Modular Differential Pressure Sensor with Sealed Diaphragm and Strain Gauge
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Solution Overview
Problem
Existing differential pressure sensors face challenges in manufacturing complexity, high costs, and the need for complex interconnections due to the requirement of sealed connections between the diaphragm section and the wall, as well as the need for fluid-tight insulation of strain gauges, making them costly and difficult to adapt to different application areas.
Innovation Solution
A differential pressure sensor design featuring a membrane directly connected to the housing wall with a sealing connecting section, fluid-tight insulation of the strain gauge, and a modular structure with integrated electronic components, allowing for easy assembly and adaptation to various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sealed connection between the diaphragm section and the wall is required, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent integrates the diaphragm section directly with the housing wall, eliminating the need for separate sealing components. The diaphragm section is formed as an integral part of the housing structure, where the back side of the diaphragm section directly abuts against the inner wall surface, creating a sealed connection without additional seals or mounting brackets.
Solution Approach 2:
The housing wall serves multiple functions: it provides structural support, creates the reference volume, and directly seals the diaphragm section. The integration of the diaphragm section with the wall allows the same structural element to fulfill both mechanical support and sealing functions simultaneously.
2Reliability
If strain gauge is fluid-tight insulated from the measuring volume, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The strain gauge is integrated directly onto the diaphragm section, and the diaphragm section itself serves as the fluid-tight barrier. The strain gauge is positioned on the front side of the diaphragm section, which is in direct contact with the measuring volume, while the back side abuts against the housing wall, creating a natural seal without additional insulation layers or protective housings.
Solution Approach 2:
The diaphragm section itself provides the fluid-tight insulation for the strain gauge through its position and integration with the housing wall. The structure serves its own sealing function, eliminating the need for separate insulation components.
3Measurement precision
If complex interconnections between components are required, then measurement precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent combines multiple functions into integrated components: the housing wall simultaneously provides structural support, defines the reference volume, and seals the diaphragm section. The diaphragm section is directly formed with the housing, eliminating separate mounting operations and reducing assembly steps while maintaining the precise geometric relationships needed for accurate measurement.
4Measurement precision
If differential pressure sensor is adapted to specific application areas, then measurement precision is improved, but adaptability deteriorates
Solution Approach 1:
The integrated design of the diaphragm section with the housing wall creates a universal structure that can be adapted to different application areas without requiring complex customizations. The basic integrated structure remains the same, but the housing geometry and diaphragm dimensions can be modified to suit different pressure ranges, fluid types, and installation requirements while maintaining the sealed connection principle.
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 enables a cost-effective, easily manufactured, and robust differential pressure sensor suitable for adverse environments, with reduced measurement errors and simplified integration into fluid-carrying systems, while maintaining precision under fluctuating conditions.
Implementation Method 1
a strain gauge arranged on the diaphragm within the diaphragm section... a strain gauge changes its electrical resistance depending on a mechanical force load
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5b
AI summary
The invention relates to a differential pressure sensor 1 comprising a housing with a wall and a diaphragm 3 extending horizontally over a diaphragm section having a first and a second horizontally extending flat side, wherein the wall and the diaphragm section with its first flat side together define a measuring volume in the housing and wherein the second flat side of the diaphragm section adjoins a reference volume, wherein the differential pressure sensor 1 has a strain gauge 4 arranged within the diaphragm section on the diaphragm 3.The membrane section is completely enclosed by a connecting section of the membrane 3 and is continuously sealed to the wall by the connecting section, and the strain gauge 4 is fluid-tight insulated from the measuring volume, wherein in particular the wall has a connection nozzle with a connection opening 100, 200 opening into the measuring volume in a wall section spaced apart from the membrane section.