阅读说明：本技术 防爆压电超声波检测器 (Explosion-proof piezoelectric ultrasonic detector ) 是由 M.格兰特 J.卡特勒 R.R.沃茨 于 2017-12-20 设计创作，主要内容包括：本公开涉及一种防爆压电超声波检测器。实施例总体上涉及防爆超声波检测器。该防爆超声波检测器包括：金属外壳,其被配置成面向超声压力波；感应元件,其中该感应元件经由焊料附接到金属外壳；压缩元件,其被配置成与感应元件接触；以及印刷电路板,其被配置成对压缩元件进行压缩并且电连接到感应元件。(The present disclosure relates to an explosion-proof piezoelectric ultrasonic detector. Embodiments are generally related to explosion-proof ultrasonic detectors. This explosion-proof ultrasonic detector includes: a metal housing configured to face an ultrasonic pressure wave; an inductive element, wherein the inductive element is attached to the metal housing via solder; a compression element configured to contact the inductive element; and a printed circuit board configured to compress the compression element and electrically connected to the inductive element.)

1. An explosion-proof ultrasonic detector (100) comprising:

a metal housing (2);

a sensing element (4) attached to the metal housing (2);

a compression element (5), wherein the compression element (5) is electrically conductive; and

a Printed Circuit Board (PCB) (6),

wherein the sensing element is compressed between the metal housing and the PCB using the compression element, the compression element electrically connecting the sensing element with the PCB.

2. An explosion proof ultrasonic detector (100) according to claim 1, wherein the sensing element (4) comprises one or more electrodes, the metal housing (2) functions as an electrode of the sensing element (4), and the metal housing (2) is directly attached to the PCB (6) via screws (9), thereby connecting the sensing element (4) to the electronic circuitry of the printed circuit board.

3. An explosion proof ultrasonic detector (100) according to claim 1, wherein the sensing element (4) comprises a piezoelectric sensing element.

4. The explosion proof ultrasonic detector (100) of claim 1, further comprising an instrument housing (8) sealed to the metal housing (2) and a sealing material (7) between the metal housing (2) and the instrument housing (8), wherein the sealing material (7) provides isolation between the instrument housing (8) and the metal housing (2), thereby protecting the sensing element (4), the compression element (5) and the PCB (6).

5. An explosion proof ultrasonic detector (100) according to claim 4, further comprising a locking ring (10) configured to retain the metal housing (2) within the interior of the instrument housing (8).

6. A method for assembling an explosion-proof ultrasonic detector (100), the method comprising:

welding a first surface of the sensing element (4) to an inner surface of the metal housing (2);

applying compression to a second surface of the sensing element (4), wherein the second surface is opposite to the first surface; and

attaching a Printed Circuit Board (PCB) (6) directly to the metal housing (2), wherein the PCB (6) is in contact with an electrically conductive compression element (5) thereby compressing the sensing element (4) via the compression element (5) to electrically connect to the sensing element (4) and provide explosion protection.

7. The method of claim 6, further comprising applying a coating (13) to at least a portion of an outer surface of the metal housing (2).

8. The method of claim 6, further comprising sealing at least a portion of an outer surface of the metal housing (2) to an instrument housing (8).

9. The method of claim 8, further comprising attaching a locking ring (10) to the PCB (6) and/or the metal housing (2) configured to retain the metal housing (2) within the instrument housing (8).

10. The method according to claim 6, wherein the welding heats the sensing element (4) to a temperature below the Curie temperature of the material of the sensing element (4).

Background

Explosion protection devices may be used in hazardous environments, such as gas pipelines, hydrocarbon well sites, gas pipeline compression stations, chemical refineries, and other environments that may be subject to the effects of an explosion. For example, when a bad pipe joint leaks or a pipe is damaged, for example, due to accidental hitting of the pipe with metal equipment, a pressurized gas leak may occur inadvertently. A spark or other event may trigger ignition of the leaking gas. As the case may be, the ignition of the leaking gas may be accompanied by an initial explosion that produces a very high instantaneous pressure.

