Compact High-Temperature Solid-State Potentiometric Oxygen Sensor

The Need

Oxygen sensors are crucial for monitoring oxygen levels in combustion and industrial processes, but current sensors require complex plumbing for reference gas, limiting their placement and operational temperature range. There is a pressing need for a robust, high-temperature oxygen sensor that is both compact and cost-effective, capable of functioning without external gas sources or complex setups.

The Technology

Our invention is an advanced solid-state potentiometric oxygen sensor designed to operate in extreme temperatures ranging from 450°C to 800°C, extendable up to 1600°C. This sensor utilizes a metal and metal oxide mixture enclosed within a homogeneous material, such as yttria-stabilized zirconium, capable of withstanding high temperatures and thermal cycling. The sensor's internal reference is sealed through plastic deformation, ensuring durability and eliminating the need for brittle glass seals. This compact design simplifies installation and enables precise oxygen level monitoring in harsh environments.

Commercial Applications

  • Combustion Systems: Monitoring oxygen levels directly within combustion chambers for optimized fuel efficiency.

  • Industrial Processes: Tracking oxygen content in effluent streams and industrial waste streams for regulatory compliance and process optimization.

  • Turbines: Enhancing performance and safety by monitoring oxygen levels in high-temperature turbine environments.

  • NOx Traps: Ensuring effective operation of NOx reduction systems by providing accurate oxygen measurements.


  • High-Temperature Operation: Capable of functioning in temperatures up to 1600°C, surpassing the limitations of conventional sensors.

  • Cost-Effective: Simplified design and fabrication process reduce manufacturing costs and complexity.

  • Robustness: Resistant to thermal cycling and harsh environmental conditions, ensuring long-term reliability.

  • Compact Design: Eliminates the need for external plumbing and bulky setups, allowing for flexible installation locations.

Patent Protection

  • United States Patent No. 8,012,323

  • United States Patent No. 8,057,652

  • United States Patent No. 8,152,980

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