IP Library › Granted Patent US 12,405,238
Granted Patent B2
US 12,405,238 · App. 17/659,909 · Granted Sep 2, 2025

Ultrasensitive, ultrathin vapor sensors and arrays

Inventors: Otto J. Gregory (Narragansett, RI); Peter P. Ricci (West Warwick, RI)
Assignee: Trace Sensing Technologies Inc.
G01N25/488A61B5/6833G01N33/4975
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Quick Facts
Patent No.
US 12,405,238
App. No.
17/659,909
Granted
Sep 2, 2025
Kind
B2
Abstract

Ultrasensitive, ultrathin thermodynamic sensing platforms for the detection of chemical compounds at trace levels are disclosed. Embodiments of the ultrathin sensor comprise substrate, adhesion, microheater, and catalyst layers. A sensor array may include a plurality of sensors each having a different catalyst. When a sensor array exposed to an analyte, each of the various sensors of the array may experience an endothermic reaction, an exothermic reaction, or no reaction. A comparison of the reaction results to data comprising previously-obtained reaction results may be used to determine information on the analyte. Advantageously, these ultrathin vapor sensors utilize less power and provide greater sensitivity, and may be used to detect and identify analytes at the PPT level. Specialized sensors configured to detect analytes falling into a certain category (e.g., explosives, drugs and narcotics, biomarkers, etc.) are disclosed, as well as general purpose sensors capable of detecting analytes from a plurality of categories.

Claims (37)

1. A detection device comprising:

a first sensor comprising a first microheater and a first catalyst in contact with the first microheater;

a second sensor comprising a second microheater;

a controller in electrical communication with the first sensor and the second sensor, the controller configured to:

cause power to be provided to the first and second sensors to heat the first sensor to a first setpoint temperature and to heat the second sensor to a second setpoint temperature;

vary power applied to the first sensor and/or the second sensor to account for a thermal response caused by reactions between an analyte and the first catalyst to maintain the first setpoint temperature and the second setpoint temperature; and

determine an existence, identity, and/or concentration of the analyte based on the varied the power.

2. The detection device of claim 1 , wherein the first setpoint temperature is the same as the second setpoint temperature.

3. The detection device of claim 1 , wherein the second sensor is a reference sensor without a catalyst, the reference sensor in electrical communication with the controller.

4. The detection device of claim 1 , wherein the second sensor comprises a second catalyst in thermal communication with the second microheater.

5. The detection device of claim 4 , further comprising a third sensor comprising a third microheater and a third catalyst in thermal communication with the third microheater, a fourth sensor comprising a fourth microheater and a fourth catalyst in thermal communication with the fourth microheater, and a fifth sensor comprising a fifth microheater and a fifth catalyst in thermal communication with the fifth microheater.

6. The detection device of claim 5 , wherein the first catalyst comprises aluminum copper oxide (Al 2 CuO 4 ), the second catalyst comprises iron oxide (Fe 2 O 3 ), the third catalyst comprises indium-tin oxide (ITO), the fourth catalyst comprises tin oxide (SnO), and the fifth catalyst comprises tungsten oxide (WO).

7. The detection device of claim 6 , further comprising a sixth sensor comprising a sixth catalyst selected from copper oxide (CuO) or manganese oxide (MnO).

8. The detection device of claim 5 , wherein the first catalyst, the second catalyst, the third catalyst, the fourth catalyst, and the fifth catalyst each comprise aluminum copper oxide (Al 2 CuO 4 ), aluminum zinc oxide (AZO), chromium oxide (CrO 2 ), copper oxide (CuO), cobalt oxide (CoO 2 ), iron oxide (Fe 2 O 3 ), indium-tin oxide (ITO), iridium oxide (IrO 2 ), manganese oxide (MnO), ruthenium oxide (RuO 2 ), tungsten oxide (WO), or tin oxide (SnO).

9. The detection device of claim 1 , wherein the setpoint temperature is between 25° C. and 175° C.

10. The detection device of claim 1 , wherein the first sensor comprises a substrate layer formed from yttria-stabilized-zirconia.

11. The detection device of claim 1 , wherein the first sensor comprises a substrate layer formed from aerogel.

12. The detection device of claim 1 , wherein the first sensor further comprises an adhesion layer in contact with the substrate layer.

13. The detection device of claim 1 , wherein the detection device is incorporated in a wearable configured to be worn by a user.

14. The detection device of claim 13 , further comprising a disposable layer configured to be adhered to the user's skin.

15. The detection device of claim 14 , further comprising a passivation layer between the disposable layer and the first and second sensors.

16. The detection device of claim 1 , wherein the detection device is incorporated in a scanning wand.

17. A method of detecting an analyte, the method comprising:

providing a sensor array comprising a first sensor and a second sensor, the first sensor comprising a first microheater layer and a first catalyst layer in contact with the first microheater layer, the second sensor comprising a second microheater layer;

delivering power to the first and second sensors to heat the first sensor to a first setpoint temperature and to heat the second sensor to a second setpoint temperature;

exposing the first and second sensors to an analyte such that the first catalyst layer reacts with the analyte to generate a thermal response;

varying power applied to the first sensor and/or the second sensor to account for the thermal response to maintain the first setpoint temperature and the second setpoint temperature; and

determining an existence, identity, and/or concentration of the analyte based on varying the power.

18. The method of claim 17 , wherein the first setpoint temperature and the second setpoint temperature are each between 25° C. and 175° C.

19. A detection device comprising:

a substrate layer;

a microheater layer configured to receive power at a first power level to reach a setpoint temperature; and

a catalyst layer in contact with the microheater layer, the catalyst layer comprising a catalyst configured to undergo a chemical reaction when exposed to an analyte, the chemical reaction being endothermic or exothermic,

wherein the microheater layer is configured to receive power at a second power level to maintain the setpoint temperature after the catalyst begins the chemical reaction, and

wherein a heat effect indicative of information on the analyte is determined by comparing the second power level to the first power level.

20. The detection device of claim 19 , further comprising an adhesion layer in contact with the substrate layer and in contact with the microheater layer.

21. The detection device of claim 19 , wherein the substrate is aerogel.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 22, 2023
From: PGR HOLDINGS, LLC
To: TRACE SENSING TECHNOLOGIES INC.
Reel/Frame 063066/0659 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 26, 2022
From: GREGORY, OTTO J.; RICCI, PETER P.
To: PGR HOLDINGS, LLC
Reel/Frame 059740/0501 →
Continuity (2)
Continuation In Part 17356392 · Jun 23, 2021
Related Publication 20220412905A1 · Dec 29, 2022
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