Flat-Port Pressure Sensor with Auxiliary Connections for Isolation
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Solution Overview
Problem
Pressure sensors used in frictionless braking systems face challenges with media isolation and connectivity issues, particularly when dealing with hazardous fluids and corrosive chemicals, which affect their performance and reliability.
Innovation Solution
A pressure sensor design featuring a base port with a funnel-shaped proximal open end, a throat with a reduced diameter neck, and a connector portion with molded pin assemblies that facilitate secure connections to both internal and external devices, ensuring reliable signal transmission and media isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pressure sensor is used to measure hazardous fluids, then the measurement function is achieved, but media isolation becomes critical and reliability deteriorates
Solution Approach 1:
The pressure sensor is divided into separate isolated chambers: a process chamber for hazardous fluid measurement and a reference chamber for stable reference pressure. The diaphragm separates these chambers, allowing pressure measurement while maintaining media isolation. This segmentation prevents contamination between chambers and maintains reliability when measuring hazardous fluids.
Solution Approach 2:
A flexible diaphragm acts as an intermediary element between the process chamber containing hazardous fluid and the reference chamber. The diaphragm transmits pressure changes from the hazardous fluid to the sensing mechanism while maintaining complete media isolation, allowing accurate pressure measurement without direct contact between the reference chamber and hazardous substances.
2Ease of manufacture
If traditional connector designs are used, then manufacturing is simpler, but connectivity and signal transmission reliability deteriorate
Solution Approach 1:
The connector assembly integrates multiple components into a single molded unit: the connector body, sealing elements, and electrical contacts are combined into one piece. This merging maintains ease of manufacture through injection molding while significantly improving connectivity reliability by eliminating assembly errors and ensuring proper sealing and electrical contact alignment.
Solution Approach 2:
The connector assembly serves multiple functions simultaneously: it provides mechanical connection, electrical signal transmission, and media sealing. This multi-functionality is achieved through integrated design where the same molded component performs all three functions, improving reliability without complicating manufacturing.
3Adaptability or versatility
If auxiliary connections are added to the pressure sensor, then adaptability and connectivity improve, but device complexity increases
Solution Approach 1:
The connector assembly adds connectivity in multiple spatial dimensions: primary connections for pressure signals, auxiliary connections for reference pressure, and additional contacts for control or sensing functions. This multi-dimensional connection approach increases adaptability while the integrated molded design prevents complexity from escalating.
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 provides robust media isolation and improved connectivity, enabling precise control of frictionless braking systems by allowing seamless communication between the pressure sensor and external devices, enhancing system reliability and performance.
Implementation Method 1
a pressure transfer fluid to translate movement of the diaphragm to the sense die
Data Source
AI summary
A pressure sensor comprises a base port connected to fluid source whose pressure is to be sensed, a sensing portion to receive the fluid via the base port, and a connector portion comprising a main body and first and second pluralities of connector pins. The sensing portion comprises a diaphragm, a sense die, a pressure transfer fluid, and a printed circuit board (PCB). Each of the first plurality of connector pins has a first end electrically connected to the PCB and a second end exposed via an open end of the main body. Each of the second plurality of connector pins has a first end exposed through a side wall of the main body and a second end exposed via the open end of the main body.