Disclosure of Invention

In an embodiment, an explosion-proof ultrasonic detector is disclosed. This explosion-proof ultrasonic detector includes: a metal housing configured to face an ultrasonic pressure wave; an inductive element, wherein the inductive element is attached to the metal housing via solder (holder); a compression element configured to contact the inductive element; and a printed circuit board configured to compress the compression element and electrically connected to the inductive element.

In an embodiment, a method for assembling an explosion-proof ultrasonic detector is disclosed. The method comprises the following steps: welding a first surface of the inductive element to an inner surface of the metal housing; applying compression to a second surface of the inductive element, wherein the second surface is opposite the first surface; maintaining compression of the second surface of the inductive element via the compression element; and attaching a printed circuit board to the metal housing, wherein the printed circuit board is in contact with the compression element.

Drawings

For a more complete understanding of this disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

Fig. 1 is an illustration of an explosion-proof ultrasonic detector according to an embodiment of the present disclosure.

Fig. 2 is an exploded view of some components of an explosion-proof ultrasonic detector according to an embodiment of the present disclosure.

FIG. 3 is a diagrammatic view of another explosion-proof ultrasonic detector in accordance with an embodiment of the present disclosure.

FIG. 4 is a diagrammatic view of yet another explosion-proof ultrasonic detector in accordance with an embodiment of the present disclosure.

Detailed Description

It should be understood at the outset that although an illustrative implementation of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or in existence. The present disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.

The following brief definitions of terms will apply throughout the application:

the term "comprising" means including but not limited to, and should be interpreted in the manner in which it is commonly used in the patent context;

the phrases "in one embodiment," "according to one embodiment," and the like generally mean that a particular feature, structure, or characteristic described in connection with the phrase may be included in at least one embodiment of the invention, and may be included in more than one embodiment of the invention (importantly, such phrases do not necessarily refer to the same embodiment);

if the specification describes something as "exemplary" or "an example," it should be understood that it refers to a non-exclusive example;

the terms "about" or "approximately" or the like, when used in conjunction with a number, may mean a particular number, or alternatively, a range close to a particular number, as understood by those skilled in the art; and

if the specification states a component or feature "may", "might", "should", "would", "preferably", "might", "typically", "optionally", "for example", "often", or "might" (or other such language) be included or has a characteristic, that particular component or feature may not necessarily be included or may not necessarily have that characteristic. Such components or features may optionally be included in some embodiments, or may be excluded.

Embodiments of the present disclosure include methods and systems for providing an explosion-proof piezoelectric sensor. Since leaking gas may be dangerous to the environment or may cause severe product loss, it is desirable to detect accidental leakage of gas from the pressurizing device, which may be caused by a faulty pipe joint or pipe break, as quickly as possible. Once a leak is detected, it may be indicated to a monitor or supervisor, which may contain or otherwise mitigate the leak. Due to the nature of gas leaks, the detection instrument may need to be explosion proof, so that even if an explosion occurs in the vicinity of the instrument, detection may continue and/or so that the explosion initiated within the instrument does not propagate to the external environment.

Gas leakage from a pressurized source may produce sound, typically having frequencies in the audible and ultrasonic range. The ultrasonic detector may be configured to detect ultrasonic frequencies generated by gas leaks, and thus detect gas leaks. The ultrasound detector may signal the level of detected ultrasound and may be configured to activate an alarm if the detected ultrasound level is above a certain threshold.

Embodiments of the present disclosure are directed to explosion-proof ultrasonic detectors, which may include one or more piezoelectric elements encapsulated in a metal housing, wherein the piezoelectric elements may convert the pressure of a sound wave from mechanical energy to an electrical signal.

