Piston isolation type glass micro-melting pressure sensor for high-pressure, high-viscosity and high-temperature media

Abstract

The invention discloses a piston isolation type glass micro-melting pressure sensor for a high-pressure, high-viscosity and high-temperature medium, and relates to the field of pressure measurement, and the piston isolation type glass micro-melting pressure sensor is characterized in that a circuit unit is fixedly connected with a core shell, and the core shell is connected with an equipment pipeline through a thread; the glass micro-melting pressure sensing unit is arranged in the circuit unit, the edge is fixed at the top of the core shell, and the center is connected with the piston rod pressure sensing end; the edge of the isolation diaphragm is welded with the bottom of the core shell to form a sealing cavity, and the center is welded with the tested end of the piston rod. And the circuit unit is electrically connected with the pressure sensing unit and is connected to an upper computer. During measurement, the rigid piston rod transmits medium pressure to the pressure sensing unit, so that the pressure sensing unit deforms to cause resistance change, and the circuit unit reads and uploads a resistance value. Piston type mechanical transmission is used as a front-end isolation and force transmission mechanism, the pressure of an extreme medium is directly transmitted to the rear-end high-pressure and high-temperature-resistant glass micro-melting pressure sensing unit without lag, and the accuracy and reliability of medium pressure measurement under the extreme working condition are improved.

Description

Technical Field

[0001] This application relates to the field of pressure measurement, and in particular to a piston-isolated glass micro-fusion pressure sensor for high-pressure, high-viscosity, and high-temperature media. Background Technology

[0002] In modern industrial fields such as energy and chemical engineering, polymer synthesis, and high-end materials manufacturing, processes are becoming increasingly complex and precise, placing extremely high demands on the real-time and accurate monitoring of production parameters. This is especially true in reactions or transport processes involving high-viscosity melts, slurries, and other special media, which are often subjected to extreme conditions of high temperature (often exceeding 200°C) and high pressure (reaching tens or even hundreds of megapascals). Accurate and stable pressure measurement is directly related to the safety of process control, the consistency of product quality, and the optimization of production efficiency.

[0003] However, existing mainstream pressure sensing technologies all have significant shortcomings when dealing with such extreme conditions of "high pressure, high temperature, and high viscosity." The metal diaphragm of direct-contact glass micro-fusion sensors is easily adhered to and blocked by high-viscosity media, leading to measurement failure; while the silicone oil relied upon by oil-filled isolation sensors is prone to carbonization and property deterioration at high temperatures, making sealing difficult under high pressure, and the oil damping causes slow system response, failing to meet the requirements of accurate and rapid measurement. Summary of the Invention

[0004] The purpose of this application is to provide a piston-isolated glass micro-melt pressure sensor for high-pressure, high-viscosity, and high-temperature media. By using a piston-type mechanical transmission as the front-end isolation and force transmission mechanism, the pressure of the extreme medium can be directly and without hysteresis transmitted to the high-pressure and high-temperature resistant glass micro-melt pressure sensing unit at the back end, thereby improving the accuracy and reliability of medium pressure measurement under extreme working conditions.

[0005] To achieve the above objectives, this application provides the following solution: This application provides a piston-isolated glass micro-melt pressure sensor for high-pressure, high-viscosity, and high-temperature media. The sensor includes: a circuit unit, a glass micro-melt pressure-sensing unit, a core housing, a rigid piston rod, and an isolation diaphragm. The circuit unit is fixedly connected to the core housing, and the core housing is threadedly connected to the pipeline of the target device corresponding to the measured medium. The glass micro-melt pressure-sensing unit is disposed inside the circuit unit, and the annular edge of the glass micro-melt pressure-sensing unit is connected to the top of the core housing. The center of the glass micro-melt pressure-sensing unit is in contact with the rigid piston rod fitted inside the cavity of the core housing. The circuit unit is connected to the following: the annular edge of the isolation diaphragm is welded to the bottom of the core shell to form a sealed cavity; the center of the isolation diaphragm is connected to the measured end of the rigid piston rod; the input end of the circuit unit is electrically connected to the glass micro-fusion pressure sensing unit, and the output end of the circuit unit is electrically connected to the host computer; the rigid piston rod transmits the pressure of the measured medium to the glass micro-fusion pressure sensing unit without damage, and the glass micro-fusion pressure sensing unit generates an electrical signal of resistance change through deformation; the circuit unit reads the resistance value of the glass micro-fusion pressure sensing unit and uploads it to the host computer; the measured medium is a high-pressure, high-viscosity, and high-temperature medium.

