Seal Board Assembly for Field Device Bulkhead Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pressure transmitters face challenges in cost-effectively passing a high density of individual electrical signals through a bulkhead while maintaining electrical isolation and environmental sealing, as current methods like stamped brazed RFI filter tub assemblies are complex and costly, and individual screw-in filter assemblies are not efficient.
Innovation Solution
A seal board with a printed circuit board, conductor pins, solder joints, and surface-mount capacitors is used to pass electrical signals between compartments, providing electrical isolation and EMI filtering, and is securely attached to the bulkhead using anchor holes and O-rings for environmental sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stamped brazed RFI filter tub assembly is used to pass electrical signals through the bulkhead, then electrical isolation and EMI filtering are improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The invention divides the bulkhead into multiple sections with individual openings for each signal path. Each opening receives a separate connector that provides EMI filtering and electrical isolation independently. This segmentation allows multiple signals to pass through the bulkhead while maintaining isolation without requiring a complex assembled filter tub structure.
Solution Approach 2:
The connectors used in the invention serve multiple functions simultaneously: they provide electrical connection, EMI filtering, and environmental sealing. This multi-functionality eliminates the need for separate RFI filter tub assemblies, reducing overall device complexity while maintaining the required electrical isolation and filtering performance.
2Reliability
If individual screw-in filter assemblies are used to pass signals through the bulkhead, then electrical isolation is improved, but device complexity and installation complexity increase
Solution Approach 1:
The invention combines the electrical connection function and the EMI filtering function into a single integrated connector assembly. Each connector is designed to be installed as one unit through the bulkhead opening, eliminating the need for separate screw-in filter assemblies. This merging simplifies installation while maintaining electrical isolation.
Solution Approach 2:
The connectors are pre-configured with EMI filtering capabilities and sealing elements before installation. This preliminary preparation allows for straightforward installation through the bulkhead without requiring complex assembly steps or specialized tools during installation, improving ease of operation.
3Productivity
If a higher density of electrical signals is passed through the bulkhead, then productivity and signal capacity are improved, but maintaining electrical isolation and environmental sealing becomes more difficult
Solution Approach 1:
The bulkhead is divided into multiple discrete openings, each accommodating a separate connector. This segmentation allows high signal density by enabling multiple independent signal paths through the bulkhead while maintaining environmental sealing at each individual opening. Each connector independently seals its own opening, preventing contamination even as the number of signals increases.
Solution Approach 2:
The connectors incorporate flexible sealing elements such as O-rings or gaskets that conform to the bulkhead opening and provide reliable environmental sealing. These flexible sealing components can accommodate slight variations in manufacturing tolerances and thermal expansion, maintaining seal integrity even when multiple connectors are installed in close proximity for high signal density.
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 allows for accurate and precise signal transmission between compartments while preventing environmental noise from affecting electronic assemblies, offering a cost-effective method for higher signal density with enhanced reliability and leak resistance during thermal cycling.
Implementation Method 1
an O-ring seal positioned between the seal board and the bulkhead about a perimeter of the seal board
Implementation Method 2
a solder joint sealing each conductor pin to the circuit board
Implementation Method 3
a via in the circuit board material and electrically connecting the conductor pins to one another
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A seal board (14) includes a circuit board (22) with vias (30), conductor pins (24), and solder joints (26). The solder joints (26) connect and seal each conductor pin (24) to a single via (30), such that each conductor pin (24) extends through the via (30) and extends from a first side of the circuit board (22) and a second side of the circuit board (22). The seal board (14) is mounted to cover an opening (18A) in a bulkhead (18) that separates a first compartment (such as a terminal block compartment (16)) from a second compartment (such as an electronics or feature board compartment (20)). The seal board (14) provides electrical paths between the compartments (16,20) while protecting components within one of the compartments from the surrounding environment.