2) United States Patent Filippi et al (54) DIAPHRAGM STRUCTURE AND METHOD. OF MANUFACTURING 4 DIAPER: STRUCTURI (73) Inveators (73) Assignee: (9). Notice: Dario Fiippl, Houston, TX (US); Giovanni Filippi, Houston, TX ( P 1 Components Corporation, ‘Brenham, TX (US) Subject to any dislaimer the term of this patent is extended or adjusted under 35 USC. 1S4(b) by 37 days. (21) Appl. Nos 12212280 (22) Filed: Sep. 17,2008, ws) Prior Publication Data US 201000064816 AI Mar 18, 2010 (1) Ineo. GoiL 708 (2006.01) (2) US.CL rms (58) Field of Clasifcation Search nas ‘446010 4.36603, 4209159 454123 susesta somds soseaM Ssi938 GasK964 6.120033 See application file for complete search history References Cited USS. PATENT DOCUMENTS a a 71964 Popott rans 71972, Murata a 3208 11977 Akeley 7306 11979. Doyle Se o298 LUIDSL Forse 9298 911985 Auerweck eal was 12/1989. Zavoda S204 1992. Rapoca “39566 21993 Cc et al 7306 71999 Cc etal so Kokabang 26428 Hepner tal 26 31996 Lownie ta 706 + 3:2000 Flip ea oe = 92000 Fp ea 2738 ‘USOOT814798B2 a0) Patent No.: US 7,814,798 B2 4s) Date of Patent: Oct. 19, 2010 267,009 BL 72001 Drewesct a sais 6.363.790 BL 42002. Hlgsl eta 23708 6568274 BL $2003 Lucas aa ass 6675655 B2* 12004 Broden ot 7316 770377 B2* 82004 Hegner ea 8.469 6945118 B2 92005 Maidand, Je etal nn 37S (Continved) PORPIGN PATENT DOCUMENTS Coninved) OTHER PUBLICATIONS Wikipedia, npen wikipedia on wiki Brazing, “Bazing” May ous (Continsed) Primary Bxaminer—Anee J Allen (74) Anorney, lgent.or Firm Westaan, Champlin & Kelly, PA. on ABSTRACT Ina particular embodiment, a process transite includes corrosion resistive housing including a flange portion, where the corrosion resistive housing is formed from a frstmaterial. The process transmitter also includes an outer ring formed From second material, The outer ring as an inner diameter and is brazed to the Mange portion. The process trasmiter Further incudes adeformable diaphragm formed from a thind ‘material, the deformable diaphragm is welded to the outer ringat a weld seam between the diaphragm and the ovter ring adjacent tothe inner diameter to form a Bid sea 21 Claims, 7 Drawing SheetsUS 7,814,798 B2 Page 2 USS. PATENT DOCUMENTS w const? i994 7288089 B2_— 82007 Buressk ta Wo woI2077#96 1072002 740.798 B2* 102008 Kur ea 20080177 AL* 9.2005 rodent a 200¥0221656 AL* 11/2008 Kuz : 20080288218 AL 11/2008 Schimavanza ta (OTHER PUBLICATIONS 20060231507 AL 102006. Ananthanarayanan cal 1734 “Notifcation of Tansmital of the International Seach Report and 20070241169 AL 102007 Ammett tal. 228165 dhe Wrien Opinion ofthe Inerngtional Searching Autor, or ths FOREIGN PATENT DOCUMENTS. @ ootosst 1999 Deslataton” for PCT/S2009056579 fled Sep 1, 2009 14 pags, * cited by examinerU.S. Patent Oct. 19, 2010 Sheet 1 of 7 US 7,814,798 B2 10 104N\ Control System 123 (08 ; \ 142 109 41—~ [—— 151 PROCESS FLUID Process PipeU.S. Patent Oct. 19, 2010 Sheet 2 of 7 US 7,814,798 B2 200 ™ FIG. 2 (Related Ari)U.S. Patent Oct. 19, 2010 Sheet 3 of 7 US 7,814,798 B2 300“ FIG. 3U.S. Patent Oct. 19, 2010 Sheet 4 of 7 US 7,814,798 B2 306 i 322 FIG. 4 504 FIG. 5U.S. Patent Oct. 19, 2010 Sheet 5 of 7 US 7,814,798 B2 600“ 728U.S. Patent Oct. 19, 2010 Sheet 6 of 7 US 7,814,798 B2 802—~| ,Place a brazing material on an annular portion of a flange associated with a process transmitter housing v Position an outer ring on the brazing material, the outer ring including a diaphragm receiving structure to receive a deformable diaphragm 804—~] ¥ 806—~| Braze the outer ring to the annular portion of the flange ¥ 808 ~| Position the deformable diaphragm at the receiving structure of the outer ring Y Weld the deformable diaphragm to the receiving 810 structure of the outer ring 812 = FIG. 8U.S. Patent Oct. 19, 2010 Sheet 7 of 7 US 7,814,798 B2 Braze the outer ring to a flange of a process transmitter housing formed from a corrosion resistant material, the outer ring including a diaphragm receiving structure 902 ~~} ¥ Position an attachment portion of a diaphragm onto 904—N\ the diaphragm receiving structure, the diaphragm being deformable across substantially an entirety of the diameter Y Weld the diaphragm to the outer ring at the 906 | attachment portion to form a weld seal between the diaphragm and the outer ring 908 End FIG. 9US 7,814,798 B2 1 DIAPHRAGM STRUCTURE AND METHOD, ‘OF MANUFACTURING A DIAPHRAGM. ‘STRUCTURE FIELD OF THE DISCLOSURE The present disclosure is generally related toa diaphragm, structure and method of manufacturing # diophragm siric- ture. More particularly, the present disclosure is related to an isolating diaphragm structure including dissimilar metals. BACKGROUND Process transmitters are used fo monitor process variables, suchas pressure, temperature, flow and level of process fluids used in a variety of industrial processes. In some instances, process irinsmiter to measure pressure andor ow param ‘eters can include an isolating diaphragm that is coupled t0 industrial process equipment, such