Sensor Fillet Design for High Pressure Resistance
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Solution Overview
Problem
Conventional sensors face challenges in enhancing pressure resistance to withstand high pressures exceeding several hundred MPa, as the stress on joining portions between different materials leads to potential peeling and leakage issues.
Innovation Solution
The sensor design incorporates a pressure vessel filled with enclosed liquid, a diaphragm, a sensor body, an electric wiring member, a fixing member, and fillets made of brazing material at critical joining portions to prevent peeling and leakage, with the electric wiring member and fixing member made of materials that enhance strength and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If high pressure exceeding several hundred MPa acts on the enclosed liquid, then the pressure transmission function is maintained, but large stress acts on joining portions causing potential peeling and leakage
Solution Approach 1:
The patent applies fillet portions with curved surfaces at the joining portions between the pressure vessel and housing, and between the housing and pin. These curved fillet surfaces distribute the stress more evenly across the joint, preventing stress concentration that would otherwise cause peeling under high pressure conditions.
Solution Approach 2:
The patent uses sealing glass as a bonding material to join the housing to the pressure vessel and the pin to the housing. This sealing glass creates a composite joint structure that provides both sealing function and mechanical strength, preventing leakage while maintaining structural integrity under high pressure.
2Adaptability or versatility
If different materials are joined together, then the sensor can achieve functional requirements, but the joining portions are difficult to strengthen
Solution Approach 1:
The patent introduces sealing glass as an intermediary bonding material between the housing and pressure vessel, and between the pin and housing. This sealing glass acts as a mediator that bonds different materials together while providing both sealing and structural strength, enabling material diversity without compromising joint integrity.
Solution Approach 2:
By adding fillet portions with curved surfaces at the material joints, the patent creates a gradual transition in the joint geometry. This curved geometry distributes stress more uniformly across the interface between different materials, preventing stress concentration and improving the overall strength of the joining portion.
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 solution effectively improves pressure resistance and prevents leakage by distributing stress and enhancing the strength of joining portions, allowing the sensor to operate reliably under high pressure conditions.
Implementation Method 1
a first fillet made of brazing material is formed at a joining portion between the electric wiring member and the fixing member, which is in contact with the enclosed liquid, and a second fillet made of brazing material is formed at a joining portion between the fixing member and the pressure vessel
Data Source
AI summary
A sensor includes: a pressure vessel filled with an enclosed liquid; a diaphragm that seals the pressure vessel; a sensor body contained in the pressure vessel; an electric wire comprising a wiring electrically connected to the sensor body; a fixture that fixes the electric wire to the pressure vessel; a first fillet at a joining portion between the electric wire and the fixture, wherein the first fillet contacts the enclosed liquid; and a second fillet at a joining portion between the fixture and the pressure vessel, wherein the second fillet contacts the enclosed liquid.