Fig. 1 illustrates an explosion-proof ultrasonic detector 100, wherein here arrow 1 illustrates an ultrasonic pressure wave from the environment. The explosion-proof ultrasonic detector 100 may comprise a metal housing 2 facing the ultrasonic pressure waves, where the metal housing 2 may function as one electrode of the inductive element 4 (which may be a piezoelectric inductive element or may also be referred to as a piezoelectric inductive element). The inductive element 4 may be attached to the metal housing 2 via solder 3. The inductive element 4 may also include one or more electrodes, which may be silver electrodes. Additionally, the inductive element 4 may be in contact with a conductive compressive element 5 and a Printed Circuit Board (PCB) 6. The PCB 6 may be configured to compress the conductive compression element 5 and electrically connect to the electrodes of the inductive element 4. The explosion-proof ultrasonic detector 100 may further include an instrument housing 8, and the instrument housing 8 may be sealed to the metal housing 2 via a layer of the sealing material 7.

As shown in fig. 1, the inductive element 4 may be soldered directly to the metal housing 2, and the metal housing 2 may be attached directly to the PCB 6 via screws 9. The metal housing 2 may function as an electrode by directly contacting the PCB 6 and connecting the inductive element 4 to the PCB 6. The conductive compression element 5 may provide explosion protection to the sensing element 4 and possibly other elements of the explosion-proof ultrasonic detector 100. The conductive compression element 5 may further provide for a mounting fit of the component in the context of dimensional variations within tolerance limits of the manufactured component. When the explosion-proof ultrasonic detector 100 is assembled, the inductive element 4 may be under compression between the metal housing 2 (and solder 3) and the PCB 6 via the conductive compression element 5. Such compression may reduce the risk of separation between the inductive element 4 and the electrodes and/or PCB 6 that may occur due to strong mechanical shock, vibration, thermal shock and/or excessive piezoelectric resonance. The use of a conductive compression element 5 between the sensing element 4 and the PCB 6 allows for maintaining compression of the sensing element 4 over a large temperature range without damaging the explosion proof ultrasonic detector 100 assembly, wherein the elasticity of the conductive compression element 5 may be configured to evenly distribute the compression force. The solder 3 may be resistant to a very wide temperature range and thermal cycling, and may be able to withstand shock and impact without failure of the solder 3 joint. The solder 3 may also provide a reliable electrical contact between the inductive element 4 and the PCB 6 via the metal housing 2.

The surface of the metal housing 2 attached to the inductive element 4 may act as a membrane to transmit the ultrasonic pressure wave 1 from the external environment to the inductive element 4 while also protecting the inductive element 4 from the force of the explosive shock wave. The sealing material 7 may provide a waterproof seal with the metal housing 2, protecting the inductive element 4, the conductive compressive element 5, and the PCB 6. The sealing material 7 may provide electrical isolation between the metal housing 2 and the instrument housing 8. The sealing material 7 may also provide isolation (i.e., acoustic insulation) to prevent the propagation of ultrasonic signals from the instrument housing 8 into the sensing element 4 and/or the metal housing 2. The ultrasonic signal may originate from the instrument housing 8 due to impact or vibration. In an embodiment, the sealing material 7 may comprise silicone. In an embodiment, the sealing material 7 may be provided as a pre-molded component, for example a pre-molded silicone component. In an embodiment, the sealing material 7 may have a length or height of about 15.9 mm. In an embodiment, the sealing material 7 may have a length or height sufficient to resist an explosion up to a predetermined maximum strength.

The inductive element 4 may operate in a faraday cage surrounded by a metal surface via the metal housing 2 and the PCB 6. Stated another way, the metal housing 2 and the PCB 6 may form a faraday cage enclosing the inductive element 4. In an embodiment, the faraday cage formed by the metal housing 2 and the PCB 6 may further enclose some of the electronic devices mounted on the PCB 6. The PCB 6 may include a continuous metal layer that may be in contact with the metal housing 2 of the explosion-proof ultrasonic detector 100. Such a configuration may minimize the effects of electromagnetic interference (EMI), provide electromagnetic compatibility, and may allow the explosion-proof ultrasonic detector 100 to achieve high signal-to-noise ratio (SNR) performance.

