Sensor Seal Compression for Corrosive Fluid Ingress Prevention
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Solution Overview
Problem
Conventional sensors in rotary machines, such as compressors and turboexpanders, face challenges in sealing against corrosive gases and liquids, particularly in the Oil and Gas industry, where materials like stainless steels, PTFE, or FEP have been used to improve corrosion resistance but fail to prevent the ingress of corrosive fluids at electrical connections.
Innovation Solution
A sensor design featuring a monobloc seal made from a softer material than the housing, which is compressed by a movable compressor to create a sealing force on both the wire and the housing, preventing the passage of corrosive gases or liquids, and optionally using PTFE or FEP for the seal and FEP or Kapton-Daglass for the wire's insulator, with potting material enhancing the electrical connection sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional sealing materials (stainless steel, PTFE, FEP) are used to improve corrosion resistance, then material durability is improved, but sealing effectiveness deteriorates allowing corrosive fluid ingress
Solution Approach 1:
The patent employs a flexible sealing element comprising a softer material (such as elastomers or polymers) that can deform to create effective seals around wires and electrical connections. This flexible membrane approach allows the sealing element to conform to irregular surfaces and maintain sealing pressure, preventing ingress of corrosive fluids while accommodating thermal expansion and contraction of the sensor components.
2Strength
If harder sealing materials are used to resist corrosion, then material strength is improved, but sealing adaptability deteriorates
Solution Approach 1:
The patent utilizes composite sealing structures that combine materials with different properties - typically a corrosion-resistant outer layer (such as PTFE or FEP coating) over a softer, more compliant base material (such as silicone or rubber). This composite approach allows the seal to simultaneously achieve high corrosion resistance from the outer layer and excellent conformability from the inner layer, resolving the contradiction between strength and adaptability.
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 prevents the passage of corrosive gases and liquids between the seal and the wire, ensuring a hermetic seal and maintaining the integrity of the electrical connection, even under high pressure and corrosive conditions.
Implementation Method 1
the displacement of the compressor deforms the seal so that a compression force is applied by the seal onto said portion of the wire
Implementation Method 2
The deformation of the seal creates another compression force of the seal onto an inner portion of the housing so as to prevent any passage of corrosive gases or liquids between the seal and the housing
Data Source
AI summary
A sensor for operating in an environment subjected to corrosive gases or liquids under pressure, including a housing inside which are installed: a sensing portion, at least one wire electrically connected to the sensing portion, and a seal for sealing the connection between the sensing portion and the at least one wire, with at least one through-hole receiving a portion of the at least one wire. The sensor further including a compressor installed inside the housing, movable with respect to the housing and adapted to contact the seal in order to compress. The seal is made from a single material that is softer than the material constituting the housing. Upon displacement of the compressor, the seal is deformed until the creation of a compression force exerted by the seal onto the portion of the at least one wire, prevents any passage of corrosive gases or liquids between the seal therebetween.