[0006] According to the specific embodiments provided in this application, the following technical effects are disclosed: This application achieves high reliability and high precision measurement under extreme conditions through an oil-free, all-metal, and high-rigidity structural design. The all-metal, oil-free design limits the upper temperature range to only the material's melting point, ensuring stable operation without oil carbonization or characteristic drift. The sensor mainly consists of a circuit unit, a glass micro-fusion pressure-sensing unit, a core housing, a rigid piston rod, and an isolation diaphragm. The circuit unit is fixedly connected to the core housing, which is threaded to the equipment piping. The glass micro-fusion pressure-sensing unit is placed within the circuit unit, its annular edge connected to the top of the housing, and its center connected to the pressure-sensing end of the rigid piston rod fitted within the housing cavity. The isolation diaphragm's edge is welded to the bottom of the housing to form a sealed cavity, and its center is welded to the measured end of the piston rod. The circuit unit and pressure-sensing unit are electrically connected to a host computer. This application utilizes a precision piston-type mechanical transmission assembly (i.e., a combination of a rigid piston rod and an isolating diaphragm) as an all-metal isolation and force transmission mechanism. This directly and seamlessly transmits the pressure of extreme media to the high-pressure, high-temperature resistant glass micro-fuse pressure-sensing unit at the rear end. The force flow path is a simple, rigid mechanical structure, eliminating the risk of hydraulic cavity bursting. Furthermore, the all-metal, oil-free design limits the upper temperature range to the material's melting point, ensuring stable operation without oil carbonization or characteristic drift. The pressure-sensing unit deforms and changes resistance accordingly, which is read and transmitted by the circuit unit. This application enables the sensor to effectively cope with the triple harsh conditions of high pressure, high viscosity, and high temperature, ensuring direct pressure transmission and measurement stability, thereby achieving superior long-term reliability and measurement accuracy. Attached Figure Description

[0007] To more clearly illustrate the technical solutions in the embodiments of this application or related technologies, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0008] Figure 1 This is a schematic diagram of the structure of a piston-isolated glass micro-melting pressure sensor for high-pressure, high-viscosity, and high-temperature media, provided in an embodiment of this application.

[0009] Reference numerals: 1. Circuit unit; 2. Glass micro-melt pressure sensing unit; 3. Core shell; 4. Rigid piston rod; 5. Isolation diaphragm; 6. Pressure ring; 11. Circuit bracket; 12. Circuit board; 13. Circuit shell; 14. Electrical connector; 21. Glass micro-melt pressure sensing head; 22. Push rod; 23. Pressure sensing diaphragm; 24. Strain gauge. Detailed Implementation

[0010] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0011] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0012] Example 1, such as Figure 1 As shown, this embodiment provides a piston-isolated glass micro-melt pressure sensor for high-pressure, high-viscosity, and high-temperature media. The sensor includes: a circuit unit 1, a glass micro-melt pressure sensing unit 2, a core housing 3, a rigid piston rod 4, and an isolation diaphragm 5.

[0013] The circuit unit 1 is fixedly connected to the core housing 3, and the core housing 3 is connected to the target equipment pipeline corresponding to the measured medium through threads.

[0014] The glass micro-melting pressure sensing unit 2 is located inside the circuit unit 1. The annular edge of the glass micro-melting pressure sensing unit 2 is connected to the top of the core shell 3, and the center of the glass micro-melting pressure sensing unit 2 is connected to the pressure sensing end of the rigid piston rod 4 sleeved in the cavity of the core shell 3.

[0015] The annular edge of the isolation diaphragm 5 is welded to the bottom of the core shell 3 to form a sealed cavity; the center of the isolation diaphragm 5 is connected to the measured end of the rigid piston rod 4.

[0016] The input terminal of circuit unit 1 is electrically connected to glass micro-fusion pressure sensing unit 2, and the output terminal of circuit unit 1 is electrically connected to the host computer.

[0017] The rigid piston rod 4 transmits the pressure of the medium to be measured to the glass micro-melting pressure sensing unit 2 without damage. The glass micro-melting pressure sensing unit 2 generates an electrical signal of resistance change through deformation. The circuit unit 1 reads the resistance value of the glass micro-melting pressure sensing unit 2 and uploads it to the host computer. The medium to be measured is a high-pressure, high-viscosity, and high-temperature medium.