asa pipe, a reservoir, oF ‘ther process equipment, Generally, te isolating diaphragm, seals atleast portion ofa process transmitter housing. rom ‘exposure to the process fluids. Pressure measurements may be tken direedy fom the disphragm based on the dia- phragm delfection in response to pressure or may be taken indirectly by a remote pressure sensor that is couple to the isolating diaphragm by a fl filled capillary, Such pressure micasurements may be used directly or may he wsed to eale- Tate fui flow rate, for example Conventionally, a process transmitter housing is formed from 2 corrosion resistant material, such as stainless ste! “The diapnragm is typically one-piece diaphragm including an outer ring portion and a deformable diaphragm portion, ‘which are typically formed from Tantalum or another eoro- son resistant material To jin the diaphragm structore to the process iransmiter housing, a brazing proces is performed, ‘which includes applying brazing material between the outer ring of the diaphragm and the transmitter housing. The di phragm structure and the ransmitter housing are heated and ‘cooled to join the dissimilar metals. Unfortunately, the di erent mairials of the digphragm structure and the transit ter hosing have different eoeiients of thermal expansion. The brazing process may cause buckling and other defects 10 form in the diaphragm stracture as the diferent metals ‘expand and contrat at diferent rates. “Tantalum ean be expecially difficult to braze in this con- figuration because the coefficient of thermal expansion for Tantalum under temperatures significantly different than the ‘coefficient of thermal expansion of the stainless tee! trans> miter housing. Upon cooling, the stainless stee! contracts about thee times more than the Tantalum diaphragm strve- ture, the stctre coos, the tanta diaphragm structure ‘can buckle, causing visible damage. In some instances, such buckling may not be visibly detectable, but may nevertheless result in variability in the performance of the diaphragm structure. Traditionally, the diaphragm structure included fea- tures ints shape to overcome such defect; however, perfor ‘mance of individual pressure trasmiters could be inconsis- tent, Hence, there is a need for an improved diaphragm structure and method of manufacturing 4 digphragm strve- SUMMARY, Ina particular embodiment, a process transmitter inches 4 comrasion resistive housing including a flange portion, ‘where the corrosion resistive hosing is formed Irom a first material. The process transmiter also includes an outer ring 0 o 2 {Formed from a second material. The outer i ameter and is brized to the Hange portion. The process ‘eansmittr further inludes a deformable diaphragm Formed froma third material, the deformable digphragm is welded to ‘the quter ring ata wold seam between the diaphragm and the ‘outer ring adjacent tothe inner diameter to fom a fluid sel. ‘In another particular embodiment, 2 method of manvtac- toring pressure transmitters disclosed that includes brazing an outer ring to a flange of a process transmiter housing {formed from a corrosion resistant material, where the outer ‘ing including a diaphragm receiving structure. The method Tuner includes positioning an attachment portion of a dia- phragm onto the digphragm receiving structure, where the ‘Saphragm is deformable aeros substantially an entirety of ‘the diameter. The diaphragm is welded othe cuter ring atthe attachment portion to form a weld seal between the dia- ‘hragm and the outer ring Tnstill another particular embodiment, a trnsmiter device includes ange portion having fist inner diameter circum seribinga Mid cavity. The raasmsiter device also includes an ‘outer ring having a second inner diameter corresponding t0 the frst inner diameter. The outer rng ineludes a diaphragm eocving stnicture adjacent tothe second inner diameter. The cuter ring is brazed to the flange portion. The transmiter device further includes a deformable diaphragm having @ ‘mounting stneture sized wo mate with the receiving srtre ‘The deformable diaphragm is welded tothe outer ring at Weld seam between the diaphragm receiving structureand the ‘mounting stractore, BRIEF DESCRIPTION OF THE DRAWINGS, PIG. isa diagram ofa particular illustrative ermbodiment of a process control system including pressure transmiter having a digphragm structure with stamped diaphragm and separate outer ring: IG. 2 is an exploded view of a conventional diaphraga structure including one-piece diaphragm with an outer ring stamped from a single pieve of material FIG. 3 is an exploded view of a particular illustrative embodiment of ¢ disphragm structure incloding & stamped ‘Saphragm and a separate outer ring: FIG. 4 is atop view ofthe separate outer ring of FIG. 3; FIG. Sis a top view ofthe separate diaphragm of FIG. 3 FIG. 6 is a bottom view ofa particular embodiment of 3 iaphragm structureater the outerring is braze toa pressure ‘wansmitter housing and