Contoured Pressure Sensor Insert for Bubble-Free Fluid Flow
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Solution Overview
Problem
Disposable pressure sensors in fluid delivery tubes often create turbulent fluid flow, leading to undesirable bubble formation due to inadequate interaction with the fluid delivery tubes, which is particularly problematic in medical applications where bubbles can cause severe medical issues.
Innovation Solution
A pressure sensor assembly with a contoured sensing insert and inner/outer sensing media, designed to fit flush with the fluid flow container, using silicone-compatible materials and coupling gaskets for secure attachment, ensuring a smooth and laminar fluid flow by matching the container's curvature and providing a continuous interface surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a disposable pressure sensor is universally applied in fluid delivery tubes, then the sensor can be easily installed and used, but it creates turbulent fluid flow and encourages bubble formation
Solution Approach 1:
The sensor assembly incorporates a contoured mating face with specific curvature radii (e.g., 0.5mm to 2mm) that locally matches the interior curvature of the fluid delivery tube. This localized geometric adaptation at the interface between the sensor and tube eliminates turbulent flow and bubble formation, while the sensor itself remains a universal disposable component that can be applied to different fluid delivery tubes.
2Ease of manufacture
If the pressure sensor interface is simplified for universal use, then manufacturing cost is reduced, but fluid flow turbulence increases
Solution Approach 1:
The mating face of the sensor assembly is formed with a curved contour that corresponds to the interior curvature of the fluid delivery tube. This curvature is integrated into the sensor housing during molding, allowing the complex curved interface to be manufactured in a single step without additional machining or assembly operations, thus maintaining manufacturing simplicity while eliminating flow turbulence.
3Ease of operation
If the sensor is made disposable for ease of use, then installation simplicity is improved, but precision in pressure measurement may be compromised
Solution Approach 1:
The sensor assembly includes an intermediate mating face structure that mediates between the disposable sensor requirements and precision measurement needs. The contoured mating face ensures precise alignment and intimate contact with the fluid delivery tube, while the force transmitting member accurately transfers pressure forces to the sensing element, maintaining measurement precision despite the disposable nature of the sensor.
Data Source
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AI summary
A pressure sensor assembly and method of manufacturing the same are provided. The pressure sensor assembly includes a contoured sensing insert. The contoured sensing insert includes an outer sensing insert having an open interior through-hole and a top contoured surface configured to be secured at least partially within the fluid flow container. The top contoured surface has a surface contour corresponding with an interior wall contour of the fluid flow container. The contoured sensing insert also includes an inner sensing medium defined within the through-hole of the outer sensing insert. The inner sensing medium defines a conforming contoured surface at least substantially matching the surface contour of the top contoured surface. A corresponding method of manufacturing is also provided.