[0018] Optional, high pressure means pressure greater than or equal to 100MPa; high temperature means temperature greater than or equal to 250℃.

[0019] Furthermore, the circuit unit 1 specifically includes: a circuit support 11, a circuit board 12, a circuit housing 13, and an electrical connector 14; the circuit housing 13 is a tubular structure, one end of the circuit housing 13 is fixedly connected to the electrical connector 14, and the other end of the circuit housing 13 is fixedly connected to the core housing 3; the circuit support 11 is fixed inside the circuit housing 13, and the circuit board 12 is mounted on the circuit support 11; the input end of the circuit board 12 is electrically connected to the glass micro-melting pressure sensing unit 2, and the output end of the circuit board 12 is electrically connected to the electrical connector 14; the electrical connector 14 is electrically connected to the host computer.

[0020] Optionally, circuit board 12 integrates high-precision temperature compensation and amplification circuitry for a wide temperature range (e.g., -40°C to +225°C).

[0021] Furthermore, the glass micro-melting pressure sensing unit 2 specifically includes: a glass micro-melting pressure sensing head 21, a push rod 22, a pressure-sensing diaphragm 23, and a strain gauge 24; one end of the push rod 22 is connected to the center of the glass micro-melting pressure sensing head 21, and the other end of the push rod 22 is connected to the pressure-sensing end of the rigid piston rod 4; the annular edge of the glass micro-melting pressure sensing head 21 is welded to the core shell 3; the pressure-sensing diaphragm 23 is disposed on the upper surface of the glass micro-melting pressure sensing head 21; the strain gauge 24 is inorganically bonded to the pressure-sensing diaphragm 23 by glass sintering, and the strain gauge 24 is connected to the circuit unit 1; when the rigid piston rod 4 transmits the pressure of the measured medium to the pressure-sensing diaphragm 23 without damage, the pressure-sensing diaphragm 23 undergoes physical deformation, and transmits the physical deformation through the glass medium to the strain gauge 24, and the strain gauge 24 uses the resistance strain effect to convert the physical deformation into an electrical signal of resistance change. In practical applications, the glass micro-fusion pressure-sensing unit 2 adopts a reinforced structural design. The pressure-sensing diaphragm 23 is inorganically bonded to the strain gauge 24 via high-temperature glass powder, achieving an inherent pressure resistance of over 300 MPa and excellent long-term stability. The inherent inorganic aging characteristics of glass micro-fusion technology, combined with the durability of the mechanical structure, ensure extremely low long-term drift.

[0022] Furthermore, the piston-isolated glass micro-fusion pressure sensor for high-pressure, high-viscosity, and high-temperature media also includes: a pressure ring 6; the pressure ring 6 is welded onto the isolation diaphragm 5; after the threads on the core housing 3 are tightened, the pressure ring 6 seals the surface extrusion deformation through the installation interface of the target equipment pipeline corresponding to the measured medium.

[0023] Furthermore, the diameter of the measured end of the rigid piston rod 4 is larger than the diameter of the pressure-sensing end of the rigid piston rod 4. In practical applications, the rigid piston rod 4 exhibits the characteristics of a thicker measured end and a thinner pressure-sensing end, which can effectively transmit pressure without instability, while also meeting the design requirements of the glass micro-melting pressure sensor.

[0024] Furthermore, the measured end of the rigid piston rod 4 is spherical or planar. In practical applications, the spherical or planar shape can accurately act on the mechanical center of the glass micro-melting core pressure-sensitive diaphragm 23, ensuring a direct and efficient force transmission path.

[0025] Furthermore, the rigid piston rod 4 is made of a high-strength alloy with a low coefficient of thermal expansion. In practical applications, the high-strength alloy is an alloy whose surface has undergone ultra-precision machining and hardening treatment. High-strength alloys include at least: Kronenbourg 718 and special stainless steel.

[0026] Optionally, the rigid piston rod 4 is connected to the center of the isolation diaphragm 5 by welding or threading to transmit the medium pressure sensed by the diaphragm.

[0027] Furthermore, the three side walls of the core casing are also equipped with heat dissipation fins and cooling interfaces. In practical applications, the heat dissipation fins and cooling interfaces are used to dissipate heat from the high-temperature medium and protect the internal electronic components.