afier the diaphragm is resistance welded tothe outer ring: FIG, Tis a cross-sectional view ofthe diaphragm steutare ‘of FIG. 6 taken along line 7-7 in FIG. 6; FIG. isa Howe diagram ofa particlarilastraive embodi- sof a method of manufecturing a diaphragm structure Jhaving stamped diaphragm and a separate outer rings and FIG. 9 isa flow diagram ofa second particular illustrative embodiment of a method of manufacturing @ trnsmiter {ovice including a stamped diaphragm and a separate outer ring, DETAILED DESCRIPTION OF ILLUSTRATIV EMBODIMENTS IG. 1 isa diagram ofa particular illustrative embodiment ‘of a process congo! system 100 including a pressure trans- ‘iter 102 that communicates with a contro system 104 via ‘Wiring 106, nan alterative embodiment, the pressure tans ritter 102 may inclidea wireless trnsceiverto communicate ‘ith the control system 104 via a wireless communicatoUS 7,814,798 B2 3 Tink. The pressure transmitter 102 is illustrated in partial cross-sectional view, The pressure transmitter 102 is coupled ‘oa manifold 108 (or oheratachment mechanism) viaabase housing portion 110. [na particular embodiment, the mani ‘old 108 may’ be coupled toa pipe 109 via a first line 141 and ssccondline 151, Inanother particular example, themanifold 108 or another attachment feature, such ss a clamp, may ‘couple the pressure transmitter 102 toa wall of a reservoin,10 other equipment, orany combination thereon particular ‘embodiment, the pressure transmitter 102 and the manifold 108 may be located ata distance from the process pipe 109 ‘and he fist and second lines 141 ad ISI may be extended tues. ‘The pressure transmitter 102 preferably includes the base housing portion 110, which is thresdably attached ton upper housing portion 112, The base housing portion 140 defies a sensor cavity 126, a first id cavity 146 and a sceond oid ‘cavity 186. The seasor cavity 126s isolated from the stand second fluid cavities 146 and 186 by a fist isolation barrier Ms, “The pressure transmitter 102 may preferably include 3 ‘ransmitterhousing portion 144 andan input interface portion 118 that are threadably attached tothe upper housing portion 1112. The upper housing portion 112 andthe tansmitterhous- ing portion 114 define a transmitter cavity 124. The tansmit- ter bousing portion 114 further includes a transmitter cover 16, which is adapted to protect transmitter circuitry 134 roma process environment. The inp interface 18 includes ‘one or more fasteners 120 for coupling to wiring 106. The ‘input interface 118 andthe upper housing portion 112 define an inputloutput interface cavity 122 that includes an inp ‘output interface eireuit 132. The inputioutput interface cavity 122 is isolated from the trnsmiter cavity 124 by a second ‘solution barier 128. The inputioutput interface cireuit 132 is ‘coupled to the iaput interface 118 and to the transmitter ‘ircuitry 134 andis adapted vo communicate data between the transmitter ciuitry 132 and the contol system 104 ‘The sensor cavity 126 is isolated from the transmitter cir. ‘cuit cavity 124 and from the input interfacecavity 122, by a third isolation barrier 119. The sonsor cavity 126 is adapted 10 secure a sensor circuit 136, such as a pressure In this embodiment, the pressure transmitter 102 includes fist ensure interface 14D and a second pressure interface 150, The first pressure interface 140 includes a diaphragm structure 142 having a first diaphragm 144, The first dae phragm 144 includes a first isolation surface that contacts & process fli received via the manifold 108 an the fest line 141 and ineludes a first Mud cavity surfce tht contacts an ‘isolation ill Haid within the first uid cavity 146. The fist diaphragm 14 isolates the frst id cavity 146 from the process fluid. Te irs pressure interface 140 further includes ‘fit capillary tube 148 that couples the His Muid cavity 146 to a first pressure inlet 149 of the sensor ciruit 136. ‘The second pressure interface 180 includes a second di Phragm stricture 152 having a second diaphragm 184. The Second diaphragm 184 includes a second isolation surface that contacts the process tid received va the manifold 108 ‘and the second line 1S1 and includes a secood Maid cavity surface that contac isolation ill uid within te second uid ‘cavity 186. The second diaphragm 184 isolates the second fluid cavity 156 from the process fui. The second pressure Jmerface 150 father includes a second capillary tube 158 that ‘couples the second Mid cavity 186 toa second pressure inlet 159 ofthe sensor circuit 136, ‘Inapanicularembodiment, the first diaphrogm 144 andthe second digphragim 154 are adapted to deform in response toa 0 o 4 process fluid pressure, applying a compressive force fo the fil ‘Tid within the fist and second fui cavities 146 and 156 and \within the coresponding fist and second capillary tubes 148 And 158 in response to such deformation. The fill Rud is adapted to convey the process fd pressire tothe frst peo ‘sre inlet 