Delphi Technologies, Inc.

Delco Electronics Corporation

Paul J Pitzer

Philip D Kuznia

Andres Deogracias Viduya

Daniel A Lawlyes

Steven T Reyburn

Joseph M Ratell

James Ira Moyer

Clyde H Johnson

John Patrick Amos

Perry L Martinson

A sensor apparatus includes pressure and temperature sensors for measuring the pressure and temperature of high-pressure fluid media within a vessel. The pressure sensor is disposed in a sensor cavity that is coupled to a measurement port, and the leads of a temperature sensor that is disposed in the measurement port pass through the body of the sensor apparatus to a termination cavity that is physically isolated from the sensor cavity.

Sensor apparatus responsive to pressure and temperature within a vessel

An improved self-retaining pressure sensor assembly includes a pressure sensor having a housing, a depending ported stem terminated in an enlarged foot, and a flanged resilient seal disposed about the stem between the pressure sensor housing and foot, with the seal flange having one or more notches about its circumferential periphery to ease insertion and extraction of the assembly with respect to a circular opening formed in a pressure vessel. The notches reduce the effective area of the flange, proportionately decreasing the force (insertion force) needed to insert the assembly at the time of installation and the force (extraction force) needed to subsequently remove the assembly for repair or replacement. The number and size of the notches can be adjusted to provide acceptable insertion and extraction forces, without lubricant, while not significantly compromising the self-retention capability of the assembly.

Self-retaining pressure sensor assembly having notched seal retention flange

An improved low-cost pressure sensor assembly incorporates a stainless steel sensor element welded to an outboard face of a stainless steel insert captured in a low-cost metal pressure port adapted for attachment to a pneumatic valve. The pressure port includes outboard and inboard cavities separated by neck portion; the stainless steel insert is captured in the outboard cavity, while the inboard cavity is adapted for attachment to the pneumatic valve. The stainless steel insert includes a base portion that seats against an O-ring in a floor of the outboard cavity, and a stem portion within the O-ring that extends axially through the neck portion of the pressure port and into its inboard cavity. The insert has a first bore that extends axially from its outboard face into, but not through, the stem portion, and a second bore that intersects the first bore and opens into the inboard cavity of the pressure port. When the pressure port is attached to the pneumatic valve, the stem portion of the insert depresses a spring-biased plunger that opens the valve, and fluid (gas or liquid) escaping through the open valve is placed in direct communication with the sensor element via the first and second bores of the stainless steel insert.

Low-cost stainless steel pressure sensor assembly for a pneumatic valve

A three-piece pressure sensor assembly includes a one-piece pressure port formed of cold rolled steel, a stainless steel sensor element having an elongated annular side-wall, and an O-ring. The pressure port has a threaded slug at one end for attaching the sensor assembly to the wall of a pressure vessel and an annular cup at the other end. The annular cup has side-walls defining a cavity, and an annular axial recess formed in the center of the cavity receives the O-ring and a lower portion of the sensor element side-wall. A central post of the pressure port supports the inner periphery of the sensor element side-wall, and a portion of the pressure port material surrounding the recess is displaced radially inward against the sensor element side-wall, staking the sensor element in the cavity and compressing the O-ring between the sensor element and the bottom of the axial recess. An axial opening through the central post of the pressure port places the sensor element in communication with the interior of a pressure vessel to which the assembly is attached.

Three-piece pressure sensor with high pressure stainless steel sensing element

An improved pressure sensor assembly incorporates a stainless steel pressure sensing element that is welded to a stainless steel pressure port insert-molded into a molded plastic pressure vessel. Sealing between the pressure port and the pressure vessel is enhanced by a O-ring seated in a groove on the outer periphery of the pressure port, or by a sealant applied to the periphery of the pressure port prior to the insert molding operation. The pressure port is insert-molded with the pressure vessel so as to expose an axial end of the pressure port having a stepped annular surface, and the pressure sensor element is welded to the exposed end of the pressure port. The plastic material of the pressure vessel extends into a central axial bore of the pressure port to minimize leakage by maximizing a potential leakage path for the medium contained by the pressure vessel, and over a shoulder of the pressure port to secure the pressure port in the body of the pressure vessel.