[0028] Furthermore, the threads of the core housing 3 are threadedly connected to the target equipment pipeline corresponding to the measured medium via a flange. During connection, the flange is flush with the surface of the measured medium. The flange is a hexagonal flange. In practical applications, the piston's contact surface with the medium is flush with the process connection flange, employing Hastelloy or tantalum coating to prevent high-viscosity media retention and crystallization. The flush, corrosion-resistant end face has no dead zones, eliminating media buildup and resisting chemical corrosion. Through rigid transmission, the sensor in this embodiment achieves a response speed to high-viscosity media that is an order of magnitude faster than oil-filled sensors.

[0029] Optionally, the core housing 3 is connected to the glass micro-melting pressure head by laser welding.

[0030] Optionally, the circuit housing 13 can provide rigid support and overload protection for the entire sensor.

[0031] Optionally, the front piston module, consisting of the core housing 3, rigid piston rod 4, and isolation diaphragm 5, has quick-replaceable components, which can significantly reduce maintenance costs.

[0032] This application also provides an optional implementation method, as follows: The pressure of the measured medium (such as a polymer melt at 300°C) acts on the flush Hastelloy end face of the piston. This pressure pushes the nickel alloy piston rod (rigid piston rod 4), overcoming the elastic force of the bellows seal, and directly contacts the glass micro-melt pressure sensing unit 2, which has a rated pressure of 400MPa. The millivolt signal generated by the glass micro-melt pressure sensing unit 2 is compensated and amplified by the built-in wide-temperature-range ASIC chip, outputting a standard 4-20mA signal. Throughout the process, the high-temperature melt is completely isolated outside the sensor housing, and the core pressure sensing unit operates in a protected, safe temperature and clean environment. The sensor in this embodiment successfully achieves continuous and stable monitoring under conditions of 250MPa, 280°C, and high-viscosity melts, with a lifespan far exceeding that of traditional oil-filled sensors.

[0033] In summary, the technical effects of this application are as follows: This application achieves high reliability and high precision measurement under extreme conditions through an oil-free, all-metal, and high-rigidity structural design. The all-metal, oil-free design limits the upper temperature range to only the material's melting point, ensuring stable operation without oil carbonization or characteristic drift. The sensor mainly consists of a circuit unit, a glass micro-fusion pressure-sensing unit, a core housing, a rigid piston rod, and an isolation diaphragm. The circuit unit is fixedly connected to the core housing, which is threaded to the equipment piping. The glass micro-fusion pressure-sensing unit is placed within the circuit unit, its annular edge connected to the top of the housing, and its center connected to the pressure-sensing end of the rigid piston rod fitted within the housing cavity. The isolation diaphragm's edge is welded to the bottom of the housing to form a sealed cavity, and its center is welded to the measured end of the piston rod. The circuit unit and pressure-sensing unit are electrically connected to a host computer. This application utilizes a precision piston-type mechanical transmission assembly (i.e., a combination of a rigid piston rod and an isolating diaphragm) as an all-metal isolation and force transmission mechanism. This directly and seamlessly transmits the pressure of extreme media to the high-pressure, high-temperature resistant glass micro-fuse pressure-sensing unit at the rear end. The force flow path is a simple, rigid mechanical structure, eliminating the risk of hydraulic cavity bursting. Furthermore, the all-metal, oil-free design limits the upper temperature range to the material's melting point, ensuring stable operation without oil carbonization or characteristic drift. The pressure-sensing unit deforms and changes resistance accordingly, which is read and transmitted by the circuit unit. This application enables the sensor to effectively cope with the triple harsh conditions of high pressure, high viscosity, and high temperature, ensuring direct pressure transmission and measurement stability, thereby achieving superior long-term reliability and measurement accuracy.

[0034] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0035] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. Furthermore, those skilled in the art will recognize that, based on the ideas of this application, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A piston-isolated glass micro-fusion pressure sensor for high-pressure, high-viscosity, high-temperature media, characterized in that, The sensor includes: a circuit unit, a glass micro-melting pressure sensing unit, a core housing, a rigid piston rod, and an isolation diaphragm; The circuit unit is fixedly connected to the core housing, and the core housing is connected to the target equipment pipeline corresponding to the measured medium by a thread; The glass micro-melting pressure sensing unit is disposed inside the circuit unit. The annular edge of the glass micro-melting pressure sensing unit is connected to the top of the core shell, and the center of the glass micro-melting pressure sensing unit is connected to the pressure sensing end of the rigid piston rod sleeved in the cavity of the core shell. The annular edge of the isolation diaphragm is welded to the bottom of the core shell to form a sealed cavity; the center of the isolation diaphragm is connected to the measured end of the rigid piston rod. The input terminal of the circuit unit is electrically connected to the glass micro-melting pressure sensing unit, and the output terminal of the circuit unit is electrically connected to the host computer. The rigid piston rod transmits the pressure of the measured medium to the glass micro-melting pressure sensing unit without damage. The glass micro-melting pressure sensing unit generates an electrical signal with a change in resistance value through deformation. The circuit unit reads the resistance value of the glass micro-melting pressure sensing unit and uploads it to the host computer. The measured medium is a high-pressure, high-viscosity, and high-temperature medium.

