Corrugated Isolator Support for Dynamic Pressure Sensor Protection
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Solution Overview
Problem
Pressure sensors with corrugated foil disc isolators face damage from dynamic pressure events, leading to reduced sensitivity, accuracy, and precision due to crushing and puncturing of the isolator, especially at high pressures and uneven pressure distributions.
Innovation Solution
A pressure sensor design featuring a corrugated isolator support made of material with a low coefficient of thermal expansion, matched with the isolator's corrugations, and a constant-width gap to prevent damage by supporting the isolator's center and acting as a hydrodynamic damper, reducing the need for additional oil and minimizing temperature-related volume fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a corrugated foil disc isolator is used to protect the sensing element, then the sensor can operate in hydraulic systems with pressure spikes and dynamic pressure events, but the isolator itself becomes vulnerable to crushing and puncturing under extreme pressures
Solution Approach 1:
A cushioning member is positioned between the isolator and the process connection to absorb and distribute the impact forces from pressure spikes and dynamic pressure events. This cushioning element prevents direct transmission of extreme forces to the isolator, thereby protecting it from crushing and puncturing while allowing the sensor to reliably operate under dynamic pressure conditions
Solution Approach 2:
The cushioning member acts as an intermediary element between the external hydraulic system and the isolator. It mediates the interaction by absorbing transient pressure forces and providing a more gradual force distribution to the isolator, preventing direct contact with damaging pressure spikes while maintaining the isolator's protective function
2Measurement precision
If the isolator is made thinner to improve sensitivity, then the sensor output becomes more responsive to pressure changes, but the isolator becomes more susceptible to damage from dynamic pressure events
Solution Approach 1:
The cushioning member provides protective pre-cushioning for thin-walled isolators, allowing them to maintain high sensitivity while being protected from damage. The cushioning element absorbs extreme forces before they reach the thin isolator, enabling the use of thinner, more sensitive isolators without sacrificing reliability under dynamic pressure events
Solution Approach 2:
The isolator can be designed with varying thickness profiles, being thinner in regions where sensitivity is most needed while having reinforced areas or receiving localized protection from the cushioning member where structural integrity is critical, thereby optimizing both sensitivity and durability
3Ease of manufacture
If traditional isolator supports are used, then the structure is simple to manufacture, but they fail to prevent isolator damage during dynamic pressure events and do not maintain linearity over temperature ranges
Solution Approach 1:
The cushioning member is integrated into the isolator support structure, combining mechanical support with protective cushioning functionality. This integrated approach maintains manufacturing simplicity while providing the necessary protection against dynamic pressure events and temperature-induced linearity issues
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 the sensor's accuracy and durability by preventing isolator damage during dynamic pressure events, maintaining sensitivity and precision over a wide temperature range, even under extreme pressures.
Implementation Method 1
a constant-width gap to prevent damage by supporting the isolator's center and acting as a hydrodynamic damper
Implementation Method 2
A pressure sensor design featuring a corrugated isolator support made of material with a low coefficient of thermal expansion
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A pressure sensor includes a header (116) with a cavity, a pressure sensing element (128), an isolator, an isolator support, a damping gap, and oil. The pressure sensing element (128) is in the cavity. The isolator has corrugations and is mounted to a top of the header (116). The isolator covers the cavity. The isolator support is in the cavity of the header (116) above the pressure sensing element (128). The isolator support is corrugated. The corrugations of the isolator support align with the corrugations on the isolator. The damping gap is between the isolator support and the isolator. The damping gap has a constant width between the isolator support and the isolator. Oil fills the damping gap and the cavity in the header (116). The oil moves between the damping gap and the header cavity in response to external pressure changes moving the isolator.