Flame Arrestor Acoustic Sensor for Gas Leak Detection

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Solution Overview

Problem

Conventional explosion-proof and flame-proof sensors face challenges in effectively detecting gas leaks in hazardous environments, particularly high-pressure gas systems, due to limitations in acoustic energy transmission and environmental protection, leading to inaccurate or delayed detection.

Innovation Solution

The integration of a miniature MEMS microphone or speaker within an explosion-proof housing, utilizing a flame arrestor such as a sintered metal disc or metal screen, which allows acoustic energy transmission while preventing ignited flames or explosions, and a hydrophobic membrane for environmental protection, enabling reliable ultrasonic gas leak detection in hazardous settings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a flame arrestor is introduced to protect the acoustic device, then safety against flames and explosions is improved, but acoustic energy transmission may be attenuated

Engineering Contradiction:

Improvesafety protectionVSAvoidacoustic energy attenuation

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent employs a sintered metal disc as a flame arrestor, which utilizes porous material structure to allow acoustic energy transmission while blocking flames and explosions. The porous structure enables sound waves to pass through while the material's physical properties prevent combustion propagation, resolving the contradiction between safety and acoustic transmission.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The flame arrestor is strategically positioned only at the acoustic device opening where flame protection is most critical, while maintaining open pathways for acoustic energy. This localized application of protective material ensures safety without unnecessarily attenuating acoustic transmission across the entire device structure.

Inventive Principle:

Principle #3Local quality

2Measurement precision

If the acoustic device is placed directly in the hazardous environment, then detection capability is improved, but protection against dust and moisture is reduced

Engineering Contradiction:

Improvedetection capabilityVSAvoiddust and moisture damage

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a hydrophobic membrane as an intermediary barrier between the acoustic device and the hazardous environment. This membrane allows acoustic energy to pass through while blocking dust and moisture, enabling the device to maintain detection capability without direct exposure to harmful environmental factors.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The hydrophobic membrane serves as a thin film protective layer that is acoustically transparent but environmentally resistant. This flexible barrier protects the acoustic device from dust and moisture while maintaining the necessary acoustic transmission for detection functionality.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If conventional explosion-proof sensors are used, then safety containment is improved, but detection accuracy in high-pressure gas systems deteriorates

Engineering Contradiction:

Improvesafety containmentVSAvoiddetection accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent modifies the traditional explosion-proof sensor design by changing the acoustic transmission parameters through the use of a sintered metal disc flame arrestor and hydrophobic membrane. These parameter changes enable the sensor to maintain safety containment while improving acoustic energy transmission and detection accuracy in high-pressure gas systems.

Inventive Principle:

Principle #35Parameter changes

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

This solution provides a reliable and accurate means for detecting high-pressure gas leaks by transmitting ultrasonic acoustic energy through hazardous environments, minimizing attenuation and ensuring sensor protection against dust and moisture, thus enhancing safety and detection efficiency.

Implementation Method 1

a flame arrestor such as a sintered metal disc or metal screen, which allows acoustic energy transmission while preventing ignited flames or explosions

Methodology Applied

Scientific EffectFlame arrestor:

Implementation Method 2

a hydrophobic membrane for environmental protection

Methodology Applied

Scientific EffectHydrophobic: Hydrophobe

Implementation Method 3

The acoustic transducer includes a microphone which detects sound pressure waves that have passed through a flame arrestor

Methodology Applied

Scientific EffectMicroelectromechanical systems: Microelectromechanical Systems

Data Source

PatentUS8792658B2Techniques for protection of acoustic devices

Publication Date: 2014.07.29 MSA TECHNOLOGY LLC

AI summary

An exemplary embodiment of an acoustic sensor system includes a housing structure, and a miniaturized acoustic transducer mounted in the housing structure. A flame arrestor structure is mounted on or within the housing structure between the acoustic transducer and the external environment, so that ambient acoustic energy passes through the flame arrestor structure before reaching the acoustic transducer.