2. The piston-isolated glass micro-fusion pressure sensor for high-pressure, high-viscosity, and high-temperature media according to claim 1, characterized in that, The circuit unit specifically includes: a circuit bracket, a circuit board, a circuit housing, and an electrical connector; The circuit housing is a tubular structure, one end of the circuit housing is fixedly connected to the electrical connector, and the other end of the circuit housing is fixedly connected to the core housing; The circuit support is fixed inside the circuit housing, and the circuit board is mounted on the circuit support; The input terminal of the circuit board is electrically connected to the glass micro-melting pressure sensing unit, and the output terminal of the circuit board is electrically connected to the electrical connector. The electrical connector is electrically connected to the host computer.

3. The piston-isolated glass micro-fusion pressure sensor for high-pressure, high-viscosity, and high-temperature media according to claim 1, characterized in that, The glass micro-melting pressure sensing unit specifically includes: a glass micro-melting pressure sensing head, a push rod, a pressure sensing diaphragm, and a strain gauge; One end of the push rod is connected to the center of the glass micro-melting pressure-sensitive head, and the other end of the push rod is connected to the pressure-sensitive end of the rigid piston rod; The annular edge of the glass micro-melting pressure head is connected to the core shell by welding; The pressure-sensitive diaphragm is disposed on the upper surface of the glass micro-melting pressure-sensitive head; The strain gauge and the pressure-sensitive diaphragm are inorganically bonded to the pressure-sensitive diaphragm by glass sintering, and the strain gauge is connected to the circuit unit; When the rigid piston rod transmits the pressure of the measured medium to the pressure-sensitive diaphragm without damage, the pressure-sensitive diaphragm undergoes physical deformation and transmits the physical deformation through the glass medium to the strain gauge. The strain gauge uses the resistance strain effect to convert the physical deformation into an electrical signal of resistance change.

4. The piston-isolated glass micro-fusion pressure sensor for high-pressure, high-viscosity, and high-temperature media according to claim 1, characterized in that, The piston-isolated glass micro-melting pressure sensor for high-pressure, high-viscosity, and high-temperature media further includes: a pressure ring; The pressure ring is welded to the isolation diaphragm; after the threads on the core shell are tightened, the pressure ring seals the surface extrusion deformation through the installation interface of the target equipment pipeline corresponding to the measured medium.

5. The piston-isolated glass micro-fusion pressure sensor for high-pressure, high-viscosity, and high-temperature media according to claim 1, characterized in that, The diameter of the measured end of the rigid piston rod is larger than the diameter of the pressure-sensing end of the rigid piston rod.

6. The piston-isolated glass micro-fusion pressure sensor for high-pressure, high-viscosity, and high-temperature media according to claim 1, characterized in that, The measured end of the rigid piston rod is spherical or planar.

7. The piston-isolated glass micro-fusion pressure sensor for high-pressure, high-viscosity, and high-temperature media according to claim 1, characterized in that, The rigid piston rod is made of a high-strength alloy with a low coefficient of thermal expansion.

8. The piston-isolated glass micro-fusion pressure sensor for high-pressure, high-viscosity, and high-temperature media according to claim 1, characterized in that, The core housing is also provided with heat dissipation fins and cooling interfaces on its side wall.

9. The piston-isolated glass micro-fusion pressure sensor for high-pressure, high-viscosity, and high-temperature media according to claim 1, characterized in that, The threads of the core shell are connected to the target equipment pipeline corresponding to the measured medium via a flange.

10. The piston-isolated glass micro-fusion pressure sensor for high-pressure, high-viscosity, high-temperature media according to claim 9, characterized in that, The flange is flush with the surface of the medium being measured during the connection process.

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