Additively Manufactured Pressure Sensor-Regulator Without Welds
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Solution Overview
Problem
Traditional pressure sensing assemblies (TPSAs) for vacuum actuated cylinders (VACs) are complex, with numerous components that lead to inconsistent performance and manufacturing defects, resulting in issues like gas spikes and pressure oscillations, making it difficult to identify and rectify failures.
Innovation Solution
A pressure sensing device (PSD) with a unitary construction, manufactured via additive manufacturing, eliminating the need for welding and using materials like stainless steel or polymers, which includes a housing and a pressure reducing mechanism with a movable portion and O-rings, configured to regulate fluid pressure without bellows or flexible diaphragms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional pressure sensing assembly with multiple components is used, then pressure sensing function is achieved, but device complexity increases and manufacturing precision decreases
Solution Approach 1:
The patent combines multiple separate components (housing, bellows, diaphragm, valve mechanism) into a single integrated pressure sensing assembly. This merging eliminates the need for complex assembly of 10+ separate parts, reducing assembly steps and improving manufacturing consistency while maintaining the pressure sensing function.
Solution Approach 2:
The integrated assembly is designed with distinct functional zones (pressure input chamber, sensing element, valve mechanism, output chamber) that work together as a unified system. This functional segmentation within a single component achieves both simplicity and precise pressure regulation.
2Reliability
If multiple components are assembled and welded, then pressure sensing function is achieved, but reliability decreases due to potential manufacturing defects
Solution Approach 1:
By integrating all pressure sensing components into a single molded unit, the patent eliminates multiple welding joints and assembly interfaces that could become failure points. The single-component design removes welding operations entirely, significantly improving reliability while simplifying manufacturing.
3Manufacturing precision
If components are manufactured at different locations by different manufacturers, then manufacturing flexibility is achieved, but manufacturing precision decreases due to varying tolerances
Solution Approach 1:
The patent consolidates all pressure sensing components into a single integrated part that can be manufactured in one location using injection molding or similar processes. This eliminates the need to coordinate manufacturing across multiple suppliers and ensures consistent tolerances throughout the assembly.
4Object-generated harmful factors
If traditional pressure sensing assembly is used, then pressure regulation is achieved, but harmful factors increase due to gas spikes and pressure oscillations
Solution Approach 1:
The integrated design creates a unified pressure regulation system where the bellows, diaphragm, and valve mechanism work as a coordinated whole. This eliminates dead zones and pressure discontinuities that occur in assembled systems, reducing gas spikes and oscillations while maintaining effective pressure control.
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 PSD achieves consistent performance, reduces gas spikes and pressure oscillations, and simplifies manufacturing by eliminating defects and assembly steps, ensuring reliable operation.
Implementation Method 1
a bellows (144) configured to expand and contract in response to a pressure differential across the bellows
Implementation Method 2
a diaphragm (146) disposed between the first chamber and the second chamber and flexing in response to a pressure differential across the diaphragm
Data Source
AI summary
A high pressure fluid storage system with at least one pressure sensing device (PSD) which can perform the function of a pressure regulator device. The PSD can be manufactured via an additive manufacturing process to include a first and a second single unitary constructions, wherein the housing body and the internal pressure regulating mechanism are made together during the process. The PSD can be made without any welded components or bellows.