Pressure Sensor Adapter Screen for Stress Isolation

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Solution Overview

Problem

Pressure sensors with front seals face challenges in reducing stress transfer to the sensing element, leading to reduced accuracy in high-pressure and high-temperature environments, and there is a need to improve sensors with Helmholtz resonators.

Innovation Solution

The design incorporates a sensing element with a header, housing, and adaptor, where first and second gaps are used to isolate stress from the sensing element and header, and a screen integrated with the adaptor forms a Helmholtz resonator to control geometric tolerances and reduce stress transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If a front seal is formed directly between the header surface and the engine surface or on an adaptor welded close to the header, then the sensor can be used in combustion measurements requiring reduced volume, but the seal places undue stress on the header which transfers stress to the sensing element

Engineering Contradiction:

Improvesensor volumeVSAvoidmeasurement accuracy

Core Design Contradiction:

Volume of moving objectVSMeasurement precision

Solution Approach 1:

The patent divides the adaptor structure into multiple segments: a first adaptor portion welded to the screw housing, a second adaptor portion with the front seal surface, and a screen portion. These segments are separated by gaps that prevent stress transfer to the header while maintaining the compact front seal configuration for combustion measurements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The screen and gap structures act as intermediary elements between the second adaptor portion and the header. These intermediaries absorb and isolate stress from the front seal, preventing it from reaching the sensing element while still allowing the compact sensor design to function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a metal-to-metal front seal is used on the adaptor, then the sensor can seal against the mating surface, but a large amount of stress is generated and transferred to the sensing element

Engineering Contradiction:

Improvesealing reliabilityVSAvoidsensing element accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The adaptor is segmented into a first adaptor portion that handles the sealing function against the mating surface, and a second adaptor portion that is isolated from the header by gaps. This segmentation allows the seal to generate necessary stress for reliability while preventing that stress from transferring to the sensing element.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The screen and gaps serve as intermediary structures that decouple the stress-generating seal from the sensitive sensing element. The screen provides structural support and stress distribution, while the gaps provide stress isolation, allowing the seal to maintain reliability without compromising accuracy.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If multiple adaptors are welded or press fitted to the screw housing, then the sensor assembly can accommodate the front seal configuration, but dimensional tolerances and stress distribution become difficult to control

Engineering Contradiction:

Improvefront seal configurationVSAvoiddimensional tolerance control

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent merges the screen and adaptor portions into a single integrated component. This consolidation reduces the number of separate parts and welding operations, thereby improving dimensional tolerance control while still providing the necessary front seal configuration and stress isolation features.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

While merging the screen and adaptor, the design maintains functional segmentation through gaps that separate different stress zones. This allows the integrated component to achieve better manufacturing precision while still accommodating the complex front seal configuration required for various applications.

Inventive Principle:

Principle #1Segmentation

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 configuration reduces stress transfer and improves frequency response accuracy, allowing for precise pressure measurements while minimizing wear and corrosion, and achieving a response time of less than 50 microseconds.

Implementation Method 1

a screen integrated with the adaptor forms a Helmholtz resonator to control geometric tolerances and reduce stress transfer

Methodology Applied

Scientific EffectHelmholtz resonator: Helmholtz Resonance

Data Source

PatentUS10295426B2Pressure sensor having an adapter joined with a screen for dimensional tolerance control

Publication Date: 2019.05.21 KULITE SEMICON PROD INC

AI summary

This disclosure provides example methods, devices, and systems for a sensor having a front seal. In one embodiment, a system may comprise a sensing element; a header coupled to the sensing element; a housing coupled to the header; a screen joined to an adaptor and coupled to the housing, wherein a first gap separates the adaptor and the sensing element and a second gap separates the adaptor and the header; and wherein a stress applied at a front surface of the adaptor is transferred to the housing, and the first gap is used to isolate the sensing element from the stress and the second gap is used to isolate the header from the stress.