相互匹配的两个模块， 从而避免了补偿不佳的问题。 以下通过特定的具体实例说明本发明的实施方式， 本领域技术人员可由本说明书所揭示 的内容轻易地了解本发明的其它优点与功效。 本发明还可以通过另外不同的具体实施方式加 以实施或应用， 本说明书中的各项细节也可以基于不同观点与应用， 在不背离本发明的精神 下进行各种修饰或改变。 须知， 本发明的一种防爆型小型化可燃气体传感器的说明书所附图式所绘示的结构、 比 例、 大小等， 均仅用以配合说明书所揭示的内容， 以供熟悉此技术的人士了解与阅读， 并非 用以限定本发明可实施的限定条件， 故不具技术上的实质意义， 任何结构的修饰、 比例关系 的改变或大小的调整， 在不影响本发明所能产生的功效及所能达成的目的下， 均应仍落在本 发明所揭示的技术内容得能涵盖的范围内。 同时， 本说明书中所引用的如 "上" 、 "下" 、 "左" 、 "右" 、 "中间"及 "一"等的用语， 亦仅为便于叙述的明了， 而非用以限定本发 明可实施的范围， 其相对关系的改变或调整， 在无实质变更技术内容下， 当亦视为本发明可 实施的范畴。
请参阅图 1和图 2， 分别显示为本发明提供的一种防爆型小型化可燃气体传感器的立体 图及其结构分解图。 结合图 1和图 2， 本发明防爆型小型化可燃气体传感器 1包括： 金属壳 体 11、 金属丝网 13、 绝热模块 15、 检测模块 17、 补偿模块 19、 以及密封胶。
以下对上述各个部件进行详细说明。
金属壳体 11， 内有容置空间。 在本实施例中， 金属壳体 11大致呈六面体的盒状， 较佳 地， 采用不锈钢材料制成， 具有高的强度及良好的散热性能。 所述金属壳体 11 的一个面 (例如， 底面） 为敞口， 这样， 就可以提供将检测模块 17、 补偿模块 19、 绝热模块 15等经 由所述敞口放入金属壳体 11 的容置空间中， 之后， 由所述密封胶将所述敞口封闭。 另外， 金属壳体 11 的与敞口面相垂直的一个侧面 （在以下描述将这一个侧面称为正面） 开设有一 个开口， 在对应所述开口处烧结有金属丝网 13。 在本发明中， 将与金属丝网 13所在的侧面 及与其相对的另一侧面相垂直的垂直面作为可燃气体的传输面 （即图 1 中所示的 T)。 可以 看出， 可燃气体的传输面即决定了传感器的整体高度。 在这里， 金属丝网 13与金属壳体 11 的容置空间相接， 不仅具有保持透气以供被检测气体经由金属丝网 13传输至金属壳体 11内 进行气体交换的效果， 进一步地， 更具防护效果以防止可燃气体的火焰传递出来引爆周围环 境。 较佳地， 金属丝网 13 为不锈钢丝网， 其孔目可按生产工艺的要求或可燃气体的特性而 设置。
绝热模块 15， 嵌入于金属壳体 11 的容置空间内， 用于起到绝热作用。 在本实施例中， 绝热模块 15可以采用热阻材料 （例如塑料） 制成， 所述热阻材料的导热系数〈0. 6 / (!11. 10， 所述热阻材料为气态、 液态或固态， 当所述热阻材料为固态时， 其形状可以是棒状、 块状、 片状、 甚至是粉末状。 一方面， 为使得绝热模块 15有效地嵌入于金属壳体 11内， 本发明还 提供了用于固定绝热模块 15 的夹子 14， 具体地， 夹子 14可以大致 Π 型， 将绝热模块 15 予以夹持。 另一方面， 为使得绝热模块 15与金属壳体 11更紧密地结合， 在绝热模块 15与 金属壳体 11之间还采用了密封胶连接 （例如环氧树脂 epoxy浇注）， 以封住任何缝隙。 更进 一步地： 一方面， 在绝热模块 15的外壁上还可以设置供增强绝热模块 15与金属壳体 11之 间结合度的法兰、 桩栓或延伸部等； 另一方面， 金属壳体 11 的内壁特别设置有与所述密封 胶相接触的止口槽 （未在图式中予以显示）， 这样， 就可以使得所述密封胶在密封时嵌入所 述止口槽， 防止密封胶滑出， 增强密封的结合度。 