Pressure Sensor Header Assembly for High-Pressure Sealing
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Solution Overview
Problem
Existing pressure sensors face challenges in achieving high-pressure sealing due to complex designs requiring precise machining and welding, which can lead to sealing issues and increased manufacturing costs.
Innovation Solution
A pressure sensor design featuring a hex bolt assembly with a hex port and header, utilizing a retainer ring or circlip to secure a header with an O-ring for sealing, eliminating the need for complex welding joints and reducing machining complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pressure sensor designs with multiple components and joints are used, then high-pressure sealing can be achieved, but manufacturing complexity and welding requirements increase
Solution Approach 1:
The patent combines multiple components (header, retainer ring, O-ring groove, and sealing elements) into a single integrated header assembly. The header includes integrated features such as the O-ring groove, retainer ring positioning structures, and media inlet pathways, eliminating the need for separate welding joints and reducing assembly complexity while maintaining high-pressure sealing integrity.
Solution Approach 2:
The sealing function is segmented into distinct functional elements: the O-ring provides the primary sealing interface, the retainer ring secures the header in position, and the groove structures provide precise positioning. This segmentation allows each element to be optimized independently while simplifying the overall assembly process.
2Reliability
If precise machining and welding joints are used in conventional designs, then sealing integrity can be maintained, but manufacturing costs and production time increase
Solution Approach 1:
The patent replaces welding joints with mechanical retention systems. The retainer ring, positioned within the hex port, mechanically secures the header assembly without requiring welding operations. This substitution eliminates the need for precise welding procedures, reduces manufacturing costs, and accelerates production while maintaining sealing integrity through the O-ring and groove interface.
Solution Approach 2:
The header assembly includes self-aligning features such as the O-ring groove and retainer ring positioning structures that automatically ensure proper sealing contact during assembly. This self-service mechanism eliminates the need for complex alignment procedures and precision welding, reducing both manufacturing cost and production time.
3Reliability
If complex welding joints are used to achieve high-pressure sealing, then sealing reliability can be improved, but the risk of weld leaks and manufacturing defects increases
Solution Approach 1:
The patent eliminates welding joints entirely by using a mechanical retention system with the retainer ring and O-ring groove interface. This substitution removes the source of weld leaks and welding-related manufacturing defects, providing a more reliable sealing solution that is free from the harmful effects associated with improper welding operations.
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 enhances high-pressure sealing by minimizing weld leak paths and manufacturing costs while maintaining effective sealing integrity.
Implementation Method 1
an O-ring in the groove that forms a sealing joint between the groove and a sidewall of the hex port
Data Source
AI summary
A pressure sensor comprising a hex bolt assembly comprising a hex port and an inlet that is coupled to a base of the hex port; a header that is configured at the base of the hex port, wherein the header comprises (i) a groove within a circumference of the header and (ii) an O-ring in the groove that forms a sealing joint between the groove and a sidewall of the hex port; and a retainer ring that is configured in the hex port to retain the header between the retainer ring and the inlet.