Compact Pressure Temperature Sensor Assembly with Metal Passageway
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Solution Overview
Problem
Conventional pressure/temperature sensor assemblies are expensive, large in size, and prone to damage, with plastic-coated temperature sensor elements offering limited protection and requiring costly injection molds for adjustments in length.
Innovation Solution
A sensor assembly featuring a rectangular-shaped pressure sensor element, metallic probes, and a closed-ended fluid-tight passageway made of metal to house the temperature sensor element, preventing fluid exposure and allowing adjustable lengths without the need for new injection molds, combined with a mid-plate assembly for efficient signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic coating is used to protect the temperature sensor element, then the sensor assembly can be manufactured using injection molding, but the protection against damage is insufficient and the sensor element cracks easily
Solution Approach 1:
The patent applies composite materials by combining a metal protective coating (such as nickel or chrome) over the temperature sensor element with the plastic housing. This composite structure provides both the manufacturing advantages of injection molding and the enhanced mechanical protection of metal, resolving the contradiction between ease of manufacture and reliability against damage.
2Strength
If the plastic coating on the temperature sensor element is made thicker to increase strength, then the sensor assembly becomes more robust, but the sensor assembly becomes very large in size
Solution Approach 1:
Instead of increasing the thickness of the plastic coating, the patent uses a thin metal coating (nickel or chrome) that provides high strength and protection without adding significant volume. This composite approach maintains a compact sensor assembly size while achieving the desired strength and robustness.
3Ease of manufacture
If a circular pressure sensor element is used with a hole bored through it for temperature sensor leads, then the assembly can be constructed, but the manufacturing is expensive and difficult requiring precise hole location
Solution Approach 1:
The patent segments the sensor element design by using a rectangular pressure sensor element instead of a circular one, and separately positions the temperature sensor leads through dedicated channels in the housing rather than through holes in the pressure sensor element itself. This segmentation eliminates the need for precise hole location in the pressure sensor element, significantly simplifying manufacturing.
4Reliability
If conventional sensor assemblies are designed to be robust against damage, then they can withstand harsh environments, but they become large in size
Solution Approach 1:
The patent uses a metal coating (nickel or chrome) on the temperature sensor element that provides high strength and corrosion resistance in a thin layer, combined with a rectangular pressure sensor element that offers high strength-to-volume ratio. This composite design achieves robustness against damage in harsh environments while maintaining a compact sensor assembly size.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a smaller, more robust sensor assembly that can withstand drops without damage, providing improved thermal response and cost savings by eliminating the need for expensive molds and reducing size and manufacturing costs.
Implementation Method 1
a temperature sensor element disposed in an end of the closed-ended fluid-tight passageway within the metal tubular element
Implementation Method 2
an open-ended fluid-tight passageway in which to convey the fluid from a portal opening of the sensor assembly to a surface of the rectangular-shaped pressure sensor element that senses the pressure
Data Source
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AI summary
A sensor assembly includes a rectangular-shaped pressure sensor element and an electronic circuitry coupled to receive a signal from the pressure sensor element. An open-ended fluid-tight passageway of the sensor assembly conveys fluid from a portal opening of the sensor assembly to a surface of the rectangular-shaped pressure sensor element. The sensor assembly further includes a closed-ended fluid-tight passageway, at least a portion of which is fabricated from metal. The closed-ended fluid tight passageway extends from at least from the portal opening of the sensor assembly to the electronic circuitry on at least a portion of a path adjacent to the rectangular-shaped ceramic pressure sensor element. The sensor assembly includes a temperature sensor element disposed in an end of the closed-ended fluid-tight passageway. Conductive links disposed in the closed-ended fluid tight passageway electrically couple the temperature sensor element to the electronic circuitry.