本发明在材料选择上格外讲究， 所选择的 环氧树脂印 oxy的线膨胀系数大致为 10—6 in. /in. /°C~10— 5 in. /in. /°C， 与绝热模块 15它们 的材料热膨胀系数足够接近， 并与金属壳体 11 的线膨胀系数接近， 这样， 即使经过防爆认 证标准规定的长达一个月的极限高低温度 （高温不小于 95°C和低温 -40°C ) 循环， 密封胶与 不锈钢壳体之间仍能保持足够的粘结强度， 不会产生裂缝， 爆炸性实验也不会使金属壳体 11壳体裂开， 足以抵抗接下来的高达 4 MPa的静态水压压力测试。
本发明提供了对可燃气体敏感的检测模块 17和对可燃性气体不敏感的补偿模块 19。 在 实际应用中， 检测模块 17和所述补偿模块 19可以通过固定支架固定于金属壳体 11 内， 但 并不以此为限， 例如， 检测模块 17与补偿模块 19之间还可以通过互相耦合、 嵌套或者卡牢 以相互固定并固定于金属壳体 11内。
检测模块 17检测可燃性气体， 包括： 组装于绝热模块 15内的检测元件 171、 与检测元 件 171 的两端分别连接并从金属壳体 11 的侧面经由所述密封胶延伸出的一对检测引脚 173、 以及用于支撑这一对检测引脚 173 的检测引脚框 175。 补偿模块 19 用于补偿环境温 度、 湿度、 压力、 气流等对检测模块 17信号造成的影响， 包括： 组装于绝热模块 15内的补 偿元件 191、 与补偿元件 191 的两端分别连接并从金属壳体 11 的侧面经由所述密封胶延伸 出的一对补偿引脚 193， 以及用于支撑这一对补偿引脚 193 的补偿引脚框 195。 由于检测模 块 17和补偿模块 19各自配置的检测引脚 173和补偿引脚 193是从金属壳体 11的侧面延伸 出， 相比于从正面或底面延伸出的现有技术， 大大降低了产品的整体厚度， 实现了产品的小 型化。 检测模块 17和补偿模块 19的结构基本相同， 它们的主要区别在于： 检测模块 17中的 检测元件 171要比补偿模块 19中的补偿元件 191具有更高的可燃气体检测敏感性， 即， 检 测模块 17中的检测元件 171具有相对较高的可燃气体检测敏感性， 补偿模块 19中的补偿元 件 191具有相对较低的可燃气体检测敏感性甚至没有可燃气体检测敏感性。 在这里， 所谓可 燃气体检测敏感性是指： 随可燃气体浓度的变化， 用于指示可燃气体变化的物理量或化学量 的变化率。 在本实施例中， 检测元件 171包括： 贵金属负载件和在所述贵金属负载件上包裹 的陶瓷材料件， 较佳地， 所述贵金属负载件为 Pt 丝线圈， 所述陶瓷材料件上还负载有对可 燃气体敏感的单质或化合物。 补偿元件 191包括： 贵金属负载件和在所述贵金属负载件上包 裹的陶瓷材料件， 较佳地， 所述贵金属负载件为 Pt丝线圈。 显然， 这检测模块 17和补偿模 块 19 的热导方面的性能须足够接近才能实现补偿的作用， 他们的热导性能越接近， 则环境 温度， 湿度， 压力以及气流对整个可燃气体传感器的性能影响越小。 但已有可燃气体传感器 由于结构设计缺陷， 往往做不到其中的检测部件和补偿部件足够匹配。 使得可燃气体传感器 性能明显逊色， 或者需要额外的补偿。 而本发明的防爆型小型化可燃气体传感器在设计上充 分考虑了这一点： 将检测模块 17和补偿模块 19设计为两个独立的硬件模块， 在生产制备时 将这两个模块预先进行配对匹配操作， 待匹配操作完成之后再移往绝热模块 15 进行封装， 从而避免了补偿不佳的问题， 使得补偿模块 19 可以补偿环境温度、 湿度以及压力、 气流等 对检测模块 17 的信号造成的影响。 在实际应用中， 上述补偿模块 19 的电阻与检测模块 17 相匹配指的是补偿模块 19的电阻与检测模块 17的电阻相匹配 （例如： 电阻配对， 使得两者 的电阻值相等或相差很小）。 具体地， 检测模块 17与补偿模块 19的电阻之比范围为 0. 