1. Field of the Invention
The present invention is generally directed toward pressure relief devices that include circuitry printed directly thereon for sensing operational conditions associated with the device. Particularly, the circuitry comprises an electrically conductive ink that is electrically isolated from the metallic pressure relief device by a nonconductive material also directly applied to the device. A protective topcoat is optionally applied over the conductive ink to not only protect the integrity of the circuit, but also to permit stacking of individual circuits on the device.
2. Description of the Prior Art
Burst indicators are commonly used in conjunction with rupture disc monitoring systems so as to alert an operator when a disc ruptures so that the over-pressure condition causing the rupture can be investigated and the rupture disc replaced. Conventionally, burst indicators have comprised simple electrical circuits encased in a non-conductive material, such as Kapton film, and placed against or adjacent to a rupture disc, so that upon bursting of the disc, the circuit will be severed causing the monitoring system to alert an operator. U.S. Pat. No. 8,354,934 illustrates one such type of conventional burst indicator.
These traditional burst indicator designs have drawbacks that limit their use in certain systems. First, conventional designs require multiple installation steps when installing a burst indicator in conjunction with a rupture disc, requiring multiple installation technicians. For example, a plumber is required for installation of a rupture disc into a pipe system, while an electrician is necessary for installation of the burst indicator. Second, the conventional burst indicators are typically constructed as laminate structures with the aid of adhesives. Often, the adhesives are temperature sensitive and can begin to degrade upon exposure to mildly elevated temperature conditions. For example, certain conventional burst indicators comprise a circuit sandwiched between plies of Kapton films that are secured together with an adhesive. At temperatures of 200° F. or greater, the adhesives making up the burst indicator can break down resulting in delamination of the Kapton films and exposure of the conductive material making up the circuit. Additionally, when used in low-pressure systems, the energy transferred by the rupture disc petal may be insufficient to tear a burst indicator formed comprising a Kapton film and signal a ruptured disc. Moreover, conventional designs involving simple circuitry encased in non-conductive films are limited to detecting only disc rupture events. However, it would be desirable in many instances for monitoring systems to alert operators of other changes in process conditions. Thus, there is a need for a one-piece burst indicator that can operate under extreme high temperatures and low pressures, as well as detect both disc rupture events and other changes in process conditions.
In one embodiment according to the present invention, there is provided an over-pressure relief device comprising a metallic member. The metallic member comprises a central rupturable section and an outer flange section in surrounding relationship to the central section. The metallic member has a pair of opposed faces, and a nonconductive coating is applied to at least a portion of one of those faces. The over-pressure relief device further comprises an electrically conductive ink trace applied over at least a portion of the nonconductive coating. The conductive ink trace is electrically isolated from the metallic member by the nonconductive coating. The conductive ink trace defines an electrical circuit capable of conducting an electrical signal, and the circuit is operable to detect a change in a process condition associated with the over-pressure relief device.
In another embodiment according to the present invention, there is provided an over-pressure relief device comprising a metallic member. The metallic member comprises a central rupturable section and an outer flange section in surrounding relationship to the central section. The metallic member further comprises a pair of opposed faces. The metallic member carries at least a first and second electrically conductive circuit, which are formed upon one of the opposed faces. Each of the electrically conductive circuits are capable of conducting an electrical signal and are operable to detect a change in a process condition associated with the over-pressure relief device. The first electrically conductive circuit comprises a nonconductive coating that is directly applied to at least a portion of one of the opposed faces of the metallic member. A first conductive ink trace is applied over at least a portion of the nonconductive coating and is electrically isolated from the metallic member by the nonconductive coating. The second electrically conductive circuit comprises a second conductive ink trace that is electrically isolated from the metallic member and from at least one of the other electrically conductive circuits.
In yet another embodiment according to the present invention, there is provided an apparatus for holding an over-pressure relief device. The apparatus comprises a first and second holder member configured to receive and secure an over-pressure relief device according to the present invention therebetween. At least one of the holder members comprises an open electrical circuit configured to be closed by the over-pressure relief device upon being secured between the holder members.
In still another embodiment according to the present invention, there is provided in combination an over-pressure relief device and a first and second holder member configured to receive and secure the over-pressure relief device therebetween. The over-pressure relief device comprises a metallic member having a central rupturable section and an outer flange section in surrounding relationship to said central section. The metallic member has a pair of opposed faces, and a nonconductive coating is applied to at least a portion of one of the opposed faces. An electrically conductive ink trace is applied over at least a portion of the nonconductive coating and is electrically isolated from the metallic member by the nonconductive coating. The ink trace defines an electrical circuit capable of conducting an electrical signal. The circuit is operable to detect a change in a process condition associated with the over-pressure relief device. Moreover, at least one of the holder members comprises an open electrical circuit configured to be closed by the over-pressure relief device upon being secured between the holder members.
In one embodiment of the present invention, there is provided an over-pressure relief device 10, as shown in
Turning to
Metallic member 12 comprises a line of opening 20 formed in concave face 16 that defines a burst area of central rupturable section 14. Line of opening 20 comprises a line-of-opening recess 22 having a depth that extends from face 16 toward face 17. The line of opening 20 may comprise nearly any desired configuration. However, in certain embodiments, line of opening 20 may be substantially C-shaped, resulting in formation of a single petal upon opening of member 12, or have a cross-pattern shape configured to provide multiple petals upon opening of member 12. Metallic member 12 may optionally comprise a point of opening initiation 21 located along or proximal to the line of opening 20 and generally opposite of a hinge region 13 defined between ends 23, 25 of the line of opening 20. Line of opening 20 may be formed by any process known to those of skill in the art including die scoring, chemical electropolishing, mechanical milling, or laser machining Preferably, the line of opening 20 is formed in central rupturable section 14 following at least a pre-bulging or final bulging operation. Metallic member 12 may further include a reversal initiation feature (not shown) that is located within central rupturable section 14, and preferably at or near the apex of the bulged region 15.