Insert-molded pressure sensor with high pressure stainless steel sensing element

A pressure sensor connector ( ) for use with a pressure sensor element ( ) that includes a plurality of pressure sensor terminals ( ). The pressure sensor connector ( ) includes a housing ( ), a plurality of connector terminals ( ) and a flexible circuit ( ). A plurality of electrical pathways ( ), formed on the flexible circuit ( ), connect each of the plurality of connector terminals ( ) to a corresponding pressure sensor terminal ( ).

Pressure sensor connector

An improved, low-cost, back-side sensing pressure sensor assembly having a high integrity seal between the sensor element and the pressure port. The pressure port has a stud portion at an inboard end for attachment to a pressure vessel wall, and a cup portion at an outboard end for housing the sensor and interface circuitry. A central well extends inward from an inboard face of the cup portion, and a central axial bore in the stud portion opens into the well. A planar carrier disc carrying the sensor element closes the outboard end of the well. The sensor element comprises a silicon diaphragm formed on the outboard end of a glass pedestal that passes through a complementary opening formed in the carrier disc, and the inboard end of the pedestal includes an integral radially extending rim or shoulder that seats on the inboard face of the carrier disc about the opening. A suitable adhesive is used to bond the pedestal rim to the disc, and in operation, the fluid pressure in the vessel places the adhesive joint in compression to provide a long term, high integrity, seal between the well and the remainder of the cup portion. In a first embodiment, the interface circuitry and conductor traces and pads that interconnect the sensor terminals are formed on the outboard face of the carrier disc, whereas in a second embodiment, the circuitry and conductor traces and pads are formed on a flexible circuit glued to the outboard face of the carrier disc.

Pressure sensor assembly with direct backside sensing

A pressure port for attaching a stainless steel high pressure sensor to an automotive pressure line includes a cold rolled steel ring having a hex-shaped perimeter and a central bore, and a stainless steel stud welded in the ring. A flange of the stud abuts one face of the ring and an interlocking feature between the stud and the ring relieves stress on the weld during installation and removal of the assembly. An end of the stud extends beyond the ring and is threaded for attachment to the housing of a pressure vessel.

Pressure sensor assembly

An improved pressure sensor assembly includes a low-cost pressure port comprising a casing formed of cold rolled steel, a small stainless steel insert and an O-ring. The casing has a threaded slug at one end for attaching the sensor assembly to the wall of a pressure vessel and an annular cup at the other end. The annular cup has a hex-shaped periphery to facilitate installation and removal of the sensor assembly, and defines a cylindrical interior cavity including an annular recess in which the O-ring is disposed. The stainless steel insert has a base portion disposed within the cylindrical cavity atop the annular recess so as to compress the O-ring between the insert and casing, and a neck portion that extends out of the cavity to form a pedestal to which the stainless steel pressure sensor element is welded. The insert is retained relative to the casing by a staking operation in which a portion of the casing is deformed against the neck of the insert. The casing and insert have central axial openings which align when so assembled, placing the sensor element in communication with the interior of the pressure vessel. A connector assembly covering the sensor element environmentally seals the sensor element and provides access to its electrical pressure signal output. Compared to previously known sensor assemblies, the stainless steel content and required machining are significantly reduced, contributing to an overall cost reduction of the sensor assembly.

Three-piece pressure sensor with high pressure stainless steel sensor

A pressure sensor comprises a diaphragm mounted on a housing and subject to pressure. Stress sensitive resistors are connected to circuit traces on the diaphragm which in turn are wirebonded to a compensation IC. The IC is directly mounted on the diaphragm principally or wholly in an area which is not subject to flexing. A connector has a dome partially covering the diaphragm and holds terminal blades having ends extending away from the diaphragm and opposite ends carrying bond pads located adjacent the diaphragm. An opening in the dome permits wirebonder access to connect bond pads on the traces with terminal bond pads. A cover is installed over the connector and sensor.

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Kokomo, IN, United States of America

Paul J Pitzer