Yarn-Wrapped Sensor Housing for High-Pressure Transducers
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Solution Overview
Problem
Conventional measuring transducers face a significant increase in mass and manufacturing costs when scaling to withstand high internal pressures over 100 bar, making them unsuitable for applications with media under high static pressure.
Innovation Solution
A measuring transducer design featuring a metal measuring tube and a sensor housing with a partially prestressed yarn outer shell, composed of glass, carbon, or aramid fibers, which provides enhanced pressure resistance with minimal additional mass by wrapping the yarn around the inner shell multiple times and embedding it in a plastic matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sensor housing is scaled to withstand high internal pressures over 100 bar using conventional designs, then the pressure resistance is improved, but the mass and manufacturing costs increase significantly
Solution Approach 1:
The patent applies composite materials by combining a metallic inner shell with a polymer outer shell containing reinforcing fibers (glass, carbon, or aramid). This composite structure achieves high pressure resistance exceeding 100 bar while maintaining low mass, as the fiber-reinforced polymer provides exceptional strength-to-weight ratio compared to conventional solid metal housings
Solution Approach 2:
The patent implements local quality by distributing fiber orientation and density strategically within the polymer matrix. The fibers are arranged to provide enhanced strength specifically in regions subjected to highest stress during pressure loading, while maintaining thinner wall sections in less critical areas, thus optimizing the overall mass-strength balance
2Strength
If the sensor housing is scaled to withstand high internal pressures over 100 bar using conventional designs, then the pressure resistance is improved, but the manufacturing costs increase significantly
Solution Approach 1:
The patent utilizes parameter changes by varying the fiber type (glass, carbon, aramid), fiber orientation angles, and fiber volume fraction to achieve the required pressure resistance. This allows optimization of manufacturing cost by selecting appropriate fiber materials and processing parameters for different application requirements
Solution Approach 2:
The composite construction enables cost-effective manufacturing of high-pressure housings by combining relatively inexpensive metallic inner shells with fiber-reinforced polymer outer shells. The layered composite structure can be manufactured using established processes like filament winding or pultrusion, avoiding the need for expensive thick-walled metal fabrication
3Strength
If the yarn outer shell is wrapped around the inner shell multiple times, then the pressure resistance is improved, but the device complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-tensioning the yarn during the wrapping process before final curing. This pre-tensioning establishes the required fiber orientation and density in advance, ensuring optimal pressure resistance is achieved without requiring complex post-processing or adjustment mechanisms
Solution Approach 2:
The yarn-wrapped polymer shell functions as a flexible yet strong containment structure that conformally fits around the inner shell. This flexible composite layer provides pressure resistance through its tensile strength rather than rigid structural support, simplifying the overall design compared to thick-walled rigid metal housings
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 achieves compressive strengths exceeding 100 bar with a significant reduction in installation mass and volume, allowing conventional transducers to be easily modified for higher pressure resistance while maintaining a compact design.
Implementation Method 1
an outer shell (102), formed at least partially by means of a yarn (102), for example under mechanical pretension and/or monofilament, which surrounds the inner shell
Implementation Method 2
the yarn is elastically stretched, and thus pre-tensioned
Data Source
Figure 1a~1b
Figure 2
Figure 3a~3c
AI summary
The invention relates to a measuring transducer comprising at least one measuring tube (10) for conducting a flowing medium and comprising a sensor housing (100) which is mechanically coupled to the at least one measuring tube (10). The sensor housing (100) has an inner envelope (101), namely an envelope which forms a cavity (100') that receives the at least one measuring tube, and an outer envelope (102), namely an envelope which is placed outside of the cavity, said outer envelope being at least partly constituted of a thread (102#) and surrounding the inner envelope.