Sensor Isolation Diaphragm Radial Recess Design
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Solution Overview
Problem
Conventional sensor isolation elements face challenges in withstanding hostile environments, maintaining accuracy and repeatability, and accommodating large fluid volume changes due to pressure and temperature fluctuations, especially in high-pressure and corrosive conditions like those found in downhole oil and gas applications, where they often fail to accurately transmit pressure and thermal expansion to the sensing element.
Innovation Solution
The use of isolation elements with diaphragms attached to recesses on the longitudinally extending sides of a housing, which form a hermetic seal and allow for increased volumetric displacement of a low thermal expansion fluid, minimizing interference from debris and contaminants, and enabling accurate pressure and temperature measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the size and mass of the isolation element are minimized, then orientation sensitivity due to gravity is reduced, but the isolation element may not accommodate large fluid volume changes due to pressure and temperature fluctuations
Solution Approach 1:
The diaphragm is configured to displace fluid not only in the axial direction but also in the radial direction by protruding into the bore. This multi-dimensional displacement capability allows the isolation element to accommodate large fluid volume changes while maintaining a compact, minimized mass and size.
2Reliability
If the isolation element is made more robust to withstand high pressure and corrosive environments, then reliability improves, but the size and mass increase, leading to increased orientation sensitivity
Solution Approach 1:
The diaphragm is constructed from corrosion-resistant materials such as Hastelloy, Inconel, or Titanium, providing robust protection against corrosive environments and high pressures. Despite using these durable materials, the diaphragm maintains a thin, flexible structure that minimizes mass and size, thereby reducing orientation sensitivity while ensuring reliability.
3Quantity of substance
If the isolation element uses traditional bellows configuration, then it can accommodate fluid volume changes, but debris and contaminants can interfere with its operation
Solution Approach 1:
The diaphragm protrudes radially into the bore, creating a configuration where the sensing element is positioned away from the harsh external environment. This spatial arrangement allows the diaphragm to accommodate fluid volume changes while shielding the sensing element from debris and contaminants, preventing interference with operation.
4Quantity of substance
If the isolation element is designed with larger fluid volume, then it can accommodate thermal expansion and contraction, but the stroke or travel required increases, preventing accurate pressure transmission
Solution Approach 1:
The diaphragm's radial protrusion into the bore enables fluid displacement in multiple directions. This multi-dimensional configuration allows the isolation element to accommodate thermal expansion and contraction of the isolation fluid while maintaining a compact stroke length, ensuring accurate pressure transmission to the sensing element.
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 configuration enhances the accuracy and reliability of pressure and temperature measurements by preventing interference from environmental contaminants and allowing for effective transmission of pressure and thermal expansion, while being durable and serviceable in harsh conditions.
Implementation Method 1
at least one diaphragm is attached to the housing proximate a periphery of the at least one recess and seals the at least one recess and the longitudinal bore from an environment exterior to the housing
Implementation Method 2
a fluid-filled longitudinal bore is formed in the housing and extends through the connection portion
Implementation Method 3
allow for increased volumetric displacement of a low thermal expansion fluid
Data Source
AI summary
Isolation elements comprise a housing comprising a longitudinal bore formed therein and at least one recess formed in at least one longitudinally extending side of the housing. The at least one recess is in communication with the longitudinal bore. At least one diaphragm is attached proximate a periphery thereof to the housing and seals the at least one recess at the at least one longitudinally extending side of the housing. Sensor assemblies may include an isolation element including a housing and a diaphragm coupled thereto. Methods of forming an isolation element for use with a sensor comprise forming a longitudinal bore in a housing; forming at least one recess in at least one longitudinally extending side of the housing; coupling at least one diaphragm to the housing; and positioning the at least one diaphragm such that a primary direction of displacement of the at least one diaphragm extends into the at least one recess.