The front side of the metal housing 2 facing the incoming ultrasonic pressure waves 1 may comprise a coating 13, which coating 13 may comprise a polymer such as Polytetrafluoroethylene (PTFE), another similar material or a plastic label. The coating 13 may act as a shield for the metal housing 2 against many aggressive chemicals, may act over a wide temperature range, and may not compromise the acoustic properties of the metal housing 2, thereby allowing the passage of ultrasonic waves. In embodiments, the coating 13 may improve the acoustic transfer of energy from the ultrasonic pressure waves 1 to the metal housing 2 and/or sensing element 4.

The explosion-proof ultrasonic detector 1 depicted in fig. 1 may comprise very few components, which facilitates simple assembly optimized for manufacturing. Typical ultrasonic testing products may not include an explosion proof element. Explosion-proof, highly reliable ultrasonic sensing elements (which may include microphones) may be preferred for detecting gas leaks by airborne ultrasonic pressure waves, particularly where there may be a presence of, for example, H₂Harmful substances of S.

Fig. 2 illustrates an exploded view of an explosion-proof ultrasonic detector 100, which includes a metal housing 2 for assembly, one or more piezoelectric sensing elements 4, a conductive compression element 5, a PCB 6, and screws 9. In an embodiment, the conductive compression element 5 may comprise a rubber material. Note that fig. 2 does not depict the presence of solder 3, and the solder 3 may not be provided prior to final assembly or manufacture of the explosion-proof ultrasonic detector 100. In other words, the solder 3 may be considered to be separate from the components of the kit for assembling and manufacturing the explosion-proof ultrasonic detector 100, and may be provided as a consumable tool or consumable material during the manufacturing process.

Fig. 3 illustrates the explosion-proof ultrasonic detector 100 attached to an exemplary instrument 300. As an example, the example instrument 300 may need to continue to be used at a pressure of at least 600 psi from the outside toward the instrument and/or from the inside of the instrument toward the environment. Alternatively, the example instrument 300 and the explosion-proof ultrasonic detector 100 may need to continue to be used at other predetermined pressures. The explosion-proof ultrasonic detector 100 installed in the instrument 300 may be fixed from the inside of the instrument 300 by a lock ring 10 or other similar mechanical element. In some embodiments, the explosion-proof ultrasonic detector 100 may be separated from the interior of the instrument 300, such as via a layer of sealant 12. The sealant 12 may include silicone. One or more leads 11 from the PCB 6 may extend through the lock ring 10 and/or encapsulant 12 to the interior of the instrument 300.

The soldering of the inductive element 4 to the metal housing 2 can be done with a solder 3 having a low melting temperature, lower than the curie temperature of the material of the inductive element 4, thereby preventing any loss of sensitivity of the inductive element 4. As an example, the curie temperature of the inductive element 4 may be approximately 300 ℃. The coating 13 (which may comprise PTFE) on the metal housing 2 may prevent bimetallic corrosion between the metal housing 2 of the ultrasonic sensor and the instrument housing 8, as these housings may be made of different metals.

Embodiments of the present disclosure may include methods of assembling explosion-proof ultrasonic detector 100. The inductive element 4 may be welded directly to the metal housing 2. Compression may be applied to the inductive element 4 via the conductive compression element 5, wherein a consistent pressure is applied to the solder 3 material, thereby improving the reliability of the connection. The PCB 6 may then be attached to the metal housing 2 via screws 9, wherein the PCB 6 may contact the conductive compression element 5 and maintain compression from the conductive compression element 5.

The metal housing 2 may be sealed to the instrument housing 8 via a sealing material 7. Additionally, a coating 13 may be applied to the front of the metal housing 2, wherein the coating 13 may reduce corrosion due to exposure to harmful chemicals and may improve ultrasonic transmission through the metal housing 2.

In some embodiments, a locking ring 10 may be attached to the metal housing to further retain the metal housing within the instrument housing. In some embodiments, a layer of sealant 12 may be applied over the metal housing 2 to separate the metal housing and other elements from the interior of the instrument housing 8.

