Pressure Sensor Header Elastic Sealing Design
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Solution Overview
Problem
Existing pressure sensors face challenges in manufacturing simplicity, durability, and accuracy due to the use of multiple components and O-rings, which can lead to increased costs, mechanical stress, and temperature-related errors.
Innovation Solution
A pressure sensor design featuring a sensor header with a flange and diaphragm configuration, where the flange is spaced apart from the sensor housing, and a manufacturing method using an exclusive jig to pressurize the flange without the diaphragm, reducing the number of parts and preventing mechanical stress and temperature-related errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components and O-rings are used in the pressure sensor assembly, then sealing capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates the sealing function directly into the sensor header structure by forming an elastic deformation portion that directly contacts the housing, eliminating the need for separate O-rings and gaskets. This merging of sealing function into the structural component reduces part count while maintaining reliable sealing.
Solution Approach 2:
The sensor header's elastic deformation portion automatically provides sealing through its inherent elasticity when pressed against the housing during assembly. The material properties of the sensor header itself enable the sealing function without requiring additional sealing components, making the system self-sufficient.
2Reliability
If multiple components and O-rings are used in the pressure sensor assembly, then sealing capability is improved, but manufacturing time and cost increase
Solution Approach 1:
The sensor header is designed as an integrated component where the sealing function is built-in through the elastic deformation portion. This eliminates the need for separate assembly steps to install O-rings and gaskets, reducing manufacturing time and simplifying the production process.
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate components (O-rings, gaskets, sealants) from the assembly process. By removing these extra parts, the manufacturing process becomes more efficient with fewer assembly steps, directly reducing production time and cost.
3Reliability
If O-rings are used for sealing between sensor header and housing, then sealing is achieved, but O-ring corrosion and mechanical stress occur
Solution Approach 1:
The patent removes O-rings and other separate sealing components from the design, eliminating the source of corrosion and mechanical stress problems. The sealing function is transferred to the sensor header structure itself, which is made from materials resistant to these issues.
Solution Approach 2:
Instead of using expensive O-rings that are prone to degradation, corrosion, and mechanical stress, the patent employs the sensor header's own structural elasticity for sealing. This eliminates the need for replaceable sealing components that have limited service life.
4Ease of manufacture
If the flange is pressed against the sensor housing during assembly, then the sensor header is secured, but mechanical stress and temperature-related errors are introduced
Solution Approach 1:
The patent segments the contact interface by providing a dedicated contact surface on the sensor header that is separated from the diaphragm sensing area. This allows the flange to be secured to the housing without transmitting mechanical stress or temperature variations to the sensitive diaphragm, preserving measurement accuracy.
Solution Approach 2:
The patent introduces a dedicated contact surface as an intermediary between the flange and the sensor housing. This intermediary surface allows mechanical securing while preventing the transmission of harmful stresses and temperature variations to the diaphragm, thus protecting measurement precision.
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 reduces manufacturing costs and time, enhances durability by preventing O-ring corrosion and mechanical stress, and improves accuracy by minimizing errors caused by temperature changes and the press-in process.
Implementation Method 1
A portion of the sensor header may be elastically deformed to seal with the sensor housing
Implementation Method 2
a press-in part positioned behind the insert based on a direction in which the port is inserted into the housing pathway
Data Source
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AI summary
A pressure sensor according to one embodiment can comprise: a sensor housing including a fastening part fastened to an object for which pressure is measured, and a housing pathway penetrating the fastening part so as to guide a fluid introduced from the pressure measurement target; and a sensor header including a port fixed to the housing pathway by an indentation method, a header pathway penetrating the port so as to guide the fluid introduced from the housing pathway, and a diaphragm located at an end part of the header pathway.