Pressure Sensor Double-Stage Fluid Protection
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Solution Overview
Problem
Current pressure sensors designed for fluid tanks require high tightness and complex assembly, making them costly and maintenance-intensive due to direct exposure to aggressive fluids, which complicates integration and calibration.
Innovation Solution
A compact pressure sensor design with double-stage fluid protection, featuring a cap connected to a chemically resistant board and integrated circuit, allowing the sensor to be fully submerged in the fluid with minimal external components, facilitating easy installation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the pressure sensor is designed with direct exposure to aggressive fluids for accurate measurement, then measurement precision is improved, but reliability deteriorates due to fluid corrosion and damage
Solution Approach 1:
The pressure sensor is divided into two functional segments: a measurement diaphragm that contacts the aggressive fluid for accurate pressure detection, and protected housing containing the electronics that remains isolated from the fluid. This segmentation allows the sensor to maintain measurement precision while protecting sensitive components from fluid corrosion and damage.
2Reliability
If the pressure sensor uses complex assembly with high tightness requirements for fluid protection, then reliability is improved, but device complexity increases
Solution Approach 1:
The housing is designed to integrate multiple functions into a single component: it provides mechanical protection for the electronics, ensures fluid tightness through integrated sealing structures, and facilitates installation. This merging of functions reduces the number of separate parts and simplifies assembly while maintaining high reliability for fluid protection.
3Volume of moving object
If the pressure sensor is designed with compact size for space efficiency, then volume is reduced, but ease of manufacture deteriorates due to tighter tolerances
Solution Approach 1:
The pressure sensor employs a nested structure where the measurement diaphragm is integrated into the housing, and the electronics are housed within the same compact unit. This nesting allows multiple components to occupy overlapping or adjacent spaces, achieving a compact overall volume while maintaining manufacturability through standardized component integration.
4Measurement precision
If the pressure sensor requires extensive calibration and integration work for tank installation, then measurement precision is maintained, but loss of time increases
Solution Approach 1:
The pressure sensor is pre-calibrated and pre-assembled as a complete functional unit before delivery to the customer. The housing is pre-integrated with mounting features and sealing elements, allowing the sensor to be installed in the tank without requiring extensive on-site calibration or assembly work. This preliminary preparation maintains measurement precision while significantly reducing installation time.
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 compact design enhances assembly and positioning flexibility, reduces space requirements, and enables cost-effective, maintenance-friendly integration within fluid tanks, while maintaining accurate pressure measurements and temperature compensation.
Implementation Method 1
measuring resistors are arranged, by means of which the change in resistance is used to determine the effect of applied pressure or a pressure change. This change in resistance results from a deflection of the diaphragm from its rest position due to a change in applied pressure and the associated tensile or compressive stress on the diaphragm.
Implementation Method 2
The materials of the pressure sensor must therefore be resistant to the various components of the fluid. This protection is provided by a cap connected to a board holding the circuit and the sensor chip.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
The sensor (1) has an integrated circuit (13) mounted on a board (3) for processing and forwarding electrical signal of a pressure transmitter (7). A cap (21) is sealingly connected with the board so that the transmitter and the circuit are sealingly enclosed by the cap, which is made of fluid resistant material. A protection unit is arranged in a chamber (25), which encloses the cap and the board, for fluid-resistant protection of the transmitter and the circuit. A conductive path (9) is covered by a protective layer made of glass. An independent claim is also included for a fluid tank for storage and transport of fluid media.