Device 10 further comprises a nonconductive coating 24 applied to at least a portion of at least one face of metallic member 12. Generally, nonconductive coating 24 is applied directly to the face of central rupturable section 14 that does not exposed to a process stream; however, it is within the scope of the present invention for nonconductive coating 24 to also be applied on the process side of central rupturable section 14 should that ever be desired. In certain embodiments, coating 24 is applied as a liquid or paste and cured in situ on the face of section 14 without there being an intermediate adhesive composition. Thus, coating 24 is not separated from the face of section 14 by an interposed material, such as an adhesive or film (e.g., a Kapton film), nor does coating 24 itself comprise an adhesive or pre-made film.
Nonconductive coating 24 may comprise a nonconductive paint, primer or ink. In certain embodiments, coating 24 may comprise a nonconductive etching primer. In other embodiments, nonconductive coating 24 comprises a UV-curable material that is applied to member 12 and cured in place through exposure to UV radiation. The nonconductive coating 24 may be formulated to maximize adhesion to the surface of metallic member 12, as a number of applications for device 10 involve exposure to extreme temperature and pressure conditions, as well as corrosive environments. Exemplary nonconductive coatings 24 may comprise non-conductive metal oxides (such as titanium dioxide compounds), non-conductive polymers, ceramics, epoxy-based components, silicone elastomers, or PARYLENE (poly(para-xylylene) polymer). In certain embodiments, nonconductive coating 24 is applied to the surface of metallic member 12 using inkjet printing techniques, although other types of printing technologies can be used such as screen printing, lithography, and the like. Coating 24 can be applied to an entire face of metallic member 12 as illustrated in the Figures, or coating 24 can be selectively applied to only a predetermined portion of the desired face to which the conductive ink will later be applied.
Device 10 further comprises an electrically conductive ink trace 26 overlying nonconductive coating 24, which physically separates and electrically isolates ink trace 26 from metallic member 12. Electrically conductive ink trace 26 may comprise a variety of inks or coatings that are capable of transmitting an electrical signal. In certain embodiments, the electrically conductive ink can comprise metal particles that are sized so as to be jettable through an inkjet printing head, preferably having a particle size of less than 1 micron. The metal particles may be any transition metal such as silver, gold, copper, aluminum, iron, titanium, platinum, or tungsten. In addition to these materials, the ink may also comprise conductive non-metals such as carbon particles, or semi-conductive metalloids such as silicon or doped silicon. Conductive polymeric inks may also be employed for this purpose. One factor to be considered when selecting the specific conductive ink to be used for ink trace 26 is the temperature the ink will be required to withstand when device 10 is placed into service. A conductive ink will be considered to “withstand” a certain temperature if the ink remains adhered to the non-conductive coating and retains certain conductive properties at the required maximum operating temperature. In preferred embodiments, the conductive ink is capable of withstanding temperatures of at least 400° F., at least 600° F., or at least 800° F. In alternate embodiments, the conductive ink is capable of withstanding temperatures of from about 400° to about 1200° F., from about 500° to about 1000° F., or from about 600° to about 900° F. Of course, the nonconductive coating 24 and optional topcoat, described below, should also be capable of withstanding similar temperature conditions of the particular application. The thickness of conductive ink trace 26 can be varied, depending on the desired functions of ink trace 26. For example, the thickness of ink trace 26 may be varied to order to provide a desired level of sensitivity needed for detecting changes in the signal carried by the ink trace 26.
As shown in
Turning to
This further nonconductive layer may be in the form of a topcoat 28. As illustrated in
Nonconductive coating 24, conductive ink trace 25, and topcoat 28 may all be applied to metallic member 12 after bulging of central rupturable section 14 and creation of line of opening 20. Preferably one or more of these layers is applied using inkjet printing technologies. Thus, deposition of at least one of these materials occurs on a three-dimensional, formed substrate and not on a flat film or surface as is typical with inkjet printing.
In certain embodiments, holder 42 comprises electrical contacts 46,48 configured to engage corresponding terminals 52, 54 on the metallic member 12b to close the electrical circuit. Similar configurations may be employed in embodiments where metallic member comprises a plurality of conductive traces. In such embodiments, holder 42 may comprise a plurality of open electrical circuits and corresponding contacts that are configured to be closed upon securing of a pressure relief device between the holders.
The electrical contacts 46, 48 carried by holder 42 may comprise any number of alternate configurations. However, as illustrated, contacts 46, 48 comprise a pair of pins projecting from the flat relief device-engaging surface 56. Terminals 52, 54 comprise a pair of openings through flange 18b into which the contacts 46, 48 are inserted. Therefore, not only do contacts 46, 48 provide a means of engaging terminals 52, 54, they also ensure that the device 10b is properly oriented when installed between holder members 42 and 44. Other means of integrating electrical contacts within one of holder members 42, 44 are possible, and the foregoing description should not be viewed as limiting the scope of the present invention. Alternate configurations may comprise the use of a “zebra” strip comprising an elastomeric material as commonly used in assembly of circuit boards or LCD displays.
Number | Date | Country | |
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62047377 | Sep 2014 | US |