Housing apparatus for sensitive gas sensor

1. A sensor housing apparatus, comprising:

a housing defining a central longitudinal axis, the housing including:

an enclosure including first and second shells coaxially arranged with respect to a central longitudinal axis extending through the enclosure, the first shell defining an opening therethrough;

an outer assembly including at least one outer shell disposed in spaced relation to the first shell of the enclosure;

at least one flow path defined between the first shell of the enclosure and the at least one outer shell of the outer assembly to permit passage of air, and being in fluid communication with the opening in the first shell of the enclosure;

a filter membrane positioned adjacent the opening in the first shell of the enclosure;

a gas sensor disposed in the enclosure in alignment with the opening, the gas sensor configured to detect presence of gas in the air passing along the at least one flow path, through the filter membrane and entering the opening in the first shell;

a thermal mass mounted within the enclosure in thermal communication with the gas sensor, the thermal mass configured to:

transfer thermal energy from the gas sensor to an ambient environment surrounding the housing; and

minimize temperature gradients adjacent the gas sensor.

2. The sensor housing apparatus according to claim 1 wherein the outer assembly includes a lower outer shell and an upper outer shell, each of the lower outer shell and the upper outer shell being in spaced relation to the enclosure, the lower outer shell and the enclosure defining a first flow path therebetween in communication with the opening in the first shell of the enclosure, the upper outer shell and the enclosure defining a second flow path therebetween.

3. The sensor housing apparatus of claim 2 wherein the filter membrane is disposed within the enclosure.

4. The sensor housing apparatus of claim 3 wherein the filter membrane is configured to minimize transfer of thermal energy to the gas sensor.

5. The sensor housing apparatus of claim 3 wherein the gas sensor is spaced from the filter membrane a predetermined distance, the predetermined distance being less than 2 millimeters (mm).

6. The sensor housing apparatus of claim 2 including a thermally resistant spacer positioned within the enclosure adjacent the gas sensor, the spacer configured to minimize transfer of thermal energy to the gas sensor.

7. The sensor housing apparatus of claim 2 wherein the spacer is an annular gasket.

8. The sensor housing apparatus of claim 1 including an enclosure wall extending from the thermal mass to the first wall of the enclosure to enclose the gas sensor and the thermally resistant spacer.

9. The sensor housing apparatus of claim 1 wherein the gas sensor is an optical gas sensor.

10. The sensor housing apparatus of claim 9 including a thermally conductive pedestal in thermal contact with the optical gas sensor and the thermal mass.

11. The sensor housing apparatus of claim 2 including a base adjacent the lower shell of the outer assembly, the base including circuitry to control operation of the gas sensor.

12. The sensor housing apparatus of claim 1 wherein the thermal mass comprises one of aluminum, copper or graphite.

13. A sensor housing apparatus, comprising:

an enclosure including first and second shells, the first shell defining an opening therethrough;

an outer assembly including a lower outer shell and an upper outer shell;

a first flow path defined between the lower outer shell of the outer assembly and the first shell of the enclosure, and being in fluid communication with the opening in the first shell of the enclosure;

a second flow path defined between the upper outer shell of the outer assembly and the second shell of the enclosure;

a filter membrane positioned adjacent the opening in the first shell of the enclosure;

an optical gas sensor disposed in the enclosure in alignment with the opening, the gas sensor configured to detect presence of gas in the air passing from the at least one flow path and through the opening in the first shell; and

a thermal mass mounted within the enclosure in thermal communication with the gas sensor, the thermal mass configured to establish an overall thermal resistance R T with an ambient environment less than 30° C./W and a thermal time constant τ greater than 100 seconds.

14. The sensor housing apparatus of claim 13 including a thermally resistant spacer mounted adjacent the optical gas sensor, the thermally resistant spacer configured to minimize transfer of thermal energy to the optical sensor.

15. The sensor housing apparatus of claim 14 wherein the thermally resistant spacer and the opening in the first wall are cooperatively configured to establish a thermal resistance shunt R S about the optical gas sensor, wherein R S >5 R T .

16. The sensor housing apparatus of claim 12 including a base for supporting the enclosure and the outer assembly.

17. A method for detecting gas, comprising:

assembling an enclosure having first and second shells defining an enclosed interior therebetween;

positioning a gas sensor within the enclosure adjacent an opening in the first shell;

mounting a thermal mass within the enclosed interior of the enclosure;

detecting, with the gas sensor, gas in an air flow path in communication with the opening in the first shell of the enclosure; and

transferring thermal energy from the gas sensor to the thermal mass to maintain the gas sensor within an operable temperature range.

18. The method of claim 17 including minimizing temperature gradients adjacent the gas sensor with the thermal mass.

19. The method of claim 18 including positioning a filter membrane over the opening in the first wall to minimize transfer of thermal energy to the gas sensor.

20. The method of claim 19 including positioning a thermally resistant spacer within the enclosed interior of the enclosure to minimize transfer of heat to the gas sensor.