93至 1. 07， 进一步地， 检测模块 17与补偿模块 19的电阻之比范围为 0. 983 至 1. 020。 特别地， 在 -40°C至 +7CTC的范围内， 所述检测模块与所述补偿模块的电阻之比范围为 0. 975 至 1. 013。 为使得检测模块 17和补偿模块 19牢固地封装于绝热模块 15 内， 本发明还提供了用于 固定检测模块 17和补偿模块 19的固定框架 16。 在使用时， 固定框架 16作为绝热模块 15 与检测模块 17、 补偿模块 19之间的连接装置， 具体地， 固定框架 16 的一端用于收置绝热 模块 15， 固定框架 16的另一端用于收置检测模块 17的检测元件 171和补偿模块 19的补偿 元件 191。 实际应用中， 所述检测模块和所述补偿模块通过固定支架固定于所述传感器内， 或者， 所述检测模块与所述补偿模块之间互相耦合、 嵌套或者卡牢以相互固定并固定于传感 器内。
密封胶 （未在图式中予以显示） 是用以将上述的绝热模块 15、 检测模块 17 以及补偿模 块 19封装于所述金属壳体 11 的容置空间内。 在本发明中， 所述密封胶渗入金属壳体 11 的 容置空间内的粘结长度 （与图 1中所示的 W相对应） 作为有效粘结面， 所述有效粘结面与所 述可燃气体的传输面相垂直。 这样， 所述密封胶的有效粘结面与所述可燃气体的传输面相互 不影响， 防爆认证要求的粘结长度 （例如， 至少 3 mm) 不占据传感器的高度 （即可燃气体 的传输面距离）， 这样就减小了传感器的整体高度， 从而金属壳体 11可制成呈扁平型盒状， 其尺寸可以小到 14 mm * 14 mm * 5 mm (即， 图 1中的 L*W*T)， 其中， 5 mm为金属壳体 11 中与所述可燃性气体的传输面相对应的厚度， 相比于传统传感器一般不小于 8 mm 的高度， 要相对小得多。 本专利所公开的传感器的实际应用例： 本发明的可燃气体传感器一种为催化燃烧可燃气体检测器， 其工作原理是： 检测模块 17中的检测元件 171对甲烷有催化燃烧活性； 补偿模块 19中的补偿元件 191对甲烷无催化 燃烧活性或者有相对较低的催化燃烧活性。 因此， 当有可燃气体出现时， 检测元件 171的电 阻升高， 补偿元件 191的电阻降低、 不变或者相对低的幅度升高。 通过惠斯通电桥将检测元 件 171与工作元件可以扑捉到二者电阻相对变化的信息， 将这一信息与甲烷气体浓度关联并 通过预先的标定处理， 即可得到甲烷气体的浓度值。
综上所述， 本发明提供的防爆型小型化可燃气体传感器， 包括金属壳体、 设在所述金属 壳体上的金属丝网、 嵌入于所述金属壳体内的绝热模块、 组装于所述绝热模块的检测模块和 补偿模块、 以及密封胶， 这样的结构具有如下优点：
1、 可燃气体的传输面与密封胶的有效粘结面相垂直， 这样， 防爆认证要求的粘结长度 (例如， 至少 3 mm) 不占据传感器的高度， 这样就减小了传感器的整体高度。 另外， 对于 检测模块和补偿模块， 其各自配置的检测引脚和补偿引脚是从金属壳体的侧面延伸出， 相比 于从正面或底面延伸出的现有技术， 大大降低了产品的整体厚度， 实现了产品的小型化； 再 有， 在检测模块和补偿模块的周围垫有绝热模块， 这样可避免因这两个模块与金属壳体之间 留有较大的空隙， 从而防止热量损失， 如此， 可以进一步减小传感器的整体尺寸。
2、 在本发明中， 提供了对可燃气体敏感的检测模块和对可燃性气体不敏感的补偿模 块， 所述检测模块要比所述补偿模块具有更高的可燃气体检测敏感性。 特别地， 是将检测模 块和补偿模块做成独立的两个模块， 并在生产制备时将这两个模块进行配对匹配操作， 匹配
(例如： 电阻配对， 使得两者的电阻值相等或相差很小） 之后再进行封装， 从而避免了补偿 不佳的问题， 使得所述补偿模块可以补偿环境温度、 湿度以及压力、 气流等对所述检测模块 的信号造成的影响。
