Ceramic Pressure Sensor Membrane via 3D Screen Printing
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Solution Overview
Problem
The production of ceramic pressure sensors is labor-intensive and limited by geometric restrictions, requiring elaborate post-processing steps and thick, uneven layers, which complicates the creation of membranes with precise dimensions and accuracy.
Innovation Solution
A pressure sensor with a membrane and support section produced using 3D screen printing, where the membrane is made from ceramic material with sections thinner than 0.2 mm, allowing for precise dimensions and reduced production effort, and the support section can be fully or partially ceramic, improving media resistance and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pressing processes are used to manufacture ceramic sensor bodies, then production can be performed with conventional methods, but the membrane requires complex post-processing steps including grinding or lapping to achieve sufficient thinness and accuracy
Solution Approach 1:
The membrane is pre-formed with the correct thickness and geometry during the additive manufacturing process itself, eliminating the need for subsequent grinding or lapping operations. The 3D printing process directly creates the membrane at the desired dimensions, performing the precision work in advance rather than requiring corrective post-processing.
Solution Approach 2:
The mechanical pressing process is replaced with additive manufacturing (3D printing) technology. This substitution enables direct fabrication of the membrane with precise thickness control without relying on mechanical removal of material through grinding or lapping, thereby simplifying the overall manufacturing workflow.
2Manufacturing precision
If pressing processes are used to manufacture ceramic sensor bodies, then conventional production methods can be employed, but the membrane thickness and accuracy are insufficient without extensive mechanical rework
Solution Approach 1:
The membrane is pre-formed with the correct thickness and geometry during the additive manufacturing process itself, eliminating the need for subsequent grinding or lapping operations. The 3D printing process directly creates the membrane at the desired dimensions, performing the precision work in advance rather than requiring corrective post-processing.
3Adaptability or versatility
If pressing processes are used to manufacture ceramic pressure sensors, then conventional production can be utilized, but geometric shapes and dimensions are restricted
Solution Approach 1:
The additive manufacturing process enables continuous variation of geometric parameters such as membrane thickness, diameter, and overall sensor geometry without requiring tooling changes or process modifications. This allows customization of geometric shapes and dimensions while maintaining manufacturing simplicity through a single versatile process.
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
This approach enables the production of pressure sensors with high measurement accuracy and sensitivity, reduced production effort, and improved media resistance, facilitating the use in aggressive media environments with compact and precise designs.
Implementation Method 1
the membrane is produced at least in sections from a ceramic material by additive manufacturing, in particular 3D screen printing
Data Source
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AI summary
Molded body, in particular for a pressure sensor, comprising a membrane and a support section carrying the membrane, wherein the membrane is produced at least partially from a ceramic material by means of additive manufacturing, in particular 3D screen printing, and the maximum possible distance between two points lying on the outer circumference of the membrane (12) is less than 20 mm.