149 vie the fist capillary tube 148 in response to {deformation ofthe firs diaphragm 148. The fill uid is aso ‘adapted to convey the process pressure to the sceand presse inlet 159 via the second capillary tube 158 in response t0 deformation of the second diaphragm 154. Ina particular ‘embodiment, the sensor eecuit 136 is adapted to determine a Tit process Muid pressure based on the deformation of the fist diaphragm 144 via the fil ud within the frst capillary tube 148 and to determine a second process Muid pressire ‘based onthe deformation of the second diaphragm 154 viathe sl fd within the second capillary tbe 188. Ina particular example, the process pipe 109 may include an orifice plate, a shedding bar. an annubar structure, a Venturi tbe, or another Flow impedance device adapted to produce differential pees- sure betwen the Hines 141 and 481, such thatthe fist and second diaphragm structures 142 and 182 experience differ ent uid pressures ‘Ina particular embodiment, the fist dinphragm 144 includes a deformable diaphrigm portion (such as the deformable diaphragm 304 illustrated in FIG. 3) anda sepa- ‘ate mounting sing portion (such as the outer ring 306 illus- ‘rated in FIG. 3), where the separate mounting ring is brazed to the base housing portion 110 aod where the deformable aphragm portion is resistance welded or otherwise fixed to the separate mounting ring, Ina particular example, the sepa- ‘te mounting ringant the deformable diaphmgm portion are Tormed from differeat materials andl are both formed from ‘materials that are different fom the base housing portion 110, whieh may be fomed from stainless steel. Ina particular embodiment, the separate mounting ring and the deformable yphragm portion are formed from different materials and fare attached to each other after the separate mounting ring is ‘mounted tothe base housing portion 110, FIG. 2 is an exploded view of a conventional diaphragm structure 200 including a one-piece diaphragm 202 having @ deformable diaphragm portion 204 and an outer ring portion 206. The one-piece diaphragm 202 is stamped froma single piece of material, such 2s a single sheet of Tantalum. The Giaphragm structure 200 also includes a base transmiter ‘housing 208, such asthe base housing portion 110 in FIG. 1 ‘The base transmitter housing 208 includes a flange portion 20 that has an inner diameter (D), which eireumseribes ‘uid cavity 214 including a plurality of ridges 216. The deformable diaphragm portion 204 also iocludes a eore- sponding plurality of ridges 21%. The diaphragm steuctare 200 further inclides a braving ring 212, which ix positioned ‘between the outer ring portion 206 of the one-piece dae phragm 202 and the Mange portion 210 ofthe base transmiter housing 208, Conventionally, daring a brazing process to join the one picce diaphragm 202 to the flange portion 210 of the base {ransmitter housing 208, the flange portion 210 of the base ‘ransmitter housing 208 has clferent coefficient of thermal expsinsion fom the one-pioce diaphragm 202, After brazing, the flange portion 210 cools ats different rte from the one- piece diaphragm 202, which may cause te outer ring portion 206 andior the deformable diaphragm portion 204 19 buckle Such buckling ofthe one-piece diaphragm 202 may result in tefects, which can eause device failures andor inconsistent pressure readings. IG. 3 is an exploded view of # particular illustrative embodiment of a diaphragm structure 300 including aUS 7,814,798 B2 5 stamped disphrapm 304 and a separate outer ring 306. The diaphragm structure 300 also includes a base transmitter housing 308, such as the hase housing portion 110 in FIG. 1 ‘The base trismiter housing 308 incides a base ange por- tion 310 having a diameter (D) that cireumseribes hid ccvity Hd inchadinga plurality ofridges 16. Thedeformable «diaphragm portion 304 also includes a corresponding plural> fay of ridges 318. The diaphragm structure 300 further Jnchudes a brazing ring 312, whieh is positioned between the separate outer rig 306 and the atge portion 310 of the base transmitter housing 308. The separate outer ring 306 includes ‘8 flange portion 322 that is adapted to mate with the base ange portion 310 ofthe base tansmitter housing 308 via the brazing ring 312. The separateouter ring 306 also includes:an inner diameter (D,) anda diaphragm receiving structure 320 ‘adjacent tothe inner diameter (D,,) that is adapted to receive the deformable diaphragm 304, The deformable diaphragm 304 includes a mounting structure 330 thats adapted to mate ith the ciaphrogm receiving strsture 320 of the outer ring 306, Tn. particular embodiment, the brazing ring 312 is pos tioned on the base Mange portion 310 ofthe base transmitter hosing 308, The separate oer ring 306 s positioned on the brazing ing 312. The separate outer ring 306, the base trans- miter housing 308, and the brazing ring 312 ae heated ton ‘elevated temperature and cooled to brize the separate ovter ring 306 tothe