3、 所选用的密封胶的线膨胀系数 10—6 in. /in. /V ~10— 5 in. /in. /°C与不锈钢的线膨胀 系数接近， 这样， 即使经过防爆认证标准规定的长达一个月的极限高低温度循环， 密封胶与 不锈钢壳体之间仍能保持足够的粘结强度， 足以抵抗接下来的高达 4 MPa的静态水压压力测 试。
上述实施例仅列示性说明本发明的原理及功效， 而非用于限制本发明。 任何熟悉此项技 术的人员均可在不违背本发明的精神及范围下， 对上述实施例进行修改。 因此， 本发明的权 利保护范围， 应如权利要求书所列

Claims

权利要求书
1、 一种防爆型小型化可燃气体传感器， 其特征在于， 包括：
金属壳体， 内有容置空间；
在所述金属壳体的其中一个侧面上设有与所述容置空间相接的进行气体交换的金属丝 网， 以供被检测气体经由所述金属丝网传输至所述金属壳体内； 将与所述金属丝网所在的侧 面及与其相对的另一侧面相垂直的垂直面作为可燃气体的传输面；
嵌入于所述金属壳体的容置空间内的绝热模块；
对可燃气体敏感的检测模块；
对可燃性气体不敏感、 且与所述检测模块相匹配的补偿模块;所述检测模块要比所述补 偿模块具有更高的可燃气体检测敏感性；
用以将上述的绝热模块、 检测模块以及补偿模块配置于所述金属壳体的容置空间内的密 封胶， 将所述密封胶位于所述金属壳体的容置空间内的粘结长度作为有效粘结面， 所述有效 粘结面与所述可燃气体的传输面相垂直。
2、 如权利要求 1 所述的防爆型小型化可燃气体传感器， 其特征在于， 所述检测模块和所述 补偿模块通过固定支架固定于所述传感器内， 或者， 所述检测模块与所述补偿模块之间互相 耦合、 嵌套或者卡牢以相互固定并固定于传感器内。
3、 如权利要求 1 所述的防爆型小型化可燃气体传感器， 其特征在于， 所述检测模块包括： 组装于所述绝热模块内的检测元件以及与所述检测元件的两端分别连接、 且从所述金属壳体 的侧面经由所述密封胶延伸出的一对检测引脚； 所述补偿模块包括： 组装于所述绝热模块内 的补偿元件以及与所述补偿元件的两端分别连接、 且从所述金属壳体的侧面经由所述密封胶 延伸出的一对补偿引脚。
4、 如权利要求 3 所述的防爆型小型化可燃气体传感器， 其特征在于， 所述补偿模块中的补 偿元件与所述检测模块中的检测元件相比具有相对较低的可燃气体检测敏感性甚至没有可燃 气体检测敏感性。
5、 如权利要求 1、 3或 4所述的防爆型小型化可燃气体传感器， 其特征在于， 所述补偿模块 与所述检测模块相匹配包括所述补偿模块的电阻与所述检测模块的电阻相匹配； 在 -40°C至 +70°C的范围内， 所述检测模块与所述补偿模块的电阻之比范围为 0.975至 1.013。
6、 如权利要求 3 所述的防爆型小型化可燃气体传感器， 其特征在于， 所述检测模块还包括 用于支撑所述一对检测引脚的检测引脚框， 所述补偿模块还包括用于支撑所述一对补偿引脚 的补偿引脚框。
7、 如权利要求 1 所述的防爆型小型化可燃气体传感器， 其特征在于， 所述绝热模块由热阻 材料构成， 所述热阻材料的导热系数 <0.6w/(m.K)， 所述热阻材料为气态、 液态或固态。
8、 如权利要求 1 所述的防爆型小型化可燃气体传感器， 其特征在于， 所述金属壳体的内壁 设置有与所述密封胶相接触的止口槽。
9、 如权利要求 1 所述的防爆型小型可燃气体传感器， 其特征在于， 所述密封胶的线膨胀系 数为 10—6 in./in./。C ~10"5 in./in./。C。
10、 如权利要求 1所述的防爆型小型化可燃气体传感器， 其特征在于， 所述金属壳体的一个 面为敞口， 所述检测模块， 补偿模块， 绝热模块经由所述敞口放入金属壳体内的容置空间， 由所述密封胶将所述敞口封闭。
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