Compressible Couplant for Ultrasonic Propane Level Measurement
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Solution Overview
Problem
Current methods for accurately measuring the propane level in portable propane tanks are plagued by inaccuracy, reliability issues, and high costs, with existing solutions failing to provide consistent and precise measurements due to factors like temperature variations, pressure changes, and compatibility with different tank types and ages.
Innovation Solution
A sensor arrangement comprising a housing, a transducer, and a couplant with a compressible viscoelastic material that acoustically couples with the tank bottom to measure liquid height, using a low-power wireless link to transmit data to a display module for precise propane level determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If temperature difference correlation method is used to determine propane level, then the measurement can be performed without additional hardware, but the accuracy and resolution are poor and the appliance must be in use
Solution Approach 1:
The patent replaces temperature-based correlation methods with acoustic ultrasonic pulse echo technology. The transducer emits acoustic pulses that travel through the propane liquid, and the reflected echoes are analyzed to determine liquid level and tank bottom position, providing accurate measurements without requiring the appliance to be in use.
Solution Approach 2:
The patent introduces a couplant as an intermediary medium between the transducer and the tank bottom. This couplant ensures efficient acoustic energy transmission by eliminating air gaps, allowing accurate measurement of the acoustic travel time through the propane liquid while protecting the transducer from direct exposure to harsh environmental conditions.
2Device complexity
If pressure sensing devices are used to indicate low propane level, then the device structure is simple, but the measurements are inaccurate due to temperature variations and pressure changes during gas flow
Solution Approach 1:
The patent replaces pressure-based sensing with acoustic ultrasonic pulse echo technology. By measuring the time for acoustic pulses to travel through the propane liquid and reflect off the liquid surface or tank bottom, the system determines propane level independently of temperature and pressure variations that affect gas flow dynamics.
3Device complexity
If weight measuring devices are used to indicate gas level, then the measurement principle is simple, but the accuracy is poor due to varying tare weights of tanks of different ages
Solution Approach 1:
The patent replaces weight-based measurement with acoustic ultrasonic pulse echo technology. The transducer emits acoustic pulses through the propane liquid, and by analyzing the reflected echoes and travel time, the system directly measures liquid level and tank bottom position, eliminating the need to account for varying tank tare weights.
4Measurement precision
If visual gauges with floats are used to measure propane level, then the measurement accuracy is good, but the tank cost is high and the tank cannot be used with exchange services
Solution Approach 1:
The patent separates the measurement function from the tank structure by using an external transducer that couples to the tank bottom. This external device can be attached to any standard propane tank regardless of age or service type, providing accurate measurements without modifying the tank itself or preventing its use with exchange services.
Solution Approach 2:
The patent uses the tank bottom as an intermediary surface to couple the external transducer to the propane liquid inside. This approach allows the measurement device to remain external and removable, maintaining compatibility with tank exchange services while achieving accurate level measurement through acoustic pulse echo technology.
5Measurement precision
If ultrasonic pulse devices are used to detect propane level, then the measurement principle is accurate, but the devices are single point application requiring manual coupling to multiple locations
Solution Approach 1:
The patent creates a universal measurement system where a single transducer device can measure propane level at any tank location by coupling to the tank bottom. The device determines both the liquid level and tank bottom position through acoustic echo analysis, eliminating the need to manually position sensors at multiple predetermined locations.
Solution Approach 2:
The patent transitions from single-point surface measurement to through-wall acoustic measurement. By emitting acoustic pulses through the tank bottom and analyzing the echoes returning from the liquid surface and tank bottom interfaces, the system determines liquid level in a different dimensional space, allowing measurement from a single coupling point rather than multiple surface locations.
6Measurement precision
If ultrasonic transducers are used for large tanks, then the measurement capability is sufficient, but the transducers require very strong power and large batteries making them unsuitable for portable tanks
Solution Approach 1:
The patent optimizes the ultrasonic transducer for low-power portable tank applications by selecting transducer characteristics appropriate for the smaller tank geometry and lower required measurement ranges. The system uses minimal acoustic power sufficient for penetrating the tank bottom and measuring liquid level in portable tanks, dramatically reducing battery requirements compared to large-tank systems.
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 provides accurate, reliable, and cost-effective propane level measurement, compatible with various tank types and ages, and allows for easy integration with existing tank exchange services, enhancing user convenience and operational efficiency.
Implementation Method 1
a couplant with a compressible viscoelastic material that acoustically couples with the tank bottom
Implementation Method 2
a couplant with a compressible viscoelastic material
Implementation Method 3
transmit an acoustic pulse from the transducer to a tank bottom for measuring height of a liquid overlaying the transducer
Implementation Method 4
transmit an acoustic pulse from the transducer to a tank bottom
Data Source
AI summary
A sensor arrangement for measuring liquid height in a tank can include a housing, a transducer, and a couplant. The housing can have an interior and an aperture, the aperture placing the interior of the housing in communication with the environment external to the housing. The transducer can be seated within the aperture. The couplant can be mechanically connected to the transducer and can have a compressible couplant body. The couplant body can extend between the transducer and the external environment for transmitting an acoustic pulse from the transducer to a tank bottom for measuring height of a liquid overlaying the transducer.