In-Line Gas Sensor Flow-Aperture Optical Path Control

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Solution Overview

Problem

Existing gas sensors face challenges in accurately measuring low concentrations of target gases due to blockages or impediments that disrupt the optical path between the light source and detector, necessitating improved design to minimize obstructions and enhance optical path control.

Innovation Solution

The apparatus includes an illumination carrier and a detector carrier coupled with a sample chamber, where ports are fluidly coupled behind the light source and detector, allowing for controlled geometry and passage of gas through substrates with flow apertures, enhancing the measurement of target gas concentrations using non-dispersive infrared detection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional gas sensor design is used, then device complexity is reduced, but measurement precision deteriorates due to blockages in optical path

Engineering Contradiction:

Improvegas concentration measurement accuracyVSAvoidoptical path control structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The device is divided into separate functional modules: illumination carrier with light source, detector carrier with detector, and sample chamber. Each carrier is a distinct component that can be independently manufactured and assembled, reducing overall device complexity while maintaining precision through modular optical path control

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Flow apertures in the substrates of illumination and detector carriers serve as intermediaries to control gas flow between the carriers and sample chamber. These apertures enable precise optical path control by allowing gas to pass through specific locations, eliminating blockages while maintaining measurement accuracy

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If ports are positioned behind light source and detector, then optical path unobstruction is improved, but device complexity increases due to substrate integration requirements

Engineering Contradiction:

Improveoptical path unobstructionVSAvoidsubstrate flow aperture integration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The flow apertures are integrated directly into the substrates of the illumination and detector carriers, merging the gas flow control function with the structural support function. This integration ensures unobstructed optical paths while avoiding additional complex components by combining multiple functions into single substrate elements

Inventive Principle:

Principle #5Merging (Combining)

3Measurement precision

If non-dispersive infrared detection is used, then measurement precision for low concentrations is improved, but use of energy increases due to continuous illumination requirements

Engineering Contradiction:

Improvelow concentration gas detectionVSAvoidlight source energy consumption

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The light source operates in periodic cycles rather than continuously, with illumination pulses separated by dark periods. This periodic operation enables the detector to measure absorbance changes at specific wavelengths for low concentration detection while significantly reducing overall energy consumption compared to continuous illumination

Inventive Principle:

Principle #19Periodic action

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 design minimizes obstructions, enabling accurate measurement of target gas concentrations by ensuring unobstructed light paths and allowing for precise sensing of low concentrations of gases, particularly in environments like wellsites and industrial facilities.

Implementation Method 1

The apparatus may be a non-dispersive infrared detector. The light source may be a light emitting diode.

Methodology Applied

Scientific EffectNon-dispersive infrared detection: Absorption Spectroscopy

Implementation Method 2

Spectroscopy offers a useful approach for sensing the concentration of a chosen target gas, as it can be specific to a target gas even in a mix of other gases

Methodology Applied

Scientific EffectInfrared absorption: Absorption (EM radiation)

Implementation Method 3

The illumination circuit board may include at least one flow aperture which allows passage of fluid through a thickness of the illumination circuit board, and the detector circuit board may include at least one flow aperture which allows passage of fluid through a thickness of the detector circuit board

Methodology Applied

Scientific EffectFluid flow through apertures:

Data Source

PatentUS20250305946A1In-line gas sensor and sensing methods

Publication Date: 2025.10.02 INTEGRITY COMM SOLUTIONS INC

AI summary

Apparatuses, systems, and methods for in-line gas sensor. The gas sensor includes a first circuit board which supports an illumination source and a second circuit board which supports a detector with a sample chamber positioned between the first and the second circuit board. A gas sample passes through the first circuit board and the second circuit board to enter/exit the sample chamber. Each circuit board may have one or more flow apertures which allow the gas sample to pass through the circuit board to get to/from an interior of the sample chamber.