base transmitter housing 308. After the esul- ing structure is cooled, the deformable diaphragm 304 is Positioned to mate the mounting sirvcture 330 with the di phragm receiving structure 320. The deformable diaphragm 5304 is welded to the separate outer sing 306. In a particular ‘embovliment, the deformable diaphragm 304 is welded tothe separate outer ing 306 using a resistance welding process, In ‘another particular embodiment, the deformable diaphragm 304 is welded to the separate outer ring 306 va a laser weld process, In other embodiments, different welding or attach- ment processes may be used to attach the deformable di phragm 304 to the mounting structure 320 of the separate ‘outer ring 306. In a particular embodiment, a weld seam is, formed at an interface between the diaphragm receiving strvcture 320 ofthe outersing 306 and the mounting structure 330 of the diapiraam 304, In general, multiple performance and manufocturing improvements can be realized by separating the outer ring 306 und the deformable diaphragm 304 and by separately ‘attachingte deformable diaphragm 3041 theouterring 106 Inone particular example, a digphragm material anda eore- sponding thickness ofthe deformable diaphragm 304 can be selected to enhance a diaphragm spring rate, resulting in reduced temperature effects, reduced diaphragm stitiness, snd improved measurement accuracy ofthe overall pressure sensing system. In some instances, the diaphrogm spring rate ‘may’ be comparable to spring rates of similar parts that have resistanee-welded diaphragms. “Additionally, unlike conventional diaphragm structures that may experience buckling and deformation duc to thermal ‘coefficient of expansion effects (such as the one-piece din phragm structure 202 illustrated in FIG. 2), the diaphragm Structure 300 can be manufactired with reduced buckling and reduced deformation, resulting in enhanced spring rate per Jormance from piece-to-piece and more consistent perfor mance overall na paticular example, the active area of the ‘deformable diaphragm 304 isnot subjected to brazing so the ‘doformable diaphragm 304 performs more consistently. Ina Particular example, a diaphragm having a thickness of 2 mils ‘ban he mansfactured andl welded tothe outer ring 306 reli ably, resulting in enhanced accuracy for such thin-ligphragm, 0 o 6 products. Further, diaphragms having such thicknesses can be ‘made more widely available a standard products. Adition- ally, by separating the outer ring 306 from the deformable diaphragm 304, the process disclosed provides prea exii ity in choosing diaphragm thicknesses, The diaphragm thick- ess can he selected to accommodate eustomer performance ‘requirements. Further, by spitingthe deformabledliaphragm 404 from the raised face af the outer ring 306, standard ‘éiaphragm can be used that is common to ather existing pradcts rather than requiring # custom diaphragm, Another particular advantage is provided in thatthe dia. phragm structure 300 may be produced with a thicker outer Fing 306 and a thinner deformable diaphragm 304, which enhances robustness for certain outer ings and which reduces "unwanted temperature effets. Yet another advantage is pro- vided in that production scrap material is reduced improving ‘overall profit, redcing disruptions in protoetion schedoling, improving on-time delivery, and eahancing elliciency of ‘operating. equipment. Such reduced production of scrap ‘aerial resulls from a more reliable manufacturing process. Punter, the overall manufacturing process is simplified, since the deformable diaphragm 304 is not exposed to the brazing process. Since the overall process is simplified, mod- rately skilled workers may be used instead of specials Additionally, even with less skilled workers, the manufactur 1 process witha braze proces fo attach the outer ring 306 and a separate weld process 0 attach the deformable dia- phragm 304 co the outer ring 306 results in very high yield rates, allowing for signifieant reductions in rejected work pivees. Moreover, the process allows for double stacking of paris in a braze oven resulting in more efficient use of the ‘ovens and up to-a hundred percent (100%) improvement in pradiction rate. In partictlar example, combined with the reduction in serap, the improved yield rae from each oven batch can be up to approximately one thousand percent 1000%), FIG. is top view of the separate outer ring 306 of FIG. 3. The separate outer ring 306 includes a flange portion 402 that is adapted to mate witha corresponding Range portion of the base transmitter honsing and with a coreesponding brvz~ ing ring, sich as the braving ring 312 and the flange 310 illustated in FIG. 3. The separate outer ring 306 forher includes a diaphragm receiving stricture 320 tht is adapted toreceiveor interface with anattachmeat portion of deform- able diaphragm, such asthe mounting structure 330 of the {deformable diaphragm 304 illustrated in FIGS. 3 and 5 FIG. 8 isa top view