Fig. 4 illustrates the explosion-proof ultrasonic detector 100 attached to an exemplary instrument 300. The explosion-proof ultrasonic detector 100 attached to the exemplary instrument 300 is similar in all respects to the embodiment described above with respect to fig. 1-3, except that: in the embodiment illustrated in fig. 4, the instrument housing 8 has been extended so that there is an offset between the left-facing surface of the metal housing 2 and the right-facing surface of the locking ring 10, the sealing material 7 has been extended to contact the edge of the locking ring 10 and the sealing material 7 extends between the metal housing 2 and the locking ring 10 (i.e. between the left-facing surface of the metal housing 2 and the right-facing surface of the locking ring 10). The extension of the sealing material 7 between the metal housing 2 and the locking ring 10 may provide additional electrical insulation and/or isolation of the explosion proof ultrasonic detector 100 from the instrument housing 8, additional mechanical cushioning of the explosion proof ultrasonic detector 100 in the event of an explosion, and additional acoustic insulation and/or isolation of the explosion proof ultrasonic detector 100 from the instrument housing 8. In an embodiment, the sealing material 7 may have a length or height of about 15.9 mm. In an embodiment, the sealing material 7 may have a length or height sufficient to resist an explosion up to a predetermined maximum strength.

Embodiments of the present disclosure may include a method for protecting an ultrasonic detector from an explosion. Compression may be applied to the inductive element of the ultrasonic detector via a compression element. Shocks, vibrations and other mechanical forces affecting the ultrasonic detector may be absorbed by the compression element.

In a first embodiment, an explosion-proof ultrasound detector may include: a metal housing configured to face an ultrasonic pressure wave; an inductive element, wherein the inductive element is attached to the metal housing via solder; a compression element configured to contact the inductive element; and a PCB configured to compress the compression element and electrically connected to the inductive element.

A second embodiment may comprise the explosion-proof ultrasonic detector of the first embodiment, wherein the sensing element comprises one or more electrodes.

A third embodiment may comprise the explosion-proof ultrasonic detector of the second embodiment, wherein the metal housing functions as an electrode of the sensing element.

A fourth embodiment may include the explosion-proof ultrasonic detector of the second or third embodiment, wherein the metal housing is directly attached to the PCB via screws, thereby connecting the inductive element to the electronic circuitry of the PCB.

A fifth embodiment may include the explosion-proof ultrasonic detector of any of the first to fourth embodiments, wherein the sensing element comprises a piezoelectric sensing element.

A sixth embodiment may incorporate the explosion-proof ultrasonic detector of any of the first through fifth embodiments, wherein the compression element provides explosion protection to the sensing element and other elements of the detector.

A seventh embodiment may include the explosion proof ultrasonic detector of any of the first through sixth embodiments, wherein the inductive element is under compression between the metal housing (and solder) and the PCB via the compression element when the detector is assembled.

An eighth embodiment may incorporate the explosion-proof ultrasonic detector of the seventh embodiment wherein the compression reduces the risk that separation between the sensing element and the electrodes may occur due to strong mechanical shock, vibration, thermal shock and/or excessive piezoelectric resonance.

A ninth embodiment may incorporate the explosion-proof ultrasonic detector of any of the first to eighth embodiments, wherein a surface of the metal housing attached to the sensing element functions as a membrane to transmit acoustic pressure waves from an external environment to the sensing element.

A tenth embodiment may incorporate the explosion-proof ultrasonic detector of any of the first to ninth embodiments, further comprising an instrument housing sealed to the metal housing.

An eleventh embodiment can include the explosion-proof ultrasonic detector of the tenth embodiment, further comprising a sealing material between the metal housing and the instrument housing, wherein the sealing material provides isolation between the instrument housing and the metal housing, thereby protecting the inductive element, the compressive element, and the PCB.

A twelfth embodiment may include the explosion-proof ultrasonic detector of the tenth or eleventh embodiment, further comprising a locking ring configured to retain the metal housing within the interior of the instrument housing.

A thirteenth embodiment may incorporate the explosion proof ultrasonic detector of any of the tenth to twelfth embodiments, wherein the metal enclosure is separated from the interior of the instrument enclosure via a sealant layer.

A fourteenth embodiment can include the explosion-proof ultrasonic detector of any of the first to thirteenth embodiments, wherein the inductive element operates in a faraday cage surrounded by a metal surface via a metal housing and a PCB.

