Compact Differential Pressure Sensor with Perpendicular Diaphragms
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Solution Overview
Problem
Conventional differential pressure sensors with diaphragms oriented parallel to gravity require bulky mounting brackets and separate housing members, leading to complexity and increased costs, while existing solutions fail to simplify assembly and reduce material expenses.
Innovation Solution
A compact differential fluid pressure sensor design featuring diaphragms mounted on one side of a base with a U-shaped passageway filled with incompressible oil, allowing for perpendicular orientation to gravity and simplified assembly, using less expensive materials and a single robust housing part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If diaphragms are oriented parallel to gravity to prevent accumulation of substances, then reliability is improved, but device complexity increases due to bulky mounting brackets and separate housing members
Solution Approach 1:
The patent merges the diaphragm mounting function into the single housing member itself, eliminating the need for separate mounting brackets. The housing member is designed with integrated features that allow diaphragms to be mounted perpendicular to gravity while maintaining structural integrity and preventing substance accumulation.
Solution Approach 2:
Instead of orienting diaphragms parallel to gravity as in conventional designs, this patent inverts the orientation by placing diaphragms perpendicular to gravity. This inversion allows the diaphragm surfaces to be positioned at the bottom of the housing member, naturally preventing accumulation of substances while simplifying the overall structure.
2Reliability
If diaphragms are oriented parallel to gravity to prevent substance accumulation, then reliability is improved, but manufacturing cost increases due to use of more expensive materials
Solution Approach 1:
By integrating the diaphragm mounting functionality into the single housing member, the design eliminates the need for separate mounting brackets and multiple housing members. This reduction in component count allows for the use of less expensive materials while maintaining the reliability of preventing substance accumulation through the perpendicular orientation.
Solution Approach 2:
The inverted orientation of diaphragms perpendicular to gravity, combined with the integrated housing design, enables the use of more economical materials and simpler manufacturing processes while still achieving the reliability goal of preventing substance accumulation on the diaphragm surfaces.
3Strength
If separate housing members are used to support diaphragms facing opposite directions, then structural integrity is maintained, but assembly time increases
Solution Approach 1:
The patent combines multiple housing members into a single integrated housing member that supports both diaphragms. This unified structure maintains the necessary structural integrity while significantly reducing assembly time, as only one housing member needs to be installed rather than multiple separate components.
Solution Approach 2:
The single housing member is pre-designed with integrated mounting features and passages that accommodate both diaphragms and the sense element in their final positions. This preliminary integration of functions into the housing member design eliminates the need for complex assembly operations and reduces overall assembly time.
4Measurement precision
If conventional differential pressure sensor design is used, then measurement function is achieved, but device size increases
Solution Approach 1:
The patent merges the diaphragm mounting function into the single housing member, eliminating the need for separate mounting brackets. This integration significantly reduces the overall volume of the sensor while maintaining the differential pressure measurement capability through the properly oriented diaphragms and sense element arrangement.
Solution Approach 2:
By inverting the diaphragm orientation to be perpendicular to gravity rather than parallel, the patent enables a more compact arrangement of components. This inverted orientation allows for a more efficient use of space within the housing member, reducing the overall sensor size while preserving measurement precision.
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 results in a more compact, cost-effective, and easier-to-assemble differential pressure sensor with reduced material costs and enhanced reliability, eliminating the need for bulky brackets and separate housing members.
Implementation Method 1
An incompressible fluid, typically silicone oil, is used to transfer pressure from the diaphragm to the sense element
Implementation Method 2
solid state pressure sense elements, such as piezoresistive pressure sense elements
Data Source
AI summary
A differential liquid pressure sensor (10) has an upper housing (12) that mounts a connector portion (12a) and receives in a recess a sense element module (14). The sense element module is a body in which a generally U-shaped oil filled passageway (14h) is formed with openings at opposite ends provided on respective first and second diaphragm mounting surfaces. A fluid pressure sense element, such as a piezoresistive sense element (15) is disposed in one of the passageway openings and flexible metal diaphragms (14a, 14b) are mounted on the respective diaphragm mounting surfaces of the module facing a common direction. A lower housing (18) having first and second port connections for the respective diaphragms is disposed on the lower surface of the module.