of the separate diaphragm 304 of FIG. 3. The deformable diaphragm 304 includes the mounting Structure 330 that corresponds 10 the digphrapm receiving structure 320 of te separate outer ring 306 Istated in FIG. 4. The deformable diphmgm 304 includes a plurality of ridges 318. The mounting structure 330 js adapted to mate With the diaphragm receiving strcture 320 of the outer ring 306 (illstrated in FIG. 4) to facilitate attachment of the ‘deformable diaphragm 304 tothe separate outer ring 306, In apanicular embodiment, a esistance seam weld process may Deused to attach the deformable digphrgm 304 to the outer ring 306. A weld seam is formed between the diaphragm receiving siucture 320 ofthe separate outer ring 306 (ilus- trated in FIG. 4) and the mounting structure 330 of the sdformable digphragin 304, The weld seam forms a process seal ‘In general, resistance welding refers to a welding process ‘in which an electrical current and pressure are applied to @ ‘Work pieve in andr to Weld the work piece toa second work picoe a joint. Ina particlar example, electrical resistance ofthe outer ring 306 to an applied elecrieal current results inUS 7,814,798 B2 1 heat that partially melts work piece material atthe mounting structure 320, Concurrent application of pressure to the outer ring 306 and the deformable diaphragm 304 as the electrical ‘curent js applied causes a seam weld that can attach the ‘deformable diaphragm 304 othe outer Fing 306, Resistance seam welding i an example. In ather examples, the deform- able diaphragm 304 may be fixed to the omer ring 306 via laser weld process, other precision weld processes, or any ‘combination thereof TIG, 6 isa bottom view ofa particular embodiment of 3 diaphragm structure 60 aller aa outer ring 604 is brazed to 3 pressure transmitter housing and after a diapiragm 602 is resistance weld to the outer ring 694, The digphragm 602 ‘includes a mounting structure 606 and a plurality of rides 610. resistance weld seam between te diaphragm 602 and the outer ring 604 is generally indicated st 608, In. particular embodiment, by separating the diaphragm structure 600 into two pieces, the outer ring 604 can be brazed to a stainless stee! housing and the digphragm 602 ean be resistance seam welded to the outer ring 604 via separate 2 processes. The diaphragm 602 is welded tothe oxter ring 604 ‘earian inner diameteroF the outer ring 604, By separating the aiachment of the onter ring 604 from the afachment af the ‘diaphragm 602, distortion resulting from the braze process is reduced forthe aetivediaphragm area, ie, fora portionof the ‘diaphragm 602 that is deformable in response to tid pres= sure. In 2 particular example, the diaphragm 602 ean be formed of 8 diflerem material from the outer ring 604. For ‘example, the otter ring 604 may be formed from Tantalum and the deformable diaphragm 606 ean be formed from Flas> telloy.Gold, Zirconium, Platinum, Titanium, other materials, ‘or any combination thereof In another particelar embodiment, the outer ring 604 and the diaphragm 602 may have different thicknesses. In a par- ticular example, diflerent diaphragm thicknesses can be used ‘o comply with customer requests and to enhance particular performance parameters, sich as pressure sensitivity. Por ‘manufactaring, the sme outer ring 604 may'be used with 2 ‘variety of diaphragms having different thicknesses according ‘othe particular implementation Ina particular embostimest, scparation of the diaphragm 602 fom the outer ring 604 allows forthe use of attachment processes capableof welding thinner diaphragm materials on the same part so thatthe same ‘outer Fing 604 may be used with different deformable di pPhmgms 602, ‘Ina particular example, by separating the diaphragm strc~ ‘ure 600 ino a diaphragm 602 and. separate outer ring 604 the spring rate performance of the diaphragm 602 may’ be improved. Further, piece-to-piece performance variability may be reduced, in part, due to revetion or elimination of deformation areas at periphery ofthe diapinigm 602 ducto brazing. Additionally, elimination or reduction of such defor- mation areas eahances long-term duabili ration of the outer ring 604 from the thicker lining to be used fora gasket area (i.e. a thicker outer Fing 604 may be used) without impacting performance ofthe ‘diaphragm 602. Further, such separation enhances potential ‘or supplying parts with Tantalum outer ring 604 with dia- phragm of other material types, such as Hastelloy, Gold, 2Zivconium, Platinum, Titanium, other materials, or any com bination thereof. n'a pardcular example, the diaphragm ‘material may be selected based on desired performance char- acteristics, availablity, cost, or any eombination thereof TIG. 7 is a cross-setional view 700 of the diaphragm structure 600 of FIG. 6 taken along line 7-7 in FIG. 6. The igphragm stricture 600 incides an omer ring 604 coupled to a digphrapm 602 ata mounting steuture 606 and a core- 0 o 8 sponding receiving