A fifteenth embodiment can include the explosion-proof ultrasonic detector of any of the first through fourteenth embodiments, wherein the PCB comprises a continuous metal layer in contact with the metal housing.

A sixteenth embodiment can include the explosion-proof ultrasonic detector of any of the first to fifteenth embodiments, further comprising a coating on an outward-facing surface of the metal housing, wherein the coating is configured to allow ultrasonic waves to pass through the metal housing.

A seventeenth embodiment may include the explosion-proof ultrasonic detector of any of the first through sixteenth embodiments, wherein the detector is configured to continue to be used at a pressure of at least 600 psi from outside towards the detector and/or from inside the instrument towards the detector.

An eighteenth embodiment can include the explosion-proof ultrasonic detector of any of the first to seventeenth embodiments, wherein the solder comprises a melting temperature lower than the curie temperature of the material of the sensing element.

In a nineteenth embodiment, a method for assembling an explosion-proof ultrasonic detector can comprise: welding a first surface of the inductive element to an inner surface of the metal housing; applying compression to a second surface of the inductive element, wherein the second surface is opposite the first surface; maintaining compression of the second surface of the inductive element via the compression element; and attaching a printed circuit board to the metal housing, wherein the printed circuit board is in contact with the compression element.

A twentieth embodiment may incorporate the method of the nineteenth embodiment, further comprising applying a coating to at least a portion of the outer surface of the metal shell.

A twenty-first embodiment may incorporate the method of the nineteenth or twentieth embodiment, further comprising sealing at least a portion of an outer surface of the metal housing to the instrument housing.

A twenty-second embodiment may include the method of the twenty-first embodiment, further comprising attaching a locking ring configured to retain the metal housing within the instrument housing to the printed circuit board and/or the metal housing.

A twenty-third embodiment can include the method of the twenty-second embodiment, further comprising attaching a locking ring configured to retain the metal housing within the instrument housing to the printed circuit board and/or the metal housing.

While various embodiments in accordance with the principles disclosed herein have been shown and described above, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the disclosure. The embodiments described herein are merely representative and are not intended to be limiting. Many variations, combinations, and modifications are possible and are within the scope of the disclosure. Alternative embodiments resulting from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the present disclosure. Accordingly, the scope of protection is not limited by the description set out above, but is instead defined by the claims that follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as a further disclosure, and the claims are for the embodiment(s) of the invention(s). Moreover, any advantages and features described above may relate to particular embodiments, but the application of such issued claims should not be limited to processes and structures implementing or having any or all of the above advantages.

Additionally, section headings as used herein are provided for consistency with or to otherwise provide organizational cues as suggested under 37 c.f.r 1.77. These headings should not limit or characterize the invention(s) that may be set forth in any claims that issue from this disclosure. In particular and by way of example, although a title may refer to a "domain," the claims should not be limited by the language chosen under this title to describe a so-called domain. Furthermore, the description of a technology in the "background" should not be construed as an admission that a technology is prior art to any invention(s) in the present disclosure. The summary of the invention is also not to be considered a limiting characterization of the invention(s) set forth in the issued claims. Furthermore, any reference to "the invention" in the singular in this disclosure should not be used to qualify as only a single point of novelty in the present disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and thus such claims define the invention(s) and their equivalents, which are protected thereby. In all cases, the scope of the claims should be considered in light of their own merits and should not be limited by the headings set forth herein in accordance with the present disclosure.

The use of broader terms such as "including," "including," and "having" should be understood to provide support for narrower terms such as "consisting of," "consisting essentially of, and" consisting essentially of. The use of the terms "optionally," "may," "potentially," or the like, with respect to any element of an embodiment, means that the element is not required, or alternatively, the element is required, both alternatives being within the scope of the embodiment(s). Moreover, references to examples are provided for illustrative purposes only and are not intended to be exclusive.

While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, various elements or components may be combined or integrated in another system or certain features may be omitted, or not implemented.

Moreover, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.