Fluid Pressure Sensor Crimped Seal Mechanism
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Solution Overview
Problem
Existing pressure sensors, such as Automotive Pressure Transducers, face limitations in maximum application pressure and sealing issues due to deformation and clearance in high-pressure systems, leading to seal extrusion and accuracy hampering.
Innovation Solution
A pressure sensor design featuring a conductive support ring with annular ridges and a crimped seal mechanism that maintains contact with contact pads, distributing load effectively to prevent seal extrusion and ensure alignment of components, thereby enhancing sealing and accuracy under high pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a crimping process is used to retain components and create a gland, then assembly is simplified and components are retained, but seal extrusion occurs in high pressure systems due to clearance and tolerances
Solution Approach 1:
The gland is segmented into multiple functional zones: a first gland portion for component retention and a second gland portion forming a backup ring. This segmentation allows the backup ring to specifically address seal extrusion prevention while the first portion maintains assembly simplicity.
Solution Approach 2:
The backup ring is pre-formed as an integrated feature of the gland structure before final assembly. This preliminary formation ensures proper geometry and positioning for extrusion prevention without requiring additional assembly steps.
2Stress or pressure
If the maximum application pressure is increased beyond 35 bar, then the sensor capability is improved, but seal extrusion occurs due to deformation and clearance in high pressure systems
Solution Approach 1:
The backup ring acts as a pre-positioned cushioning element that prevents seal extrusion before it can occur. By providing this protective structure in advance, the system can withstand high pressures up to 100 bar without seal failure.
Solution Approach 2:
The design converts the potential harmful effect of high pressure causing seal extrusion into a beneficial feature where the backup ring utilizes the pressure environment to maintain seal integrity. The clearance and tolerances that previously led to extrusion are now managed by the backup ring structure.
3Reliability
If backup rings are used to prevent seal extrusion in high pressure systems, then seal integrity is improved, but device complexity increases
Solution Approach 1:
The backup ring is merged with the gland to form an integrated structure with two functional portions. This combination eliminates the need for separate backup ring components while maintaining seal integrity, thus reducing device complexity.
Solution Approach 2:
The gland structure serves multiple functions: it retains components, creates the sealing environment, and provides the backup ring for extrusion prevention. This multi-functionality eliminates the need for separate dedicated backup ring components.
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 solution increases the maximum allowable pressure range while maintaining an effective seal and accuracy, preventing seal extrusion and ensuring reliable operation in high-pressure environments.
Implementation Method 1
An annular seal, seated at least partially within the recess, is compressed between the sense element and the port body to seal the interior from the fluid
Implementation Method 2
As a result of the opposing annular ridges, extrusion of the annular seal is beneficially reduced or prevented
Data Source
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AI summary
A sensor (100) includes a port body (102) which defines an axial passage (108) for receiving fluid. An electrical connector (104) extends through an opening in the port body near a crimp portion (112) opposite the axial passage and forms an upper seal with the port body. Within the interior of the port body, a support ring (140) and base cover (130) form a cavity (127) which retains a sensing element (134). The sensing element is exposed to the fluid within the axial passage and determines the pressure. An annular seal (132) is retained by the base cover. The crimp portion of the port body is crimped to provide an upper seal and apply a force on the components within the interior, pinching the annular seal between the sensing element and the base of the port body to create a lower seal.