Gel-Coupled Force Sensor for Bubble and Blockage Detection
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Solution Overview
Problem
Conventional fluid occlusion sensors are limited by features such as a steel ball that blocks light from reaching the photosensitive force sensing element, reducing accuracy in detecting bubbles and blockages.
Innovation Solution
A gel-coupled force sensor with a substrate, force sensing element, ASIC, gel, mesh, barrier, and membrane layers, and optionally an ultrasonic transducer, which allows for increased accuracy in detecting occlusions by eliminating the steel ball and using light sources or ultrasonic transducers to measure changes in light or ultrasonic signal amplitudes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a steel ball is used in conventional force sensors, then the sensor structure is simple, but the steel ball blocks light from reaching the photosensitive force sensing element, reducing detection accuracy
Solution Approach 1:
The patent removes the steel ball component from the sensor structure entirely. Instead of using a steel ball that blocks light, the invention uses a gel-coupled force sensing element that directly contacts the fluid and transmits force to the photosensitive element without blocking light paths, thereby eliminating the source of light obstruction while maintaining structural functionality.
Solution Approach 2:
The patent introduces gel as an intermediary coupling material between the fluid and the force sensing element. This gel coupling allows direct mechanical contact and force transmission from the fluid to the sensor without requiring a steel ball, enabling light to pass through to the photosensitive element while maintaining detection capability.
2Measurement precision
If light sources are used to illuminate fluid in the flow tube, then bubble and blockage detection is enabled, but the steel ball blocks the light path, reducing measurement precision
Solution Approach 1:
The patent eliminates the steel ball that causes light obstruction by replacing it with a gel-coupled force sensing system. This removal allows light sources to illuminate the fluid in the flow tube without being blocked, enabling accurate detection of bubbles and blockages through light transmission measurements.
Solution Approach 2:
The patent replaces the mechanical steel ball system with an optical measurement system using light sources. Instead of relying on mechanical components to detect occlusions, the system uses light transmission through the fluid to detect bubbles and blockages, substituting mechanical obstruction with optical measurement capability.
3Reliability
If conventional sensors with steel balls are used, then the device structure is straightforward, but the steel ball prevents accurate detection of occlusions
Solution Approach 1:
The patent removes the unreliable steel ball component that prevents accurate occlusion detection. By extracting this problematic element and replacing it with a gel-coupled force sensing system, the patent achieves more reliable detection while maintaining a manageable device structure through modular design.
Solution Approach 2:
The patent uses composite material structures including gel coupling material combined with force sensing elements and photosensitive components. This composite approach integrates multiple functional materials to achieve both reliable force transmission and optical transparency, improving detection reliability without excessive complexity.
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 provides enhanced precision and accuracy in detecting the presence and size of occlusions in fluid flow tubes, such as in infusion pumps, by eliminating light obstruction and utilizing direct mechanical contact and signal amplitude changes.
Implementation Method 1
The light source is configured to emit light through the fluid flow tube to illuminate the fluid contained within the fluid flow tube
Implementation Method 2
ultrasonic transducers to measure changes in light or ultrasonic signal amplitudes
Data Source
AI summary
A device comprising a gel-coupled force sensor for detecting bubbles and/or blockages in fluids using light sources and/or ultrasonic transducers is provided. The devices may include a housing having a gel-coupled force sensor, wherein the gel-coupled force sensor comprises a substrate, at least one force sensing element, at least one application-specific integrated circuit (ASIC), a cover for the at least one force sensing element and the at least one ASIC, a gel for covering the force sensing element, a mesh layer proximate to the top of the gel, a barrier layer proximate to the mesh layer, and a membrane layer proximate to the barrier layer protruding at least a distance past an edge of the cover. The gel-coupled force sensor may surround a fluid flow tube. The housing may comprise a first light source and a second light source and/or an ultrasonic transducer.