Modular Flow Sensor with Disposable Element for Drug Delivery

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Solution Overview

Problem

Existing flow sensing devices are inadequate for accurately measuring low flow rates in drug delivery systems, often resulting in over- or under-dosing due to inaccuracies and high-pressure drops, and are prone to damage from harsh cleaning conditions.

Innovation Solution

A modular flow sensing device with a disposable sensing element and separate processing circuitry, featuring a heating control circuit to detect bubbles and maintain temperature stability, allowing for precise flow rate measurement and resistance to harsh cleaning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a flow sensing device is used to measure low flow rates, then measurement precision is improved, but the device is prone to damage from harsh cleaning conditions and high-pressure drops occur

Engineering Contradiction:

Improveflow rate measurement precisionVSAvoiddevice durability under cleaning conditions

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The flow sensing device is divided into separate modules: a disposable flow sensor module containing the sensing element and flow path, and a reusable processing module containing the electronics. This segmentation allows the disposable module to be replaced after cleaning cycles, protecting the expensive electronics while enabling continuous use of the device for low flow rate measurements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flow sensor module with the sensing element and flow path is designed as a disposable component that can withstand harsh cleaning conditions. After a certain number of cleaning cycles or when performance degrades, this module is discarded and replaced, while the expensive processing electronics are retained and reused, solving the reliability issue without compromising measurement precision.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Measurement precision

If a flow sensing device measures low flow rates, then measurement precision is improved, but pressure drop increases

Engineering Contradiction:

Improvelow flow rate measurement precisionVSAvoidpressure drop

Core Design Contradiction:

Measurement precisionVSStress or pressure

Solution Approach 1:

The device uses a thermal flow sensing mechanism where a heating element heats the flow path and a temperature sensor detects temperature changes caused by fluid flow. By measuring the temperature differential rather than using restrictive mechanical components, the device can measure very low flow rates (including ultra-low flow rates) without creating significant pressure drops in the fluid path.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If a modular design with disposable sensing element is used, then reliability under cleaning conditions is improved, but device complexity increases

Engineering Contradiction:

Improveresistance to cleaning agentsVSAvoidmodular assembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The disposable flow sensor module integrates multiple functions including the flow path, heating element, temperature sensor, and bubble detection capabilities into a single unified component. This merging of functions simplifies the overall system architecture and makes the modular design more manageable despite the increased complexity of having replaceable modules.

Inventive Principle:

Principle #5Merging (Combining)

4Measurement precision

If a heating control circuit is used to detect bubbles, then measurement precision is improved, but energy consumption increases

Engineering Contradiction:

Improvebubble detection accuracyVSAvoidheating element energy consumption

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The heating element operates continuously at a controlled power level to maintain a temperature differential across the flow path. This continuous operation enables real-time bubble detection as bubbles pass through the heated zone, providing precise measurement without requiring intermittent high-energy heating pulses, thus balancing measurement precision with energy consumption.

Inventive Principle:

Principle #20Continuity of useful 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

The modular design enhances accuracy and durability, preventing damage from cleaning agents and enabling reliable bubble detection, thus ensuring precise flow rate measurement and reducing the risk of errors in drug delivery systems.

Implementation Method 1

controlling a thermal output of a heating element to maintain a predetermined temperature

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

the flow path is disposed proximate the sensing element such that at least a portion of the flowing media makes direct contact with the sensing element

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11959787B2Flow sensing device

Publication Date: 2024.04.16 HONEYWELL INTERNATIONAL INC

AI summary

Methods and apparatuses associated with flow sensing devices are provided. An example flow sensing device may include a sensing element disposed at least partially within the housing, and a plurality of channels disposed within the housing defining a flow path configured to convey a flowing media through the flow sensing device, wherein the flow path is disposed proximate the sensing element such that at least a portion of the flowing media makes direct contact with the sensing element.