structure 706 va a resistance seam weld 608. The disphragm 602 includes a plurity of ridges 610. ‘The outer ring 604 is coupled (0 a flange portion 722 of a process transmitter housing 720 via 8 braze joint 724. The process transmitter housing 720 defines id eavity 726and ‘capillary tuhe 728 that are filed with a substantially incom pressble fil ai, generally indicated st 730 Ina particular example, during operation, the diaphragm {602 can deform in response uid pressure, compressing the substantially incompressible fill lid 730 and applying a ‘compressive force tothe fill Mud 780, The applied peessore may be detected by a sensor that is coupled to the capillary tube 728, sich asthe sensor circuit 136 coupled tothe cai Jary tubes 148 and £58 illustrated in FIG. 1 FIG. 8 isa ow diagram ofa particularilostrative embod sof a method of manufécturing a diaphragm structure ‘having stamped diaphragm and a separate cuter ring. At 802, ‘brazing material isplaced ona portion ofa ange associated ‘witha process transmitter housing. The lange portion may be ‘annular and may have an inner diameter (D) that surrounds (Gircumscribes) a fluid cavity, such as the id cavity 314 illustrated in FIG. 3. Advancing to 804, an outer ring is pos tioned on the brazing material, where the outer ring includes ‘diaphragm receiving sinicture adapted o receive a deform: ableiapiragm. Moving to 806, the outer ring is brazedto the ‘annular portion ofthe flange. The brazing process includes levating a temperature of the lange, the brazing material, and the outer rig and cooling the structure to weld the outer ring tothe lange, Continuing i 808, a deformable diaphragm is positioned at the receiving structure of the outer ring, Pro ceeding to 810, the deformable diaphragm is welded to the eceivingstructure ofthe outerring. The method terminates at si. FIG, 9s flow diagram of a second particular ilusteative embodiment of a method of manufacturing a transmiter devive including stamped diaphragm and a separate outer ring. At 902, an outer ring is brazed to a lange ofa process ‘transmitter housing formed from a corrosion resistant mate- ‘al, the outer ring including a aphragm receiving stracture Ina partieularembodiment, the corrosion resistant material is stainless steel andthe ter rng is formed from Tanta ln particular example, multiple outer rings ean be brazed t0 respective transmitter housings concurrently. Continuing t 94, an tachment portion ofa diaphragm is psitioned onto the Giaphinigm receiving strveture, where the digphragm is {deformable across substantially an entirety ofthe diameter. In ‘particular embodiment, the diaphragm is selected that has a éiaphragm thickness of approximately 2 mil. In another pare ‘icular embodiment, the diaphragm is formed from Hasteloy Gold, Zirconium, Platinum, Titanium, another material, oF any combination thereof. Proceeding to 906, the diaphragms ‘welded tothe outer ring atthe attachment portion to form @ Weld seal between the digpimgim and the outer ring. The ‘method terminates at 908, In a particular embostiment, the outer ring has an ianer ameter and the diaphragm receiving strctare is adjacent to the inner diameter. The digphrapm includes mounting stve- turecorresponsing‘o the diaphragm receiving structure ofthe ‘outer rng, andthe weld seals ommed between The diaphragm receiving structure and the mounting structure. In another particular embodiment, welding the diphrapm to the outer Fing includes positioning the mounting structure of the dia- phragm telatve tothe diaphragm receiving structure of the ‘outer ring, applying an electrical eurent oat least one ofthe ‘outer ring andthe diaphragm, and concurrently pressing the ‘ter ring andthe diaphragm together to resistance weld the aphragm tthe outer ring.US 7,814,798 B2 9 Ina particular example, the method further includes deter- ining desired performance paraieters for process tans- miter. Such performance parameters may be determined based on how the process transmitter sto be used, A mterial ‘composition of the diaphragm (such as Hastelloy, Gold, Zir- ‘con, Platinum, Titanium, or other materials) and a corr sponking diaphragm thickness are determined that satisfy the desired performance parameters, and the diaphragm formed, from the material composition and having the crtesponding diaphragm thickness is selected that satisies the desired per- Jormance parameters In general, though the above-examples were directed 1 & pressure transmitter and to isolating diaphragms it should be understood thatthe process of joining dissimilar metals may be applied to other structures as well. The methods and the associated stratus illustrate particular examples of tech niques for brazing a fits material ta second material and for welding a third material to the second material so that the resulting structure is fe from detects that might otherwise result fom brazing material that have different hemaal cet ficients of expansion, Although the present