Compressible Sensor Element with Closed Areas
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Solution Overview
Problem
Compressible plugs for sensor assemblies made from solid elastomers lack sufficient compressibility to compensate for volume variations in fluids, especially under freezing and thawing conditions, due to uneven pore distribution and structural weaknesses, leading to potential damage of the sensing element.
Innovation Solution
A compressible element with an elastomer matrix and distributed closed areas, each with varying compressibility, formed using polymeric microspheres or hollow voids, ensuring uniform thickness and mechanical strength, preventing fluid infiltration and maintaining resilience during cyclic temperature changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid elastomers are used for compressible plugs, then mechanical strength is maintained, but compressibility is insufficient to compensate for volume variations in fluids
Solution Approach 1:
The patent uses a composite material consisting of an elastomer matrix combined with closed-cell porous elastomer material. This composite structure provides both the mechanical strength of the elastomer matrix and the compressibility of the porous structure, resolving the contradiction between strength and compressibility.
Solution Approach 2:
The patent incorporates closed-cell porous elastomer material with controlled pore structure into the compressible plug. The porous structure enables sufficient compressibility to compensate for fluid volume variations while the closed-cell design maintains mechanical integrity.
2Adaptability or versatility
If closed-cell porous elastomer material is used to increase compressibility, then volume compensation improves, but pore structure control becomes difficult leading to uneven distribution and weak walls
Solution Approach 1:
The patent specifies particular parameters for the closed-cell porous elastomer material, including pore size range (10-500 micrometers) and porosity (10-80%), to achieve optimal compressibility while maintaining structural control and uniformity.
3Ease of manufacture
If closed-cell elastomer material is cut from formed material, then manufacturing is simplified, but pores are exposed on cut edges leading to liquid infiltration
Solution Approach 1:
The patent employs a continuous elastomer matrix that encapsulates and seals the closed-cell porous structure. This flexible matrix acts as a barrier that prevents liquid infiltration through cut edges while maintaining the ease of manufacturing the compressible plug.
4Adaptability or versatility
If porous structure with thin walls is used, then compressibility increases, but mechanical vulnerability increases and ability to maintain compressibility through cyclic freezing and thawing is reduced
Solution Approach 1:
The patent creates a composite where the elastomer matrix provides mechanical strength and durability for withstanding cyclic freezing and thawing, while the embedded closed-cell porous structure provides compressibility. The matrix reinforces the porous structure, preventing collapse during thermal cycling.
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 compressible element effectively compensates for volume variations in fluids, maintaining mechanical strength and preventing damage to the sensor element by ensuring even compressibility and resistance to fluid infiltration, enhancing the reliability and accuracy of the sensor assembly.
Implementation Method 1
The compressible plug compensates for volume variations in the surrounding fluid to protect the sensing element from damage
Data Source
AI summary
A compressible element for a sensor assembly includes an elastomer matrix having a first compressibility and a plurality of closed areas distributed within the elastomer matrix and each surrounded by the elastomer matrix. Each of the closed areas has a second compressibility greater than the first compressibility.