Pressure Transducer Structure for 1000 Bar Hydrogen Sensing
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Solution Overview
Problem
Pressure measuring sensors face challenges in measuring high pressures, particularly in hydrogen-containing environments, due to hydrogen diffusion through metallic diaphragms leading to measurement errors and mechanical instability, and limitations in pressure measurement range due to clamping forces and seal materials that are not diffusion-tight, posing explosion risks.
Innovation Solution
A pressure measuring sensor with a pressure sensor mounted on connection elements within a sensor housing, comprising two deformable measuring bodies and an electromechanical transducer that converts pressure-dependent deformations into an electrical measurement variable, ensuring isostatic pressure exposure and using hydrogen-diffusion-tight feedthroughs and a metal or stainless steel housing for enhanced durability and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallic diaphragm seal is used to transmit pressure, then pressure transmission is achieved, but hydrogen diffusion occurs leading to measurement errors and embrittlement
Solution Approach 1:
The patent introduces a hydrogen-diffusion-tight feedthrough as an intermediary component between the hydrogen-containing medium and the pressure sensor. This feedthrough acts as a mediator that transmits pressure while blocking hydrogen diffusion, thereby resolving the contradiction between maintaining pressure transmission and preventing hydrogen embrittlement
Solution Approach 2:
The patent employs composite construction by combining the pressure sensor with a hydrogen-diffusion-tight feedthrough made of different materials (ceramic or metal). This composite structure integrates the pressure-sensing function with the hydrogen-barrier function, allowing simultaneous achievement of pressure transmission and hydrogen protection
2Ease of operation
If clamping devices with seal materials are used to mount the pressure sensor, then the sensor is secured in the housing, but the seals are not diffusion-tight creating explosion risks
Solution Approach 1:
The hydrogen-diffusion-tight feedthrough serves as an intermediary mounting structure that replaces conventional non-diffusion-tight seals. It provides both mechanical securing of the sensor and hydrogen-tight sealing, eliminating the need for separate seal materials that compromise diffusion protection
Solution Approach 2:
The patent replaces the mechanical sealing system (clamping devices with elastomeric seals) with a feedthrough structure that provides inherent hydrogen-tight sealing. This substitution eliminates the reliance on seal materials that are permeable to hydrogen, thereby removing explosion risks while maintaining sensor mounting functionality
3Ease of operation
If conventional clamping methods are used to secure the pressure sensor, then the sensor is fixed in place, but high clamping forces limit the pressure measurement range
Solution Approach 1:
The feedthrough acts as an intermediary mounting structure that distributes and accommodates clamping forces differently than conventional direct clamping methods. This intermediary structure enables secure sensor fixation while withstanding higher pressure loads, thereby expanding the measurable pressure range
Solution Approach 2:
The patent changes the mounting parameters by using a feedthrough structure with specific mechanical properties (strength, stiffness, geometry) that allow higher clamping forces to be applied without limiting the pressure measurement range. This parameter change enables both secure fixation and extended measurement capability
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
Enables accurate measurement of high pressures up to 1000 bar with reduced mechanical stress on connections, maintaining measurement accuracy and preventing hydrogen diffusion, thus overcoming limitations of existing technologies.
Implementation Method 1
an electromechanical transducer which converts a mechanical variable that is dependent on a sum of the pressure-dependent deformations of both measuring bodies into a measurable electrical measurement variable
Implementation Method 2
a layer of aluminum oxide is arranged on the outer side of the separating diaphragm. Aluminum oxide has a hydrogen diffusion coefficient which is significantly lower than the hydrogen diffusion coefficients of metallic layers
Data Source
AI summary
An overload-resistant pressure measuring sensor includes a pressure sensor arranged in an interior of a sensor housing and can be exposed, through an opening in the sensor housing, to a medium under pressure of up to 1000 bar. The medium may be a hydrogen-containing medium and can be measured with high measurement accuracy. The pressure sensor is mounted on connection elements protruding into the interior and free-standing in the interior such that the pressure sensor is exposed to the pressure prevailing in the interior on all sides. The pressure sensor includes two ceramic measuring bodies connected to one another while enclosing a pressure chamber, and are each deformable by the pressure acting thereon, and further includes an electromechanical transducer which converts a mechanical variable that is dependent on a sum of the pressure-dependent deformations of both measuring bodies into a measurable electrical measurement variable.