invention has been described with reference to preferred embodiments, workers skilled inthe at will recognize that changes may be made inform and detail ‘without departing from the spirit and scope ofthe invention, ‘What is claimed is 1.A process transmitter compri sacortosion resistive housing including ange portion, the ‘corrosion resistive housing formed roma lstatetial: ‘an outer ring formed froma second material, the outer ring braved to the flange portion, the outer ring having an inner diameter; and deformable digphragm formed from a third material the deformable diaphram welded tothe outer ring at weld seam between the deformable diaphragm and the outer ‘ing adjacent to the iner diameter, the weld seam form ing a fluid sel 2. The process transmitter of claim 1, wherein the outer ring inchudes a diaphragm receiving structure disposed ada- ‘ent to the inner diameter, and wherein the deformable phragm includes a mounting strcture adapted to mate with the diaphragm receiving structure. '3. The process transmitter of claim 1, wherein the outer ring has first thickness that sarater than a second thickness ‘ofthe delormable diaphragm. 4. The process transmitter of claim 1, wherein the second ‘material comprises Tantalom. '. The provess trnsmiter of claim 1, wherein the third material comprises one of Hastelloy and Titanium. 6. The process transmitter of elaim 1, wherein the third ‘material comprises one of Gold, Zirconium, and Platinum. 7. The process transmitter of claim 1 wherein the di phragm is resistance seam welded to the outer rng 8, The process transmitter of claim 1, wherein the frst, material comprises stainless stee! 9. A method of manufaturing a pressure transmite, the method comprising: brazing an outer ring to a flange of @ process transmitter housing formed from a comrsion resistant material, the ‘uterring ineluding a diaphragm receiving structure, the Nlange of first material and the outer ring of a second material: positioning an attachment portion ofa diaphragm onto the iaphragm formed of a third material receiving struc- 0 o 10 ture, the diaphragm being deformable across substan- tially an entirety ofthe diameter: and ‘welding the diaphragm t the outer ring at de attachment ‘portion to form a weld seal between the deformable digphragm and the outer rng to the weld seal forming 2 fil sel 10. The method of claim 9, wherein the outer ring has an inner diameter and wherein the diaphragin receiving structire is adjacent othe inner diameter. 11. The method of claim 10, wherein welding the selected iaphragm to the outer ring comprises: ‘applying an electrical current to at Teast one of the outer ring and the diaphragm; and concurrently pressing the outer ring and the diaphragm together to resistance weld the diaphragm to the outer ring 12, Themethod of elaim 9, wherein the process transmitter housing is formed of stainless steel and wherein the outer ring is formed of Tantalum. 13. The method of claim 12, wherein the diaphragm com- prisesoncof Hastlloy, Gold, Zirconium, Platinum, and Tit 14, The method of claim 9, wherein the diaphragm has @ iaphragm thickness of approximately 2 mil 15, The method of claim 9, wherein selecting the dia- phragm comprises: detemnining desired performance parameters for a process veansmiter: ddotemnining a material composition and a corresponding diaphragm thickness that satisfy the desiod perfor: mance parameters; and selecting the digphragm formed from the material compo- sition and having the corresponding diaphragm thick ness that sisi the desired performance parameters 16. The method of claim 9, wherein brazing the outer ring ‘comprises brazing multiple outer rings to respective transi ter housings concurrently. 17. transmitter device comprising ‘flange portion forme! froma frst material having an rst inner diameter circumscribing a uid cavity; fan outer ring formed from a second material inclding 3 second inner diameter corresponding tothe first ianer diameter, the outer ring comprising a diaphragm receiv- ing structure adjacent to the second inner diameter, the ‘outer ring braze tothe Nange portion; and deformable diaphrogm formed from a third material including a mounting stucture sized to mate with the receiving stroetre, the deformable diaphragm welded to the outer ring ata weld seam between the diaphragm receiving structure and the mounting structure the weld seam forming a fui seal. 18. The transmitter device of claim 17, wherein the deformable diaphragm has a irs thickness that isles than @ second thickness ofthe outer ring. 19, The trnsmitier device of claim 17, wherein the outer ring comprises Tantalum and wherein the deformable dia- phragm is formed from a second materia 20.The transmitter device of claim 19, wherein the second material comprises at least one of Hastelloy, Gold, Zireo- ‘ium, Platinum, and Titanium, 21. The transmitter device of claim 17, wherein the deformable diaphragm is resistance seam welded to the outer ring,