Pressure Sensor Stepped Inlet for Ice Damage Mitigation
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Solution Overview
Problem
In fuel cell and electrolyzer systems, pressure sensors are prone to damage due to residual water condensation and freezing, which applies excessive force on the thin sensing diaphragm, leading to deformation or damage, especially during power loss when external heating is not feasible.
Innovation Solution
The pressure sensor design includes a connecting portion with separate gas and water openings at different elevations, allowing condensed water to drain out and reducing ice formation without an external power source, featuring a transducer portion with a pressure sensing diaphragm and a connecting portion having a bore with a stepped inlet and outlet configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure sensors are used to monitor process streams in fuel cell and electrolyzer systems, then pressure monitoring and control functions are achieved, but the sensing diaphragm is vulnerable to damage from residual water condensation and freezing
Solution Approach 1:
The connecting portion is segmented into multiple openings (first opening for gas/liquid mixture, second opening for water drainage) positioned at different elevations. This segmentation allows separate pathways for process fluid intake and condensate drainage, preventing water accumulation that would otherwise freeze and damage the sensing diaphragm during power loss conditions.
Solution Approach 2:
The invention introduces a vertical elevation dimension to the opening configuration, with the first opening positioned at a higher elevation than the second opening. This dimensional arrangement enables gravitational drainage of condensed water from the sensing cavity through the lower second opening, eliminating ice formation damage without requiring external heating during power loss.
2Object-affected harmful factors
If external heating is used to prevent ice formation, then sensing diaphragm protection is improved, but device complexity and power consumption increase
Solution Approach 1:
The pressure sensor utilizes its own structure (elevated first opening, lower second opening) to enable self-drainage of condensed water through gravity. This self-service mechanism eliminates the need for external heating systems or additional power consumption to prevent ice formation, maintaining diaphragm protection while reducing device complexity and power requirements.
Solution Approach 2:
The invention converts the harmful effect of condensed water into a beneficial drainage flow by positioning openings at different elevations. The condensed water that would normally freeze and cause damage is instead channeled through gravity-driven flow out of the sensing cavity, transforming a harmful factor into a self-cleaning mechanism that protects the sensing diaphragm without external intervention.
3Device complexity
If the connecting portion has a single opening for process fluid, then device simplicity is maintained, but water drainage capability is insufficient
Solution Approach 1:
The single opening is segmented into two separate openings positioned at different elevations: the first opening for process fluid intake and the second opening for water drainage. This segmentation provides dedicated pathways for different functions, ensuring reliable water drainage while maintaining relatively simple device structure.
Solution Approach 2:
The connecting portion with multiple openings at different elevations serves multiple functions simultaneously: it allows process fluid to enter through the first opening while enabling condensed water to drain through the second opening. This multi-functional design improves water drainage efficiency without significantly increasing device complexity.
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 effectively prevents damage to the sensing diaphragm by allowing water drainage and reducing ice formation, ensuring the pressure sensor operates reliably even during power loss without the need for an external heater, thus maintaining sensor integrity.
Implementation Method 1
The outlet is located closer to the first end than the stepped inlet. The stepped inlet includes a first surface having a gas opening and a second surface having a water opening. The first surface is located closer to the first end than the second surface.
Data Source
AI summary
A pressure sensor includes a transducer portion containing a pressure sensing diaphragm, and a connecting portion having a first end in fluid communication with the transducer portion and a second end located opposite to the first end. The connecting portion includes a bore having an outlet and a stepped inlet. The outlet is located closer to the first end than the stepped inlet. The stepped inlet includes a first surface having a gas opening and a second surface having a water opening. The first surface is located closer to the first end than the second surface.