One-Piece Ceramic Header Insert for Pressure Sensor Sealing
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Solution Overview
Problem
Traditional header assemblies for pressure sensors, whether glass-to-metal or ceramic-to-metal, face challenges in providing a reliable seal over the operating temperature range and are complex to manufacture due to the use of individual ceramic pieces for each pin.
Innovation Solution
A header assembly featuring a one-piece ceramic header insert with a hollow protrusion having metalized inner and outer surfaces, which is coupled to both the header and header pin through brazing, forming a seal between the header, insert, and pin, thereby simplifying manufacturing and enhancing seal reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass-to-metal seals or brazed ceramic-to-metal seals are used in traditional header assemblies, then sealing capability is achieved, but manufacturing complexity increases and reliability decreases
Solution Approach 1:
The patent combines the ceramic insert and metal header into a single integrated component where the ceramic insert is directly brazed to the metal header body, eliminating the need for separate glass sealing operations. This merging of functions reduces the number of manufacturing steps and potential failure points while maintaining sealing integrity.
Solution Approach 2:
The patent employs composite construction by brazing ceramic material to metal material, creating a hybrid structure that leverages the advantages of both materials: ceramic provides chemical inertness and thermal stability for sealing, while metal provides mechanical strength and ease of fabrication. This composite approach resolves the contradiction by achieving reliable seals without complex glass sealing processes.
2Reliability
If individual pieces of metalized ceramic are used for each pin in ceramic headers, then sealing is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The patent merges multiple individual ceramic pieces into a single integrated ceramic insert that accommodates all pins. This insert is then brazed as one unit to the metal header, dramatically reducing the number of brazing operations from multiple individual piece assemblies to a single operation, thereby improving manufacturing efficiency while maintaining sealing reliability.
3Reliability
If glass frit is compressed inside the metal header at high temperature, then a seal is formed, but the process requires complex high-temperature heating and cooling cycles
Solution Approach 1:
The patent replaces the complex mechanical compression and thermal cycling process of glass frit sealing with a simpler brazing process. The metalized surfaces of the ceramic insert and metal header are joined through brazing, which eliminates the need for high-temperature melting and compression cycles required for glass frit, thereby simplifying manufacturing while achieving reliable seals.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a robust and reliable seal with reduced pressure leaks and manufacturing complexity by using a single-piece ceramic insert with increased surface area for sealing, addressing the limitations of traditional methods.
Implementation Method 1
brazing the metalized outer surface of the hollow protrusion to the inner surface of the header and the metalized inner surface of the hollow protrusion to the header pin
Data Source
AI summary
A header assembly for a pressure sensor and methods for manufacturing and using the same are provided. In one example embodiment, a header insert may include a base; a hollow protrusion coupled to the base and having a metalized inner surface and a metalized outer surface, wherein the metalized outer surface of the hollow protrusion is used to couple to a header and the metalized inner surface of the hollow protrusion is used to couple to a header pin; and wherein a seal is formed between the header, the header insert and the header pin.