Pre-formed Convex Diaphragm for Pressure Sensor Stability
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Solution Overview
Problem
Conventional pressure sensors exhibit instability and poor performance over time, particularly in high proof pressure applications, due to residual stresses in the diaphragm, leading to inaccurate pressure measurements and failure in applications with large pressure spikes.
Innovation Solution
A pressure sensor design featuring a pre-formed metal diaphragm with a convex outer surface and a concave inner surface, attached to a housing, which includes a strain gauge to measure deformation, providing increased mechanical stability and reliability, and can be used in both high and low proof pressure applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional flat diaphragm is used in pressure sensors, then the manufacturing process is simple, but the sensor exhibits instability and poor performance over time due to residual stresses
Solution Approach 1:
The diaphragm is pre-formed with a convex outer surface and concave inner surface before being installed in the pressure sensor. This preliminary shaping action removes residual stresses that would otherwise cause instability during operation, thereby improving sensor reliability without adding complexity to the overall system.
Solution Approach 2:
The diaphragm is transformed from a flat shape to a curved shape with convex outer surface and concave inner surface. This curvature change eliminates residual stresses and improves mechanical stability, resolving the contradiction between reliability and manufacturing complexity.
2Strength
If a flat diaphragm design is used, then the structure is simple, but the sensor fails in applications with large pressure spikes
Solution Approach 1:
The diaphragm incorporates convex outer surface and concave inner surface curvature, which distributes stress more effectively during pressure spikes. This curved geometry enhances the proof pressure capability without requiring additional structural elements or increasing device complexity.
3Measurement precision
If residual stresses are present in the diaphragm, then the manufacturing process is straightforward, but the sensor output drifts over time
Solution Approach 1:
The diaphragm is pre-formed with the desired convex-concave curvature before installation, which eliminates residual stresses that cause measurement drift. This preliminary action ensures long-term measurement precision while maintaining ease of manufacture through a single forming operation.
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 design enhances mechanical stability, allowing accurate pressure measurements and increased reliability, even in applications with high proof pressures, while maintaining a stable sensor output over time.
Implementation Method 1
a strain gauge to measure deformation
Data Source
AI summary
A pressure sensor includes a pre-formed diaphragm located at the distal end of a pressure sensor. The diaphragm has a convex surface on a first side of the diaphragm which is exposed to a fluid to be measured. A strain gauge is attached to a second surface on the opposite side of the diaphragm. The diaphragm may be deformed to have the convex curvature on the first surface, and heat treated.