Integrated Pressure Sensor Substrate for Exhaust Aftertreatment
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Solution Overview
Problem
Existing exhaust aftertreatment systems for internal combustion engines, particularly those using selective catalytic reduction (SCR), face high costs due to complex pressure sensing systems required for accurate pressure measurement and response.
Innovation Solution
A pressure sensing system with a substrate that flexes based on fluid pressure, utilizing voltage dividers and a control module with switches and an amplifier to convert analog signals to digital values, allowing for precise pressure measurement and adjustment of fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional pressure sensors with separate controllers and wiring are used, then pressure measurement functionality is achieved, but system cost increases
Solution Approach 1:
The patent combines the pressure sensor and controller into a single integrated pressure control module. The substrate integrates the sensing element, voltage dividers, switches, capacitor, amplifier, and ADC circuitry all on one board, eliminating the need for separate controllers and extensive wiring harnesses, thus reducing system complexity and cost while maintaining measurement precision
Solution Approach 2:
The integrated substrate serves multiple functions: it acts as the structural support, the sensing element detects pressure, the voltage dividers condition signals, the switches route signals, the capacitor stores charge, the amplifier boosts signals, and the ADC converts analog to digital. This multi-functionality reduces the number of discrete components needed in the system
2Adaptability or versatility
If multiple discrete components are used in the pressure sensor, then functional requirements are met, but manufacturing cost increases
Solution Approach 1:
Multiple discrete components (sensing element, voltage dividers, switches, capacitor, amplifier, ADC) are merged onto a single substrate, reducing the total component count and simplifying assembly processes, which directly lowers manufacturing costs while maintaining full pressure sensing functionality
Solution Approach 2:
The patent changes the physical state and integration level of components by transitioning from discrete through-hole or surface-mount components to integrated circuit implementation on a substrate, which simplifies manufacturing and reduces assembly steps
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 solution reduces the cost and complexity of pressure sensing while maintaining precision, enabling effective adjustment of fluid flow in exhaust aftertreatment systems, thereby improving emission control.
Implementation Method 1
a substrate that is fixed within the housing, that includes a first side that is in contact with a fluid of the exhaust aftertreatment system, and that flexes based on a pressure of the fluid at the first side
Implementation Method 2
a first voltage divider that is connected between a first reference potential and a ground potential and that varies a first potential based on flexing of the substrate; and a second voltage divider connected in parallel with the first voltage divider between the first reference potential and the ground potential and that varies a second potential based on flexing of the substrate
Data Source
AI summary
A pressure sensor includes: a housing; a substrate that is fixed within the housing, that includes a first side that is in contact with a fluid of an exhaust aftertreatment system, and that flexes based on a pressure of the fluid; a first voltage divider that is connected between a first reference potential and a ground potential and that varies a first potential based on flexing of the substrate; and a second voltage divider connected in parallel with the first voltage divider between the first reference potential and the ground potential and that varies a second potential based on flexing of the substrate. A pressure control module is configured to selectively switch switches to connect and disconnect different reference potentials to and from an amplifier, to sample an output of the amplifier, and to convert samples of the output of the amplifier into corresponding digital values.